Case Ih 5100 Maxxum WSM Vol1

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uk Maxxum Tractors
Table of Contents
SECTION NO. FORM NO.
GENERAL
Sectional lndex 7-32752
Safety, General lnformation and Torque Specifications .................. .1001" B-86530
Specifications .................. ....1 002 7-30801
Specifications (for Tractors from PIN JJF1030000) ................ .......1002** 7-39640
ENGINE
Sectional Index 7-32762
Engine Removal and lnstallation................ ..................2002 7-30810
.............,.-,
Engine Specifications ............2401 8-26063
Cylinder Head and ValveTrain ................2415 8-26073
..........
Cylinder Block ...........242s 8-26084
LubricationSystem ..............2445 8-26093
Cooling System ..................24Ss &26103
Turbocharger.................. ....2465 8-26110
Analysis
Turbocharger Failure .................2565 9-78235
FUEL SYSTEM
Fuel Tanks... .....3005 8-85032
Fuel System and Filters .......3410 8-26131
Fuel lnjection Pump (CAV) ...3411 8-9771 1
Fuel lnjection Pump and Drive Gear (Bosch)........ .......3412 8-261 43
Fuel lnjectors .....................9413 8-26152
ELECTRICAL
Sectional Index 7-32780
Electrical Troubleshooting and Schematics
JJFl015046).......
(lor Tractors Prior to PIN .........4001* 8-85042
({or Tractors with PIN JJF1013658, JJF1013661 , JJF1013665,
JJFl013667, JJF]013669, JJFl 013771 , JJVAfi772,
JJF1013773, JJF1013981 and for Tractors from PtN JJ 1015046..............4001* 7-38440
(for Tractors from PIN JJF1030000) .....,............. .4001** 7-39270
Starter Motor.......... ..............4003 7-41780
Battery Testing, Maintenance and Booster Battery Connections ..,..4004 8-8511 0
Alternator..... ..4009 7-41790
* Schematic Set
Sections (for Tractors prior to plN JJF10300OO)
** Schematic
Set Sections (for Tractors from plN JJF103O0O0)
Copyright @ 1994 Case Corporation

Don 7-32936 Printed in U"S.A.
CASE CORPORATION
September 1994
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk SECTION NO. FORM NO.
STEERING
Steering Hand Pump (DANFOSS) ...........5001 8-8s1 30
Steering Hand Pump (EATON) ................5001 7-38770
Steering Cylinder 2WD............ ................5002 8-851 41
Front Axle 2WD ............ .......5003 8-851 60
MFD Steering Cylinder ........5004 B-851 51
TRANSMISSION
Sectional lndex i -JJ4J I
Separating the Tractor - Engine from Speed Transmission

(for Tractors prior to PIN JJF 1030000) ............. 6002 8-8501 0
Separating the Tractor - Engine from Speed Transmission
(for Tractors from PIN JJF 1030000) .................. .................... 6002 7-6921 0
Separating the Tractor - Speed Transmission from Range Transmission........... 6003 8-8521 0
Torque Limiter......... ............6004 7-30842
Servicing the Synchromesh Transmission............._ ..... 6005 B-851 92
Servicing the Powershift Transmission............".. ......._ 6006 8-85202
Servicing the Range Transmission .........6007 B-85221
Powershift Transmission Troubleshooting Prior to PIN JJF1 015046................... 6008* B-88422
Powershift Troubleshooting and Schematics
(for Tractors with PIN JJF1 013658, JJFl 013661 , JJFl013665,
JJFl013667, JJF1013669, JJF1013771, JJFl 013772,
JJF 1 01 3773, JJF 1 01 3981 and for Tractors from PtN JJFt 015046 .......... 6008* 7-37470
Powershift Troubleshooting and Schematics
(for Tractors from PIN JJF1030000) .... ., ..... ... . 6008** 7-39460
PowershiftVa1ve........... ...... 6009 8-85450
Creep Transmission........... ..................... 60.11 B-8s250
Synchronizer Creep Transmission
..
(for Tractors from PIN JJF]030000) .. .. . ., . ..................... 60't1 7-39420
Lock...............-......:.....
Differential and Differential ......6012 8-85241
MFD Drive Shaft........... ,,.., 6014 8-85290
MFD Clutch.. ... 6017 8-85461
Rear Axle and Planetaries,...,.......... ..,.... 6018 B-85320
Hydraulic PTO (Reversible) ............. ....... 60j 9 8-8s301
MFD Axle..... ...6021 8-85271
PTO front Drive Shaft and Hydraulic Pump Drive Gear... ................6023 7-32870
* Schematic Set
Sections (for Tractors prior to PIN JJF1030OO0)
** Schematic Set Sections (for Tractors
from PtN JJF1O3OO00)'
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powrquadplus www.thebestworkshopmanuals.co.uk SECTION NO. FORM NO.
BRAKES
Sectional lndex 7-3281Q
Parking 8rake........... ............7001 8-85351
Controls.......
Brake Cylinders and ............7002 8-85340
HYDRAULICS
Hydraulic Troubleshooting and Schematics
(for Tractors Prior toptNJJFl030000 ............._....8001* B-85383
Hydraulic Troubleshooting and Schematics
...................
(for Tractors from PIN JJF1030000) .8001** 7-3961 0
024468)
Hydraulic Pump (for Tractors Prior to PIN JJFl ..................8002 8-85401
..................
Hydraulic Pump(for Tractors from PIN JJF1024468) .....9002 7-37121
Charge/LubricationPump............................-.. ..............8003 8-8541 1
Sensor
Hydraulic Lift Cylinder and Position .........,.......9004 8-85420
Hitch Adjustments-....."...... ..BoOs 7-31 880
Remote Valves ....................9006 8-85431
Front Hitch... .....g007 8-85470
Shuttle Va1ve........... .............8009 8-88721
Hydraulic Housing andFilter..... ...............8009 B-85230
Draft SensingVa1ve........... ...8010 7-32100
Shuttle/PTO Valve.......... .....8011 7-39630
CHASSIS
Pedal and Lever Adjustments .......... ........9001* 8-85493
Pedal and Lever Adjustments
(for Tractors from PIN JJF1030000) ................. .900l** 7-39440
Air Conditioning - Troubleshooting
(for Tractors prior to PINJJF1034500)....... ..................9002 B-85501
Air Conditioning - Troubleshooting
(for Tractors from PIN JJFl034500 with HFC-134a Refrigerant) ................9002 7-69030
Air Conditioning - Gauges and Testing
(for Trabtors prior to PINJJF1034500)....... .................9003 8-8551 1
Air Conditioning - Gauges and Testing

(for Tractors from PIN JJFl034500 with HFC-134a Refrigerant) ................9003 7-69040
Air Conditioning - System Servicing
(for Tractors prior to PINJJF1034500)...,... ..................9004 B-85s21
Air Conditioning - System Servicing
(for Tractors from PIN JJF1034500 with HFC-l34a Refrigerant) ................9004 7-69050
Air Conditioning - Component Servicing
JJF1034500)
(for Tractors prior to PIN ................9005 8-86351
Air Conditioning - Component Servicing
(for Tractors from PIN JJF1034500 with HFC-134a Refrigerant)................9005 7-691 50
* Schematic Set
Sections (for Tractors prior to PIN JJFI03OOO0)
** Schematic Set
Sections (for Tractors from plN JJFI O30OOO)
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CHASSIS www.thebestworkshopmanuals.co.uk
(Continued)
cab Removal (for Tractors prior to PtN JJFl030000) ..9006 8-85550

Cab Removal (for Tractors from PIN JJF1030000)................... .......9006 7-69220
Cab Servicin9.................. .....9007 8-85560
Hood and Pane1s......... .........9008 8-85540
Operators Seat............. ........9009 8-88730
Decal Location ................. ....9010 8-88740
Battery Box.............. .............9020 8-89060
Platform Removal...... ...........9030 7-32300
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Sectional lndex
1 GENEML SECTION NO.
E Electrical System Specificaions .. .....1002
T Torque Data
tar' Hydraulic Fittings SpecialTorques .................... 1001

Standard Nut and BoltTorques ..... 1001
CASE CORPORATION Copyight @ 1992

Don 7-32752 Printed in England
August 1992
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Section
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
Prinled in England
CASE CORPORATION June 1 989
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1001-2
TABLE OF CONTENTS
SAFEry ' .... ..., ... .. '..... ' 3
STANDARD TORQUE DATA FOR NUTS AND BOLTS .. .. ,...,..,. .. 6
TORQUE DATA FOR HYDRAULIC FITTINGS
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1001-3
SAFETY
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
keyswitch when servicing or rcpairing the machine One
warning tag is supplied with each machine. Additional
tags Part Number 331-4614 are available {rom your
service parts supplier,
See Other Side Reason
JlCd mT
\/i
^r.'<c..*-
hturb
,!-r. 5. S,rlncd by
u
-
Bm4
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1001-4
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1001-5
GENERAL INFORMATION
CLEANING GEARS
Clean all metal parts except bearings, in mineral spirits Check all gears for wear and damage. Replace gears
or by steam cleaning. Do not use caustic soda for that have wear or damage.
steam cleaning. After cleaning dry, and put oil on all
parts. Clean oil passages with compressed air. Ciean OIL SEALS, O-RINGS AND GASKETS
bearings in kerosene, dry the bearings completely and
put oil on the bearings. Always install new oil seals, o-rings and gaskets. Put
petroleum jelly on seals and o-rings.
INSPECTION
SHAFTS
Check all parts when the parts are disassernbled.
Replace all parts that have wear or damage. Small Check all shafts that have wear or damage. Check the
scoring or grooves can be removed with a hone or bearingandoil seal surfacesof theshaftsfordamage.
crocus cloth. Complete visual inspection for
indications of wear, pitting and the replacement oi parts
necessary will prevent early failures. SERVICE PARTS
Always install genuine Case service parts, when

BEARINGS ordering refer to the Parts Catolog for the correct part
number of the genuine Case replacement items.
Check bearings for easy action. lf bearings have a Failures due to the use of other than genuine Case
loose fit or rough action replace the bearing. Wash replacement parts are not covered by warranty.
bearings with a good solvent or kerosene and permit to
air dry. DO NOT DRY BEARINGS WITH COMPRESSED
AIR. LUBRICATION
NEEDLE BEARINGS Only use the oils and lubricants specified in the
Operator's or Service Manual. Failures due to the use
Before you press needle bearings in a bore always of non specified oils and lubricants are not covered by
remove any metal protrusions in the bore or edge of the warranty.
bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.
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1001-6
STANDARD TOHQUE DATA FOR NUTS AND BOLTS
Where no special torque data is specified, the following torque figures should be applied. Threads should be lubricated
with engine oil or chassis grease.
TOROUE SPECIFICATIONS .r 1O%
GRADE 8.8 GMDE 10.9 GRADE 12.9

SIZE
rb-fl Nm kg/m tb-fr Nm kg/m tb-ft Nm kg/m
5mm 4 5.5 0.56 5.5 7.5 0.76 b.b I 0.92
6mm 6.6 o 0.92 9.2 12.5 1.27 11 15 1.s3
8mm 'r6.5 22.5 2.3 31 5 3.2 26.5 JO 3.67
10 mm 32 44 4.5 45 ol 6.3 55 75 7.65
12 mm 57 77.5 7.9 81 110 11.2 95 130 13.2
'14 mm 88 120 12.2 125 170 17.3 155 210 21.4
16 mm 'r40 190 19.4 195 265 27 236 320 32.6
18 mm 192 260 26.5 269 365 37.2 320 435 44.3
20 mm 273 370 37.7 383 s20 53 457 620 63.2
ca 516 700 71.4 619 840 85.6

22 mm 369 500
24 mm 471 640 65.2 665 900 92 796 1 080 110
27 mm 702 9s0 ooA 1 3s0 137.7 1 195 1620 165.2
1328 '1800 183.6 593 60 220.3

30 mm 955 1 300 132.5 I 21
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1001-7
TORQUE DATA FOR HYDRAULIC FITTINGS
FITTINGS CONNECTIONS AND PLUGS
Diameter x Pitch Newton / Metres Pounds / Feet Kilogram / Metres

10mmx1 20 I4.5 2
12 mm x l.5 26 J.E)
14 mm x 1.5 45 33.2 4.6

16 mm x 1.5 60 44 6.1
18 mm x 1.5 70 51 7.1
22 mm x 1.5 100 t3 10.2
27 mmx2 200 147 20.4

33mmx2 280 207 28.6
42mmx2 380 281 388
NUTS TOR TUBES AND HOSES
Diameter x Pitch Newton I Metres Pounds / Feel Kilogram / Metres
16 mm x 1.5 2A 14.5 2
18 mm x 1,5 3s 26 3.6
20 mm x 1,45 45 22C 4.6
24mmx15 60 44 61
FLANGES
Diameter x Pitch Newton / Metres Pounds / Feet Kilogram / Metres
8 mm x.1 .5 ,a tt 2.9
10 mm x 1.5 55 41 5.6
12 mm x 1.75 90 67 9.2
14mmx2 145 107 14.8
16mmx2 230 170 23.5
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Section
1 002
SPECIFICATIONS
Don 7-30801 Printed in U.S.A.

CASE CORPORATION October 1991
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TABLE OF CONTENTS
GENERAL SPECI FICATIONS
GEN ERAL SPECI FICATIONS
Capacities
Engine Oil Capacity (with Filter Change) .... ..,. 15 Litres 15.8 US Quarts
Engine Oil Capacity (wilhout Filter Change) . . . .. . 14.3 Litres 15.1 US Quarts
Cooling System (with Cab) .... . 20.8 Litres 22 US Quarts
..........
Cooling System (without Cab) 18.9 Litres 20 US Quarts
System
Transmission/Hydraulic .. 76 Litres 80.3 US Quarts
MFD Axle - Differential 6.5 Litres 6.8 US Ouarts
MFD Axle - Planetaries 0.9 Litres 0.9 US Quarts
Fuel Tank - Standard 130 Litres 137 US Quarts
Fuel Tank - Optional 170 Litres 180 US Quarts
Electri cal Specif ications

Type of System 12 Volts, negative ground
Batteries
Number ol Batteries Required
Voltage of the Battery 12 Volts
Reserve Capacity 170 minutes
Cold Cranking Capacity (SAE) at - '18"C (0.4'F) 700 Amperes
Starter Motor
No-Load Test at 27"C (80.6"F)
....
Current Draw ,,,. 170 Amperes maximum
Armature Speed ... ...... 8000 rpm minimum
Brush Length ..,,. 8.55 mm minimum 0,336 inch minimum
Armature Runout 0.03 mm maximum 0,001 inch maximum
Commutator Diameter 42,5 mm minimum 1,67 inch minimum
Armature End Play 0.10 to 0.30 mm 0.004 to 0.012 inch
Alternator
Output (Part No A187623) 14 Volts At 95 Amperes

Output (Part No A187873) 14 Volts AT 65 Amperes
(4187623)
Besistance of Rotor Winding 3.0 Ohms *
0.3 Ohms
(4187873)
Resistance of Rotor Winding 2.8 Ohms -r 0.2 Ohms
Brush Length Wear Limit 14 mm 0.55 inch

Maximum Botor Shaft Run-out 0.051 mm 0.002 inch
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1 002-3
Steeri ng Specifications
Front Axle - 2WD
Toe-in Adjustment ...,..,... ..... 2 to B mm 0.79 to 0.314 inch
Front Axle - MFD
Toe-in Adjustment .......,.. ..... 0 to 2 mm 0 to 0.79 inch
Steering Hand Pump
Model
Rated Flow
2WD ......., ........ 101/min 2.6 US/gpm
MFD .. ........ .. ..... 16 l/min 4.2 US/gpm
Rotor - Stator Wear Limit . ... . .. 0.127 mm 0.005 inch
Rotor - Stator Thickness Ditference . ...........,... 0.051 mm 0.002 inch
Transm ission Specifications

Torque Limiter
Belleville Spring Free Height 10.82 to 11.33 mm 0.425 to 0.444 inch
Rear Axles
Axle Shaft Bearing Pre-load 3.4 to 5.7 Nm 30 to 50 lb inch
MFD Axle
Torque
Pinion Shaft Rotating 1.7 to 2.2 Nm 15 to 20 lb in
Crown wheel Backlash 0.15 to 0.25 mm 0.006 to 0.010 inch
Float
Swivel Pin Bearing End 01 to 0.2 mm 0.003 to 0.008 inch
Pianetary and Wheel Hub Lubricant ............... . SAE 85W140 Gear Lubricant
Planetary and Wheel Hub Capacity .............. 1 Litre 1.05 US Quart
Swivei Housing End Play . 0 to 0.1 mm 0 to 0.003 inch
Pinion Bearing Pre-load ...92 to 137 N 20.71o 30.8 lb
Prnion Bearing/Differential Bearing Total Pre-load ...92 to 137 N + 31 to 47 N 20.71o 30.8 lb + 7to 10.5 lb
Bevel Gear Babklash 0.17 to 0.24 mm 0.007 to 0.009 inch
Dilferential Plate Thickness

Separator Plates 1.47 io 1.53 mm 0.057 to 0 06 inch
Friction Plates .. 1.57 to '1.63 mm 0.061 to 0.064 inch
Thrust Plates 2.77 lo 2.83 mm 0.109 to 0.111 inch
Lubricants
Planetary and Wheel Hub
Type Case SAW B5W-140 EP Gear Oil (MS 1316)
Capacity 1 Litre per Hub 1.05 US Quarts
Axle
TyPe...
Capacity ... 6 Litres 6.3 US Quarts
Grease Case 251 H EP or equivalent Multi-Purpose Lithium Grease
MFD CIutch
MFD Clutch Friction Plate Thickness .. ..,......... .,.2.45 to 2.60 mm 0.096 to 0.'102 inch
MFD Clutch Separator Plate Thickness .......,.....,, 2.16 to 2.3.1 mm
.11.00
0.085 to 0.090 inch
Height
Belleville Washer Free mm 0.433 inch
MFD Clutch Assembly End Play ..................1.00 mm 0.039 inch
MFD Bearing Housing End Play 0.025 to 0.102 mm 0.001 to 0.004 inch
MFD ldler Gear End Play ........... 0.025 to 0.102 mm 0,001 to 0.004 inch
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1002-4
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Transmission
lntermediate shaft End Play . .. .... 0.025 to 0..102 mm 0.001 to 0.004 inch
.
Shuttle Shaft End Play .......... .... 0.025 to 0'102 mm 0.001 to 0.004 inch
Friction Plate Minimum Thickness 2.40 mm 0.094 inch
Separator Plate Minimum Thickness ..,....... 2.10 mm 0.082 inch
Powershift Transmission
Friction Plate Thickness ........,,..,.. . Z 43 lo 2.60 mm 0.96 to 0.102 inch
Steel Separator PlateThickness .... 2.11 to 2.31 mm 0.083 to 0.091 inch
lnput Shaft Diameter 44.99 to 45.00 mm 1 .7721o 1.773 inch
1st Gear lnside Diameter ........,..... 50.009 to 50,02 mm 1 .968 to 1.970 inch
3rd Gear lnside Diameter ......,...,.... 50.009 to 50.025 mm 1.968 to 1.971 inch
Dropshaft Diameter (2nd Gear) 44 389 to 44,404 mm 1 748 to 1.749 inch
Dropshaft Diameter (4th Gear) 39 985 to 40.000 mm
.1.594
to 1 .574 inch
2nd Gear lnside Diameter 57.117 to 57 137 mm 2.2481o 2.249 inch
4th Gear lnside Diameter . ... ..,. . 45 009 to 45.025 mm 1.772 to 1 .773 inch
Differential and Ditferential Lock

Transmission Oil ...........,, .,..... HY-TRAN PLUS (MS 1207)
Ring Gear and Pinion Backlash . .. 0.15 to 0.30 mm 0 0059 to 0.01'l inch
Differential Lock C lutch Plate Thickness

Friction Plate .. 1 98 to 2.13 mm 0.078 to 0 083 inch
Separator Plate .... .... . 1.05 to 1.18 mm 0.041 to 0.046 inch
Piston Return Plate .... ..... 4.11 to 4.23 mm 0.161 to 0.166 inch
Parking Brake
Friction Plate Thickness .....,..,...,.. .. 6.25 to 6.40 mm 0.246 to 0.251 inch
Backing Plate Thickness ....,..,.,..... 2-16 to 2 31 mm 0.085 to 0.090 inch
Hyd rau lic Specifications

Hemote Flow (minimum) at 34.5 bar (500 psi) 60 l/min 16 US/gpm
Remote Flow (minimum) at 138 bar (2000 psi) ..57 llmin 15 US/gpm
Charge Pump Flow ,. 1021o 121 llmin 27 to 32 US gpm

Charge Pump Prcssure .. 3.4 to 4.8 bar 50 to 70 psi
Differential Lock Pressure (engaged) 17.9 to 20.0 bar 260 to 290 psi
Differential Lock Pressure (disengaged) . 17.9 to 20.0 bar 260 to 290 psi
Forward and Reverse Lubrication Pressure .. 1 4 to 2.1 bat 20 to 30 psi

Forward and Reverse Pressure 17I to 20 0 bar 260 to 290 psi
Hydraulic Oil Specification CASE HY-TBAN PLUS (MS 1207)

Hydraulic Oil Test Temperature 50'c 122'F
Low Pressure Standby .27sto41 4bar 399 to 600 psi
MFD Pressure . 17 I to 20.0 bar 260 to 290 psi
PFC Hydraulic Pump Maximum Pressure 190 bar +- 3.4 bar 2755 t 50 psi
PTO Pressure (engaged) 17.9 to 20.0 bar 260 to 290 psi
PTO Pressure (disengaged) 17I to 20.0 bar 260 to 290 psi
Powershift Prcssure 17 I to 20.0 bar 260 to 290 psi
NOTE: The dilferences between pressure readings for each gear must be no more than 0.7 bar (10 psi)
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1 002-5
Regulated Pressure P.1 17.9 to 20.0 bar 260 to 290 psi
Steering pressure (maximum) 172 1 3.4 bat 2495 -t- 50 psi
NOTE: The steering cylinder pressure could be up to 6.9 bar (100 psi) more than the steering maximum pressure.
Draft and Position Control

Position Sensing Connecting Rod Length ,,. 159 mm 6.259 inch
Hitch Drop Rate Time ... 1.8 to 2 seconds
Transmission Test Oil Temperature 50"c 122"F
Lift Arm
Rockshaft Bearing Diameter - Large End .. 69.825 to69.774 mm 2.7491o 2.747 inch
Rockshaft Bearing Diameter - Small End .. 60/300 to60.249 mm 2.3741o 2.372 inch
Rockshaft Eearing Bushing - Large End 70.0104 to 70.002 mm 2.76 to 2.756 inch
Rockshaft Bearing Bushlng - Small End . 60.566 to60.465 mm 2 384 lo 2.38 inch
Cylinder Bore Diameter 105.0 to 105.07 mm 4.13 to 4.136 inch
Remote Valves
Remove Valve Type Double acting Single acting for front hitch
Maximum Number of Remote Valves 4
Remove Valve Systcm Oil Pressure 190 bar 2755 psi
Maximum Oil Flow to Remote Valves .. . ... . 57 l/min 15 US/gpm
Spool Centering Spring Free Length ...... . 60.05 mm 2.364 inch
Flow Control Outer Spring Free Length (Single acting) 54.33 mm 2.138 inch
Flow Control lnner Spring Free Length (Single acting) 67.71 mm 2.665 inch
SINGLE REMOfE CIRCUIT PR|ORITY VALVE: Port load check valve on raise circuit. Break-away couplers
DUAL, TRIPLE AND QUAD remote valve circuits. Priority on first remote. Port load check valves on raise or lowcr
circuits Break-away couplers.
TRACTORS WITH FRONT HITCH. Priority on first remote. Single acting remote valve. Port load check valve on lower
circuit.
Shuttle Valve
Circuit Pressur-e
Forward Circuit Pressure ...,,,..,.,... 17.9 to 20.0 bar 260 to 290 psi
Reverse Circuit Pressure ..,.....,..,.. 7.9 to 20.0 bar
"1
260 to 290 psi
Modulation Outer Spring

Free Length 97.81 mm 3.85 inch
Outside Diameter 18.14 mm 0.714 inch
Modulation lnner Spring (Early Machines)

Modulation lnner Spring (Later Machines)

lnching Spool Spring

Free Length 40.95 mm 1 .6'12 inch
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Spool Cap/Plug Spring
Frce Length ,. 19,3 mm 0.76 inch
Sequencing Spool Spring

Air Conditioning Specifications

Refrigerant
,rPv . ,..,. R-12, to Case Specification 86
Boiling Point at Atmosphere Pressure ......,. ..., -30.C -22"F
System Capacity 2 13 kg 4.69 rb
Compressor
Type .... .. .. 5 Horizontal Pistons Operating on a Cam Plate
Bore 35 mm 1.38 inch

Stroke . ., .. ........ 28.6 mm 1.13 inch
Displacement per Revolution ....,..,.,.... 133 cc 8.42 inch3
Clutch Voltage . . 12 Volt
Clearance Between Front Plate and Pulley Air Gap 0.4 to 0.8 mm 0.016 to 0 031 inch
Drive Belt Tension

New Belt 422 to 516 N 95 to 116 lb
Used Belt 400 to 489 N 90 to 110Ib
Compressor Lubrication
Typc .. .. Positive Pressure
Lubricant Suniso 5GS, Tcxaco Capella WFl00, or Shell Clavus I29
Capacity (Compressor only) 170 ml 6floz

System Lubrication-
Capacities (Add to Compressor)

Rcceiver - Drier 29.6 ml llloz
Condenser..,.. 59.2 ml 2ll oz
Evaporator <ODml 2tloz
Hoses (Total) 29.6 ml l fl oz
High Pressure Switch

Location ... Discharge Hose from Compressor
Operation .,...... Closed by Excessive pressure
Cut-Out Pressure 25 I to 26.4 bar 365 to 3g5 psi
Low Pressure Switch

Location . ., Evaporator Outlet in the Cab Roof
Cut-Out Pressure ........ O.Z7 to 0 41 bar 4to6psi

Temperature Control Switch
Locatron Cab Roof Sensor in Evaporator
Cut-Out Temperature . . ...2"C 35.6',F
Cut-lnTemperature (Variable) . . . ... .6to7'C 43 to 45'F
Cutln Temperature (Variable) cont '1
6 to 21'C 61 to 70"F
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1002-7
powrquadplus www.thebestworkshopmanuals.co.uk SPECIAL TORQUES

Starter Motor
Drive Housing Nuts .4.5 to 6.0 Nm 3to4lbft
Starter Motor Mounting Bolts ,.....,.. 43 Nm 32rbft
Alternator
Alternator Mounting Bolts 24 Nm 18rbft
Pulley Retaining Nuts ,., 68 Nm s0 lbft
2WD Steering Cylinder and Axle

Wheel Bearing Retaining Nut ......,...,., . .. .. .. 100 Nm 74lb ft
Front Wheel Nuts .,........,. ...... .. 300 Nm 221 lb ft
Steering Arm Clamping Bolt . ..... 280 Nm 206 lb ft
Axle Pivot Pin Retaining Nut and Bolt ... ......... 150 Nm 111 tb ft
Steering Cylinder to Mounting Bracket 380 to 420 Nm 280 to 310 lb ft
Steering Cylinder Mounting Bracket Bolts .. ......,, 330 Nm 244|b ft
Steering Cylinder Ball Joint (1.H. Side) ...,... 400 Nm 295 lb ft
Cylinder Mounting Bracket to Axle Bolts ....... .. 460 Nm 339 lb ft
Steering Nut (R,H Side) .. .. ..... 200 Nm 148 lb ft
MFD Steering Cylinder and Axle

King Pin Retaining Bolts
8.8 Grade Bolt (with Washers) 137 Nm 101 lb ft
'10.9 Grade Bolt (without Washers) 190 Nm 140 lb ft
Track Rod to Steering Cylinder 300 Nm 221 lb ft
Ball Joint to Swivel Housing 230 Nm 170 Ib ft
Ditferential Housing to Axle
12 mm Bolts (with Washers) 120 Nm 88 lbft
12 mm Self Locking Bolts...,....... 169 Nm 125 lb ft
....
Ring Gear Bolts (Use Loctite 270) ..... ... 78 Nm s7 lbft
Differential Bearing Cap Bolts
Self Locking Bolts 266 Nm 196 lb ft
Locking Nuts . .. .. . 156 Nm 115 lb ft
Steering Cylinder Bolts ....... . ... 90 Nm 66 Ib ft
Wheel Carri6r to Swivel Housing Bolts . .. .... . 220 Nm 162 lb ft
Planetary Carrier to Wheel Hub Studs 70 Nm 52 lbft
Planetary Carrier to Wheel Hub Screws ........ 80 Nm 59 lb ft
Planetary Ring Gear Retaining Bolts ... ...... . 220 Nm 162 rb ft
Wheel Hub Drain/Filler Plug ... .. .. 60 Nm 44 lbft
Front Weight Carrier Retaining Bolts .......... 610 to 730 Nm 450 to 539 lb ft
Axle Pivot Pin Allen Screw and Locknut ,.. .. 150 Nm 110lb ft
Front Wheel Nuts . ....., . 185 to 221 Nm 137 to 163 lb ft
Transmission
Engine to Transmission Mounting Bolts
(16 mm) 335 to 375 Nm 247 lo 277 lb tI
.151
(12 mm).. .... 134 to Nm 99 to 1'11 lb ft
Speed lnput Shalt and Dropshaft Bearing Covers
Without Shims to Seat Bearings ......,.,........ I Nm 80 lb in
Without Shims to Measure Shim Cap ... ... 2 8 Nm 25 lb in
With Shims when installcd .... .... ..... 40 to 46 Nm 29 to 34 lb ft
Dropshaft Retaining Bolt ..... . .. . 101 to 113 Nm 75 to 83 lb ft
Front Bearing Carrier Plate Retaining Bolts ... '..' 70 to 79 Nm 52to58 lbft
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1 002-8
Creep
Dropshaft Gear Retaining Bolt .. ..... '101 to 103 Nm 75to76lbft
MFD Drive shaft

Drive shaft Retaining Bolts 39 to 44 Nm 29to32 lbft
MFD Clutch
MFD Clutch Mounting Bolts 265 Nm 195 lb ft
Pinion Shaft Bolt ...
... .. 265 Nm 195 lb ft
Hydraulic PTO
PTO Housing Retaining Bolts .. ... . . 195 to 250 Nm 144 to 185 lb ft
Lower Link Sensing Bar Retaining Bolts ....... 610 to 730 Nm 450 to 539 lb ft
Oil Baffle Plate Retaining Bolts .. ... 37 to 43 Nm 27 lo 32lb ft
PTO Valve Betaining Bolts ,...,..,.. . . 73 to 87 Nm 54 to 64 lb ft
PTO Clutch Hub Retaining Bolts . "10'l to '113 Nm 75 to 83 lb ft
Output Shaft Cover Retaining Bolts 73 to 87 Nm 54to64 lbft
Clutch Hub Seal Carrier Retaining Bolts .. ,.... . 37 to 43 Nm 27 to 32lb ft
Differential and Differential Lock

Ring Gear Retaining Bolts . .. ..... 256 Nm 189 lb ft
Diiferential Lock Clutch Cage Retaining Bolts
l0 mm 62 Nm 46rbft
12 mm (12 Poing Flange Type) ... .... . 130 Nm 96 lbft
Differentral Bearing Carrier Retaining Bolts .,........ 77 to 87 Nm 57to64 lbft
Parking Brake
Parking Brake Housing Mounting Bolts
l2 mm 125 to 150 Nm 92 to 1.10lb ft
16 mm 310 to 380 Nm 2291o 2B0lb ft
Bellcrank Pivot Bolts 270 lo 3'10 Nm 199 to 229 lb ft
Hydraulics
Hydraulic Pump Mounting Bolts 134 to 15'l Nm 99 to 111 lb ft
Compensator - Draft Control Valve Retaining Screw 50 Nm 37 lb ft
Solenoid Valve Installation Torque 15 to 25 Nm 11 to 18 lb ft
Draft Control Valve Port Housing Screws 62 Nm 46 lb fr
Draft Control Valve Side Housing Screws 24lb ft.
Remote Valve Retaining Nuts

12 mm .... 61 to 69 Nm 45to51 lbft
10 mm ...35 to 40 Nm 26to30 lbft
Load Check Valve Body ... 34 to 41 Nm 25to30 lbft
..
Load Check Valve End Cap .. . ... ......34 to 41 Nm 25 to 30 lb tt
Load Check Poppet Spring Retainer .. .. . 4 to 5 Nm 3to4lbft
Flow Control Spindle Housing Plug ..... .. .. 41 to 47 Nm 30 to 35 lb ft
.t0
Flow Control Spindle Rotating Torque ..0.9to11Nm B to lb ins
Check Valve Body 16 to 19 Nm 12 to 14 lb ft
Check Valve Plug 4to45Nm 3 to 3 .Slb ft
Lever Kickout Adlusting Plug Locking Nut . .. .... . 36 to 42 Nm 27 to 31 lb ft
Main Spool Detent Stud 12 to 16 Nm 9to12 lbft
Detent Housing Retaining Screws ...5to7Nm 4to5lbft
Don 7-3080 1 lssued 10-91 Printed in England
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1002-9
Shuttle Valve
Forward Solenoid Valve.......,. ..,.,..... 15 to 25 Nm 11to18lbft
,,,.,...,,
Reverse $olenoid Valve .,'.".,.. 15 to 25 Nm 11to18lbft
,,,.,.....
Differential Solenoid Valve ,...,. 10 to 20 Nm 7to15 lbft
.,,.,.
Modulation Solenoid Valve ,., .".' 10 to 20 Nm 7to15 lbft
Screws
Shuttle Valve Mounting ........ 73 to 87 Nm 54to64lbft
..,........
Modulation Plug 47 to 54 Nm 35to40lbft
Plug
lnching Spool ."... 70 to 80 Nm 52to59lbft
Plug
$equencing Spool 34 to 41 Nm 25to30lbft
Pressure Switch ,.,...,.. 0.8 to 1.0 Nm Tto9lbins
\ir Conditioning
Compressor Cylinder Head Bolts .........30 to 34 Nm 22lo 25lb tL
Compressor Rotor Shaft Nut ............. ..' 34 to 41 Nm 25to30lbft
Tube and Hose Fittings (1/a inch fittings without o-rings)

..........
Steel to Steel ..... 16 to 20 Nm 12 to'15 lb ft
Brass or Copper toSteel 15 to 20 Nm 11 to 15 lb ft
Aluminium to Steel ....,. 12 to 18 Nm 9to13 lbft
oon 7-30801
lssued 1G91 Printed in England
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Section
1002
SPECIFICATIONS
For Maxxum Tractors From P.l,N JJF1030000
Copyright O 1994 Case Corporalion

CASE CORPORATION Don 7-39640 Printed in England
January 1 994
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GEN ERAL SPECI FICATIONS
Transmission Specif ications e

SPECIAL TORQUES
G EN ERAL SPECI FlCATIONS

Capacities (51 20 I 5220)
Engine Oil Capacity (with Filter Change) ... 10 4 Litres 2.7 US Gal
Engine Oil Capacity (without Filter Change) . 9 5 Litres 2.5 US Gal
Cooling System (with Cab) . . 17 6 Litres ' 4.6 US Gal
Cooling System (without Cab) 15 7 Litres 4.1 US Gal
Transm ission/Hydraulic System 76 Litres 20.0 US Gal
MFD Axle - Differentiat 6.5 Litres 1.7 US Gal
MFDAxle-Planetaries.. .,,... ... ,.,.,.,.. .,.. :.. , . 0gLitres 0.2 US Gal
Fucl Tank - Standard 135 Litres 35.7 US Gal
Fuel Tank - Optional 170 Litres 45.0 US Gal
Capacities (5130/5230, 514015240 and 5150/5250)
Engine Oil Capacity (with Filter Change) .. 15 Litres a.0 US Gal
Engine Oil Capacity (without Filter Changc) 14 3 Litres 3.8 US Gal
Cooling System (with Cab) 20 8 Litres 55USGal
Cooling System (without Cab) .. . ... 18 9 Litres 5,0 US Gal
Transmission l1ydr aulic System 76 Litres 20.0 US Gal
MFD Axle - Differential . 6,5 Litres lTUSGal
MFD Axle - Planetaries . 0 9 Litres 0.2 US Gal
Fucl Tank - Standard 135 Litres 35.7 US Gal
Fucl Tank - Optional 170 Litres 45.0 US Gal
Electrical Specifications
Type of System 12 Volts, Negative Ground
Batteries
Cold Cranking Capacity (SAE) at - 18"C (0 4"F) 700 Amperes

Starter Motor
No-Load Test at 27"C (80.6'F)
Current Draw (5120/5220) .........., 125 Amperes maximum

Armature Speed (512015220) 7000 rpm minimum
Current Draw (5130/5230, 514015240 and 5150/5250) 170 Amperes maximum
Armature Speed (5130/5230, 514015240,5150/5250) .. ... ......8000 rpm
Brush Length . .. . 8 55 mm minimum 0.336 inch minimum
Armature Bunout 0.03 mm maximum 0.001 inch maximum
Commutator Diameter 42.5 mm minimum 1.67 inch minimum
Armature End Play(512015220) . 0.10 to 0.40 mm 0.004 to 0.016 inch
Armature End Play (5130i5230, 514015240 and 5150/5250) 0.10 to 0.30 mm 0.004 to 0.012 inch
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1 002-3
Alternator
Manufacturer Bosch
Output (Part No 4187623) at 6000 rpm 14 Volts at 95 Amperes
Output (Part No A187873) at 6000 rpm 14 Volts at 65 Amperes
Resistance of Rotor Winding (A187623) 3.0 Ohms -+ 0.3 Ohms
Resistance of Rotor Winding (A187873) 2.8 Ohms r- 0.2 Ohms
Resistance of Stator Winding (A187623) ..... 0.055 Ohms t 0.005 Ohms
Resistance of Stator Winding (A187873) 0.1 Ohms -r0.0'1 Ohms
Brush Length Wear Limit 14 mm 0.55 inch
Maximum Rotor Shaft Run-out 0.051 mm 0.002 inch
Steering Specifications
Front Axle - MFD
Toe-in Adjustment ,., .. ... .......0 to 2 mm 0 to 0.79 inch
Steering Hand Pump

Type (30 km/h Tractors Danfoss
Rated Flow 16 l/min 4.2 US gallmin

Rotor - Stator Wear Limit ........... 0.127 mm 0.005 inch
Rotor - Stator Thickness Difference ..... .....,.... 0.051 mm 0.002 inch
Displacement................ ...........96m1/rev 5.9 in3/rev

Thickness
Gerotor 13.26 mm 0.522 inch
Transm ission Specifications

Torque Limiter
Belleville Spring Free Height (25 mm Width) .10.82 to 11.33 mm 0.426 to 0.446 inch
MFD Axle
Pinion Shaft Rotating Torque 17to2.2Nm 15 to 20 lb in
Crown wheel Backlash 0.15 to 0.25 mm 0.006 to 0.010 inch
Swivel Pin Bearing End Float 0.1 to 0.2 mm 0.004 to 0.008 inch
Planetary and Wheel Hub Lubricant . .. ........... ...... Case SAE 85W140 Gear Lubricant
Planetary and Wheel Hub Capacity ... . ..... ... 1 Litre 0'26 US Gal
...
Swivel Housing End Play ........ 0 to 0.1 mm 0 to 0.004 inch
Pinion Bearing Pre-load ..... 92 to 137 N 20.7 lo 30.8 lbi
PinionBearing/Differential BearingTotal Pre-load....92to137N r 31 to47N 20.7to30.8|bf +7to'l0.5lbf
Bevel Gear Backlash . 0..17 to 0.24 mm 0.007 to 0.009 inch

Differential Plate Thickness
Separator Plates .... 1.47 to '1.53 mm 0.057 to 0.06 inch
Friction Plates ......... 1.57 to 1.63 mm 0.061 to 0.064 inch
Thrust Plates 2.77 lo 2.83 mm 0 109 to 0.111 inch
Lubricants
Planetary and Whcel Hub
.
Type .. .. .. Case SAE 85W-140 EP Gear Oil (MS 1316)
Capacity 1 Litre Per Hub 0.26 US Gal
Axle
..
Type .... Case SAE 85W-140 EP Gear (MS 1316)
Clpacity ..... .. 6Litres 1.6 US Gal
Grease .... Case 251 H EP or equivalent Multi-Purpose Lithium Grease
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1002-4
powrquadplus
MFD Clutch www.thebestworkshopmanuals.co.uk
MFD Clutch Friction plate Thickness .2.451o 2.60 mm 0.096 to 0.102 inch
MFD Clutch Separator plate Thickness 216to231 mm 0.085 to 0 091 inch
Belleville Washer Free Height .. 11.00 mm 0.433 inch
MFD Clutch Assembly End play 1.00 mm 0 039 inch
MFD Bearing Housing End play .0.025 to 0 102 mm 0.001 to 0.004 inch
MFD ldler Gear End play . 0.025 to 0 '102 mm 0.001 to 0.004 inch
Bange Transmission
lntermediate Shaft End play
. . .0025to0102mm 0.001 to 0.004 inch
Shuttle Shait End Ptay ... . . . 0 025 to 0 102 mm 0.001 to 0.004 inch
Friction Plate Minimum Thickness .. 2.40 mm 0.094 inch
Separator Plate Minimum Thickness 2.10 mm 0.082 inch
Powershift Transmission
Friction Plate Thickness 2.45 lo 2.60 mm 0.96 to 0.102 inch
Steel Separator Plate Thickness 2.11 lo 2 31 mm 0.083 to 0.091 inch
Ring Gear and Pinion Backlash 0.15 to 0.30 mm 0.0059 to 0.011 inch
Friction Plate .. .. .. . .. 1.98 to 2.13 mm 0.078 to 0.084 inch
Separator Plate .... . . 1.05 to 1 18 mm 0.04.1 to 0.046
.
inch
Piston Return Plate 4.11 to 4.23 mm 0.162 to 0.167 inch
Rear Axles
Axle Shaft Bearing Pre-load 3,4 to 5.7 Nm 30 to 50 lb inch
Parking Brake
Frictron Plate Thickncss 6.25 to 6 40 mm 0.246 to 0.252 inch
Backing Plate Thickness .2.16 to 2 31 mm 0.085 to 0.091 inch
Lubricants
Transmission Oil .
Case HY-TRAN PLUS@ (rVS t2O7)
Transmission Oil with Additivo
(Use for the first 1000 hours after installation of new brake friction platcs) . Case HY-TRAN PLUS@ (MSl223)
Don 7-39640
kaukazz@yahoo.co.uk
.1002-5
Hyd rau lic Specifications
Remote Flow (minimum) at 34 5 bar (500 psi) 60 l/min 15.9 US gal/min
Remote Flow (minimum) at 13.8 bar (200 psi) 57 l/min 15.1 US gallmin
Charge Pump Flow 1.t7 to 136 l/min 31 to 36 US gal/min

Charge Pump Pressure .. 3.4 to 4.8 bar 50 to 70 Psi
Differential Lock Pressure (engaged) 19.3 to 21 .4 bar 280 to 310 Psi

Differential Lock Pressure (disengaged) 19 3 to 21 .4 bar 280 to 310 Psi
Forward and Reverse Lubrication Pressure at 900 rpm . 0.3 to 0.8 bar 5 to 12 Psi
Forward and Reverse Lubrication Pressure aI 2200 rpm ........ . 1.0 to 1.7 bar 15 to 25 psi
Foruvard and Reverse Pressure 19.3 to 21 .4 bar 280 to 310 Psi
Hydraulic Oil Specification .....,,...., Case HY-TRAN PLUS@

Hydraulic Oil Test Temperature .. 49'C 120'F
Low Pressure Standby . 27.5 to 41.4 bat 399 to 600 psi
MFD Pressure . 19.3 lo 21 .4 bar 280 to 310 Psi
PFC Hydraulic Pump Maximum Pressure 186.6 to 193.4 bar 2700 to 2805 Psi
PTO Pressure (engaged) 19.3 to 21.4bar 280 to 310 Psi
PTO Pressure (disengaged) 19 3 to 21 .4 bar 280 lo 310 Psi
Powcrshilt Prcssure 19 3 to 21 .4 bar 280 to 310 Psi
NOTE: The difference beNveen pressure. readings for each gear must not be more than 0.7 bar (10 psi).
Regulated Pressure Pl .. 19.3 to 21.4 bar 280 to 310 psi

Steering pressure (maximum) 168 6 to 175.4 2445 lo 2545 psi
NOTE: The steering cylinder pressure could be up to 6.9 bar (100 psi) more than the steering maximum pressure
Draft and Position Control

Position Senslng Connecting Rod Length ., 159 mm 6 26 inch
Hitch Drop Rate Time 1.8 to 2 seconds
Transmission Test Oil Temperature ,., . . ,., ..... 49"C 120"F
Lift Arm
Rockshaft Bearing Diameter - Large End . .. ...... 69.825 to 69 774 mm 2.7491o 2.747 incn
Rockshaft Bearing Diameter - Small End . .. ..... 60.300 to 60.249 mm 2.374 to 2.372 inch
Rockshaft Bearing Bushing - Large End ..
. .. 70104 to 70.002 mm 2.760 to 2 756 inch
Rockshaft Bearing Bushing - Small End .... .... 60.566 to 60.465 mm 2.384 to 2 381 inch
Cylinder Bore Diameter ..... .. . .... 105 0 to 105.07 mm 4.134 to 4 137 inch
Remote Valves
Type ... ....... Single Acting for Front Hitch
Maximum Number of Remote Valves 4
Remote Valve System Oil Pressure 189.6 bar 2750 psi

Maximum Oil Flow to Remote Valves . .57 l/min 15.1 US gal/min
Spool Centering Spring Frce Length 60.05 mm 2.364 inch
Flow Control Outer Spring Free Length (Single acting) 54.33 mm 2 ]39 inch
Flow Control lnner Spring Free Length (Single acting) 67.71 mm 2 666 inch
SINGLE HEMOTE CIRCUIT PRIORITY VALVE: Port load check valve on raise circuit. Break-away couplers,
DUAL, TRtpLE AND QUAD REMOTE VALVE CIRCUITS: priority on first remote port load checkvalves on raise or lower
circuits. break-away couplcrs.
TRACTORS WITH FRONT HITCH: Priority on first remote . single acting remote valve. Port load check valve on lower
circuit.
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1002-6
powrquadplus
Shuttle/PTO www.thebestworkshopmanuals.co.uk
Valve
Circuit Pressure
Fonrrard Crrcuit pressure (5-l50) 19 3 to 21 .4 bar 280 to 310 psi
Reverse Circuit Pressure (5i50) 19 3 lo 21 .4 bar 280 to 310 psi
Modulation Spring (Outer)
Free Length 107.34 mm 4 23 inch
outside Diameter 20 09 to 20 35 mm 0.791 to 0 801 inch
Test Length . ,. 88 60 mm 3.49 inch
Tcst Load .
37 23 to 45.51 N 8.83 to 10.23 lbf
Modulation Spring (lnncr)
Free Length 78,36 mm 3.09 inch
Outside Diamcter i3.05 to i3.31 mm 0.504 to 0 524 inch
Test Length ... 39 5 mm 1.56 inch
Test Load 96.08 to ti7.4z N 21.6 to 26,4lbf
lnching Spool Return Spring
Outside Diameter 20.44 lo 20.70 mm 0.805 to 0.815 inch
Test Length 26.67 mm 1.05 inch
Test Load ..4003to4893N 9.0 to 11 .0 lbf
PTO Spool Return Spring
Free Length j00.44 mm 3.95 inch
Outsidc Diameter 21 97 lo 22.23 mm 0.865 to 0.875 inch
Tcst Length . 26.67 mm 1 05 inch
Test Load io4.o8 to tzt.2p N 23 85 to 29.15 lbf
Feathering Spring (Low pressure)

Outside Diameter 10.84 to 1 .10 mm
'1
0.427 to 0.437 inch
Test Length t4.db mm
rcst Load 0.59 inch
2214 to 27.06 N 4.98 to 6.08 lbf
Feathering Spring (High Pressure)
Free Length 23 63 mm 0,93 inch
outside Diameter .11 45 to 11.71 mm 0.451 to 0.461 inch
Test Length 16.25 mm 0 64 inch
Testload ... ... 86.1 to 105 2 N 19.35 to 23 65 lbf
Dctcnt Spring (lnner)

Free Length . .15.79
mm 0.622 inch
Outside Diameter 8.50 to 8.76 mm 0.335 to 0.345 inch
Test Length ........ 12.29 mm 0.484 inch
Test Load 68 06 to 83.18 N 15.3 to 18.7 lbf
Detent Spring (Outer)

Free Length ....,,.... 38 87 mm 1 53 inch
Outside Diameter 10 66 to 10 92 mm 0.4201o 0.430 inch
Test Length 17.40 mm 0.685 inch
Test Load 12.01 to1467N 2.7 to 3.3 lbf
Accumuiator (European Powershift Tractors Only)

Capacity 0 32 Litres 0.34 US quarls
Maximum Working Pressure ... 210 bar 3045 psr
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1002-7
Air Conditioning Specifications
Refrigerant
Type R-'12, to Case Specification 86
Boiling Point at Atmosphere Pressure . -30'c -22'F
System Capacity 2.13 kg 4.69 lb
Compressor
Type 5 Horizontal Pistons Operating on a Cam Plate
Manufacturer SANDEN (Sankyo)
Model . . .. SD 508 HD
.. 35 mm 1 38 inch
Stroke 28.6 mm 1 .13 inch
D splacerrent per Revolution 133 cc 8.42 inch3

Clutch Voltage 12 Volt
C carance Bewecn Front Platc and Pulley 0.4 to 0.8 mm 0 016 to 0.031 inch
Drive Belt Tension

New Belt ..., .. . 422 to 516 N 95 to 1 '16 lb
Used Bell 400 to 489 N 90 to 110lb
Compressor Lubrication
Type Positive Pressure
Lubricant ., ... Suniso SGS, Texaco Capella WF100' or Shell Clavus 129
Capacity (Compressor only) .. ...... 170 ml 6fl oz
System Lubrication
Lubricant See Compressor Lubricant
Capacities (Add to Compressor)
Receiver - Drier 296ml lfloz
Condenser ........ 592m| 2floz
a(la-
Evaporator ...,... 592m|
Hoses (Total) ... 296ml llloz
High Pressure Switch
Location Discharge Hose from Compressor
Operation Closed by Excessive Pressure
Cut-Out Pressure . ....... 25 1 to 26.4 bar 365 to 385 psi
Low Pressure Switch

Location ,... Evaporator Outlet in the Cab Roof
Cut-Out Pressurc o.27 lo 0.41 bar 4to6Psi

Location Cab Roof, Sensor in EvaPorator
Cut-Out Temperature 2'c 35.6'F
Cut-ln Temperature (Variable) 6 to 7"C and 16 to 21"C 43 to 45'F and 61 to 70'F

Location Cab Roof, Sensor ," ."r%11."J
Cut-Out Temperature . ,"C
Cut-ln Temperature (Variable) 6 to 7'C and 16 lo21'C 43 to 45"F and 61 to 70"F
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1 002-B
SPECIAL TORQUES
Starter Motor
Drive Housing Nuts 4.5 to 6.0 Nm 3to4lbft
Starter Motor Mounting Bolts 43 Nm 32lb It
Altcrnalor
Aiternator Mounting Bolts . 24 Nm 18 tb ft
Pulley Betaining Nuts 68 Nm 50 lb ft
MFD Steering Cylinder and Axle

King Pin Retaining Botts
8.8 Grade Bolt (with Washers) .137 Nm 101 lb ft
10 9 Grade Bolt (without Washers) .190 Nm 140 tb ft
Track Rod to SteeringCylinder . 300 Nm 221 tb ft

Ball Joint to SwivelHousing . .. 230 Nm 170 lb ft
Differential Housing to Axle
12 mm Bolts (with Washers) 120 Nm 88 tb f1
12 mm Self Locking Bolts...,...,,, I 69 Nm 125 lb fl
Ring Gear Bolts (Use Loctite 270) .. .. .. . . .. . 78 Nm 57 ib fr
Differential Bearing Cap Bolts
Self Locking Bolts 266 Nm 196 lb fl
Locking Nuts 156 Nm 115 tb ft
Stccring Cylindcr Bolrs . 90 Nm 66rbft
Wheel Carrier to Swivel Housinq Bolts 220 Nm 162 lb ft
Planetary Carrrer to Wheel Hub Studs 70 Nm 52 Ib ft
Planctary Carrier to Wheel Hub Screws 80 Nm 59rbft
Planetary Ring Gear Retaining Bolts . . 220 Nm 162 lb fl
Planetary Cover Plate Screws .. 34 Nm 25 lb ft
Wheel Hub Drain/Filter Plug .. .. 60 Nm 44 tb tI
Front Weight Carrier Retaining Bolts . . 610 to 730 Nm 450 to 539 lb ft
Axle Pivot Pin Allen Screw and Locknut .... .. .. 150 Nm 110 tb ft
Front Wheel Nuts .137
185 to 22'l Nm to 163 lb ft
Transmission
Engine to Transmission Mounting Bolts
(16 mm) 220 lo 250 Nm 162 to 1B4 lb ft
(12 mm) 134 to 151 Nm 99to 111 lbft
Speed lnput Shaft and Dropshaft Bearing Covers
Without Shims to Seat Bearings . . ..... ... ., . . ...9Nm 80 lb in
Without Shims to Measure Shim Gap 2.8 Nm 25 lb ln
With Shims when installed . . 40 to 46 Nm 29 to 34 lb ft
Dropshaft Rctaining Bolt 101 to 113 Nm 75 to 83 lb ft
Front Bcaring Carrier Platc Rctaining Boits . 70la 79 Nm 52to58lbft
Rear Whecl Retaining Nuts , .. .. 450 to 500 Nm 332 to 369 lb ft
Creep
Dropshafl Gcar Retaining Bolt 130 Nm 96tbft
MFD Drive Shaft
Drive shaft Retaining Bolts 39 to 44 Nm 29 to 32 lb ft
MFD Clutch
MFD Crutch Mounting Bolts . 265 Nm 19s lb ft
Pinion Shaft Bolt 265 Nm 195 tb ft
Don 7-39640 lssued '1-94 Printed in England
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Hydraulic PTO
PTO Housing Retaining Bolts .. 195 to 250 Nm 144 to 185 lb ft
Lower Link Sensing Bar Retaining Bolts 610 to 730 Nm 450 to 539 lb ft
Oil Baffle Plate Retaining Bolts . ........ 37 to 43 Nm 27 to 32lb fl
PTO Valve Retaining Bolts . ..,...... .. ..73 to 87 Nm 54 to 64 lb ft
powrquadplus
PTOwww.thebestworkshopmanuals.co.uk
Clutch Hub Retaining Bolts 101 to 113 Nm 75 to 83 Ib ft
Output Shaft Cover Retaining Bolts . .. .. 73 to 87 Nm 54 to 64 lb ft
Clutch Hub Seal Carrier Retaining Bolts ... 37 to 43 Nm 27 to 32lb fI

Ring Gear Retaining Bolts 335 to 375 Nm 247 lo 277 lb ll
Differential Lock Clutch Cage Retaining Bolts
10 mm 62 Nm 46 lb ft
12 mm (12 Point Flange Type) . .. 130 Nm 96 lb ft
Di{ferential Bearing Carrier Retaining Bolts ... 77 lo 87 Nm 57 to 64 lb ft
Parking Brake
Parking Brake Housing Mounting Bolts
12 mm 125 to 150 Nm 92lo 110 lb ft
16 mm 310 to 380 Nm 229 lo 280 lb ft
Bellcrank Pivot Bolts 270 lo 310 Nm 199 to 229 lb ft
Hydraulics
Hydraulic Pump Mounting Bolts 134 to 1 51 Nm 99 to 111 lb ft
Compensator - Draft Control Valve Retaining Screw 50 Nm 37 lbft
Torque
Solenoid Valve lnstallation . . .... 15 to 25 Nm 11 to 18 lb ft
Draft Control Valve Port Housing Screws 62 Nm 46 lb ft
Draft Control Valve Side Housing Screws . .. ...32 Nm 24lb ft
Remote Valve Retaining Nuts
12 mm 61 to 69 Nm 45 to 51 lb ft
10 mm 35 to 40 Nm 26 to 30 lb ft
Load Check Valve Body 34 to 41 Nm 25to30lbft
Load Check Valve End Cap . .. .34 to 41 Nm 25 to 30 lb ft
Load Check Poppet Spring Retainer 4to5Nm 3to4lbft
Flow Control Spindle Housing Plug ... .. . 41 to 47 Nm 30 to 35 lb ft
Flow Control Spindle Rotaling Torque 0.9 to 1.1 Nm 8 to 10 lb ins
Check Valve Body . ..... 16 to'19 Nm 12 to 14 lb ft
Check Valve Plug .. ... . .. .. 4 to 4.5 Nm 3 to 3.5 lb ft
Lever Kickout Adjusting PIug Locking Nut ...... 36 to 42 Nm 27 to 31 lb ft
Main Spool Detent Stud . . . .... 12 to 16 Nm 9to12lbft
Detcnt Housing Retaining Scrcws .. .... .. 5 to 7 Nm 4to5lbft
Drop Rate Screw Locknut 15 Nm 11 lbft
Charge/Lubrication Pump Mounting Bolts ...... . .. ... 134 to151 Nm 99 to 112|b ft
Screws
Shuttle/PTo Valve Fletaining . . 73 to 87 Nm 54 to 64 lb ft
..,,
Forward Solenoid Valve ...... 12 to 18 Nm 9to13lbft
Reverse Solenoid Va1ve.,.....,.... 12 to 18 Nm 9 to'l3 lb ft
Va1ve.........
Differential Lock Solenoid .....12 to 18 Nm 9to13lbft
PTO/lnching Spool End Cap Betaining Screws ..... .....10 to 12 Nm Tto9lbft
PTO Spool End Plug ....... ...47 to 54 Nm 35to40 lbft
..........
lnching Spool End Plug .. ..............47 to 54 Nm 35to40 lbft
PTO Piston Detent End Plug ........ ...........34 to 41 Nm 25 to 30 lb ft
Forward/Fleverse Spool End Plug ,,.........34 to 4'1 Nm 25to30 lbft
..
Modulator Piston End P1u9.......... .........47 to 54 Nm 35 to 40 Ib ft
Modulator Spool End P1u9........... . .....34 to 41 Nm 25 to 30 lb ft
Fonrrard Pressure TestFitting 8 to 14 Nm 6to10lbft
7116-20 Blanking Plugs.. .... 8 to 14 Nm 6to10lbft
9/16-18 Blanking Plugs. .....20 to 27 Nm 15 to 20 lb ft
kaukazz@yahoo.co.uk
'1002-10
Airpowrquadplus
Conditioningwww.thebestworkshopmanuals.co.uk
Compressor Cylinder Head Bolts . . 30 to 34 Nm 22lo 25 lb ft
Compressor Rotor Shaft Nut .....,..,.... 34 to 4l Nm 25 to 30 lb ft
10 to 15 lb ft
Tubre and Hose Fittings (1/d inch fittings without o,rings)
Steel to Steel ... 16 to 20 Nm 12 to 15 lb ft
.
Brass or Copper to Steel 15 to 20 Nm

Aluminium to Steet ,.
11to15lbft
12 to 18 Nm 9to13lbft
Don 7-39640
lssued '1-94 Printed in England
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk Sectional lndex
2 ENGINE SECTION NO.
A Aftercooler "" 2411
B Bearings.....,. 2425
Belt Tensioner
Balancer 2447
Camshaft 2425
Cooling System (Engine)
Cleaning and Maintenance ............ 2455
By)
Crankshaft Pres sure Check (Blow .....................2425
Crankshaft ..... 2425
Cylinder Block
Cylinder Head 2415
Engine Special Toruques 5130/5140 2441

Engine Special Torques 5120 . ..... . . 2402
Engrne Specifications 51 30/40 2401
Engine Specifications 51 20 2402
Engine
Removal 2oo2
Expansion Plug Fleplacemenl

Cylinder Block 2425
Cylinder Head 2415
Fan Pulley 2455

Flywheel 2425
Fuel Specifications 51 30/40 2401
Fuel Specifications 5120 ... 2402
o Oil Cooler (Engine Oil) 2445
Oil Pressure Relief Valve 2445
Oil Seals 2425
Copyright @ 1992
August 1992
kaukazz@yahoo.co.uk
Section
2002
ENGINE REMOVAL
For 5130 and 5140 Series Tractors
Don 7-30810 Prinled in England

)ASE CORPORATION January l$n
kaukazz@yahoo.co.uk
2002-3
TABLE OF CONTENTS
ENGINE REMOVAL AND INSTALLATION .......... 4
SPECIFICATIONS
Air Conditioning Compressor Drive Belt Tension
New Belt ......... 422 to 516 N 95 to 115 lb
Used Belt ......., 400 to 489 N 90to110lb
SPECIAL TORQUES
Side Rail Bolts ........... ....... 134 to 151 Nm 99to111|bft
Engine to Frame Mounting Bolts .......,... 335 to 375 Nm 247 to 277 lb ft
SPECIAL TOOLS
BELT TENSION GAUGE

cAs 10808
kaukazz@yahoo.co.uk
2002-4
ENGINE HEMOVAL
STEP 2
h'W"+;
the exhaust
Don 7-30810
kaukazz@yahoo.co.uk
2QQ2-5
powrquadplus
STEPwww.thebestworkshopmanuals.co.uk
3
Loosen the clamp and remove the air inlet tube from the
machine.
STEP 6
#l .',-
ro,tffit
ing the rear hood bracket.
Remove the rear hood bracket from the engine
STEP 4
W
Disconnect the air condltioning compressor clutch

electrical connector.
Disconnect the air filter restriction switch
Don 7-30810 lssued l-90 Printed in England
kaukazz@yahoo.co.uk
2002-6
@o@@
STEP 7 STEP 8
oo
Disconnect the air conditioning hish p*.sui;switch
Loosen or remove all parts attaching the air

conditioning compressor. Carefuily remove the
compressor from the engine. Secure the compressor in
a safe horizontal position.
Don 7-30810
,ssued l-90 Printed in England
kaukazz@yahoo.co.uk
2002-7
STEP I (Con't)
powrquadplus www.thebestworkshopmanuals.co.uk STEP 12
For Engine lnstallation, measure the compressor belt

tension using belt tension gauge, CAS 10808. Test the
belt tension half way between the compressor and the
fan pulleys to the following specifications :
N
New Belt ... .. . .......... 422 to 51 6
.1
95 to 1 5 lb ft
N
Used 8e1t.,........, ,,.400 to 489 90 to 110|b ft
Tighten the pivot bolt and adjusting bracket bolt when
the belt tension is correct.
STEP 9
Disconnect the coolant temperature switch
STEP 13
Disconnect the left hand steering tube bracket.
STEP 1O
Put a suitable container with a capacity of at least 17.6

Iitrcs (4.6 US Galls) under the tractor, Remove the drain
plug and drain the coolant, After draining install and
tighten the drain plug,
NOTE : For Engine lnstallation, fill the radiator with

coolant to the carrect level.
STEP 14
Disconnect the injection pump fuel shutoff lead
STEP 11
Loosen the clamp and remove the top coolant hose
Disconnect the oil pressure switch

Don 7-3081 0 Issued 1-90 Printed in England
kaukazz@yahoo.co.uk
2002-8
STEP 15
Loosen the clamP and nisconnect the alternator electrical leads, terminals
D + and W, and move the electrical harness forward
clear out of the way.
STEP 1B
Remove the alternator protective shield

Don 7-30810
kaukazz@yahoo.co.uk
2002-9
STEP 19 STEP 21
lnstall a sling to the engine lifting eyes and connect to a Remove the side rail bolts (both sldes).
suitable hoist.
NOTE : For Engine lnstallation, tighten the side rail bolts
STEP 20 to a torque of 134 to 151 Nm (99 to 111 lb ft).
ry1fFiffiffifr$4$Yr'"'
STEP 22
..DOr710
Remove the tvvo bottom engine to frame mounting

bolts
Remove the engine.
NOTE : For Engine lnstallatian, tighten the engine to
frame mounting bolfs to a torque o/335 to 375 Nm (247 NOTE : For Engine lnstallation, follow the same
to 288lb ft). procedure in reverse order.
Don 7-3081 0 lssued 1-90 Printed in England
kaukazz@yahoo.co.uk
Section
2401
SPECIFICATION DETAILS
6-590 Diesel Engine
IMPORTANT: This engine was made using the metric measurement system. Nl
measurements and checks must be made with metric tools to make sure of an
accurate reading when inspecting parts.
CASE CORPORATION
Copyright O 1992 ,
Rac 8-26063 Printed in U.S.A,

October, 1984 (Revised February, 1992)
kaukazz@yahoo.co.uk
2401-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS,,
IDENTIFICATION MARKS
Crankshafl
Cylinder Block .. .... .
Cylinder Head .., . ..,.
ENGINE SPECIFICATION DETAILS

Cylinder Block ..
Service Cylinder Sleeve
Piston Pin..... .
o
Piston Rings,..,..,
t)
Cylinder Head
Lifters ., , . , .. .,. ,
. ... ..7
Connecting Rod .. . .
8
Crankshatt
..9
Camshaft
....9
Turbocharger..,., .,,,..,,.,,. .. . ,.
Gear Train.,.,
10
Rocker Arm Assembly.. . .. . .... .. ..
lntake Valve
10
Exhaust Valve ....,..,,.,
11
Valve Springs
. .11
Valve Seat lnstallation Dimensions
12-14
SPECIALTORQUES.. ..
Revised 2-92 Printed in U.S.A.

Hac 8-26063
kaukazz@yahoo.co.uk
2401-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the 6-590 engine crankcase with CC/SF CD/SF, CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. lnstall new oil filters after the engine is rebuilt.
Fill the 6T590 and the 6T4 590 engine crankcase with CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. lnstall new oil filters after the engine is rebuilt.
Run-ln Procedure for Rebuilt Engine

Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start. Crank the
engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit.
Step 3 Run the engine at 1000 HPM minimum load for 5 minutes and check for oil leaks.
Step 4 During the Run-ln, continue to chcck the oil pressure, coolant level, and coolant temperature.
Run-ln Procedure for Rebuilt Engines (with a Dynamometer)

The following procedure must be followed when using a PTO dynamometer to Run-ln the engine. The dynamometer will
control the engine load at each speed and will remove stress on new parts during Run-ln.
During the Run-ln, continue to check the oil pressure, coolant level and coolant temperature.
STEP TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

1 5 Minutes lOOO RPM 50
2 5 Minutes 1 lOO RPM 112
3 5 Minutes 22OO HPM Full
Run-ln Procedure for Rebuilt Engines (without a Dynamometer)

STEP TIME ENGINE SPEED LOAD
1 5 Minutes 1000 RPM No Load
2 5 Minutes 1100 RPM Light Load
3 5 Minutes 2200 RPM Light Load
Run-ln Procedure (Agriculture Equipment)

For the first I hours of field operation stay one gear lower than normal: For the next 12 hours DO NOT "lug" the engine.
Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPM
during early hours of life.
Run-ln Procedure (Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The
engine must not be "lugged" below the Rated Engine RPM (Do not stallthe engine more than 10 seconds).
Rac 8-26063 Revised 2-92 Printed in U.S.A,
kaukazz@yahoo.co.uk
Crankshaft
Letter N : Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time
the crankshaft has been reconditioned.
powrquadplus
Cylinder Block www.thebestworkshopmanuals.co.uk
Letter X : The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker head gasket (two
notches).
Lelter XX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches)
Cylinder Head
Lettcr G - Thermostat passagc in cylindcr did not need to be machined.
Lettcr M : Thermostat passage in cylinder head was machined.
Letter V = Valve seats have been machined.
Lettcr X : The cylinders in the cylinder block have been bored oversize. Use this gasket for standard replacement and
oversize cylinder holes (one notch).
Lctter XX '= The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (two
notches).
Lettcr XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.
ENGINE SPECIFICATION DETAILS

Cylinder Block
Metric Value
Cylinder Out of Round (Maximum) .......0.03g mm
0 5 mm Oversize Piston
Machine Cylinder Bore to ..................102.40 to 102.44 mm
Hone to (Finished Diameter) .. ..........102.50 to 102.54 mm
'l 00 mm Oversize Piston
Machine Cylinder Bore to ................102.90 to 102.94 mm
Hone to (Finished Diameter) .............103.00 to 103.04 mm
Rac 8-26063 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2401-5
Service Cylinder Sleeve
Machine Cylinder Block Bore to,..,.,,,....,.,,. ........ .104485 to 104.515 mm
Machine Sleeve Bore to:

Standard Size Piston (Finished Diameter) ., ..... .. ..,. ]02 00 to 102 04 mm
0.5 mm Oversize Piston
Machine Cylinder Bore to .. .. .....102.40 to 102.44 mm
Hone to (Finished Diameter) ....... . ...102.50 to 102.54 mm
Machine Cylinder Bore to . .102.90 to i02.94 mm
Hone to (Finished Dlameter) ..... ...i03.00 to 103.04 mm
Main Bcaring Bolt Maximum Length . 119.25 mm
Piston
'_yyu. ...... Cam Ground
OD at 12 mm From the Bottom,90 Degrees Piston Pin

Standard Size Piston .. .. . 101.873 to 101 887 mm
....
Minimum Service Limit.... .. ... 101.823 mm
0,5 mm Oversize Piston .. . . .........102.373 to 102.387 mm
MinimumServicelimit.... ..101.323mm
10 mm Oversize Piston .,... . ..........102.873 to 102887 mm
Minimum Service Limit. 102 823 mm
lD of P.ston Pin Bore..
. . .....40.006 to 40.012 mm
Width oi 1st Ring Groove (Top) .. . ........2,465 to 2,485 mm

Width of 2nd Ring Groove (lntermediate) .......2.425 to 2.445 mm
Width of 3rd Ring Groove (Oil Ring) . . . 4 040 to 4 060 mm
Protrusion Above Cylinder Block (Maximum) 0.660 mm
Piston Pin
i9.997 to 40 003 mm
Minimum Service Limil 39.990 mm
Rac 8-26063 Revised 2-92 Printed in U,S.A
kaukazz@yahoo.co.uk
2401-6
Piston Rings
No. 1 Compression 6T-590 and 6T4-590 Engine,. .,,.. . Key Stone Type (Barrel Face)
EndGapin10202lD........... ...............0.41o0.70mm
No, 1 Compression 6-590 Engine Rectangular Type (Barrel Face)
End Gap in 102.02ID ..... . . . 0 25 to 0,55 mm
Maximum Service Limit 0.806 mm
No 2 Compression ..... , .....,, Rectangular Type fT-apper Face)

End Gap in 102 A2 lD .. ... . . 0.25 to 0 55 mm
0 075 to 0 120 mm
No. 3 Oil Control Rings Two Piece

End Gap in102.02|D ........... ...... 0 25 to 0.55 mm
Maximum Service Limit.... .. . . 0 806 mm
Sidc Clearance .. 0 130 mm
Cylinder Head
Warpage (Maximum) .. 0'20 mm
Maximum Material Removal 100mm
Minimum Head Height.. ... 93 75 mm
Engines Manufactured in U SA :
Prror to Engine Serial Numbet 45511034 lnjector Nozzle 9 mm

Engine Serial Number 45511034 and After lnlector Nozzle 7 mm
Engines Manufactured in Darlington England
Prior to Engine Serial Number 21092870 . lnjector Nozzle 9 mm
Engine Serial Number 21092870 and After lnjector Nozzle 7 mm
Engines Manufactured in Neuss Germany:
Prior to Engine Serial Number 52107489 .. lnjector Nozzle 9 mm
Engine Serial Number 52107489 and After Injector Nozzle 7 mm
Lifters
Material ..... . Hardened lron
OD of Llfter 15.961 to 15 977 mm
Minimum Service Limit.. . .. .. i5 960 mm
Bore Diameter in Block .. .. . '16.000 to 16.030 mm
Maximum Service Limit 16 055 mm
Rac 8-26063 Bevised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2401-7
Cylinder Block
Connecting Rod
Bushing lD lnstalled (Ream to Size).... . .40.053 to 40.067 mm
Journal lD Without Bearing Liners 72987 to 73,013 mm
Side Clearance 0.100 to 0 300 mm
Connecting Rod Bend (Maximum)

Without Bushing 0 200 mm
With Bushing . 0.150 mm
Connecting Rod Twist (Maximum)
Connecting Rod Bolt Maximum Length. .... ... 59.25 mm
Rac 8-26063 Revised 2-92 Printed in U.S,A
kaukazz@yahoo.co.uk
2401-8
Crankshaft
Type
... Hardened Steel, Balanced
Main Bearing Liners
..,., Replaceable
End Clearance, Center Main Bearing Cap .. .. ..
0.13 to 0.25 mm
Center Main Bearing Thrust Surface Thjckness.
2.50 mm
Connecting Rod Journal
OD Standard
68.987 to 69.013 mm
Maximum Service Limit
68 962 mm
0.25 mm OD Undersize, Grind to
.68 737 to 68 763 mm
Maximum Service Limit,
68 712 mm
0,50 mm OD Undersize, Grind to
..68 487 to 68.513 mm
Maximum Service Limit.. .. . .. .
68.462 mm
0 75 mm OD Undersize, Grind to
...68237 to 68.263 mm
Maximum Service Limit.
68.212 mm
...........67.987 to 68.013 mm
.. .. 67.962 mm
Connecting Rod Journai Maximum Taper
. . .....0.013 mm
Journals Out of Round Maximum
0.050 mm
Undersize Main Bearing Liners For Service .
. . ....0.25,0.50, 0 75 and '1,00 mm
Main Bearing Oil Clearance
. .. 0.041 to 0..119 mm
O i40 mm
Main Bearing Journai
OD Standard
82.987 to 83.013 mm
Maximum Scrvicc Limit .
. 82 962 mm
.......82.737 to 82,763 mm
...82.712 mm
0,50 mm OD Undersize, Grind to .. . ..,. .. .. 82,487 to 82.513 mm
Maximum Service Limit.
82.462 mm
0.75 mm OD Undersize, Grind to.
...82237 to 82.263 mm
Maximum Service Limit.. .. .. . ..
82.212 mm
1.00 mm OD Undersize, Grind to.
.81 987 to 82.013 mm
Maximum Service Limit... . .. .
81.962 mm
Main Bearing Journal Bore lD No Liners....
982 to BB.01B mm
88.031 mm
Main Journal Width:
1 st, 2nd, 3rd Sth . ..
.
. .
. . ....37.4241o 37.576 mm
4th
... ....... ......37.475 to 37.525 mm
Connect Rod Journals Width .. . .. ..38.950 to 39 050 mm
Rac 8-26063
Hevised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2401-9
Camshaft
Bushing Lubrication:
lD of No. 1 Bushing, lnstalled.,...... .........54.107 to 54133 mm
ID of No. 1 Oversize (57.24 mm OD) Service Bushing 54 089 to 54139 mm

Maximum Service Limil 54.'146 mm
lD of No. 2, 3, 4 and 5 Service Bushing ..,.. ........54 0Bg to 54,'139 mm
Width of No. 1 Bushing. . ..... ...........25.15 to 25 65 mm

Width of No.2 3,4 Bushing
and 5 Scrvice 17.751c 18,25 mm
Camshaft Bushing Journal OD . .. . 53.987 to 54.013 mm
Camshaft Bore Diameter in Block
1o..........,.,,.
No. 1 Oversize Bushing, Machine .,.',...57,722 to 57.758 mm
No.2,3,4 and 5, Less 8ushings,.,,.,,.,,,...,.,. ..... ....54'089 to 54.139 mm
No.2,3,4 and 5 Ovcrsize for Bushings, Machine 1o,.... ....,.. . ..57.222 to 57.258 mm
Camshaft Thrust Thickness.......,.,,.,. ... . . .. .. 9.42 to 9 58 mm
Minimum Service Limit " ' '934mm
Camshaft Thrust C1earance,,,........... . . . ..,...0 130 to 0.340 mm
Camshaft Lobes:
Minimum Diameter at Peak 1ntake........... . ... .. .47.265 mm
Minimum Diameter at Peak Exhaust.. ,.... 46.994 mm
Turbocharger
Horizontal Travel of Turbine Shaft 0 10 to 0.16 mm
Gear Train
Backlash:
crankshaft Gear to camshaft Gear " 0 08 to 0'33 mm
...
crankshaft Gear to ldler Gear. "" " 0'08 to 0 33 mm
Camshaft to Fuel Pump Gear ..0 08 to 0.33 mm
ldler Gear to Oil Pun-,p .. .

0 0B to 0.33 mm
Camshafi to Auxiliary.... .,. 0.08 to 0.33 mm

Maximum Service Limit (All Gears) 0.45 mm
Rac 8-26063 Revised 2-92 Prinled in U.S.A
kaukazz@yahoo.co.uk
2401-10
Rocker Arm AssemblY .18.963 to 18.975 mm

OD of Shaft. . . .
18.938 mm
Minimum Service Limit....... '
19.000 to 19.026 mm
lD of Arm Bore,... ..,.' .
19.051 mm
Maximum Service Limit......"."" " " '
Pressure From Oil Gallery
Lubrication . .. .. .
. Down
Shaft Oil Holes
lntake Valve . .0 254 mm

Tappet Clearance (Cotd) .29 Degrees
Face Angle... . .0 038 mm
FaCC HUN-UUI 150mm
Valve Head Edge Thickness, Minimum "" .128 84 to 129.46 mm
Lcngth,,,. 7.960 to 7 980 mm
OD ot Stem 7 940 mm
Minimum Service Limit .. .. . ..
44870 to 45.130 mm
OD of Head 30 Degrees
Seat Argle. .
1.321o 1.92 mm
Seat Contact Width... .. .. .
0.10 mm
Seat Run-Out ... . .. . .. . ..
.... .. . . ...6 84 to 6.96 mm
lnsert Height . .. ....47.063 to 47.089 mm
OD of lnsert. .... Tapered
lD of lnsert ,, 0.99 to 1.52 mm
Valve Recession Below Head Surface " '
'1.52 mm
8.019 to 8.039 mm
lD of Valve Guide Bore ,
8.089 mm
Exhaust Valve 0.508 mm

Tappet Clearance (Cold) 44 Degrees
Face Anglc . .
0.038 mm
Face Run-Out. 1.50 mm
Valve Head Edge Thickness, Minimum 41.8701o 42.130 mm
OD of Head 7.960 to 7.980 mm
OD of Stem ... .. ..
7.940 mm
Minimum Service Limit. '
128.74 to 129.36 mm
Length 45 Degrees
Insert Seat Angle .. .. .... 1.47 lo 2.07 mn
Seat Contact Width . .. . '
0.10 mm
SeatRun-Out... .. ......
6 65 to 6.77 mm
lnsert Height 43.713 to 43.739 mm
OD of lnscrt.. .
TaPered
lD ot lnsert,., .
0.99 to 1.52 mm
Valve Recession Below Head Surface 1.52 mm
Maximum Scrvice Limtt.. '
I019 to 8 039 mm
lD of Valve Guide Bore 8.089 mm
Maximum Service Limit....
Bevised 2-92 Printed in U S.A
Rac 8-26063
kaukazz@yahoo.co.uk
2401-1 1
Valve Springs
Compressed to 38,53 mm .. .. (Valve Open) 785 to 839 N

Maximum Service Limit. ....765 N
Compressed Io 49,25 mm,.,,..,,..,.,., ............. (Valve Closed) 285 to 321 N
Minimum Service Limit... .... , .270N
Valve Seat lnstallation Dimensions

Exhaust Seat
Machine lnsert Bore 1o.,.,.. .,,....,.. . .. .. .43647 to 43.669 mm
lntake Seat
Diameter of lnsert 47.063 to 47.089 mm
Machine Qnra ln 46.987 to 47.0'13 mm
Depth of Bore .. .10 30 to 10.50 mm
Press Fit. 0,05 to 0.102 mm
Valve Guide lnstallation Dimensions

1l mm Valve Guide lnstallation Dimensions
Valve Guide OD 11.150 to 11.'163 mm
Machine Guide Bore to 11.112 to 11.138 mm
Press Fit 0 012 to 0.051 mm
lnstalled Height (above top of valve guide boss on head) 11.25 to 11 ,75 mm
Guide lnstalled lD . 8.19 to 8.39 mm

l4 mm Valve Guide lnstallation Dimensions
Valve Guide OD. .. ....... .14 026 to 14 038 mrn
Machine Guide Bore to. .. ...... ..... .13.987 to 14.013 mm
Press Fit .013 to .051 mm
lnstalled Height (above top of valve guide boss on head)........ .....11.25 to 11,75 mm
Hac 8-26063 Revised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2401-12
SPECIAL TOHQUES
Metric Value
Altcrnator Brackct Bolts (Uppcr) 21 to 27 Nm
Alternator Retaining Bolt." .. ...... 39 to 47 Nm
21 to 27 Nm
Connecting Rod Bolts (Lubricate Threads with Engine Oil) ... . 60 Nm Plus 60 Degrees
Cylinder Head Bolts (Short) . 90 Nm Plus 90 Degrees
Cylinder Head Bolts (Long) 120 Nm Plus 90 Degrees
Fan Pulley Bolts
Grade 8.8 Size M10 51 to 62 Nm
Grade 10 9 Sizc Ml0 51 to 62 Nm
Flywheel tousing Bolts.. 54 to 66 Nm
Flywheel Retaining Bolts. ... . 130 to 144 Nm
Flylvheel Housing Cover Bolts 21 to 27 Nm
Fuel Line Fitting (High Pressure) .. ..22 to 28 Nm
Rac 8-26063 Bevised 2-92 Printed in u.s.A.
kaukazz@yahoo.co.uk
2401-13
Metric Valve
Fuel Line Fitting (Low Pressurc) 22 to 28 Nm
lnjection Pump Drive Gear Nut ... . .59 to 71 Nm
lnlection Pump Lock Bolt (Lock Position).,.. . . .......8 Nm
lnjection Pump Lock Bolt (Unlock Position) .....20Nm
lnjection Pump Retaining Nuts 21 to 27 Nm
lnlection Pump Bracket Bolts. 21 to 27 Nm
lnjector Leak Off Bolt .......5to7Nm
lntake N/anifold Bolts .. .. 21 to 27 Nm
Lifter Cover 8o1ts.............
Main Bearing Bolts. .... .. B0 Nm Plus 60 Degrees

(Lubricate the Thread with Engine Oil)
Oil Pan Drain Plug.... 68 to 82 Nm
r08 to 132 Nm
Oil Pan Heater Plug .
Oil Pump Retaining Bolts 21 to 27 Nm
Oil Filter Housing Bolts 21 lo 27 Nm
Oil Bclicf Valve Plug. . ... 108 to 132 Nm
Rocker Arm Bolts 21 to 27 Nm
Starter Retaining Bolts .... .

39 to 47 Nm
Tachometer Drive Retaining Bolts "" ' 2 to 4 Nm
Rac 8-26063 Revised 2-92 Prinled in U.S.A
kaukazz@yahoo.co.uk
2401-14
Metric Value
Timing Pin Retaining Bolts.. .. .,... .

4to6Nm
Thrust Bearing Screws (Tox Head)
4to6Nm
Turbocharger Mounting Bolts . .... 30 to 34 Nm
Turbocharger Drain Tube Bolts ,.. .
21 to 27 Nm
Turbine Housing Bolts
9to13Nm
Center Housing to Back Plate Bolts
. .5 to 7 Nm
Compressor Housing Bolts
5to7Nm
Compressor Lock Nut (LH Thread) 13 to 15 Nm
Water Pump Mounting Bolts
21 lo 27 Nm
Valve Cover Bolts .......21 to 27 Nm
Rac B-26063 Bevised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
Section
241 5
CYLINDER HEAD AND VALVE TRAIN
6-590 Diesel Engine
IMPORTANT: This engine was made using the metric measurement system. All
Copyright @ 1992
Rac 8-26073 Printed ir. J s.A.
CASE CORPORATION October, 1984 (Revised February, 1992)
kaukazz@yahoo.co.uk
2415-2
TABLE OF CONTENTS
z
SPECIAI_ TOOLS 5
SERVICING THE CYLINDER HEAD AND VALVE TRAIN
Cylinder Head Disassembly. .. .
CHECKING AND RESURFACING THE CYLINDER HEAD .................. I t- I Z
EXPANSION PLUG REPLACEMENT .. . .,, 12.13
VALVE GUIDE REPLACEMENT

14 mm Reolacement Valve Guides .... ......'14
.l
I rnm Reolacement Valve Guidcs
INSPECTION OF THE VALVE AND VALVE SEATS tb- |b
VALVE SEAT INSTALLATION. . 19
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS.. ..
DIAGNOSIS OF DIFFERENT DYE PAITERNS. tz-to

LOCATING TOP CENTER .....37
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE . .. ..... .. ......37-41
THERMOSTAT SERVICE.. ....41-42
Letter G = Thermostat passage in cylinder did not need to be machined.
Letter M : Thermostat passage in cylindcr head was machined.
Letter V = Valve seats have been machined.

Lcttcr X = The cylinders in the cylinder block have been bored overs jze Use a head gasket with oversize cylinder holes
(one notch)
Letter XX = The cylinder block has been refaced and up to 0 25 mm has been removed Use a thicker head gasket (two
notches).
Letter XXX = The cylinder block has been refaced and up to 0 50 mm has been removed. Use a thicker head gasket
(three notches)
Numbers : RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.
Rao 8-26073 Bevtsed 2-92 printed in U.S.A,
kaukazz@yahoo.co.uk
241s-3
SPECIFICATIONS
Engine Manufactured in U.S A
Prior to Engine Serial Number 45511034 ..... . . . ,.,.lnjector Nozzle 9 mm
Engine Serial Number 45511034 and After .. .. ...,,, lnjector Nozzle 7 mm
Engines Manufactured in Darlington England
Prior to Engine Serial Numbe r 2109287a lnjector Nozzle 9 mm
Engine Seria Nurrber 2t092870 and Afte. lnjector Nozzle 7 mm
Engine Manufactured in Neuss Germany
Prior to Engine Scrial Number 52107489 lnlector Nozzle 9 mm
Engine Serial Number 52107a89 and After lnjector Nozzle 7 mm
Cylinder Head
Maximum Warpage 0.010 mm in any 50 mm diameter area or more than
0.075 mm overall end to end or side to side
Maximum amount of material thatcan be removed during resur{acrng.., ., , 1.0 mm
Minimum total height of cylinder head
l4 mm replacement valve gulde
Valve guide OD .14 026 to 14 038 mm
Bore cylinder head to .13.987 to 14.013 mm
lnstalled height above top of valve guide boss on cylinder head ....11.25 to 1"1,75 mm
1i mm replacement valve guide
Valve guide OD 11 150 to 11.163 mm
Bore cylinder head to 11.112 to 1'1 138 mm
Press fit 0 0]2 to O 051 mm
lnstalled height above top of valvc guide boss on cylinder head 1 1.25 to 11 75 mm
Exhaust valve inscrt

Diameter of inscrt 43.713 to 43,739 mm
Diameter of bore 43.647 to 43 663 mm
Depth of bore '10.10 to]0 30 mm
Press fit .. . . .. ..
Intake valve insert
Diameter of insert 47.063 to 47 089 mm
Diameter of bore 46.987 to 47,013 mm
Depth ol bore . . . ..10.30 to 10 50 mm
Bac 8-26073 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2415-4
SPECIAL TORQUES
Alternator Bracket Bolts Metric Value

......,...21to 27 Nm
Belt Tensioner Bolt.
39 to 47 Nm
Belt Tensioner Bracket Bolt (Allen head)
21 to 27 Nm
Cylinder Head Botts (Short)
90 Nm plus g0 Degrees
Cyiinder Head Botts (Long)
.. ..,.... 120 Nm plus 90 Degrees
Exhaust Manifold Bolts
39 to 47 Nm
Fan Belt Pulley Bracket Bolts
23 to 25 Nm
Fan Belt Pulley Bolts
Grade B.B Size MB
.......26 to 3t Nm
Grade 10.9 Size MB
.,.. 37 to 43 Nm
Grade 8.8 Size M1O
..... 5t to 62 Nm
Grade '10
9 Size Ml0.
51 to 62 Nm
Filter inlet Fitting
29 to 35 Nm
Fuei Filter Housing Nut
29 to 35 Nm
lnlector Cap Nut
55 to 65 Nm
Injector Leak Off Fitting
5to7Nm
lntake Manifold Cover Bolts
..21 to 27 Nm
Lilt Bracket Bott (Fear)
71 to 83 Nm
Rocker Arm Bracket Bolts
21 to 27 Nm
Thermostat Housing Bolts
21 to 27 Nm
Valve Cover Bolts
2'1 to 27 Nm
Rac 8-26073
Hevised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2415-5
SPECIAL TOOLS
CAS-1694 9 mm INJECTTON BORE CLEANER

CAS..I743 VALVE GUIDE REAMER CAS-2155 7 mm INJECTION BORE CLEANER
SEE PAGE 15 SEE PAGE 29
(r(riii)
CAS-1066A WHENCH
SEE PAGE 8
CAS-2162 TORQUE ANGLE GAUGE

SEE PAGE 33
kaukazz@yahoo.co.uk
24 t5-o
SERVICING THE CYLINDER HEAD AND VALVE TRAIN
Cylinder Head Removal
STEP 1 STEP 4
Lrft the belt tensioner and remove the fan be t, Remove the beli tensioner bolt and the belt tensioner
STEP 2 STEP 5
Ren'ove the {an pulley bolts and the fan oulley Remove the Allen read bolts and the belt tensioner
bracket.
STEP 3
STEP 6
Remove the fan pulley bolts and Inr-' pu' cy brackc:

Sec sect,or 2465 to'crrove the t-rboci-arger
Rac I 26071-:
qt-'v scr' 2'92 Plrrlod rr J.S.A
kaukazz@yahoo.co.uk
2415-7
STEP 7 STEP 1O
Rcmovc thc bolts that noid the altcrnator and remove Rcrrove thc bolis and the cxhaust manifold
the alternator
STEP 1 1
STEP B ffi
Bernove the leak off frttings, gaskets and tne ieak o1T
Remove the boits and the alternaior brackel iine
STEP 9 STEP 12
Removc the bol:s and the thermostat noustng as- Disconnect and remove the fuel lines. lnstail protective
sembly. covers on the injector pump and the fuel lines.
Rac 8-26A73 Rcvlsed 2-92 Printeo ln U.S A
kaukazz@yahoo.co.uk
2415-8
INJECTION PUMP
STEP 13
the
Disconnect the iniection pump inlet Iine and remove
Looscn thc nut on the inlcctors'
inler line
NOTE: The iniector must not rotate in the bore of
the
the cylinder head.
cylinder head. This will damage CAV INJECTION PUMP
STEP 14
Disconnect the leak off line,
Remove the injectors from the cylinder head STEP 18

from the
NOTE: Make sure the iniector seal is removed
cylinder head.
STEP 15 BOSCH INJECTION PUI'/E
Disconnect and remove the fuel line
ffiffi
Disconnect the injection pump inlet llne and remove
the
inlet line
Revised 2-92 Printed in U'S'A'

Bac 8-26073
kaukazz@yahoo.co.uk
2415-9
STEP 19 STEP 22
Use a strap wrench to ren ove tt e fle'f tte.s. Remove the intakc manrfold bolts and the iniakc
manifold cover.
STEP 20
STEP 23
Remove the fuel filter housino and the inlet fittiho

Remove the rocker arm bolts, rocker arm assemblies
and the cush rods,
STEP 21
STEP 24
Remove the valve cover bolts and the valve covers
Remove the cylrnder head bolts and the cylinder head
Rac 8-26073 Revised 2-92 Printed rn U.S.A
kaukazz@yahoo.co.uk
2415-10
STEP 25
Covcr the cylinder bores and pistons. Clcan all foreign

matcrial from the cylinder head mounting surface
NOTE: The cylinders and pistons must be covered ta

prevent damage lo lhe prslons and cylinder walls
Cylinder Head Disassembly

STEP 28
TB01 61
Put the cyltnder hcad on a clcan work surfacc Rcmove the valve spring retainers and the valve spring
STEP 27 STEP 29
Usc a valve spr ng comoressor to push down the valve Remove the vaive seals
springs and remove the valve keepers.
Rac B-26073 Revisec 2-92 P.inted in U.S.A
kaukazz@yahoo.co.uk
241 5-1 1
STEP 30
ffi
#uHi..
Remove the valves.
# .ffi;
IMPORTANT: Using paint, make a mark on the valves,
keepers and retainers. This will make sure the parts are
installed in the onginal location.
CHECKING AND RESURFACING THE CYLINDER HEAD

STEP 31 STEP 33
rall
IU\ 738
Clean the cylinder head complctcly, removing carbon
and other deposits. Check for cracks and any sign of
damage in the area of the fire ring contact. Resurface the cylinder head in increments necessary to
straighten the surface and maintain surface finish ac-
STEP 32 cording to the following specifications.
iiiii:i:j:ri'ir:
A: 1.0 mm totai amount of material removed.
liiLr: ijliilnB;llirikii itiliil
:' l: rlri,l !!!
i';i:iii,:,:,1:l::ifi$l:,:ll:,irI B= 93.75 to94.25 mm minimum total height of the
cylinder head.
: Surface finish 0 5 to 3.2 micrometers.
D : Use this area to stamp the total thickncss of
cylinder head material removed in mm.
Check the cylinder head surface with a straight edge

and feeler gauge. Resurface the cylinder head if
warpage or erosion is more than 0 010 rnm ln any 50
mm diamcter arca or il there is rnore than 0.075 mrn
ovcrall cnd to enC or sidc to srdc.
kaukazz@yahoo.co.uk
2415-12
STEP 34 STEP 35
Check the bore gauge with a micrometer'
NOTE: tf the diameter is more than 8.089 mm, a valve

guide must be installed
89810
Check the valve guides in three positions with a bore

gauge
EXPANSION PLUG REMOVAL AND INSTALLATION

STEP 36
-"
Rernove the expansron plug from the cylinder head
Clean the sealing surface of all foreign material
Revised 2-92 Printcd in U S A

Rac 8-26073
kaukazz@yahoo.co.uk
2415-13
STEP 38 STEP 39
1. EDGE
Apply Loctite 277 b fie sealing surface of the expan-

sion plug.
lnstallthe expansion plug into the cylinder head untilthe

top edge of the expansion plug is even wjth the boftom
edge of the chamfer.
Rac B-26073
Bevised 2-92 Printed in U.S,A
kaukazz@yahoo.co.uk
VALVE GUIDE REPLACEMENT
14 mm Replacement Valve Guides
There are two drlferent diameters of replacement valve STEP 41
guides for your engine. You can get either 14 mm or 1 1
mmpowrquadplus www.thebestworkshopmanuals.co.uk
OD replacement valve guides. Measure the re- tb'
placernent valve guides before you machine the
sHfis''i
cylinder head.
WI
Specifications
Valve guide OD ........ .. ...... .....14.026 to 14.038 mm I
Bore cylinder head to.,..,..... . ... i 3.gg7 to 14.013 mm
lnstalled height above top of valve
guide boss on cylinder head.,.. .., 1.l.25 to 11.75 mm
STE P 40
1
,'rtii6'{
INDER HEAD
Makc a bushing 16.038 mm lD x 11.25 to 1 1 .75 mm

long. lnstallthe bushing ovcrthe newvalve guide. press
l, the ncw valvc guidc into the cylinder head until the
ts.sez ro 14.013 mm
I Dress contacrs thc bushinq
STEP 42
303191
Drill the valve guide bores to 13 987 to 14.013 mm

diameter,
Drill the new valve guides to a diameter of 8,0 mm.

Ream the new valve guides to a finished diameter of
B 019 to 8 039 mm
Rac 8-26073 Rcvised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2415-15
1 1 mm Replacement Valve Guides
Specifications
Valve guide OD...................11.150 to 11 163 mm
Bore cylinder head to.,,., .... ... 11.112 to 11 138 mm
lnstalled height above top of valve
guide boss on cylinder head.. ..,..11 25 to '11,75 mm
SURFACE OF OF VALVE GUIDE

CYLINDER HEAO
1
'l .25 TO 11.75 mm
_-L_-_t_
Make a bushing i6.038 mm lD x 11.25 to 11 75 mm

long. lnstallthe bushing overthe newvalve guide. Prcss
thc new valve guide into the cylinder head until the
prcss contacts the bushing.
30319 1 STEP 45
Driii thc valve guidc bores to 11 112 ta 11 138 mm
diamcter.
Drill the valve guides to a diameter of 8.0 mm, Beam the

ncw valve guides to a finished diameter of B 0'1 9 to
B 039 mm
Bac 8-26073 Revised 2-92 Pr nted in U.S.A.
kaukazz@yahoo.co.uk
2415-16
INSPECTION OF THE VALVES AND VALVE SEATS
STEP 46
STEP 47 (Cont'd)
56718
NOTE: THIS lS A NORMAL CONDITION'
on the
Small amounts o{ very fine pitting can be found
valves are
surfaces of thc valve face or seat after the
will not change the
cleaned. These are normal and
engine performance. This fine pitting is caused by
noimal oxidation procedure and can occur on any
Do not
Clean the valves with a power driven wire brush the run-in period lt is not necessary to
engine during
scralcn the valve sterrs
griid vatves Jr seats if this fine pitting is found' because
iitting*irf generaliy occur after the engine is run for
STEP 47 several hours.
HEAVY CARBON AND VARNISH DEPOSITS
Check the valves for the followino conditions
VALVE STEM,WITH A NARROW NECK
NOTE: GBIND OR REPLACE THE VALVE

56318 OCCURS,
OCCURS
NOTE: REPLACE THE VALVE lF THIS CONDITION valve guides
This condition is generally caused by worn
go by the
or bad seals on ine vatv"es permitting oil to
This Condition Can be Causcd bY:
ualves Low operating temperature is a secondary
l Valve does not have lubrication'
.ur.. Worn piston rings and cylinder walls will also
2 Bestriction in the water passages' p"irlt too much oil to reach the combustion chamber'
Operating the engine under contrnued overload
at
i
too much engine RPM RUST OR PIfiING ON VALVE STEM
IN VALVE FACE
56818
IF THIS CONDITION OCCURS

/E lF
NOTE: REPLACE VALVE
OCCURS.
qualitY
56418 This condition can be caused bY using bad
keePing the
engine oil or fuel and by not correctlY
NOTE: GRIND OR REPTACE VALVE lF THIS CONDITION
engine in storage.
OCCURS,
This condition can be caused by foreign material

the engine through the intake system or not
"nt"rlng
grving servlce to the air intake system'
aotticnd )-Q2 Printed in U.S.A

Fac 8-26073
kaukazz@yahoo.co.uk
2415-17
STEP 47 (Cont'd) STEP 48
INTAKE VALVES
BUST OR PITTING IN VALVE FACE
7.960 TO 7.980 mm
89910
NOTE: THIS CONDIT|ON CAN BE CAUSED By USTNG BAD
QUALITY ENGINE OIL OR FUEL.
DEEP BURNED VALVE FACE
7.960 TO 7.980 mm
89710
Check the intake valve stem diameter at three points
CONCAVE VALVE HEAD
along the stem lf the stem diameter is less than 7.960
mm, the valve must be replaced.
57018
NOTE: lF EITHER OF THESE CONDTTTONS OCCUR, REPLACE EXHAUST VALVES

THE VALVES.
These conditions are generally caused by running the

engine at very high engine temperatures, grinding the
7.960 TO 7.980 mm
valve face too thin or valve grinding that is not correct.
WORN RETAINER GROOVE
Y# WORN STEM TIP
NOTE: lF EITHEB Or rxede CONDITIONS OCCUR. REPLACE

56918
7.960 TO 7.980 mm
Check the exhaust valve stem diameter at two points as

shown. lf the stem diameter is less than 7.960 mm or
the stem tip diameter is less than 7.g60 mm, the valve
must be replaced.
THE VALVE.
Rac 8-26073 Revised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2415-18
STEP 49
EXHAUST VALVE WTHOUT HEPLACEABLE SEATS
INTAKE VALVES WITHOUT REPLACEABLE SEATS
Put the valves in the cylinder head and check to see if

the valve heads are recessed in thc cylinder head lf the
valve head is recessed more than 1.52 mm below the
cylinder head surface, the valve must be replaced or a
valve insert must be installed to make sure that there is
equal compression ratios between cylinders.
Rac 8-26073 Revised 2-92 Printed in U,S.A,
kaukazz@yahoo.co.uk
z4 t3- tv
VALVE SEAT INSTALI-ATION
STEP 51
t
Machine the cylinder head to the following specifica- Clean the recessed area in the cylinder head. Put the
tions lor valve seats nerrv valve seais in dry ice for a minimum of one hour to
shrink the vaive seats for easy installation. Use a driver
Exhausl Valve Seal Specilications. and install the valve seats,
Diameter of Valve Seai . ..43 713 1o 43.739 mm

Diameter of Bore . . . . .43.647 to 43.663 mm Always wear gloves to prevent frostbite to
Depth of Bore,,,. .. .. .. 10 l0 to 10 30 mm your hands when handling frozen parts.
Press Fit 0 05 to 0 092 rnm SMl 18A
lntake Valve Seat Specifications:

STEP 52
Dia'neter of Varve Sear . .. .47.063 to 47.089 mm
Diarreter o{ Bore..,,..,., ..... .46.987 to 47.013 rnm
Depth of Bore,..,,,,,. . .. .10.30 to 10,50 mm
Prcss Fit ..005to0102mm
Use a center punch and stake the valve seats in three

positions, Grind the valve seats to the correct angle.
Rac 8-26073 Revised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
2415-20
REFACING INTAKE AND EXHAUST VALVES AND
VALVE SEATS
STEP 53
STEP 54
VALVE AND SEAT GRINDING ANGLES

VALVE IDENTIFICATION
DEGR>\+
t\
29
ANGLE \
The 45 degree exhaust valves are smaller 90 DEGREE Vn[Vr

in diameter
than the intake valves.
The 30 degree intake valves are larger in

diameter than
the exhaust vaives.
45 DEGREE VALVE
+s
ANGLE
s
oecnEe \\
t
N
\\".."\\
45 DEGREE SEAT
299191
dimension A and B is iess than 1 .5 mm, the valve must
If
be replaced.
NOTE: Use a precsion seat grinder. Take very light

cuts with the grinding stones so
Tusl enough metat is
removed, to end up with a good smooth seat finrsh.
Rac 8-26073
Revised 2-92 printed in U S.A.
kaukazz@yahoo.co.uk
2415-21
STEP 55 STEP 57
30 DEGREE VALVES
45 DEGREE VALVES
Put a small amount of blue dye on the valve face, lnstall

the valve in the head and rotate the valve on the seat.
STEP 56
57518
Correct refacing of valves and seats will give a dye

pattern as shown.
NOTE: lf the dye pattern is otl'ter than the patterns

shown, checkthe dlagnosis of differentdye pattems on
the following pages.
Remove the valve and look ai the contact area on the

valve face and seat. The blue dye will be gone from the
valve face where the valve made contact with the seat.
kaukazz@yahoo.co.uk
Bac 8-26073 Bevised 2-92 Printed in U.S.A.
2415-22
DIAGNOSIS OF DIFFEBENT DYE PATTERNS
45 Degree Exhaust yalyes
IF THE YALVE OS{'ACT AREA ON T}IE .....> USE A
'I5
DEGHEE S'ONE TO LIFT AI{D .-+ USE A A USE A 60 OEGHEE S?ONE 70 }TARBOW .....> CHECK THAT THE VALVE HEAD tS NOT -.+ IF THE VALVE HEAD tS RE.
SEAT LOOrS UG ?HrS (A" SEAT rHA? TO MATE rlDE*, TTIE CO}TTAST A*ET flG L( THE LOWER CONTACT AREI, II{. RECESSED ilOhE THAX l.S2 mm, BE- CESSED IIORE THA|{ 1.SZ mm,
HAs AEEN CBOTITO). cFElsE CREASED AY ?HE i|s DEGREE s?oTiIE. LOW THE CYLINDER HEAO SUHFACE. REPLACE THE VALVE AHD II{.
STALLA YALYE SEAT..
SEAT COI{TACT AREA ON TIIE YALVE

TO L'Oy
IF THE VALYE C@ITACTINEA Oil ?HE '....> usE A rl5 DECREE STOIIIE TO LFT Tl€ + USE I o USE A 60 OEGREE STOilE TO TIFT AI{D .* CHECK TIIAT Tt{E VALYE ttEAO tS XOT .....r, tF ?HE VALVE HEAO tS
SEAT LOOXS LI(E ?HIs. COilTACTABEI. }IAf,BOI I'IARROW ?HE LOWER CON"AC? AREA RECESSEOHORETHAT{1S2mrrBELOIy CESSED llORE THAx ts2 ari,
RE-
THE CYLI}{DER HEAD SURTACE. FEPLACE THE YALVE AND IN.

STALL A YALVE SEAT.
N
IF THE YALVE CilTACT AREA Oil THE ..+ USE A iIs DEGREE STO}IE LOSER +usE a3 USE A 3O DEGREE STO}IE TO I{IRROW
-...r' CIIECX THAT THE YALYE HEAO tS XOT
SEAT LOOKS Lre THIS (A SEA? AilD ?O XAI(E WIOEB, THE"O
COfiTTfi TlrE rI rHE UPPER COT{TACT AREA. IX. RECESSED IORE THlil 1E:t mm, BE- -..> lF Tl{E YALYE HEAD tS RE-
"HA? CREAS€ CBEISED BY THE {5 DEGBEE S"ONE. CESSED HORE THAN 1.5Z mllr,
LOW THE CYLI}IOER HEAD SU*rACE. REPLACE THE VALYE AI{D }X.
STALL A VALYE SEAT.
8ETT COi'TACT AREA OII ?Hg VALYE

lIclr
N
TOO
IF THE VALYE OilTAC? AREA OX ?TIE THE YALVE 5.ET BE REDLACED AI5 A
SEAT LOOXS [.reTHrS. YALYE SEAT N.}ST BE IXSTTIIED B=.
Ctt.E€ IORE GBI}EING wlI.L IF"
cfi lrcE TIE LonEe cox?AcrPort{T-
kaukazz@yahoo.co.uk
Rac &26073 Her/ised 2-S2 Printed in U.SA

2415-23 2415-23
!F ?HE YALVE CO'I?ACT ANEA OII THE -....,.)' USE A its DEGREE S?ONE TO FTCFEASE '+ cHEcK TltA? THI 'EASE C}IECT THAT THE YALYE HEAD IS TIOT + CIGCIIHITTHE YILYE IGID
sEA? LOOr(S L|KE TH|S (A SEIT THAT THE COHTACT AAEA RECESSED IIORE
HAS BEEil GROUI|O.) ?HE CYLIXDER HI
RECESSEO HORE THAN 152 .lmt SEIOY l TO'ECASS€DrcTHAT
t5lr.REPTICETICV LE
ffin ATD llsTAUAVALTESCAI.
SEAT CO}I?AC? AREA ON THE VALVE

TO trlARROl[
ffi
I
I
IF THE VALYE COT{TAC? AREA OH T}IE ....+TI{E YALVE iiUST SE FE.

YALVE SEAT LOOTS UKE ?HIS. PLACED AND A VALVE SEAT IN.
CO}ITACT AREA STALLED BECAUSE
( TTORE
GRi}IOIIIG WILL }IOT CHINGE
THE LOY'EB COXTACT AREA
IF THE VALVE CONTACT AHEA Oil ?HE A 30 DEGREE S"ONE TO LOWER .....+
SEAT LOOrS Ll(E THIS (t SEAT THAT
-..>USE
tHE UPPEB CO||TACT ABEA.
t,{iE A 00 DECFET }WER .r...> I'S€ A 60 DEGREE STONE TO LIFTTHE -+C!GEI ?HA?THEYILYE lGrrD lS llOT +IF THE VILYE HEAD IS RE.
LOWER CON?ASI
LOSER COI{TAC? REA. RECES3CD IOSE nql 152 n, BE CESSED IJ|OBE TI{AN 1.52 nm,
Lfr TIG g'U}TDER }CTD g.ffTCE. REPTJCE THE YALYE AHO I}I.
ffi S?ALL A VALT'E SEAT.
ffi
ry
SEAT COIITACT ABEA ON THE YALYE
TO lf,lDE.
IT YHE YALYE COITACT AHEA OI{ THE -..+USE A 30 DEGREE .....>usE A 00 DEGBET
SEAT LOOXS LIIG THIS.
STOXE TO LOWEB IWER ....+US€A 60 DEGREE STONE TO UFT?}IE ..+CIGCTfl{ATTHE YTLIE IGAD }S IIOT +F THE YTLYE HEAD IS iE.
TTIE UPPER COilTACT IREA LOUEB COT?ACI
LOSER CON?AC?AREA RGCESSE rcAE Ttlri I5I N EEOI CESSCD IOBE rHrX 1.52 mn.
COXTAC? AREA
TIG E}I,.FEN HEAD g.FTCE FEPTTCE YALYE A}ID I}{.
'HE SEAT.
S?TLL AYTLVE
-
EEn290AJ
kaukazz@yahoo.co.uk
Rac &,26073 Bevised 2-92 ' Printed in U.S.A.

in U.S.A.
2415-24
IF ?HE YALVE GOI'TACT AREA O'{ T}IE ...+USE A 30 DEGBEE STONE TO TAX= +I'SE A !5 DEGRS \ T5 DEGREE STONE TO LOIYEB -...}C}IECX THAI THE YALYE I{EAD IS HOT .-} IF THE YALVE HEAD IS RE-
SEAT LOOXS L|XE ?HrS (A SEAT rHA? WIDER AXO TO LOTER TI{E COI|?IGT THE UPPER COITII PPER COiITACT AREA. RECESSED TOEE THAil,J2 mln EELOW CESSED HORE THAN I.52 mm,
AREl. THE CYUIIIOEB TEAO SUNFACE. REPLACE TTIS YALVE AND IT{.
STALL A VALVE SEAI.
SEAT CONTAC? AREA OT{ ?HE YALYE

TO Htclt.
IF THE VALVE CO}I?AC? ABEA O}I ?HE -.+ THE VALYE HUST BE REPLJTCED ttI!}T + IFIHEVALVEHErl I IS BECES8ED IIORI
YILVE HEAD
SEAT LOOKS LIXE ?H'S. VALYE SE^T INSTALLEO BECIUSE TltAr{ 1.s1 arE, t 15l! nlt!,
REPLACE THE YALVE
uoBE G8lltotilG $ill, ror cHArcE AfiO tNs:rillAY/ }TS'ALL A VALVE SEAT,
THE LOWEB COiltrCT FO|XT.
IF THE VALVE COT{?AS? AREA O}I T}tE .....> USE A 30 DEGREE STOXE ?O HAxE +CHECX tHlTTl€ I THA" T}TE VALVE HEAD IS IiIO?
8€ T LOOXS L|XE Tt{tS {A SEAT TI{AT IYIOER fHE COilTACT AREI. FECESSED TORE] XIED IIORE Tl{At{ 152 mm BELOW
T}* CYUIIDER }E YUTTIDER HEAD SUNFACE.
SEA? COffiAC? AREA Oil TI{E YILYE

TO XARROW
CO}I?ACT AiEA
IF T}IE YALYE COilTTC? AREA O'{ THE ....+ TltE YALVE IUST BE REF!-iCED Axg I
SEAT LOOXS Lt(E TlilS. YALYE SEAT |HSTALLED SECTUSE
UORE GBI}{OIXG WTLL t'O? CHTilGE
?HE LOUER COIfTACT POIITT.
kaukazz@yahoo.co.uk
Rac &26073 Revised 2-92 Printed in U.S.A.

2415-25 2415-25
THIS tS THE CORREC? SEIT COttlAC?..+?HE CORFECT ETHIUST VIwE COx- .r.{> -.+,I OEGHEE ffTERFEB€NCI ....+ .I OEGFEE II{TERFERE}ICE .....COflN8CT BEFAC]G OF ....+ IF
AREA O}I TTIE VALYE. TAC? AREA O}l THE SEAT WILL GIYE A AT{GLE EXHAUST TTIE VALVE HEAO !S BE.
YAIYES AT'E YALUE S€ANS TILL GIYE A CESSED ilOAE TXAN 1.52 mm
SErf ltrlDff OF 1.4? TO zO? mtn.
1 DBBNEE I}'TERFESE''CE ANGLE. ?HIS REPLACE ?HE VALYE AilO !I{.
AllGlI IS ITPOBTAIIY 3ECAUSE THE STALL A YALYE SEAT.
ilGll GIYES ASSEiTTXC€ ila CUTnllG
C,rmfi AlE TO SATTHE YALYES.
30 DEGBEE INTAKE VALVES ONLY

IF THE YALYE COITTACT ABEA OTI ?HE !{> USE I30 DEGREE STOilE TO UFT AIIO .....t- USE A'15 DEGREE OR 60DE A}IO -.+ USEA'OSDEGREEOR6ODEGREESTO}IE .+CTGCTTHATTHEYILYE IGAD ls ilOT r.r{> IF THE VALVE HEAD IS
SEAT LOOKS Ut(E TH|S (A SEAT ?!tlT IiAKE flDEB THE COI{TAC? AREA ?O RE.
HAS BEEI{ cROUt{D). "O
T{ARBOIY TI{E LOY'E REA TO I{ARROYI T!{E LOWER CONTACT RECAIS@ IORE il{rX 151 lrgtt BE- CESSED MOiE THAN T52 mm
AREA INCREASED BY THt AREA INCREASEO 8Y THE 30 DEGREE L(il nc cnuilDa IGAD straFAcf-
sToilE. REPLACE ?HE YALVE AND II{.
sTotlE. S.rALL A VALYE SEAT.
ffi
ffi
IF ?XE YALYE CO'{TACT AREA OI* A 30 OEGRES S?OilE TO LFI ?HE USE} 4SDEGEEEOR60DE .T}IE
USE } DEGNEE OR 60 DEGBEE STOilE +C}ECT THAT ?HEYrlYE}CAD IS I}O' _.> IF TI{E VALVE HEAD IS
SEAT LOOI(S LII(E THIS. 'ITE ->USE
CO}ITACT AR€T TO il.\RfiOW THE LOUE 'I5
TO II.\RROW THE LOIYER COXTACT ECESSCD IORE THAI t.5I r't
BELOU CESSED HORE THAN 1.52 mm
RE.
AREA" AREI" T}IE gN.rcEN HETD SINFACE REPI.ACE THE YALVE AT{D '
ffi STALL A YALYE SEAT.
ry B(A2910.J
kaukazz@yahoo.co.uk
Rac &26073 Hevised 2-92 Printed in U.S.A. I in U.S.A.

2415-26
IF ?HE VATVE Co|TACT AREA OT THE -+ USE A ,5 DEGREE STONE TO LOI?ER "+USEA/Is JSEA45 DEGREE OR SODEGBEESTOHE
-...>CHECX tltA? THE VALVE IIEAO !S
SEAT LOOXS utc THls (A SEA' THAT Y}IE UPPER C1ONTACT iRFd TO LIFT rO LIFT ?HE LOWER COI{TAC? AREA" IraO? THE VALYE HEAD IS RE.
RECESSED ilOnE THA'{.t.52
?HE CYLIHDER HEAD SURFACE.
nim BELOW ->IFC€SSED ilOAE TI|AN 1-92 n,'r
REPLACE ?I{E YALYE IND ITII.
STALL A VALYE SEAT.
$EAT COXTACT AREA O}I TNE VALYE

TO WroE N
IF ?HE VALVE CSITACT AREA 03{ TH€ "..'>USE A 15 DgGeEE STOXE TO LosER .+USEA+ JSEA45 DEGEEE OR OODEGRTESTOI{E
?HAT IHE VALYE }IEAO IS ilOT
YALYE SEAT LOMi LlxE THIS., THE UPPEE COilTAC? AREI. TO LIFT rO LFTTHE LOT'EB COilTACTABEA.
->CHECK lF THE YALVE I|EAO tS HE
RECESSED IIORE ?HtI{ t.52 rnm, BE- -+ CESSED mOeE THAi{ .t.52
LOW?I{E CYLIUDEN HEAD SUNF^LE. mm,
EEPLACE THE VALYE ANO III.
STALL A VALVE SEAT.
N
THIS IS THE CORRECI SEAT COXTACT TI{E CORRECT VALYE COIITACT AREA rrrrr..} 1 DEGNEE NTEBFEBENCE A}IGLE +coBeEr ,.ORRECT RETAc|NG OF THE II{TAIG
VALYE IALYE AI.IO VALVE sEA?
ANEA OX THE YALYE. OT{ T}IE SEAT WI,LGIYEA SEATWID?H r WILL GIVE A I
OF 1.32 TO l.*l il. OEGBA }EGREE IilTEHFERETTCE AIiIGLE. THIS
ANGLE THGLE IS ITIPORTAilT SECAUSE I?
GIYES J irvEs ASSTS?A}|CE tN cuTnilc cA8-
BON AT ION AIIU TO SEAT THE VALVES.
890291 tJ 10J
kaukazz@yahoo.co.uk
Bac 8-26073 Revised 2-92 Printed in U.S.A.

2415-27
Cylinder Head Assembly
STEP 58 STEP 60
1. LETTEB V
If you grind the valve seats, mark the cylinder head with
the letter "V"
STEP 59
i.i:i,,'t>i;t:r lJ.ct., ."' -@ T: T80171

Apply lubrication to the valves. lnstall thc valves in thc
1. i/ABK cylinder head.
90410
lf thc cylinder head has been machined, mark the STEP 61

amount removed on the RH rear corner of the cylinder
head
IMPORTANT: Do not machine more than 1.00 mm

from the cylinder head. The head height must not be
/ess Inan 93./b mm.
install new valve seals,
STEP 62
Chcck the valvc springs ivith a valvc spring tcster Thc

springs musl havc thcsc spccifications.
Free Lengrh 55 63 mm
Outside Diameter 33 81 mm
Wire Diameter.,.,..,.,.,.....,... .......4.88 mm
Number of Coils .. . .
Compress to 49.25 mm,.,,64 to 72lb (285 to 321 N)
Rac 8-26073 Bevised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
2415-28
STEP 63 STEP 65
ru'!r;;
ffi,
ffi ##r{ffi
lnstall the valve springs and the valve spring caps Remove the spring compressor and hit the end of the
valve stems with a soft hammer to seat the valve
keepe rs.
STEP 64
STEP 66
Push down the valve springs with a spring compressor.

lnstall the valvc keepers,
Clean the inlector bores with a bore cleaner. Early pro-
NOTE: Nways rnstall new valve keepers when new duction engines have 9 mm injectors and the late pro-
valves are tnstallecl ductjon engincs nave 7 rnrn inlectors See the following
illuslralrorr
[.rsc a CAS 1694 inlcclor Dorc cleaner for hcads that
have 9 nrrr inleclors
Use a CAS-2'1 55 inlector bore cleaner for heads that
have 7 mm inlectors.
307191
7 mm DIAMETER TIP 9 mm DIA[.4ETER TIP
Rac 8-26073
Bcvised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2415-29
Rocker Arm Disassembly
STEP 67 STEP 69
)4,
)ffi-@
305191
Remove the snap ring, washer and rocker arm from the Measure the rocker arm with a bore gauge in three dif-
shaft. ferent locations around the bore.
STEP 68 STEP 70
Use a micrometer and measure the rocker arm shaft for Use a micrometer to measure the bore gauge, If the
out of round. Measure three different iocations around diameter of the bore is more than 19.05 mm, the rocker
the shaft, lf thc rocker arm shaft is Ie ss than 8,938 mrn
'1
arm must be replaccd.
in diametcr, the rockcr arm shaft asserri-Jiy must be re-
placed
Fac 8-26073 Revised 2-92 Printcd in U.S.A
kaukazz@yahoo.co.uk
241 5-30
Rocker Arm AssemblY
3. ROCKER ARM
5. ROCKER ARM
t 6. wASHER
-/
4. ROCKER ARM SHAFT
@
{'-^':::
arm
with the lnstall the washers and the snap rings on the rocker
lnstall the rockcr arm on the rockcr arm shaft
cnd as the large hole in shaft.
udjrtting screws on the same
the bracket
Revised 2-92 Printed in U S A'

Rac 8-26073
kaukazz@yahoo.co.uk
2415-31
Cylinder Head lnstallation
STEP 73 STEP 75
Use the correct tap and clean all head bolt holes of lnstall the cylinder head
foreign material
STEP 76
STEP 74 1. RUST OR PITTING 2. NARROWING
Y M".'"'"'
tl
EE
t=
t=
ti
bi r=
E'5
Check all cylinder head bolts for rust or pitting, corro-

Install the correct head gasket on the engine block, sec sion and narrowing, if any of these conditions are
below. present the head bolt must be replaced,
9ncnJ
STEP 77
:1l:l
\/ \ l
c\--,/ol
o
1. NOTCHES
,/
90s10
2. MAXIMUM LENGTH
Head Gasket Application
'1 Notch - Replacement Gaskct
2 Notches - 0.25 mm oversize thickness
3 Notches - 0 50 mm oversizc ihickness 91 7191
Use the bolt length gauge to check the length of the

IMPOHTANT: Oversize thickness gaskets are used head boits. Use the correct slot to check the bolt length
where the cylinder block has been machined. if the bolt length is maximum the bolt must be replaced
IMPORTANT: Each bolt length must be checked

before installation.
kaukazz@yahoo.co.uk
t4 t1-JZ
STEP 78 STEP 81
91 7191
Put a small amount of clean enginc oil on thc hcad bolt Use thc bolt length gauge to check the length of the
head bolts Use the correct slot to check the bolt length
threads tighten the bo ts a small amount
if the bolt length is maximum the bolt must be replaced
NOTE: Do not torque the head bolts at this time

IMPORTANT'. Each bott length must be checked
STEP 79
STEP 82
lnstall the push rods in ihe cylrndcr head

Put a small amount of oil on thc thrcads of the rocker
STEP 80 arm head bolt
lnstall the rocker arm assemblY
Revised 2-92 Printed in U.S.A

Rac 8-26073
kaukazz@yahoo.co.uk
2415-33
STEP 83 STEP 85
@ r@ /o /@ {@
@o@@@
@- @ o @ @ @
ghtcnn
Tiigh thc rockcr shaft bracket bolt to a torquc of 21 io
z Nnr.
2 7N I.
S TEP)86
B r,,
st
:x
?i
Tighten the cylinder head bolts to the correct torque,

following the torque sequence shown above
Usc thc following steps to get the correct torque,

.1
Step - torquc to 4.1 Nm
Step 2 - torque to 90 Nrr
Step 3 - torque bolts 6, 3, 14 11 ,22 and 19 to i 20 Nm
lnstall the intake manifold gasket and the intake man-

STEP 84 ifold
STEP 87
lnstall the torque angle gauge. Position and lock the

holding rod, Turn the pointer to 90 degrees. Tighten the
bolt until the pointer is at 0 degrees,
Put loctite liquid teflon on the intake manifold bolts
Rac 8-26073 Bcvlscd 2 92 Printed in U.S.A
kaukazz@yahoo.co.uk
2415-34
STEP 88 STEP 90 BOSCH INJECTION PUMP
BOLT TORQUE SEOUENCE
lnstall the inlection pump inlet line and tighten the inlet
tube nut.
STEP 91 CAV INJECTION PUMP
Installthe intake manifold bolts and tighten to a torque

of 21 to 27 Nm following the torque sequence shown in
the rnset.
STEP 89
Connect and tighten the leak off line
STEP 92 CAV INJECTION PUMP
lnstallthe rear Iift bracket bolts and tighten to a torque of

71 to 83 Nm
lnstall tne injection pump iniet iine and tighten the inlel
lrne
Rac B-26073
Fevised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2415-35
STEP 93 STEP 96
Install thc filtcr outlct fittinq and tightcn thc fucl ortlct lnstall thc lift punrp outlet tube
fittlng to a torque of 21 to 27 Nm
IMPORTANT. There must be a gasket on each srde of STEP 97

the tube.
STEP 94
install the gaskcts and fitting. Tighten the filter inlet

fitting to a loroLre of 29 to 35 Nm)
IN4PORTANT'. There must be a gasket on each side cf

Ins:allihe filter inlet tube lnstall a new o-rrrrg on the filter the inlel tube
housing and install tnc filtcr housrng
STEP 98
STEP 95
Conrect and irghten :he outlet tube to the lifl pump

install the {ilter housrng nu: and iighten tc a lorquc ol 29
to 35 Nm
Bac 8-26073 Revised 2-92 Prr:ied n U S.A
kaukazz@yahoo.co.uk
241 5-36
STEP 99 101
For correct fuel filter installation see the fuel filter Install the thermostat housing assembly and bolts
scciion. Tighten ihe bolts to a torque of 21 to 27 Nm.
STEP lOO STEP 102
4 LIFT BMCKET +
1. THERMOSTAT HOUSING 298191
J:1;
Assemble thc thermostat housing.
NOTE: See Page 41 to check the diameter of the ther-

mostat openrng in the cylinder head.
lnstall the manifold, bolts and gaskets on the cylinder

head Tighten ihe bolts to a torque of 39 to 47 Nm follow
the torque sequencc shown abovc.
Rac B-26073
Rcvised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2415-37
LOCATING TOP CENTER
STEP 103 STEP 104
Remove the plug and install the engine turn over tool While turninq the engine with the turn over tool, push the
into the flywheel housing. Turn the engine over four re- lock pin ln. When the lock pin moves into the camshaft
volutions to make sure the push rods are seated cor- gear the engine will be at top center.
rectly
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE

Cold Setting
STEP 105 STEP 106
Check and adjust the intake and exhausl valves as the

arrows show below.
FAN ->-
6 5 4 3 21
E E rEt
nJ
I
6O m-,,fr
tffi€il//
@t9.@ M ffi M ffi#r ffi#
+ + + +++ <aat o
Number one cylinder top center compression stroke lnstallthe engine turn over tool. Move the engine a small
amount in cach dircction Pull the lock pin out. Turn the
Valve Clearance, Cold. Intakc Valves - 0 254 mm engine over one complete rcvolution.
Exhaust Valves - 0 508 mm
Bac 8-26073
Rcviscd 2-92 Prinlcil r' ;.S.4
kaukazz@yahoo.co.uk
241 5-38
STEP 107 STEP 109
7 mm DIAMETER TIP 9 mm DIAMETER TIP

30719 1
lnstall the plug rn the flyrruheel housing. Beforc you order new injectors or seals, you must deter-
minc which injectors were installed in your engine. See
Page 3 for engine serial numbers.
STEP 108
STEP 110
Check and adjust the intake and exhaust valves as the

arrows show below
Put new seals on the injectors and install the injectors
FAN +E-
654321 STEP 111
IE
Mffiffiffiffiffi
++ ++ ++
Number six cylrnder top centcr comprcssion stroke
Valve Clearance, Cold: lntake Valves - 0.254 mm
Exhaust Valves - 0.508 mm

Tighten the injector nut to a torque of 55 to 60 Nm
Rac 8-26073 Rcviscd 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
2415-39
STEP 112 STEP 115
lnstall the leak of{ line, fittings and gaskeis Tighte n the lnstall the alternator bracket and tightcn the bo ts to a
fitting to a torque of 5 to 7 Nm torque of 2l to 27 Nm.
STEP 1 13 STEP 116
lnslall lhe injector lrrrcs Connect artl irgrr:Cn lile lnstall lhc altcrnator and tightcn the bolts
inlecior rncs to ihc rn,cci0rs ancl lhc rnlct lOr Pr..lmD
STEP 1 17
.14
STEP 1
lnstaii tlre fan belt pullcy bracket and tighten the bolts to
lnstall thc brackct and iightcn a iorque ot 23 lo 25 Nm
kaukazz@yahoo.co.uk
2415-40
STEP 118
Allen Lift the belt tcnsioner and install the fan belt'
lnslall the belt tensioncr bracket and tighten the
head bolts to a torque ol 21 to 27 Nm
STEP 122
STEP 119
To install the turbocnarger, see section 2465 in the

service manual.
lowtng:
Grade 8.8 bolts Size MB . ..25 to 31 Nm STEP 123
Grade l0 9 Size NllB ... .. .....37 to43Nm
Starl and operate the engine' Check the engine
oil
51 to 52 Nm
Gradc 8 8 pr..rrr. indicator :o make sure of correct engine oil
to make sure that the
Graoc 10 9
51 to 62 Nm br."==rr.. Check the rocker arms
arms are rccciving oil.
STEP 120
STEP 124
to a torquc
lnstall the bclt tensioner and tighten the bolt
oi 39 to 47 Nm
lnstall new gaskets on the valve covers'
Bevised 2 92 Printed in U S A
Rac 8.26073
kaukazz@yahoo.co.uk
2415-41
STEP 125
lnstall new seals the valve cover bolts Tighten tne bolts
to a torque of 21 to 27 Nm.
THERMOSTAT SERVICE
STEP 126 STEP 128
.:__
i;.-..r0 i\
c..i
f
L !a I
lo
1, NEW THERIVOSTAT 2. OLD THERMOSTAT 0
30919 1 0,)
A new thermostat has been released for use in your \
engine, lf you removed an oid thermostat frorn your
engine, do the following steps to install a new ther-
mostat. 31 0191
lfthc cylinder head coolant passage is smaller than the

lD of the template, the coolant passage will have to be
STEP 127 made larger. Mark the ID of template on the cylinder
\}.rl t/ hcad
t'-
1 STEP 129
S
g
n
)J rl
r\.
-a tl
I 1l
r=l
lllf\')r I
I
I
31 1 191
lnstallthe template that comes with the new thermostat

kir
31 2191
Remove the template, Use a shop cloth in the coolant

passage to keep all foreign material out of the engine.
Usc a rotary grinder to remove the material.
kaukazz@yahoo.co.uk
2415-42
STEP 130 STEP 131
31 4191
31 3191
Remove all foreign rnaterial from the cylinder head. Mark the cylinder head on the intake side next to the
lnstallthe scal and new thermostat Tighten the bolts to serial number as follows:
a torque of 21 to 27 Nm
Stamp the letter "G" for cylinder heads that were rn-
spected and did not need to be machined
Stamp the letter "M" for cylinder heads that were mach-
ined.
in design or
NOTE: The casE coRpoRArloN reserves the right to make improvements
in specifications at any time without incurring any obligation to install them
changes
on units previouslY sold.
Bevised 2-92 Printed in U.S.A

Rac 8-26073
kaukazz@yahoo.co.uk
Section
2425
CYLINDER BLOCK
Crankshaft, Pistons, Rods, Sleeves, Camshaft,
Bearings, Seals and Flywheel
6-590 Diesel Engine
IMPORTANT: Thts engine was made using thc metric measurement system. All
Coovrioht O 1992
Rac 8-26084 Drinted in U.S.A.
CASE CORPORATION October, 1984 (Bevised February, 1992)
kaukazz@yahoo.co.uk
2425-2
TABLE OF CONTENTS
SPECIFICATIONS,
4-5
SPECIAL TORQUES
6
SPECIAL TOOLS
7-8
SERVICING THE ENGINE BLOCK
Front Oil Seal Beplacement ,,, ,.
Rcar Oil Seal Replacement..,.. . . .
Front Oil Seal and Wear Sleeve lnstallation
Rcar Oil Seal and Wear Sleeve lnstallation

10_).)
Removal of pistons and Rods
23-24
Cylinder Wall lnspection .. .
.25-28
RECONDITIONING THE CYLINDER BLOCK
Checking and Resurfacing the Cylinder Block
)o
Reconditioning the Cylinder Block for Oversize Prstons
. .30
Reconditioning the Cylinder Block for Slccves
21 ,2.C
Piston and Connecting Rod Disassembly and lnspcction

1' DE
Piston Assembly. . ..
35-39
REPLACEMENT OF MAiN BEABINGS WITHOUT REMOVING
THE CRANKSHAFT
Rcrroval.,
.. . .40
lnstailatior,
4A-42
CRANKSHAFT AND MAiN
Rcn:oval .,
43-47
Gear Bemoval..
47
lnspection
Gear lnstallation, .,..

..50
lnstallation
ql _(o
CRANKSHAFT RECONDiTIONING
Crankshaft ldentlf ication
49
Machining a Crankshaft
49
Crankshalt Rehardening
49
Rac 8-26084
Revised 2-92 prinled in U.S.A
kaukazz@yahoo.co.uk
t4z3-J
CAMSHAFT
Bore lnspection
Disassembly and In spection
Gear lnstallatron.. ... .. . 65
Instaliation b5-b5
FLYWHEEL
Removal.,. .68
Ring Gear Removal and Installation.... . ..... 69
lnstallation bv
EXPANSION PLUG BEMOVAL AND INSTALTATION

60 mm Expansion Plug, Camshaft 70
58 mm Expansion Plugs . ..... .. .. . 71
7D
26 mm Expansion Plugs . .
22.5 mm Expansion Plug ,

73
l8 mm Expansion Plugs. . 74-75
10 mm Expansion Plugs. .
75-76
CRANKCASE PRESSUNE CHECK (BLOW BT
Manometer Removal
Bac 8-26084 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2425-4
SPECIFICATIONS
CYLINDER BLOCK
102.00 to 102.04 mm
102.116 mm
0 038 mm
Cylindcr Out of Round (Maximum)
0.076 mm
Cylinder Taper (Maximum) , ,

.102.40 to 102,44 mm
Machine Cylinder Bore to
.102 50 to 102,54 mm
Hone Cylinder Bore to (Finished Diameter)
1 .00 mm Overstze Piston
102 900 to 102.940 mm
Machine Cylinder Bore to ....,..,..
.. .... .103.00 to 103 04 mm
Hone Cylinder Bore to (Finished Diametcr)
Waroage (Maximum) '. ..
0 075 mm
,.,,, ...0.50 mm
Maximum Material Removal ... .
CYLINDER SLEEVE
104 485 to 104 515 mm
Machine Cylinder Block Bore to ,, ,.
Machine Cylinder Sleeve Bore to.,. .
. .....101 90 to 101 94 mm
102.00 to 102.04 mm
Hone Cylindcr Sleeve Bore to (Finished Diameter)
PISTON
Cam Ground
Type
. ..,..Aluminum AlloY
Material
AD aI12 mm from the Bottom, 90 Degrees Piston Pin
101 873 to 101.887 mm
Standard Sizc Piston 101 823 mm
Minimum Service Limit .
ioi iii
," 102 387 mm
0.5 mm Oversize Piston..
102 323 mm
Minimum Service Limil
1.0 mm Oversize Piston...,,,.,
.
.
. . 102.873 to 102 BB7 mm
102 823 mm
Maximum Servtce Limit .....
40.006 to 40.012 mm
lD ot Piston Pin Bore. . ,.
40 025 mm
Maximum Service Limit . . .. .
2.465 lo 2 485 mm
Wrdth of lst Rrng Groove (ToP)
2.4251o 2.445 mm
Width of 2nd Ring Groove (lntcrmcdiatc)
4.040 to 4 060 mm
Wldth of 3rd Ring Groove (Oil Bing) 0.660 mm
Protrusion Above Cylinder Block (Maximum)
PISTONS RINGS
No, 1 Compression
.025to055mm
End Gap in 102 02lD CYlinder
0 806 mm
Maximum Service Limit . . .
0.075 to 0 120 mm
Side C1earancc ..,,,.....,,....
. 015 mm
Maximum Service Limit .
No, 2 Compression
....0.25 to 0.55 mm
tro Gap i:102a2lD CYlinder
0,806 mm
Maximum Service Limil .
0.075 to 0,120 mm
Side Clearance . ... .. ...., 015 mm
Maximum Service Limtt .
No 3 Oil Control Ring .025to055mm

End Gap in 102 A2lD CYlinder
0.806 mm
Maximum Scrvice Limit . .
0.660 mm
Protrusion Above Cylinder Block (Maximum)
PISTON PIN
39.997 to 40.003 mm
OD of Pin .
39 990 mm
Minimum Service Limit,
Reviscd 2-92 Printed in U.S A

Rac 8-26084
kaukazz@yahoo.co.uk
2425-5
CONNECTING ROD
Bushing tD tnstalted . .. . .......40.0sS to 40.067 mm
fimit .
5;,H:,:H:;:l;;;;;:;
Maximum Service .
g'":'ffi ;,fiij:j3,liinn
Connecting Rod Bolt Maximum Length 59.25 mm

CRANKSHAFT
..,..
Crankshaft End Clearance.......,,,.
.. ..I.131to 0.264 mm
Center Main Bearing Thrust Surlace Thickness .....,.2.50 mm
Connecting Flod Journal Standard OD.. .......... ... ...68.9g7 to 69.013 mm
Maximum Service Limit...,......... ... 6g.962 mm
0.25 mm OD Undersize, Grind to............ . .
..68.737 to 68.763 mm
0.50 mm OD Undersize, Grind to ., ,..,. .., .,. ...68.487 to 68.513 mm
0.75 mm OD Undersize, Grind to . .. . , ,
...68.237 to 68.263 mm
100 mm OD Undcrsize Grind to.,.. .. .,,.,,.,, .........67.987 to 6g.013 mm
Connecting Rod Journal Maximum Taper...,,..,,,. ,..0.013 mm
Connecting Rod Journal Out of Round Maxrmum
.... ...0.050 mm
Main Bearing Oil Clearance .0.041 to 0.1i9 mm
Maximum Service Limit.. . .. ..0 140 mm
Main Bearing Journal Standard OD
82.987 to 83.013 mm
Maximum Service Limit.. .... ....g2.962 mm
0 25 mm OD Undersize, Grind to .,. ,.
82.737 to 82.763 mm
0 50 mm OD Undersize, Grind to .
,. ., ,
82.487 to 82 513 mm
i00mmODUndersize,Grind1o........ . ......g1.987tog2.013mm
Main Bearing Journal Bore lD No Liners ............87.982 to 88.018 mm
Maximum Servjce Limit... .. ..... ....gg 031 mm
Main Bearing Bolt Maximum Length 1j9.25 mrn
CAMSHAFT
lD of Bushing Installed .. .
54.107 to 54 133 mm
Maximum Service Limit,.
54,146 mm
lD of Camshaft Bore .. .. .....54.107 to 54.133 mm
Maximum Service Limlt ..... .. ..
.. .. 54,146 mm
OD of Each Camshaft Bearing Surface . .. .. ........ .53.987 to 54 013 mm
Minimum Service Limit. . .....53.962 mm
Camshaft Thrust Clearance ... 9.42 to 9.58 mm
Minimum Service Limit. .
CAMSHAFT LOBES
LIFTERS
Bore Diameter ln Block ... . 16 00 to 16.030 mm

Maximum Serice Limit.. .. . ,. .16
055 mm
GEAR TRAIN BACKLASH
Crankshaft Gear to Camsha{t Gear.. 0 08 to 0.33 mm
Maximum Servicc Limit (AIl Gears)
045mm
Bac 8-26084
Revised 2-92 Printed in U S.A
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2425-6powrquadplus www.thebestworkshopmanuals.co.uk
SPECIAL TOROUES Metric Value

39 to 47 Nm
Belt Tensioner 8o1t.... .,. . ..,. ,.'
21 to 27 Nm
Ca'nshaft Plate Bolls , ..
. 60 Nm Plus 60 Degrees
Connect'ng Rod Bolts .
120 to '130 Nm
Crankshaft PullcY Bolts
.23 to 25 Nm
Fan PulleY Bracket Bolts
25 to 31 Nm
Fan Prllcy Bolts .... .. .. ,
26 to 31 Nm
Grade 8.8 Size M8 .. ...
37 to 43 Nm
Grade 10 9 Size M8
51 to 62 Nm
GradeBBSizeMl0
51 to 62 Nm
Grade 10,9 Size M10
130 to 144 Nm
Flywheel Bolts.....,
54 to 66 Nm
Flywneel Housing Bo ts
29 to 35 Nm
Fue' Inrel N;t . ., . , .
59 to 7.1 Nm
Injcctron DumP Nut
BNm
CAV lnjcction Pump Lock Bolt (Lock
Position)
20 Nm
Posiiion)
CAV lniection Pump Lock Bolt (Unlock
30 Nm
Posttion)
Bosch Injection Pump Lock Bolt (Lock
30 Nm
Positlon)
Bosch lnjection Pump Lock Bolt (Unlock
21 to 27 Nm
lnjection PumP Mounting Nuts '
21 to 27 Nm
lnjection PumP Bracket Bolts ""
21 to 27 Nm
Front Cover Bolts . .
21 to 27 Nm
Front Housing Bolts
. 80 Nm Plus 60 Degrees
Main Bearing Bolts . . .. ."
21 to 27 Nm
Oil Suction Tube Bolt
.8to10Nm
Seal Carrier Bolts .,..,,
. .. ..39 to 47 Nm
Startcr Retainer Bolts ,
... ...22 to 28 Nm
Fuel lnletBolts.. ....
22 to 28 Nm
Fuel Outlet Bolt. .. ... . . .
21 to 27 Nm
Li{ter Cover Bolts. . .. .
a^,,icad )-Q2 Printeo in U.S A

nac 8-26084
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2425-7
SPECIAL TOOLS
INSTALLATION TOOL
(INCLUDED IN SEAL KIT)
INSTALLATION TOOL
(INCLUDED IN SEAL KIT)
PROTECTIVE SLEEVE
/
9o
PROTECTIVE
SLEEVE
FRONT SEAL KIT
REAR SEAL KIT
rh
WEAR SLEEVE KIT FRONT
114t91
w@:Ls
WEAR SLEEVE KIT REAR
CAS-1690 ENGINE TURN OVER TOOL

SEE PAGE 44
CAS-I358 RIDGE REAMER

SEE PAGE 24
Rac 8-26084 Revised 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
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CAS-2162 TORQUE ANGLE GAUGE
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SEE PAGE 38 \t/ a>.v.@
CAS.1412 CAM BEARING SERVICE KIT

SEE PAGE 62
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CAS.1O9OO CONNECTING ROD PIN BUSHING

REMOVAL AND INSTALLATION TOOL SEE PAGE 33
Crankcase Pressure Check (Blow By)
CAS-1692A MANOMETEB
0,221 INCH ORIFICE 4 CYLINDER
0.302 INCH ORIFICE 6 CYLINDER
SEE PAGE 77
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2425-9
SERVICING THE ENGINE BLOCK
Front Oil Seal Replacement
STEP 1 STEP 4
Make surc thc upper anc iower mark on thc crankshafi Rcrrove thc crankshaft oulrey bolts and the crankshafl
pulley arc in aJrgn il ihc rnark is noi in align lhc crank- or cy
shaft pulcy must bc rcplaccd
STEP 5
Lift the be It tens;onc' a"rd 'cnrove the lan bcll
STEP
STEP 3
rr,, "t':,1:
Clcan i:c cranksnaft sca surface vrith [ociite safety

?c-ore l:c'a-. plr'rcy boils ar- :^c'al l.r.'c/ SO VCT'I
If\,4POBTANT. Tlte seal sur{ace cn the crankshaft must

be t'ceo{ all oil anC grease lo prcvcnt dantage to the oil
lac 8 2eli :lcvrsrc 2 !12 Prir-lcr,r in U S A
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STEP 1O
Rcrnovc thc scat and clcan the scal surface with Loctite Tightcn the front covcr bolts to a torque of 21 lo 27 Nm
salcry sclvcnt and remove the installation tool.
STEP B STEP 1 1
lnstall the gaskei, frorrt cover and thc cover bolts, Do Put Loctite 277 on the outsrde surface of the seal.
not trghtcn ihe bolts
STEP 12
STEP 9
Carefu,ly lnstali thc protcctive slceve and seal on the

lnsia i thc scal installation lool into thc front cove r wtth cranksnalt Push lhc seal on thc crankshaft until the
thc small diametcr loward the cngtnc Thrs will center scal makes contact wiih the seal surface.
the 'ront cover with the crankshalt.
nac 8-26084 Reviscd 2 92 Printed ln U.S.A
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2425-11
STEP 13 STEP 16
Rcmove the protective sleeve lnstall thc fan pullcy and bolts
STEP 14 STEP 17
1 34t.91 B
T80240
lnstall thc installalion tool and push the seal to the Llft the belt tensioner and install thc fan belt
correct de pth Thc scal will be at thc corrcct de pth whcn
Ihc outsioc diarncter of thc inslallation tool ,'nakes
conlacl wlth lhe 'ron: cover. Rcrnove thc sea insialla- STEP 1B
:ion tool
STEP 15
Tightcn thc fan pullcy bolts as follows

G'adcBSSzcMB 25 to 31 Nm
Graoc l0 9 S zc VB 37 to 43 Nm
GraocBSSzcMl0 51 to 62 Nm
lrs:all :hc crankshaft pullcv and cranxshalt pulley bolis Gracc 1C 9 Srzc N/10 51 tc 62 Nm
Tigir:cn:hc bolts to i] torque of 120 to 130 Nm
na3 B-2ii084 Rovrscd 2-92 Prinled il ll S n
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a Aac 1a
Rear Oil Seal Replacement
STEP 19 STEP 22
Remove the enginc oii pan. See Seciion 2445 Ior oll oan Conncct a chain and hoisl 1o thc flywheel housing
removal Rcmove the bolts from thc f lyvuheel housing and
rernove the flywheel housing.
STEP 20
STEP 23
Bemovc the siarlcr lrom the fiywhccl housing

Rcmove the seal carrier bolts and the seal carrier from
the crankshaft,
STEP 21
STEP 24
Rcmove the flywheel bolts and thc flywhccl from thc

flyr,vhcel housing Femove the scal from thc scal carricr and clean the
scal surlace with Loctite sarety solvent.
Bac B-26084 Rcv scd 2-92 Printcd ,n U S.A
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2425-13
STEP 25 STEP 28
Clean the seal surfacc on thc crankshaft with Loctite Install the scal inslallation tool into the seal carrier with
safety solvcnt. the small diameter toward the engine Th s will cen:er
ihe seal carrier to thc crankshaft.
IMPORTANT. The crankshafl sealing surface mu-sl be
free of all oll and Errease ta prevent damage to the cil
5Ud/. STEP 29
STEP 26
Tghtcn thc scal carr er bo ts to a torquc of B to I0 Nrn

and remove the installation tool.
lnstal two guide bolts (M6 x 1 00 x 50 mm) and a new

seal carrier gasket, STEP 30
STEP 27
Install the scal and protcctivc sleevc over tnc cran-

kshaft unti ihe outs dc dramcter of thc seal r^nakcs
conract wi'h thc scal carrier
lnslall the seal carncr and the seal carrier boits Do t'o1
tightcn thc scal carrier bolts.
Rac 8-26084 Bevised 2-92 Prinled . U S.A
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2425-14
STEP 31 STEP 34
s .+1x
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i, j: i:;:riiw i:l:%ql:l:X'iri::::1.: ::r:,r::iiLr::iiiii,iiinvr:l

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Rcmcvc the protcctive slccve lnstail a ncw o-ring on the rear scal carricr
STEP 35
:i.l:.iflE *
lnstall the seal installatlon tool with the small diamctcr Apply Loctitc 515 to thc seallng surface of the engtnc
lolvard the seal block.
STEP 33 STEP 36
-..-.--i
' ,'-'' .."*;
133191C
Push thc seal into the seal carricr until thc oulside lnstall two guidc bolts in the engine block
cJiamcter ol thc seal nstallalion lool makcs contact wl:h
the scal carrier. Rcmove tnc inslallation tool
Rac B-26084
tlev scc 2-92 Prrn:od in U S A
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2425-15
STEP 37 STEP 39
j ei
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.,..,.i1tlifiI11,-W1,i,,.;ffi ,.'i 49'r
lnstall the flyr,vhccl housing and the flywheel housrng lnstall thc startcr and thc retaining bolts. Tghtcn thc
bots. Tighten the bolts to a torque oi 54 to 55 Nrn bolts to a lorquc of 39 to 47 Nm.
STEP 38 STEP 40
TOFOUE HERE
lnstall thc flywhcc anC ihc flyvrhccl retaining bolts lnstall tnc e ngine oil pan Scc Scction 2445for ori p3n
Tighlen the bolts to a torque of 130 to 144 Nm instalta:,on.
Rac B-26084 Revised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
t4t?- la
Front oil seal, sear and wear sreeve rnstailation
Uscd when crankshaft frange is worn and standard seal does not stop
oil frow
STEP 41 STEP 44
Makc surc the uppe r anC lower mark cn the cr-anxsraf: sNWNNN\::]]:.i::]].ji].:ll.]li.:::]]i:iilli....'.l'."...:,:,.l:iI78.9,75
cn ovc Ihc crankshaft puilcy colis and ine irintifratt
pulley are ln align lf the mark rs not in align the cran, Pr., 0v
kshaft ouiiey rnusl De replaced.
STEP 45
,{S\
a' '
i
Rcrnovc thc front covcr. bolts and the lront cover

Lrtt :hc bclt tcnsioncr and rcr-ovo
STEP 46
STEP 43
Remove iire Ian puliey bo ts alcj thc ian or, ey
i)1
ltr'::i:: 2 92 Printcd ir U.S.A
kaukazz@yahoo.co.uk
aAac 11
STEP 47 STEP 50
T80351
Put Locirte 277 on thc ouisidc d arneter ol thc seal Clcan :hc crarkshali with Lociite safcty solvent.
surlacc and insia I tnc scai r: thc ironi cover.
NOTE: The seal suiace must be free of all oil and
grease ta prevent damage to ihe orl seal.
STEP 48
STEP 51
T80349
Put the scal installation lool on thc oil seal ihc small
diamcicr cf thc se al instailation locl rnust bc toward ihc
scal l'r:iiil :.: wcar slccvc on lhc crankshafi wtth the flange
lowa'd lirc cngrnc.
STEP 49
STEP 52
ffi 1 3219
'v -;k**
.*"-*".T80.j50
Push thc scal in:o thc covcr Lrr.rl lilc ou:srde c arnc:cr ol
j*I.* TgO+14"
thc insiallalron iool r.rakcs contacl wrlh lhc cover Insiair :he wear sJccvc nstallaiicn tool over the wear
s ccvc Push thc wear sleeve on thc crankshaft untilthe
flangc makcs ccntact with the lace o{ thc crankshaft
9c:lr
nac 8-26084 Fcvlsed 2-92 Prlnted rn U.S A
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STEP 56
./ rco$s T80235
Bcrrovc thc wcar slccve rnstalla:ion iool lnslall thc lronl cover bolts anc tiqhten the bolts to a
torquc of 2'l to 27 Nm
STEP 54
5tt_H 5/
lnstali iwo guide bolts (M8 x 1 2 5 x75 mrn) and a new

front cover gaskei. insral rhc crankshaft pulley and thc crankshaft pulley
bolls rrghicn thc b,olls to a:orque of 130 to 144 Nm
STEP 55
STEP 58
Carefully install thc front covcr

nsl.til thc !an cL,ilcy and the fan pullcy bolls
Ilac E'26084 Rcvrscc 2-92 Printed in U.S.A
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2425-19
STEP 59 STEP 60
belt.
ioner and instali the fan belt
Llft the be lt tcnsioner Tigh:cn the fan pullcy bolts as follows.
Gradc B B Size MB . 25 to 31 Nm
Gradc 10 9 Size MB 37 to 43 Nm
Gradc B B Szc MIO 51 io 62 Nm
Grade 1C 9 Size lvlO 5l to 62 Nm
Flear Oil Seal and Wear Sleeve installation

Used whcn thc crankshaft tlangc is r,,rorn and standard scal docs not stop oil flow.
STEP 61 STEP 63
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Remove thc engirc o ; Car Scc Scclton 2"145 in ihc Rerncvc the bolts and the flywhccl from the flpvhccl
service marual fcr c, p;.ir rcrnoval
STEP 62 STEP
Removc ihc star:er frorr lrrc ri1'rnrhccl hol,i r,,- lnstall a lift chain and a iorst to the flyrvhccl hous irg
Rcmovc thc bots and ilyrvhccl hot sing
Rac B 26084 IlcviscC 2 92 Pr.tco n ,, S A
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2425-2A
STEP 65 STEP 68
Rcmove the seal carrier from the crankshall lnstall thc scai installaiion tooi Push the seal into the
se alcarricr until lhc outsidc diarnctcr of the seal instal-
lation tool -akcs contact with thc scal carrier
STEP 66
STEP 69
Bcmove the seal and clcan ihe seal surfacc with Lociite
qafn'.i cnlrron,
Ciean the cranksnall seal surface with Loctte safetv
STEP 70
install the seal rn the seal carricr
Put the wear slecve on the crankshaft with the flange

toward the cngrnr:
nac 8-26084 Bcviscd 2-92 Printed in U.S A
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t4z)-z I
STEP 71 STEP 74
lnstall the wear slccve insta lation tool on the wear Clean the scal surfacc with Loctltc safety soivcnl
sleeve.
IMPORTANT The crankshaft seal surface must be f ree
of all oil and grease to prevent damage to the seal.
STEP 72
STEP 75
Push the wcar slccvc on thc crankshaft until the fiangc

of the lvcar slccvc is even with the rear seal surface on
the crankshaft lnstall two guide bolts (M6 x 1 00 x 50 mrn) and a ncw
scal carr er gaske:.
IMPORTANT. The wear s/eeye flar:gt: rriust be evt:n
with the rear seai surface al [he (.t..)ik::t a,ll.
STEP 76
STEP 73
Carefully install the seal carrier
Rcmove the wear slccve installation tool
Rac B-26084 ncvised 2-92 Pr nlcd ,. L S A
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aArtr )a
STEP 77 STEP 80
:i,n s
rfi:i::tiir.'ffiw{W$N\''ii$$Sffi, :' -tq&iiim riir;:,:9
il'
[ ,,, ''i s
'i'c
lnstall thc seal carrier bolts and tightcn thc bolls lo a

W
::,i]:::':::i:j]iw
Install thc flywheel housing and thc flyr,vheel housing

torque of B ic 10 Nm boits. Trghten thc bolts tc a torque oi 54 to 66 Nm
STEP 78 STEP 81
1. TORQUE BOLTS
lnstall a ncw o-ring on the seal carrter lnstall thc flywhccl and tnc ilyrarhcel bolts. Tighten the
bolis to a torquc of 130 to 144 Nm,
STEP 79
STEP 82
Apply Locr ic 515 to lhc scallng 's!rr:ace oi: lire englnc

lnstall ihc slartcr and :hc starter bolts Tightcn thc bolts
block
to a lorquc of 39 lo 47 Nm
Rcviscd 2-92 Prlnted in U.S.A.

Bac 8-26084
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2425-23
STEP 83
lnstall thc cngrnc orl pan Scc Scclior 2445 ut thc

servcc n"anual lor oil pan instailation
Flemoval of Pistons and Rods

STEP 84 STEP 86
Rcrrovc thc manifolds and cylindcr hcaci "orir Chcck thc side clearance of thc piston connecting
cng 'rc Scc Scctior 2415 ci thc scrvrcc 'ra"La rods Rcr,iacc thc connccirng rods il lhe sidc clcarance
rcrnorral is morc ihan 0 330 mrn
STEP 85 STEP 87
Rernovc the cngine oil can and nlct iube Scc Sec: cn Remove the carbon from thc top of the cylinder walls.
2445 ot tnc service manuaL ior :cmoval Check the cylinder walls for a ridge at thc top of the ring
movcment zone, A ridge will cause damage to the
piston whcn the piston is removed. A ridge will have to
bc removcd wiih a ridgc reamer.
nac 8'26084 Rcvised 2'92 Printcd in U S.A.
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2425-24
STEP 88 P91
lnstall a ridge reamer and rcmove the ridge from the Rcrnovc lhc rod cap bolts and the rod caps
cylindcr walls
STEP 89
Bcmovc the pistons from the top of the engine bloct<

Put a ,'nark on cach rod cap for cylindcr rdeniifrca:ron
STEP 90
Pu't a rde ntification mark on cach p ston lcr assemb,ly
Rac 8-26084 Revlsed 2-92 Printed in U.S.A
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z4za-lc
Cylinder Wall lnspection
STEP 93
lnspect the cylinder walls for the following conditlons
Normal Wear Worn Cylinder Wall
1 0766CDC 231 9CDC

A smooth surface witn sornc ol ihc cross-hatch pattern A smooth surfacc bctween the upper and lower limits ol
showing between the upper and Jowcr lirrits of the ring the ring movcmcnt area shows a worn cylinder wall
movement area shows normal wear There will always See Steps 94 and 95 to measurc the cylinder borc for
bc a small amount of wcar prcscni bccause of com- out-of-round and taper,
bustion pressure moving the top ring against the
cylinder wall,
Normal wear shows acccptablc cylindcr wali condt-

tions. See Steps 94 and g5 to measurc thc cylinder bore
for tapes and out-of-round.
Rac 8-26084 Revlsed 2-92 Printcd in U.S.A
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2425-26
Scoring on Cylinder Walls Dusted Cylinder
-ZO17BCDC
1 0764cDC
Too much area in thc piston ring movcmcnt area shows
a dusting failure,
A dustrng failurc wiii causc the fo lowing:

1 Lower area of pision wall lvill show wear,
2. Tao much ptston rrng groovc wcar.
3 Too much pistort lng side clearance.
4. Washcd away arcas of the oiston ring lands where
the aluminum will bc gone
5. Piston rings will have too much face contact and
wear which can be seen as a reduction in radial
width and increase in end gaP.
6 Chrome pislon rings will show wcar through the face.
The chromc wlll be worn off the face and base iron
can be seen.
7 The cylinder hcads can have smooth intake ports
ard wo'^ valve gu'des.
232OCDC All of these conditions arc caused by dirt which is mixed

Scoring on cylindcr rryalls is causcd by metal moving with the intake air.
from one locatton io a diffcrcnt localion This ls shown
by heavy vertical incs The vcll cal '.rcs are causcd by
mctal corning in contact with thc pision. The scoring
can be in one soecif ic area ar it can occur the complete
length of thc piston movernent. lf this condition is
prescnt, the cylinder must be machined and the p ston
and rings replaced.
Rac 8-26084
Revrsed 2-92 Printed in U.S.A
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2425-27
STEP 95
j'1':
w,'
ffiffi. w'
'1 Mcasure thc borc carallci :o thc cranksreril at the
top
cnd of thc rino iravel zonc
Mcasirc the borr: ir the sarrc posil,crr a: thc bc:lorn
cnd of the rrng lravel zonc
Mcasure ihc borc at right anglcs to the crankshaft at
the top cnd of the ring travcl zonc
Measure the bore n the samc posrtion at the bottom
end of the travel zone
Comparc the rcsults of thc mcasurcmcnts (l) and (3)

with (2) and (4), to flnd out ii thc bore has tapcr To
rneasurc use a insidc micrometcr, bore gauge or taper r+k
gauge lf the taper is morc than 0 076 mm, borc thc Mcasure thc cylinder
cylinder. follows.
.1
Measui'c ihc bore parallcl ro lhc crankshaft at the top
ond of t1e r ng iravc .
2 McasL.rc :l'rc borcr ihc same position at the bottom

-.:,C u' ..tc .,r3 :ravCi
3. Mcasurc thc borc at right anglcs io thc crankshalt al
:hc top cnd of lhc ring travel
4. Mcasure the bore in the samc position at thc bottom
eno of thc lng travcl
Compare the measurcments (1) and (3) to find the out-

of-round wcar at the rop end of the bore.
Comparc the measurements (2) and (4) to find the out-

otround wear at the bottom of the bore
lf out-of-round rs more than 0.038 mm, bore the cylin-

dcrs.
STEP 96
IMPORTANT: Before removrng glaze, cover thc cran-

kshaft journals with a clean cloth to prevent abrastves
and dirl caused by the cylrnder hone from falling on the
crankshaft.
Bac 8-26084 Rev sed 2-92 Printed in U.S A
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2425-28
STEP 97 STEP 98
F .1ruSlIf-o,.,, -..rffi
*;@i&car**'W$ffi 3/8 rnch or 1/2 inch Crill to power the cylinder
li ncw rings are uscd, the glazc must bc rcmovcd from Use a
hone. Use a lubricant/coolant with the hone to keep the
the cylinder bore so that the piston rings can correctly
honc and the stones free of foreign material
seat against the cylinder wall during the run-in time
Start the hone at thc top of the cylinder bore and actuate
Removing glaze can bc done by using a cylinder hone the hone up and down until the correct cross-hatch
wrth 250 to 300 grlt stone, paitcrn ts rcachcd The corrcct cross-hatch pattern is
40 to 60 degrces from horizontal.
Too much glazc (smooth surfacc) on cyllnde r walls of a
Usc a 80 to.1 50 grit stone to reach the correct cross-
ncw enginJ or an engine with an overhaul is caused by
hatch pattern,
run-tn procedure that is not correct.
Usc a 250 to 300 grit stone to rcach the correct cylinder
Glaze does not permit the prston rings to seat corrcctly bore finish
in the cylinder sleeves This wjll cause too much
oil con-
sumPtion. STEP 99
Too much glaze on the cylinder walls can bo prcvented
by giving your customer instructions in the correct
run'
in p-,o"eiur,e See Section 2401 tn the service manual
for the correct run-in Procedure
1076scDC
with a
After removing thc glazc, clean thc cylindcr walls
warm water and a mild detergent soap
clean cloth,
walls
Alter clean ng tho cylindcr walls, clcan thc cylinder
agair with clcan cnginc oil
NOTE: Ctean the cylinder walls untrl a clean whrte cloth

is not
keeps completely clean, one cleanrng operation
enough.
IMPORTANT'. Do not use gasoltne' diesel

fuel or
kerosene to clean cylinders becausc these materials
will not remave the abrasives from the sleeve surface'
Revised 2-91 Prrntec in U'S A

Rac 8-26083
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2425-29
RECONDITIONING THE ENGINE CYLINDER BLOCK
Checking and Resurfacing the Cylinder Block
STEP 1OO STEP 102
A
Clean the cylinder block completely. Remove carbon
and outer deposits, Check for cracks and other
!^*^^^
ud.r r dgu.
STEP 101
Check the cyiinder block surface with a straight edge

+
and feeler gauge. Resurface the cylindcr biock if
warpage or erosion is more than 0.010 mm in any 50
mm diameter area or if thcre is more than 0.075 mm
361 191
overall cnd to end or sidc to srde,
Resurface the cylinder block in increments necessary
to strarghten the surface and maintain the surface f inish
according to the following specifications
A= 0 25 mm lirsl refac'ng,
0.35 mm second refacing.
0.50 mm total amount of material that can be
rcmoved.
3 =- 322.90 to 323 10 mm standard

322.65 to 322.85 mm first refacing
322.4A to 322.60mm second refacing
C - Surface finlsh 1.5 to 3.2 micromete rs
D - Use this area to stamp an "X" when the first

refacing of 0 25 mm is done. Stamp a second
"XX" when the second refacing 0.50 mm total is
done.
NOTE: When resurfacing the block it is always neces-

sary to machine the block to the specified dimensions
There are hazo thickness es of head gasketto make up for
the material removed from the cylinder block. See
Section 2415, Page 31 for selection of the correct head
gasket.
Rac 8-26084 liev sed 2-92 P'tnleo l^ u 5 A
kaukazz@yahoo.co.uk
2425-30
Reconditioning the Cylinder Block for Oversize Pistons
NOTE: Many of the photographs rn this section show a STEP 105
cyllnder block that has been cut in halt for photographrc
purposes.
STEP 103
,:{r*.,.. r:l
,'w,
,!:\\W!&i ,3\
. *"-
rffimffiffWtu$$ ]^,ts$ffi
rW{
:'ffi il:lii:,,,,,
a.
a f.:T }_djt::.r.
:'li..d'*',
.wl 1
1'r*-tt,l1ffi.tlrit. r. ' '

ffiffiI
:t.:. ''+{
, ,.
:^':'' 1: :6
.',i:,,'
'',ffi,i : ::::t:i:t':it::l
:' :' ':1' . :
102 940 mm for the 1 0 ,rm ovcrsize pistons. See Step
!'li ,,ttlf
';1"i"1::'
i
, , 1i..,1,,. +
114 f or the correct procedurc to hone the cylinder bore
".' ' : ,: ': ':'ii:'j-. :::l I i
:i:i :.;i]u1-..-:
I OYJUS to '!C 'jnrShco dr3'relC'.
Thc cylinder oiock mlst bc disassernblcd before the
cyl nder can be machined for overstze oistons.
STEP 106
STEP 104
\s'. '
*M, dp
"';l ,,.i$
- Eq'i'\,S,,1'1 ffi
&k'
" lus;ea$ xr*B'
*ffiS$$r*
*;+e iss4l,flfiffi$M
Usc a 3/8 or 112 inch drill to power the hone Use a lub-
rrcant/coolant with ihe hone to keep the hone and the
Machrnc thc cylinder L:ore to a dianretcr of 10?_ 40 io sloncs free from forcign material.
102 44 rnm for thc 0 5 mm ove rsrzc cistcns Scc Step
114 Ior the corrcct crocedurc to honc the cylinder borc Start thc hone at:he top of ihe cylinder bore and actuate
ro trc {i^ s-co d.amctcr tnc honc up and down uniil the corrcct cross-hatch
pattcrn is rcachcd. Thc correct cross,hatch pattern is
40 to 60 dcgrecs from horizontal.
Usc a 80 to I50 grii stone to rcach thc correct cross-

hatch pattcrn
Usc a 250 to 300 grit slonc lo reach ihe correct cylrnder

bore finish
HONiNG SPECIFICATIONS (Finished Diameter)

0 5 mm Ovcrsize Bore . .
]02 50 to 102.54 mm
'1
0 rnm Oversizc Borc .,,..
103 00 to 103 04 mm
Eac I 26084 ?c.v s:d 2-92 Filnteo in USA
kaukazz@yahoo.co.uk
2425-31
Reconditioning the Cylinder Block for Sleeves
STEP STEP 110
.:
, ..,,xsi -, :- .'* ,,. '.:., ,
f..tgi. ,il}* . ;:l:i :, r
..,,,
;r:,,.,:..j,].
. -,;JT,ffi'.1sffi ,, I
ilffim
:.q41t$,ii
,.,:l;llrli;iii
YYII:iiiill
, t,
i iiii
:iti:,i:ii !:i
li:i:il:lil
*ffikr l:
The cylindcr block must bc disasscmblcd beforc thc Freezc ihc cylindcr slceves and push the cylindcr
cyllnder b ock can bc machincd ior s ccvcs siccvcs in the borc rntil thc sleeve makes contact with
the ridgc at the bottom of the cy inder bore
STEP 108 NOTE: '{ou rnust ireeze the cyltnder s/eeves betore rn-
d ;ft -.-
stallation
1. MARK HERE
s,e. I #fi
*i&
Gft
tffiff
I,W* Always wear gloves to prevent frostbite to
iQ& t.ffig
EB:lSD your hands when handling frozen rrk,,uo
ffiffi1$il
iffiilffi# *
!
&i&* :t
-i I a,l. ),
f{t*:ir::: ,: :, .,ri,,,I I ,, ^ I J r^
STEP 111
. t..:i :
MEASUBE HERE
: u!!:rtr tiiit::i: i I t:: : . ':: 'q-' I SLEEVE
,6
4 ..1 I ..+1. : :
: :; :l::.: ::;,,t::|:i::, ::1{:,
:, i rji!;i! l
r " 'a:.
-' ,lt6g3gs
Measure 6 35 mm L,c fron" lire bolion' of t[re cylindcr
rrr : :riir :fnintif
bore. Put a rnark on thr.. cylrndcr at rrc 6 35
Ud5UI U,
ffiffi
ffiffi ,
.: #ffi,
ffiB,,
STEP 109 ffi ..ffij
ffi.ffi ffi r6e3s5
lf the cyl rndcr sleeve is not even with thc cylinde r block
su rf acc. thc siccve must be machined.
NOTE: The cylinder s/eeve must be even with the

cylinder block
ore
of
bor
Beviscd 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
a
a+aJ'a 1a
âF L
STEP 112 STEP 114
' .:, : i :: :i :1:

i:iliirii
..
i
.,. ,1r!, r:r,irirr
I.i : r::fir!:rt:rii:nai,ri
f thc piston slecvc with a borc

ffiIil Use a 3/B inch or 112 tnch drill to power the hone'
Use a
lubricantlcoolant with thc hone to keep the bore and the
stone frcc from loreign matertal
actuate
STEP 113 Start the hone at the top of the cylinder bore and
, .,.t .
";';;';::''''t
ihe honc up and down until thc correct cross-hatch
pattern is rcached The corrcct cross-hatch pattern is
: ,,,,:::r:r
. r::. i,i:a: iilti
40 to 60 degrees from horizontal
Use a 80 to 150 grit slone to reach the correct cross-

hatch pattern.
cylinder
Usc a 250 to 300 grri stone to rcach the correct
borc Iin sh
HONING SPECIFICATIONS (Finrshed Diameter)

Cylinder Slceve Bore ,..,... ..
10200 to 10204 mm
Measurc thc bore gaugc with a micromcter' Thc

cylinder diamctcr rnust b; machincd to.a Olame]e1-1]
rbl.gOO io 101 940 mr.rr. Scc Step 114 fr:r the corrccl
proccdurc to honc thc cylinder borc to tirc iinished dia-
MCiCT,
Rcvised 2-92 Prinled in U'S A

nac B-26084
kaukazz@yahoo.co.uk
2425-33
Piston and Connecting Rod Disassembly and lnspection
STEP 1 15 STEP 117 :.. . ri:' .: r::.1
2, PIS TON PIN
3. BETAINING RING
Q@
4. CONNECTING ROD
36419i T6881 0
Remove the retaining ring, piston pin and the con-
necting rod from the piston.
STEP 116
/Z^\
(( )) . 1. roP R|NG
V
,zR\
+t lNrERl',EDlArE RING
U,
,4.
K=)*
3 oILRING
((r)
,z:\
*:4 + 4. PlsroN
Measure the insidc diameter o{ the connecting rod for
wear and out-of-round. lf the inside diamcter is more
tuul
I
\-Y
ltfuu 3tj5le1
than 40 092 mm the connccting rod bushing must be
replaccd
Rcmove the comprcssion rings and thc oil ring from the
piston.
STEP 118
NOTE: The oil ring $ 2 tvvo piece ring
I
e@ S. 4
i05 191
To remove and install the connecting rod bushing usc a

CAS-I0900 connccting rod pin bushing removal and
installation tool.
Rac 8-26084 Revised 2-92 Prinled in U.S.A.
kaukazz@yahoo.co.uk
2425-34
STEP 1 19 STEP 122
Measure the diameter of the piston pin. lf the diameter Break an old piston ring in half and usc the brokcn lng
is less than 39 990 mm thepiston pin must be replaced hali to cican the plston ring grooves. Too much dcposit
in the ring grooves can force the rings out and will cause
scoring
STEP 120
STEP 123
Measurc lhc piston pin borc lf thc piston pin bore is

morc than 40 A25 mm thc pistcn must be replaced. T80ts43
Check the slde clearance of the oil ring in the piston.
lnsert a feeler gauge bctr,veen the upper surface of a
STEP 121 new ring and the piston iands to check the clearance.
Feplace the piston il side ciearancc is morc than 0 l3
rnm.
STEP 124
Measure the diameter of the piston across the thrust

lace 12 mm from the bottom of the piston at right
angles to the piston pin holes Repiacc the piston if the
diameter rs less lhan l0i B23 rnm
Check the srde clearance of the second compression

ring. Repiace the piston rf thc srde clearance rs more
than 0 15 mm.
Rac 8-26084 2-92
Rcviscc Prlntcd ir U.S.A
kaukazz@yahoo.co.uk
2425-35
STEP 125
Clean the piston holcs wth a small drill or
Piston Assembly
STEP 126 STEP 128
,l.liiliirt.ttiliil i,l: :'ilii.,,i,,,,,. ,,.
.l:li.i,l;i:riii iillilillril:iri:r:iiir,i,i
I i r: : :' : :) it i i i i I it i i: i: it: i i: i l:l: i: li:1 i : i: it i i : i: i i i i: i ii i i i j i i : I : : i
Put the piston rings in thc cylindcr and check end gap. lnstall the sccond comprcssion ring, The prston ring
Rcp ace the piston nnEs if the cnd gap is more than must be installcd with the side marked TOP toward the
0 806 rnm top of the piston to givc good oil control.
STEP 127
STEP 129
Installthe oil ring lnstalllhc spring first and thc oilring

second. lnstall the first compressron ring on the pision. The
pistorr ring mus: be installe d with the side marked TOP
NOTE: The sprrng musl be beh,reen the oll ing and the toward the top of thc piston to give good oil control
piston.
nac B-26084 nevscC 2 92 Printod ir USA
kaukazz@yahoo.co.uk
2425-36
STEP 130 STEP 133
1. SPEC
358191
The first compression ring, in a replacement set of

rings, must have a special lap design on the surface Apply lubrication to thc pistons, piston rings and
that contacts the cylinder wall. cy inder walls, using clean engine oil.
NOTE: lnstall the plslons in the correct bore"

STEP 131
STEP 134
Botate the piston rings so that the

rated by 120 degrees,
lnstall a ring compressor on the piston and carelully
install thc piston rn thc cylindcr
STEP 132
IMPORTANT: Make sure that the arrow on top of the
piston is toward the front of the engine.
PrsroNPrN
ffi *'\ STEP 135
PISTON
@t 4. RETAINING RING
2. CONNECTING HOD
364191
lnstallthe connecting rod, piston pin and retaining rings

in thc piston,
Mcasure thc connecting rod iournals on the crankshaft

Measure the iront and rear of each iournal, checking for
lar:cr il thc tapcr is more ihan 0.013 n'r recon-
dr:ioning of thc ,ournals must bc done.
Rac 8-26084 Rcviscd 2-92 Pri.lcC n U.S A.
kaukazz@yahoo.co.uk
2425-37
STEP 136 STEP 139
T68783
Thc connccting rod journals must bc chcckcd again, lns:al ihc bcanng caps,
90 dcgrccs lrom the first mcasurcmcnts for out-
of-round. If out-of-round is more than 0.050 mm, recon- NOTE: Make sure that the number on the beanng cap
ditioning of the journals must be done. rs lhe same as the number on the connecting rod.
STEP 137
STEP 140
IV1AXIMUM LENGTH
59.25 mm
7L92
Install the liners The linr:r locks rnust be in aliqnn cni
Measurc thc bolt length of the connecting rod bolt lf thc
NOTE: When installing lhe lrners, make sure that the boll lcngth is more than 59.25 mm the bolt must be re-
liner locks are in alignment. Use a sliding iypc placcd
movement when installrng the lrners. Never push ort ihe
center ol lhe ltnet lacks. IMPORTANT: Each bolt length must be checked
STEP 138
STEP 141
Clean thc connecting rod .iournals and thc rod bearing

lincrs Put a piccc oi plastigage on thc L:earing cap Lubricate the connecting rod bolts with clean cngine oil
joL;rnal or the jolrr:al on the crankshaft and tighten the bolts to a torquc of 60 Nm
Bao 8-26084 ncviscd 2-92 Dr ltcd i'r .J S A
kaukazz@yahoo.co.uk
2425-38
STEP 142 STEP 145
MAXI[/UM LENGTH
59.25 MM
7L92
lnstall the torque anglc gauge. Position and lock the Measure the bolt length of the connecting rod bolt, lf the
holding rod Turn the pointer to 60 degrecs Tighten the bolt le ngth is more than 59 25 mm the bolt must b'e re-
bolt until thc pornter is at 0 degrees placed.
STEP 143 IMPORTANT: Each bolt length must be checked

STEP
w Iffi
Rcmovc thc bcaring caps and check the clcarancc
The clcarancc musi bc between 0 038 mnr io 0129
n":n lf the ciearancc is more than 0.129 mrr, undersizc
bcaring lrncrs must be installed and rcconditioning of
Lub:'rcate the connecting rod bolts with clean e ngine oil
tho bearing iournals must be done by grirding
and lighten the bolts io a torquc of 60 Nm
NOTE: A clearance of O.a3B b A 116 mm rs reaui'ed
when installing new bearing hners
147
STEP 144
,iB:BU+i
rl 168794 Install the torque anglc gauge Position and lock tltc
holding rod. Turn the pointer to 60 dcgrecs' Tightcn the
App)y lubrrcation to the bcaring lincrs bciorc installa-
bolt until thc oornter is at 0 degrees.
tion usrng clean cngine oil
Scvrscd 2-92 Pr nlcd in rl S A
Rac 8-26C8a
kaukazz@yahoo.co.uk
2425-39
STEP 148 STEP 150
lnstall the engine oil inlet tube See Section 2445 ol lhc lnstall the cylinder head and manjfold See Section
service manual for thc inlct tubc and the oil pan instalia- 2415 ol the servrce manual.
tion
STEP 149
Use a dlal indicalcr to check prs:on Drotrusion. Thc

piston protrusion must noi be n'ore than 0.660 mm
abovc thc cylinder b ock
Rac 8-26084 Revised 2-92 Printed in U S.A
kaukazz@yahoo.co.uk
2425-40
REPLACEMENT OF THE MAIN BEARINGS
WITHOUT REMOVING THE CRANKSHAFT
Removal
STEP 151 STEP 153
Femove the engine oil parr and gaskel Scc Section Bcmovc the main bearing cap bolts and the bearing
2445 ol the service manual cap
NOTE; Rernove only one cap at a time to prevent the
STEP 152 crankshart from moving.
STEP 154
Remove the bolts from the oil inlet tubc Scc Scction a
2445 of lhe service manual for thc orl rnicl tubc rcmo.;al
To removc thc front main bearing liner, use a thin piece
of plasrrc :o oush the bearing liner oui
lnstallation
STEP 155 STEP 156
: I E',i.'i*:.,{.\}B
:i:{lll3l iqilrtSEEl
,LL&i&i&\h\\
I
- r-.r T68818
Pu: a new bearing lrner on the crankshaft. Use a thin Put a piece of plasligage on the crankshaft journal
p ecc of plastic to push the bearing lincr in position
Rac I 26C84 Bevised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2425-41
STEP 157 STEP 160
Put a new bearing liner in the bcaring cap. lnstall the torque angle gauge Position and lock the
holding rod, Turn the pointcr to 60 degrees Tightcn tnc
NOTE: Makc sure the bearlng lrner locks are aligned boli untrl thc pointer is at 0 degrees.
when installing the liners. Slrde the hncr in position.
Never push an the center af the llners.
STEP 161
STEP 158
MAXIMUM LENGTH
.1
19.25 mm
l a 16B8I
6192 Fcmove the bearing cap and check the clcarancc.
bolt lf the bolt
Measuree the lenglh of the main bearing Clearancc musi be 0 041 to 0 140 mm New liners rnust
length 1ss more lhan 119.25 mm thc bolt must bc re- bc installed if thc clearance is more than 0.140 nrm
piaced
NOTE' The crankshaft must be machined if the clear'
IMPORT,IANT: Each bolt length must be checked ance rs more than 0.119 mrn with the new liners.
before innstallation.
STEP 159
1 S TEP 162
ffi
ffi.I f,
m"l
t a
lnstall thc bearing cac and tightcn 'hc t our'rting'bolts to AdJ tubrication to the beanng liners and install the
a torq,Jc oi B0 Nm. bcaring cap
Bac 8-26034 Reviscc 1-92 Printed in U S.A
kaukazz@yahoo.co.uk
2425-42
,163 STEP 166
STEP
MAXIMUM LENGTH
119.25 mm
Measure the length of the main bearing oort rt ilrc6oL]t lnstall a new oil inlet tube gasket, See Section 2445 ol
length is more than 119 25 mm the bolt must bc rc- thc scrvice manual for lhc installation of the oil inlet
placed tube.
IMPORTANT: Each bolt length must be checked

before installation. STEP 167
STEP 164
=a-
i
Add lubricalron to thc cap bolts. lnstalt ihc cap bolts
and t ghten to a torque of 80 Nm
tS
lnstall the oil pan. Sce Section 2445 of thc service
manuai
STEP 165
lnstall the torquc angle gauge Position and lock the

holding rod. Turn the pointer to 60 degrecs T ghten the
bo': unt,l tne pointcr is at 0 dcgrccs
Rac B'26084
tlcvised 2-92 Prlnted in U S A
kaukazz@yahoo.co.uk
2425-43
CRANKSHAFT AND MAIN BEARING
Removal
STEP 168 STEP 171
Rcmove the cylinder head See Section 2415 ot the Bemovc the oil pan. Sec Section 2445 in the service
service manual for cylindcr head removai manual for oil pan removal,
STEP 169 STEP 172

iiiilirili]iiiii;ir,r, rirlirirlr:.lrl:;:i: iii;:i::i:iililillli:i!:lii:illi;liiiriililllliii:ijt,i,l:rirrir::,l::ii! f.,
Make surc thc uppcr and lowcr mark on thc crankshaft Remove the oil inlct tube bolts, Sce Section 2445 for the
pulley arc 1n align li the rrark is nol ln alrgn replace lhc oil inlet tube removal.
crankshaft pulicy
STEP 173
STEP 170
Remove the front cover bolts and the froni cover

Rennove the crankshaft pulley bolts and inc crankshafl
puliey
Rac I 2608,1 Rcvrsco 2-92 P'lr:co r U SA
kaukazz@yahoo.co.uk
24?,5-44
STEP 174 STEP 176 CAV ln
Rcmovc thc inlcction pumo and primer pump Sec

Section 341 1 in the service manuai for the CAV inlection
pump
STEP 177
: ll3$:;,lt,,s^g$;it
;iN;
-.r.t:=i:.=:i.5t;.!i
l.li::
,l:1.;ll, fi.r;i
l:.rr'-i iiiirl: i
tl $
{t
,:: ili
Turn thc engtnc ovcr with a cnglnc iurn ovcr :ool and ,., t
.$.
push thc iock lnto the camshaft gear L;.
9ii,
STEP '175 Bosch lnlection Purn

'a
I
Rerrove lhe iter covcr bolls hc
brcaihcr covcr
STEP 178
Remove the inlection pump. See Sectron 3412 in 1te

service manual for the Bosch Pumo
lnstali pins to hold the lifters in place
Fevisec 2-92 Printed in [.] S A

Rac B 26084
kaukazz@yahoo.co.uk
2425-45
STEP 179 STEP 182
Remove the bolts that hold the camshaft thrust platc Remove the front housing bolts and the front housing
STEP 1BO STEP 183
Remove the camshaft thrust plate Rcmove thc startcr bolts and the starter
STEP 181 STEP 184
Rcmovc the camshafi See Steps 61 and 62 :o removc the flywhce ard
flywheel housing
Bac 8-26084 Fevised 2-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2425-46
STEP 185 STEP 188
2. FLYWHEEL
Rcmovc the seal carrier bolts and the seal carrrer

Each bearrng cap has a number for assembly identifi-
cation.
STEP 186
STEP 189
$l
Fi::-or,'c ihc connccting rod bolts and inc bcaring
STEP 187
Rcmove thc cranksnaft lrom thc cngine
nac B-26084 Revised 2-92 Printcd in U.S.A
kaukazz@yahoo.co.uk
2425-47
STEP 191 STEP 193
Remove the main bcaring lincrs from the enginc
STEP 192
\
\
2. EARLY PRODUCTION
OIL SPRAY NOZZLE
OIL SPRAY NOZZLE
36219 1
Rcmove thc oil spray nozzle from the bearing cartier
Clean the ori spray nozzlc wtth a small wire ll ihe nozzlc
is damaged it must be rcplaced.
Crankshaft Gear Removal

STEP 194 *
STEP 195
".***,"*Leiir;1,t, ,
i,i.T,S.9S6.7
the crankshafi Rcmove the pin from the crankshaft if the pin has been
darnagcd
Bac I 26084 Revised 2-92 Printed in U S.A
kaukazz@yahoo.co.uk
2425-48
Crankshaft lnspection
STEP 196
STEP 198
T69070
Measurc the main bearing journals to see if the journais
Measure thc connecting rod journals for taper.
are v/orn, Measurc the front and rear of each journal. lf
Mcasure the front and rear of each journal. Grind the
thc diamcicr is lcss than g2.962 mm, grind the cran_ journals if the taper is more than 0.0'13 mm.
kshai: lcurnals.
NOTE: Grind the crankshaft fournals underslze 0.25

STEP 199
mm, 0.54 mm, a.7S mm or 1.OA mm, if the crankshaft
journals are worn more than 0.025 mm.
STEP 197
REAR
Cncck ire connccting rod lournals again, g0 degrees

from :hc lirst mcasurements (Stcp -1 gg) for out of round.
Grind the lournais if out of round is more than 0,050
,,, ii:i:ii"' .iiii$$iiiri :
T6g07i
Mcas;rc thc marn bcalng journals, again 90 degrees
fron :lc lirst rneasurements (Step 196) for out of round.
if the out of round is more than 0 050 mm, grind the
lolrnals and use undersizc liners
Rac 8-26084
Reviscd 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2425-49
CRAN KSHAFT RECONDITIONING
Cran kshaft ldentification Machining a Crankshaft
STEP 2OO STEP 201
See Crankshaft lnspection on Page 48 l{ the crankshafl

is worn or damaged, it is rccommended that you have a
qualified engine shop machine the crankshaft ac-
cording to the following instruciions
There are two hardening methods used to harden the

journals of the crankshaft, One hardening method is in-
ductron hardening which hardens the journals to a 360191
depth of 2.00 mm, The othe r hardening method is deep Machine the crankshaft to the following specifications.
nitroc which is a gas nitriding process. This hardening
metho hardens the journals to a vcry shallow dcpth A .= Main Bearing Journals
Any time you grind a journal on a crankshaft that has
been deep nitroc hardened, you must reharden the Standard diametc' 82.987 to 83.0'13 mm
crankshaft, 0.25 mm undersize diameter,. 82737 to 82.763 mm
0.50 mm undersize diameter,. 82 487 to 82.513 mm
Crankshafts hardened by the deep nitroc process are 0.75 mm undersize diameter,. 82 237 to 82 263 mm
siamped with the letter "N" on thc pulley end (nose) of 1.00 mm undersize diameter.. 8'1 987 to 82 013 mm
the crankshaft. Induction hardened crankshafts arc n01
identified Connecting Rod Journals
Standard diamcter ...... 68 987 to 69 013 mm

0 25 .rrr u'de'srze dian erer 68.737 to 68 763 mm
0.50 mm undersize diameter 68.487 to 68 513 mm
0.75 mm undersize diameter 68 ?37 to 68.263 mm
1.00 mm undersrze diameter 68 987 to 68.013 mm
C -= 1 .23 lo 1 ,27 mm radius smoothiy blended to the

machined journal
Surface finish : 0.4 micrometers.
Crankshaft Rehardening
STEP 202
Benrember ihat any time you machine a crankshaft that

was hardened with the deep nitroc process, you must
reharden the crankshaft. Reharden the crankshaft to a
minimum hardness of 350 V 0.2 Rockwell
Fac 8-26084 Revised 2'92 Printed in l..l.S.A.
kaukazz@yahoo.co.uk
2425-50
Crankshatt Gear lnstallation
STEP 203 STEP 204
:.i..'.'i
...... 1.,...i ....,1

:;.:::.,l,...,
: jrl:irrir:tii::j:ii : :: :
T69069
Heat the crankshaft gear for a min mum of 25 minutes
at 250"F (1 21"C). Use a bearrng heale r oven lnstall the
heated gear on thc crankshaft.
Always wear heat protective gloves to prevent

burning your hands when handling heated
^^4^
Lt.
P<7r sM12.A
lnstall thc crankshaft gear pin The pin must be 1 02

mm abovc thc crankshaft surface.
Rac 8-26084
Revised 2-92 Prlnted in U.S.A
kaukazz@yahoo.co.uk
2425-51
Crankshaft I nstal lation
STEP 205 STEP 2OB
USED FAN BELTS
lnstali the oil spray nozzle into the bearing carrjer lnstall the crankshaft in the enoine block
STEP 206 STEP 209
lnstall thc bearing liners Clean thc r"i':ain bcaring journals and put a picce of plas-
tigage on lhc journals to check main bearing oil c car-
ance.
STEP 207
STEP 210
Add lubrrcalion to the bearing liners Use ciean cngtne

oil
Install the liners rn the bcaring caps. Make sure the Iiner
locks are aligned. Use a sliding type movement when
installing the lincrs. Nevcr push on the center of the
liners
Bac B-26C84 Revise d 2-92 Printec ir USA
kaukazz@yahoo.co.uk
2425-52
STEP 21 1 STEP 214
FAN 1 36t 91
Make sure the number on main bearing cap is in thc lnstall thc torque angle gauge Position and lock ihe
corccl nun ber seqLcnce holding rod Turn the pointer to 60 degrees Tighten the
bclt until the pointer is at 0 degrees.
STEP 212
STEP 215
1. MAXIMUM LENGTH
119.25 mm
=l 6192
Measure the length of the main bearrng bolt. lf the bolt

lcngth is more than 119 25 mm the boit musl bc re- Fc,'ncve the bolts and the rnain bearing caps.
placcd.
IMPORTANT: Each bolt length must be checked STEP 216

STEP 213
Cncck the main bearing oil clearance, Clearance must

bc 0 041 to 0140 mm lf the clearancc is more:han
0 140 r'r'n. unCcrsrzc bcaring Ilncrs musl be installed.
l.rslarl revr undcrsrze lincrs which will give a c carance
of 0 041 :o 0 119 mm
Add lubricatlon to the cap bolts and tightcn io a torquc
of 80 Nm NOTE: ll the clearance is more than 0.140 mm, the
crankshatt musl be machined,
Pi:r 8 2ii)E4 Revisec 2 92 Printed in U S.A.
kaukazz@yahoo.co.uk
2425-53
STEP 217 STEP 220
Add lubrlcation to the liner Use clean engine oil lnstall thc torque angle gauge. Position and lock the
holdrng rod. Turn the pointer to 60 degrees Tigh:cn t:c
bolt untll the pointer is at 0 degrees.
STEP 2]B
STEP 221
MAX|MUM LENGTH
1 19.25 mm
619 1
Measure the length of the main bearing bolt lf the bolt

length is more than 119.25 mm thc bolt must bc re-
claccd.
IMPORTANT'. Each bolt length musl bc checked

STEP 219
Pul a d,al indrcator on thc crankshafl gear Chcck lnc

crankshatt cnd clcarance Thc cnd clcarance must DC
0 137 to 0 264 mm. lf the clearance is more ihan 0 332
mn:, aftcr all ihe main bearinq liners havc becn re-
placed, the cranksha{i must be replaced
NOTE: T:: rget an accurate readrng, use a pry bar

Add lubricaiion to the cap bolts Insta I thc cap bolts bci'ween the crankshali and the number tuvo and
number four main bearing caps as shown abave.
and tighten io a torque of 80 Nm
Rac 8-26084 Fevisec 2-92 Printed in U S.A
kaukazz@yahoo.co.uk
2425-54
STEP 222 STEP 225
lnstall thc gaskct housing and thc housing bolts lnstallthc thrust plate and tightcn thc bolts to a torque oi
Irghten ihc bolts to a toroue at 21 io 27 Nm 18 lb 2l to 27 Nm
STEP 223 STEP 226
Pul a dral inc cator on lhc camshaft gear' Check the

clcan eng nc oli cao<lasn Dciwccn :frt-' camshaf: gcar and thc cran-
kshafl gcar Backiasf' rnusl bc 0 08 to 0 33 mm lf
bac<lash rs ,rorc ihan O 33 mm, ihc gears must be rc-
STEP 224 oiaccd
NOTE: Too much backlash can also be caused by a

war'. camshan bush'ng
STEP 227
Makc sure thc timing marks on the cranksha+t and

cai-rshaft are aligncd
Bcmovc :hc o:ns irom thc littcrs
Ilac B-26084
Bcv scd 2-92 Printed in U S A
kaukazz@yahoo.co.uk
2425-55
STEP 228 STEP 231
lnsial hruo guide bolls and thc brcather cover Install the ifter covcr and the lifter cover bolts Tigh:cn
lhe bolts lo a torquc of 21 to 27 Nm
STEP 229
STEP 232
Re movc thc protcct vc cove r f rom the gaskct l:stall thc

gaskcl cn lhe liiicr covcr' lnstall the nlection pump and the hand primer purro
Scc Scclion 341 I ior thc CAV oump and Scction 3a 1 2
for thc Boscl'r pLrrap rn the se rvrcc manual.
STEP 230
STEP 233
Install ncw scals on ti.rc r'ir:r cover Dolis

Add lubrication to thc cvlrnder walls and ptston rings
Use ciean enginc o i
NOTE: To remove the glaze from the cylinder walls do

Sleps 95 through 97.
nac B-26084 Revised 2-92 Printod in U.S A
kaukazz@yahoo.co.uk
Install thc ring compressor on the piston and carcfully Clean irc connccting rod iournals and thc bearlng
push the piston down into thc cylinder. incrs. Put a prcce of plastigage on thc rod cap llner or
lhc rod iournals
IMPORTANT: Make sure that the word FBONI is
STEP 237
toward the front of the engine. Make sure the correc[
connecting rad is in the correcl cylinder' ,1, |l
..,r4",i:}*€i:
_"-** ,r5*
T687
lrs:al :i-c b,ca'tng caos.
NOTE: Make sure the numbcr on lhe bearrng cap rs
eeual to lhc number on the connecting rod.

lnstallthc bearing liners on the connccting rods and rod STEP 238
caps
IN4PORTANf . Make sure the liner locks are aligned

when tnstalling the liners. Use a sliding type maventent
when installing tne liners Never push on thc center of MAXIMUM LENGTH
thc liners. 59.25 mm
Measurc thc lcngth of the connecting rod bolt lf the bolt

length is more than 59 25 mm the bolt must be re-
placcd
IMPORTANT: Each balt tength must be checked

before rnstallation.
Rcvised 2-92 Prinled in U.S A

Bac B-26084
kaukazz@yahoo.co.uk
2425-57
STEP 239 STEP 242
Tignlcn thc connecring rod bolts to a torqL;e of 60 Nm Add lubr cation to the bearing liners Usc clcan eng ne
oil.
STEP 240
STEP 243
lnstall the torque angle gauge. Posilion and lock ihc

holding rod. Turn the pointer to 60 dcgrccs T ghicn lhc Measurc the length of the conne cting rod bolt. lf the bolt
bo t untjl thc po ntcr is at 0 dcgrccs length is morc than 59.25 mm the bolt rnust be rc-
piaccc
STEP 241 IMPORTANT: Each bolt length must be checked

before lnstallation.
STEP 244
Remove thc bcaring caps and check thc clca!'ancc

The clcarancc musl bc 0 023 to 0 089 mn' if i1c clear-
ancc is morc than 0 114 mm, undcrsizc [.rr:ar'rg incrs
rrusl bc lnstal cd and reconditioning o' lnc bcaring
lournals rnust be donc. lnstall ncw beartng liners which Add lubrlcation to thc rod bolts lnstall the rod bolts and
wi 1 givc a clcarance of 0 023 to 0,089 rrnr righten :o a torque of 60 Nm
Rac E'26C84 Rcvised 2-92 Prinled in U.S A
kaukazz@yahoo.co.uk
ma-
Clcan the rear crankshaft seal surface of all forelgn
lnstall the torque angle gauge. Positlon and lock thc solvcnt See seal installation
tcrial, using Loctitc safety
holdrng rod Turn the pointcr to 60 Ccgrccs Tightcn thc and
in this sectlon for installing thc rcar crankshalt scal
bolt unlil the pointcr is at 0 degrees housrng
the flywhcel
STEP 246
installing
lnslall the cYlindcr head Sce Section 2415lor
:hc cv ,nder head
lo a iorquc ol 54 to 66 Nm
STEP 247 STEP 250
forctgn ma-
Cican tnc iront crankshaft sea surfacc of all 2445lor
lnstall a ncw oil inlet tube gaskct See Section
tc,iat using l-ocllic safcty solvcnt. Sec scal installation :nlet tuoc installattor
seal and oil
rn tnrs secitn for lnstalling thc fronl cranksnaft
rhe crankshaft PulleY
Fevisco 2-92 Printci r USA

Rac B-26084
kaukazz@yahoo.co.uk
2425-59
STEP 251
lnstall thc e ngrne oil oan. Scc Section 2445 iar oil pan
instailation
CAMSHAFT
Removal
STEP 252 STEP 254
Bc'r:ovc thc ian oullcy bolls and thc far puticy
STEP 255
Hcn ovc rhe cranksnaft pulley bolts and tne crankshaft

pulicy
thc belt tcr-'sioner a.C ri-'move ''.e 'Ar bc :
nac 8-26084 Rcvlsed 2-92 Plnted in U.S.A
kaukazz@yahoo.co.uk
242s-60
STEP 256 STEP 259
(e,l
Removc the front covcr boits and tnc froni covcr Romovc thc valve cover bolts and the valve covers
STEP 257 STEP 260
Disconnect ihe lucl lines and rcrnove thc inlectlon Removc the rockcr arm bolts, rocker arm assemblrcs
pump Sce Se ction 341 1 for thc CAV pump and Soction and the push rods.
3412icr the Bosch pumc in the scrvcc man'',;a!
STEP 261
STEP 258
Removc thc liftcr cover bolts, breather cover and the

Disconncct thc luol lincs and remove the prtmer pump littcr covcr
Rac B-26084
Revised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
1415-A I
STEP 262 STEP 264
Raisc thc iiflers and install rctaining pins to ho d the Bemove thc camshaft thrust platc
iftcrs in p1acc, whcn thc carnshaft is removed
STEP 265
STEP 263
Rcmovc thc camshaft irom the enginc block

Bemove the bolts from thc carnshaft ihrust platc.
Camshaft Bushing Removal and lnstallation

STEP 266 STEP 267
Fcrnovc ihe engine oil parr Scc Scc:ron 2415 in i:c Mcasurc thc camshafi bores. Use a borc gauge. The
scrvrcc rnanual borcs must be measurerJ in two positions. Takc a
second measureTncrl 90 o'cgrccs from the first mcasu-
rcn cnl
Pao B'26084 Bevrscd 2-92 Printed n U.S A
kaukazz@yahoo.co.uk
It thc bushing diamcter is morc than 54.146 mm, thc Put a bushing pullcr in the engine block and pull the
front camshaft bushrng must be replaced bushing ou: of thc cylinder block.
STEP 269 STEP 272
lf ihe intermcdiate or the rear bores are more than lnstall the bushing on the puller, Align the oil holes Pull
54.146 mrr, disassemble the cnginc block and linc thc bushing into the cylinder block until it is even with
bore the bores. See Section 24A1 tn the scrvicc manual thc housrng.
for rrachintng dimcnsions
STEP 273
STEP 270
lnstall thc gaskei housing and the housing bolts

Bemovc thc front housrng bolts and the front housing Tightcn thc bolts to a torquc oi 21 to 27 Nm
Ra:8 26184 Rcvrscc 2'92 Printed in U.S A
kaukazz@yahoo.co.uk
242s-63
Valve Lifter lnspection

STEP 274 STEP 277
r*
Remove thc retaining pins from thc liftcrs and remove Measure the outsidc diameter of thc valve liftcr stem.
the lifters Bcplace thc valve lifters if the outsidc diarneter of thc
lillcr sicrn ls e ss thar 15 936 mm
STEP 275
STEP 278
Mcasurc the li*tcr b,crcs Use an cxpandable bore

gaugc. n cnginc oil on thc lrltcrs beforc installation
STEP 276
;@e
ramol
l: thc diamelcr of thc iftcr borc is rnore :han 16.055 mm
thc cnginc block must bc rcplaccd
8ar B-26084 Revisod 2 92 Printcd in U.S A
kaukazz@yahoo.co.uk
1425-44
Camshaft Disassembly and lnspection

STEP 281
STEP 279
i,;:iilXiir iiiiii
nEnn iii
!r rt riiii:irii:
,rirtlffili+ii
T69065
Measrre thc front and reai'of each bearing surface

on
Press thc gear off the camshaft micrometer'
thc camsi'afi. Usc a
STEP 280 STEP 282
T69064
Removc the shaft keY post-
Eaci bcarrrrg suriacc must be mcasured in four
inn. Measlrc ihc fronl and rcar bearing surfaces
again 90 dcgrccs fron thc first mcasurcment
af
NOTE: Replace the camshaft if the outside diameter
any bearing sulace ls /ess than 53 962 mm
Ilevlsec 2-92 Printed in U S A

nac 8-26084
kaukazz@yahoo.co.uk
Camshaft Gear lnstallation
STEP 283 STEP 285
lnstal the shaft key. lnstall thc camshaft gear on the camshaft with the lock
pin hoJe down.
STEP 284
l-1cat lhc camshaft gcar a minimum o{ 45 m nutes at a Always wear heat protective gloves to prevent
tempcrature of 250"F (121"C) Use a bcarlng heater burning your hands when handling heated
OVCN, parts. sM121A
Camshaft lnstallation
STEP 286 STEP 288
Lubrrcalc thc camshaft bcaring surface with clean Install the camshaft thrust plate and tighten tl^re ilolts to
cnginc oil a torquc ci 21 lo 27 Nrn
STEP 287
./,t4$j
ffili-,,iiffi
1. TII,,4ING MARKS
Ai gn the timing marks on the camshaft with thc timing

mark on the crankshaft
Rac B-26083 Revised 2-91 Printed in U.S A
kaukazz@yahoo.co.uk
Install two gurdc bolts and lnstal thc oil brcather cover
Check thc camshatt cnd clcarancc \^/lih a d al indtoator
Thc cnd clearance must not bc more than 0130 to
0 470 mm lf lhe c earancc is morc than 0 470 mm ihe STEP 293
camshaft thrust platc rnust be repiaced
STEP 290
lnstall a new gasket on thc liftcr cover

::]'](,::lw:):@,r
Put a dial indrcator on thc camshaft gear and check
thc
gcar c carance bcueen thc carrshaft gcar and thc STEP 2it
Irankshaft gcar Gcar clcarancc mlrsi bc 0 08 to 0 33
mrn ihe glars must bc rcplaceci 'i :hc ciearancc is
more than 0 45 rnm.
NOTE: Too much gear clearance can also be caused

by worn camshalt bushings
STEP 291
lnstall the ifter covcr and liftcr cover bolts Tightcn the
bolts to a torquc ol 21 io 27 Nm
Rerrc;ve lhc rctaining pins frorn ihc liiicrs

RcviscC 2-92 Prinicd in U S A'
nac B'2608,1
kaukazz@yahoo.co.uk
2425-67
295 STEP 298
lnstal thc inlcciion purnp on thc f.ont housrng Scc Sce Section 2415 tn thc scrvicc manual for rockcr arm
Section 341 1 for thc CAV purnps and Secticn 3412 tor installat on
the Bosch pumps in the scrvicc manual for inicc:ion
pump irstallation.
STEP 299
STEP 296
Sce Scction 2465ia ihe scrvice manual to installthc lur-

bocrarge:r
Clcan .l'rc cranksha't scal suriacc ,vilh Loctitc salcly
soJvcnl Scc iront seal nsta ia: or r iiris scction
i
STEP 3OO
st-EP 297
r'l:lt. l, (' a" :,1'cy and bolts
lf thc enginc oi pan v/as removed, see Scclior'- ?445 ta
ihe scrvice manual for rnslalla:ron.
Fac I 26084 Rcvised 2-92 Printcd in U S.A
kaukazz@yahoo.co.uk
STEP 302
Lift the bcit tensioner and install the fan belt Tighten the fan pulley bolts as follows:
GraoeBBS,zcVB 25 to 31 Nm
C'a:e-09SzcVB 37 to 43 Nm
Crarc B B S.zc ll 10 51 to 62 Nm
C'acc '0 9 S:zc M10 51 to 62 Nm
FLYWHEEL
Removal
STEP 303
Remove the flywheel bolts and the flywhecl from the

flywheei housing,
kaukazz@yahoo.co.uk
2429-69
Ring Gear Removal and lnstallation
STEP 306
Remove the ring gear from the flyr,vheel, using a drift lnsrall the llywheel bolts and the the flywheel Tighten
and hammer Work around the circurrference of the the retaining bolts to a torque of 130 to 144 Nm
ring gear,
STEP 305
Heat the new ring gcar, 400 to 450"F (204 to 232"C) ln

oven. Do not use a torch to heat the ring gear.
orl or in an
lnstall the ring gear on the flywhccl.
Always wear heat protective gloves to prevent

burning your hands when handling heated
parts. sll l 21 A
Rac 8-26084 Revised 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
2425-70
EXPANSION PLUG REMOVAL AND INSTALLATION
60 mm ExPansion Plug, Camshaft
NOTE: The ftywheel and flywheel housing must be
rernoved to replace the camshaft expansion plug.
STEP 307 STEP 309
Rcr.ovc thc cxpansron plug lrom thc cylindcr block Aocly loctite 277 la ihe sealing surlace of the expan-
sion plug
STEP 308
STEP 310
Usc L octtre safcty solve nt to clcan thc sealing slrfacc

lnstall thc cxcansion c ug into ihe cylindcr block Hit the
of il forerqn matcrral.
expans on oluq in the ccntcr to lock the expansion plug
in pos : on

Rac 8-26084
kaukazz@yahoo.co.uk
2425-71
58 mm Expansion Plugs
STEP 31 1 STEP 314
1, CHAMFER
Removc thc expansion plug from the cylinder block
STEP 312
Clean thc sealing surfacc of ail forcign matcrrai

lns:a I thc cxpansion clug into the cylindcr block unitl
thc lop cdgc of thc cxpansion plug is cven wtth thc
STEP 313 bottorn ecEe or lre chan fcr
Apply Lcctrlc 277 :o'.te sealing surfacc of thc cxOan-

sion plug.
kaukazz@yahoo.co.uk
26 mm ExPansion Plugs
STEP 318
STEP 315
2. EDGE
1. CHAMFER
block
Bemove the exPansion Plug from the cYlrnder
STEP 316
of all Ioreign rralerial

lnstall thc expansion plug lnto the cylinder block
until
edge of thc expansion plug is cven with the
thc top
ooilom edgc of thc cham{cr
Apoy Loctite 277 lo thc seal ng surracc ol lhc

cxpan-
ston o lg.
Revised 2-92 Printed in U'S'A

Fac 8'26084
kaukazz@yahoo.co.uk
2425-73
22.5 mm Expansion Plug
STEP 319 STEP 322
CHAMFER
1. EXPANSJON PLUG
re
B93LO
Remove thc expansion olug from thc cylinccr b,locx
STEP 320
Install the cxpansron plug into the bore, until the top
edge of the expansion plug is evcn with the boitorn
cdgc ol lhc chamfer
C can thc expansion plug borc of all forcign rnatcrial,

use Loctitc safcty so vcnt
STEP 321
Aoply Loctrtc 277 lo ',itc scaling surfacc of thc cxoal-

sion p ug
Fac E-2638.1 Rovised 2-92 . Pr nted in U S.A
kaukazz@yahoo.co.uk
2425-7 4
1B mm Expansion PIug
STEP 323 STEP 326
Put a small amount of grease rn the expansion piug Use Loctite safcty solvcnt to clcan the scaling surface
oi ali fcreign maleriai
STEP 324
STEP 327
Dr r a small holc rn t!c ccnter oi thc cxoar.rston Plug

Apo y *cct la 277 '.c:he sealing surface o{ the expan-
sion piug
STEP 325
1ns:al a scrcw rn thc expans on plug and rcmovc lhc cx-

pansrc)r olug frori- thc cylinder bLock
Rac B-26084 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2425-75
STEP 328
2. CHAMFER
3. EXPANSION PLUG
Insiall the expansion plug inlo tne cylinder brock unt'l

thc top cdgc of ihc cxoansrorr ciuq is cvcrr with thc
botiom cdgc ol Ir rc u"a''"u'
10 mm Expansion Plugs
STEP 329 STEP 330
Put a small amount of grease rn lhe expansion plug Driil a small rolc in the ccntcr of the exoansion plug
nac 8-26084 Revised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
STEP 333
lnstalla screw in thc expansion plug and pullthc cxpan- Aoply Loctitc 277 lo the sealing surface of the expan-
sion plug out of the cylindcr block sion plug
STEP 332 STEP 334

1, CHAN,IFER
3. EXPANSION PLUG
Use l-oclite safety so vcnt to clean the sca/rng surfacc

o; atl {orcien materrai
l':sia I :hc r::.lransron p ug ,nto thc cylindcr block until

oc coge of the expansion plug is cven to the
1:1,.-.
ccl:crrr edgc oi the chamfcr
Rac B-26084 Reviscd 2-92 Printod in U S.A
kaukazz@yahoo.co.uk
z4t5-/ /
CRANKCASE PRESSURE CHECK (BLOW BY)
Manometer I nstallation
STEP 335 STEP 338
Loosen the clamp and removc the breather hose Turn cach connector on the manometer one turn
countcrclockwise.
STEP 336
STEP 339
instal the brcather adaptcr wrth the six cylinder orifice

Connect ihe tube from thc breather adaptcr to one oi
NOTE: Use the 7.67 mm ior slx cyiinder erlgincs. thc conncctors on the manometcr
STEP 337 STEP 340
lnstall thc manometcr Push the button on the gaugc and move the gauge u0
or down, untrlthc zcro on the gauge and thc iiquid in thc
tube are alrgned
Rac 8-26084 ncvisec 2-92 Pr n-cd ir J S A
kaukazz@yahoo.co.uk
2425-78
Testing
NOTE: Do the followrng Steps to get the correct man- MANOMETER READING
ometer readings.
lnches ot
- Warm the engine to operating tempcrature Water Umin
Step 1 '
:t , EO
Step 2 - Operate the engine at the rated speed,
2 84
- Use the hydraulics to apply a load to the 3: 103

Step 3
engine during the manometer test 4 119
J 13;31
o 145
STEP 341
It55
B 164
I 17i
10 180
11 187
12 193
13 ioo'
14 luo
15 211
lf) ?_17
17 222
Take a manometer reading from thc engrnc Add thc tzo
1B
number of lowered inchcs to the number of raised
.22.9
nches for the correct manornclcr rcading' Scc 19
cxar'nplc below. 20 231
LOWEBEDll';61-165 +15
RA]SED INCHES 1,5
CRANKCASE PRESSURE
TOTAL 3,0 INCHES
(BLOW BY) LIMITS
Scc thc chart for manometer reading and crankcase
pressurc (Blow BY) limrts Engine Enginc Umin Umin
Model Specd Maximum New Worn Limit
6-590 2100 ,c( 51.0

:::
2200 260 520

2600 3O.0 60,ts':
6T-590 21 00 600 120 0
220tA 63.0 12.6..0
6TA-590 21 00 600 120.0
2200 6a,o 126.0

Rac 8-26084
kaukazz@yahoo.co.uk
2425-79
Manometer Removal
STEP 342 STEP 345
D sconncct the tube from the connector Remove thc adapter trcm the brcather tub,e
STEP 343 STEP 346
iurn cach connoctor cn the manomctcr one turn clock- Inslall brcather hosc and tighten thc clamp
lvisr:
STEP 344
Remove thc manomcicr
Bac B-26084 Revrsed 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
Section
2445
LUBRICATION SYSTEM
Oil Pan, Oil Pump, Oil Cooler and Oil Filter Housing
6-590 Diesel Engine
IMPOHTANT. This engine was made using the metric measurement system. All
accurate readrng when rnspecting parts.
Coovrroht @ 1992
Rac 8-26093 Printed in U.S.A.
CASE CORPORATION October, 1984 (l?evised January, 1992)
kaukazz@yahoo.co.uk
2445 2
TABLE OF CONTENTS
SPECIFICATIONS
SERVICING THE LUBRICATION SYSTEM

Orl Pump Bemoval
OIL PRESSURE RELIEF VALVE

Rclief Valve Disassembly ...,
Relief Valve Assembly
O]L FILTER HOUSING AND OIL COOLER

Oil Filter Housing and Oil Cooler Removal . 10
Orl Cooler and Filter Housing lnstallation ,. 11-12
OIL PAN AND OIL INLET TUBE

O,l Pan Removal. . ... .12
Orl lnlet Tube Ren oval ,
12
13
Oil Inlet Tube lnstallation
O,, Par lr-stallation . ..... 14
Rac B-26093 Fevised 1-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2445-3
SPECIFICATIONS
Oll Pressure
New Engine at Low |dle............ .. 1,9 to 3.0 Bar 28 to 43 PSI
New Engine at High ldle..... .. .. . 3 0 to 3.7 Bar 43 to 54 PSI
Used Engine at Low ldle (Minimum) . . . ,,.,...,.0 7 Bar 1O PSI
Used Engine at High ldle (Maximum).. . 2.1 Bar 30 PSI
Oil Pump ldler Gear to Crankshaft Gear Back|ash,,,,.,,..,..,,,,. ...,.,,.0 450 mrn
Oil Pump Rotor Clearancc,........,... .0178mm

;
Oll Pump Relief Valve Spring Specification (2 Hole Helief Valve)
Free Length . 55.83 mm
Compress to 39,98 mm 95 ro 113 N
Oil Pump Reliei Valve Spring Specilication (4 Hole Relief Valve)

.,,64 0 mm
Compress to 41 .25 mm.. ........ .. .. . 104 7 N
SPECIAL TORQUES
Front Cover Bolts 21 to 27 Nm
Cranksna+t Pulley Bolts .... 1201o 130 Nm
Fan Pulley Bracket Bolts .

23 to 25 Nm
Fan Pulley Bolts

Crade88SizcM8 26 to 31 Nm
Gradc 10 9 Srzc MB 37 to 43 Nm
Gradc 8 B Sizc Ml0 51 to 62 Nm
Grade 10 9 Slzc M 10 51 to 62 Nm
Fihcr Hcad Bolts . .. .. .......21 to 27 Nm
Oil Inlet Tube Brace Bolt. 21 to 27 Nm
Oil lnlet Tube Flange Boll .18 to 30 Nm
Oil Pan Bolts .

...21 lo 27 Nm
Oil Pan Drain Pl;g . .. 68 to 82 Nm
Oil Pump Mountlng Bolts 21 to 27 Nm
Relief Valve Plug 108 to 132 Nm
Rac 8'26093 Revised 1-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2445-4
SERVICING THE LUBRICATION SYSTEM
Oil Pump Removal
STEP 1 STEP 4
Lift the belt tensioner pulley and remove the fan belt Fcmove the front cover bolts and the front cover.
STEP 2 STEP 5
Remove the bolts and thc fan beli culley Remove the oil pump bolts and thc oll pump
STEP 3
Removc thc crankshaft pullcy bolts and thc crankshait

PI, CV
kaukazz@yahoo.co.uk
2445-5
Disassembly, lnspection and Assembly
STEP 6 STEP B
T68767
Put the oil pump on a clean work surface Mcasurc the clearance belween the lobe on the gcar
and lobe on the pump body if the clearance is morc
than 0 178 mn' thc pump must be replaced
STEP 7
STEP 9
f :@"=
'i",@
\,
e.d
T68765
Remove the back cover plate
lnstall the back cover plate on the oil pump.
Bac 8-26093 Revised 1-92 Prlnted in U S.A
kaukazz@yahoo.co.uk
2445-6
Oil Pump lnstallation

STEP 12
niirf f ti oil pump and tighten the bolts to a torque of

f
Clean the seal sur{ace on the crankshaft with loctite
21 lo 27" Nm. Follow the torque sequence above' safcty solvent Sce Section 2425 in the service manual
for front cover installation,
NOTE: To prevent damage to the oil pump do nol
tighten thc bolts more than 27 Nm. Therc will be a small
c"learance betvveen the oit pump flange and the cyhnder
block.
lnsiail thc crankshaft pullcy bolts and tighten to a torque

of 120 to 130 Nm
STEP 14
Check the backlash between the oil pump idler gear
and the crankshaft, Put a dial indicator on the otl pump
idlcr gcar l{ thc backlash is more than 0 450 mm thc oil
pump must be rePlaccd.
Install the fan pulley and the bolts
116vi5sl 1-92 Printed in U S.A

Rac 8-26093
kaukazz@yahoo.co.uk
2445-7
STEP 15 STEP 16
Lift the fan belt tensioner puiley arrd instail thc fan belt Torque thc tan pullcy bolts as follows:
Graoe 8.8 Size MB 26 to 31 Nm
G"aoc l0 9 Size IVB 37 to 43 Nm
Cradc8BSrzeM'10 . 51 to62Nm
Graoe 10 9 Size V10 . 51 to62Nm
Rac 8-26093 Revised 1-92 Printed in u.s.A
kaukazz@yahoo.co.uk
2445-8
OIL PRESSUHE RELIEF VALVE
Disassembly and lnspection
Bottom Mounted Relief Valve Top I Relief Valve
1, PLUG
\
\
ooa*r,
I
_*o
uotut\F]
- --
ru!lrrl
HOUSING
/s RELIEFVALVE
U-5 4. FILTER HOUSING
RELIEF VALVE SPRING

*S-3
2 cASKET
^\S-
Nl- 1. PLUG
STEP 17 STEP 18
Femove the p1ug, gasket, spring and rclicf valve from Check the relief valve spring for the following specif ica-
the filter housing tions:
Relief Valve Spring (2 Hole Relief Valve)

Free Length .. 55.83 mm
Compress to 39.98 mm , .. .. .. ., . .. . 95 to 1 13 N
Relief Valve Spring (4 Hole Relief Valve)

Free Length ...640Nm
Compress lo 41 .25 mm,,..,...,..,.. 104.74
Rac B-26093 Revised 1-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2445-9
Relief Valve Assembly
Bottom Mounted Relief Valve Top Mounted Relief Valve
1. PLUG
5,
U-
OIL FILTER HOUSING
RELIEF VALVE
5. OIL FILTER HOUSING

.St\
-t\\-,
,tN-:+3. RELIEF VALVE SPRING
rN:-
S--2. cASKET
N.- 1. PLUG
401 191
STEP 19
lnstall the relief valve, relief valve spring, gasket and

plug Tighten the plug to a torque ot 108 to 132 Nm
Rac 8-26093 Hevised 1-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2445-10
OIL FILTER HOUSING AND OIL COOLEH
Removal
STEP 20 STEP 23
Bemcve the oil filter
S'|EP 21 6T-s90 and 6T4-590
Disconncct the turbocharger pressure tLjbe
STEP 22
Rcmove thc filtcr head bolts and the oil frlter head
Rac B-2ti093 Reviscd 1-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2445-11
Oil Cooler and Filter Housing lnstallation
STEP 25 STEP 28
*iiil
B,iili.
:t.&'
**8 ,',.
} :,r .:, ,i
a ,,:;,,,4a",;,,, .
u:i
r,,;',iB.',,
,rG1
,#
8,*,i
#. Ai,
ss
lnstall the cold oil relief valvc in the oil filter head lnstall a new frltcr head gasket
STEP 26 STEP 29
lnstall tvvo guide bolts 8M x 1 25 x 75 and a new oil Inslall the oil f iltcr head and the f ilter head bolts. Tighten
cooler gasket, the bolts to a torque ol 21 Io 27 Nm
STEP 27 STEP 30 6T-590 and 6T4-590 E
lnstall lhe oi cooler Connect and tighten the turbocharger pressure tube
8ac B-26093 Feviscd 1-92 P:intcd in U S.A
kaukazz@yahoo.co.uk
See thc opcrators manual for servicing the oil filter
OIL PAN AND OIL INLET TUBE

Oil Pan and lnlet Tube Removal
STEP 32 STEP 33
L
Remove the inlet tube bolts and the iniet tube
Remove the oil pan bolts and the oil pan
Revised 1-92 Printed ln U.S A.

Hac lJ-ZbUvJ
kaukazz@yahoo.co.uk
2445-13
Oil lnlet Tube lnstallation
STEP 36
lnstall a new gasket lnstallthe inlet tube brace bolt and tighten to a torque ol
21 rc 27 Nm
STEP 35
lnstall the oil inlet tube bolts and iighten :he bolts tc a
torque of 1B to 30 Nm
kaukazz@yahoo.co.uk
Oil Pan lnstallation
STEP 39
lnstall the oil pan drain plug and tighten to a torque of 68

Install a new oil pan gasket
1() u2 t\n
STEP 38
lnstallthc oil pan and tighten the bolts to a torque of 21
to 27 Nrn,

Rac 8'26093
kaukazz@yahoo.co.uk
Section
2455
COOLING SYSTEM
Thermostat, Water Pump, Fan Pulley
and Belt Tensioner
6-590 Diesel Engine
measurements and checks must be made with metric tools fo make sure of an
Copyrighl @ 1992
Fac 8-26'103 Printed in U.S.A.
CASE CORPORATION Ocotber, 1984 (Fevised January, 1992)
kaukazz@yahoo.co.uk
2455-2
TABLE OF CONTENTS
SAFETY RULES . .. .
SPECIAL TOROUES
SPECIFICATIONS
SERV|CING THE COOLING SYSTEM

Water Pump Removal ...,
Water Pump lnstallation
TH ERN/OSTAT REPLACEM ENT

Thermostat Removal
Thermostat Inspection
7-B
Thermostat lnstallation
COOLING INLET SERVICING

Coolant lnlet Removal . .. ... . .. .
10
Coolant lnlet lnstallation,,,. , ,....
.11
COOLING SYSTEM AIR REMOVAL
FAN PULLEY SERVICING .tz

Fan Pulley Bracket Removal ...
.13
Fan Pulley and Pulley Bracket lnstallation
BEtT TENSIONER SERVICING 14

Belt Tensioner and Bracket Removal... ..
15
Belt Tensioner and Bracket lnstallation
lo-l/
THERMOSTAT SERVICT .. .
Fcviscd 1-92 Printed in u.s.A

Rac 8-261 03
kaukazz@yahoo.co.uk
2455-3
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READTHE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILIW OF PERSONAL INJURY
OR DEATH. r/1718
SAFETY RULES
Add coolant to the radiator only when the engine is sfopped or slowly
idling.To avoid being scalded when the pressure-type filler cap is being
removed, turn the cap slowly to the first stop position to relieve prcssure
before removing the cap. M346
To remove the system pressure, slowly turn the radiator Never put coolant in a hot engine, The engine block or
cap counterclockwise to thc FIRST stop. This willpermit cylinder head can get cracks because of the diFference
a gradual release of pressure with little coolant loss. in temperature between the metal and coolant,
How to Clean the Cooling System

CIean the cooling system a minimum of one time each 3. Remove the radiator cleaner solution. Flush the
year. ln areas where the water has minerals, clean the system with clean water. Fill the system with anti-
system with more frequcncy. freeze and water for operation. Check the hoses,
radiator and water pump for leaks.
1 , When the coolant is hot, open the radiator drain
valveandremovctheengincblockdrarnplug Close NOTE: Afterthecoolingsystemiscompletelyfilled,run
after
thc valve and install thc cngine block drain plug the engine for approximately 20 minutes to remove all
the system is empty. the air from the system. Check coolant level and add
coolant if needed.
2. Add a radiator cleaner and iill the system with clean
water. Use a good type ot radiator cleaner. Follow
the instructions given with thc radiator cleaner,
Rac 8-26 1 03 Bevised l-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2455-4
SPECIAL TORQUES
Metric Value
21 to 27 Nm
Water PumP Houslng Bolts
21 to 27 Nm
Thermostat Housing Bolts .. .,
39 to 47 Nm
lnlct Housrng 8olts...,..........,..
23 to 25 Nm
Fan Pulley Bracket Bolts . .
Fan Pulley Bolts 25 to 31 Nm

Grade 8,8 Size M8 . .. .
37 to 43 Nm
Grade 10.9 Size M8
51 to 62 Nm
Grade 8.8 Size M10
51 to 62 Nm
Grade 10.8 Size M10...... .... .
21 to 27 Nm
Tensioner Bracket Bolts . ..
39 to 47 Nm
TensionerBolt . ..
21 to 27 Nm
Alternator Bracket.,.......
SPECIFTCATIONS
Belt Tension: 24 Nm
Spring Tension at 35 degree angle (minimum)
Revised 1-92 Printed in U S A

Fac 8'261 03
kaukazz@yahoo.co.uk
2455-5
STEP
Lift the belt tensioner oulley and remove lhe fan Dell Ren ove thc water pump bolts and the water oump
Water Pump lnstallation

STEP 3 STEP 5
Install a ncw o-ring in lhe waicr oump itousrntt Lrtt thc belt tcnsioncr puiley and install the fan beli.
IMPORTANT: See Steps 23 through 27 to remove the

STEP 4
air from the cooling systern.
lnstall thc wa:cr pump ano tnc waier purlp bol:s

Tightcn lhc bolts to a lorcrre ctl ?1 to 27 Nrn
Rac 8-26 1 03
Revised 1-92 Prlntcd in U S.A
kaukazz@yahoo.co.uk
z4c3-o
THERMOSTAT REPLACEMENT
Thermostat Removal
STEP 9
L ft thc bc 11 lCnsioncr puitey ano rcrrovc trc far bcrt Rcmovc thc thcrmostat housing asscmbly
STEP 7 STEP ]O
3 IIFT BRACK='\
tg
1-s N
4, THEBMOSTAT HOUSING
t's .,
.d. d
rs ',i -s
Bcrnovc the allcrnalor bolts and the altcrnator

T80041 &
Disassemble the thcrmostat housing
THEEMOSTAT
2. SEAL
STEP 8
180,044
Rcmovc thc alternator brackct bolis and ihc bracket
nac 8-26103 Reviscd ,92

1 Printed in U S.A
kaukazz@yahoo.co.uk
2455-7
Thermostat lnspection
STEP 11
40919 l
Check the thermostat for corrcct operation Put the

thermostat in a container of hot water (approximately
175'F (79.4"C). The thcrmostat should be completely
open at 203"F (95"C) Replace the thermostat if it does
not meet the above specifications.
Thermostat I nstallation
4. LIFT BRACKET
1, THEBMOSTAT HOUSING
2. THERMOSTAT
N
STEP 12 STEP 13
4. L,FT BRACK=,*A
1. THEHMOSTA''.'OU''*:^
aLv \)
&\-);
S
lnstallthe template that comcs with the new thermostal Assemble the thermostat housing
housing kit. lf the coolant passage in the cylinder head
is smaller than the template, Sce Page 16
Rac 8-261 03 Revised 1-92 Printed in U S.A
kaukazz@yahoo.co.uk
STEP 16
lnstail the thermostat housing asscmbly. Tighten thc

bo rs to a torquc of 21 to 27 Nm
STEP 15
T80043 Lifi the bclt tensioner pulicy and install the fan belt
lnsiall ihe alternator bracket and tighten thc bolts to a
torcue of 21 lo 27 Nm IMPORTANT: SeeStep 25 through 27 to remove the alr
from the cooling system.
Fac 8-261 03 tlevised l-92 Printed in U.S.A
kaukazz@yahoo.co.uk
COOI-ANT INLET SERVICING
Coolant lnlet Removal
STEP 1B STEP 20
Lift the belt tensioner pulley and remove the fan oell Remove the coolant inlet bolts and the coo ant bolt
STEP 19
\:,:
T80041
Rcmove the alternator bo ts and the alte rnator
Rac 8-26142 Rcvised 5-9 1 Printed in U.S.A.
kaukazz@yahoo.co.uk
2455-1 0
Coolant Inlet lnstallation
1, COOLANT INLET
e. \ 1. cooLANr rNLEr
41 '1t91
STEP 21 STEP 23
rffit{l
&Oll
&;
r. iJLL FLCi'i
J3C326,1
T80056
lnstall a new o-ring for tho coolant inlet lnstall thc alternator and tighten the bolts
STEP 22 STEP 24
lnstall the coolanl inlct bolts and tlghten to a torque of Lift the belt tensioner pulley and install the fan belt
39 to 47 Nm,
Reviscd 1-92 Printed in U.S.A

Rac 8-261 03
kaukazz@yahoo.co.uk
2455-11
COOLING SYSTEM AIR REMOVAL
Engine STEP 27 6.590 E
Loosen the plug on the cylinder head to remove the air Loosen tne plug on the cylinder head to rcrnove the arr
from the coollng system. from the cooling systcrn.
NOTE: See the operalars manual far the correct frlhng NOTE: See the opcrators manual for the correct frllrng
praceCurc. procedurc.
STEP 26
Looscn the plug on thc attcr coolcr to remove thc air

frorn the coolino systcm
NOTE: See lhe operatars manual for the correct frlling

procedure.
nac 8-261 03 Revised 1 -92 Printed in U.S.A
kaukazz@yahoo.co.uk
2455-12
FAN PULLEY SERVICING
Fan Pulley Bracket Removal
STEP 28 STEP 30
Lrfi ihe belt tensioncr pulley and rcmove the fan bc i Bcmove thc bracket bolts and :he bracket
STEP 29
Pc;-ove :"e 'a. pu ey boiLs arrd |hc 'ar pu cy
Fac 8-261 03 Revised l-92 Printed in U S.A.
kaukazz@yahoo.co.uk
aAtrc 1')
Fan Pulley and Pulley Bracket lnstallation
STEP 31 STEP 33
lnstall the pulley brackel and pulley bracket bolts Lift the beit tensioner pulley and install the fan bell
Tighten the bracket to a torquc of 23 to 25 Nnr
STEP 34
STEP 32
Torquc ihc fan pullcy bolts as tollows:

insta Ine fan cuJley and bclts Graoe8BSzeMB 25 to 31 Nrn
C'aoc l0 9 Szc Nl8 37 to 43 Nm
G'attcB8S,zcM10 51 tc 62 Nm
Graoc 10 9 Sizc V10 51 to 62 Nm
Fac 8-26 1 03 Rcvrsed 1-92 Printed in U.S.A
kaukazz@yahoo.co.uk
2455-14
BELT TENSIONER SERVICING
Bett Tensioner and Bracket Removal
STEP 37
pullcy
R"oou" thc bolts and the fan belt
Lift thc belt tensioner pulley
and remove the fan bcli
STEP 38
,tii':
belt tensioner
o"ror. the bclt tcnsioner bolt and the
anci the belt tensioner

ncmoue lhc Allcn head bolts
bracket.
wrench to
NOTE: Do not usc a click b/pe torque
measure he s7ing ension' Revised 1-92 Printed in U'S A'
Rao 8-261 03
kaukazz@yahoo.co.uk
2455-1 5
Belt Tensioner and Bracket lnstallation
STEP 40 STEP 43
lrsia lhe tensior:er crackct and :r-rc Ailcn hcad bolis Lft the belt tcnsioncr pLr cy and install thc fan b,cL:
Trghtcn thc Al cn head bolts to a torque oi 2.1 io 27 Nm
STEP 44
STEP 41
Torquc lhc ian pullcy bolts as follows

lnstall the bcli tens oner anC :hc bclt lcnsioncr boli GradcBBSizcMS 25 to 31 Nm
Trghten thc boli to a iorcL,c oi ll9 lo 47 Nr G'aoc 10 9 Szc It/B 37 to 43 Nm
GradcBBSizcM'10 5l to 62 Nm
C'aoc 10 9 S,zc M l0 51 to 62 Nm
STEP 42
Rac 8-261 03 Revised 1-92 Printed in U.S.A
kaukazz@yahoo.co.uk
STEP 45 STEP 47
1. NEWTHERMOSTAT 2. OLDTHERMOSTAT
309191 31 0191
A new thermostat has been released for use in your cylinder head coolant passage is smaller than the
lf the
engine. lf you removed an old thermostat from your lD of the template, the coolant passage will have to be
engine, do the following steps to install a new ther- made larger Mark the lD of the template on the cylinder
mostat, head.
STEP 48
STEP 46
9
lW
0
3 2191
rN,
1
l,| Remove the template. Use a shop cloth in the coolant

Ir r\ passage to kcep foreign material out of the engine. Use
31rL9l a rotary grinder to remove the material.
lnstall the template that comes with the new thermostat
kir.
Rac 8-261 03 Revised 1-92 Printed in U.S.A.
kaukazz@yahoo.co.uk
2455-17
STEP 49 STEP 50
31 4191
Remove all foreign material from the cylinder head Mark the cylinder head on the intake side next to the
lnstall the seal and new thcrmostat Tighten the bolts to serial number as follows:
a torque of 21 to 27 Nm,
Stamp the letter "G" for cylinder heads that were in-
spected and did not need to be machined,
Stamp the letter "M" for cylinder heads that were mach-
ined
Revised
.1-92 Printed in U.S.A
nac 8-261 03
kaukazz@yahoo.co.uk
Section
2465
TURBOCHARGER
Written ln Clear
And
Simole
Engilish
IMPORTANT: fhis Turbocharger was made using the Metric Measurement

system, All measurements and checks must be made with metrictoolsto make
sure of an accurate reading when inspecting parts-
Rac 8-261 10 Printed in u.s.A.

3ASE CORPORATION October,1984
kaukazz@yahoo.co.uk
2465-2
TABLE OF CONTENTS
SPECIFICATIONS
2
SPECIAL TORQUES a
J
SPECIAL TOOLS
J
SERVICING THE TURBOCHARGER

Removal
4,5
lnspection
.6
Disassembly .... 7_13
lnspection After Disassembly . 13_14

Assembly ...-..1s-z}
lnstallation
.. 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement . 0.10 to 0.16 mm
Rac 8-261 1 0 lssued 10-84 Printed in U.S.A.
kaukazz@yahoo.co.uk
2465-3
SPECIAL TOROUES
U.S. Value Metric Value
TurbineHousingBolts. ....96 lbinch 11 Nm
(1.1kgm)
Center Housing to Back Plate Bolts 48 lb Inch 6Nm

(0.6 kgm)
Compressor Housing Bolts . 48 lb inch 6Nm

(0.6 k9m)
Compressor Lock Nut .... '120 lb inch 14 Nm

(1.4 kgm)
Thrust Bearing Screws (Torx Head) ... '.. 36 lb inch 5Nm

(0.5 kgm)
Turbocharger Mounting Nuts . z{lbll 32 Nm

(3.2 kgm)
Drain Tube Bolts . ..... 18 lb ft 24 Nm

(2.4 kgm)
SPECIAL TOOLS
CAS-I0032 L8 INCH TOROUE WRENCH

CAS-10033 LB FT TOROUE WRENCH
cAs-r0066-'l A DIAL INDICATOR
Rac 8-261 1 0 lssued 10-84 Printed in U.S.A
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2465-4
SERVICING THE TURBOCHARGER
Removal
STEP 1
STEP 4
Turbocharger with the air cleaner and the exhaust Disconnect the oil supply tube
prpe removed.
STEP 5
STEP 2
Disconnect the oil supply tube clamp from the

Loosen the air intake hose clamps tu rbocharger.
STEP 3 STEP 6
Remove the air intake hose Disconnect the oil drain tube
Rac 8-261 10 lssued 10*84 Printed in U S.A
kaukazz@yahoo.co.uk
2465-s
STEP 7 STEP 10
Remove the nuts that hold the turbocharger to the Clean the mounting surface on the turbocharger
exhaust manifold. and the exhaust manifold.
STEP 8 STEP 11
Remove the turbocharger from the exhaust mani- Clean the mounting surface on the turbocharger
old.
f and the oil drain tube.
STEP 9
Remove the gasket.
Fac 8-261 1 0 lssued 10-84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-6
Inspection
STEP 12 STEP 13
Put the turbocharger on a clean work surface Use a dial indicator to check the horizontal move-
ment of the turbine wheel assembly. The horizon-
tal movement must not be more than 0.10 to 0.16
mm. The turbocharger must be rebuilt if the move-
ment is more than 0.16 mm or less than 0.10 mm.
Rac 8-261 1 0 lssued 10-84 PrinteC in U.S.A
kaukazz@yahoo.co.uk
2465-7
Disassembly
STEP 14 STEP 17
Put a identification mark on the compressor hous- Remove the compressor housing clamp plates.
ing and back plate. This idenlif ication is to make
sure the parts are rn the cr:rrect position at assem-
blv STEP 18
STEP 15
Lift the assembly off the compressor housing.
Put a identification mark on the turbine housing STEP 19

and the back plate. This identification is to make
sure the parts are in the correct position at assem-
bly.
STEP 16
Make the tabs straight on the lock plate.
Remove the retaininq bolts lrom the compressor

housi ng.
kaukazz@yahoo.co.uk
Put the turbine end of the center housing assembly

into the holding fixture.
STEP 21
dl
S.r$.,.
.0.$ sj
plates from the

Use a double universal joint to remove the com-
turbine housing pressor wheel lock nut. This procedure will pre-
vent the turbine shaft Jrom bending'
STEP 22
STEP 25
Y-
Lift the center housing assembly f rom the turbine

hous tng.
Remove the compressor wheel lock nut'
hand
NOTE: The compressor wheel lock nut is left
thread.
lssued 1O-84 Printed in U'S'A

Rac 8-261 1 0
kaukazz@yahoo.co.uk
2465-9
STEP 26 STEP 29
- --r
Inl+iryIr:" n r'lTlpr: :
Remove the compressor wheel.
STEP 27
Remove the seal ring
Lift the center housing trom the turbine shaft. STEP 30
Turbocharger center housing"
Bemove the heat shield
Bac 8-261 1 0 lssued 10*84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-1 0
STEP 31 STEP 34
Make the tabs straight on the lock plate Remove the center housing f rom the back plate
STEP 32 STEP 35
: .i : . 1i1:,i .:., .,:.Ii i
Remove the retaining bolts f rom the center hous- Remove the oil baffle from the back plate.
ing
STEP 36
STEP 33
-...\ .i\* "t*" Femove the seal from the back plate.
Remove t he lock plates f rorn the center housing
Rac 8-261 1 0 lssued 10-84 Printed in U.S-A
kaukazz@yahoo.co.uk
2465-11
STEP 37
.L E'S
Remove the oil slinger f rom the back piate Remove the torx head screws from the center
housing.
STEP 41
Remove the seal ring from the oil slinger.

Femove the thrust bearing
STEP 39
STEP 42
Turbocharger center housing "
Remove the thrust collar
kaukazz@yahoo.co.uk
STEP 46
,,u\:;.,
Turn the center housing over and removetheouter

Remove the outer bearing retaining rinq bearing retaining ring
STEP 44
Use a wire hook and Pull the bearing

irom the trom the
Use a wire hook and pull the bearing
center housing. center housinq.
STEP 45 STEP 48
" l'i
.1..
Remove inner bearing retainlng rlng Remove the inner bearing retaining
ring'
lssued 10*84 Printed in U'S A

Rac 8-261 1 0
kaukazz@yahoo.co.uk
2465-1 3
STEP 49
Center housing disassem bled
lnspection After Disassembly

STEP 50 STEP 52
:1.. . r:.::r::rrlL. idr.
ii,i.,ll::
'ciIri.l(
i. -.1:.!rlI
r:
. :r'. :r-:r
.:tt - ,' _: !tl:..:::i
r:lil I'.1:nij,,i;llil:3si'il
:,:l'lii.iril,ilii if-*!;
-r'll.lt.:i
:":it. ".'_i
,.,r.:i;l'-r
:.: :r. l)
- .::.ii,. :: r':;
: j
, ':.:-lli:ls,l
. . r,: i::l
;r::l -ij .l+is
Replace the turbocharger il the outlet openings Replace the turbocharger if the turbine wheel is
show warpage or cracks. damaged or if the turbine shaft has grooves or
scratches.
STEP 51
STEP 53
Replace the turbocharger if the compressor hous-

ing shows damage caused by wheel friction' Replace the turbocharger if the back plate has
wheel frictlon wear.
Rac 8-261 '10 lssued 10-84 Prrnted in U.S.A
kaukazz@yahoo.co.uk
2465-14
STEP 54 STEP 56
lnspect the compressor wheel for bent blades and Beplace the turbocharger if the oil slinger shows
scratches. Replace the turbocharger if the wheel damage.
shows damage.
STEP 57
STEP 55
lnspect the center housing bearing surfaces for

Replace the turbocharger if the heat shield shows scoring or scratches. Replace the turbocharger if
damage. there is damage.
Bac 8-26110 lssued 10-84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-15
Assembly
COMPRESSOH HOUSING
COMPRESSOR WHEEL
LOCK NUT
BACK PLATE
/\
\'r( I
'@'r L<l -\\-\
TORX SCREW \
,/ tfiflii'fA
",@
,-J.=4
ri, RING
/t
RETATNTNG
--.._
""^(o
.//
K{@/I :TELD----
\l
cENrERHousrNG \l
\l \
ff \Yf
/^ TURBINE SHAFT I
@
.r* / IA
/Y*,,(
GASKET t\ /
R,NG
cLAMP
/re
,/t
PLArE
w 'EAL
{D
ll
@\\.t
M
,/" ,w
//
LOCK PLATE CLAMP PLATE
TURBINE HOUSING
NOTE: Lubricate all bearings, sea/s and the tur'

bine shaft with clean engine oil before assembly.
lac 8-261 1 0 lssued 10-84 Printed in u.s.A
kaukazz@yahoo.co.uk
2465-1 6
STEP 58 STEP 61
Install a new inner bearing retaining ring. The Turn the center housing over and install a new
round edge of the retaining ring must be toward inner bearing retaining ring. The round edgeof the
the top. retaining ring must be toward the top.
STEP 59 STEP 62
lnstall a new center housing bearing. lnstall a new bearing in the center housing.
STEP 60 STEP 63
lnstall a new outer bearing retaining ring with the lnstall a new outer bearing retaining ring with the
round edge down. round edge down.
Rac 8-261 1 0 lssued 10-84 Printed in U.S"A.
kaukazz@yahoo.co.uk
2465-17
STEP 64 STEP 67
ggffi,rir{ii'I
lnstall the thrust collar with the large OD down Tighten the thrust bearing screws to a torque ol
lb inch (5 Nm)(0.5 kgm).
STEP 65
STEP 58
lnstall a new thrust bearinq on the center housrng

lnstall the oil baffle on the center housing with the
cup side down.
STEP 66
STEP 69
lnstall new torx head screws in ther center houslng
lnstall a new seal ring on the oil slinger
Fac 8-261 1 0 lssued 10-84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-1 8
STEP 70 STEP 73
,'i
'f lB'i
s{ffi
Carefully install the oil slinger in the back plate' tnstall new lock plates and new mounting bolts'
STEP 71
lnstall a new seal in the back Plate. Tighten the back plate mounting bolts to a torque
of 48 lb inch (6 Nm)(0.6 kgm).
STEP 72
STEP 75
lnstall the center housing on the back plate' Make

sure the mark on the back plate and the center Bend the tabs on the lock Plate.
housing are aligned.
lssued 10-84 Printed in U.S.A.

Rac 8-261 1 0
kaukazz@yahoo.co.uk
2465-1 9
STEP 76
lnstall a new seal ring in the groove of the turbine lnstall the compressor wheel on the turbine shaft.
wheel.
STEP 80
STEP 77
,t
lnstall a new compressor wheel lock nut

lnstall the turbine wheel in the fixture and install
the heat shield on the tur[rine wheel NOTE: The compressor wheel lock nut is left hand
thread"
STEP 78
-\* STEP 81
\h
I l;1'1;::";1 ,::i ; ',,
\ dlr \:il1i.s.6,r;iiiii:i;..,liilr *1,'

* {ri,,1,',,t',,..- . ,.,. ,:
.
lnstall the center housing on the turbine shaft. Be

careful not to damaqe the seal ring. Use a double universal joint socket to tighten the
lock nut on the compressor wheel. This procedure
will slop the turbine shaft from bending
Hac 8-261 1 0 lssued 10-84 Printed in u.s.A.
kaukazz@yahoo.co.uk
Tighten the lock nut to a torque of 120 lb inch (14

Nm)(1.4 kgm).
ql
STEP 83
ryi'r'r':''.tli'''
'\
I . r,:,
Caref ully install the center housing on the turbine

housing. Make sure the mark on the turbine hous-
ing is in align with the mark on the center housing.
Remove the center housing assembly from the fix-

tu re. STEP 85
.t i"
.,4.
vs
If
lnstall the clamp plates and the new lock plates.
Rac 8-261 l0 lssued 10-84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-21
STEP 86 STEP 89
:11
@{
,\
ts*
lnstall the new turbine housing bolts and tighten to lnstall the compressor housing mounting plates.
a torque of 96 lb inch (11 Nm)(1.1 kgm).
STEP 90
STEP 87
lnstall new lock washers and bolts In the compres-

Bend the tabs on the lock plates sor housing. Tighten the bolts to a torque of 48 lb
inch (6 Nm)(0.6 kgm).
STEP 88
STEP 91
lnstall the turbine housing assembly on the com-

pressor housing. Make sure the mark on the center Turbocharger com pletely assembled.
housing is In align with the mark cn the compres-
sor housing.
Bac 8-261 1 0 lssued 10-84 Printed in U.S.A
kaukazz@yahoo.co.uk
2465-22
COMPBESSOR HOUSING TUBINE HOUSING
TUBINE SHAFT
kaukazz@yahoo.co.uk
2465-23
lnstallation
STEP 92 STEP 95
lnstall a new gasket on the exhaust manifold. lnstall a new gasket on the oil drain tube.
STEP 93 STEP 96
lnstall the turbocharger on the exhaust manifold lnstall the oil drain tube bolts and tighten the bolts
to a torque of 18 lb ft (24 Nm)(2.a kgm).
STEP 94
STEP 97
lnstall the turbocharger mounting nuts and tighten

to a torque of 24 lb ft (32 Nm)(3.2 kgm). lnstall and tighten the bolt for the oil supply tube
clamp.
kaukazz@yahoo.co.uk
2465-24
STEP 98 STEP 1OO
Connect and tighten the oil suPPly tube to the lnstall and tighten the air intake hose clamps.
tu rbocharger.
STEP 101
STEP 99
Turbocharger installed on engrne.

lnstall the air intake hose.
NOTEThe CASEcoRPoRATIoN reserves the right to make improvements in

design or changes in specif ications at any time without incurring any obliga-
tion to install them on units previously sold-
lssued 10-84 Printed in U.S.A

Rac 8-261 1 0
kaukazz@yahoo.co.uk
Section
2565
TUHBCCHARGilR FAI LURE ANALYSIS
CASE CORPOBATION
700 State Street
Racine, Wl 53404 U.S.A.
CASE CANADA COHPORATION

O 1996 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bac 9-78235 February,1996
kaukazz@yahoo.co.uk
?cAq_9
CAU$E$ &F PRESVOATURE TUBBOGF{ARGER FAE LI.! RE
Certain operating and n:raintenance conditions Push ln the fuel shutoff control and press
can arise *frici, could cause premature turbc- the start button. Run the englne (about 2 rnin'
cirarger failure. NOEE: The total solution to max.) at 1000 RPM until normal engine oil
the probtrern is not in repairing ttrTe failure, but pressure shows on the engine oil pressure
in dete rmining the cause. Replacing a damaged gu,rge assuring proper lubrication to the tur-
turbocharger without. determining the cause wilI bocharger"
frequently resuit in a repeat failure' 4. If the engine fires and stops, wait for the star-
ting motor to stop spinning before atternpting
Laeil< *f LubrEcatimg &it another start'
5, llo not use the starting rnotor longer than 30
This type of failure can occur when the a- seconds withor.et interruption. Wait at treast
rflount of oil i:eing supptied to the turbocharger 3 minutes between crankings so batteries
is insutticient to lubricate on cool bearing can recuperate and the starting motor can
and journal surfaces. cool.
6. Sirould the engine kill when operating under
Operating temperatures affect the volume ioad, irnrnediately restart the engine to
of oii required by the turbocharger. .4s turkro- prevent over-heating caused by stopping the
charger speed or engine ioad increases, the ttow of oil for turl:ocharger, cooling and
need for iubricating oitr increases" NOTH: In lubrication.
sufficient oil for periods as short as five sec-
onds can causa faiiure. This is why it is nec- F*sre$grt ftl?mterEal or Dirt irs the
essary to prirne the turbocharger as part of LuhrEca*img Systeaxn"
the everyday operating procedure' Ifi{FOR"
T,&N?: It is very irnportant tkrat adequate Operating the engine with contaminated oil
luLrrication reaches the turbocharger bear- wiil cause damage to the turbocharger bear-
ings and throughout the engine trefore opera- ings if the particles are of sufficient quantity'
ting the engine at rated sPeed. If the particles are large enough, they can
ctog the internal oii passages and starve the
bearings. This is another reason why it is im-
Priming The TuYbocharger portant to chrange the engine crankcase oil and
1. Place the transrnission range shift lever in oil fllters at regular specified intervatrs.
"N" Neutral position. Foreign lUlater*al irn Exha!,!st or
2. Set the throttle lever not more than 1/3 open Air lmtake $Ystea'ns"
position (1000 RPM).
The rotating parts of the turbocharger can be
3. Push in the fuei shutoff control' Fress starter damaged by particles introduced through ttie air
button untitr engine starts. gSmP$EnT',&l{T; Ilo intake, which mal<es proper maintenance of the
nct increase throttle or apply load until nor- air cleaner svstem verY imPortant'
mal oii pressure shows on the engine oil
pressure gauge, assuring proper lutlrication e{igh ffixhaalst TernPerature
to the turbocharger.
I:jxcessive ternperature in the exhaust system
XMPOXTTANT: In very coXcl weather, at oil wiii cause }ubricating oil to coke in the center
liiter change or when the tractor has been housing drain annulus at the turbine end' Oil
idle for several weeks or rnore, proceed as leakage, carbon deposits and eventual darnage
follows to Prime the tunbocharger, to the back of tlee turi:ine wheel wiil result'
High exhaust ternperature can also erode the
truil out the fuel shutoff control, press the turi:rine housing creating pitting and deposits
start button and hold. Aliow the engine to on tlie turbine wheel.
crank until the engine oil pressure gauge High exhaust temperature can be caused by
pointer reaches the green zone. Fle) not the turbocharger itself. Carbon build up on the
exceed 30 seconds eran[rimg tirne. turbine wheel, if severe, witi slow the rotating
assemtrliy, reducitlg the arnount of inlet air'
kaukazz@yahoo.co.uk
2565-3
TE."$MBOCg"{ARGER FAI tUHE ANALYSIS
NATE: Following are discussion and exanrples

of darmaEed parts which are typical turbocirarger
failures. In analyzing tur*:ocharger failure it is
irmportant to recogmize what caused t$re faih.lre,
Replacing of the parts will, of course, repair
tl-ae darnage but, ue'lless you caG correct ti"re
cail$es, a reoccurance o{ these problerns can be
expected.
Turhine Contae€ Samage Sompres$or Contact Damage
Coretact darnage to the turtrine usually ryreans

there was bearing darnage a*d/ar sha{t rnoti*n
caused by lack of Iubricant or contarninated
oit. ln this pictnrre w€ see the {$rrbi$e end
showing wheel rub frsrm Lrearing failure as a
resurlt of oil staavation"
ffarmage to bearir:Es frorn contarninated lr-.qb-

ricant or {ron'r lack *f {uhricant wiii allow
rnotion of the shaft. perrnittins ths corfipressor
whee$ to eontaet tt:e housing. Mar$air:g wi8l be
vEsible on both t$re t^lor.rsing and t$'te corylpres-
son wl"leel. in these pictures we see t}-te corrt-
pressor end showinE wheel rub frorn bearing
failt"rne as a result of oil stanvatioer.
kaukazz@yahoo.co.uk
2565 4
fficlked eenter Heuslng Scored Bearing Surface
Coked (sIr.ldged] cer:ter houasing {ailunes are T["re bearing sunfaces o{ this shaft were scored
generally caused by high exhaust terfiperatuyes due to dirty engime oil. Evldence o{ a contamina-
due to over-fueling" over-loading the enEine, Eed oiE failure calls for careful, thorough exa-
dirty enEine oil, or plugged cil return. Also mrinatiorg of engine lube systern.
examine bearings for sludge.
Scored BearinEs
$cqrred Turbine S*raft
Scoring oc"! tfie inside and outside surfaces

The scoring of this sltaft was caused by of the bearinEs is def initely attributed to
loose compressor wheel lock nut. dirty engine oil.
kaukazz@yahoo.co.uk
2565-5
Scored Thrust CoBlar Damage - Hard
Scorimg sn the tirrust caused by dirty

cel&an
oil usually because engine oil and,/or oil filters
;:.:ilr
Mrere rnot changed at tlce recofi'rrnended !ntervals.
Coffirpressor Damage * $oft
F{ard material such as a nut, wire, wrench

or bolt getting into the inlet will darnage the
cornpressor blades as shown. The compressor
housing will be marked by the bits of foreign
rnaterial. lf dannage to blades is so extensive
::ia,ii:i':'::1.,;::;,i:.'t. ... that whee! balance is destroyed, son'le wheel-
to-housing contact damage may also be pre-
Soft rfiateriaB getting int* the 6n[et wil! darsi - sent.
age the c0rnPre$sor biades as showrl The
damage to this biade was caursed bY a sirop
towel being left in tl-se intake $ysteffi.
kaukazz@yahoo.co.uk
2565-6
#mmpr*ss&r Blade ffir,msBesrr Turbffme Shmft Siscolorffitiom
Evosion of connpressor blades fronr Fngest6on Disccloy*tion of the turbine shaft is due to
of dust. Blades on one wl-aeel are thimned whEle overheating caused by oit starvaticn. Lack ot
the other whee[ is almost corvlpletely wor*l iuhricatiom genera!iy is a rnatten of lmproper
away. Firae erosion of the inlet edEes elf the start-{.!p *r shut-down practioes.
coffrpressor wheel suggests sand or other fine
abrasive in the inNet system, entering thnough
a darnaged air cleanen elernent or a leak in
in[et piping. There will generally be no dam- ffiaek6nE Plate tf,flheef, ftnrb
age to the turbine whee! or bearings unless the
problern was so severe tl-rat the rotating ur"rit
becarne unbaianced.
Turbine Wheel Darnage
W!'reel rub against the backing plate can be

caused tly a bemt shaft on irnproper assemrbly.
ForeiEn rnateria! in the eNhaust sys?ern wil!

c*use ehipped or broken t{.rrfoine wheel b6ades.
Foreign rnaterial is usr..ea{ly sornething left by
aecident is: the exhaus{ s.manifold, on debris fron:
am engine cornpo!.!ent suefi as a valve which {ailed.
lf darnage is ext!,es.r-!e, tf-te turbisle wpreel balance
will be destnoyed and further darvrage will occr,rr.
!f you find this proh[em.r cfreclcout the er.lEine.
kaukazz@yahoo.co.uk
2565-7
Blade Edges Lfl#ted Bearing Darnage
Blade edges o'f the cornpre$$or wheel Nifted Engine bearing material imbedded in the
by improper removal o{ the corfipres$or hous- bearing surfaces. Checkout the engine for
ing, Housing s!-reuld no{ be pried of{ but lif ted possible bearing failure.
straight off.
Bearing Failurre
fp*rbine $haft & BearEngs
Bearing failulres occur in two separate

l"urbine shadt and bearings showinE effect of areas. Scoring on the inside as well as the
3i{ starvation. outside is attributed to dirty oil. Abrasive
wear can also cause erosion around the oil
holes in the bearings. A good bearing is shown
in ihe lower right for conrparison.
kaukazz@yahoo.co.uk
2565 8
F$cte Senatches &YI S$taft Bent or Broken $haft
Flne scratchres on both bearing iournals ane ffiearing darnage and extneme shaft motion
evidence tlrat abrasive materiai has contarnina- caused by lack of lubricatiorx or abrasives in
ted the {uhricating oii' the oii rneY elreilttiaily caulse the s*'laft to bend
or eveex bieak. Wheqr this type of darnage is
ev[dent. check the bearings
N&{'E: The eoge Compony reeives rhe right to moke improvemenis

in design or ehcnges in speci{icclions ot dnY iime withoul incurring
ony
obligclion lo instql! them on unils previously sold'
kaukazz@yahoo.co.uk
Sectional lndex
3 FUEL SYSTEM SECTION NO.
A AirRemoval .... .. 3410
Fuel Filters 34"10

Fuel lnjectors .. . .. . .. 3413
Fuel Shutoff Solenoid (Bosch) J4 IZ
Fuel Shutoff Solenoid (CAV) . . 3411
Fuel Specifications ..,.. . . 3410
lnjectors aAla
Injection Pump (Bosch) . . 3412
lnjection Pump (CAV) . 341 1
lnjection Pump Drive Gear (Bosch) 3412

lnjection Pump Drive Gear (CAV) 341 1
lnjection Pump Trming (Bosch) 3412

lnjection Pump Timing (CAV) 341 1
L Lift (Prrmer) Pump (Bosch) 3412

Lifl (Primer) Pump (CAV) 341 1
Primer Pump (Bosch) 3412

Primer Pump (CAV) . . 3411
aA1.)
Timing Lock Pin (Bosch)
Timing Lock Pin (CAV) 341 1
Troubleshooting Guide (Bosch) 34tZ

Troubleshooting Guide (CAV) 341 1
1992 Case Corporatton

Don 7-38660 PrintedinUSA
CASE CORPORATION November 1992
kaukazz@yahoo.co.uk
Section
3005
FUEL TANK AND FUEL TANK SENDER
Copyright 1992 @
CASE CORPORATION Don 8-85032 Prinled in Engtand

June 1 992
kaukazz@yahoo.co.uk
300s-2
TABLE OF CONTENTS
SPECIFICATIONS ..
SPECIAL TOROUES ,..'..'.2

SHOP EQUIPMENT TOOLS
2
GENERAL INFORMATION
2
FUEL TANK
Removal and lnstallation
3
FUEL TANK SENDER

6
Testing
7
SPECIFICATIONS
Fuel Tank Capacity
Standard Tank 135 Litres
OptionalTank. 170 Litres
Fuel Tank Sender (Up to ptN No 4669)

FLOAT HEiGHT RESISTANCE
135 Litre Tank 170 Litre Tank
Empty
Full ..
' '" 0mm 0mm 218 to 264 OHMS
.
349 mm 429 mm 29.5 to 37.5 OHMS
Fuel Tank Sender (From PIN No 4620)

FLOAT HEIGHT RESISTANCE
c_^r.
trrrrpry........ ...........0 mm 0mm 218 to 264 OHMS
HalfFull l5g mm 215 mm 89 to 111 OHMS
Full. .... .... .... 349 mm 429 mm 32 to 40 OHMS
SPECIAL TORQUES
Rear Wheel Nuts
434 to 515 Nm

1, TOROUE WRENCH
oEM 6476
GENERAL INFORMATION
WAHNING : Smoking or open flame should be avoided any time the luet system is Oeng ,epa,red or seruiced.
The area should be property ventilated. lmproper handhng of fuel coutd result in explosiin oifire
causing bod1y
harm or death to yoursell or others
kaukazz@yahoo.co.uk
3005-3
powrquadplus www.thebestworkshopmanuals.co.uk FUEL TANK

Rernoval and lnstallation STEP 4
STEP 1
Put the tractor on hard, level ground, Apply the parking

brake and put blocks in front and behind the front
wheels
NOTE: For lnstallation, fill the fuel tank with at least 10

litres of fuel, refer to Section 341 0 to remove the air from
/he system.
STEP 2
Rcrnove the lcft hand step retaining bolts and remove
STEP 5
/{ Eozru
Disconncct the battery, negative (-) terminal(s) (1)
first
NOTE: For lnstallatton, connect the positive (+)

i.: . .._::t::t: ]:
terminal(s) (2) first. :
-: c02m3
Put a container with a capacitv
apacity of at least 170 litres
STEP 3 under the fuel tank, remove the drain plug (1) and
discard the o-ring. When the fuel has drained from thc
tank install and tighten the plug with a new o-rrng
Remove the left hand rear wheel and support the axle
on an axle stand with a capacily of 5000 Kg (5 Ton).
NOTE: For lnstallation, tighten {he rear wheel nuts to a

tarque of 450 to 500 Nrn
kaukazz@yahoo.co.uk
3005-4
Two Strap Version
NOTE: ltems are numbered in order of Removal
Ad'
{-)\ -.
U
) o.-
v
H
@16
('.'
o@
v
a
-Nr'
o( r
%\aiz
I
a
I
:Lj4
;$f
(
Lt
o SM0397A
NOTE: ltems marked * musl be replaced.
NOTE: Support lhe fuel tank usrng a hydraulic iack
NOTE: When the fuel tank has been removed, remove the luel tank sender, refer to Page 6, Step 4
Don 8-85032 Issued 6-92 Printed in England
kaukazz@yahoo.co.uk
300s-5
Four Strap Version
v
NOTE: ltems are numbered in order of Removal.
rS ,2
tf
l.'4
*r@ B,*- \\ -t-\
--.\
o@
V
@
a
L a
ll
P-b
--/
G\
sM0397
NOTE: ltems marked * must be replaced,

NOTE: Support the fuel tank using a hydraulic iack.
NOTE: When the lueltank has been removed, remove the lueltank sender, refer to Page 6, Step a.
kaukazz@yahoo.co.uk
300s,6
FUEL TANK SENDEH
Removal and lnstallation STEP 4
STEP 1
Put the tractor on hard, level ground. Apply the parking

brake and put blocks in front and behind the front
whcels.
NOTE: For lnstallation, fillthe tuel tank with at /easl 70

litres of fuel, reler toSeclion 341 0 to remove the air from
the system.
STEP 2
Disconnect the {uel sendcr harness connector (1)

Looscn the hose clamps and disconnect the supply
hose (2) and return hose (3).
STEP 5
j.' ,r'.! eO27&}

Disconncct the battery, ncgativc (* ) icrminal(s) (1)
f irst
NOTE: For lnstallation, connect the positive (+ )

termrnal(s) (2) first.
STEP 3
o\
Remove the seat
d
Turn the fuel tank sender (1) counterclockwise and
remove the sender. Remove and discard the o-rrng (2)
NOTE: For lnstallation, install a new o-ilng onto the

sender. Care must be taken that the o-ring remains in
the groove (A), beween lhe tabs (B) and outer hp (C)
and that the labrs do not cut the o-ring during installation.
Hold the o-nng in position with petroleum jelly.
NOTE: For lnstallation, follow the same procedure in

reverse order.
Don 8-85032 lssued 6-92 Pnnted in England
kaukazz@yahoo.co.uk
3005-7
Fuel Tank Sender Testing
STEP 1
Put the fuel sender on a clean work surface. Use a

mulitimeter between the terminals of the sendcr to
check the resistance of the fuel sendcr in thc ernpty and
full postions as shown. Also check the resistance in the
half full position for scnder units installed on machines
from PIN No 4670 and replacement units installed on
machines up to PIN No 4669 refer to Specifications
Page 2
sM0398
FLOAT HEIGHT
EmpV 0mm 0mm

B= Hali Full 158 mm 215 mm
Full 349 mm 429 mm
Don 8-85032 lssued 6-92 Prinled rn England
kaukazz@yahoo.co.uk
Section
341 0
FUEL SYSTEMS AND FILTERS
Written ln Clear
A,nd
Simole
Eng'lish
IMPORTANT: This engine was made using the metric measurement system.
All measurements and the checks must be made with metrictools to make sure
of an accurate reading when inspecting parts.
CASE CORPORATION Rac 8-26131 Printed in U.S.A.

October, 1984 (Revised March, 1985)
kaukazz@yahoo.co.uk
3410-2
SPECIFICATIONS
Every 500 hours or when loss of
Filter Replacement (First and Second Stage)
engine Power occurs
Full Flow, turn on tYPe
First Stage Filter .
Full Flow, turn on tYPe
Second Stage Filter 5toTPSl
Fuel System Operating Pressure
(34.475 to 48.265 kPa)
(3.448 lo 4.827 Bar)
For Acceplable Number Two Diesel Fuel

30
A.P.l. Gravity (Min)
OPour Point (Max) 1O"F (5'C) below ambient operating temperature'
. . . . . . 540 to 625o F (282 to 329" C)
Distillation (900/o Poi 125" (52" C) or legal
Flash Point (Min) ..
Kinematic ViscositY Centistokes 2.0 to 4.3 Seconds'
At 100oF (38"C)
40 (45 to 55 For Cold TemPerature
Cetane Number (Min) .
or High Altitude Use).
0.050/o
Water and Sediment Volume (Max) 0.010
Ash Weight (Max) 0.50
Sulphur Weight (Max) 0.20
Carbon Residue or 10" Residuum (Max) Number 3
Corrosion, Copper Strip,3 hours at 212'F (100"C)
(' 32 to 40 Saybolt Universal Secondsl
FUEL SYSTEM
Filter Removal and lnstallation
filter NOTE: When the filters are too tight, you can
NOTE: At the first fitter change and each cause damage to the gaskets and filters'
Part
change after that, always install f ilter kit' Case
Number A77470.
5. Make sure there is fuel in the fuel tank'
1, Clean the filter head, elements and the engine
6. Loose the air removal screw above the filter
area next to the filters'
head. Actuate the hand primer pump' Close the
filter' air removal screw when clear fuel with no air
2. Remove the drain plug from the first stage
bubbles flows from the screw.
3. To remove the filters, use a clamp type filter 7. The ignition switch must be turned to the ON
wrench. position to energize the fuel shutoff solenoid'
on the Do not turn the engine over until Step I is com-
4. Put a small amount of clean oil or grease pleted.
Turn
seals of the new filters' lnstall the filters'
in con-
the f ilters clockwise until the seal comes Loosen the air removal screw on the fuel iniec-
tact with the filter head' Use your hand to L
turn' To get the tion pump. Actuate the hand primer pump' close
tighten the filter one half of a
the air removal screw when clear f uel with no air
cJrrect seal, loosen the filters and again tighten bubbles f lows from the screw. Actuate the hand
one half to three {ourths of a turn after the seal primer pump five more times to {inish the air
comes in contact with the filter head' removal.
Revised 3-85 Printed in U'S A

Hac 8-261 31
kaukazz@yahoo.co.uk
3410-3
Filter Replacement and Air Removal

STEP 1 STEP 2
Case 6T-590 engine Use a clamp wrench to remove the fuel filters
STEP 3
Case 6T4-590 engine
Lubricate the filter seal a small amount before in-

stallation.
Case 6-590 engine
kaukazz@yahoo.co.uk
34 1 0-4
STEP 4 STEP 6 6T-590 and 6TA-590 Engine
Turn the f ilters clockwise until the filter seal makes Turn the ignition switch to the ON position to ener-
contact with the filter head. Use your hand to gize the shutoff solenoid. Loosen the air removal
tighten the filter one half of a turn. To get the screw on the fuel inlet line. ,Actuate the hand
correct seal, loosen the filters and again tiqhten primer pump Close the air removal screw when
the filters one half to three fourths of a turn after clear f uel with no air bubbles, f lows lrom the screw.
the seal makes contact with the filter head When
the lilters are too tight, you can cause damage to NOTE: lf the hand lever on the primer pump can
the seals and f ilters. not be actuated, turn the engine until the pump can
be actuated.
STEP 5
STEP 7 6-590 Engine
'1r.ri}-
Make sure there is f uel in the f uel tank. Loosen the

air removal screw and actuate the hanrJ primer Turn the ignition switch to the ON position to ener-
pLlmp. Close the air removal screw when clear f uel gize the shutoff solenoid. Loosen the air removal
with no bubbles flows from the screw screw on the injection pump. Actu6te the hand
primer pump. Close the air removal screw when
NOTE: lf the hand lever on the primer pump can clear f uel with no air bubbles, f lows from the screw.
not be actuated, turn the engine over until the
pump can be actuated. NOTE: lf the hand lever on the primer pump can
not be actualed, turn the engine untilthe pump can
be actuated
NOTE:The cASl coRporiAlroN reserves the right to make improvements in

design or changes in specifications at any time without incurring anyobliga-
tion to install them on units previously sold.
Rac 8-261 31 Revised 3-85 Printcd in U.S,A
kaukazz@yahoo.co.uk
Section
341 1
CAV INJECTION PUMP

Pump Drive Gear, Timing Pin, Fuel
Shutoff Solenoid, Primer Pump and Pump Timing
6-590 Diesel Engine
IMPORTANT: This engine was ntade using the metric measurement system. All
measurements and Checks must be madC wtth metrrc tools tO make sure Of an
accurate reading when rnspccttng parLs.
CASE CORPORATION Rac 8-977 1 1 Prinled in u.s.A,

1991 (Revised September, 1991)
kaukazz@yahoo.co.uk
3411-2
TABLE OF CONTENTS
SPECIAL TOOLS
.....',...''.'.2
SPECIAL TORQUES
GENEBAL INFORMATION .. .
TROUBLESHOOTING GUIDE. .
SERVICING THE FUEL SYSTEM

lnlection Pump Removal
.. 5-7
Injection Pump lnstallatjon .... .
. B-10
lnjection Pump Gear Removal ..

10-12
lnjection Pump Gear lnstallation
12-14
TIIVING LOCK PIN
Removal
.14
lnstallation
15
FUEL SHUTOFF SOLENOID

Bemoval and Disassembly.
15
Assembly and lnstallation ..

16
PRIMEB PUIVP
Removal ... .
16
lnstailatlon
16-17
INJECTION PUMP TIMING

17-20
SPECIAL TOOLS
sg
CAS.I690 ENGINE
TURN OVER TOOL
CAS-1691A GEAH PULLER
P,ac 8-97711
kaukazz@yahoo.co.uk
341 1-3
SPECIAL TORQUES
lnjection Pump Mounting Bolts ....21 lo 27 Nm
lrjcct,on Purrp Nut 59 to 71 Nm
Crankshaft Pulley Boits 120 to 130 Nm
Inlcction Pump l-.ock Bolt (L-ock Positiort) .. 7Nm
Injection Pump Lock Bolt (Unlock Position)
Fan Pulley Bolts

Gradc88(SizeIVB) 25 to 31 Nm
Grade 10 9 (Size M8) 37 to 43 Nm
GraoeBB(SizeVt0) 51 to 62 Nm
Grade 10 9 (Size M 10) 51 to 62 Nm
GEN ERAL INFORMATION

The function of the inlection pumo is to supply the It is very important that you take extra care to prevent
correct amount of luel under pressure to the fuel injec- any dust or foreign materlal from entering the fuel
tors. The fuel must be pressurtzed with accurate timing system when service is done on the fuel system.
to the cngine firing ordcr
?ac 8-97711 Fevised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3411 -4
Troubleshooting guide
lor lhe diesel luel iniection system'
/t is assumed that the engtne ts in good

NOTE:
working order and properly tuned' and that
the
/ {/** electrtial sysrem has been checked and repaired
*"/c/, as necessary
CAUSE t REMEDY
lmproper fuel in the tank t Drain tank' flush system' fill with
proPer f uel
Tank empty or lank ve
/bleed system' check
tank vent (See Section 3410)
Air in the f uel system tEre"ti t"t system' eliminate air leaks (See
Section 3410)
t RcPlace as necessarY (See
Section 341 1 )
stoP solenotd fective + Correct
@nalfL,nction tsee Section 3411)
electrical f a;'ts replace stop solenoid
-f
Fuel filter blocked Beplace {uel
filter (See Section 3410)
t Test all f uel supply lines

Fuel-supply lines btockedlElncted
flush or rePlace
leak or broken f Tighten the
connection, eliminate the leak no
esel Fuel
%trff ,n deposit in fuel filter + Beorace lrlter'
1
( Se e O Pe rato ts-Vr an!3!

ad just timinq (See Section
lnjection nozzle defective t Repair or replace (See Section 3413)
Engine air filter blocked f Replace air f ilter element

iring order f lnstall
lnjection sequence dc
order (Sce Section 9t] J ) - - -
f uel iniection lrnes rn the corrcct
itting t lnstallfittings tn
A
thei'Prooer Pos'tions isee Secti )
uiPPed) t Check cold-start

mechanism (lf equiPPed)
BePair as necessarY (See
uFTvLrv'I s
Sectron iev'
2425)
oannot beI adjusted f Feplace
f relrrf ectron pump defectrve or
{See Sectron 34-l I )
Lssued 9-91 Prlnied in U.S.A
Aac I 977:1
kaukazz@yahoo.co.uk
341 I -5
lnjection Pump Removal
STEP 1 STEP 4
Clcan lhe enginc bcf ore any scrv ce v,rork rs donc on thc lnsra i dust ccvcrs on :hc f ucl injcctors and thc nicc: o"l
f uC SyStCrn. PU P
STEP 2 STEP 5
Disconneci and rcmovc lhc fucl rnjccior iCS Rcrrovc ihc fucl rnlct litting and gaskets
STEP 3 STEP 6
lcr-novc t'tc 'ucl ;n.ccTo' lrnc b'ackcts Disconnecl and remove thc fucl nlct line
Fair 3 !;7 lsslec 9-91 P.,^rcc i- !. S A
kaukazz@yahoo.co.uk
341 1-6
STEP 7 STEP 1O
_' ',t
-ralrxi;;
;s,$. 'iir,
Disconnect the leak off linc lnstall a dust covcr tn thc rn-
jcction pump and on the leak off line .
STEP B
Rcmovc tnc clug frorn thc flywhccl houstng and insIall

thc cngine tLrn ovcr tool, push rn on the lock pin and
turn thc cnginc ovcr untii the lock pin cngages into the
camshalt gcar
Rcmove thc covcr
IMPORTANT: Make sure there is a precislon mark on
the injection pump and front cover.
STEP 9
STEP 1 1
Rc,-'r)vc lhs and washcr f 'orr :*': rn-CCl o'l JJ-Q

slart "r'
L oosen ihc our-o sraft cck bolt and move the slot
washer of ihe locK bo t shouldcr Tightcn the iock bolt
to a torquc of 7 Nm
NOTE: Thc slol. washcr wrll bc loosc altcr tha lock bolt
has bacn tarqued.
Uac E-g7l' lssucc 9-91 Printcc rn U.S.A
kaukazz@yahoo.co.uk
3411-7
STEP 12 STEP 14
lnstall a gcar pullcr and tighten the bolls until the gear is Carefully rcmove thc injection pump nuts and thc r'1cc-
loosc lrcm ihc pump sha't tior purro from rhc fronl housing.
IMPORTANT. lf the key for the injection pump shalt ts

STEP 13 not on the pump shaft vthen the pL,mp rs removed, :he
fran[ cover must be removed lo remale the pump shaft
key
STEP 15
Bcmove the bracket and the nuts ihal hold lhc inicction
prrmp io thc front housing
Rcrncvc lnc gcar pullcr from thc inlection pump drivc

gcar
Rac 8-9771 1 lssued 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
34'l 1-Bpowrquadplus www.thebestworkshopmanuals.co.uk
lniection PumP lnstallation

'16 STEP T9
STEP
{k'"
v
;fr-
..l:l:tii
pumo and ihe 'ro'1
i::iir..,:rii!l.i @
Align thc rr-a'k on :l-c nicction
lnslall a new gasket lnc r":tl Ita: holc li-'ciniccl on p1lrp io
f'.to-using lns;laii
front housinQ al-l :i'c brackcl Llci
STEP 17 pump vttll have a nark
NOTE: A ne,t' or re built iriectiort
cn the PumP flar)ge
lnslallinc,nlcciion pump Make sufe jl'llj^'^"i

llrc
l.?!atc
inlcction pun'p sha'l allgncd
i"u, u"J,"" r"y lr lhe
remcvcd see Seciion

NOTE: if ne front cover was
2425 icr irtsruliattcn' iic rrrl: r'1i.,.s anc
c;, 21 '.:. i)
STEP 18
ino v",asncr and nut on

ghlcr^ a srall amoL;ri
lssucC 9 31 Printoc l'r U S A
kaukazz@yahoo.co.uk
341 1-9
STEP 21 STEP 24
UNLOCK
35919 l B
t t:-:: : :,: lr;tiiH\.ffiw

l,:t.
&;,::,:: : , 2. LOCK BOLT
Loosen the lock bolt on thc injcctron cump, move the Install thc cover
s ot washer on the lock boll Tighten thc lock bolt to a
torque of 20 Nm
STEP 25
NOTE: The slot v'tasher wtil not move after the lock bolt
has been torqued.
STEP 22
lns:a;l tnc clug n thc fiyviheel housing
STEP 26
Pull lhc lock crn out ol thc carnshalt gcar
STEP 23
Connect and tighten the leak off linc to the inlectron

pumD
Trghten ihc nut to a torquc of 59 to 71 Nm
Bac I 9771 1 lssuod 9-91 Prlntcd in U.S A
kaukazz@yahoo.co.uk
34 1 't-10
STEP 27 STEP 29
Connect and
at tighten the fucl rnlet linc to the Connect thc nlcctor lincs to thc f ucl injectors and thc in-
pump
lection pump
STEP 28 STEP 30
insiali thc fucl inlet fltting and new gaskcts There musl To removc thc air from the iuel systcnr sce Section
bc a gaskct on cach side of thc fuel inlci linc. T ghton 34.1 O in the scrvtcc manual.
thr: fL;cl inlet iitting :o a torquc ol 22 lo 28 Nrn
lnjection Pump Gear Removal

STEP 31 STEP 32
Lifl thc bcil tcnsioner and rcmovc thc ian bclt Rc'r'ovc thc ouiley bolts and ihe fan puilcy
Rac B'9 i /' ' ssr.. 9 9l P'intec il: U S.A
kaukazz@yahoo.co.uk
3411-11
STEP 33 STEP 36
,,.,.,.,, 7i8975
Bemovc thc crankshaft puiley oolts and thc crankshaft llcrnovc thc plug from the fly,vheel housing and install
pi.;iley. thc cnginc lurn over tooi Turn thc cnginc ovcr and cush
the icck pin into the camshaft gear
STEP 34 NOTE: lvlake sure there tis a mark on the tn.iectian pump
and tront cover.
STEP 37
Remove thc front covcr bolls and lhc froni covcr 1, SLOT WASHER
i :3k. z. LocK BOLT
STEP 35 Loosen thc pump shaft lock bolt and move the sloi
washer off thc lock bolt shouldcr Tightcn the lock boll
to a torquc of 7 Nm.
NOTE: Thc slot v'tasher will be loose aftcr the lock boll
has been tcrqued
STEP 38
Looscn the nut on the inlcction purnp shafl
Bcrrovc lhc nu1 and washcr'rorn the rnlcctton pump

s rd i
nac I 9771 1 SSUcd 9.91 Prirrlcd ir) U.S.A.
kaukazz@yahoo.co.uk
Install the gear puller and push thc drivc gcar of{ the in-
lcciion pump shaft
lnjection Pump Drive Gear Installation

STEP 40 STEP 41
lnstail thc washer and nut on thc injectlon pump shaft

anc lrghton a small ar.ount
LETTERD=CAVPUMP
STEP 42
4??L9',
lnstall the drive gear on ihe inlection pump shaft. Make 1, SLOT WASHER
surc the correct letter on drive gear and the timing mark
, B#jl, '' 2. LocK BoLT
on the camshaft gear are in align.
Looscn the pump shaft lock bolt, move the slot washer
NOTE: The slot tn the drive gear and the key rn the in-
on thc lock bolt. Tighten thc lock bolt to a torquc of 20
jection pump shaft must be in align
Nrr
NOTE: Ihe s/ol t^/asher wtll not move after the lock balt
has been taeuec.
Rac I 9771 1 issued 9-91 Printed in U.S A
kaukazz@yahoo.co.uk
341 1 -13
STEP 43 STEP 46 .&a.
rull thc lock Oin ou1 oi the camshart gcar Clcan the crankshaft scal surlacc wiih loctite sateiy
so vcn:. Scc Sect,on 2425 ra thc scrvtce manual io
nslall lhc lronl covcr and oil scai
STEP 44
STEP 47
nstail the p ug r^ trc ri;"r,vrcc hors 'rg
lr-.slall :hc crankshait cu lcy and thc crankshaft puiley

-l
STEP 45 ooiis ,qhlcr- io a lcrouc ol 120 to 130 Nm
STEP 48
l-ighten thc Crivc qear nut to a torquc ol 59 to 71 Nm
Inslail thc ian pullcy and thc pullcy bo ts
.\sL-co 9 9l o: -:cc t ' . S. \

lac B-9771 1
kaukazz@yahoo.co.uk
a^11 1/
STEP 49 STEP 50
{ri!ii:itil
Li{t the bell tcnsioncr and rnstall thc fan bclt Torquc ihe fan oulley bolts as follows
Gradc8BiSizellB) 25 to 31 Nm
Gradc 1C 9 (Szc MB) 37 lo 43 Nm
Gracc B 8 (Srzc Vl0) 5l io 62 Nrn
Gracc 10 9 (Srze ltl I0) 51 to 62 Nm
TIMING LOCK PIN

Removal
STEP 51
Rcmovc thc rclaining r n0 and lhe l'ri.o o. irc.i' inc

ock pin nousrng
Fac B-9771 1
lssLred 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
341 r -15
lnstallation
3 LocK PrN
..,N-
sli,'=,;;[,-.
STEP 52 STEP 53
nsta a rrcw o-rng on thc lock o n lnstallthc timing oin and the rctaining ring in tnc iock prn
houstng.

Removal and Disassembly
STEP 54 STEP 55
1. SOLENOID
,{ -/
t *--""e#
e 2 o-Rt\G
6_
-/ 4 PLUNGEF
./ -r\ '\'*
,r1
3, SPqING
r69273
lernovc the fucl shutoff from thc injcclion purnc Disassemble thc fucl shutoff solenoid, Check the
plungcr and solenoio for scoring
lac 8-9;'/11 lssuco 9-91 l)rintcc rn i.-.] S.A
kaukazz@yahoo.co.uk
3411-16
Assembly and lnstallation
STEP 56 STEP 57
1 SOLENOID
./
; "' :,i:;i i liii: i , , 2. O-RING
,/
\dh
ial
/
,-/ 3. SDBTNG
Q*'-,/
\Q*
i*-fo
4. PLUNGER
TAO)-7'1
Asscmble the fuel shuioff solcnord lnstall the fucl shulc'f so enoid and t ghtcn to a lorcL'lc
of 15 Nr
PRIMER PUMP
Removal
STEP 59
fuc nlc' 'rc Fcmovc thc prlmcr purrp tlolls and the primer from the
Disconnect and rcmovc thc
cnernc block
Pum p lnstallation
STEP 61
$ /Y
lnstall inc crimor ptriro and tigntcn ine bolts that hold
lns.a I thc bolts in ihe orimcr Pui'TrP and rnsta a
nclv
gaskct ovcr the bolts
lhc pr rncr c-rc to :hc cngine b ock
lss:ec 9'91 Pr nicC i. U.S.A'
RaOt977l1
kaukazz@yahoo.co.uk
341 1-17
STEP 62
B@@@q
lnstall thc iuel inlet line, gaskct and frtting. Tightcn the
inlcl f iltinq to a torque ot 22 I.a 28 Nm
NOTE: There must be a qaskel on each side ol the tuel

inlet line
INJ ECTION PUMP TIMING

STEP 63 STEP 64
Makc surc the timing pin ls cngagcd rn thc camsha;t

Qear
lf thc oump shaft is not in the locked position, rotate the

shafi clockwisc urrtil the slot in the drivc gcar and thc
kcy on ':he siraft arc aligned.
Flac 8'9771 1 ssucd 9-91 Prinlcd in u s /^\
kaukazz@yahoo.co.uk
341r-18
STEP 65
UNLOCK
359191 B
2 LOCK BOLT
Looscn tlc lock ooit on lhc nicction pump Move thc

ln,.l: ::lc tr cctlot- Our-r'p sira't ltlio ii-r" dr' "l' 'lt::" it'i:lkc
slot rvashcr cn il'c lock bcir Tightcn thc iock bolt to a
si,ra'h(-'sict in the drvc qcar and iê kcy c'r :"rl t 'r torquc oi 20 Nrr
tton r:.,r-'p arc a :.)ned
NOTE: Ihe s/c;l ',ttasher will not rnovc afle r thc lock bolt
STEP 66 has bcen torqtted
STEP 69
!..,t. I l'-.a 1.,aC...:S 3.^ 1-.::3!.t

lt-..: ."2.:lt':' bo 1 :l srl:: I alrr'alr-'
Pull ll^c ttr:. r-rg :'r a,: oi ihc can^Si.rai: gcar
STEP 67
lssr,od I 91 Prlntcd ji U S'A

ll;1 !t l-- ' 1
kaukazz@yahoo.co.uk
341 1-19
STEP 70 STEP 72
Tighte n thc injcction pump shaft nut to a torque of 59 to Fotate the injcction pump untilthe mark on thc inlection
71 Nm pump flangc and the mark on the front housing arc
aligncd
STEP 71
STEP 73
Tightcn rhc rnlcction pump mounting nuts and lrrc

bracket boll lo a torquc of 21 to 27 Nm.
STEP 74
Bcmovc llrc Dlr:q artd rnsiaii :i:c crt^ i'rc lLrn tlvi-'r ioc-'1,
push in on thc lock prn anc :urn :ho cngrnc ov(-'!' r:il: :nc
lock p n cngages lnto :nc camshali gcar
Pull thc lock prn out of thc camshaft gear
Rac 8-97711 lssued 9-91 Printcd i. ..l.S.A
kaukazz@yahoo.co.uk
341 1-20
STEP 75 STEP 77
lnsiall thc p ug in lhc flywhcel housing Conncct and tighten the fucl in ct line
STEP 76 STEP 78
Conncct and tightcn the fucl lcak oii lrnC Fc ow Stcp 26 through Stcp 30 to nsta I the injectron
lincs.
Bac B 9771 1
lssucd 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
Section
341 2
BOSCH FUEL INJECTION PUMP

Pump Drive Gear, Timing Pin, Fuel
Shutoff Solenoid, Primer Pump and Pump Timing
6-590 Diesel Engine
accurate reading when inspecting pafts.
CASE CORPORATION Coovrioht @ 1991

Rac 8'26143 Printed in U.S A.
October, 1984 (Hevised Sepiember, 1991)
kaukazz@yahoo.co.uk
3412-2
TABLE OF CONTENTS
............... . .. 13-14
TIMING LOCK PIN

14
15

16
to
PRIMER PUMP
SPECIAL TOOLS
sg
CAS-1691A GEAR PULLER
CAS-I690 ENGINE
TURN OVER TOOL
DIAL INDICATOR
Rac 8'261 43 Revised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-3
SPECIAL TORQUES
lnjection Pump Mounting Bolts 21 to 27 Nm
Injection Pump Nut.. 59 to 71 Nm
Fuel Line lnlet Bolt 22 to 28 Nm
Fuel Shutoff Solenoid .... 43Nm
Crankshaft Pulley Bolts . 120 to 130 Nm
lnjection Pump Lock Bolt (Lock Posltion) .. 30 Nm
lnjection Pump Lock Bolt (Unlock Position) 13 Nm
Fan Pulley Bolts
Grade 10I (Size MB) 37 to 43 Nm

G.adeBB(SizcM10) 51 to 62 Nm
Grade 10.9 (Size M10) 51 to 62 Nm
lnjccrion Pump Plug . Btol0Nm
GENERAL INFORMATION
The function of the injection pump is to supply the It is very important that you take extra care to prevent
correct amount of fuel under pressure 1o the fuel iniec- any dust or forergn material from entering the fuel
tors. The fue must be pressurized with accurate timing system when service is done on the fuel system
to the engine firing order.
Rac 8-261 43 Revised 9-91 Printed in U.S.A.
kaukazz@yahoo.co.uk
3412-4
Troubleshooting guide
for the diesel fuel injection system.
NOTE: /t is assumed that the engine is in good

working order and properly tuned, and that the
electrical system has been checked and repaired
as necessary.
CAUSE t REMEDY
lmproper fuel in the tank f Drain tank, flush system, fill with
proper fuel
Tank empty or tank vent blocked t Fill tank/bleed system, check
tank vent (See Section 3410)
Air in the fuel system t Bleed fuel system, eliminate air leaks (See
Section 3410)
Pump rear support bracket loose t Replace as necessary (See
Section 3412)
Voltage supply malfunction/stop solenoid defective t Correct
electrical faults/replace stop solenoid Section 341
Fuel filter blocked t Replace fuel filter (See Section 3410)
Fuel-supply lines blocked,/restricted t Test all fuel supply lines -

flush or replace
Loose connections, injection lines leak or broken f Tighten the
connection, eliminate the leak
Paraffin deposit in f uel f ilter f Replace f ilter, use Diesel Fuel no. 1
(See Operators Manual)
Pump-to-engine timing incorrect f Beadjust timing (See Section
3412)
lnjection nozzle defective f Repair or replace (See Section 3413)
Engine air filter blocked f Replace air filter element

lnjection sequence does not correspond to f iring order f lnstall
fuel iniection lines in the correct order (See Section 3412)
Overf low fitting interchanged with inlet f itting f lnstall fittings in
their proper positions (See Section 3412)
Cold-start device malfunction (lf equipped) t Check cold-start
mechanism (lf equipped)
Low or uneven engine compression f Repair as necessary (See
Section 2425)
Fuel inlection pump defective or cannot be adjusted f Replace
(See Section 3412)
nac 8-261 43 Revised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-5
lnjection Pump Removal
STEP 1 STEP 4
Clean the enginc before any service work is donc on :he Bernovc thc tuel inlcl fitting and gaskets
fuel system.
STEP 5
STEP 2
Disconncct and rcmovc thc 'ucl inlet ltne and instail

Disconnect the fuc rnjcclor lrncs 'rorir tlc inlcClion dus: covcr-s in thc'ucl ,nlet holes and on the fuel inlc:
pump and the injcciors Qct'0,",c tirc rcs irom thc I ::e conncci on
e ngrne.
STEP 6
STEP 3
Remove ihc leak off friting and gaskets, Instali a dust

lnstall dust covcrs on thc irlcl ,nlcctors and ihc rnlection covci' in thc leak off hole in the injection pump.
purnp
Eac 8-2614-1 Revlsed 9,91 Printed n USA
kaukazz@yahoo.co.uk
3412-6
STEP 7 STEP 9
Reniove the nut and washer from the in1cctron pump

sha'l
STEP 8
lnstall the cngine turn over tool, push in on thc lock pin
and turn the engine ovcr until the lock pin engages into
the camshaft gear
Bemove the plug irom the flywheel houstng IMPORTANT'. Make sure there is a precision mark on
the injection pump and front cover.

Rac 8-261 43
kaukazz@yahoo.co.uk
34tZ-/
STEP 1O STEP
Install a gear puller and tighten the bolts untii the gear is
loosc from the pump shaft.
STEP ]3
Loosen the pump shaft lock bolt and remove the slotted
STEP 11
Carcfully rcmove the inlection pump nuts and the inlec-
tion pump from thc lront hous ng
IMPORTANT: llthe key for thc injecilcn pump shaft is

not on the pump shaft when the pump is remaved, the
front cover must be removed to remove the pump snat't
key.
STEP 14
Tighten the pump shaft lock bolt to a torque of 30 Nm
Hemove the qear puller from the injection pump drive

gear.
Bac 8-261 43 Rcviscd 9'91 Prrnted in U.S.A.
kaukazz@yahoo.co.uk
3412-8
lnjection Pump lnstallation
STEP 18
lnstall a new gaskel lnsiall the washer and nut on the injection pump shaft
and lighten a smali arnount
STEP 16
.19
STEP
r,
:::'i',iil*Iffi ffi'.l'+,:
Installthe injcction pump Makc sure lhc slol in thc clr vc
gcar and the kcy in:hc inlcclron purrc shart arc alrqnod rnounting nuts and the bracket bolt to a
to 27 Nm
NOTE: lf the frcnt caver \\/as :e')):,vcc ;{;a, }aclron
2425 for insiallalron
STEP 17
Looscn tne purrp shaft lock bolt
Align the mark on the in]cctron plrnc and the front

housing instail thc nuts that hold lhc inlection pump io
front housing and the bracket bolt
NOTE: A new or reburlt in jectiot-, pt;':tD rriiti h,s,'e a rnark

on the pump t'lange.
Rac 8-261 43 Rcvised 9-91 Printed in U S.A.
kaukazz@yahoo.co.uk
STEP 21 STEP 23
Tighten the nut tc a torque of 5g to 7l Nm
STEP 24
lnstall the slottcd tab and iightcn thc lock bolt to a

torque of 13 Nm
STEP 22
Pull the lock pin out of the camshaft gear
lnstall the oiug rn the flywheel housing
Rac 8-261 43 Revised 9-91 Printed in U,S.A
kaukazz@yahoo.co.uk
3412-10
STEP 26 STEP 29
Install the leak off f rttrng and gaske: Tighien the leak ofl Connect the injector lrnes to the f uel injectors and the in-
fittlng to a torque of 2? Io 28 Nm jection pump
NOTE: There must be a gasket on each side of the leak

off line STEP 30
STEP 27
lnstall the fuel line brackeis and tighten
Connect and trghten the :uci inict irne lo the inlcclron STEP 31
pump
STEP 28
To rerncve ihe air from the fuel system see Section

3410 rn lhe service manual
lnstall lhe fuel inlet fitting and gaskets, Tighten the fuel
inlei 'itting to a torque al 22 to 28 Nm
NOTE: There must be a gasket on each side of the tuel

inlet ltne
Rac 8-261 43 Bcvised 9-91 Prinled in U.S A
kaukazz@yahoo.co.uk
3412-11
lnjection Pump Gear Removal
STEP 32 STEP 35
tr';t
ri.i- l ')
r'j,
ri:..
#-.1
'.^ ...:
Lift the bclt tcnsioncr and rcmovc ihc fan beli Remove thc bolts and the iront cover
STEP 33 STEP 36
Bcrnove thc pullcy bolts ano thc ian pLrllcv Loosen the nut on the injection pump shaft
STEP 34 STEP 37
Remove the bolts and thc crankshaft pullcy Remove the plug from the flywheel housing
Bac 8-261 43 Hevised 9-91 Printed in U S.A.
kaukazz@yahoo.co.uk
3412-12
STEP 38 STEP 40
:a
Install the engine turn over tool Turn the engine over
and push ihe lock pin into the camshaft gear'
STEP 41
NOTE; Make sure there ls a markon the rniection pump
and frcnt cover.
puller and
Bemove the nut and washer lnstallthe gear
pL,sh the drive gear off the injection pump shaft'
tab
Loosen the lock bolt and remove the slotted
Revised 9-91 Printed in U S A'

Fac 8-261 43
kaukazz@yahoo.co.uk
3412-13
lnjection Pump Drive Gear lnstallation
STEP 42 STEP 44
LETTER C = BOSCH
PUMP
422t91
lnstall the drive gear on the injcction pump shaft Make lnstall the slotted tab and tighten the lock bolt to a
sure the correct letter on drive gear and the timing mark torque of 13 Nm.
on the camshaft gear are in align.
NOTE: Ihe s/ot in the drive gear and the key in the in- STEP 45
lection pump shaft must be in atign.
STEP 43
Pull the lock pin out of the camshaft gear
lnstall the washer and nut on the injection pump shaft

and tighten a smail amount.
lac 8-261 43 Bevised 9-91 Printed in U S.A
kaukazz@yahoo.co.uk
3412-1 4
STEP 52
Torcuc lhc fan oulley bolts as foliows,

G'adcSBlSizc\48) 25 to 3l Nm
Grace l(. S, (Sze VB) , 37 '.a 43 Nm
Gradc8B(Srzelvl0) 51 io 62 Nm
Grade 10I (Srze M10) . . 51 io 62 Nm
TIMING LOCK PIN

Removal
Remove the reiainlng ring and lock pin lrom thc Iock pin
housing
Fac 8-261 43 Revised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-15
lnstallation
2. LOCK T'*
\
1. RETATNTNG H,NG
\ - .s
BSY-3c'RNG
STEP 54 STEP 55
lnstall a new o-ring on the lock pin lnstall the lock pin and retaining ring in the lock pin
housing,
Hac 8-26 1 43 Revised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-16
Removal and DisassemblY
STEP 56 STEP 58
, SOLENOID :'i,
l l . .,i.i
a a olNlc
T78897
Loosen the fuel shutoff solenord Disassemblc thc fuel shutoff solenoid Check the
prunger and so enoid for scorirg.
STEP 57
STEP 59
.:.::i,*i:4
::,:i
,t::
,,',,i,iiii'
-,'qr"rVltiiS
qr?ri:ii
o.,i,.|,.fui,,
. ::r.:
ii,: iii:i:: :! ri ii
T78899
shutoff solenoid
Use a smallwire to make sure the orifice in the plunger
ls free of foreign material.
Assembly and lnstallation

STEP 60 STEP 61
1. SOLIENOID
\a
, 3. o-RING ,,,;.
*= 'lp,o
rdd'*.
T78897
Assemble the fuel shutoff solenoio lnstallthe fuel shutori solcnoid and tightcn to a torque of
15 Nrn
Fevised 9'91 Printed in U.S A

Bac 8-261 43
kaukazz@yahoo.co.uk
3412-17
PRIMER PUMP
Removal
STEP 62 STEP 63
Femove the fuel inlet line. Remove thc primcr bolts and the primer pump from the
engine block
lnstallation
STEP 64 STEP 66
lnstall the boits in the primer pump and instail a new Install the rnlet tube inlet fitting and gaskets Tighten the
gasket over the bolts. intei li:trnc to o torque ol 22 lo 28 Nm
NOTE: There must be a gasket on each side of the inlet

STEP 65 tube.
lnstall the primer pump and tighten the bolts
Bac 8-261 43 Bevised 9-91 Printed in L.l.S.A
kaukazz@yahoo.co.uk
3412-18
INJECTION PUMP TIMING
STEP 67 STEP 70
pin is engaged in the camshaft lnstall thc washer and nut Tighten the drive gear nut a
small amount
STEP 71
Installthe injcction pump into thc drivc gear. Makc surc

the slot in the drive gear and the key on injection are
aiigned.
NOTE: lf the punp shar? is nat tn the locked posilron

rotate the sha{t clockwise until the s/ol in the drive gear
and the key on the shaft are aligned.
STEP 69
lnstall the slotted tab and the lock bolt a

torque of 13 Nm.
lnstall the three nuts and the bracket boii Tighten the
nuts and thc bracket boll a small arnount
Rac 8-261 43 Feviscd 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-19
STEP 72 STEP 75
Pull the lock pin out of thc camshaft gear
STEP 73
lnstall the engine turn overtool, push in on the iock pin

and turn the eng ne over until the Iock pin engages into
the camshaft gear.
Tighten the nut to a torque of 59 to 71 Nm
STEP 76
STEP 74
Remove the dust covers

Remove the plug frcr thc rlywhecl housi.g
Rac 8-261 a3 Revised 9-91 Printed in U.S.A
kaukazz@yahoo.co.uk
3412-20
STEP 77 STEP 79
Puil the tin rng pin out of thc camshaft gear
STEP 80
Remove thc plr,g irom thc rear oi :he inlcct on pump
STEP 78
nstali a dial lndicator in the inlectron pump lnstall the engine turn over tool into the f lywheel nousing
and turn thc enginc counterclockwise until there is no
movcrncnt in thc dial indicator.
Fac 8-26 1 43 Revised 9-91 Printed in U.S.A.
kaukazz@yahoo.co.uk
J4tt-ll
STEP 81 STEP 83
Turn the dial indicator diai to zero Loose n the bracket bolt and the three nuts that hold the
lnjection pump to thc front cover.
STEP 82
STEP 84
Boiaic 1tlc'n cctjon pump until the dial indtcator reading

rs r 5u mm.
NOTE; lf 1 .5a mm can not be reached go to Step 42 tn

lhis section.
STEP 85
lnstall the engine turn over tool, push in on thc lock pin
and turn thc cnginc clockwisc unlr' :hc iock pin engagcs
into the camshaft gcar thc dia irdrcator should read
1 50 mm li the rcading is ccrrcct go to Siep 85
Tigirlcn tfrc brackct bolt and the three mounting nuts to

a torque of 21 to 27 Nrn
Rac 8-261 43 Bcviscd 9-91 Prinlcd r. USA
kaukazz@yahoo.co.uk
.1t+ I t-lt
STEP 86 STEP 89
Flemove the dial indicator from thc injcction pump lnslall and tightcn the injector line brackel
STEP 87 STEP 90
Installthe njection pump plug and tighten to a torque of lnstall thc front covcr
B to 10 Nm.
STEP 91
STEP B8
Pull the lock pin out of the camshaft gear.

Connect and tighten injection lines to tfre inlectron
p,mp and 'uel rnjectors.
Fac 8-261 43
Revised 9-9'1 Printed in U S.A
kaukazz@yahoo.co.uk
3412-23
STEP 92
lnstall the plug in the flywheel housing
Rac 8'261 43 Revised 9-91 Printed in U,S.A.
kaukazz@yahoo.co.uk
Section
341 3
FUEL INJECTORS
6-590 Diesel Engine
IMPOHTANT. This engine was made using the metric measurement system. All
CASF CORPORATION Copyright O 1992

Rac 8-261 52 Printed ln U,S.A.
October, 1984 (Bevised February, 1992)
kaukazz@yahoo.co.uk
3413-2
TABLE OF CONTENTS
-4
SPECIAL TORQUES.. 5
SPECIAL TOOLS
GENERAL INFORMATION,. .. . .. . .. .. .. . .. .
5
OPERATING PNOCEDUHES
6
LOCAIING BAD INJECTORS

Locating Bad lnjectors at lhc Fue t Pump .
7
Locating Bad lnjectors at the Cylinder Head, . .. 7
7_A
INSTALLING INJECTOBS o-1 n
FUEL INJECTOR TESTER

Nozzie Tester Preparation .
.'10
TESTING INJECTORS
Checking Seat Leakage 12
Sp'ay Paltcrn .12
N4AINTENANCE OF IHE INJECTOR
Asscmbly l5-l/
INJECTOR ADJUSTMENTS
Adjusting Opening Pressure . .18
INJECTOB SLEEVE (B mm BORE TO 7 mm BORE)

lnsrallatjon ,
.. 19
Aac 8-261 52 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
34r 3-3
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO IHE POSS/B|Ury OF PERSANAL INJURY
OR DEATH. M1718
WARNING
When testing or adjusting diesel fuel injectors, do not place your hands,
arms, or any other part of your body into the fuel injector spray.
A rr", p ray f rom an i nj ecto r hassuff i cientve loc ity to penetrate theski n and
"
cause serious infection or other reactions. lf iniured by fuel penetration,
see your doctor immediately.
Wash the injured part with boric acid solution, suppon the injured finger or ha nd with a splint and
sling so the injured part will remain absolutely at rest until a physician can examine it.
SPECIFICATIONS
Engines Manufacturcd in Darlington, EngLand
Prior to Engine Serial Number 21092870 . . 9 n'rr Injector Nozzles
Engine Serial Numbcr 21a92870 and After. ..7 rrff Injcctor Nozzlcs
Engines Manufactured in Ncuss, Gcrmany.

Prior to Engine Serial Number 52107489 .... 9 mm lnjector Nozzles
Enginc Serial Numbcr 52107489 and After 7 mm lnjector Nozzles
Engines Manufactured in North Amerrca.

Prior to Engine Serjal Numbcr 44511034., 9 mm lnjector Nozzlcs
Englne Serial Number 4451 1034 and Afier 7 mm lnjector Nozzles
Rac 8'261 52 Heviscd 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
DA1' A
Robert Bosch lnjectors
Part Number
Number of Spray
Casc Robert Bosch Spray Angle Oriliccs Orificc Size Nozzle Size Opening Pressure
J909464 0432r31877 ,155 Degrees 4 0.28 mm 9mm ' $'t<il253,Bar
.:
tffi:ro,s6ioPsl)
J9094 7s 04321 31 881 1 55 Degrees 4 0.28 mnt 9mm 22A b 228 Bat
(3190 to 3307 PSI)
J909476 0432131880 155 Degre€s 4 0.29 mm 9mm 245 to 653 Bar
(3553 to,3670 PSI)
J949472 04321 3t 869 1 55 Degrces 4 0.28 mm 9mm 224 b 228 Bar
(3190 to 3307 PSI)
J909474 043213'r85.r 155 Dcgrecs 4 0,29 mm 9mm 220'lo 28 Bar
(3190,to 3307 PSI)
io 1 01nn 1 55 Degrccs 4 028mm 7 m']1 oon r^ aao o^.
(3190 to 3307 PSI)
J91 9304 '155 Degroes A 028 mm tmm 22A b 2281ar
(3190 io 3307 PSI)
101 0220 1 55 Dcgrees 4 0.30 mm 7 rrm 245 to 253 Bar
(3553 to 3670 PSI)
J919343 tsi Degrecs 4 0.29 mm 7mm 245 to 253 Bar

(3553 to 3670 P's0
CAV lnjectors
Pad Number
Numbcr ol Spray
Casc Fobori Bosch Spray Ang c Orif iccs Orilicc S zc Nozzlc Sizc Opcning Prcssurc
Jg 1 6745 670508 '155 Degrees 4 032 mm 9mm 255 to 263 Bar
(3698 to 3814 PSl)
J917567 67051 4 I 55 Degfces 4 4.27 nm 9mm 22a rc 228 Bar
(3190 to 3307 PSI)
J919331 6760525 155 Degrees 4 0 28 mrr 7mm 2?0 toi62p],8a1

(3190 to:33S7'PSl)
lo 101?, 6760s23 '1
55 Degrccs A 0.32 :nrr 7mm 225 io 263 Bar
(3698 to 3814 PSI)
loiotaa 676051 I 1 55 Degrees 4 0.27 mm 7mm 22A \a 2281ar
(3190 to 3307 PSI)
J91 9760 6760528 '155 Dcgrces 4 0 30 rnm 7nn 22a b 228 Bar
(3190 to 330i PSI)
Valve Leakage Rate No Leakage Permtssible

Slight Moistenrng of Nozzle Tip Permissible
Maximum Opcning Pressure Variation Bctween Each Cylinder .10 34 Bar 150 PSi
Rac 8-26152 Rcvised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
34 1 3-5
SPECIAL TORQUES
SPECIAL TOOLS
CAS-10664 WRENCH CAS-1694 9.mm INJECTION BORE CLEANING TOOL

SEE PAGE B CAS-2155 7 mm INJECTOR BORE CLEANING TOOL
SEE PAGE 9
GENERAL INFORMATION
The fuel injectors are in the cylindcr head Therc is one INJECTOR VALVE - The valve controls thc flow of thc
inlector for cach cylindcr, The fuel inicctor scnds a fuel from the injector.
measured amount ol fucl to the combustion chamber VALVE STOP - The valve stop has two dowel pins which
from the inleclion pump. Each quantity of fuel must be
hold the valve tip to the body. This will make a spray
sent to the combustion chamber in the form of fine par- pattcrn that is correct Both faces of the valve stop have
ticles This will make sure that there is complete com- a fine surface finish. The valve stop controls the
bustion and efficient engine pcrformance.
distance that the valve will move.
IMPORTANT The injector tip end and the iniector
OPENING PRESSURE CONTROL SPRING - Thc spring
valve are a matched assembly. The tvvo parls are mada
controls the fuel pressure that is necessary to lift the
smooth to fit together with accuracy. The inlector ttp or
valve from the scat
the injector valve can not be replaced scparately for
se,rzice. /Fit is necessa ry to replace etther the valve or trp, SHIMS - The shims push down on the spring to keep a
replace the complete tip assembly. gtvcn prcssurc on the valve.
IMPORTANT'. Do not mix tip assemb/ies and bodies INJECTOR TIP - The valve and the valve seat are ln the
while the rnjectors are betng rJisassemb/ed. injcctor tip Thcre are orrfices in the injector tip that
atomizc the fuelfor better combustion and separate thc
INJECTOR BODY - Thc body holds the iniector parts in
fuel spray to mix thc fuel spray with air.
the correct position in thc cylindcr head. The body has a
high pressure channel and a leak off channel. The lowcr NOZZLE SEAL - The seal is under the cap nut and stops
face of the body has a finishcd surface and has two engine compression leakage.
holes in the surface for locating dowel pins.
4. INJECTOB
2. EDGE FILTEH
3. HIGH PRESSURE
CHANNEL 5. OPENING PBESSURE INJECTOR TIP
(IF EOUIPPED) CONTROL SPRING
SPRAY ORIFICES
NOZZLE SEAL
14. LEAK CHANNEL 12, SPF]NG SEAT
10. INJECTOR VALVE
13. SHIN4S
VALVE STOP
15. LEAK OFF
420191
?ac 8-26152 Revised 2-92 Prinled ln U.S A.
kaukazz@yahoo.co.uk
J4 t.J-b
OPERATING PROCEDURES
The operation of the injector is easy and positive. When thc fucl delivery stops, the pressure against the
valve rs decreased and the control spring immediately
A measurcd quantity of fucl undcr high pressurc move s rcturns thc valvc to the seat This removes the danger of
from the inlection pump to thc high pressurc channcl in lcakage, aftcr the measured amount of fuel has been
the inlcctor body. The f ue I then moves through thc vaivc rclcased Thc valvc opcns and c oses very rapidly with
stop channeland enters the prcssure chambe r which is a very clcar noise
around thc valve in the inlector tip
A smail amount of fuel leaks, during injection, through
Whcn thc pressure of the fuel against the valve is more thc controlled clearancc betwcen the tip assembly and
than the sct spring orifice, the valve is movcd from the the injector body Thrs lcakagc adds lubrication to all
scat. This permrts the fue I under high pressure to entcr thc moving parts in thc injector. This fuel then moves
thc inlcctor tip The fuel thcn moves through thc spray through thc ieak oll channcl, lcak off lines and rcturns to
orilrcos and to the combustion chamber The fucl thc fucl tank.
reaches the combustion chamber rn an atomized con-
dition
1. HIGH PRESSURE
CHANNEL
2, INJECTOR BODY
12. INLET SPRAY OBIFICES
\
5 sAt,
OPENING PHESSURE
CONTROL SPRING
1 1. LEAK OFF 10, LEAK OFF CHANNEL 8, VALVE 7. PRESSURE
CHAMBER 6. TIP ASSEMBLY
42019 1
Rac 8-26'152 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
3413-7
LOCATING BAD INJECTORS
lf there is a loss of power during engine operation, the in jectors can be bad Do the following procedure to find the bad in-
jectors,
Locating Bad lnjectors Locating Bad lnjectors

at the Fuel Pump at the Cylinder Head
STEP 1 STEP 2
1 Loosen the tubc nut on the Iuel lrne This will release 1 . Loosen the tube nut on ihe iuel inlet line for thc
the fuel and the injector wili not work. lf tnis injector is in.;ector at the cylinder head. lf the inlcctor is bad,
bad, there will not be any dlffercnce in the engine there will not be any differcnce in the engine perfor-
performance , Connect and tighten thc tubc nut on mance. Conncct and tighten the tube on the f ue I rnlet
the fuel line, line,
2 Do this proccdurc again for thc re mainder of the in- 2, Do this proccdurc again for the remainder of the in-
jectors jectors.
REMOVING INJECTORS
STEP 3 STEP 4
Clean lhe location around the fuel iniectors Disconncct the fuel Irne from thc rnjector and tnstall a
dust covcr ovcr the inlct of thc inlector
nac 8-26 I 52 ncvlsed 2-92 Printed ln U S.A
kaukazz@yahoo.co.uk
34.13-8
STEP 5 STEP 7
Remove the leak off bolt and the leak off line gasket. Remove the fuel injector from the engine. Always
replace the injector sealing gasket when a fue/ injector
is removed. Remove the remainder of the injectors
STEP using the same procedure.
i,iltiri:t:iii;,tl t
...'. :i::, i:i !

IMPORTANT: Make sure that thc iniector sealing
tlL
.il:liii;iililii ;iiilr
irriir!iljtjlitiill
:
gaskel comes out with the injector. Use an acceptable
table tool or wrre to remove the sealing gasket from the
engine bore.
lnstall the special tool and a wrench on the flal surface

of the injector. Loosen the injector.
IMPORTANT'. Do not let the iniector body rotate when

/oosening. lf the injector body does rotate t will damage
the cylinder head bore.
Bac 8-261 52 Rcviscd 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
3413-9
I NSTALLI NG INJECTORS
STEP B STEP 1O
lnstall a injector bore clean ng tool Turn thc tool c ock- lnstall the inlector in thc cylinder hcad bcre. The ball in
wise. Use a ratchet wrench. Ccan the bore wth arr the inlector must align ivith thc s o1 in thc cylrndcr hcad
under prcssure or turn the engine over to rcmovc i'lc borc
^^-+iî^^
tldt LtL,tES
STEP 1 1
STEP 9
Tighlcn thc nlcctor rctaining nut to a torquc of 55 to 60

Install a ncw se aling gaskct on ihc irjcctor Put a srna l\n'r
amount of whitc grcasc or lrghl oil on thc g;askei lo keep
the gaskct in posliion
STEP 12
IMPORTANT: Do not aCi": ,'b',cait:,n !a. :;'(: Llcry:i) l)tr;
nOzzle esSembr/ ar fiatl!,:: b.':). ,"2 -..::'..c'lri' '^',,
become hard Curtng aperattan oi tlte enitinc /7,e
rn jector will be dillrculi to rerncve lrcr. the cyiinder head.
NOTE: Use only a 7 mm sealrng gasket with a 7 mm

injectar and a I mm sealing gasket vrth a I rrrn in jector.
lnstailthc gasket and the leak oif bolt Tghtcn the ieak
off bolr lo a torque cl 7 to 9 Nm.
NOTE: Make sure the tap of the gasket cJaes not [ouc't
the leak cfl itne
Fac 8-261 52
qcviscd 2-92 !-'r:c3 ,' .. S .r,
kaukazz@yahoo.co.uk
34r3-10
STEP 13
Remove the protectivc cover. Connect and trghten the

injection line to the injector and to the inlection pump
FUEL INJECTOR TESTER

Fuei inleclors must be checked on the tester when
making thc foilowing scrvice operations;
1 . An injector that has been removcd from the engine

for cleaning, must be checked on the tester before
the injcctor can be installed in the engine.
A new tnlcctor assembly must be checked on the

tester bcfore the injector can jnstalled in the engine
All the inlcctors must be removed and checked on

,i,,',;'i"
f ,',',,t'..,,:1, the tcster during an engtne overhaul.
,',,,,t',,l11'.i,,,.,'
%;
A Diesel Fuel lnjection Nozzle tester (CAS,-10249) is An injector must be removed and checked on the
needed ior checking and adlusting the injectors Thc tester before the injector is disassembled, if the
following instructions wiil work for all modeis o1 tcslers injector is the cause of engine performance that is
cxccpt for dcscriptions on adlustrncnts io thc leslcr. not acceptable
Opcratrng nstructions are givcn wrih the lcsicr
The tcster is used to make the following checks:
1 Check and adjust the injector opening pressure

2 Check the injector assembly for luel leakage
3 Check the injector for accurate spring pattern,
Nozzle Tester Preparation

1 Fili the reseryoir with clean fuel 4. To remove thc air lhat is in the system, closc the
prcssurc relcase valvc and the gauge protection
'2 Connect the correct connectors to the conncction valve, open the pump valve. Operate the pump
tubc. rapidly to remove the air from the system.
3 Connect the injector to the tester
Rac 8-26 1 52 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
341 3-1 1
TESTING INJECTORS
The injector must be cleaned before testing the injector,
Wash the body, nozzle tip and the cap nut in a solvent to
remove external dirt, greasc and carbon deposits from
the cap, body and outside diameter of the tip.
IMPORTANT'. Do not permit the wire brush to contact

the tip (spray hole area) of the nozzle.
-d.
%r
Connect the injector to the nozzle tester. The nozzle tip
must be down. Use adapter elbow (Part Number YSOO-
3) straight adapte r (Part Number Y900-5) and adaprer
nut (Part Number Y900-6)
When testing or adjusting fuel injectors, do

not put your hands or arms in front of spray.
The spray will penetrate the skin causing
serious personal injury. sMr26A
Fucl from the spray orificcs can enter clothing and skin
causing serious damage, The tip must always be put in
a rccptacle to hold the spray.
Checking Opening Pressure

Ciose thc prcssurc rclcasc valvc and thc gauge protcc- lf the injectors do not meet the given opening pressure:
tion valvc, operatc the pump rapidly to ilush the inlcctor.
Opcn the gauge protcction valve and raise the prcssurc 1. New injectors can be adjusted to the given opcning
slowly until the injector valve opens (the gaugc reading pressures See Page 1 B.
will fall quickly at this point) Check the opening
pressure against the specifications: 2. lnjectors ln use must be disassembled and cleaned.
See Page 13 and 14
NOTE: There must not be more then 150 PSI 0A34
bar) difference between any of the injectors that have 3 Check for broken or weak opening pressure control
been removed lrom the enotne. sprlngs.
Rac 8-26152 Revised 2-92 Printcd in U.S A
kaukazz@yahoo.co.uk
3413-12
Checking Seat Leakage
C ose thc pressure release valve and the gauge protec- 4. Open the pressure release valve and remove the in-
tion valve. Open the pump valve and operatc thc pump lector
rapidly to flush the injector.
The following procedure must be followed if drops of
1 Dry the injector tip completely Open thc Aauge pro- fuel are seen on the nozzle tip.
tection valve.
'1. Disassemble and clean the injector, see Pages i3
2. Lift the pressure at the iniector to 100 PSI (6.9 bar) and 14
under thc opening pressurc
2. lnjector assembly, see Pages 15 through 17
3 Close the pump valve for five seconds and check
the nozzlc tip (spray hole location. Thc nozzle leaks if
drops of fuel are seen on the nozzle tlp, A small
amount of moisture on the nozzle Iip is permitted,
Spray Pattern
Close thc pressLrre release valve and the gaugc protcc- Thc inlector will make a very clear noise when the test
tion valve . Open the pump valve and operatc the lester stand is ope rated rapidly Thls noise wili not necessarily
at 60 strokes a minute, check the spray pattern. The occur in the operation of the inlector in the engine The
nozzle must have a spray pattern that will atornizc the noise is an indication of good seat width and interfer-
fuel Thc nozzic must not have a solid soray patlern cnce angles. This noise can change between nozzles
Thc noisc in thc nozzles must not b,e compared for
purpose of maktng nozzlcs acceptable of not accept-
able.
lf this injector makes a solid typc spray pattern, do this
1. Check the ori{ices that are not open and check

orifrccs for scratchcs and hcavy damage.
Disassemble and clean the inlcctor,
Chcck for pitting of the valve scat, wear of valve in-

lcrlcrence angies, bent valves and distortion ln the
body Rcplacc the complete iniector assembly if
SPHAY PATTERN THAT WILL ATOMIZE Ft]EL lhcre is distorlion in the body Under other condi-
lions, rcplacc the tip asscmbly only.
60 I -8C
SOLID TYPE SPRAY PAIIERN
Fac 8-24'52 Revised 2-92 Printed in U S A
kaukazz@yahoo.co.uk
341 3-1 3
MAINTENANCE OF THE INJECTOR
Disassembly
STEP 14 STEP 16
g
&s + 5, NozzLE HoLDER
-L'
*o.o, ffi
1. SEALING GASKETFi I
./
-/q
V .. 4. pRESSURE SpRING
6. SHIMS Y'
/./"3- 3. yALVE ST6P

./
7, SPBING SEAT @
L_..r
2. NozzLE ASSEMBLY
IJ.+
[> .+
1. cAP NUr
4:.:,i T69078 LJ
Put the injector in a solt face vise with the two flat Disassemble the iflector assembly
surfaces toward the vise face The tip of thc injector
must bc up Remove the scaling gaskct NOTE: The injector pafts have tight tolerances. Dirt will
damage a smooth suiace. Keep the work location and
tools clean. Disassemb/e and assemble all pafts care-
STEP 15 fully to prevent damage.
NOTE: \//et the nozzle and the holder assembly tn a

cleaning solution that v,till remave carbon. Use Gunk,
Bende's Kleaner or a sclutton that is the same as these.
The cleantng solution wrl/ give assrs tance ta f ree the cap
nut.
Usc a srnall amount of force to turn :he cap nut. Check

the nozz e when there is a small amount of moveme nt.
Look to see rf the nozzle turns with the cap nut lf thc
nozzle turns with the cap nut, see below.
IMPORTANT: The nozzle rs berng held in position with

the cap nut. lf the nozzle turns with the cap nut. carbon
deposits between the two parts will cause thrs. Do not
/oosen the cap nut. Thrs wrll cause damage to the dowel
pins, valve stop and holder body pressure face. Wet the
nozzle and the holder assemb/y tn a cleaner so/utlon
that removes carbon, untjl the nozzle is free in the cap
nut. Replace the valve slop assemb ly if there rs damage
to the dowel pins or valve stop.
Bac 8-26152 Rcvised 2 92 Pri'tco in J S.A
kaukazz@yahoo.co.uk
3413-14
Cleaning and lnspection
All parts must be put in a solvent to looscn the
carbon deposits,
A brass wire brush must be used to clean the

outside of thc tip body. Use cleantng wires to
rcmove the carbon from the soray orificcs. Usc
cleaning wrres that are (0 0127 to 0 0254 mm)
smaller in diameter than the spray holc Put the
c eaning wire rn a pin vise. The end of the wire must
extend 0.79 mm past the tip of the p n vise. A longer
length of wire wl hit the oppos te wall of the sac hole
and wiil break
SPFAY ORIFICE 4. Clean a channe ls with air under pressure. Direct the
air through both enCs of the nozzle tip asscmbly.
Carbon deposits must bc removcd.
I
2. PIN VISE
T69089
3 Use a stone to removc sharp eoges from the end of
:hc wire A small flat on onc sidc of thc wirc will make
it casrer to cut the carbon from the orifice. Put thc
clcaning wire in the spray orifice and turn the wire
unlil thc wrrc is ircc. Wash thc bcdy with c car 5. Make surc that thc nozzle valve slides freely in the
sovcnl and look at thc tip. fhc.roz,: c lic m'.,s1 bc nozzlc body
rcplaccd if the ori{ cc n trc tip slovrs darlagc :rl ihc
cdgcs Damagc lo thc orilicc wril crangc lhc spray iarc'i. \' ccafr lic noz,zlc valvc and thc inside
pattern. diarrreier of lhe body to re.iove all dirl, varnish and
othcr forcign dcoosits.
The njector valve must be cleaned with a brush to

rernove deposits from the seat location. Varnish
must bc rcmovcd with a soivcnt and a clcaning pad
madc o{ fcli Do not put thc valve in a motor driven
lathe to clean the valve. This method can remove too
much material from the valvc which can change
valve lift, Look at the valve for pitting or damage
which can cause leakage,
B. Replace all parts that show damage
?ac 8-261 52 Rcviscd 2-92 Printed in U.S A
kaukazz@yahoo.co.uk
J4tJ-t5
Assembly
1 GASKET\ 3. NOZZLE HOLDER

a/
mQ)
2. LEAK oFF BoLr .*@*
4, SHIM AS NEEDED
9,/
@ eRESSURE spRtNG
g-/ -,5.
tr),t
&
w, -/-6 spRr\GsEAr
v
o-/,// - 10 vALVE sroP
;=,1
Kig
fl'/
9. NOZZLE TIP ASSE[i1BLY
l.l -, 8. CAP NUT
NOTE: Clean all parts in clean diesel fuel before assembly

n- 421L91
STEP 17
Install the pressure adjusting shims that arc nccded to lnstall thc pressure spring in the nozzle holder
set the opening pressurc
Rac 8-26 1 52 Eevised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
STEP
L PINS
S&ii'i
Instali the spring scat on the Drcssure sprlnc The small Align thc dowel pin holes ln the nozzle tio assembly with
dlameter end of the spring seat rnust be toward :rc thc dowei pins in the stop valve assembly lnstall the
pressurc spring nozzle lip assembly on the valve stop assernbly
STEP 20 STEP 23
DOWEL PINS
lnslali the valvc slop assembly Ai gn thc dowel p r)s Add ubricalion to thc nozzlc shouidcr Do not put
that arc in thc valvc stop wih lhc co',vci orrr lrolcs lhai grcasc on thc holocr or thc threads of the cap nut
are n the nozzle holdcr insta I lhe cap nut ovcr the end of the nozzle tip
assembly and turn lhe cap nul clockwise two or three
times.
STEP 21
Put a small amount of clean f uei on lhe nozzle va ve and

slide thc nozzle vave up and down a nuniber oi :rmes n
lhe nozzle tio to rrakc sure that ihe re is lrec rnr:vement
Hac d'lb 52
Fevised 2-92 Prlnted in U S A
kaukazz@yahoo.co.uk
3413-17
STEP 24 STEP 25
T69080
Put the injector in a soft face vise with the tip of the Check the fuel injector on the test stand
injector up The flat surface of the injector must be
toward the face of the vise, Tlghten the cap nut to a
torquc of 24 Nm.
NOZZLE HOLDEB 2. SHIMS - AS NEEDED 3. PBESSURE SPRING

4. VALVE STOP
6 DOWEL PIN 8. NOZZLE TIP

ASSEMBLY
5. SPRI SEAT 7. CAP NUT
Rac 8-26 1 52 Revised 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
341 3-1 8
I NJ ECTOR ADJUSTMENTS
Adjusting the Opening Pressure
STEP 26 STEP 28
':r:;::;.
T69080
Bemovc:hc fuel inlector trom thc nozzlc tcstcr Put :hc Assemble :he fucl niector, See Pages 15 through 17
injcctor ln a soft face vise Thc f lats of thc inicctor holder
rrust bc ioward the iacc of ihe visc The iniector tip
STEP 29
rnusl bc uc Loosen thc cap nut. To dlsasscmble thc
nlector sce Pagcs 13 and l4
STEP 27
ffi ' ..:'

";1
,fr
d
!:irji:i:ll
tu,
Chcck aga n thc opening prcssurc of thc tucl inlcctor
on ihc nozzle testcr. Bcpcat Stcps 26 through 29 on tris
page, as necessary, until the needed opening is
169087 corrcct
Add pressurc adlusting sh ms to increase t:re opcnrng
0rcssurc Rcmove pressure adjusting snin :o s
dccrcase opcning prcssurc Do :h s unl I ihc correcl
pressi,rc is reachcd.
IfUPORTANT: The opening pressr.rre is changed by

about 55 PSI (3.79 ba) for each (0.254 mm) of shim
Ihlckness that is added or removed.
Rac 8-261 52
Bcvisod 2 92 Printed in U.S A
kaukazz@yahoo.co.uk
341 3-1 I
INJECTOH SLEEVE
lnstallation
This sleeve must be used to change the 9 mm injector bore in the cylinder head to a 7 mm inlector bore to use the 7 mm
inlectors.
STEP 28 STEP 30
Use the injector bore clcaning tooi, Sce Spcciai Tools Use thc special wrench and tighten the injector re-
page for corrcct sizc cleaning tool, clcan thc injector taining nut to a torque of 55 to 65 Nm
bore. Usc compressed air to clean the injector bore.
STEP 31
STEP 29
7 mm INJECTOB
SLEEVE lnstall thc seal and the lcak off screw and tightcn thc
leak off bolt to a torque of 8 Nm.
NOTE: Make sure the top of the gasket does not touch
351.92 the leak off line
lnstall tfie sleeve on thc injector, STEP 32
IMPORTANT'. Do not rnstall a sealing washer on the
injector when sleeve r,s used.
Remove the dust cap. Connect and tighten thc injection

linc to thc lnlector'
Fac 8-261 52 Revtscd 2-92 prinrcc n u sA
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk Sectional lndex
ELECTRICAL SECTION NO.
A Alternator
Removal, Disassembly and lnspection .,,.............. ..,,...,........... 4008
Testing on the Machine ..........,....... 4008
Booster Battery Connections .............. 4004
Starter Motor
Removal, Disassembiy and lnspection .....,........... .... .., ......... 4003
Starter, Solenoid Voltage Test ..,........ .,............. . 4001
Testing on Machine .., 4003

CASE CORPORATION February 1990
kaukazz@yahoo.co.uk
Section
400 1
ELECTRICAL TROUBLESHOOTING AND SCHEMATICS
CASE CORPORATION Copyright @ 1992

Don B-85042 Printed in England
March 1992
kaukazz@yahoo.co.uk
4041-2
TABLE OF CONTENTS
J
SHOP EQUIPMENT TOOLS . . .. ,. . .
3
GENERAL INFORMATION
4
FUSES
SCHEMATIC SYMBOLS
q
FUSES AND RELAY LOCATION
BULKHEAD CONNECTORS AND ELECTRICAT COMPONENT LOCATION

,. .. . 6
7
STABTEE KEY SWITCH KEYED POWER FUEL SHUT-OFF AND
ETHER START
to
ALTERNATOR AND INSTBUMENT CLUSTER
J\,/
FORWARD/REVERSE AND TFANSMISSION CONTROL
46
ACCESSOBY POWER RELAY SENS.O-DRAULIC SHR HITCH CONTROL
56
FRONT PTO MFD AND DIFF LOCK
HEADLAMPS TAIL LAMPS TUFNSIGNALAVARNING LAMPS 68

RIGHT HAND CONSOLE LAMP AND HORN (FOR TRACTORS
WIIH CAB)
HEADLAMPS TAIL TAMPS TURNSIGNAT,^/VARNING .80

LAMPS AND HORN (FOR TRACTORS WITHOUT CAB)
(FOB TRACTORS WITH CAB) .92
REAR FENDER FRONT CAB AND REAB CAB WORK LAN/PS
'
(FOR TRACTORS WITHOUT CAB) . 100

REAR FENDER FRONT FENDER AND CANOPY WORK LAIV1PS
.110
AUXIL|ARYPOWERCONNECTOR;CIGARETIELIGHTERANDELECTRICSEAI
. 114
RADIO RADIO CLOCK AND INTERIOB LAMP . .
. 120
FRONT AND REAB WINDSHIELD WIPER,A/VASHERS .
128
BLOWER MOTOB AND AIR CONDITIONER
TO CAB NO JKJ46968) 136

BLOWER tvlOrOR AND AIR CONDITIONER (FOB TRACTOBS UP
144
TRAILER CONNECTOR
Befer to Section 6008
POWERSHIFT

Don 8-85042
kaukazz@yahoo.co.uk
4001 -3
)t
-f J
1. SIGNAL GENERATOR/COUNTER OEM 1336A
1. MULTIMETER OEM 1049
GENERAL INFORMATION
NOTE, Nl electrical checks must be made with the tractor parked on hard level ground wrth the parking brake engaged
and the engine OFF uniess othenwise staled
NOTE: Nl componenls, wires and connectors disconnected during any electrical checks must be cannected wnen the
checks are complete.
Don 8-85042 lssued 3-92 Prinlec in England
kaukazz@yahoo.co.uk
4001-4
FUSES
rUSE AMPS CIRCUIT FUSE AMPS CIRCUIT
F1 15 Front Work Lamps F17 15 Horn, Flasher Relay

F2 10 Rear Windshield WiPer Washer FlB 7.5 Forward Solenoid
rJ 30 Auxiliary Power Cigarette F19 10 Forward/ReverseRelay
Lighter, lnterior LamP r zl) 75 Powershift
CA
15 Rear WorkLamps(Cab) azt 75 Reversc Solenoid
F5 15 Turn Srgnal F22 15 Ether Start Solenoid
F6 5 Warning LamPs F23 10 M F D, Ditf Lock
F7 F24 75 lnstrurnent Cluster
F8 5
'1
Front Windshie d WiPerAilasher F25 5 Powershiit Solenoid 1
F9 5 Tail Lamps F26 5 Powershift Solenoid 2
F10 15 HeadlamPs High Beam F27 5 Powershift Solenoid 3
F11 15 Headlames Low Beam F28 5 Powershift Solenoid 4
- tz F29 5 Radio lnstrument Cluster
trrn 10 Fron.l P,T.O
F13 5 lnstrument Clusier lllumtnatton,
H H Console Lamp F31 30 Keyed Power, Seat.
F14 ac
IJ Rear Fender Worklamps F32 7.5 Senso-Draulic S H.B
Hitch Control
F15 r5 Front Fender WorklamPs (Non
-Cab)
l- to '10 Fuel Shut-Cff
SCHEMATIC SYMBOLS
Schematic Wire Reference
-20
CONNECTOB A
Connector Wrlh ldentification Numbers or Letters For Example Connector A Pin or
-ffi- Terminal A.
Component Connector With ldentification Numbers or Letters
Component Connector With ldentification Number or Letter Secured to the Component by

a Screw or Nut.
-f-TBl
Connector Without loentification \umbe's or Letters
CLEAN GROUND Circuits Grounded Drreci to the Bat1ery Negatrve Posl
CHASSIS GROUND
Circuits Grounded to Tractor Chassis
//,///
o Test Pcini
Component Location Number

(,
Don B -85C42 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001-5
FUSE AND RELAY LOCATION
LEFT HAND FUSE RELAY BLOCK RIGHT HAND FUSE RELAY BLOCK
TRACTORS WITH CAB

1. FRONT PTO HETAY (OF CREEP RELAY TRACTORS UP TO PtN NO JJF100s652)
2. FRONT PTO RELAY (OR CREEP RELAY TRACTORS UP TO PrN NO JJF1005652)
3. FRONT WORK LAMP RELAY
4, REqR WORK LAMP RELAY
5, OPEN
6, OPEN
7, FUSES 1 TO 16
8. FUSES 17 rO 32
9. FORWABD/REVERSE RELAY (DIODE SUPPRESSED)
10. ACCESSORY POWER RELAY
11. WAFNING LAMP TEST BELAY
12. TRANSMISSION CONTFOL RELAY (DIODE SUPPRESSED)
TRACTORS WITHOUT CAB

1. FRONT PTO RELAY (OR CBEEP RELAY TMCTORS UP TO PIN NO JJF100s652)
2. FRONT PTO RELAY (OR CBEEP HELAY TBACTORS UP TO PIN NO JJF1005652)
3. OPEN
4, REAR WORK LAMP REL-AY
5, CANOPY WORK LAMPS
6, OPEN
7. FUSES 1 TO 16
8. FUSES 17 rO 32
9. FORWABD/REVERSE RELAY (DIODE SUPPHESSED)
10, ACCESSORY POWER RELAY
1, WARNING IAMP TEST RELAY
'1
12. TRANSMISSION CONTROL RELAY (DIODE SUPPRESSED)
kaukazz@yahoo.co.uk
4001-6
BULKHEAD CONNECTORS AND ELECTRICAL COMPONENT I-AYOUT
STARTER RELAY
CONNECTOR B (ENGINE HANi{ESS)
BATTERY JUNCTION
BLOCK (POWER)
CONNECTOR D (CAB HARNESS OR PLATEFORM)
+
I
I
RADAR BULKHEAD CONNECIOR
VIEWED FROM THE ENGINE
CANOPY WORK LAMPS OR

CHASSIS POWER RELAY KEYED POWER AIB CONDITIONER CIRCUIT BREAKEB
JUNCTION BLOCK
FLASHEH RELAY
HEADLAMP DIMMER HELAY
AUDIBLE A[-AHM
LEFT HAND FUSE RETAY BLOCK RIGHT HAND FUSE RELAY BLOCI{
--t -__I i
--=]
oONNECTOR B (ENG|NE HABNESS) - CONNECTOR A IRANSMISSION HARNESS)

\ A ,__T.
\.. .' /)
...,r
:-:',-/ BATIEBY JUNCTION BLOCK
^
.a' i ',.,1 '
CONNECTOR D (CAB HARNESS OE PLATEFORM) '--.- -1-, 1 -.{-- CONNECTOH C (POWERSH|FT HAFNESS)
l* -:-,
/
l.
I
I
I
I
RADAF BULKHEAD CONNECTOR
VIEWED FROM THE CAB
ior 8.85042
tssued 3-g2 Prlnied ln Enqland
kaukazz@yahoo.co.uk
4001-7
STARTEH, KEY SWITCH, KEYED POWER, FUEL SHUT-OFF AND ETHER
START
Sectional lndex
CIRCUIT TESTING
Starter Solenord Circuit Test o
Starter Felay Circuit Tesi .. .. o
Range Switch Test (Neutral Start Circurt). .. 10
PTO Neutral Start Switch Test (lf Equipped) 11
Forward/Reverse Neutral Start Switch Circuit rest .......... 11
Neutral Start Diode Test .... 11

Starter Belay Diode Module Circuit Test tz
Key Switch Test 12
Chassis Power Relay Circuit Test (Keyed Power) IJ
aa
Fuel Shut'oif Circuit Test . IJ
Don 8-85042 ssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001 -8
WIRING CODE
BEF COLOR FROM TO WIRE
GAUGE
Chassis Ground 210
1 Black Battery (Negative)
Starter Motor Solenord fierm B) 210
2 Bed Battery (Positive)
Baltery Junctron Block 6
3 Bed Starter Motor Solenord flerm B)
I
Starter RelaY ft-erm 30)
4 Red Battery Junction Block
Starter Motor Solenoid (T-erm S) 9
5 White Starter RelaY (Term B7)
Battery Junction Block Keyswitcn (BAID 13
6 Red
Warning Lamp Test Relay (1-erm 86) 18
7 Whtte Key Switch (START)
86) Connector F f-erm 8) 18
7 Warning LamP Test RelaY flcrm
For"wardlReverse Switch fTerm 8)
White 18
8 Black Connector F fTerm 8)
Forward/Revcrse Switch (Term 7) Connector F [erm 7) 18
9 Black
Connector A (Pin A) 18
10 White/Pink Connector F fl-erm 7)
Connector A (Pin A) Starter Relay Diode Module (l'-erm A) 18
10 White/Pink Neutral Start Diode
.18
10A Brown Connector A (Pin A)

Starler RelaY (1-erm 85) 18
10A Brown Neutral Start Diode
Starler RclaY fTerm 86) 18
11 White Starter Belay Diode Module [Term C)
11A White Starter BelaY (Tcrm 86)
Connector 18
PTO Neutral Starl switch flerm A)
'18
'11A White Connector
Starter RelaY (Term 85) 3rd/4th Bange Switch [erm B) 18
12 Brown/Orange 1 sV2nd Range Switch ft-erm A)
18
12A Wnite,Yellow PTO Neutrai Start Switch (Term B)
l sV2nd Range Swiich (l-erm B) 18
13 BrownAVhite 3rd/4th Range Switch [1-erm A)
1st/2nd Range Switch fl-erm B) 3rd/4th Range Switch (1'-erm A) 18
13A Whrte/Dark Blue Chassrs Ground 18
14 Brown 1st/2nd Range Srvitch fl-erm A)
From PIN No JJFl005524 A) 18
PTO Neutral Start Switch fl'erm
14 st/2nd Range Srvitch fierm A)
.1
Brown,Yellow
Up To PIN No JJFl005523
lf Equrpped
1B
Splice
144 White/Pink 3rd/4th Range Switch [Term B) 18
PTO Neutral Start Switch [T"errn B) Chassis Ground
I5 Brown
lf Equrpped 18
Conncctor
154 Brown Splice
Chassis Ground 18
15A Brown Connector
Chassis Power RelaY flerm 86) 1B
16 Red/Orangc Key Switch (lGN)
Battery Junction Block
Chassis Power RelaY (Ierm 30) 7
17 Red Keyed Power Junction Block 7
18 flsflA,^/hite Chassis Power BelaY flerm 87) 18
Chassis Ground
19 Brown Chassis Power FelaY (Term 85) 1q
Fuse F22
20 Bed/Light Blue Key Switch (lGN) 15
Fuse F16
20 Red/Light Blue Fuse F22
Connector B (Pin G) 15
21 Dark Bluc/Red Fuse F1 6
Fuel Shutoff Solenoid 15
21 Dark BlueiRed Conncctor B (Pin G)
15
Ether Start Switch fl-erm 1)
22 Dark Blue/GraY Fuse F22
Connector B (Pin B)
IJ
23 Dark BlueAffhite Ether Starl Switch fl-erm 2) .13

Ether Staar Solenoid
23 lark BlueMhite Connector B (Pin B) 15
Chassis Ground
24 Brown Ether Start Solenoid
NoTE:Atlwirecodereferencesmarked,A'arefortractorsUptoPlNNoJJF100a602
lssued 3-92 Prinied in England

Dcn 8-85042
kaukazz@yahoo.co.uk
4001-9
CIRCUIT
powrquadplus www.thebestworkshopmanuals.co.uk TESTING
NOTE: Thebafteymustbeatfull chargeandall conneclions mustbecleanandtightbefore testmg. Useamultimeterfor
fhe tesls.
NOTE: Any reference to wire codes A' are for traclors up to PIN NO JJF1004602.
NOTE: Far testing and repair of the starter motor, see Section 4003 in this se,1/ce manual.
Starter Solenoid Circuit Test

NOTE: Put the range lever in neutral, the forvvardlreverse lever in fonvard, drsengage the PTO and hold the key in the
START position.
Check Points Beading Possible Cause ot Bad Reading
Q ferminal for cable 2 Red to ground 12 Volts Check the battery cables between the
starter motor solenoid terminal B and the
positive terminal of the battery. Check the
connections of the battery box junction
block (if equipped).
@ ferminal for wire 5 White to ground 12 Volts Check wire 5 and check the starter relay
circuits
NOTE: lf the readings are correct see Section 4003 and check the stafter motor solenoid.
Starter Relay Circuit Test

NOTE: Put the range lever in neutral, the forvvard reverse lever tn lorward. disengage the PTO and turn the key to the OFF
position.
Check Points Reading Possible Cause of Bad Reading
Terminal for wire 12 Brownlarange or 11A Continuily Bad chassis ground circuit
White to ground
NOTE: lf the reading is not correct go to check point 7.
NOTE: Hold the key in the SfARI position.
@ terminal for wire 4 Red to ground 12 Volts Check wire 4 and battery junction block
connection.
Terminal for wire 11 White or 10A Brown to 12 Volts Bad circuit between the key switch and the
ground starter relay. Check the key switch and the
fonvard/reverse switch neutral start circuit.
Also check the neutral sta( diode or starter
relay diode module.
Terminal for wire 5 White to ground 12 Volts Bad starter relay

@
kaukazz@yahoo.co.uk
4001 -1 0
Check Points Reading Possible Cause oi Bad Reading
@ terminal for wire 12 Brown/Orange or 11A Continuity Bad chassis ground oircuit
Whrre to ground
NOTE. lf the reading is correct check wtre 12 or wire 1 1 A and the connector if equipped
Terminal for wlre 13 BrownftVhite or 12A Contnuity Bad chassis ground circuit
Whiie/Yellow to ground
NOTE. lf thereadinqiscorrectcheckwirel3orl2A Alsocheckthe3rdl4thrangeswitcharPTOneutral sla/tswlch
@ termlnal for wire 14 Brown to ground for Continuity Check wire 14 and the chassis ground
traclors from PIN No JJF]005524 con,lect ons
NOTE: lf the reading is correct check the 1st.t2nd range switck
Terminalfor wire 14 BrownrYellow to qround Cont,nuiV Bad chassis ground circuit

for tractors from PIN No JJF1004602 io
JJ F1 005524
NOTE: tf the reading is correct check wtre 14 and the lstl2nd range switch
Terminal for wire 13A White/Dark Blue to Continuity Bad chassis ground clrcurt
qround for tractors uP to PIN No
JJFl 004602
NOTE: tf the reading is correct check wtre 13A and the lstl2nd range switch
@ H'n::' Contrnuity Check wire 15 and the chassis ground

L"J#'8,1,' i;Ti: fffi;i':J connecllon.
JJFl 00ss24
NOTE: lf the readtnq is correct check the PTa neutral. slad swlch
Terminal lor wire I44 Whrte/Pink to ground Continuity Bad chassis ground circuit
for tractors up to PIN No JJF1004602
NOTE: lf the readng ts correct check the 3rdl4th range switck
Range Switch Test

(Neutral Start Circuit)
NOTE: The pracedure for checking the range switches ls the sa,me for both lstlznd and 3rdl4th range switches
NOTE: Disconnect the range switch from the harness and put the range lever in the NEUTRAL position.
Check Points Readrng Possible Cause of Bad Reading
Between terminais A and B of the range ContrnuihT Bad range switch. Adjust or replace switch
swrtch as necessary, refer to Section 9001
Beiween termtnals C and D oi :he range No ContinL,rty Bad range switch Adjust or replace switch
SW:Ch as necessary, refer io Section 9001
lcn 8-45042
lssled 3-92 Printed in England
kaukazz@yahoo.co.uk
NOTE: Put the range lever in 1st or 2nd range (for the lstl2nd range switch) or 3rd or 4th range (for the 3rdl4th range
swrtch).
Between terminals A and B of the range No Continuity Bad range switch. Adlust or replace switch
switch
powrquadplus www.thebestworkshopmanuals.co.uk as necessary. refer io Section 9001.
Between termtnals C and D ol the range Continulty Bad range switch. Adjust or replace swi:ch
switch as necessary, refer to Section 9001
PTO Neutral Start Switch Test

NOTE: Disconnect the PTO switch from the harness and put the PTO lever in the D/SENGAGED posttton
Between terminals A and B of the PTO Continuily Bad PTO switch. Adiust or replace switch
SWItCh as necessary, refer to Section 9001.
NOTE: Put the PTO lever in the ENGAGED posrtion.
Between terminals A and B of the range No Cont nuity Bad PTO switch Adrust or replace swrtch
ForwardiReverse Neutral Start Switch Circuit Test

NOTE: Disconnectthe forwardtreverse swtch fron the harness at connector F and hold the key in the START position.
Check Points Beading Possible Cause of Bad Reading
@ ferminal for wire 7 White to ground 12 Volts Bad circuit between the key switch and
connector F. Also check the key switch.
NOTE: Turn the key to the OFF posrtion and put the torwardlreverse lever in the FORWARD position
Between terminals 7 and B oi Continuity Bad forward/reverse switch. Also check

connector F (swrtch side) wires 8 and 9.
NOTE: lf the readings are carrect check wires 10 and 10A. Also check the neutral staft diode or starler relay drode
module.
Neutral Start Diode Test

NOTE: Turn the key to the OFF position and disconnect the diode trom the harness.
NOTE: The positive lead of the multimeter must go to the female terminal of the diode.
Between terminals of the diodc No Continuity Bad diode
NOTE: Change the leads of the multimeter over so lhe positlve iead of the multimeter goes to the male terminal of the
diode.
Beween terminals of the diode Contrnuity Bad diode

,on 8-85042 lssued 3-92 Printed in Engla.C
kaukazz@yahoo.co.uk
4001-12
Starter Relay Diode Module Circuit Test
NOTE: Turn the key to the aFF position and disconnect the diode module from the harness
position.
NOTE: put the forvvardlreverse lever in the FOBWARD pasitian and hold the key in the START
Check Points Beading Possible Cause of qaq rceq'n-g
Termrnal for wire 10 White/Pink to ground 12 Volts Bad circuit between the key switch START
liD termina and the diode module terminal A
Check the key swrtch and the forward/
reverse switch neutral start circuit
NOTE: The positive lead of the multtmeter must go to termtnal A of the drode madule.
Between terminals A and c of the diode continuity Bad diode module

module
NOTE: Change the teads of the multrmeter over so the positive tead of the multimefer goes to terminal C of the diode
module.
Berrveen rerminals A and c of the diode No continuity Bad diode module

module
Key Switch Test

NOTE: Turn the key to the OFF position
Check Points Rcadrno Possible Cause of Bad Reading
Gl Te,m,nal for wire 6 Red to ground iil Bad connection at the battery iunction
block. Aiso check wire 6.
positian
NOTE: Disccnnect the key switch t'rom ihe harness, and turn the key to the ON
3eNveen termrnals BATT and IGN Continuity Bad keY swttch
Bewveen termrnals BATT and ACC Coniinuity Bad keY switch
NOTE: Hald the key tn the SIABI pastfian
Belween terminals BATT ard START conlinui! Bad key switch
NOTE: Turn the key to the ACCESSORy position'
Bctween terminals BATT and ACC Contrnuity Bad key switch

D31 8 85C42
kaukazz@yahoo.co.uk
4001 -1 3
Chassis Power Relay Circuit Test (Keyed Power)
NOTE: Turn the key to the OFF position.
Cl terminal forwire 19 Brown to ground Continuity Check wire 19 and the chassis ground
connectron
NOTE: Turn the key to the ON pasition
lD terminal for wire 17 Red to ground '1

2 Voiis Bad connection at the battery lunction
block. Also check wire I7.
@ tur.;nul for wire 16 Bed/Orange to ground l2 Volts Check wire 16. Also check the key switch
@ lerminal for wire 18 RedAVhite to ground 12 Volts Bad chassis power relay
@ ferminal for wire 18 RedAVhite ro ground 12 Volts Cneck wire 18
Fuel Shut-off Circuit Test

NOTE: Check tuse f16
NOTE: Turn the key ta the ON positron
Terminal lor wue 21 Dark Blue/Red to '1

2 Volts Bad circuit between the key switch terminal
ground 54 and the fuel shut-off solenoid
NOTE: lf the readrng ts correct check the fuel shut-off solenord connection or replace the fuel shut-off solenoid as
necessal/
NOTE: Disconnect connector B.
Belween Pin G of connector B (thebulxhead 12 Volts Bad circuit beh,veen the key switch terminal
side of the conncctor) to ground 54 and connector B.
Behrveen Pin G of connector B (the harness Continuity Chcck wire 21 and connector B
side of the connector) and the fuel shut-otf
solenoid terminal
Don 8-85042 ssued 3-92 Printed in EnEland
kaukazz@yahoo.co.uk
4001 -1 4
Ether Start Circuit Test
NOTE: Check fuse F22.
Possible Cause of Bad Feading

Check Points &gg!_g
for wire 24 Brown to ground Continuity Check wire 24 and the chassis ground
@Terminal connection.
NoTE: Turn the key to the oN position and hold the ether starr switch in the energized position.
Terminal for wire 23 Dark BlueAVhite to 12 Volts Bad circuit between the key switch terminal
ground 54 and the ether starl solenoid
NOTE; lf the readings are Correct replace the ether staft solenoid
Terminal for wire 22 Dark Blue/Gray to 12 Volts Bad circuit between the key switch terminal
ground 54 and the ether start switch terminal 1
Terminal for wire 23 Dark BlueMhite 1o 12 Volts Bad ether start switch
ground
at connector B
NOTE: lf the readings are correct check wire 24 for contjnui\ and the connection

Don 8-85042
kaukazz@yahoo.co.uk
r
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4001- ls 4001-15
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I scLENOID (ETHER
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Contacts oPen or
SoLENOID (FUEL
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FORWAFDfl1EVEHSE SWITC}I
,LENOIO (FUEL
UTOFR RELAY 30 AMP
A tnagfletic coil that
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SH BUTTON
START}
Schematic Circuit (STARTEF} closed bY FO B1I/ARD/REVEHSE SWITCT I NGLE POLE) A rnagnetic coil that
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AMP Controls more than one circui' Controls mors than one circui' aduates a Plunger
A source of Power FH'gBl=*o'o An electric motor A magnetic switch th
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JUNCTION BLOCK Forward/reverse switch to
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WARNING LAMP
TEST RELAY
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kaukazz@yahoo.co.uk
lssued 3-92 Printed in Enl
lssued 3'92 Prinlcd in Errg!116
Don 6-85O42
4001 -1 6
ALTERNATOR AND INSTRUMENT CLUSTEH
Sectional lndex
WIRING CODE tt
lnstrument Cluster Power and Chassis Ground Crcuil Test 'lB

10
lnstrument Cluster Engine RPM Display and Hourmeter Circuit Test ............ 19
Hydraulic Filter Restriction Warning Lamp Circuit Test ............ 20
Air Filter Restriction Warning Lamp Circuit Test ............ D1
Parking Brake Warning Lamp Circuit Test 21
Warning Lamp Test Relay Circuit Test ........... aa

Warning Lamp and Audible Alarm Diode Test ............ ZJ
lnstrument Cluster lllumination Circuit Test 23
High Beam Warning Lamp Circuit Test ............ ZJ
Turn Signal Warning Lamp Circuit Test 24
Ground Speed Sensor Circuit Test (Delux lnstrument Cluster Only) .......... zt+
Ground Speed Radar Circuit Test (Delux lnstrument Cluster Only) ..........
Fuel Gauge Sender Circuit Test ............ 25
4th Range/Feverse Warning Lamp (Master Flasher) Circuit Test 26
lnstrument Cluster 1000 RPM pTO Display 27
Engine Coolant Temperature Gauge Circuit Test ............. a7
Engine Oil Pressure Warning Lamp Clrcuit Tcst ............ ao
ao
Engine Oil Pressure Switch Test ............
Schematic Circuit ,Q
kaukazz@yahoo.co.uk
40ct-17
WIRING CODE
REF COLOR OB FBON/ TO ]IBI-
COLOR,&VIBE NO trAUtrt
A Aor1 Battery Junction block Key Switch (BAn) i3
7 Whrte Key Switch (START) Warning Lamo ,est Relay (Terrn 86) l8
26 Red/Dark Green Keyed Power Junction Bloo< Fuse F24 1 5
?-7 Yellow/Bed Fuse F24 lnstrument Cluster Connector (Pin 2) 16
28 Red Starlcr Motor Soienoid (Terrr B) Aliernator (Term B *) 7
29 Ye low Alternator (Term D*) Connector B (Pin P) 16
29 Yellow Connector B (Pin P) lnstrument Cluster Connector (Pin 30) l6
30 Yellow/Brown Alterna:or (Ierm W) Connector B (Pin K) 18
30 Ye low/Brown Connector B (Pin K) lnstrument Cluster Connector (Pin 27) 'l B
31 Yellow/Brown Hydraulic Filter Restriction Slvitch Hydraulic Filter Temperature Switch (B) t8
32 Yellow,A,a/hite Hydraulic Filter Temperature Switch (A) Connector A (Pin C) 18
32 Yellow,A&hite Connector A (Pin C) l-ydraulic Filter Test Diode 18
32 Yeilow,zWhite Hydraulic Filter Tesi Drode lnstrumcnt Cluster Connector (Pin 21) 18
33 Brown Arr Filter Restriction Switcn Cnassis Ground 18
34 Dark Green Air Fi ter Restriction Swrtch Connector B (Prn N) 18
34 Dark Green Connector B (Pin N) Air Filter Test Diode 18
34 Dark Green Air Filter Test Diode lnstrument Cluster Connector (Pin 29) 18
35* Brown Parking Brake Switch (Term B) Chassis Ground IB
36 Yellow/Black Parkrng Brakc Switcn (Term A) Conncctor D (Prn A) 1B
36 Yellow/Black Connector D (Pin A) Sclice i8
36 Yellow/Black Audii;le Alarm (- Term) For Tractors Parking Brake Tesr Diode 18
Not Eqipped with Audible Alarm Diode
364 Yellow/Brown Audibie Alarm (- Term) For Tractors Audibie Alarm Diode ro
Equippcd Wiih Audiblc Alarm Diode
36 Yellow/Black Audrble Alarm diode If EqutpPcd Parkinq Brake Test Drode 18
36 Yellow/Black Parking Brake Test Diode Spiice 18
36 Yellow/Black Splice Inslrument Cluster Connector (Pin 17) l8
37 Whrte/Dark Blue Audlble Alarrn (- Term) Transmission Control Relay (Term BO) lB
3B BrowniDark Blue Parking Brake Test Diode Air Filter Test Diode 18
38 Brown/Dark Blue Arr Filier Test Diode Hydraulic Filter Test Diode 18
38 Brown/Dark Blue Hydrar:1c Filter Test Diode Warnrng Lamp Test Relay (Term 30) 18
39 Brown Warn ng !-amp Test Relay (Tcrm 87) Warning Lamp Test Belay (Term 85) l8
39 Brown Warnrng Lamp Test Relay (Term 85) Accessory Power Reiay (Term 85) 16
39 Brown Accessory Power Belay (Tern 85) Transmission Control Belay (Term 85) 16
39 Brown Transmrssion Control Relay (Term 85) Chassrs Ground 18
40 Red/Dark Green Fuse F10 lnstrumcnt Clusler Connector (Pin 32) 16
4t lan Fuse ;1 3 lnstrurncnt Cluster Connector (Pin 36) l6
42 Prnk/Yellow Flasher Relay ferm 3) lnstrument Cluster Connector (Pin 10) 16
43 Brown Flasher Relay (Term 4) Chassis Ground 'l
8
43 Brown Flasher Belay (Term 4) Instrument Cluster Connector (Pin 7) lB
44 PinlVDark Blue Flasher Relay (Term 6) lnstrument Cluster Connector (7tn 24) 1B
45 Light Green/Red Radar Connector (Term C) Radar Eulkhead Connector (Term A) 1B
45 Light Green/Red Baoar Bulkhcad Connecior [errn A) Instrument Cluster Connector (Pin 3) 18
46 Brown/Light Green Badar Connector' (-fcrm A) Badar BL-lkheao Connector (Term 3) 18
ati Brown/Ltght Grecn Badar Bulkhead Connecior flerm 3) lnstrument Cluster Connector (Pin 26) 18
47 Light Green Radar Connector' (Term B) Radar Bulkhead Connector (Term C) 18
47 Light Green Badar Bulkhead Connector fl-erm C) Instrument Cluster Connector (Pin 33) 18
48 Light Green/Yellow Radar Connecior (Term D) Badar Br.:lkhead Connector (Term D) 18
48 Light Green/Yellow Fadar Bulkhead Connector fTcrm D) lnst.unnent Cluster Connector'(Pin 37) 18
49 Brown Grourd Speed Sensor (Tcrm B) Chassis Ground 18
50 Yellow/Dark B ue GroL;nd Soeed Sensor (Term At Connector A (Prn N) 1E
50 Yellow/Dark Blue Connector A (Pin N) lnstrumeni ClL,sler Connector (Pin 2B) lB

5'l Brown Fuel Level Sender Chassis Ground 18
Dcn 8-85042 :ss-ac i-92 P'-:ed i- :-: ?1c
kaukazz@yahoo.co.uk
4001 -1 I
REF COLOR OR FROM TO WIRE
COTORMIRE No GAUGE
52 Yellow/Light Blue Fuel Level Sender F)
Connector A (Pin 18
52 Yellow/Light Blue Connector A (Pin F) lnstrument Cluster Connector (Pin 23)
18
53 Brown Connector G fl-erm 5) Chassis Ground 18
54 Black Connector G fl-erm 5) Forward/Reverse Switch fierm 5) 18
55 Black Forward/Reverse Switch fierm 6) Connector G fl-erm 6) 18
56 Brown/Pink Connector G fierm 6) Connector A (Pin P) 18
56 Brown/Pink Connector A (Pin P) 4th Range Switch fl"erm A) 18
57 PinURed 4th Range Switch fierm B) Connector A (Pin E) 18
57 PrnURed Connector A (Pin E) lnstrument Cluster Connector (Pin )
18
58 Brown,Atuhite Battery Negative Termrnal 1000 rpm PTO Switch Connector flerm B) 1B
58 Brown,A&hite 1000 rpm PTO Switch Connector fl"erm B) 1000 rpm PTO Switch 18
59 Yellow/Dark Green 1000 rpm PTO Switch 1000 rpm PTO Swrtch Connector fl-erm A) 1B
59 YellowiDark Green 1000 rpm PTO Switch Connector fi-erm A) Connector A (Pin J) 18
59 Yellow/Dark Green Connector A (Pin J) lnstrument Cluster Connector (Pin 22)
18
60 Dark Green/Black Engrne Coolant Temperature Sender Connector B (Pin L) 18

60 Dark Green/Black Connector B (Pin L) lnstrument Cluster Connector (Pin 16)
18
61 Brown Engine Oil Pressure Switch flt-erm B) Chassis Ground 18
62 Light Blue Engine Oil Pressure Switch (T-erm A) M)
Connector B (Pin 18
62 Light BIue Connector B (Pin M) lnstrument Cluster Connector (Pin 3a)
18
63 BrownANhite Instrument Cluster Connector (Pin 31) Splice 15
63 BrownA&hite Connector flerm A) Splice '15
63 BrownAVhite Splice Connector A (Pin D) 15

63 Brown,ArVhite Connector A (Pin D) Battery Negative Terminal 15
NOTE: The following wires (64) are for cab tractars from PIN No. JJF1013576 to JJF|013596 and from PIN No. 1013876.
64 RedAVhite Key Switch (ACC) Connector 16

64 Red,4Vhite Connector Fuse F19 16
64 BedMhite Connector lnstrument Cluster Connector (Pin 15) 16
NOTE: Wtre code references marked (") are for tractors up to cab serial No JKJ46968.
36
* Yellow (258)
CIRCUIT TESTING
NOTE: The bafteries must be at full charge and all connections must be clean and tight before testmg. Use a multimeter
for the test.
lnstrument Cluster Power and Chassis Ground Circuit Test

NOTE: Disconnecl the instrument c/uster from the harness and turn the key to the OFF posltibn.
Check Point Reading Possible Cause of Bad Reading
Pin 31 of the instrument cluster connector Continuity Check wire 63 and the ciean ground
and the battery negative post (clean connection at the baftery negative post,
ground) (clean ground)
NOTE: Turn the key to the ON positton
'12
Pin 2 o.f the rnstrument cluster connector to Volts Check wires 26 and 27. Also check the
chassis ground keyed power junction block.
Dox 8-85042 lssued 3-92 Prjnted in England
kaukazz@yahoo.co.uk
4001 -1 9
NOTE: fesl3isforcabtractorsfromPtNNo JJF1a13576toJJF1A13596andlrcmPtNNo JJF1013876
Pin 15 of lhe instrument cluster connector 10 I2 Volts Bad circuit between ihe key switch terminal
ground 58 and the instrument cluster connector
Also check the key switch.
NOTE: lf the readrngs are carrect and the lnstrument ctuster tails to come ON when the key is tn the ON pasition replace
the instrumenl clustel
Alternator Circuit Test

NOTE: Checx ;ne atternator yy2rring lamp bL,tb
NOTE: Turn the key to the ON position
@ Tcrminallor wire 28 Red to ground 12 Volts Check wire 28
NOTE: Disconnect wire 29 from the alternator D-+ termrnai
fl Termlnal for wire 29 Yeltow' to ground 12 Volts Bad circuit between the tnstrumeni cluster
and the alternator D * terminal. A so check
the instrument cluster power circuit.
NOTE: lf the readrngs are correct check the alternatar see Sectron 4008
NOTE: Turn the key to the OFF positron and disconnect the instrunent cluster from the harness
Pin 30 oi the instrument cluster connector Continut:y Check wire 2g

and the terminal for wire 29 Yeliow
lnstrument Cluster Engine RPM Display and Hourmeter Circuit Test

NOTE: lf the hourmeler does not operate and the rpm display aperates correctly replace the hourmeter.
NOTE: Use lhe signal generatorlcounter for the followlng tesl (refer to Page 3.
NOTE: Disconnect wrre 30 YellowlBrown f rom the alternator W termlnal. Connect a signal generator (refer to Page 3) to
wire 30 and programme the signal generatar ta generate a srgna/ as shown tn the table be/ow (see manufacturers tnstruc-
ttons). Turn the key to the AN pasitton and press the engine rpm function button on the tnstrument c/uster (digttal ctusters
only) and check the rpm dtsplay on the instrument cluster with the table below.
SIGNAL FROM SIGNAL INSTRUMENT CLUSTEF POSSIBLE CAUSE OF

GENERATOR FPM DISPLAY BAD READING
HZ RPM
302.9 10401o 1160 BAD INSTRUMENT

CLUSTER
CHECK WIRE 30 SEE
605,8 1 940 lo 2260
CHECK POINT 7
NOTE: lf the readings are correc[ repair cr replace the alternatcr. refe, to section 40AB
Oon 8-85042 lssued 3-92 P. nied ir Eagland
kaukazz@yahoo.co.uk
40u-2a
NOTE: Turn the key to the OFF position, disconnect the tnstrumenl c/uster from the har,ress.
Check Point Beading Possible Cause of Bad Reading
Pin 27 ol ihe instrumcnt clustcr connector Continuitv Check wire 30

anc the terminal for wire 30 Yclrow/Brovrn
NOTE: lf the readings is coffecl check the instrument ciuster oower and chassis ground circuits.
Hydraulic Filter Restriction Warning Lamp Circuit Test

NOTE: Check the hydraulic frlter restrrction 'warnrng lamp bulb
NOTE: The transmisston orl must be at normal operating temperature and the hyciraulic filter must be free from
restricilons. Drsconnect the hydraulic fllter restictron switch from the harness. Turn the key to the ON position.
IMPORTANT Do not allow the drsconnected terminal for rrire 31 to shott circuit to oround.
Check Poini Beading Possible Cause of Bad Reading
fiT7 Terrninal for wrre 32 Yellow,t/Vhrte to ground 12 Volts Bad circult between the instrument cluster
connector (pin 2l) ano the hydraulic filter
temperature switch
NOTE: lf the readrng is correct ga to check paint 1A.
NOTE: Turn the key to the OFF positron and discannect the inslrument cluster from the harness
o ::n:::t?::::ffI:[1YH:iand
P n2': Continuity Check wue 32
(?rl Terminal for wire 31 Yellow/8rown to ground 12 Volts Bad hydraulic f ilter temperature switch
NOTE: Turn the key to the OFF pasition
Terminal for wire 31 Yellow/Brown and the Continuiiy* Check wire 3i between the hydraulic {ilter
hvdraulic filter restrict on switch temperature swltch and the hydraulic filter
restriction switch.
(F) t"r.*,nrl for ihe hydraulic iilter restriction No Contrnuitv Bad hydraulic filter restriction switch.
swlTCn lo orotlno
Don 8-85042 lssued 3-92 Printed ln EnglanC
kaukazz@yahoo.co.uk
4001-21
Air Filter Restriction Warning Lamp Circuit Test
NOTE: Check the air filter restriction warning lamp bulb.
NOTE: The air filter must be free from restrictions. Disconnect the air filter restriction switch from the harness and turn the
key to the ON positlon.
Gl Terminal for wire 34 Dark Green to ground 12 Volts Bad circuit between the air filter restriction
switch and the instrument cluster.
NOTE: lf the reading is corect go ta check point 15
Terminal for wire 34 Dark Green and pin 29 Continuity Check wire 34
of the instument cluster
G Terminal for wire 33 Brown to ground Continuity Check wire 33 and the chassis ground
connection.
Between the terminals of thc air filter No Continuily Bad alr filter restriction switch
restriction switch
Parking Brake Warning Lamp Circuit Test

NOTE: Check the park brake warning lamp bulb.
NOTE: Engage the parking brake, put biocks in front and behind the rear r.rrheels and turn the key to the ON position
Check Points Readlng Possibie Cause of Bad Reading
Terminal {or wire 36 Yellow/Black or Yellow 12 Vo ts Bad circuit between the parking brake
(258) to ground switch and the instrument cluster
connector.
NOTE: lf the reading is corecl go to check point 2a
NOTE: Turn the key to the OFF position and dtsconnect the instrument cluster from the harness.
Terminal for wire 36 Yellow/Black or Yellow Continuity Check wire 36.

(258) and pin 17 of the instrument cluster
connector
tll Terminal for wire 35 Brown to ground Continuity Check wire 35 and the chassis ground
connection.
Between terminals A and B of the parking Continuity Bad parking brake switch. Adjust or replace
brake switch the switch as necessary
NOTE: Disengage the parking brake.
Between terminals A and B of the parkrng No Coniinuity Bad parking brake switch. Adlust or replace
brake switch the switch as necessary
kaukazz@yahoo.co.uk
4001-22
Audible Alarm Circuit Test
NOTE: Engage the parktng brake put the range lever in 1st, 2nd, 3rd or 4th range and turn the key to the ON position.
Terminal for wire 37 White/Dark Blue and 12 volts Check wire 37,
ground
Terminal for wire 36 Yellow/Black or 364 Continuity Bad circuit between the audible alarm and
Yellow/Brown and ground the Parking Brake switch chassis ground
connection.
NOTE: lf the readings are correct replace the audible alarm.
Warning Lamp Test Relay Circuit Test

NOTE: Remove the warning lamp test relay.
NOTE: Putthe range lever in 1st,2nd,3rd or 4th range and hold the key in the START position
ferminal for wire 7 White to ground 12 Volts Bad circuit beNveen the key switch and the
@ warning lamp test relay. Also check the key
switch.
Terminal for wire 38 Brown/Dark Blue to 12 Volts Bad circuit between the warning lamp test
ground diodes and the warning lamp test relay.
ferminal for wire 39 Brown to grouno Continuity Bad chassis ground circuit. Also check the
4l chassis ground connection.
Terminal for wire 39 Brown to ground Continuity Check wire 39 between terminals 87 and 85
@ of the warning lamp test relay.
NOTE: lf the readings are correct replace the warning lamp test relay.
NOTE: llanyofthewarninglampsfaittocomeonwhentherangeleverisinlst,2nd,3rd,or4thrangeandthekeyisinthe
)taft position check the warning lamp butbs. lf the warning lamps still fail to come on check the warning lamp test diodes.
Nso, if for exampte the air lilter warning lamp comes on when the parking brake is engaged check the warning lamp test
Jiode.
lon 8-85042 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001-23
Warning Lamp and Audible Alarm Diode Test
NOTE: The procedure for checking the warning lamp and audible alarm diodes rs lhe sarne for each diode.
NOTE: Turn the key to the OFF position and disconnect the diode from the harness.
NOTE: The positive lead of the multimeter must go to the female termrnal af the diode
Between the terminals of the diode No Contlnuity Bad diode
NOTE: Change the leads of the multimeter over so the positrve lead of the multimeter goes to the male terminal of the
diode.
Between the terminals of the diode Continuiry Bad diode
lnstrument Cluster lllumination Circuit Test

NOTE: Check fuse F13 and the rnstrument clustet illumrnation bulbs.
NOTE: Disconnect the instrument cluster from the harness and turn the lamp switch to the headlamp positibn.
@ ein 36 of the instrument cluster to ground 12 Volts Check wire 41 belween fuse F1 3 and the
instrument cluster connector pin 36.
NOTE: lf the reading is correct check the instrument cluster chassis ground circuit.
High Beam Warning Lamp Circuit Test

NOTE: Check fuse Fl0 and the high beam warning lamp bulb.
NOTE: Disconnect the instrument cluster from the harness and turn the lamp switch to the headlamp position and put
the dipper switch ln the hrgh beam positron.
Check Points lgg9,lS Possible Cause of Bad Reading
@ ern 32 of the rnstrument cluster to ground '1

2 Volts Check wire 40 between fuse F10 and the
insirument cluster connector pin 32
NOTE: lf the reading is correct check the instrument cluster chassrs ground circuit
kaukazz@yahoo.co.uk
4AU-24
Turn Signal Warning Lamp Circuit Test
NOTE: Check the turn slgnal warning lamp bulbs.
NOTE: Disconnect ihe instrument cluster fram the harness.
@ Terminal ior wire 42 PinkYellow to P:n I0 oi Continurty Check wire 42

the instrument cluster connector
for wire 44 PinUDark Blue to Pin 24 Continuity Check wire 44

@ Terminal
of the tnstrument cluster connector
Pin 7 of the instrument cluster connector to Continuity Check wire 43

@ ground
NOTE: Turn the key to the ON positlon and the turn signal swtch to the RIGHT turn position.
Pin 10 of the instrument cluster connector to 12 Volts Bad flasher relay

ground ON_OFF-ON
NOTE: Put the turn signal swrlch tn the LEFT turn posttion
Pin 24 of the instrument cluster connector to .1

2 Volts Bad flasher reiay
ground ON-OFF-ON
Ground Speed Sensor Circuit Test (Deluxe lnstrument Cluster only)

NOTE: Disconnect the ground speed sensor from the harness
6P rerminal for wire 49 Brown ground ContinuihT Check wire 49 and the chassis ground
connection.
BeMeen terminals A and B or :he ground 2925 to 3575 Bad ground speed sensor
speed sensor Ohms
NOTE: Dtsconnect the instrument cluster f rom the harness.
pin
Termrnal for wire 50 Yellow/Dark Blue to Continuity Check wire 50 between the ground sensor
28 of :he instrument cluster connector and the instrument cluster connector.
NOTE: ll the readtngs ere cctrect aolust a' realace [he ground s,ceed sensor
Dc1 8-85042 lssued 3-92 Prinled i1 Ergland
kaukazz@yahoo.co.uk
4001 -25
Ground Speed Radar Circuit Test (Deluxe lnstrument Cluster only)
NOTE: Turn the key to the OFF position and disconnect the instrument cluster and the ground speed radar from the
Terminallorwire45LightGreeniBedtopin3 Contrnuitr- Checkrvire45

of the instrurnent ciuster
Terminal for wire 46 Brown/Light Green to ContinuibT Check wire 46

pin 26 of the instrument cluster
Terminal for wire 47 Light Green to pin 33 oi Contrnuity Check wire 47

the instrument cluster
Terminai for wire B Light Green,Yellow to Continuity Check wire 48

Fuel Gauge Sender Circuit Test

NOTE: Disconnect the fuel sender from the harness and turn the key to the AN positlon
Terminai for wire 52 Ycllow/Light Bluc to 9 Volts Check rvire 52 belween the fuel sender and
ground Aooroximately theinstrumentclusterconnector
NOTE: Turn the key to the OFF pasition.
6El Terminal for wire 51 Brown to ground Continuity Check wire 51.
NOTE: Disconnect the rnstrument cluster from the harness.
Terminal for wire 52 Yellow/Lrght Blue to pin Continuity Chcck wire 52

23 of the instrurneni cluster connector
NOTE: lf the readings are correct check the fuel sender refer to Secrion 3005 lVso check the instrument cluster power
and chassA ground circuits or replace the fuel gauge if necessary.
flon B-85042 lssued 3'92 Printed in Engiand
kaukazz@yahoo.co.uk
4UU I -ZO
4th Range/Reverse Warning Lamp (Master Flasher) Circuit Test
NOTE: Check the master flasher warning light bulb
NOTE: Turn the key switch to the ON position, put the range lever in 4th range
Itrl terminal for wire 57 PinUBed to ground 12 Volts Bad circuit between the 4th range switch
and the instrument cluster.
NOTE: lf the reading is correct go to iesl point 43.
NOTE: Turn the key to the OFF positron and disconnect the instrument cluster from the harness
Terminal for wire 57 PinURed to pin 4 of the Contrnuily Check wire 57 between the 4th range switch
instrument cluster connector and the instrument cluster connector
NOTE: lf the reading ts correct check the instrument cluster power and chassrs ground circuits.
NOTE: Turn the key switch to the ON position and put the lonwardlreverse lever tn the FORWARD position
lD ferminal for wrre 56 Brown/Pink to ground 12 Volts Bad 4th range switch. Adjust or replace the
switch, refer to Section 9001.
NOTE; Disconnect the forwardlreverse swilch from the harness at connector G
l?l Terminal for wire 56 Brown/Pink to ground '1

2 Volts Check wire 56 between the 4th range switch
and connector G.
NOTE: Turn the key switch ta the OFF positron.
lB Term,nal for wire 53 Brown to ground Continuity Check wire 53 and the chassis ground
conneclior
NOTE: Put the forwardlreverse switch in the REVERSE positlon.
Between terminals 5 and 6 of connector G Continuity Bad forward/reverse switch

(swrtch side)
NOTE: Put the forwardlreverse switch rn the FCRWARD position
Between termrnals 5 and 6 of connector G No Continuity Bad forward/reverse switch

(switch side)
kaukazz@yahoo.co.uk
4001-27
lnstrument Cluster 1000 RPM PTO Display
NOTE: furn the key to the OFF position and disconnect the 1000 rpm PTO swttch from the harness.
ferminal for wire 58 Brown,&Vhite to ground Continuity Check wire 58 and the battery negatrve
@ cornection
NOTE: Put the PTO output shaft in the 1000 rpm pasitian.
BeMeen the terminals of the 1000 rpm PTO Continuity Bad 1000 rpm PTO switch
switch
NOTE: Put the PTO output shaft in the 540 rpm position.
Between the terminals of the 1000 rpm PTO No Continuity Bad 1000 rpm PTO switch
switch
NOTE; Disconnect the instrument cluster from the harness.
Terminal ior wire 59 Yellow/Dark Green to Continui! Checkwire 59 between the 1000 rpm PTO
pin 22 of the instrument cluster connector switch and the rnstrument cluster
connector.
NOTE: /f the readings are correct check the instrment cluster power and chassrs ground urcutts.
Engine Coolant Temperature Gauge Circuit Test

NOTE: Drsco nnect the engine coolant sender f rom the harness and turn the key to the ON position.
Check Points Beadrnq Possible Cause oi Bad Beadtng
Terminal for wire 60 Dark Grecn/Black to Approximately Badcircuitbetweentheenginetemperature

ground 9 Volts sender and the instrument cluster'
NOTE: /f the reading is correct replace the engine coolant temperature sender
NOTE: Disco nnect the instrument cluster from the harness
Terminal for wire 60 Dark Green/Black to pin Continuity Check wire 60 between coolant
16 of the instrument cluster connector terrperature sender and the instrurnent
cluster connector.
NOTE. l/ the readings are correct checkthe instrment cluster power and chassls ground circuits.
Don 8-85042
lssued 3-92 Prinled in England
kaukazz@yahoo.co.uk
4001-28
Engine Oil Pressure Warning Lamp Circuit Test
NOTE: Disconnect the oil pressure switch t'rom the harness.
Terminal for wire 61 Brown to ground Continuily Check wire 61 and the chassis ground
4il connection.
NOTE: Turn the key to the aN positton
Terminal for wire 62 Light Blue to ground 12 Volts Bad circuit between the oil pressure switch
6) and the instrument cluster connector.
NOTE: lf the readings are carrect check the o/ pressure switch.
NOTE: Turn the key to the OFF position and check the orl pressure warning lamp bulb
NOTE: Disconnect the rnstrument cluster from the harness.
Terminal for wire 62 Light Blue to pin 34 of Continuity Check wire 62

the instrument cluster connecior
NOTE: lf the readings are correct check the tnstrument cluster power and chassrs ground connections
Engine Oil Pressure Switch Test

NOTE: Disconnect the oil pressure switch from the harness.
Between ierminals A and B of the cngine oil Continuity Bad engine oil pressure switch
pressure switch
NOTE: Start and run the engine at 1500 rpm.

Between terminals A and B of the engine oil No Continuily Bad engine oil pressure switch
pressure swiich
Dcn 8-85042 lssueo 3-92 Printed in England
kaukazz@yahoo.co.uk
il
4001-29
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Oofl S85O42 Issued $92 erintl in Ergland Issued s92 erntl ln Ergtand - T crEANGHouNo
I C}IASSIS GHOTJ}G
kaukazz@yahoo.co.uk I I CHASSTS GHOUNO
I
-l--
4001 -30
FORWARD/HEVEHSE AND TRANSMISSION CONTROL
Sectional lndex
aa
WIRING CODE
CIRCUIT TESTING
1st/2nd and 3rd/4th Range Switch Circurt Test aa
Synchromesh Neutral Switch Circuit Tesl (lf Equipped) 31+
lnching Pedal Switch Circuit Test 34

Transmission Control and Fonruard/Reverse Flelay Circuit Test ............ 2A
Jb
JCI
Forward/Reverse Switch Circuit Test 37
Reverse Solenoid Circuit Test JU

Modulation Solenoid Circuit Tesl 39
Forward Pressure Switch Test 39
Reverse Pressure Swilch Test 40
Modulation Diode Test 40
Forward Diode Module Circuit Test 40
Reverse Diode Module Circuit Test 41
Clutch Disengage lndicator Lamp Circuil Test 42
Reverse lndicator Lamp Circuit Test ............ .,......,i......,.... qZ
Forward/Reverse Valve Block 44
Schematic Circuil 45
Don 8-85042 lssued 3-92 Prinled in Englano
kaukazz@yahoo.co.uk
4001 -31
WIRING CODE
TO WIRE
REF COLON FROM
GAUGE
Key Switch (BA'[D IJ
6 Red Battery Power Stud
Chassis Ground tb
53 Brown Connector G (Term 5)
Foruvard/Reverse Switch tb
54 Black Connector G (Term 5)
Fuse F19 to
64 RedAVhite Key Switch (ACC)
FonryardiRevcrse RelaY [t-erm 30) 16
65 White/Red F:use F19
16
Forward/Reverse RclaY (Term 30) lnching Pedal Switch 1 or
65 White/Red
Creeo Harness Connector
Connector B (Pin R) 16
65 White/Red lnching Pedal Switch 1 or
Creep Harness Connector
Connector H (Term A) tb
65 Whrte/Red Connector B (Pin R)
16
Splice
65 White/Red Connector H (Term A)
l sV2nd Range Switch (Term C) to
65 whrte/Red Splice
3rd/4th Range Switch [Term C) 18
65 whrte/Red Splice
18
1st/2nd Rangc Switch [erm D) Splrce
66 Whrte/Black
Splrce 1B
66 White/Black 3rd/4th Range Switch (Term D)
Synchromesh Neutral Switch or 1B
66 White/Black Splice
Powershift Harness Connector (1-erm A)
Powershift Harness Connector fl-erm A) Powershift Harness Connector fl-erm B) 18
664 White
(lf Equipped)
(if Equipped)
67 White/Dark Bluc Powei'shift Harness Conncclor fl-erm B) Connector H fl-erm B) 18
(lf Equrpped) 1Q
Connector H flerm Connector B fierm U)
67 White/Dark Blue B)
Transmission Control Relay (I-erm 86) 18
67 White/Dark Blue Connector B f-errn U)
Chassis Ground
68 Brown Transmission Control Belay (Term 85)
Forward/Reverse RelaY fl"erm 87) 16
69 White/Brown Transmission Control Relay fl-erm 30)
Conncctor G fl-erm 2) Itl
69 White/Brown Forward/Reverse RelaY (Tcrm B7)
lnching Pedal Switch 2 16
69 White/Brown Connector G fTerm 2)
lnching Pedal Switch 1 or to
69 Whitei Brown lnching Pedai Switch 2
Creep Harness Connector
Forward/Beverse Switch 16
7A Black Connector G [-erm 2)
Forward/Reverse RelaY fl-erm 86) lo
71 White/GraY/Black lnching Pedal Swrtch 2
Transmission Control Belay (1-erm 87) 18
71 White/GraY/Black Forward/Reverse RelaY fl-erm 86)
Connector G (Term +) 18
72 Brown/Yellow Forward/Reverse RelaY fl'erm 85)
Connector A (Pin K) 18
72 Brown/Yellow Connector G 0-erm a)
Connector E (Pin P) ]B
72 Brown/Yellow Connector A (Pin K)
+th Range Diode 1B
72 Brown/Yellow Connector E (Pin P)
Connector E (Pin N) to
73 Brown Dari</Green 4th Range Diode
4th Range Switch flerm D) 18
73 Brown DarlVGreen Connector E (Pin N) 16
4th Range Switch (Term C) Chassis Ground
74 Brown
Fonward/Revcrse Switch to
75 Black Connector G (Term a) 16
Connector G (Term 1) Forward/Beverse Switch
76 Biack
Fuse F18 r6
77 RedlGreen Connector G flerm 1)
Connector A (Pin L) t6
78 Light Blue/Black Fuse F1B
Reverse Pressure Switch [Term A) 16
78 Light Blue/Black Connector A (Pin L)
Splice lo
79 Dark Blue/Black Reverse Pressure Switch (Term B)
Forward Solenoid fierm A) lb
79 Dark Blue/Black Splice
Forward Drode Module fi-erm C) 16
79 Dark Blue/Black Splice
lb
Forward Solenoid (Term B) Chassis Ground
B0 Brown
Chassis Ground 16
81 Brown Forward Diode Module (Term A)
lssued 3-92 Printed in Englanc

ilon 8-85042
kaukazz@yahoo.co.uk
4001 -32
REF COLOR FFON/ TO WIRE
GAUGE
82 Dark Blue/Yellow Forward Diode Moduic (Term B) Splice t6
82 Dark Blue//ellow Splicc Reverse Diode Module fl-erm B) 16
82 Dark Blue/Yellow Splice Modulation Solenoid fierm A) '16
82 Dark Blue/Yellow Splice Connetor A (Pin R) t6
82 Dark Blue,Yellow Connector A (Pin R) Modulation Diode i6
83 Brown Modulation Solenoid flerm B) Chassis Ground .16
84 Black Connector G fi'erm 3) Forward/Reverse Switch 16

85 Rcd//ellow Connector G fl'erm 3) Fuse F21 t6
86 Light Blue Fuse F21 Reverse lndicator Lamp 18
86 Light Blue Fuse F21 Connector A (Pin M) i6
86 Light Blue Connector A (Pin M) Forward Pressure Switch fl'erm A) l6
87 Dark Blue Fonward Pressure Swrtch |lerm B) Qnlino
vP,.vv 16
87 Dark Blue Qnlina
Reverse Solenoid fl-erm A) 16
87 Dark Blue SpIcc Reverse Diode Module (i'erm C) 16
88 Brown Beverse Solenoid fl-erm B) Chassis Ground 16
89 Brown Reverse Diode Module fl-erm A) Chassis Ground 16
90 Yellow/Dark Blue Forward/Reverse Relay fl"erm 87A) Modulation Diode 16
90 Yellow/Dark Blue Modulation Diode Clutch Disengage Lamp 18
91 Brown Clutch Disengage Lamp Reverse lndicator Lamp 18
91 Brown Reverse lndicator Lamp Powershift Fault lndicator Lamp 18
91 Brown Powershift Fault lndicator Lamp Chassis Ground 18
92 Fed/Dark Blue Creep Harness Connector Creep Inching Pedal Switch f-erm 3) 16
(lf Equrpped) (li Equipped)
93 White/Brown Creep lnching Pedal Switch flerm 4) Creep Harness Connector 16
(lf Equipped) (lf Equipped)
NOTE: Wires g2 and g3 are part off the creep harness installed on tractors with creep up to PtN No JJF1005652.
Don 8-85042 lssuec 10-91 Prinred ln EnQland
kaukazz@yahoo.co.uk
4001 -33
CIRCUIT TESTING
NOTE: The battery must be atfult charge and all connections must be clean and tight before testing.
Use a multimeter lor
lhe fests.
1st/2nd and 3rdl4th Range Switch Circuit Test

NOTE: Check Fuse F19
NOTE: Disconnect the TstlZnd and 3rdl4th range switches fram the harness and turn
the key to the ON position.
Terminal for wire 65 White/Bed to ground '12 Volts

Bad clrcuit betrveen the key switch and the
Q
forward/reverse relay terminal 30. Also
check the key switch.
&l Terminallor wires 65 White/Red ro ground 12 Volts Check wire 65 between the forward/reverse
relay terminal 30 and the inching pedal
switch 1 or creep harness connector.
Terminal for wire 65 Whrte/Red to ground

O 12 Volts Check wire 65 between the lsV2nd rangc
switch and the inching pedal switch 1 or the
creep harness connector.
ferminal for wire 65 Whrre/Red to ground 12 Volts

O Check wire 65 between the 3rdl4th range
switch and the splice
NOTE: Turn the key to the OFF position and put the range lever in 1st or 2nd range
Between terminals C and D of the l sl/2nd Continuity Bad l sl/2nd range switch. Adjust or reolace
range switch the switch as necessary. Refer to Section
900r.
NOTE: Put the range lever in 3rd or 4th range.
Between terminals C and D of the 3rd/4th Continuity Bad 3rd/4th range switch. Adlust or replace
range swrtch the switch as necessary, Refer to Section
9001
NOTE: Checks 5 and 6 are for tractors with powershift transrnissions only.
NOTE: Discannectthepowershiftharnessfromthelrans,'nrssionharness, puttherangeleverinlstor2ndrangeandturn

tl"e xey o the ON position
ferminal for wjre 66 White/Black to ground 12 Volts Bac circuit betlveen the 1sV2nd range
O switch and powershift harness connector
NOTE: Put the range lever in 3rci or 4th range
Terminal for wire 66 White/Black to ground 12 Volts Bad circuit between the 3rd/4ih
Q switch and powershift harness connector
range
Dcn 9.95942 lssued 3-92 Printed in EnglanC
kaukazz@yahoo.co.uk
4001-34
Synchromesh Neutral Switch Circuit Test (lf Equipped)
NOTE: Disconnect the synchromesh neutral switch from the harness, put the range lever in 1st or 2nd range and turn the
key to the ON position.
ferminal for wire 66 White/Btack to ground 12 Volts Check wire 66 between the 1sV2nd range
@ switch and the synchromesh neutral switch.
Terminal for wire 66 White/Black to ground 12 Volts Check wire 66 between the 3rd//4th range
@l
switch and the synchromesh neutral switch.
NOTE: Turn the key to the OFF position and put the synchromesh lever in gear.
Between terminals A and B of the Continuity Bad synchromesh neutral switch. Adjust or
synchromesh neutral switch replace the switch as necessary, refer to
Section 9001
lnching Pedal Switch Circuit Test

NOTE: Turn the key to the ON position.
Check Points Headino

*--iJ
Possible Cause of Bad Heading
NOTE :Checks 7,8 and 9 are for all tractors without creep and tractors with creep lrom PIN No JJF|005653.
ferminal for wire 65 White/Red to ground 12 Volts Bad circuit between the key switch and the
@ inching pedal switch 1 Also check the key
switch.
NOTE: Hold the inching pedalfully down.
Terminal for wire 69 Whrte/Brown to ground '12 Volts Bad inching pedal 1. Adjust or replace the
Q swrtch as necessary.
Terminalfor wire 69 White/Brown to ground 12 Volts Check wire 69 between the inching pedal
S switch 1 and the inching pedal switch 2.
NOTE : Checks 7A,8A and 9A are for tractors with creep up to ptN No JJF1005652.
Terminal for wire 92 Red/Dark Blue to 12 Volts Bad circuit between the key switch and the
ground creep inching pedal switch (terminal3), Also
NOTE: Hald the inching pedalfully down
ferminal for wire 93 White/Brown to ground '12 Volts Bad creep inching pedal switch. Adjust or
@ replace the switch as necessary,
6F Terminalfor wire 69 White/Brown to ground 12 Volts Check wire 69 and 93 between the creep
inching pedal switch and the inching pedal
switch 2,
\OTE: Turn the key to the aFF position and release the inching pedal to hall travel.
Beween terminals for wirc 71 Continurty Bad inching pedal switch 2, Adjust or
White/Gray/Biue and wire 69 WhiteiBrown replace the switch as necessary.
)or 8-85042 lssued 3-92 Prrnted in England
kaukazz@yahoo.co.uk
4001 -35
Transmission Control and Forward/Fleverse Relay Circuit Test
NOTE: Turn the key to the OFF position and put the forwardlreverse lever in the FORWARD position.
NOTE: For tractors with synchromesh transmissions pul the synchromesh lever in gear'
Check Points Feading Possible Cause of Bad Beadrng
Terminal for wire 68 Brown io ground Conlinuiir* Check wire 68 and the chassis ground
@ connection
{or wire 67 white/Dark Brue Io 12 Volts Bad circuit between the key switch and the
@ ;::n:'r transmiss on control relay lerminal 87 Also
check the key switch, the lst/2nd, 3rd/ath
range switch and synchromesh switch (if
equipped) circuits
Ternrinal for wire 65 White/Red to ground 12 Volts Bad circL,tl between the key swttch and the
&) forward/reverse relay terminal 30 Also
12 Volts Check wire 69 betureen the inching pedal

lEl Terminal for wire 69 White/Brown to ground
switch 1 and the forward/reverse relay
termlnal 87. Also check the inching pedal
switch circuil
Terminal for wire 69 White/Brown to ground 12 Volts Check wire 69 beMeen the lorward/reverse
C} relay terminal 87 and the transmission
control relay terminal 30,
Terminal for wire 71 White/Gray/Black to 12 Volts Bad transmission control relaY

ground
i'iOTE. Turn the key ta the AFF posttrcn
Terminal forw re T?SrownNellow to ground Co ntrn u ity Bad c rcuit between the forward/reverse
@ relay terminal 85 and ground Also chcck
the fonrvard/reverse switch and the chassis
ground connection
in 4th range the chassls ground

NOTE: When the fowardlreverse lever is in the fcrvvard position and the range tever is
termtnals 4 and 5'
connec.tion for the forwardlreverse relay is made through the foNvardlreverse switch
NOTE: puttheforvvardlrevetse lever jn the REVERSEposrrion and putthe range lever in 3rd
range.
-lerminalforw re T2BrownNellowto ground Continuily Bad c rcuit bet,veen the forward/reverse

@ relay terminal 85 and ground. Also check
:he 4lh range diode, the 4th range switch
ano lrc chassis groJnd conneclion
NOTE: Tun the ke/ ta the ON posrilon.
Terminal for wire 90 Yellow/Dark Blue to 12 Volts Bad forurard/reverse relaY

ground
lss,ed 3-92 Pr nied in Erglard
fo.r 8-85C42
kaukazz@yahoo.co.uk
4001 -36
Check Points Feading Possible Cause of Bad Heading
NOTE: Hold the inching pedal fully down
ferminal for wire 71 White/Gray/Black to 12Volts Check wire 71 between the transmission
ground control relay terminal 87 and the
foruvard/reverse relay terminal 86.
NOTE: Fully release the inching pedal.
Terminal for wire 69 White/Brown to ground 12 Volts Bad forward/reverse relay.

@
Terminal for wire 71 White/Gray/Black to 12 Volts Checkwire 71 betweentheforward/reverse
ground relay terminal 86 and the inching pedal
switch 2.
NOTE: Hold the inching pedal down at half travel
Terminal for wire 69 White/Brown to ground 12 Volts Check the inching pedal switch 2.
@
4th Range Diode Test
NOTE: Turn the key to the aFF position and disconnect the diode from the harness.
NOTE: The positive tead of the multimeter must go to the female terminal of the diode.
Check Points Reading Possible Cause of Bad Feading
Between the terminals of the diode No Continuity Bad 4th range diode
NOTE: Change the leads of the multimeter over so the positive tead goes to the male terminal of the diode.
Bctween the terminals of the diode Continuity Bad 4th range diode.
4th Range Switch Circuit Test

NOTE: Turn the key to the OFF position and disconnect the 4th range switch from the harness.
Chcck Points Readino Possible Cause of Bad Feading
Terminal for wire 74 Brown to ground Continuity Check wire 74 and the chassis ground
El connection.
NOTE: Putthe range lever in neutral, 1st,2nd or 3rd range.
Betwcen terminals D and C of the 4th range Coniinuity Bad 4th range switch. Adjust or replace the
switch switch as necessary
NOTE: Put the range lever in 4th range.

Between terminals D and C of the 4th range No Continuity Bad 4th range switch. Adjust or replace the
NOTE: put the foryvarrjlreverSe lever in the reverse position, turn the key to the ON position and hold the rnchrng pedal
down.
Terminal for wire 73 Brown/Dark Green to 12 Volts Bad circuit between the forward/reverse
ground relay and the 41h range switch
Don 8-85042
lssr"ec 3-92 Printed ir Englanc
kaukazz@yahoo.co.uk
4001-37
Forward/Reverse Switch Circuit Test
NOTE: Turn the key to the OFF position and disconnect the forwardlreverse switch from the harness at connector G
Check Points Readrng Possible Cause of Bad Reading
fB Terminal for wire 53 Brown io ground Continuity Check wire 53 and the chassis ground
connetion
NOTE: Turn the key to the ON, put the range lever in 4th range and hold the inching pedal fully down
@ Terminal forwires 69 White/Brown to ground 12 Volts Bad circuit between the key switch and the
forward/reverse switch. Also check the key
swrtch and the inching pedal circuit.
Terminal for wires 72 BrownNellow to l2volts Bad circuit beMeen the forward/reverse
ground relay and the forward/reverse switch, Also
check the transmission controi and
forward/reverse rclay circuit.
NOTE: Turn the key to the OFF positron and put the forwardlreverse lever rn forvvard.
Between terminals 1 and2 of connector G Continuity Bad forward/reverse switch

(switch side)
Between terminals 4 and 5 of connector G ContinuibT Bad fonnrard/reverse switch.

(switch side)
Belween terminals 7 and S oi connector G Continuity Bad forward/reverse switch

(switch side)
NOTE: Put the foruvardlreverse lever in reverse.
Between terminals 2 and 3 ol connector G Contlnuity Bad forward/reverse switch

(switch side)
Between terminals 5 and 6 of connector G Continuity Bad forwardireverse switch

(switch side)
Between all terminais of connector G to No Continuity Forward/reverse switch wires shorted to

ground (swrtch side) ground
Forward Solenoid Circuit Test

NOTE: Turn the key to the OFF position and disconnect the fonanrd solenoid trom the harness
@ Tcrminal for wire B0 Brown to ground Continuity Check wire 80 and the chassis ground
connection
0b
Y
Terminal for wire 79 Dark Blue/Black to No Continuity Bad forward diode module Also check wire
crouno 70
Betrveen terminals A and B o1 forward 5.6 Ohms Bad forward solenoid.

solenoid connector * 1a"k
at Room Temperature
Don 8-850a2 lssued 3-92 Priried ln Ergland
kaukazz@yahoo.co.uk
4001-38
NOTE: Put the forvvardlreverse lever in the forward position, turn the key to the ON position and hold the inching pedal
down.
Terminal for wire 79 Dark Blue/Black to .1

2 Volts Bad circuit between the forwardireverse
ground switch and the forward solenoid
NOTE: Turn the key to the OFF position and disconnect the reverse pressure from lhe harness.
Between terminals A and B of reverse Coniinuity Bad reverse pressure switch,

pressure switch
NOTE: Put the forwardlreverse lever in the farward position, turn the key to the ON position and hold the rnching pedal
down
Terminal for wire 78 Light Blue/Black to 12 Volts Bad circuit between the foruard/reverse
ground switch and the reverse pressure switch.
Also check the forward/reverse switch
Reverse Solenoid Circuit Test

NOTE: Check Fuse F21.
NOTE: Turn the key to the OFF positron and disconnect the reverse solenoid from the harness.
6l) Totmnrl for wire 88 Brown to ground Continuity Check wire BB and the chassis ground
connection.
6 Terminal for wire 87 Dark Blue to ground No Continuily Bad reverse diode module. Also check wire
87
Betwecn terminals A and B of reverse 5.6 Ohms Bad reverse solenoid.

solenoid connector + l)yo
at Room Temperaturc
NOTE: put the foryvardlreverse lever in the reverse position, turn the key to the ON position and hold the inching pedal
down.
Terminal for wire 87 Oark Blue to ground 12 Volts Bad circuit between the forward/reverse
@ switch and the reverse solenoid.
NOTE: Turn the key to the OFF pasition and disconnect the forward pressure switch from the harness.
Between terminals A and B of forward Continuity Bad forward pressure switch

pressure switch.
NOTE: Put the forwardlreverse lever in the reverse position, turn the key to the ON position and hold the inching
pedal
down.
6F Terminal for wire 86 Light Blue to ground 12 Volts Bad circuit between the forward/revcrsc
switch and the forward pressure switch
Also check the forward/reverse switch.
Don 8.85042 lssued 3-92 Printed in Fnqland
kaukazz@yahoo.co.uk
4001 -39
Modulation Solenoid Circuit Test
from the harness
NoTE: Turn the key to the oFF position and disconnect the modulation solenoid
ContinuitY Check wire 83 and the chassts ground
6 Terminal for wire 83 Brown to ground
connetion.
7 2 Ohms Bad modulation solenoid.

Between terminals A and B of modulation
solenoid connector :10%
at Room TemPerature
NOTE: Turn the key to the ON position'
82 Dark BluelYellow to I2 Volts Bad circuit between the foruard/reverse

Terminal for wire
relay terminal 87A and the modulation
ground
solenoid. Also check the forwardlreverse
relay and the modulation diode.
NOTE:Puttheforwardlreverseleverinfonuardandcycletheinchingpeda|
the forward diode
Terminal for wire 82 Dark Blue/Yellow to 12 Volts Bad circuit betvveen
moduie terminal B and the modulation
ground
solenoid Also check the forward diode
module.
NOTE: Put the forwardlreverse lever tn reverse'

12 Volts Bad circuit between the reverse diode
6)
v T"tmn"l for wire 82 Dark Blue/Yellow to
module termtnal B and the modulation
ground
solenoid Also check the reverse diode
module.
Forward Pressure Switch Test

to the oFF position and disconnect the torvvard pressure switch from rhe harness
NoTE: Turn the key
poeainn Possible Cause of Bad Beading

Check Points
BeNveenterminalsAandBo{theforwardContinuityBad{orwardpressureswitch
pressure switch connector (switch side)
NOTE: Apply the park brake and staft sni run the engine at 1500 rpn'
lever tn foruard.
NoTE: The range lever mUSt be tn NEI,)TRALand the forwardlreverse
NOTE: Cycle the irtching Pedal.

Contrnuity Bad forward pressure swrtch
Belween terminals A and B of the iorward
No
lssued 3-92 Printed in Englanc

Don 8-85042
kaukazz@yahoo.co.uk
4001-40
Reverse Pressure Switch Test
NOTE: Turn the key to the OFF position and disconnect the reverse pressure swlch from the harness.
Between terminals A and B of the reverse Continuity Bad reverse pressure switch.
NOTE: Applythe parkbrake and staft and run the engine at 1500 rpm.
NOTE: The range lever must be in NEUTRAL and the forwardlreverse lever in reverse
NOTE: Cycle the inching pedal.
Between terminals A and B of the reverse No Continuily Bad reverse pressure switch
pressure swrtch connector (switch side)
Modulation Diode Test

NOTE: Turn the key to the OFF position and disconnect the modulation diode from the harness
NOTE: The positive lead of the multimeter must qo ta the female terminal of the diode.
Between the terminals o* Ihe oiooe No Contrnuity Bad modulation diode
NOTE; Change the leads of the multimeter aver so ahe positrve /ead goes to the male terminal of the diode.
Between the terminals of the diode Contrnuity Baci modulation diode
Forward Diode Module Circuit Test

NOTE: Turn the key to the OFF position and disconnect the forward module and the modulation solenoid from the
harness.
terminal for wire 81 Brown to ground Continuity Check wire 8"1 and the chassis ground
@ connection
NOTE: Turn the key to the ON posllion
Termrnal for wire 82 Dark Blue/Yellow to 12 Volts Check wue 82

ground
NOTE: Put the forvvardlreverse lever in foruvard and hold the inching pedal fully down.
Qfu Term,nal for wrre 79 Dark Blue/Black

L' grouno
to 12 Volts Check wire 79
kaukazz@yahoo.co.uk
4001-41
NOTE: The positive lead of the muttimeter must go terminal C of the forvvard diode module
Check Points Beadinq Possible Cause of Bad Reading
Between termlnals C and A of the diode No Continuiry Bad for"ward diode module
module
Between terminals C and B of the diode Continuity Bad fonward diode module
module
NOTE: Change The teads of the multimeter so the negative /ead goes to terminal C of the forward diode module.
Between terminals C and A of the diode Continuity Bad fonward diode modu e.
module
Betwcen terminals C and B of the diode No Continuity Bad for"ward diode module
module
Reverse Diode Module Circuit Test

NOTE: Turn the key to the OFF pasition and disconnect the reverse module and the modulation solenoid from the
harness.
lEl Term nal for wire 89 Brown to ground Continuity Check wire Bg and the chassis ground
connectlon
NOTE. Turn the key to the ON posrtron
Terminal for wire 82 Dark Blue,Yellow to 12 Volts check wire 82

ground
NOTE: Put the foryvard/reverse lever tn reverse and hold the tnching pedal tully down
lEi rermlnal for wire 87 Dark Blue io ground 12 Volts Check wlre 87
NOTE: The positive tead of the muttimeter must go termtnal C of the reverse diode module.
Between terminals C and A c{ thc diodc No Ccnirnury Bad reverse diode modue'
module
tsetvveen terminals C and B ol the diode Contrnurty Bad reverse diode module
module
reverse diode module

NOTE: Change the teads o'f the multimeter over so the negatrve lead goes to termrnal C of the
Between terminals C and A of the d ode Continuity Bad reverse diode module
n odule
Between terminals C and B of the diode No Contrnui[i Bad reverse diode module.
module
Lssuec 3-92 Prinied ir England

Don 8-85042
kaukazz@yahoo.co.uk
4001 -42
Clutch Disengage Indicator Lamp Circuit Test
NOTE: Check the clutch disengage lamp bulb.
Terminal for wrre 90 Ycllow/Dark Bluc to 12 Volts Bad circuit between the fonvard/reverse
ground relay and the clutch disengage lamo
NOTE; Turn the key to the OFF position
ferminal for wire 91 Brown to ground Contrnulty Check wire 91 and the chassis ground
@ connection.
Reverse lndicator Lamp Circuit Test

NOTE: Check the reverse indicator lamp bulb.
\-/ NOTE: Turn the key to the ON positlon, put the fonwardlreverse lever in reverse and hold the inching pedal fully down
Check points Reading Possible Cause of Bad Reading
4!l Terminal for wire 86 Light Blue to ground 12 Volts Bad circuit between the fonrard/reverse
switch and the reverse indicator lamp
terminal for wrre 91 Brown to ground Continuily Check wire 91 and the chassis ground
@ connection.
Dcn B-B5Oa2
kaukazz@yahoo.co.uk
4001 -43
Don 8-85042 ssuec 3-92 Printed in Engiand
kaukazz@yahoo.co.uk
4001 -44
Forward/Reverse Valve Block
@
REVERSE SO LENOID
@
REVERSE PRESSURE SWITCH
9-l +
r-l |
o oltt+l' o
'o
MODULATION SOLENOID
FORWARD PRESSURE SWITCH
,/
FORWARD SOLENOID
Don 8-85042 lssued 3-92 Printed in Englaso
kaukazz@yahoo.co.uk
4001-45 4001-45
Schematic Circuit
RJSE
Protects ttto sle(fical
>r*,D
CHASSIS GROUND
Cornplater
circrit
baery
ichematic Circuit
o
:3 FIJSE
>DD77V
CHASSIS GfiOUND
Cornd6i6 bdsry
*#C*
#$"
KErS$lrTCll
C.;onne<8 a di:conaeal polrcr to
the alectrical cirqri
t"_6-\
)
lsvar
\d-er
HANGE SVJTTCH
Coatacrs opcn
aaiqr
ordG€d by
*#C."
%f$'
I,TrcH
rls or di:connects porcrto
tdica, circuif
tffi
HANGE SITfTC}I
CortactsopenordG€d by
leuer arxiar
CONNESTOF H
Engine harnasr b
trarBrnisgkm hsrn€.t
INCHING PEDAL SI,VITCH

Contacrs open or dos€d by
NCH$IG PEDAL S:WTC}I
ContacGopenordcad by HEI.AY 30 AMP
CONHESIOR G
ForrardlrEvarse i,vitEit to
instrur'}efit hsmas
FORWARO/REVERSE SlflrTClt
DIOOE
P€rrnits sl€(ficaj c,rr€flt to
flor fteoly in oredirac{ion
PBESSURE S,r/ITCH
Cofita6 dosed by lor oil
Pr6ssrlr8
D{G
ffi UOOULE
Perrrifs eleclricd cilrrent
to b, fr€€V h an€
SOLENOIO
A ro8gn€tb c.il llrd
SPUCE
Coon6 ona or fl:ont
I.AMP
Producs lud that emit3
tystsm liom hiCh
.o ProtEd! tha slscfical drarit pedal actioo pedal ac+'on A raagnatic sfrifdr thEt Conrob mor6 than one cirqrit drcdrdr
rcnratEl a lrydraulic valve
ctrcrrit! thd do tlre same
otJtpd or e groond in
6, qfstom ltom high dif€cB sl€clric crinerd nrndnxr
artifical lighl
ouF|Jt or e ground in
CONNE TOR A trr€ €l€ciricsl 3!,3t8m
CONNEqTOH B trro sl€ctical qfsbEm
Trensniraion hamesc Eigins hsrn€s! to Transn
irEtrurnent
b irrltllfrt3nt h8rncit hamass to lrstrumedt . Forward Wiring
BATTETY JUNCNON BLOCK JUNCNON BLOCK
Fieverse Wiring
POWERSHIFT H.ARNESS CONNECTOR G

BATIEFT
JUNCIION BLOCK
CONHESTOR
56 WHITE/BI.-ACK 1STI2ND FANGE
*H*E/HED *ffiJl_ * \r----no ar-ue
CONNECTOB A
1l
Pmonhilt hamesr b
Us€d to roub bd€ry
poxB bansrnbsioo hemest ct
6s - 86 Lr 5[iliTl-- 85 Lr BLUE
llt FOH THACTORS WITH C
E
€ @ 86 LT BUJE
-e, -o@ .
UP TO P.l.N. No. JJFlO0l
o IH
85 LT BLI,JE
-----/ -..{
6 rn
:
a lAl
Et E
lcI FORWARD
ET
i\
Etr
ratE]
@ +#
|
POWE
-:.
T
POWERSHIFT
HAFNESS
corqruegron
92 HED/DK BLUE
3
o
Irl
FOFIrr/AHD/EEVE
\* r*"*
FO MA/ABD/FEVERSE S1A/ITCH
\* r*.* tt
ta REVERSE INDICATOR fiTN'.H DISENGAGE
H( 0reot z2
84 BLACK
!L | 0F EAUTPPED) F
:-j{-=
M/a
lel U,/ CREEP INCHING PEDAL Sf/T
SEE NOTE
INCHING PEDAL S:WTTCH

1 '?
B 76 B|.ACK
5 cottttEctoR G
==
EE CONNECTOH A
IAMP NP€ATOR LAMP
fl='ffa*'
1 (D
CONNECTOR G
ilit i (:: \ ftr.\

\u
\ \ t:
vi M
(ACTUATED WHEI{ THE rNC}r
PEDAL IS FULLY DOWN)
(ACTUATED WHEH THE NCAING
PEDAL IS FULLY DOWN}
o
UJ
d.
TU
t0
ot ot
arr F 9I BRC
\--'l 85 REDN 91 BROWN
=
B SOYEllOYf BK BLI''E
HH
rl,
(a :7 RED/(
3HO/4TH RANGE 7
SilMTCH
o
G,
78 LT A.!=tsi-ACK
to 72 BHOU REVEHSE P8ESSURE $IMTCH
NOTE 1 : The inching pdal
ilF t CONNECTOE
=
ssatch 1 is replaced by ke rching pedal \ \t
I
64 BEDTWHTE 64 BED/WHITE E
ke
I{EDrwHn zced by
c(
creep inching pedalsrtiioh for
;:: '}.ln FUsE F1s
Jalsytrileh for
6
ID
; 73 4rH RANGE DtoDE
H.{ ) f,actors with creep. The creep
inching pedal switcil /s o. The creep
swrtch is
9']WHITSBROWN
connected ta the insnument
f
CONNECTOH E
t\
82
e instrurnent
o lrarness (wres 65 and 69) by
i and 69) by
INCHING PEDAL S:WITCH 2
73 BROWN/BK GREEN 7B
*
the creep i,amess.
F,' a.
(ACTUATED ATTHE STAHT
. ).
l- 65 *,rrrtrErFl
Rs WHITE/EED 65 WHTTSEED t-
GSWHITE/EED+
69 WHITE/B OF INCHING PEDAL MOVEMEI lFl t CONNECTOH A c7
I 72 M I
,".,i) 6E WHITEJBBOT/YN
WHITFJGHAY/BIACK
79 '82
--t 82 DK BLUEA'ELLO'}I' I 87 DK BLUE
-t c7
irit
l;:
i.'
,j
TRANS$l&SION *-@ - Ear@ REYET# DIOOE
_iJ )-.-
}IABNESS
)--
4TH ffANGE
-6@ UCDULE
CONTROL HELAY FORWABD/HEVERSE

@ FOFrut3El
o(D(D*
SOLENOID
i- w-:\r- :lo
,o MODULA NON SOI-ENCID SOLENOID
:o @ .3o @
Dtrl 8-85042
lssued 3-92
CLEA}I GROUND
{
-(E12 BROW SO YELLOWiOK BLUE
t!-
I
r6
6
13-
I
o
=
6
6
'a@
tr
6
6
6
Priflted in England lssued 392 ftinted in England CfIA,SSIS GROUND BROWN/YELLOW
88 BHOI#H
kaukazz@yahoo.co.uk
4001-47
WIRING CODE
REF COLOR FROM TO WIRE
GAUGE
6 Red Battery Junction Block Key Switch (BA'rD 13
64 RedAVhite Key Switch (ACC) Fuse F19 16
64 BedAVhite Fuie F19 Accessory Power Relay (Terrn 86) 18
6g Brown Accessory Power Relay (Term 85) Transmission Control Relay fl-erm 85) 16
68 Brown Transmission Control Relay fl-erm 85) Chassis Ground 16

94 Red/Dark Blue Battery Junction Block Fuse F17 13
94 Red/Dark Blue Fuse F1l Accessory Power Relay fl-erm 30) 13
95 Red//iolet Accessory Power Relay (Term 87) Fuse F32 15

134 Dark Blue/Bed Fuse F32 Connector A (Pin X) 16
134 Dark Blue/Red Connector A (Prn X) Splice 16
134 Dark Blue/Red Splice SHB LowTemperature Switch (Term A) 18
134 Dark Blue/Red Spllce connector E (Pin R) 16
134 Dark Blue/Red Connector E (Prn R) SHR Lockout Relay fferm 30) 16
135 Brown/lVhite SHR LowTemperature Switch (Term B) Battery Negative Post 18
136 Yellow/Dark Blue SHR Low Temperature Switch (Term C) Connector E (Pin X) 18
136 Yellow/Dark Blue Connector E (Pin X) SHR Lockout Belay fl'erm 86) 18
137A Brown sHR Flasher Relay (T-erm 31) sHH Relay f'-erm 85) 18
137 Brown SHR Relay (Term 85) SHB Lockout Relay (1'erm 85) 18
137 Brown sHR Lockout Relay (i"erm 85) chassis Ground 18

138 Bed/Dark Blue SHR Lockout Relay (Term 87A) SHR Relay (l"erm 30) 16
138 Red/Dark Blue SHR Relay (Term 30) sHH Switch fi-erm 1) 16
139 Dark Blue/Black SHR Lockout Relay fl'erm 87) SHR Flasher Diode 2 18
139 Dark Blue/Black SHR Flasher Diode 2 SHB Warning Lamp 18
cigarette Lighter
'13
140 Brown sHR Warning Lamp
140 Brown Cigarette Lighter Chassis Ground 13
141 Dark Blue/pink StiR Relay (Terrn 87) SHF Swrtch f;erm 3) 16
141 Dark Blue/Pink sHR Relay (1-erm 87) SHR Relay ['erm 86) 16
14'1 Dark Blue/Pink SHR Relay (Term 86) SHR Relay Diode 16
142A Dark Blue/Orange SHR Relay Oerm 87A) SHF Flasher Relay (Term 49) 18
142A Dark Blue/Orange SHR Flasher Relay (Term 49) SHR Flasher Diode 1 18
142 Black sHR Relay (Term 87A) sHB Flasher Relay 'lB
142 Black sHR Flasher Relay (Term 49) sHF Flasher Diode 1 18
143A Dark Blue/Dark SHR Flasher Relay fl-erm 49A) SHR Flasher Diode 2 18
Green
18
143 Violet SHR Flasher Felay SHR Flasher Diode 2
18
144 Dark Blue,&Vhite SHR Switch fi'erm 2) SHH Relay Diode
18
144 Dark BlueAilhite SHR Relay Diode SHR Flasher Diode 1
to
145 Dark Blue/Yellow SHR Switch fl-erm B) SHR Switch fl'erm 6)
lo
145 Dark BluelYellow SHR Switch fl"erm 6) Splice
145 Dark Blue/Yellow Splice SHH Diode Module (Term B) 16
145 Dark Blue/Yellow Splice Connector E (Pin f) to

to
145 Dark Blue,Yellow Connector E (Pin T) Raise Solenoid fierm A)
146 Dark Blue/Gray SHR Switch lTerm 5) SHR Diode Module (Term A) 16
'16
146 Dark Blue/GraY SHR Switch f-erm 5) Connector E (Pin U)
16
146 Dark Blue/Gray Connecior E (Pin U) Lower Solenoid f''erm A)
to
147 Dark Blue/Light SHR Switch fi'erm A) SF1R Diode Module (Term C)
Green
16
148 Brown Raise Solenoid fl-erm B)
Qnlina
IO
148 Brown Lower Solenoid (Ierm B)
Qnl,no
tb
148 Brown Splrcc Chassrs Ground
NOTE: Wre code references marked 'A' are for tractors equipped with a Cartridge type relay
Don 8-85042
lssued 3-92 Pri.lec in England
kaukazz@yahoo.co.uk
4001 -48
CIRCUIT TESTING
testlng' Use a multimeter
NOTE: The batteries must be at full charge and atl connections must be clean and tight before
lor the lests.
Accessory Power RelaY Circuit Test

NOTE: Turn the key to thc OFF position
Check Points Readinq Possible Cause o{ Beq rceg'ng
ferminal for w re 68 Brown and ground Continuity Bad circuit between terminal 85 of the
Q accessory power relay and the chassis
ground connection Also check the chassis
ground connection
NOTE: Turn the key to the ON Positron
Terminal for wire 94 Red/Dark Blue to 12 Volts Check wire 94 between the battery junction
ground block and the accessory power relay
terminal 30. Also check the battery power
Junction block connection
Termlnal for wire 64 Red/Vvhite to ground 12 Volts Bad circuit between the key switch and the
O accessory power relay terminal 86 Also
check the keY switch.
Terminal for wire 95 FedruVhite to ground 12 Volts Bad accessory power relay
@
Terminal for wtre 95 Red,&Vhite to ground 12 Volts Check wire 95 belween the accessory
O power relay terminal 87 and fuse F32'
SHR Lockout RelaY Circuit Test

NorE: Thehydrauiicoitmustbeabovelo"F puttheSHB switchintheNE.TRALpositionandturnthekeytotheoN

pasttton
Readinq Possible Cause of Bad Reading
Check Points
tcrminal for wire 134 Dark Blue/Red to 12 Volts Bad circuit between the SHR lockout relay
@ grounO
terminal 30 and fuse F32
Terminal for wire 136 Yellow/Dark Blue to 0 Volts Check the SHF low temperature switch
ground
Terrninal for vrirc 138 Red/Dark Blue to 12 Vohs Bad SHR lockout relay'
qround
NOTE: Turn the key to the aFF position
Continuity Check wire 137 and the chassis ground

ferminal {or wrre 137 Brown to ground
@ COnneCtrOI-l'
ssued 3-92 Prrnted in England

lor 8'850a2
kaukazz@yahoo.co.uk
4001 -49
NOTE: Disconnectthe SH,8 /ow temperature switch from the harness and connect a suitable iumper lead between
terrninals A and C of the SHR low temperature switch connector (harness side) and turn the key to the ON posllron'
Terminal for rvire 'l 39 Dark Blue/Black to 12 Volts Bad SHR lockout relay
ground
Terminal for wire 139 Dark BlueiBlack to 12 Volts Check wire 139
ground
NOTE: Connect the SHR low temperature switch to fhe harness
SHR Relay Circuit Test

NOTE: Ihe hydraulic oit must be above 10"F. Put the SHE switch in the NEIJTRAL position and turn the key to the ON
position.
Check Polnts Reading Possible Cause of Bad Reading
Terminal for wire 138 Red/Dark Blue to 12 Volts Check wire 138 between the SHR lockout
87A and the SHR rerav
sround i::fl,"Iril""r
Terminal for wire l4.l Dark Blue/plnk to 12Volts BadcircuitbetweentheSHRrelayterminal
ground 30 and the SHR relay terminal 86' Also
check the SHR switch and the SHR reiay
Diode
NOTE: furn the key to the OFF position
ferminal for wire 137 Brown to ground Continuity Check wire 137 between the SHR lockout
@ relay terminal 85 and the SHR relay termina
OE
()-J.
NOTE: put the SHF switch in the WORK (DRAFT) position and turn the key to the ON
position.
Terminal for.wire 142 Dark Blue/orange to .12

Volts Bad sHF relay
ground
in the NEUTRAL position, and then in the WORK (DRAFT) position

NOTE: pur the SHF switch
Terminal for wire i41 Dark Blue/Pink to 12 Volts Check wire 14.1 between the SHE relay
ground terminals 87 and 86'
Don 8-85042
lssued 3-92 Prrnted in England
kaukazz@yahoo.co.uk
4001 -50
SHR Low Temperature Switch Circuit Test
NOTE: Check fuse F32
NOTE: The hydraulic oil temperature must be above 10'F.
NOTE: Turn the key to the OFF position and disconnect the SHR low temperature switch from fhe harness.
Terminal B of the SHR low temperature Continuity Check wire 135 between the SHR low
switch connector (harness side) and the temperature switch terminal B and the
battery negative terminal battery negative post. Also check the
battery negative connection.
Terminal C of the SHR low temperature Continuity Check wire 36 between the SHR low
'1
switch connector (harness side) and the temperature switch terminal C and the SHR
terminal for wire 136 Yellow/Dark Blue lockout relay terminal 86.
Terminal A of the SHF low temperature

'12 Volts Check wire ]34 between the SHR low
switch connector (harness side) to ground temperature switch and fuse F32.
Between terminals A and C of the SHR low No Continuity Bad SHR low temperature switch
temperature switch connector (switch stde)
N OTE: /l the SHR sys tem operates when the hyd raulic oil temperature is below 1 0" F check the SH R lockout relay. lf the
readings are correct replace fhe SHR low temperature switch.
SHR Raise and Lower Solenoid Circuit Test

NOTE: Check luse F32
NOTE: Dtsconnect the raise and lower so/enolds from the harness, and put the SHF switch in the NEUTRAL
position.Then turn the key to the aN position and mcsve and lock the SHF switch in the FULL RNSE (UP) position.
Terminal A of the SHR raise solenoid 12 Volts Bad circuit between the SHR raise solenoid,
connector (harness side) to ground connector terminal A and the SHR switch
terminal B. Also check the SHR switch.
Terminal A of the SHR lower solenoid 0 Volts Check the SHR diode module and the SHR
connector (harness side) to ground switch.
NOTE: Move and lock the SHB switch rn the WORK (DRAFf) position.
Terminal A of the SHB raise solenoid '12 Volts Check wire 145 between terminal B of the
connector (harness side) to ground SHR diode module and the splice, Also
check the SHR diode module and the SHR
switch
Don 8'85042 lssued 3-92 Prjnted in England
kaukazz@yahoo.co.uk
4001 -51
Terminal A of the SHB lower solenoid 12 Volts Bad circuit between terminal A of the diode
connector (harness side) to ground module and the sHR lower solenoid
terminal A.
NOTE: Hotd the SHP swr/ch in the LOWER posrtion
Terminal A of the SHR lower solenoid 12 Volts Check the SHR switch
connector (harness side) to ground
Terminal A of the SHR raise solenoid 0 Volts Check the SHR diode module and the SHR
connector (harness side) to ground switch
Terminal B of the SHR raise solenoid Continuity Check wire 148 between terminal B of the
connector (harness side) to ground SHR raise solenoid connector and the
chassis ground connection. Also check the
chassis ground connection
Terminal B of the SHR lower solenoid Continuity Checkwire'1 48 between terminal B of the
connector (harness side) to ground SHB lower solenoid connector and the
chassis ground connection,
raise
Between terminals A and B of the SHR 7.2 Ohms Bad SHR raise solenoid.
solenoid connector (solenoid side) + 107"
at Room TemPerature
BetweenterminalsAandBo{theSHRlower 7.2 Ohms Bad SHR lower solenoid.

solenoid connector (solenoid side) * 10Y"
at Room TemPerature
SHR Diode Module Test

NOTE: Check luse F32
NOTE: DisconnecttheSHRdiodemodulefromtheharness, andputtheSHRswrtch intheneutral position.Thenturnthe

key to the ON posltron and move and lock the SHR swltch ln the WORK (DRAFT) position.
Terminalforwire 147 Dark Blue/Lrght Green 12 Volts Check wire 147 between the SHB switch
to ground terminal A and the SHB diode module
terminal C. Also check the SHR switch
NOTE: The positive lead of the multimeter must go to terminal C of the SHR diode module.
Between termrnals C and A of thc SHR Continuity Bad SHR diode module
diode module
Between terminals C and B of the SHR Continuity Bad SHR diode module
diode module
Don 8-85042 lssued 3-92 Prinled in England
kaukazz@yahoo.co.uk
4001-52
the sHR diode module'
NOTE: change the leads of the multimeter so the negative /ead goes rc rcrminal c of
Feading Possible Cause of Bad Reading
Check Points
Bad SHR diode module'
BeMeen terminals A and C of the SHR No Continuiry
diode module
BetweenterminalsBandCotthesHRNoContinuityBadSHHdiodemodule.
diode module.
and the splice
tenninar B of the sHR diode modute connedor
NorE: , the readings are correct check wire 145 be*veen sHR swltch terminal 5'
aioau module connector and the
thiign
Nso check wire 146 between terminat A of
SHR Switch Test
NOTE: Tum the ke4 to the ON Posttton

Readrng Possible Cause of Bad Fleading
Check Points
'12 Volts Check wrre 138 between the SHR switch
Terminal for wire 138 Red/Dark Blue
to
terminal 1 and the SHF relay terminal 30'
ground Also check the SHR lockout relay and the
SHR relay
12 Volts Check wire 141 between the SHR switch

Terminal {or wire 141 Dark Blue/Pink to ierminat 3 and the SHR relay terminal 86'
the
ground Atso cfreci< the SHF lockout relay and
SHF relaY
NOTE:TurnthekeytotheoFFpositionanddisconnectthesHRswtchlromtheharness.
position'
NOTE: Put the sHR /ever in the NETJTRN-
Bad SHR switch
BeNveen terminals 1 and 2 of the SHH Continuity
SWtCh
lf there is continuitY between
NoTE:Checkbetweenterminal3andtheremainingtermtnalsoftheSlRswitchinturn
the SHR switch'
Ermrnal 3 and any of tn'e remarnrng Erminals' replace
NOTE: Lack the SHF swltch in the FULL RNSE (UP) position'
SHF Continuity Bad SHR switch

Between terminals 3 and B of the
swrtch
NOTE: Lock the sHR swltch in the woRK (DRAFT) positian'

Bad SHR switch
BeNeen terminals 3 and A of the SHR Continulty
switch
LOWER position'
NOTE: Hold the SHB swrtch in the momentary
Bad SHR switch
Berrveen terminals 3 and 5 of the SHH Continuity
switch
RNSE position'
NOTE: Hold the SHB swllch in the momentary
Bad SHF switch
Between terminals 3 and 6 of the SHR Continuity
swttch lssued 3-92 Printed in England
Don B-B5Oa2
kaukazz@yahoo.co.uk
4001 -53
SHR Flasher RelaY Circuit Test
(Cartridge TYPe RelaY)
Check Points Readino

----= Possible Cause of Bad Reading
ferminal for wire 137A Brown to ground Continuity Bad circuit beiween the SHR ilasher relay
@ terminal 31 and the chassis ground
connection. Also check the chassis ground
connection.
position.
NOTE: put the SHB switch in the NEUTRAL position and turn the key to the ON
to Volts Bad circuit between the SHR flasher relay

sround 2
'1
Terminal for wire 142A Dark Blueiorange
x'J:i::l,i:t!3iffi,i[:J"{:trifr
SHR switch.
Terminal for wire 43A Dark

'1
Blue/Dark 12 Voits Bad sHR flasher relay,
Green to ground ON-OFF-ON
the key ta the

NorE: Turn the key to [he aFF positicn and tockthe SHF switch in the woRK (DRAFT) position, then turn
ON posl/lon"
Terminal forwire l42ADarkB1ue/Orange to 12 Volts Check wrre 142A beween the SHB flasher
relay terminal
ground relay terminal 49 and tfre
_SHR
B7A. Also check the SHR relaY
SHn Flasher RelaY Circuit Test

(Cylinder TYPe RelaY)
NOTE: Put the sH,q switch tn the NEUTRAL position and turn the key to the oN position
6D Terminal for wrre 142 Black to ground 12 Volts -

Bad circuit between the SHF flasher relay
and the SHR switch terminal 2 Also check
the SHR flasher diode 1 and the SHB switch
Terminal for wire 143 Violet to ground 12 Volts Bad SHR flasher relaY.
@ ON OFF.ON
the key to the

NoTE: Turn the key to the OFF position and tock the SHn switch in the $ORK (DRAFT) position, then turn
ON position.
ferminal for wrre

.142
Black to ground 12 Volts Check wire 142 beween the SHR flasher
@ relay and the SHR relay terminal 87A Also
check the SHR relaY
lssued 3-92 Printed in Exgland

Doo 8-85042
kaukazz@yahoo.co.uk
4001 -54
SHH Warning Lamp Circuit Test
NOTE: Check fuse F32 and the SHR warning lamp bulb.
NOTE: Turn the key ta the OFF position.
Check Points Rea9rng Possible Cause of Bad Reading
6F Termlnal for wire 140 Brown to ground Continuity Bad circuit between the SHB warning lamp
and the chassis ground connection. Also
chcck the chassis ground connection.
NOTE: Put the SHB swirch in the NEUTRAL posr,an and turn the key ta the ON position.
Terminal for wire 139 Dark Blue/Black to 12Volts BadcircuitbetweenthesHRwarninglamp

qround ON-OFF-ON and the SHR flasher terminal 49A. Also
check the SHR flasher diode 2 and the SHR
flasher relay
NOTE: Turn the key to the OFF position, disconnect the SHR low temperature switch from the harness and connect a
suitable jumper lead between terminals A and C of the SHR low temperature connector (harness side).
Terminal for wire 139 Dark Blue/Black to 12 Volts Bad circuit between the SHR warning lamp
ground and the SHB lockout relay terminal 87 Also
check the SHB lockout relay.
SHR Relay and Flasher Diode Test

NOTE: The procedure for checking rhe SHB relay and flasher dlodes is rhe same for each diode.
NOTE: Turn the key to the OFF position and disconnecl the SHB relay diode from the harness.
NOTE: The positive lead of the multimeter must ga to the male terminal of the diode.
Check Points Reading Possible Cause of Bad Beading
Between the terminals of the SHR relay Continuily Bad SHR relay diode
diode
NOTE: Change the multimeter leads oyer so the positive lead goes to the female terminal of the SHR relay diode
Belween the lerminals of the SHR relay No Continuity Bad SHB relay diode
diode
kaukazz@yahoo.co.uk
I
I
___ l _I_l
4001-5s 4001-s5
___
Schematic Circuit
I I ---f,7E-
T-
l- E
/-\ /-\
powrquadplus www.thebestworkshopmanuals.co.uk ^r -\
rT ) rT
W>"}D'7
CHASSIS GROUND
JUNCTION BLOC
Used to routs bi *TrrjrrrrT
CHASSIS GBOUND
BATTEBY
JUNCTION BLOCK
Used
?o!Y€r
to route battery
KEYSWTTCH
#$ SHH HTTCH CONIffOL LOW
TEMPEBATURE SI,YITCH
ContacB dosed by a Probe
I sHnH
I orooe
I Permit
SHR HTICH CONTFIOL
DIODE MODULE
Perrnils elecaJical clrrent to SHB HITCH CONTBOL
S0LENOID {SHR HfrcH
coNTHOL)
A magnetic coil that
FT.ASHEFI RETAY IF
I RELAY 30 Atr
FI..ASHER RELAY
EELAY 30 AMP
i DIODE
PermiA elec*i:d cufrsnl to
flow freely in o-e direction
LAMP
Produces heat that emits
artilical lighl
Heat
\q-l
CIGARETIE UGHTER
oper#.relement Heat
)
\s_/
CIGABETTE UGHTER
opermd element
Prc:?cts tha eleclricai
E! :rn lrom high
Completes battery
circuit
Completes battery
circuit
Condects or dtsconnectF powsrto
the electrical circuit
immersed in low temperaijre
transmigsion oil
Ear flow lreeiy in one drrection SWITCH
Controls more than cns circuil
actuates a hydraulic vafue Ete<*rcal device which
aperrs and closes a circuit I A magnelic s
EJeddcal dsyice which
oper:s and closes a circuit A magnetic swilch that
directs eles,tri directs electric cunent
ouipiJi or a ground in cordinually when actuated I coctinuaily wh€n actuated
CONNEC:OH A the electrical system
CONNECTOH E
Transmission hamess Transmission harnsss lo
to instrumsflt harress
Sens-O-Draulic SHH Hitch Control Wiring Iitch Control Wiring
hand console hamess BATIEBY JUNCT]ON BLOCK {POWER) BATTERY JUNCION BLOCK (POWER) (POWEH)
CONNEGl CONNECTOB E
134 DK BLUE/FIED
SPUCE 136 YELLOW/IK BLUE
Connects on6 or 141 DK BLUEFII"IK
mor€
circuits that do the sams
KEY SWTT(
-.-@ 138 BED/DK BLUE
function
@ @\ /'@ SWITCH POSTNONS POSITIONS
T38 RED/DK BLUE
€$(p ,:, :D/DK BLUE
SHE LOWTEMPERATURE
SWITCH
i
:;--1
1. TMNSPOBT
2. FAST BAISE
RANSPOFTT \
BAISE )c
I 45 12 3. NEUTHAL EUTFAL
o
SHB E
4. FAST LOWER D SHB LOCKOUT RELAY
o
LOWER f
J 141 SHR REI.AY
5, WORKING NG trl
)4
o @ 139 @
144 DK SLUEfiVHITE
@ -u- t BTAIE
'137
@r /
@
.T.ARETTE LrG HTEFI
146 ---.mDF- BLUE,GRAY-.r BROWN
,+s--ffiJ-1 146 DK SHR RELAY DI( SHR WABNING f (cAB TMCToR oNLYI
|
\@A
j LAMP
H
E e | ,L @ -u- r _ _ _.lg8 E)Df( BLUE I
t corururcron
I L_€rct 142A DK BLUE/OBANGE
@( 'e,
142A DK BLUEIORAT.G=
I -1g7
:a
o 146
Y Y bt -/rosHFtRELAY
I
TO SH8 REIAY .I
,w
SHR FLASHER DI SHR FLASHEH DIODE () () (rERM aq
1
!s crEHM 85)
(f,
5 5 I
M
i
@ TD
I ,aro r*o**J
{@&
N 6l
146 DK BLUEIGRAY I37A BBOWNJ
J
:a6 \
I
.--@ :<
(J { -140
o z I
( I UI 5
@ \:, IIJ
h
I
147 DK BLUSLT GREEN
I
u,
(E
(5
SHR
FLASHER
SHR
FLASHER
TD
1r.l
I
TRANSMIS'SC TBANSMISISON ACCESSORY SHR Y 3

N RELAY I
o HELAY
CONTBOL REl CONTHOL REI-AY POWER RELAY
,t@ Fi,qSHER
z
@
to
!(
\\ \\ = SHR RAISE SOLENOID SHB LOWEB SOLENOID FETAY
I u.J
3 i o
o @ o
I
o
= J o,
(TOP} F I
(7
o
to
(Borrou) llj I (r)
I
ID
u,
(} O J
o
I
:<
o CARTFTIDGE
ID
1...
(r, CARTFIIDGE I
I g) (r)
68 BROWN J SHR DI ODE MODULE
I
.+
TYPE RELAY ryPE REIAY I
I----.- --\\a t\
I I
I----\: 3
o @
2..
EU' \-,
L_,_
L
+____13s
I
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tr)
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.c
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aO
SHB FI.ASHER DIODE 2
139
E
:-\-\\:-
]\ h--:---- \\. \-_
I- -\
..'-.\ -\-. :.:s--
TRANSMISSION CLEAN GBOU
\ neRrueSS
THANSMISSION
HARNESS
CLEAN GBOUND
Don 8-85042
lssued 3-92
kaukazz@yahoo.co.uk
Printed in England lssued 3-92 Printed in England
CHASSIS GROUND
-T-
4001-56
FHONT PTO, MFD AND DIFF LOCK
Sectional lndex
Diff Lock lndicator Lamp Circuit Test ........... """""""""" 65

Schematic Circuit "" ""'67
Don 8-85042
kaukazz@yahoo.co.uk
4001-57
WIRING CODE
GAUGE
6 Red Bartery Jurction Block Key switch (BAI-D i3
7 White Key Switch (STAnf) Front PTO Relay 1 fl-erm 86) 15
26 Red/Dark Green Keyed Power Junction Block Fuse F24 15
26 Red/Dark Green Fuse F24 Fuse F23 1 5
64 Red,Ailhite Key switch (ACC) Fuse F19 16
64 RedAVhite Fuse F.] 9 Accessory Power Relay ft-erm 86) 16
68 Brown Accessory Power Relay (Terrn 85) Transmission Control Relay fl-erm 85) i6
68 Brown Transmissron Control Relay (Ternr 85) Chassis Ground i6
73 Brown/Dark Green Ditf Lock Diode 4th Range Diode 18
73 Brown/Dark Green 4th Range Diode Connector E (Pin N) t8
73 Brown/Dark Green Connector E (Pin N) 4th Range Switch fl'-erm D) tB
74 Brown 4th Fange Switch f-erm C) Chassrs Ground i6
91 Brown Diif Lock lndicator Lamp Clutch Disegage lndicator Lamp i8
91 Brown Clutch Disegage lndicator Lamp Reverse lndicator Lamp 18
91 Brown Reverse indicator Lamp Power Shift Fault lndicator Lamp lB
91 Brown Power Shift Fault lndlcator Lamp Chassis Ground lB
94 Red/Dark Blue Battery Junction Block Fuse F.17 13
94 Red/Dark Blue Fuse Fl7 Accessory Power Relay fi-erm 30) 13
95 Redl/iolet Accessory Power Belay fi-erm 87) Fuse F32 I5
95 Redlr'iolet Fuse F32 Fuse F20 i6
95 Redl'/iolet Fuse F20 Fuse F30 t6
149 Dark Green/Red Fuse F30 Front PTO Felay 1 fl-erm 30) t5
i 50 Brown Front PTO Relay 2 fferm 85) Front PTO Felay 1 fl'erm 85) 15
150 Brown
.l
Front PTO Relay ft'erm 85) Front PTO Switch ft-erm 9) 15
50 Chassis Ground
'1
Brown Front PTO Switch (Term 9) 15
151 Dark Blue/Red Front PTO Belay 1 fTerm 87A) Front PTO Switch flerm 1) 15
15'1 Dark Blue/Red Fronl PTO Switch fl-erm 1) Front PTO Switch fl-erm 6) 15
152 Dark Green//ellow Front PTO Relay 2 fT'erm 87) Front PTO Relay 2 fT-erm 86) t5
152 Dark Greenl/ellow Front PTO Relay 2 [erm 86) Front PTO Switch fl-erm 3) 15
152 Dark Green//ellow Front PTO Switch fl.erm 3) Front PTO Switch fi.erm 10) 15
152 Dark Green/Yellow Front PTO Switch fl-erm 10) Connector B (Pin X) t5
152,A Brown Connector B (Pin X) Front PTO Solenoid fl''erm A) 15
1528 Dark Green/Yellow Front PTO Solenoid fl-erm B) Chassis Ground 15
153 RedMhite Front PTO Switch f-erm 2) Front PTO Relay 2 (Term 30) 15
154 Brown M.F.D. Switch fl-erm 10) Chassis Ground
.16
155 Light Green Fuse F23 Left Hand Brake Pedal Switch 16
155 Light Green Left Hand Brake Pedal Switch M F.D Switch (1-erm 5) 16
156 Dark Blue/Dark M F D. Switch (Term 7) Connector A (Pin t/) 16
Green
156 Dark Blue/Dark Connector A (Pin VJ MF D Solenoid fl-erm A) 16
Green
157 Brown M F D. Soienoid fli-erm B) Chassis Ground Ib
158 Light Green/Yellow M F D Switch (Term 1) M F.D. Switch ft-erm 9) 18
159 Light GreenzWhite Lelt Hand Brake Pedal Swilch Rrght Hand Brake Pedal Switch 16
160 Light Green/Yellow Right Hand Brake Pedal Switch Connector A (Pin H) to
160 Light Green/Yellow Connector A (Pin H) Connector E (Pin C) tb
160 Light Green/Yellow Connector E (Pin C) Diff Lock Switch (Term 6) 16
160 Light Green/Yellow Difl Lock Switch fierm 6) Difr Lock Switch fl-erm 1) t6
.161 Light Green/Black Difl Lock Switch (erm 2) Difl Lock Relay fi-erm 30) 16
Don B-85042 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001 -58
TO WIRE
REF COLOB FROM
GAUGE
Ditf Lock RelaY fl-erm 86) to
162 Dark Blue Ditt Lock Switch (Ie'm 31
Drff Lock Relay fl-erm 87) lb
162 Dark Blue Diff Lock Switch fl-erm 86)
Connector E (Pin H)
1A
162 Dark Blue Diff Lock RelaY (i-erm 87)
Splice Itl
162 Dark Blue Connector E (Pin H)
Connector A (Pin U) 16
162 Dark Blue Splice
Diff Lock lndicator LamP Ib
162 Dark Blue Connector A (Pin U)
Difi Lock Solenoid fl-erm A) 16
162 Dark Blue Splice
Chassis Ground 16
163 Brown Diff Lock Solenord fl-crm B)
to
64 Brown/Dark
'1
Blue Di- Lock qsi3y [rs.m g5) Diff Lock Diode
CIRCUIT TESTING
useamultimeterfor
NorE: Thebatterymustbeatfull chargeandall connectionsmustbecleanandtightbeforetesting
the tests.
Front PTO Solenoid Circuit Test

Terminal for wire 152B Dark Green//ellow to Continuity Check wire 1528 and the chassis ground
ground connection,
Between terminals A and B of the front PTO 7 2 Ohms Bad front PTO sclenoid
solenoid *
107"
at Foom TemPerature
position' Hold the front PTo

NorE: Disconnect the front pro solenoid fram the harness and turn the key to the oN
switch in the MOMENTARY position and then release the switch
to the ON position'
terminal for wire 152A Brown to ground 12 Volts Bad circuit between the front PTO switch
@ terminal 3 and the front PTO solenoid
connector terminal A. Also check the lront
PTO switch cicuit.
NOTE: Remove fuse F16 (fuel shut offl and hold the key in the sIABI
position'
() ferminal for wire 152A Brown to ground O Volts Check the front PTO reiaY 1
NOTE: lnstaltfuse F16 (fuel shut offl

Don 8-85042
kaukazz@yahoo.co.uk
4001-59
Front PTO Switch Circuit Test
NOTE : Check fuse F30.
NOTE : Turn the key to the ON Position
Check Points Reading Possible Cause oi Bad Reading
Terminal for wrre 151 Dark Blue/Fed to 12 Votts Check wire 151 between the front PTO relay
ground terminal 87A and the front PTO switch
terminal 1. Also check the front PTO relay 1 .
Terminal for wtre 151 Dark Blue/Red to 12 Volts Check wire 151 between terminals 1 and 6
ground of the front PTO switch
NOTE : Hold the front PTO switch in the MOMENTARY position
Terminal for wire 152 Dark Green/Yellow to 12 Volts Bad front PTO switch
ground
ferminai lor wire 153 Red/White to ground 12 Volts Bad front PTO switch
@
Terminal for wire 152 Dark Green,Yellow to 12 Volts Check wire I52 between terminals 3 and 10
ground o'Ihe front PTO switch.
NOTE : Belease the front PTO switch to the ON position
rerminal for wire 153 RedMhite to ground 12 Vots Bad front PTO switch
o
Terminal for wire 152 Dark Green/Yellow to 12 Volts Check wire 152 between terminal 87 of the
ground front PTO relay 2 and the fronl PTO switch
termrnal 3. Also check the front PTO relay 2'
NOTE : Turn the key to the OFF position and check the front PTO swttch warning lamp bulb
ferminal for wire 150 Brown to ground Continuily Check wire 150 and the chassis ground
@ connection,
Between terminals 1 and 3 of the front PTO Continuily Bad front PTO swttch
switch
3on 8-85042
kaukazz@yahoo.co.uk
4001-60
Front PTO Relay 1 Circuit Test
NOTE : Check fuse F30.
Check Points Feading Possible Cause of Bad Reading
tt) Terminal for wire 150 Brown to ground Continuity Bad chassis ground circuit' Also check the
chassis ground connection.
NOTE : Turn the key to the ON Posttion
to 12 Volts Bad circuit between the accessory power

sround
Terminal for wire 14g Dark GreeniRed
i:lil,i:I.# XLl":[:J'"*':i:"]g;
power relaY.
Termrnal for wire'1 51 Dark Blue/Fed to 'l

2Volts BadfrontPTOrelayl'
ground
NOTE : Remove fuse F1 6 (fuet shut oif) and hold the key in the s IAFI position
lh Termlnalfor wire 7 White to ground l2Volts Check wire 7 between the key switch
terminal 50A and the front PTO relay
terminal 86. Also check the key switch
Terminal for wire 151 Dark BlueiFed tc 0 Volts Bad iront PTO relay 1'
ground
Front PTO Relay 2 Circuit Test

NOTE : Check fuse F30
rerminal for wire 150 Brown Io ground Continuity Bad chassis ground circuit. Also check the
@ chassis ground connection,
(D Terminals for wire 152 Dark Green/Yel ow Continuity Check wire 152 between terminals 87 and
86 of the front PTO relaY 2.
NOTE : Turn the key to the ON posrtion and hold the key tn the MOMENTARY position'
Terminal for wrre 152 Dark Green//ellow to 12 Volts Check wire 152 between terminal 3 of the
ground front PTO switch and the front PTO relay 2
terminal 86. Also check the front PTO
switch.
fer'".inal lor wire 153 Red,M/hrte to ground

'1
2 Volts Check wire 153 between terminal 2 of the
4il front PTO switch and the front PTO relay 2
terminal 30. Also check the front PTO
switch.
NOTE : Felease the front PTO swrtch to the ON position
Terrrinal for wirc 52 Dark Grecn.lYellow

'1
lo 12 Voits Bad front FTO relay 2
ground

Dcn 8-85042
kaukazz@yahoo.co.uk
4001 -61
MFD Solenoid Circuit Test
position and turn the key to the aN
NOTE: Disconnectthe MFD solenoid fromthe harness, putthe MFD switch in the OFF
position.
Check Points Beading Possible Cause of Bad Feading
Green 12 Volts
Terminal lor wire 156 Dark Blue/Dark Bad circuit between the keyed power
togroundlunctionblockandtheMFDsolenoid
connector terminal A Also check the MFD
switch and the keyed power circuit.
NOTE: Turn the key to the OFF positron
terminal for wire 157 Brown to ground Continuity Check wire 157 and the chassis ground
6) connection.
Between terminals A and B of the MFD 7.2 Ohms Bad MFD solenoid
sOlenoid * 107"
at Room TemPerature
MFD Switch Circuit Test

NOTE: Putthe MFD switch rn the oFF posrt/on and turn the key to the oN
posirion"
Terminal for wire 155 Light Green to ground 12 Volts Bad circuit belween the keyed power
F:!}
iunction block and the MFD switch Also
check the keYed Power circuit.
Terminal for wire 156 Dark Blue/Dark Green 12 Volts Bad MFD switch
to qround
NOTE: Put the MFD switch in the ON position
Termrnal for wire 156 Dark Blue/Dark Green 0 Volts Bad MFD switch
to ground
Terminal for wire 158 Light Green,Yellow to '1

2 Volts Bad MFD switch
ground
Terminal for wire 158 Lrght Grcen/Yellow to 12 Volts Check wire 158
ground
NoTE: Turn the key to the oFF position and check the MFD switch warning lamp bulb
fD Terminalfor wire 154 Brown to ground Continuity Check wire 154 and the chassis ground
connection
lssuecl 3-92 Printed in England

Dor 8-85042
kaukazz@yahoo.co.uk
4001-62
Diff Lock Solenoid Circuit Test
NOIE: Check fuse F23
NOTE: Disconnect the Diff Lock Solenoid from the harness, and turn the key ro the ONpos itton. Hotd the diff lock switch
rn the MOMENTARY position and then release the switch to the ON pasition
Check Points Ueading Posslble Cause of Bad Feading
6D Term,nal for wire 162 Dark Blue to ground 12 Volts Bad circuit between the keyed power
lunction block and the dill lock solenoid
connector terminal A. Also check the brake
pedal switches. the diff lock switch, the diti
lock relay and the keyed power circuits.
6'l) Term'nal for wire 163 Brown to ground Continuity Check wire 163 and the chassis ground
connectron.
Befiveen termina]s A and B of the diff lock 72 Ohms Bad difi iock solenoid
solenord - 10%
at Room Temperature
Brake Pedal Switch Circuit Test

NOTE: Cneck ruse tr23
NOTE; Turn the key to the AN position.
Check Points Reading Possrble Cause of Bad Readjng
6'F) Terminal ior wire 155 Light Green to ground 12 Volts Bad circuit between the keyed power
junction block and leit hand brake pedal
swjtch Also checkthe keyed power junction
block and the keyed power circuit.
Terminal for wire 159 Light Green,&Vhite to 12 Volts Bad left hand brake pedal switch. Adjust or
ground replace the switch as necessary
NOTE: Hold the brake pedals dcwn
Tcrminal for wire 159 Light Green/Whrte to 0 Voits Bad le;t hand brake switch Adjust or
ground replace the switch as necessary
NOTE: Belease the brake pedals
Terminal for wrre 159 Light GreenA,{hiie to 12 Volts Check wire '1 59
ground
@ Im:'rfor wire 160 Lrght Green'Yellow to 12 Volts Bad right hand brake pedal switch Adjusl
or replace the switch as necessary
NOTE; Hold the brake pedals down.
6D Ter..inal f or wire 160 L ght Green,/Yeliow to 0 Volts Bad right hand brake pedal switch Adjust
grouno or replace the switch as necessary
kaukazz@yahoo.co.uk
4001 -63
Diff Lock Switch Circuit Test
NOTE: Belease the brake pedals.
NOTE; Dr'sconnecl the difl lack switch from the harness and turn the key to the ON position
Terminal forwire160LightGreenl/ellowlo 12Volts Bad circuit between the right hand brake
ground pedal switch and the difr iock switch
terminal 6.
Terminal for wire 160 Light Greenffellow ro 12 Volts Check wire 160 between terminals 1 and 6
ground of thc dilf lock switch connector.
NOTE: Put the diff lack switch in the OFF positran
Between terminals 'l and 3 of the diff lock No Continuity Bad diff lock switch
switch
Between terminals 2 and 6 o{ the dilf lock No Continui! Bad diff lock switch
switch
NOTE: Hold the difllock switch in the MOMENTARY position.
BeMeen terminals 1 and 3 of the diff lock Continuily Bad difr lock switch
switch
Belween terminals 2 and 6 ot the dilf lock Continuity Bad diff lock switch
switch
NOTE: ,9e/ease the diff lock switch ta the ON position.
Between terminals 1 and 3 cf the difi lock No Continuity Bad diff lock switch
swrtch
Belween terminals 2 and 6 o{ the diif lock Continuity Bad dif{ lock swrtch
switch
NOTE: Connect the diff lock switch to the harness.
kaukazz@yahoo.co.uk
4001 -64
Diff Lock Relay Circuit Test
NOTE: Turn the key to the OFF position and put the range lever in 1st, 2nd, or 3rd range.
Check Points Heading Possible Cause of Bad Reading
@ ferminal for wire 164 Brown to ground Continuity Bad circuit between the diff lock relay
terminal 85 and the chassis ground
connection. Also check the diff lock diode,
the 4th range switch and the chassis ground
connection.
lll Termlnals for wire 162 Dark Blue to ground Continuity Check wire 162 between the diff lock relay
terminals 86 and 87.
NOTE: Turn the key to the ON position and hold the diff lock switch in the MOMENTARY position
@ terminalfor wire 162 Dark Blue to ground 12 Volts Check wire '162 between the diff lock switch
terminal 3 and the ditf lock relay terminal 86.
Terminal for wire 161 Light Green/Black to '12 Volts Check wire 161 between the diff lock switch
ground terminal 2 and the diff lock relay terminal 30
NOTE: Be/ease the diff lock switch to the ON postion
trh Terminalfor wire 162 Dark Blue to ground 12 Volts Bad diff lock relay
NOTE: Put the range lever in 4th range
4{ Terminalfor wire 162 Dark Blue to ground 12 Volts Check the 4th range switch

NOTE: Turn the key to the OFF position and disconnect the 4th range switch from the harness.
Check Points Beading Possible Cause of Bad reading
trD 'rerminalfor wire 74 Brown to ground Continuily Check wire 74 and the chassis ground
connection.
Termrnalfor wire 73 Brown/Dark Green and Continuity Bad circuit between the diff lock relay
the terminal lor wire 164 Brown/Dark Blue terminal85 and the 4th range switch
connector terminal D. Also check the diff
lock diode
NOTE: Putthe 4th range lever in 1st,2nd, or 3rd range.
Between terminals C and D of the 4th range Continuity Bad 4th range switch adjust or replace the
Betwcen terminals A and B of tfre 4th range No Continuiry Bad 4th range swrtch adjust or replace the
switch switch as necessary.
kaukazz@yahoo.co.uk
4001-65
NOTE: Put the 4th range lever in 4th range
Check Points Reading Possible Cause of Bad reading
Between terminals C and D of the 4th range No Continuity Bad 4th range switch adlust or replace the
Between terminals A and B of the 4th range Continuily Bad 4th range switch adJUSt or replace the
Diff Lock Diode Test

NOTE: Turn the key to the OFF position and dlsconnect the difl tock dtode from the harness.
NOTE: The positive lead of the multimeter must ga ta the female termtnal of the dtode.
Check Points Beading Possible Cause of Bad reading
Between the terminals of the diode No Continui! Bad diff lock diode
NOTE: Change the leads of the multimeter over so the poslllve lead of the muliimeter goes ta the male terminat of the
diode
Belween the ierminals of the diode Contlnuily Bad diff lock diode
Diff Lock lndicator Lamp Circuit Test

NOTE: Check the drff lock indicator lamp bulb.
NOTE: Turn the key to the ON position and hold the diff lock switch in the MaMENTARY position
Check Points Reading Possrble Cause of Bad reading
t) ferminal for wire '162 Dark Blue to ground l2 Volts Chcck wirc 162 between the diff lock
indicator lamp and the splice.
NOTE: Turn the key to the OFF position and put the diff lock switch in the OFF position
@ ferminal for wire 91 Brown to ground Continurly Check wire 91 and the chassis ground
connection.
Don 8-85042 lssued 3_92 printeo in Ingiand
kaukazz@yahoo.co.uk
4001 -66
Don 8-85042 lssued 3-92 Pflnted in Eng and
kaukazz@yahoo.co.uk
ffi
4C01-67
Schematic Circuit
D|DTDS ,DD;
BATTERY
JUNcTION BLOCK
Used to toute battgry
SOLENOID (FRONT PTO)
ffi
) (FHONT PrO) t'
S0LENOTD {DIFF LOCR
A coil
tffi
FANGE SwlTCH
Contacts open or closed
t@
EANGE SWITCH
Contacts open or closed
soLEN0rD (MrD)
I.AMP
Prodrres heat that emits
li]hi
BBAKE PEDAL SWTCH
Contacts op€n or closed
pedal action
b1
BRAKE PEDAL SWTCH
Cofitacts opan or closed by
power
KEYSWTCH etic coil that FRONT PTO SW'TCH MFD SWITCH magnetic thal by lever action by lever action BETAY 30 AMP artifica pedal ac{ion DIFF LOCK SWTTCH
CHASSIS GHOUND CHASSIS GROUND actuates a hydraulic valve actuates a hydraulic valve actuates a lrydraulic valve
Connects or disconnscts Power to i hydraulic Yalvg (oPTroNAL) Controls more than ona circuit A magnetic switch that Controls m,:re than one circuil
Completes battery Completes battery tfre electrical circuit Controls more than one circuil ! directs electric dJrrent
circuil circuit
SPUCE ti'I
Oitf Lock Pitf Loct< Wiring
Connects :'rE or more Front PTO Wiring nt Pio wiring MFD Wiring MFD Wiring
CONNECTOR B
circuits tha 30 th€ sam€
CONNECTOR A
function
Transmission hamess Engine harness lo instrumenl BATTERY JUNCTION BLOCK
to instrumant harness harnsss
KEYED POWER JUNCTION BLOCK
,a
26 BED/DK GREEN
FUSE
Protects ths elactrical DIODE
'l
f f ;l
system trom high Permits elsrcd current lo 158 LT GBEEN YELLOW GBEEN YELLOW I
I
output or a ground in ffow freely rr gre direction aG)
^ I
CONNECTOH E
Transmission harness to right
the electrical system
u.,
3
TD
vo
151 DKBLU
I
I
I
-N/1
LJ
TE' I
I
ul @ ul
1
-l q
hand consolo harnesg I or*r nnruer DIFF LOCK e FF LOCK
I
I
zz @ @ II orooe DIODE H
L:J
Y
EI FUSE F2
I
o FUSE F32 FUSE F2O o HELAY L
o
ul
E
*d, oo
== FBONT PTO MFD MFD .'-.
@H ol ol T@
@( @q (E .E
@dI
Oo
u) ln
SWITCH SVWTCH
-r]-- -.:.l
SvvITCH
-J-I* -r1
H(9
(t
(r,
GI
l
14S DK GREEN/RED r-r i -tr -:j t, I
!l I
L 161 BHOWI.I/DK BLUE
I t
i:() BLUE z
"E- ,#
s
CE
1-ffi|I62DKBLUE o
@
I
]eel'- \ \ t,
t{
I coNNecron E L- ,62 BK BLUE
@
L 5
b
lo
l- @ @ tl,
162
@
.u.=,,nfl 8.= ll
150 BROWN'
@(
CONNECTOH B
o @
T ll
tl,
E vH -
155 LT GREEN
- CONNECTOR E
l-,.,-ffin r
JI
z
\
I I
=
tIJ
ccl
e,
I
f;
E I52 ilK GREEN/
I
o
.t( =
156 DK BLUE/DK GRI 156 DK BLUE/DK GREEN
| ,on*=croRA I
o
@\i'
I g, YELLOW
= lIo UJ
Â, RH BHAKE H BBAKE
:a
o
tu
E f,
J (tz)
=l
PEDAL PEDAL
@@
95 REDII/IOLET
o (t
"' \u .o \-/ swrrcH SWITCH
ET Y
q
=l CONNECTOR A CONNECTOR A a
i'. fis4
crr
3l
o @ DIFF LOCK
SOLENOID
CLUTCH DISENGAGE
INDICATOF LAMP
CLUTCH DISENGAGE REVERSE
INDICATOfi I-AMP INDICATOB lAlvlP
(18)
\-/
t\
q
\
TBANSMISSION
CONTBOL RELAY
o
/
a
I53
-J HED/IVHITE
FBONT PTO
@ 15S LTGREEN*''"I
@
@
EI
G.
ul
lll
E @ SOLENOID 4TH RANGE
YJ
POWERSHIFT
r;'ll ;i\ ACCESSORY

f
J
ut
3
FRONT
SOLENOID SOLENOID
SWTCH rNDrcAroB LAMP
c
Io PTO
Y;j o @
POWER HEI.AY to
Y RELAY
o o
/ .!! ta,
u,
\ii 1528 DKGAEENI/ I\

{
t--\ zo - YEttow- -z -- .2.
-
D
Eb
-\-i
. o
=
=
G,
to
IE
CD
6 !t
(o rO h CHASSIS GHOUND
kaukazz@yahoo.co.uk 3-92 Printei
Don 8-85042 lssued lssued $92 Printed in E-gland
4001-68
HEADIAMPS, TAIL IAMPS, TUHN SIGNAIJ1ruARNING I-AMPS, RIGHT HAND
CONSOLE LAMP AND HOHN FOR TRACTORS WITH CAB
Sectional lndex
Lef Hand Headlamp Circuit Test ,........." ..,.......".'...'... ... 71

Right Hand Headlamp Circuit Test ............ ...........'.......... 71
Headlamp Dimmer Relay Circuit Test ......".... ....'....'........ 72
Left Hand Front Turn SignalAVarning Lamp Circuit Test ..."...'...- -.. . . 73
Left Hand Rear Turn SignalAflarning Lamp Circuit Test .....".... ....-..-... 74
Right Hand Front Turn SignalilVarning Lamp Circuit Test ............-...... 74
Right Hand Rear Turn SignalArVarning Lamp Circuit Test ............ ..- -... 75
Right Hand Console Lamp (lf Equipped) .........,........-..... 76
Lamp Switch Test (Headlamp, Tail Lamp and Warning Lamp Circuits) ................ ........................ 78
Trailer Connector (Iail lamp and Warning Lamp) Circuit Test .......... .
............ ........ 78
Don &85042 lssued 3-92 Pnnted in England
kaukazz@yahoo.co.uk
4001-69
WIRING CODE
TO WIRE
REF COLOR FROM
GAUGE
Ether Start Solenoid 15
25 Brown Right Hand HeadlamP
15
25 Brown Ether Start Solenoid Chassis Ground
Connector D (Pin J) 16
41 Tan Fuse F13 '16
41 Tan Connector D (Pin J) Right Hand Console LamP
Chassis Ground 16
43 Brown Flasher RelaY (l-erm 4) 1a
Battery junction block Fuse F'1 7 IJ
94 Red/Dark Blue Lamp Switch fl-erm 83) 13
165 Red/Yeliow Battery junction block
Headlamp DipPer RelaY flerm 30) 13
166 Red Lamp Switch fterm HD)
Headlamp DiPPer RelaY fl-erm 56) 13
166 Red Headlamp DiPPer RelaY (1-erm 30) 1.)
.166 Red Headlamp DiPPer RelaY fl-erm 56) Fuse Fl 3
Chassis Ground 16
167 Brown Right Hand Console LamP
18
168 Brown/Pink Headlamp DiPper RelaY [Term S) Connector P flerm 2)
Dimmer/TurniHorn Switch 16
169 316i,v6,ANhite Connector P [t'erm 2)
16
17A Brown Dim mer/Turn/Horn Switch Connector P fi-erm 6)
Chassis Ground 16
170 Brown Connector P (i-erm 6)
15
Headlamp DiPPer RelaY fl-erm 568) Fuse F1 1
171 Red/Dark Blue 1q
172 Pin}</Dark Blue Fuse Fl 1 Connector B (Pin D)
1E
Left Hand HeadlamP (Low Beam)
172 Pink/Dark Blue Connector B (Pin D)
Connector B (Pin tf
rtr
IJ
172 Pink/Dark Blue Fuse F1 l Itr
IJ
Right Hand HeadlamP (Low Beam)
172 Pink Connector B (Pin V)
Fuse Fl 0 15
173 Bed/Dark Green HeadlamP DiPPer BelaY ft-erm 564)
Connector B (Pin E) 15
174 Pink/Dark Green Fuse F'10
Left Hand HeadlamP (High Beam) t5
174 PinUDark Green Connector B (Pin E)
Connector B (Pin V1/) 15
174 Pini</Dark Green Fuse Fl0 "15
Right Hand HeadlamP (High Beam)
174 PinUDark Green Connector B (Pin W)
Chassis Ground 15
175 Brown Left Hand HeadlamP
15
Lamp Switch fl-erm 81)
176 Red/YellowAilhite Battery Junction Block
(From Pin No JJF1004670)
Front Cab Work LamP RelaY f-erm 30) t3
176 g"61Ys11ev/A/Vhite Battery Junctron Block
(Up To Pin No JJF1004670)
1C
176 Redl/ellowlWhite Front Cab Work Lamp Relay fl-erm 30) Lamp Switch fi-erm 81) IJ
(Up To Pin No JJF]004670)

177 Red,Mhrte LamP Switch flerm I Fuse F9 1 8
'178 PinkAVhite Fuse F9 Connector D (Pin V) 18

Connector N (Pin D) 18
178* PinkAVhite Connector D (Pin V)
178 PinkMhite connector N (Pin D) Splrce 18
178 PinkMhite SPlice Lefl Hand Tail LamP fl"erm A) 18
178 PinkAVhite SPlice Right Hand Tail LamP (1'erm A) "lB
178 PinkMhite SPlice Trailer Connector fierm 6) '18
179 Brown Left Hand Tail Lamp [T-erm B) Chassis Ground 18
180 Brown Right Hand Tail Lamp (Term B) Chassis Ground '18
181 Prnl'</Red Fuse F17 Flasher Relay fl-erm 2) 15
182 White/Red LamP Switch [erm W) Fuse F6 1 8
183 Pink/Black Fuse F6 Flasher Reiay fl-erm 1) 18
184 Red/Black Keyed Power Junction Block Fuse F5 15
185 Pink/Yellow Fuse F5 Connector P (i'erm a) 15
186 BlackAVhite/Green Connector P fferm 4) Dimmer/Turn/Horn Switch 16
187 Black&Vhrte Dimmer/Turn/Horn Swttch Connecror p fferm 5) i6

188 Pink Connector P fl-ern" 5) Flasher Relay fTerm 7) 15
188 Pink Flasher RelaY flerm 7) Connector D (Pin S) 15
i g8" pink Connector D (Pin S) Splrce 15
fi ght Hand Front Turn SignalAVarning 16

1BB* Pink SPltce
Lamp fierm A)
lssued 3-92 Prinled in Englano

Don 8-85042
kaukazz@yahoo.co.uk
400 1 -70

GAUGE
188* Pink Splice Right Hand Rear Turn SignalAffarning 16
powrquadplus www.thebestworkshopmanuals.co.uk Lamp fl-erm A)
188* Pink Splice Connector N (Pin B) 16
1BB Pink Connector N (Pin B) Trailer Connector (Pin 5) 16
1B8A Pink Connector D (Pin S) Left Hand Front Turn SignalA&arning 16
Lamp
188A Pink Left Hand Front Turn SignalMarning Left Hand Flear Turn SignalAVarning 16
Lamp Lamp
188A Pink Left Hand Rear Turn SignalAVarning Connector N (Pin B) 16
Larnp
189 Brown Right Hand FrontTurn SignalMarning Chassis Ground 16
Lamp fierm B)
'190 Brown Right Hand Rear Turn SignalMarning Chassis Ground 16
Lamp fl-erm B)
191 BlacfVGreen Dimmer/Turn/Horn Switch fl-erm R) Connector P fl-erm 1) 16
192 Pink/Dark Green Connector P fferm 1) Flasher Relay fl-erm 5) 15
192 Pink/Dark Green Flasher Relay (1-erm 5) Connector D (Pin R) 15
192* Pink/Dark Green Connector D (Pin R) Splice 15
192* PinUDark Green Splice Left Hand Front Turn SignalflVarning 16
Lamp (Ierm A)
192" PinlVDark Green Splice Left Hand Rear Turn Signal/Warning 16
Lamp fl-erm A)
192* Pink/Dark Green Splice Connector N (Pin A) 16
192" Pink/Dark Green Connector N (Pin A) Trailer Connector (Pin 3)
192A PinUDark Green Connector D (Pin R) Left Hand Front Turn SignalAVarning 16
Lamp
192A PinUDark Green Left Hand Front Turn SignalA#arning Left Hand Rear Turn SignalAilarning 16
Lamp Lamp fl-erm A)
192A Pink/Dark Green Left Hand Rear Turn Signal,&Varning Connector N (Pin A) 16
Lamp
193 Brown Left Hand Front Turn SignalMarning Chassis Ground 16
Lamp flerm B)
193A Brown Right Hand Front Turn SignalAVarning Left Hand Front Turn SignalflVarning 16
Lamp Lamp
194 Brown Left Hand Rear Turn Signal,&Varning Chassis Ground 16
Lamp Oerm B)
194A Brown Bight Hand Rear Turn SignalMarning Left Hand Rear Turn SignalMarning 16
Lamp Lamp
195 Gray/Red Fuse F17 Connector B (Pin S) 16
\? 195 Gray/Red Connector B (Ptn S) Horn 16
196 Brown/Orange Horn Connector B (Pin T) 1B
196 Brown/Orange Connector B (Pin f) Connector P fl-erm 3) 1B
197 Black Connector P fl-erm 3) Dimmer/Turn/H orn Switch 16
NOTE: Wire code references marked (*) are for tractors up to cab serial No JKJ46968.
178* Pink (708)
188* Pink (766)
192* Pink (765)
NOTE: Wre code referencces marked'A' are lor tractors from cab seria/ No JKJ49144.
kaukazz@yahoo.co.uk
4001-71
CIRCUIT TESTING
NOTE: The battery must be atfull charge and alt connections must be clean and tight before testtng. Use a multimeterfor
the tests.
Lefl Hand Headlamp Circuit Test

NOTE: Check Fuse F10 and F11 and the left hand headlamp bulb.
NOTE: Turn the lamp switch ta the HEADIAMP position and aperate the dimmer switch to the LOW BEAM position
Check Points Bcading Possible Cause of Bad Reading
Terminal for wire 172 Pinl4Oark Blue to 12 Volts Bad circuit between the left hand headlamp
ground (low beam) and the headlamp dimmer relay
terminal 568 Also check the headlamp
dimmer relay, dimmer/turn/horn switch and
the lamp switch circuits.
NOTE: lf the ilght hand headlamp low beam warks correctly, check wire 172 befween fuse F11 and the left hand
headlamp,
NOTE: Operate the dimmer switch to the HIGH BEAM pasition
Termina for wire 174 Pink/Oark Green to 12 Volts Bad circuit belween the left hand head lamp
ground (hrgh beam) and the headlamp dimmer
relay terminal 564. Also check the
headlamp dimmer rclay dimmeriturn/horn
switch and the lamp switch circuits
NOTE, lf the right hand headlamp htgh beam works correctly, check wlre 174 between fuse F10 and the left hand
headlamp
fermrnal for wire 175 Brown to ground Contrnuity Check wire 175 and the chassis ground
O connection.
Right Hand Headlamp Circuit Test

NOTE: Check fuses F1O and F11 and the right hand headlamp bulb
NOTE: Turn the lamp switch to the HEADLAMP position and operate the dimmer switch ro the LOW BEAM positron
6 Terminal ior wire 172 Pink 1o ground 12 Volls Bad circuit betlveen the right hand
headlamp (low beam) and the headlamp
dirnmer relay terminal 568 Also check thc
headlamp dimmer relay, dimmer/turn/horn
NOTE: lf the left hand headlamp low beam works correctly, check wire 172 between fuse F10 and the ilght hand
headlamp .
Don 8-85042 Lss.red 3-92 Prrnled in Englard
kaukazz@yahoo.co.uk
40a1-72
NOTE: Operate the dimmer switch to the HIGH BEAM posrtion
'12 Volts Bad cjrcurt befrveen the left hand headlamp

ferminal for wire 174 Pinl4Black to ground
O (high beam) and the headlamp dimmer
relay terminal 56,4 Also check the
headlamp dimmer relay, dimmerfiurnlhorn
switch and the lamp switch circuits.
NOTE: lf the left hand headlamp hrgh beam works correctly, check wire 174 between tuse F10 and the left hand
headlamp.
Q connection.
Headlamp Dimmer Relay Circuit Test

NOTE: Turn the lamp switch to the HEADUMP pasition.
Check ooints Reading Possible Cryse o!_Bad Reading
Terminal for wire 166 Red to ground 12 Volts Bad circuit between the headlamp dimmer
@ relay and the lamp switch. Also check the
Iamp switch
Gl Terminal for wire 166 Red to ground 12 Volts Check wire 166 between terminals 30 and
56 of the headlamp dimmer relay
NOTE: Turn the lamp switch ta the OFF posttion and hold the dimmer swrtch in the HIGH BEAM positton
ferminal for wire 168 Brown to ground Cont nuily Bad circuit Lretween the headlamp dimmer
@ relay terminal S and the chassis ground
connection. Also check the dimmer/turn/
horn switch and the chassis ground
connection
NOTE: Turn the tamp switch to the HEMLAMP position and operate the dimmer switch to the LOW BEAM position
Terminal for wire '1

7'1 Red/Dark Blue to 12 Volts Bad dimmer relay
ground
NOTE: Operate the dioper swilch to the HIGH BEAM positlon
ror wire 173 Red/Dark Green to 12 Volts Bad dimmer relay

@ I:;n:"l
D.. 8-u50.i2 lssued 3-92 Prirled in England
kaukazz@yahoo.co.uk
4001 -73
Left Hand Tail LamP Circuit Test
NOTE: Check Fuse F9 and the left hand tatl lamp bulb.
HEADLAMP posltton
NOTE: Discannect the teft hand tail lamp from the harness and turn the tamp switch to the
Check points Beading Possible Cause of Bad Reading
Terminal for wire 178 PtnkANhite or Pink 12 Volts Bad circuit between the left hand tail lamp
(708) to ground and the Iamp switch. Also check the lamp
switch
teft hand tarl lamp and the splice

NOTE: tf the right hand tait lamp works correctly, check wire 178 between the
lF rerminal for wlre 179 Brown to ground Continurty Check wire 179 and the chassis ground
:onrectio'l
Right Hand Tail LamP Circuit Test

NOTE: Check Fuse FO and the rtght hand tail lamp bulb'
NOTE: Discannect the riqht hand tall lamp from the harness and turn the lamp switch to the HEADUMP position
Terrnrnar for wire 178 pinkAVhite or pink r 2 vo ts Bad circuit between the right hand tail lamp
(708) to ground and the lamp switch Also check the lamp
switch
lamp and the sphce

NOTE: lf the left hand tatl lamp works correctly, check wire 178 between the right hand tail
lB Turr,nrl for wire 180 Brown to ground Continuity Check wire 180 and the chassis ground
connectro.l
Left Hand Front Turn signal/warning Lamp circuit Test

NoTE: check Fuses F5, F6 and F17. Nso check the left hand front turn signatlwarning lamp bulb
harness'
NOTE: Disconnect the lefl hanc front turn signallwarning lamp f rom the
Reading Possib e Cause of Bad Readrng
Check potnts
Contrnuity Bad chassis ground circuit Also check the

Terminalfor wire 193 Brown to ground
@ chassis ground connection
NOTE: Turn the lamp switch ta the WARNING UMP pos/f/on
or
Terminar for wire 1g2(A) 12 Vorts Bad circuit between the flasher relay and thc
pink/Dark Green
Pink(765)togroundoN-oFF-oNlefthandfrontturnsrgnal/warning|amp
connector terminal A Also check the
flasher relaY
the teft hand f ront turn signallwarnlng lamp and

NOTE: lf the left hand rear warning lamp works, check wire 192 be[reen
the sp/ice (tractars up to cab serra/ No JKJ49144 onl'i)
ssucc 3.92 )r1.ied rn E.glanC

Dc^ 8'85C42
kaukazz@yahoo.co.uk
4001-7 4
NOTE: Turn the key to the ON position and put the turn signal switch in the RIGHT turn position.
Check points Reading Possible Cause of Bad Feading
Terminal for wire 192(A) Pink/Dark Green or 12 volts Bad circuit befween the f lasher relay and the
Pink (765) to ground crmmer/turn/horn switch. Also check the
dimmer/turn/horn switch.
Left Hand Rear Turn Signal/YVarning Lamp Circuit Test

NOTE: Check Fuses F5, FO and Fl7. Nso check the left hand rear turn signal/warning lamp bulb.
NOTE; Disconnect the left hand rear turn signallwarning lamp from the harness"
Termlnal for wire '194 Brown to ground Continuity .1

Check wire 94 and the chassis ground
G) connectron
NOTE: Turn the lamp switch to the WARNING AMP positton
Terminal for wire 192(A) Pink/Dark Green or 12 Volts Bad circuit between the flasher relay and the
Pink (765) to ground ON-OFF-ON left hand rear turn signal/warning lamp
connector terminal A. Also check the
flasher relay
NOTE: lf the teft hand f ront warning lamp works, check wire 192 between the left hand rear turn signallwarning lamp and
fhe sp/ice or wire 192A between the left hand front and left hand rear turn stgnallwarning lamps.
NOTE: Turn the key to the ON position and put the turn stgnal switch rn the RIGHT turn position.
Terminal for wrre 192(A) PinUDark Green or 12 Volts 8ad circuit between the f lasher relay and the
Pink (765) to ground dimmerhurnlhorn switch. Also check the
dimmer/turn,/irorn switch.
Right Hand Front Turn SignalMarning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and F17. Also check the right hand front turn signallwarnrng lamp bulb
i NOTE: Disconnect the ight hand front turn signallwarning lamp from the harness.
Terminal for wire I89 Brown or 193A Brown Continuity Bad chassis ground circuit. Also check the
to ground chassis ground connectton
NOTE: Turn the lamp switch ta the WARNING IAMP pasition
Terminat for wire i 88(A) Pink or Pink (766) to 1 2 Volts Bad circuit between the f lasher relay and the
ground ON.OFF_ON right hand front turn signal/warning lamp
flasher relay
NOTE: lf therighthandrearwarninglampworks,checkwirelSSbetvveentherighthandfrontturnsignallwarninglamp
and the splice (tractars up to cab serial No JKJ49144 only)
Dor B-850a2 lssued 3-92 Prinled in England
kaukazz@yahoo.co.uk
4001 -75
NOTE: Turn the key to the ON poslfion and put the turn signal switch in the LEFT turn position
Terminalfor wire 1 gB(A) pink or pink (766) to 12 Volts Bad circuit between the flasher relay and the
ground dimmer/turnlhorn switch. Also check the
Right Hand Rear Turn signal/warning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and F17. Nso check the right hand rear turn signallwarning lamp bulb.
NOTE: Disconnect the right hand rear turn signallwarning lamp from the harness.
Check points Readinq Possible Cause of Bad Reading
Terminal for wire 1 90 Brown or 194A Brown Continurty Bad chassis ground circuit. Also check the
to ground chassis ground connection
NOTE: Turn the lamp switch to the ryARNING UMP position
Terminal for wire l gg(A) pink or pink (766) to Volts

12 Bad circuit betwecn the f lasher relay and the
ground ON-OFF-ON right hand rear turn signal/warning lamp
flasher relay
NoTE: tftherighthandfrontwarninglampworks,checkwirelSSbeweentherighthandrearturnsignallwarninglamp
lamps.
and the splrcJ or wire lBBAbetween the right hand front and rrght hand rear turn signallwaflng
NOTE: Turn the key to the oN position and put the turn signal switch in the LEFT turn positton.
Terminal for wire l gg(A) pink or pink (766) to 12 Volts Bad circuit between the flasher relay and the
ground dimmer/turn/horn switch. Also check the
dimmer/turn/horn switch
Flasher Relay Circuit Test

NOTE: Check Fuses F5, FO and F17
ferminal for wire 181 PrnVRed to ground 12 Volts Bad circuit between the battery junction
4) block and the flasher relay terminal 2 Also
check the junction block connection'
NOTE: Turn the lamp switch to the WARNING LAMP position
ferminalfor wire 183 Plnt</Black to ground 12 Volts Bad circuit between the lamp switch
6) terminal W and the flasher relay terminal 1'
Also check the lamP switch.
NOTE: Disconnect the ftasher relay from the harness
@ connection
ssued 3-92 Printed in England

3on 8-85042
kaukazz@yahoo.co.uk
4001 -76
Clect<
powrquadplus points
www.thebestworkshopmanuals.co.uk Reading Possible Cause of Bad Reading
Terminal for wire 192 Pink/Dark Green to 12 Volts Bad flasher relay.
ground ON-OFF-ON
NOTE: Put the turn signalswrtch in the RIGHT turn position
Terminal for wire 192 Pink/Dark Green to 12 Volts Bad circuit between the dimmer/turn/horn
ground switch and the flasher relay terminal 5. Also
check the dimmer/turn/horn switch.
6D Terminal for wire 188 Pink to ground 12 Volts Bad flasher relay.
ON_CFF-ON
Horn Circuit Test

NOTE: Disconnect the horn from the harness.
(t{ Terminal for wire 195 Gray/Rcd to ground 12 Volts Bad circuit between the battery junction
block and the horn. Also check the battery
junction block connection.
NOTE: Press and hold the horn switch in the H]RN position.
Terminal for wire 196 Brown/Orange to Continuity Bad circuit between the horn and the
ground chassis ground connection. Also check the
drmmer/turn/horn switch and the chassis
ground connection.
Right Hand Console Lamp

(lf Equipped)
NOTE: Check Fuse F73 and the right hand console butb.
6D ferminal for wire 167 Brcwn to ground Contrnuity Check wire 167 and the chassis ground
connection.
NOTE: Turn the lamp switch to the HEAD UMP position
6l!l Terminal for wire 41 Tan to ground 12 Volts Bad circuit between the dimmer relay
terminal 56 and the right hand console
lamp.
Don 8-85042 lssued 3-92 Prrnied in Ergland
kaukazz@yahoo.co.uk
4001-77
Dimmer/Turn/Horn Switch Test
NOTE: Disconnect the dimmerlturnlhorn switch from the harness at connectar P and turn the key to the ON position.
Check points Reading Possible Cause of Bad Beading
ferminal for wire 185 PinkA/ellow to ground I2 Volts Bad circuit belween the keyed power
@ lunction block and the dimmer/turn/horn
switch
.1
fermrnal for wire 70 Brown to ground Contnuity Check wire 70 and the chassis ground
.1
@ connection.
NOTE: Operatethedipperswitchuntit acontinuityreadingisobtainedbefweenterminals2and6ofConnectorP(switch

a contrnuity readlng can not be obtained reptace the dimmerlturnlhorn switch
side) . lf
NOTE: Operate the dimmer switch agarn
Belween terminals 2 and 6 of connector P No Continuity Bad dimmer/turn/horn switch

(switch side)
NOTE: Putthe turn signalswrch rn the RIGHT TURN position'
Between terminals 4 and 5 of connector P continuily Bad dimmer/turn/horn switch

(switch srde)
NoTE; Put the turn signal switch in the GFT TURN positron'
Between terminals 4 and I of connector P Continuity Bad dimmer/turn/horn switch'

(switch side)
NOTE: Press and hotd the horn switch in the HORN position'
BeMeen terminals 3 and 6 of connector P Continuity Bad dimmer/turn/horn switch'

(switch side)
Occ 8-85042
lssuei 3-92 Prinled in Englaro
kaukazz@yahoo.co.uk
4001,78
Lamp Switch Test (Headlamp, Tail Lamp and Warning Lamp Circuits)
NOTE: Dlsconnect the lamp switch from fhe harness.
Check points Rcading Possible Cause of Bad Reading
dl Terminal for wrre 165 Fed/Yellow to ground 12 Volts Check wire 165 and the battery junction
block connection.
Terminal for wire 176 Fed//eilowMhite to 12 Volts Check wire 176 and the battery junction
ground block connectron
NOTE: Turn the lamp switch to the WARNING UMP position.
Betlveen termrnals B1 and W of the lamp Continuity Bad lamp switch

switch
NOTE: Turn the lamp switch to the HEADLAMP position.
Between terminals 81 and W of the lamp Continuity Bad lamp switch

switch
Between terminals Bl and T of the lamp Continuity Bad lamp switch.

switch
Between terminals 83 and HD oi the lamp Continuity Bad lamp switch

switch
NOTE: Turn the lamp switch to the REAR FENDER WORK UMP position.
Between terminals 83 and HD of the larnp Continuity Bad lamp switch.

switch
NOTE: Turn the lamp switch to the CAB WORK UMP positton
Between terminals 83 and HD of the lamp Continuity Bad lamp swttch.

switch
Trailer Connector Circuit Test ffail Lamp and Warning Lamp Circuits)
! NOTE: Turn the lamp switch to the HEADUMP position.
Check points Eeading Possible Cause of Bad Reading
lEl Terminal for wrre 178 PinkAVhrte to ground 12 Vo{ts Check wire 178 between the trailer
connector pin 6 and the splice
NOTE: Turn the lamp switch to the WARNING UMP position
@ rermlnal for wire 1BB Pink to ground 12 Volts Check wire 188 between the trailer
ON-OFF-ON connector pin 5 and the splice or the right
hand rear turnsignal/warning lamp.
Terminal for wire 192 Prnk/Dark Green to 12 Volts Check wire 192 between the trailer
ground ON-OFF-ON connector pin 3 and the splice or the left
hand rear turnsignal/warning lamp.
Dcn 8-85042 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001. 4001-79
--Jn
Schematic Circuit
BATTERY
*H*
"dJ-*
^-c-u tlr-.o
^r
KEYED POVYI KEYED POWEB
( I
TRAILER coN'I{EcToR
W qW JUNCTION BLOCK JUNCTION B
Uied to rol
JUNCTION BLOCK
Used to route keyed
HORN
Emits soul HEADLAMP DIMMER HELAY HEADLAMP DIMMER BELAY
sPt_tr=
LAMP
Produces heat that emits
SOLENOID {ETHEH !
heat lhat emits
SoLENOTD {ETHER SIAnT)
I
Connects the hactor electrieal

Used to route battery DIMM EH/I..HH SIGI'IAUHOBN FLASHER RELAY Cmreris one or more A rnagnetic coil A magnetic coil that circuit lo a trsitbr
CHASSIS GHOUND CHASSIS GBOUND FOTARY SWTTCH (I-AMP p0tiYgf potYer A rnagnetic switch that dkecis A ntagnetic switch that dkects artifical light
sw{TcH Electrical device which cirais that do the same
Completes battery
POU/er REI.AY 30 AMP swTcH) electric current c( eleclric current CONNECTOR D actuates a hydraulic ! acluates a hydraulic valve
Completes battery Controls ms'e than one circuit opens and closes a circuil funfut
A magnetic switch thd
CONNECTOR P circuit circuit
dirac.ts electric current
Directs eleckical current to continually when actuated
Cr Cab harness lo instrumenl
Dimmerltum CONNECTOH N one or more circuils ha harness
signal/lnm svritch to Cab harness to fender
instument hamess hamess
CONNECTOR B
to
. ,- Turn SiganlAVarrtng Lamp Wiring Headlamp Wirinl Headlamp Wiring
Tail Lamp V{iring
Engine harness inslrument
hamess BATTERY JUNCTION BLOCK (POWEB) BATTERY JUNCTION BLOCK (POWEA}
o KEYED POWEI1 JUgfiON ELOCK
I78 PINKIWHTE 178 PINK,WHITE

FUSE
177 HEDMHTTE 1rc REDNK GREE}'.
Protscts the electrical
systom from high 171
ot tprJt or a ground in
the electrical system @
(, WT.W R,ISE F
o o-*
177 CONNEGTOB
e
178
@\ }ii%
rzoff.,r$=_
I-
I
DIMMER/TURN/HORN SY.IICH
L
ir
trl UJ
.t74 PINruBLACK
174 PINI(DK GREEN

174 PINISBLACK
174 PINI(DK GREEN
{
"5L
tu lu 172 PINK
E (5
TE
I o 172
god6'UM g
Ur HEADI.AMP DIMMEH RE1AY o
Y
C] r'@ CONNECTOB D
ryE3
8B
J Y
o
5
Q
o zI
>
il!t d!+ LH
HEADLAMP
RH
HEADI.AMP
Eg
F. i-
()
@ <-178 PINK^VHIfE
UI
d 197 _l/ LowBE
y
u,
fJ
oR P|NK (708)
EI I
3 169 16 BIACIVWHTTFJGREEN I 173 RED/DKGREEN
BEAM HIGH BEAM c)
tU
F
A
rfl:n:ffirt o {
171 RED/I]K BLUE
o 175
Y
o
P
z
=
3
z
CONNECTOR N
f, colrNeo
*@
CONNECIOB P o- E
FRONT CAB WORK
'rusrre) ruserQ
(\' @
@f
FUSE F5 o, i-
INMP REIAY FUSE F17
CONNECTOR N {-- 17S PINKWHITE
(UP TO PIN No
JJF1004670) €)(
,*t,**r,-ow *l
@E € @ {
'ts2 PTNwDK BLUE OR PINK (7E6)
. t- -
JL
,88 PINK OH PINK (765)
-r
t92 PlNl(DK BLUE OR P|NK
- 188 PINK OH PINK (765)
-l
1766) ,r, I
|
--l
H
BROWNiPTNK-
,88 188
i\ ENGINE HAI1I ENGINE HA11NESS

195 GRAYIRED GRAY/BED -1S8
HORN
HIGI"{T HAND
I I
=i[ .^ \.
CONNECTOR B @ CONSOLE I.AMP
IF EQUIPPED
1../::\
196 tsROWN/ORANGE
1€I{' PINIqBLACK qBLACK
6DT
\--l I
ETHER STAFIT SOLENOID
V\.\
L H TURN SIGI'IAL/
@@ @ @
d
LEFT HAND
WABNING LAMP$ WARNING I-AMPS LAMPS
TAIL ISMP
NK
BEAR FRONT REAR FEAR
192 PINI(/DK BLUE NI(DK BLUE
188 PINK NK 188 PINK OR PINK Ll
&$
:l
| lj i t\ 1s2 PlNlgDK BLUE - NI(DK BLUE r92 PlNtgDK BLUE OH PINK 1265)
@.-.*
CONNECTOR D
,i'ta - z 1z
N IP o
=
\ 1S4A J
1t o
ER.HARNESS
_,
*f -.?
.., iir
fE
ID
t-
@
=
CE
ID
i- 1S3 BHOWN 194 BHOWN 189 BROWN 190 BROWN
EE
1.,- Itl
N 190 BROn/N
EE
@
kaukazz@yahoo.co.uk CHASSIS GROUND CHASSIS GROUND

Don 8*85042 lssued 3-92 Printed in E
4001-80
HEADrsMp, rArL *rr+JX3No?SU,iffil[? r-AMp AND HoHN FoR
Sectional lndex
Left Hand Headlamp Circuit Test ........... ................ ........ 82

Right Hand Headlamp Circuit Test ............ ...................... 83
Headlamp Dimmer Relay Circuit Test ........... .................. 84
Left Hand Fender Turn SignalArVarning Lamp Circuit Test ......,........... 85

Right Hand Fender Turn SignalArVarning Lamp Circuit Test ................ 85
Lefl Hand Front CanopyTurn SignalMarning [-amp Circuit Test ............ ................. 86
Left Hand Flear Canopy Turn SignalArVarning Lamp Circuit Test ........... .................. 86
Right Hand Front Canopy Turn SignalflVaming Lamp Circuit Test ........... ............. . 87
Right Hand Hear Canopy Turn SignalAVaming Lamp Circuit Test ........... ................ 87
Lamp Switch Test (Headlamp, Tail Lamp and Warning Lamp Circuits) ................. ...................-.... 90
Trailer Connector fl-ail lamp and Waming Lamp) Circuit Test ............. 90
Don &85&12 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001-81
WIRING CODE
qEF COLOR FHOM TO WIRE
25 Brown GAUGE
Right Hand Headtamp Ether Start Solenoid
25 Brown Ether Start Solenoid Chassis Ground
15
43 Brown Flasher Relay (Term 4) Chassis Ground
15
94 Red/Dark Btue Baftery Junction Block Fuse F1 7
'16
165 Red/yeilow Batlery Junction Block Lamp Switch (Term 83)

13
166 Red Lamp Switch fl'erm HD) Headlamp Dimmer Relay
13
166 Red Headlamp Dimmer Retay fterm 30) fierm 30)
Headlamp Dimmer Relay fi'erm 56)
13
168 Brown/pink Headlamp Dimmer Relay fl-erm S) Connector P fl-erm 2)
13
169 Brownlilhite Connector P fferm 2) Dimmer/Turn/Horn Switch
18
170 Brown Dimmerflurn/Horn Switch Connector P fl-erm 6)
16
170 Brown Connector P fi-erm 6) Chassis Ground
16
171 Red/Dark Bluc Headlamp Dimmer Retay fl-erm 568) Fuse Fl 1
16
172 Pink/Dark Btue Fuse F1 1
Connector B (pin D)
15
172 PinVDark Btue Connector B (Pin D) Left Hand Headtamp (Low Beam)
15
172 Pink/Dark Btue Fuse F1 1 Connector B (Pin \z)
15
172 Pink Connector B (Pin V) Right Hand Headtamp (Low Beam)
15
173 Red/Dark Green Headlamp Dimmer Retay fierm 564) Fuse Fl0
15
174 PinlVDark Grecn Fuse F]0 Connector B (pin E)
15
174 PiniVDark Green Connector B (Pin E) Lelt Hand Headtamp (High Beam)
15
174 Pink/Dark Green Fuse F10 Connector B (Pin W)
15
17 4 Pink/Btack Connector B (Pin W)
15
Right Hand Headlamp (High Beam)
175 Brown Left Hand Headlamp Chassis Ground
'15
176 Red//eltowAVhite Battery Junction Block Lamp Switch (Term Bt )

15
15
(From Pin No JJF1004670)
176 Redl/ettowAVhite Battery Junction Block Left Hand Fuse Relay Block 15
176 Red/yeilowAVhite Left Hand Fuse Relay Block Lamp Switch fl-erm 81) 15
177 RedMhite Lamp Switch ft'erm T) Fuse F9
178 Pink/White Fuse F9 Connector D (pin V)
18
178 Pint<r]lVhite Connector D (pin V) Connector N (Pin D)
18
178 PinkAffhite Connector N (pin D) Fender Harness Splice
18
178 Pinkrtflhite Fender Harness Splice Left Hand Tail Lamp (T-erm A)
18
178 PinklrVhite Fender Harness Splice Bight Hand Tait Lamp fl-erm A)
18
178 PinklrVhite Fender Harness Splice Trailer connector (pin 6)
18
179 Brown Left Hand Tail Lamp fi'erm C) Chassis Ground
18
180 Brown Right Hand Tail Lamp ft'erm C) Chassis Ground
18
181 PinlVHed Fuse Fl 7 Flasher Relay fl-erm 2)

1B
182 White/Bed Lamp Switch fl-crm W) Fuse F6

15
183 PintVBtack Fuse F6 Flasher Retay (Term 1)

18
to
184 Red/Black Keyed Power Junctron Block Fuse F5
185 Pinkl/eltow Fuse F5 Connector P (Ierm 4)
15
186 BlackAffhite/Green Connector P fT'erm 4) Dimmer/Turn/Horn Switch
t5
187 BlactrMhite Dimmer/TurnlHorn Switch Connector P (1'erm 5)
16
I88 Pink Connector P fierm 5) Flasher Relay ft-erm 7)

16
188 Pink Flasher Relay fl,erm 7) Connector D (Pin S)

15
188 Pink Connector D (Pin S) Splice

15
188 Pink Splice

15
'l88 Pink Connector N (Pin B)
Connector N (Pin B) 16
Fender Harness Splice '18
188 Pink Fender Harness Splice Right Hand Turn Signat,&Varning Lamp 18
I BB
fierm B)
Pink Fender Harness Trailer Connector (pin 5)
188 Pink Splice Canopy Extension Harness fierm B)
18
188 Pink Canopy Extension Harness fl"erm B) Canopy Extension Harness Splice
16
l6
Don 8-85042
tssued 3-92 printed in England
kaukazz@yahoo.co.uk
400'1-82
BEF COLOB FROM TO WIRE
GAUGE
188 Pink Canopy Harness Splice Right Hand Front Canopy Turn 18
SignalAVarning Lamp fl-erm A)
188 Pink Canopy Harness Splice Right Hand Eear Canopy Turn 18
SignalAVarning Lamp (I'-erm A)
191 Black/Green Dimmer/Turn/Horn Switch Connector P fl-erm 1) to
192 PinUDark Green Connector P flerm 1) Fiasher Relay (l-erm 5) t5
192 PinlVDark Green Flasher Relay flerm 5) Connector D (Pin B) 15
192 PinVDark Green Conncctor D (Pin R) Splicc 15
192 Pint</Dark Green Splice Connector N (Pin A) 18
192 PinVDark Green Connector N (Pin A) Fender Harness Splice 18
192 Pink/Dark Green Fender Harness Splice Left Hand Fender Turn Signal,Marning 18
Lamp (Term B)
192 Pinl</Dark Green Fenoer Harness Spllce Trailer Connector (Pin 3) 18
192 PinVDark Green Splice Canopy Extension Harness fl-erm A)
.16
192 Pink/Dark Green Canopy Extension Harness (Term Splice 16

A)
192 PinlV:Dark Green Splice Left Hand Front Canopy Turn Signal/ lo
Warning Lamp fl-erm A)
"195 Gray/Red Fuse Fl 7 Connector B (Pin S) 16
195 Gray/Red Connector B (Pin S) Horn
.16
196 Brown/Orange Horn Connector B (Pin T) 16

196 Brown/Orange Connector B (Pin I Connector P (Pin 3) 16
197 Black Connector P (Pin 3) Dimmerflurn/Horn Switch 16
198 Brown Right Hand Bear Canopy Turn Chassis Ground 16
SignalAffarning Lamp (1-erm B)
199 Brown Right Hand Front Canopy Turn Chassrs Ground lr)
Signal,4Varning Lamp fl-erm B)
200 Brown Leil Hand Rear Canopy Turn Chassis Ground lo
Signal,Marning Lamp (Term B)
2U Brown Lefi Hand Front Canopy Turn Chassis Ground 16
SignalrWarning Lamp (Term B)
CIRCUIT TESTING
NOTE: The baftery must be at lull charge and all connecttons must be clean and tight before testing. Use a multimeter for
the tesls.
Left Hand Headlamp Circuit Test

NOTE: Check Fuse F1a and F11 and the left hand headlamp bulb
NOTE: Turn'the lamp switch to the HEADUMP posrtion and operate the dimmer switch to the LOW BEAM posiilon
Terminal for wlre 172 PinVDark Blue to 12 Volts Bad circuit between the left hand headlamp
terminal 568 Also check the headlamp
dimmer relay, dimmeriturnihorn switch and
the 'arrp swiich c'curts
NOTE: lf the nght hand headlamp low beam works correctly, check wire 172 between fuse F1 1 and the left hand
headlamp,
Don 8-85042 issued 3'92 Prinled ir Eng and
kaukazz@yahoo.co.uk
4001 -83
NoTE: operate the dimmer swtch to the H|GH BEAM positton
Check Points Be4ing
to 12 Volts Bad circuit between the left hand headlamp

Terminal for wire 174 PinVDark Green
(high beam) and the headlamp dimmer
ground
ieriy terminal 56A. Also check the
headlamp dimmer relay, dipper/turn/horn
switch and the lamp switch circuits'
NoTE:lftherighthandheacjtamphighbeamworksCarrectly,checkwirelT4beNveenfuseFlOandthelefthand
headlamP .
ContinuitY Check wire 175 and the chassis ground

ferminal for wire 175 Brown to ground
O connection.
Right Hand HeadlamP Circuit Test

hand headlamp bulb
NOTE: Checkfuses F70 and F11 and the right
NOTE:TurnthelampswitchtotheHEADLAMPpositionandoperatethedimmerswitchtotheLoWBEAMposition
Reading Possible Cause of Bad Reading
Check Potnts
I2 Volts Bad circuit between the right hand head

ferminal for wire 172 ?\nk to ground lamp (iow beam) and the headlamp dimmer
?
switch and the lamp switch circuits'
F10 and the right hand

works correctly' check wire 172 between fuse
NOTE: lf the left hand headlamp low beam
headlamp .
BEAM position'
NOTE: Operate the dimmer swltch to the HIGH
12 Volts Bad circuit between the left hand headlamp
Terminal for wire 174 Pink/Black to ground (high beam) and the headlamp dimmer
O
ief iV terminal 564. Also check the
F1O and the left hand

works correctlY' check wire 174 between fuse
NOTE: It the left hand headlamP hrgh beam
headlamp.
ConiinuilY Check wire I75 and the chassis ground

@ conncction
lssueci 3-92 Printeo in Engla'd

Don 8-850a2
kaukazz@yahoo.co.uk
4001-84
NOTE: Turn the lamp switch to the HEADUMP position.
Check points Readilg Possible Cause of Bad Reading
Terminal for wire 166 Red to ground 12 Volts Bad circuit between the headlamp dimmer
@ relay and the lamp switch. Also check the
lamp switch
ferminal for wire 166 Red to ground 12 Volts Check wire 166 between terminals 30 and
@ 56 of the headlamP dimmer relaY
NOTE: Turn the lamp swttch to the OFF position and hotd the dimmer swtch in the High Beam position.
Termlnal for wire 168 Brown to ground Continuity Bad circuit between the headlamp drmmer
@ relay terminal S and the chassis ground
connection
NOTE: Turn the lamp switch to the HEADLAMP position and aperate the dimmer switch to the LOW BEAM position
Terminal for wire 171 Red/Dark Blue to 12 Volts Bad dimmer relay
ground
NOTE: Operate the dimmer switch to the HIGH BEAM position.
o Terminal for wire 173 Red/Dark Green

ground
to 12 Volts Bad dimmer relay
Tail Lamp Circuit Test

NOTE: Check Fuse F9 and the tail lamp bulbs
NOTE: tf the 1ght hand tait lamp works correctly, check wire 178 between the left hand tail lamp and the splice-
NOTE: tf the left hand tail lamp works conectly, check wire 178 between the right hand tait lamp and the sptice.
NOTE: Disconnect the tait lamps from tf,e harness and turn the lamp switch to the HEADUMP position.
Terminal for wire 178 Pink&Vhite to grotnd 12 Volts Bad circuit between the left hand tail lamp
C) and the lamp switch. Also check the lamp
switch
Gl terminal for wire 179 Brown to ground Continuity Check wire 179 and the chassis ground
connection
Terminal for wire 178 PinkAilhite to ground 12 Volts Bad circuit belween the rrght hand tail lamp
@ and the lamp switch. Also check the lamp
switch
lF ferminal for wire 180 Brown to ground Continuity Check wire 180 and the chassis ground
connection.
kaukazz@yahoo.co.uk
4001 -85
Left Hand Fender Turn SignalMarning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and F17. Nso check the left hand front turn signallwarning lamp bulb.
NOTE: Disconnect the left hand fender turn signallwarning lamp/tail lamp from the harness.
@ Terminal for wire 179 Brown to ground Continuity Check wire 179 and the chassis ground
connection,
NOTE: Turn the lamp switch to the WARNING LAMP position
Terminal for wire 192 Pink/Dark Green to 12 Volts Bad circuit between the flasher relay
ground ON-OFF-ON terminal 5 and the left hand fender turn
signal/warning lamp connector terminal A
Also check the flasher relay.
Terminal for wire 192 Pink/Dark Green to 1 2 Volts Bad circuit between the flasher relay and the
Right Hand Fender Turn Signal/Warning Lamp Circuit Test

NOTE: Check Fuses F5, FG and F17. Nso check the left hand front turn signallwarning lamp bulb.
NOTE: Disconnect the left hand fender turn signaUwarning lampltail lamp from the harness.
Terminal for wire 180 Brown to ground Continuity Check wire 'l 80 and the chassis ground
Gl connection.
dil Terminal for wire 188 Pink to ground 12 Volts Bad circuit between the flasher relay
ON-OFF-ON terminal 5 and the right hand iender turn
signal/warning lamp connector terminal B
Also check the flasher relay
NOTE: Turn the key to the ON position and put the turn srgnal switch in the LEFT turn position
Terminal for wire 188 Pink to ground 12 Volts Bad circuit between the flasher relay and the
@ dimmer/turn/horn switch. Also check the
Dcr 8-85042 issueo 3-92 Printed i. Englard
kaukazz@yahoo.co.uk
4001 -86
Left Hand Front Canopy Turn SignalMarning Lamp Circuit Test
NOTE: Check Fuses F5, F6 and F17. Nsa check the left hand front canopy turn signal/warning lamp bulb
NOTE: Disconnect the left hand front canopy turn stgnallwarning lamp from the harness.
for wire 201 Brown to ground Check wire 201 and the chassis ground
QD T"r^tn^l
ContinuitY
connection
&?l Termir-al ;or wire 192 PinxvDark Green to 12 Volts Bad circuit between the flasher relay
v grouno ON.OFF.ON terminal 5 and the left hand front canopy
turn signal/warning lamp connector terminal
A Also check the flasher relay
NOTE: tf the teft hand rear warning lamp works. check wire 192 bet,veen the le'ft hand f ront canopy turn signallwarning
lamp and the canopy harness splice.
Terminal for wire 192 Pint</Dark Green to 12 Volts Bad circuit between the flasher relay and the
ground dimmer/turnihorn switch Also check the
Left Hand Rear Canopy Turn Signalffiarning Lamp Circuit Test

NOTE: Check Fuses F5 F6 and F17 Nsa check the left hand rear canapy turn signallwarning lamp bulb
NOTE: Disconnect the left hand front canopy turn signallwarnrng lamp from the harness.
flF Terminai for wire 200 Brown to ground Continuity Check wire 200 and the chassis ground
conncction.
NOTE: Turn the lamp switch to the WARNING UMP positron
6h for wire 192 Pink/Dark Green to 12 Volts Bad circuit between the flasher relay
v Terr,nal
grouno ON-OFF-ON terminal 5 and the left hand rear canopy turn
- signal/warning lamp connector terminal A.
Also check the flasher relay
NOTE: lfthelefthandfrontwarninglampworks,checkwirelg2betweenthelefthandrearcanopyturnsignallwarnng
lamp and the canopy harness splice
NOTE: Turn the key to the ON positton and put the turn slgna/ switch rn the RIGHT turn posrtron
12 Volts Bad circuit belween the flasher relay and the

@ I::n:'r ror wrre 1e2 Pink/Dark Green to dimmer/turn/horn switch Also check the
kaukazz@yahoo.co.uk
40a1-87
Right Hand Front Canopy Turn Signal/Warning Lamp Circuit Test
NOTE: Check Fuses F5, FO and F17 Nso check the right hand front canopy turn signallwarning lamp bulb.
NOTE: Disconnect the right hand front canopy turn signallwarning lamp from the harness,
Terminal for wire 199 Brown to ground Continuily Check wire 199 and the chassis ground
@ connection.
NOTE: Turn the lamp switch to the WARNING AMP position.
Terminal for wire 188 Pink to ground 12 Volts Bad circuit between the ilasher relay
@ ON-OFF-ON terminal 5 and the right hand front canopy
turn signal/warning lamp connector terminal
A Also check the fiasher relay
NOTE: lf the 1ghthand rearwarning lampworks, checkwire lSSbetweenthe right hand frontcanapyturn signallwarning
lamp and the canopy harness sp/lce.
NOTE: Turn the key to the ON position and put the turn signal switch in the LEFT turn positron.
Terminal for wire 188 Prnk to ground 12 Volts Bad circuit between the f lasher relay and the
@ dimmer/turn/horn switch, Also check the
Right Hand Rear Canopy Turn SignalAffarning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and F17. Nso check the right hand rear canopy turn signallwarning lamp bulb
NOTE: Disconnect the right hand rear canapy turn signallwarning lamp from the harness.
Check points Reading Possrble Cause of Bad Reading
6lD Terminal for wire 198 Brown to grouncl ContinuitY Check wire 198 and the chassis ground
connection.
NOTE: Turn the lamp switch to the WARNING UMP posrtton.
6!E termlnal for wire 188 Prnk to ground 12 Volts Bad circuit between the f lasher relay
ON-OFF-ON terminal 5 and the right hand rear canopy
turn signal/warning lamp connector termina
A. Also check the flasher relaY
NOTE: lftherighthandfrontwarningtampworks,checkwirelsBbeNveentherighthandrearcanopyturnsignallwarning
lamp and the canopy harness sp/lce.
NOTE: Turn the key to the ON posrtron and put the turn srgnal switch in the RIGHT turn position
6P Terminal for wire 188 Prnk to ground 12 Volts Bad circuit between the f lasher relay and the
dimmer/turn/horn switch. Also check the
)on 8-85042
lssuec 3-92 Prirteo in England
kaukazz@yahoo.co.uk
NU I t: Ur,eck tsuses F5. ro ano rt /
6!l Terminalfor wire 18'1 PinlVRed to ground 12 Volts Bad circuit between the battery junction
block and the flasher relay terminal 2. Also
powrquadplus www.thebestworkshopmanuals.co.uk check the battery junction block
connection.
NOTE: Turn the lamp switch to the WARNING UMP position.
6F Terminal for wire 183 PinkiBlack to ground 12 Volts Bad circuit between the lamp switch
terminal W and the flasher relay terminal 1.
Also check the lamp switch.
NOTE: Disconnect the flasher relay from the harness
6F Terminalfor wire 43 Brown to ground Continuity Check wire 43 and the chassis ground
connection.
NOTE: Connect the ftasher relay to the harness, turn the key to the ON position and put the turn signal switch in the LEFT
TURN positron.
Terminal for wjre 188 Pink to ground 12 Volts Bad circuit between the dimmer/turn/horn
@ switch and the flasher relay terminal 7. Also
check the dimmer/turn/horn switch
Terminal for wire 192 Pinlr/Dark Green to 12 Volts Bad flasher relay,
ground ON-OFF.ON
NOTE: Put the turn signal switch in the RIGHT TURN position.
Terminal for wire 192 Pink/Dark Green to 12 Volts Bad circuit between the dimmer/turn/horn
ground switch and the flasher relay terminal 5. Also
check the dimmer/turn/horn switch.
Terminal for wire 1BB Pink to ground 12 Volts Bad flasher relay.
@ ON-OFF.ON
Dcr S-85042 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001 -89
Horn Circuit Test
NOTE: Check Fuse F17"
ferminal for wire 195 Gray/Red to ground 12 Volts Bad circuit belween the battery iunction
@ - block and the horn Also check the baltery
NOTE: Press and hold the horn switch in the HORN posilion
Terminal 1or wire 1g6 Brown/Orange to Continuity Bad circuit between the horn and the
ground chassis ground connection. Also check the
dimmer/turn,horn switch and the chassis
ground connection.

NOTE: Disconnect the dimmerlturnlhorn switch from lhe harness at connector P and turn the key to the ON position
Check ooints Reading Possible Cause of Bad Reading
lD rerminal ior wrre 185 Pink/Yellow Io ground 12 Volts Bad circuit belween the keyed power
junction block and the dimmer/turn/horn
switch
,?f Terminal ior wire 170 Brown to ground Contrnuity Check wire 170 and the chassis ground
connection.
NOTE: Operate the dimmer switch until a continuity reading is obtained between terminals 2 and 6 of Connector
P
(sw4ch siO"1. n a continuity reading can not be obtained reptace the dimmerlturnlhorn switch.
NOTE: Operate the dimmer switch again"
Betlveen termrnals 2 and 6 of connector P No Continuity Bad dimmer/turn/horn switch.

(switch side)
NOTE: Put the turn signal switch in the RIGHT TURN position'
Between terminals q and 5 of conneclor P contrnuily Bad dimmerûrn/horn switch'

(switch side)
NOTE: Put the turn signalswitch in the LEFT TURN postttan'
Between terminals 4 and I of connector P Continuity Bad dimmer/turn/horn swtch

(switch srde)
NOTE: Press and hotd the horn switch tn the HORN position'
Between terminals 3 and 6 of connector P Continuily Bad dimmer/turn/horn swltch'

(switch side)
Don 8-85042
lssuec 3-92 Printed ln England
kaukazz@yahoo.co.uk
4001 -90
NOTE: Disconnect the lamp switch from the harness-
f,E{ Terminal for wire 165 Red/Yellow to ground 12 Volts Check wire 165 and the battery junction
block connection.
Terminal for wire 176 Red/YellowflVhite to l2Volts Check wire 176 and the battery junction
ground block connection.
NOTE: Turn the lamp switch to the WARNING WvlP position.
Between terminals 81 and W of the lamp Continuity Bad lamp switch.

switch
NOTE: Turn the tamp switch to the HEIDLN,IP position.
Between terminals 81 and W of the lamp Continuity Bad lamp switch.

switch
Between terminals 81 and T of the lamp Continuity Bad lamp switch'

switch
Between terminals 83 and HD of the lamp Continuity Bad lamp switch.

switch
NOTE: Turn the lamp swttch to the REAR FENDER WORK lAltlP position.
Between terminals 83 and HD of the lamp Continuity Bad lamp switch.

switch
NOTE: Turn the lamp switch to the CAB WORK l,tthtlP position.
Between terminals 83 and HD ol the lamp Continuity Bad lamp switch'

switch
Trailer Connector Circuit Test fl-ail Lamp and Warning Lamp Circuits)
NOTE: Turn the lamp switch to the HETDLAMP position'
Terminal for wire 178 Pint<,Mhite to ground 12 Volts Check wire 178 between the trailer
@ connector Pin 6 and the splice.
NOTE: Turn the tamp switch to the WARNING LAMP position
tlll Terminal for wire 188 Pink to ground 12 Volts Check wire 188 between the trailer
ON-OFF-ON connector pin 5 and the splice or the right
hand rear turnsignaUwarning lamp'
Terminal for wire 192 PinlVDark Green to 12 Volts Check wire 192 between the trailer
ground ON-OFF-ON connector pin 3 and the splice or the left
hand rear turnsignal/warning lamp'
n^^ o o(^r, lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
. --4001:91
IAl W
tt W
Schematic Circuit
EATTER
*HC.-
-#tt" CC JNECTOR P KEYED POWEH tF-ffit L\
-/'
FUSE
CHASSIS GROUND
Completes battery
JUNCN(
BATTERY
JUNCTION BLOCK Dirnmer,rtum
C(".iNECTOR P
Dirnmerltum
JUNC]]ON BLOCK N4 V_l lv.l HORN Protects the electrical
system from high CONNECTOR N LAMP
TRAITEH CONNECTOB I
circuit
Emits sot SOLEiTOID (ETHER STARI) Coflnects ths tractor electrical
Used to Used to route batt€ry signal/trorn switch to DIMMEFUTUHN SIGNAUHORN signal/horn switch to DIMMEH/TUEN SIGNAUHORN Used to rouie keyed HEADIAMP DIMMER HELAY
output or a ground in Cab harnsss to lender Produces h€d that emits
power polYsr
FLASHEFI RELAY FOTARY S-I\/ITCH (LAMP
instument hamess SY{ITCH instrument harness SY/ITCH
povret A magnetic switch that directs the electrical system hamess
artifical light
circuit to a trailer
Electricat device which s\ilTTCll) €lectric curant actuates a hydrauiic valve
opens and closes a circuil Cmtrols mora than one circuil Controls mors lhan one circuit
Direcls electical firnent to
SPUCE continuaily when actuated one or mo.e circuitrs
Connects one or mor€ -
circuits that do the samg
CONNECTOH B
Engine harnass to instrument
CONNECTOFI D
Cab harness to instrument
funct'on Dimmer/Turn Signal,{-lorn Switch Wiring Dimmerflurn Signal/Florn Switch Wiring Horn Wiring i turn SignalMarning Lamp Wiring Headlamp V Headlamp Wiring Tail Lamp Wiring
hamess hamess BATTERY JUI\ TTERY JUNCTTON BLOCK {POr,vER) BATTEHY JUNCTION BLOCK (PO\ryEB) [oN BLOCK tPOwEB]
€ o KF/ED POWEB JUNCTION BLOCK KEYED POWER JUNCT}ON BLOCK
165 FED/YELLOW
lffRED,4iVH|+
*rr.*rr"* I Fb V- @ frl rm
IFAILER CONNECTOR
@ TTWF
JU
SWTCH @- I
Al l^l I
I @[
{{t
@.- *a'"f-
DIMMEH/TURNIHORN I
DIMMEFUTURNIHORN SWITCH
I I
l\-
I 4 l*+{1 \z \r*t
,,u$UJ\
i -184
I
lU
\u :) Ul
z. er;l
^ r(il
I :) {, rfty
J
C,
o
\i3 E
I . Y',\-
I JJ 172 PINK
El to
#\
#ftHB
ry ffi-a
J or#,ffi
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Y
o
5
o
\-./ HEADIAM P DIMMEB HETAY
@
YY
oo
:<Y
Ed @- @-*
ztu
trJ
c(
(,
vo
F
178 PtNl(wHm
F
r
I
ul
E ul
tr
LH
HEADLAMP @ @ @ @ P
z
ilal
l= LOH/ BEAM HIGH BEAM LOV BEAM LOW BEAM L
I
L-
LV
E
LH FUSE/ LH FUSE/RELAY BLOCK
I
I
CONNECTO FIP
186 BLACIqWHTE/GREEN
187 BLACKAVHITE
191 BLAC}qGHEEN
16S gRowN WHITE I
CONNECTOH P
185 BLAC}VWHITE/GHEEN
187 SLACKIWHTTE
191 BLACIqGHEEN {
173 FIED/DK GHEEN
171 RED/DKBLUE {, {
ry;
^y'
t78
o,
iUP TO PIN 163 EROWN WHITE

J
\s \s
(UP TO PIN No JJF1004670)
FUSE F1 FUSE F ruse rs 197 BLACK FUSE F5 1 1S7 BLACK -
188
CONNECIOF N
o
192 PINIVDK GHEEN 192
@ @q @
@1 1s2 PINF/DK GHEEN-l
(TFEAUIPPED)
ETHEH START SOLENOID

L 185 PINI(YE
ELLO!Y 18s PTNIqYELLOW il
192 LHCANOPY 192
':::::*'s+t HOHN TURN SIGNAU
R H CANOPY
TURN SIGNAU @@*
ENG}NE HARNESS CONNECTOR E
195 GHAY/HED
CON ECTOR B @ *@@
WARNINGI 1MPS WARNINGLAMPS
-.@@
196 BHOWN/ORANGE
-
196 BROWNIOBANGE
183 PINIqBIACK 183 PIN}VBIACK FHONT
F H FENDER
- L H FENDER
@ TAIU TURN SIGNAU
WARNING I-AMP
TAIU TURN SIGNAT
WARNING LAMP
'
l{} PINK
192 PINISDK GREEN }2 PINI(DK GREEN
188
@
}8 PINK
10c
l-oo
192 PINISDK GfiEEN 12 PINIVDK GREEN
CONNECTOB D
188 z
7\ 132
D$ENSION
o
=
&,
Ig
p
Io
kaukazz@yahoo.co.uk
b' .i
.. -i-
-.-.---
CHASSI
@ CHASSIS GROUNO
6
F
CHASSIS GROUNO
o
d
Don 8-85042
lssucd 3 92 PrinteC in England
4001-92
REAR FENDER, FRONT CAB AND REAR CAB WORK LAMPS FOR TRACTORS
WITH CAB
Sectional lndex
CHCUTT TESTING 94
Left Hand Rear Fender Work Lamp Circuit Test 94
Right Hand Rear Fender Work Lamp Circuit Test 94
o<
Trailer Connector Work Lamp Circuit Test ..'..'."."
Rear Fender Work Lamp Relay Circuit Test ..'........ 95
le{t Hand Front Cab Work lamp Circuit Test ........--. 95
Righl Hand Front Cab Work Lamp Circuit Test .....'..... 96
Font Cab Work Lamp Relay Circuit Test ........... 96
left Hand Rear Cab Work Lamp Circuit Test ........." 97
Raghl Hand Hear Cab Work lamp Circuit Tesl ........... 97
Rear Cab Work Lamp Relay Circuit Test ............ 98
Lamp Switch Test (Work Lamp Circuits) ................. 98
99
tbn 8€50'12 lssued $92 ftinted in Englatd
kaukazz@yahoo.co.uk
4001 -93
WIRING CODE
GAUGE
176 Red/YellowMhite BatteryJunction Block FrontCabWorkLampRelay(l'erm30) 15
202 Red/Orange Baltery Junction Block Lamp Switch fl-erm 82) 18
203 Red/Light Green Lamp Switch fl-erm FL1) Rear Fender Work Lamp Relay flerm 86) 18
204 Brown Rear Cab Work Lamp Relay (i"erm 85) Rear FenderWorkLamp Relay (i-erm 85) 18
204 Brown RearFenderWorkLampRelayftermS5) Front Cab Work Lamp Relay fl-erm S5) lB
244 Brown Front Cab Work Lamp Relay (Ierm 85) Chassis Ground 18
205 Red/r'iolet Battery Junction Block Rear Fender Work Lamp Relay fferm 30) l 1
206 VioleVGray Rear Fender Work Lamp Relay fl-erm 87) Fuse Fl4 15
207 VioletA/ellow Fuse F14 Connector D (Pin H) 15
207" Violet/Yellow Connector D (Pin H) Connector N (Pin H) 15
2O7 Violet/Yellow Connector N (Pin H) Splice t5
207 VioletA/ellow Splice Left Hand Rear Fender work Lamp 16
flerm A)
207 VioleVYellow Splice Right Hand Rear Fender Work Lamp i6
fferm A)
207 Violet/Yellow Splice Trailer Connecto. (Pin 2) 16
208 Brown Left Hand Rear Fender Work Lamp Chassis Ground lf)
fl'-erm B)
209 Brown Right Hand Rear Fender Work Lamp Chassis Ground 16
(1-erm B)
210 Red/Brown Lamp Switch flerm FL2) Front Cab Work Lamp Relay 18
(-lerm 86)
210 Red/Brown Front Cab Work Lamp Relay fierm 86) 86) 18
Rear Cab Work Lamp Relay fl-erm
211 Vioiet/Dark Green Front Cab Work Lamp Relay fl-erm 87) F1Fuse 15
212 VioleVBlack Fuse F1 Connector D (Pin B) 13
212* VioleVBlack Connector D (Pin B) Splice 13
212* VioleVBlack Splice Left Hand Front Cab Work Lamp 15
fferm A)
212* VioleVBlack Splrce Right Hand Front Cab Work Lamp '15
fierm A)
213 Brown Left Hand Front Cab Work Lamp Chassis Ground 15
(T"erm B)
214 Brown Right Hand Front Cab Work Lamp Chassis Ground 15
(Term B)
215 VioleVRed Battery Junction Block Rear Cab Work Lamp Relay fl-erm 30) 15
216 Violet Flear Cab Work Lamp Relay fl-erm 87) Fuse F4 tc
217 VioletAVhite Fuse F4 Connector D (Pin D) IJ
217" VioleWVhite Connector D (Pin D) Splice 13
217* VioleWVhite Splice Left Hand Rear Cab Work Lamp fierm A) 15
217" VioleWVhite Qnlina Right Hand Rear Cab Work Lamp 15
fl-erm A)
2174 VioleWVhite Connector D (Pin D) Left Hand Rear Cab Work Lamp fierm A) 15
217A VioleWVhite Left Hand Rear Cab Work Lamp Right Hand Rear Cab Work Lamp 15
218 Brown Left Hand Rear Cab Work Lamp Chassis Ground 15
fierm B)
21BA Brown Rrght Hand Rear Cab Work Lamp Left Hand Rear Cab Work Lamp 15
219 Brown Right Hand Rear Cab Work Lamp Chassis Ground 15
flerm B)
NOTE: Wire code references marked (") are tor tractors up to cab serial No JKJ46968
207* P nk (78a) 212" Pink (794) 217* Vrolet (784)
NOTE: Wire code references marked'A' are for tractors from cab serial No JKJ491 44
kaukazz@yahoo.co.uk
4001-94
CIRCUIT TESTING
NOTE: The battery must be at full charge and all connection must be clean and tight before festing. Use a multimeter far
the lests
Left Hand Rear Fender Work Lamp Circuit Test

NOTE: Check Fuse F14, and the left hand fender work lamp bulb
NOTE: Disconnect the left hand fender work lamp from the harness, and turn the lamp switch to the FENDER WORK
LAMP position.
Terminal forwire 207 VioleilYellow to ground 12 Volts Bad circuit between the lamp switch
Q terminal FLl and the left hand fender work
lamp. Also check the rear fender relay and
the lamp switch.
r NOTE: lf the right hand fender work lamp works correctly check wire 2A7 between the left hand rear fender work lamp and
tha cnlira
@ terminal for wire 208 Brown to ground Continuity Check wire 208 and the chassls ground
connection.
Right Hand Rear Fender Work Lamp Circuit Test
NOTE: Check Fuse F14, and the left hand fender work lamp bulb.
NOTE: Disconnect the right hand fender work lamp from the harness, and turn the lamp switch to the FENDER WORK
UMP position.
@ terminalfor wire 207 VioletlYellow to ground 12 Volts Bad circuit between the lamp switch
terminal FL1 and the right hand fender work
lamp. Also check the rear fender relay and
the lamp switch
NOTE: tf the left hand fender work lamp works correctly check wire 207 betuveen the right hand rear fender work lamp and
the splice
Terminal for wrre 209 Brown to ground Continuity Check wire 209 and the chassis ground
@ connection,
kaukazz@yahoo.co.uk
4001 -95
Trailer Connector Work Lamp Circuit Test
NOTE: Turn the lamp switch to the FENDER WORK LAMP position.
O Terminal for wire 207 ViolefYellow lo ground 12 Volts Check wire 207 between the trailer
connector pin 2 and the splice.
Rear Fender Work Lamp Relay Circuit Test

NOTE: Turn the lamp switch to the OFF position.
Check points Reading Possib e Cause of Bad Reading
Gl T"rmnrl for wire 204 Brown to ground Continuity Bad circuit between the rear fender work
lamp relay terminal 85 and the chassis
ground connection. Also check the chassis
ground connection.
NOTE: Turn the lamp switch to the REAR FENDER WORK LAMP position
@ ferminal for wire 203 Red/Light Green to 12 Volts Check wire 203 between the lamp switch
grouno terminal FL1 and the rear fender work lamp
relay terminal 86,
O ferminal for wire 205 Redl/iolet to ground '12 Volts Check wire 205 and the battery junction
block connection.
I Terminal for wire 206 VioleVGray to ground 12 Volts Bad rear fender work lamp relay
Left Hand Front Cab Work Lamp Circuit Test

NOTE: Check luse F1 and the left hand front cab work lamp bulb.
NOTE: Disconnect the left hand front work lamp from the harness and turn the lamp swrlch to the CAB WORK UMP
position
Check points Feading Possiblc Cause of Bad Reading
Terminal for wire 212 VioleVBlack or Pink 12 Volts Bad circuit between the lamp switch
(79a) to ground terminal FL2 and the left hand front cab work
lamp. Also check the front cab work lamp
relay and the lamp switch.
NOTE: lf therighthandfrontcabworklampworkscorrectlycheckwtre2l2betweenthelelthandfrontcabworklampand
the splice
@ ferminal for wire 213 Brown to ground Contrnurty Check wie 2i3 and the chassis ground
conncctlon
Don 8-85042 lssued 3-92 Pr-inted in England
kaukazz@yahoo.co.uk
4001 -96
Right Hand Front Cab Work Lamp Circuit Test
NOTE: Check fuse F1 and the right hand front cab work lamp bulb
NOTE: Disconnect the right hand f ront work tamp from the harness and turn the lamp swtch to the CAB WORK LAMP
position.
Terrninal for wire 212 VrolcVBlack or Pink i2 Volts Bad circuit between the lamp switch
(794) to ground terminal FL2 and the right hand tront cab
work lamp Also check the front cab work
lamp relay and the lamp switch.
NOTE: lfthetelthandfrontcabworklampworkscorrectlycheckwire2l2betvveentherighthandfrantcabworklampand
the splice
lEl Terminal for wire 214 Brown to ground Continuity Check wire 214 and the chassis ground
connection.
Front Cab Work Lamp Ftelay Circuit Test

Check points Reading Possi,ble Cause of Bad leading
lP Terminal for wire 204 Brown to ground Continuity Check wire 204 and the chassis ground
connection.
NOTE: Turn the lamp switch to the CAB WORK UMP position
Terminal for wire 210 Bed/Brown to ground 12 Volts Check wie 210 between the lamp switch
Gl terminal FL2 and the front cab relay terminal
86.
Terminal for wire 176 Red,YellowMhitc 12 Volts Check wire 176 and the battery junction
@ block connection.
v@ Terminal forwire 211 VioleVDark Green to 12Volts Bad frontcabworklamp relay

ground
kaukazz@yahoo.co.uk
rtvrL. u,/uu^ rusu r.+, anQ Ute tett nano rear caD worK lamp bulb.
NOTE: Disconnect the left hand rear work lamp from the harness and turn the tamp
switch to the CAB WaRK UMp
position.
Check points Reading Possible Cause of Bad Readrng

Terminal for wire 217(A) VioteWVhite or 12 Volts Bad circuit between the lamp switch
Violet (784) to ground terminal FL2 and the left hand rear cab work
lamp. Also check the rear cab work lamp
NOTE: lf the right hand rear cab work lamp works correctly check wire 217 between the left
hand rear cab work lamp and
the splice (tractors up to cab serial No JKJ491a4 onty).
lD Terminal for wire 218 Brown to ground Continuity Check wire 218 and the chassis ground
connection.
Right Hand Rear Cab Work Lamp Circuit Test

NOTE: Check Fuse F4, and.the right hand rear cab work tamp bulb.
NOTE: Disconnect the right hand rear work lamp from the harness and turn the lampswtch to the
cAB woRK lAMp
position.
Check points Eeading Possible Cause of Bad Reading
Terminalfor wire 217A VioletAVhite or Violet 12 Volts Bad circuit between the lamp switch
(784) to ground terminal FL2 and the right hand rear cab
work lamp. Also check the rear cab work
NOTE: lf the left hand rear cab work lamp works correctly check wire 217 between the right hand rear
cab work lamp and
the splice or wire 217A beNveen the teft hand and right hand rear cab work lamps.
Terminal for wire 219 Brown or 21BA Brown Continuity Bad chassis ground circuit
to ground
Don 8-85042 lssuec 3-92 Printed in England
kaukazz@yahoo.co.uk
4001 -98
Rear Cab Work Lamp Relay Circuit Test
NOTE: Turn the tamp switch to the OFF position.
Termrnal for wire 204 Brown to ground Continuity Bad circuit between the rear cab work lamp
@ relay terminal 85 and the chassis ground
connection.
NOTE: Turn the lamp switch to the CAB WORK UMP position
Terminal for wire 210 Red/Brown to ground 12 Volts Bad circuit between the lamp switch
4l terminal FL2 and the rear cab work lamp
relay terminal 86.
Terminal for wire 2'15 VioleVFled to ground 12 Volts Check wire 215 and the battery junction
@ block connection.
Terminal for wire 216 Vlolet to ground 12 Volts Bad rear cab work lamp relay
@
Lamp Switch Test (Work Lamp Circuits)

NOTE: Disconnect the lamp switch from the harness.
Terminal for wire 2A2 Red0r ange to ground 12 Volts Check wie 202 and the battery junction
4F block connection.
NOTE: Turn the lamp switch to the REAR FENDER WORK LAMP position.
Between terminals 82 and FL1 of the lamp continuity Bad lamp switch.
switch
NOTE: Turn the lamp switch to the CAB WORK LAMP position.
Between terminals 82 and FL1 of the lamp Continuity Bad lamp switch.
switch
Between terminals 82 and FL2 of the lamp Continuity Bad lamp switch.
switch
Don 8-850a2 lssued 3-92 Printed in Englano
kaukazz@yahoo.co.uk
4001€ 4001-99
Schematic Circuit ".Wp^
o-r7fi \ed'
[ffi red FUSE
Protccts ihe electrical
tr,F' BATTERY TRALEACONNECTOR I
system lrom high

;7ffi JUNGTION BLOCK
Ussd to rout6 battery lN
CONNECTOB N
Cab hamess to lender
Connecls ihe trac{or elsctrical
circuit to a kailsr output or a ground in hsat thal emits
SPLICE
Connec{s onB or mors
CHASSISGROUND BOTARY SWTCH (I.AMP I RETAY: harnssg ths elec.trical system circuitlr thal do tho same
pOlrVef BEI.AY 30 AMP
ComplBt€s b€fsty swrcH) le,n"* A magnetic switch that
function
circuft Directs BlBctrical cunBnt lo oirecB r directs electric curent
I
sne or more circuitg
CONNECTOB D Fender Work Lamp Wring Front Cab Work Cab Work Lamp Wiring Bear Cab Work LamP Wiring
Cab hamess to instrum€nt BATTERY JUNCI1ON BLOCK (POWER}
hamess
211 VIOLEilDK GBEEN
206 VIOLETGRAY-_I
206
FUSE F
c
FUSE F1
@
207 VTOLETTELLOW 212 vloLEvBLACli
<- 2ITVIoLEVWHITE
CONNECTOR
CONNEGTOH D
zul
UI
rE E
E Y
c, o oB PINK (784) 217A VlotEf/lvHlTE
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Q 5
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E
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5 I6I
(:rt
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ii ,9:=* TRATLEB coNNEcroR

, f- 2174
iii
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o\ @
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217
REAR FENDER I FRONT CAB

\\
c
WOHKI-AMP REIAY RIGHT HAND REAR
woRKr-AMp6l LEFT HAND
LEFT HAND BEAB CAB VfORK I-AMP
CAB WORK I-AMP
FENDER WORK IAMP
\\-
-
\.
GAB HARNES
\-.t- Eq
zo+ anorvr.r_t'Q
I LEFT HAND FRONT
CAB I,YOHK I-AMP
@
iHT HANT) FRONT
rAB WORIi I.AMP
@r
"o])**=.,
*.t
218A BROWN \@
CHASSIS GROUND
kaukazz@yahoo.co.uk
lssued 3-92 Printed in En'
lssued 3-92 Printed in Engtand
Don &85042
4001-100
REAR FENDER, FRONT FENDEH AND CANOPY WORK TAMPS FOR
Sectional lndex
Lett Hand Rear Fender Work t-amp Circuit Test ,...,...... '..'..............'.. 102
Right Hand Rear Fender Work Lamp Circuit Test ............ ..'..........-..-. 1O2
Left Hand Front Fender Work Lamp Circuit Test ........... '..-.'....'..'...... 103
Right Hand Front Fender Work Lamp Circuit Test ............ .........-.....-. 103
Trailer Connector Work Lamp Circuit Test .....,...... .'.-.'... 103
Fender Work Lamp Relay Circuit Test ........... ................ 104
Left Hand Front Canopy Work Lamp Circuit Test ........... 104
Right Hand Front Canopy Work Lamp Circuit Test ............ 105
Left Hand Rear Canopy Work Lamp Circuit Test ............ 105
Right Hand Rear Canopy Work Lamp Circuit Test ........... 106
30 AMP Circuit Breaker Circuit Test .........-. 106
Canopy Work Lamp Relay Circuit Test ........... 106
Lamp Switch Test (Work Lamp Circuit) ................. 107
Schematic Circuit ........ 109
Don &85U2 lssued 3-92 kinted in England
kaukazz@yahoo.co.uk
4001 -1 01
WIRING CODE
GAUGE
2A2 Red/Orange Battery Junction Block Lamp Switch ft'erm 82) 18
203 Redilight Green Lamp Switch ff-erm FL1) Fender Work Lamp Relay fl-erm 86) 18
2A4 Brown Canopy Work Lamp Relay (ferm 85) Fender Work Lamp Relay fl-erm 85) 18
204 Brown Fender Work Lamp Relay fl-erm 85) Chassis Ground 18
205 Red/r'rolet Battery Junction Block Fender Work Lamp Relay ft-erm 30) 11
206 VioleVGray Fender Work Lamp Belay (Term 87) 4
Fuse Fl 15
2AO VioleVGray Fender Work Lamp Relay f[erm 87) Fuse F15 15
2A7 VioletYellow Fuse F] 4 Connector D (Pin H) 15
207 Violetl/ellow Connector D (Pin H) Connector N (Pin H) 15
207 VioleVYellow Connector N (Pin H) Splice 15
2A7 ViolelYellow Splice Left Hand Bear Fender Work Lamp 16
fl-erm A)
2A7 ViolelYellow Splice Rrght Hand Rear Fender Work Lamp 16
fl-erm A)
207 VioleLYellow Splice Trailer Connector (Pin 2) r6
208 Brown Lefl Hand Rear Fender Work LamP Chassis Ground 16
fterm B)
209 Brown Right Hand Bear Fender Work LamP Chassis Ground 16
fi-erm B)
210 Red/Brown Lamp Switch fl-erm FL2) Canopy Work Lamps Relay fl-erm 86) 18
220 Dark Greenl/iolet Fuse F1 5 Connector D (Pin F) 15
220 Dark GreenNiolet Connector D (Pin F) Connector N (Pin J) 15
220 Dark Green/y'iolet Connector N (Pin J) Splice '15
220 Dark Green/y'iolet Splice Left Hand Front Work Lamp (1-erm A) 16
2?0 Dark Green/y'iolet SpIce Brght Hand Front Work Lamp fl-erm A) 16
221 Brown Left Hand Fronl Work LamP fierm B) Chassis Ground 16
222 Brown Right Hand Front Work LamP fl-erm B) Chassis Ground 16
223 PinVRed Battery Junction Block Canopy Work Lamp (l'"erm 30) 11
224 VioleVDark Blue Canopy Work LamP fl-erm 87) 30 Amp Circuit Breaker 11
225 Gray 30 Anrp Circuit Breaker Connector D (Pin E) 1 1
225 Gray 30 Arnp Ci,cut: Breake' Connector D (Pin G) 11
226 Violet Connector D (Pin E) Canopy Extcnsion Harness fierm D) 15

226 Violet Canopy Enension Harness fl'erm D) Splrce 15
226 Violet Splice Left Hand Front Canopy Work LamP 16

fl-erm A)
226 Violet Splice Right Hand Front Canopy Work Lamp 16
ft.erm A)
227 Brown Left Hand Front CanoPY Work LamP Chassis Ground lr)
fl-erm B)
228 Brown Right Hand Front CanoPY Work LamP Chassis Ground 16
ferm B)
229 VioleWVhite Connector D (Pin G) Canopy Extension Harness fl-erm C) 15
2?9 VrolefMhite Canopy Extension Harness fl-erm C) Splice 15

229 VioleWVhite Splice Left Hand Rear CanoPy Work LamP 16
fT-erm A)
229 VioletAVhite $plice Fight Hand Bear CanoPy Work LamP 16
(Term A)
230 Brown Left Hand Canopy Work LamP fl-erm B) Chassis Ground tb
231 Brown Right Hand Canopy Work Lamp fl'erm B) Chassis Ground 16
Don 8-85042 ssued 3-92 Prinleo n E.gland
kaukazz@yahoo.co.uk
4001 -1 02
CIRCUIT TESTING
NOTE: The batteries must be at full charge and all conneclions must be clean and tight before testtng. Use a multimetel
For the tests.

NOTE: lf all the fender work lamps.fail to work, check the fender work lamp relay.
NOTE: Check fuse F14 and the left hand rear fender work lamp bulb.
NOTE: Disconnect the left hand rear f ender work lamp from the harness and turn the lamp switch to the FENDER WORK
LAMP position.
Check Points Reading Possible Cause of 8ad Reading
Terminal for wire 207 Violet/Yellow to 12 Volts Bad circuit between the fender work lamp
ground relay, and the left hand rear fender work
lamp.
NOTE: lf the rrght hand rear fender lamp works correctly, check wire 207 between the left hand rear fender lamp and the
sp/ice
@ Terminal for wrre 208 Brown to ground Continuity Check wire 208 and the chassis ground
connection.

NOTE: lf all the fender work lamps fail to work, check the lender work lamp relay.
NOTE: Check fuse F14 and the rtght hand rear fender work lamp bulb.
NOTE: DisconnecttherighthandrearfenderworklampfromtheharnessandturnthelampswitchtotheFENDERWORK
UMP position.
Check Points Readlng Possible Cause of Bad Beading
o Terminal
ground
Ior wue 207 VioleVYellow to 12 Volts Bad circuit between the fender work lamp
relay and the right hand rear fender work
lamp.
NOTE: lf the left hand rear fender lamp works correctly, check wire 207 belween the right hand rear fender lamp and the
sp/ice.
@ fcrminal for wirc 209 Brown to ground Continuity Check wire 209 and the chassis ground
connection.
Dor 8-85042 lssued 3-92 P(nted n England
kaukazz@yahoo.co.uk
4001 -1 03
LeftHandFrontFenderWorkLampCircuitTest
NoTE: lf ail the fender work lamps fail to work, check the fender work lamp relay'
NOTE: Check fuse F1 5 and the left hand front fender work lamp bulb
lamp swlfch to the FENDER WORK
NOTE: Disconnectthe left hand lrontfenderwork lamp from the harness and turn the
LAMP position.
Check Points Reading Possible Cause of Bad Fleading
Terminal for wire 220 Dark GreenNiolet to 12 Volts Bad circuit between the fender work lamp
ground relay, and the left hand front fender work
ramp
NorE: tfthe1ghthandfrontfenderlampworkscorrectly,checkwire22obetuveenthelefthandfrontfenderlampandthe
splice.
Terminal for wire 221 Brown to ground Continuity Check wie 221 and the chassis ground
@ connection.
RightHandFrontFenderWorkLampCircuitTest
NOTE: tf all the fender work lamps fail to work, check the fender work iamp relay'
NoTE: Check fuse F15 and the right hand rear fender work lamp bu|b.
NOTE: Disconnectthe rrght hand rear fender work lamp from the harness a nd turn the lamp swltch to the FENDER WORK
UMP position.
Check Points R"qding Possible Cause of Bad Reading
to 12 Volts
Terminal for wire 22A Dark Greenly'iolet
Bad circuit between the fender work lamp
groundrelay,andtherighthandfrontfenderwork lamP,
NorE: tfthetefthandfrontfenderlampworkscorrectly,checkwire22obetweentherighthandfrontfenderlampandthe
spllce,
fcrminal for wire 222 Brown to ground Cont nuity Check wie 222 and the chassis ground
@ connection.

post,on
NOTE: Turn the lamp switch to the FENDER WORK LAMP
to
for wire 207 12Volts
Violet/Yellow Check wire 2A7 between the trailer
Terminal
groundconnectorpin2andthesplice.
lss'red 3-92 Prrntec in Ergiald

Don 8-85042
kaukazz@yahoo.co.uk
4001 -1 04
Fender Work Lamp Relay Circuit Test
Check Points Beading Possible Cause o{ Bad Reading
@ Terminai for wire 204 Brown to ground Continuity Check wue 2A4 and the chassis ground
connection
NOTE: Turn the lamp switch to the FENDER WORK UMP position
Termrnal for wire 203 Red/Light Green to 12 Volts Check wire 203 between the lamp switch
ground terminal FLl and the fender work lamp relay
terminal 86. Also check the lamp switch
(}) Terminal for wire 205 Red/Violet to ground 12 Volts Check wire 205 and the battery junction
block connection.
lD Terminal for 206 VioleVGray to ground 12 Volts Bad fender work lamp relay
Left Hand Front Canopy Work Lamp Circuit Test

NOTE: ll all the canopy work lamps fail to work, check the 30 amp circuit breaker. Refer to page 162.
NOTE: Check the left hand front canapy work lamp bulb.
NOTE: Disconnect the left hand front canapy work lamp from the harness and turn the lamp switch to the CANOPY WORK
LAMP position
lB Terminal for wire 226 Violet to ground 12 Volts Bad circuit between the circuit breaker and
the lelt hand front canopy work lamp.
NOTE: tf the right hand frortt canopy work lamp works correctly check wire 227 between the left hand front canopy work
lamp and the splice.
G Terminal for wire 227 Srown to ground Continuity Check wtre 227 and the chassis ground
connection.
Don 8-85042 ssued 3-92 Prinled in England
kaukazz@yahoo.co.uk
4001 -1 05
Right Hand Front canopy work Lamp circuit rest
NOTE: lf all the canopy work lamps fail to work, check
the 30 amp circuit breaker. Refer to page I 62.
NOTE: Check the right hand front canopy work lamp bulb.
NorE' Disconnect the right hand front canopy work lamp from theharness ano turn
the key to the cANopy woRK uMp
posltton.
Check Points Reading possible Cause of Bad Reading

(F Terminal for wire 226 yiotelto ground 12 Volts Bad circurt belween the circuit breaker and
the right hand front canopy work lamp.
NorE: lf the left hand f ront canopy work lamp works conectty check wire
226 between the right hand front canopy work
@ Terminal for wire 228 Srownto ground continuity check wire 2zB and the chassrs ground
connection
Left Hand Rear canopy work Lamp circuit Test

NOTE If all the canopy work lamps tait to work, check the 30 amp
circut breaker. Refer to page 162.
NOTE: Check the teft hand rear canopy work lamp bulb.
NoTE: Disconnect the left hand rear canopy work lamp from the harness
and turn the lamp switch to the CANopy woRK
UMP position.
Check Pornts Reading Possible Cause of Bad Reading

(l!l term inal for wire 229 Y iotetJWhite to ground 12 Volts Bad circuit between the circuit breaker and
the left hand rear canopy work lamp.
NOTE: lf the rtght hand rear canopy work lamp works correctty check wire
z2g between the left hand front canopy work
lD Terminal for wire 230 Brown to ground Continuity check wire 230 and the chassis ground J
connection
Don 8-85042
lssuec 3-92 P.r^leo r't Er-gla-o
kaukazz@yahoo.co.uk
400 1,1 06
Ftight Hand Rear Canopy Work Lamp Circuit Test
NOTE: lf all the canopy work lamps fail to work, check the 30 amp circuit breaker.
NOTE: Check the right hand rear canopy work lamp bulb.
NOTE: Disconnect the right hand rear canapy work lamp from the harness and turn the lamp switch to the CANOPY
WORK AMP position.
Terminal for wire 229 Violet/White to ground 12 Volts Bad circuit between the circuit breaker and
@ the right hand rear canopy work lamp.
NOTE: lf the left hand rear canopy work lamp works correctly check wire 229 betvveen the right hand rear canopy work
ferminal for wire 231 Brown to ground Continuity Check wire 231 and the chassis ground
@ connection.
30 AMP Circuit Breaker Circuit Test

NOTE: Turn the lamp switch to the CANaPY WORK UMP position.
Check Points Reading Possible Cause of Bad Feading
Terminal for wire 224 Viole7Dark Blue to 12 Volts Bad circuit between the canopy work lamp
ground relay and the 30 amp circuit breaker, Also
check the canopy work lamp relay.
NOTE: Turn the lamp switch to the OFF position
Between the terminals of the 30 amp circuit Continuity Bad circuit breaker
breaker
Canopy Work Lamp Relay Circuit Test

NOTE: Turn the lamp switch to the OFF position
Check Points Feading Possible Cause of Bad Reading
6l Tcrminal lor wire 204 Brown to ground Continuity Bad circuit between the canopy work lamp
relay terminal 85 and the chassis ground
connection
NOTE: Turn the lamp switch to the CANOPY WORK UMP position
@ Terminalfor wire 210 Red/Brown to ground 12 Volts Check wire 210 between the lamp switch
terminal FL2 and the canopy work lamp
relay terminal 86 Also check the lamp
switci-
kaukazz@yahoo.co.uk
4001 -1 07
Fleading Possible Cause of Bad Beading
Check Points
12 Volts Check wire 223 and the battery ;unction

flh Terminal for wire 223 Pink/Red to ground
block connection.
12 Volts Bad canoPy work lamP relaY.

Termrnal for wire 224 Yiole7Dark Blue to
ground
Lamp Switch (Work Lamp Circuit) Test

NOTE: Disconnect the lamp switch from the harness'
Reading Possible Cause ot Bad Reading
Check Points
Check wire 202 and the battery iunction
(h Terminalforwire 2O2RedlOrange to ground
12 Volts
block connection.
LAMP position'
NOTE; Turn the lamp switch to the FENDER WORK
Beween terminals 82 and FL1 of the lamp Continuity Bad lamP switch.
swrich
UMP position'
NOTE: Turn the lamp switch to the CANOPY WORK
Between terminals 82 and FL1 of the

lamp Continuity Bad lamP switch
SWItCh
lamp Continuity Bad lamp switch

Bclween terminals 32 and FL2 of ihe
switch
Issuec 3-92 Pri'rted in Englanc

Don 8-85042
kaukazz@yahoo.co.uk
ssued 3-92 Pflnted rn Englang
kaukazz@yahoo.co.uk
q
I
I
4001-109 4001-109 rd
qlJp
I
\
Schematic Circuit
I
I o-|rfr \*-L, l( FUSE I ru5r u)
BATTEHY -ry,F" te
THATLEB cotlt{Ecroa I Protects the electrical ]TOR I Protects ttle electrical
CIRCUIT BFtt -,XER
,,Dtr'7"7 JUNCTION BLOCK
CONNE
Cab hat CONNESTOB N LAMP Connects ths tractor electrical
system from
ouFut or a ground in
high
tor electrical sy:stem korn
ouFut or a ground in
high
Heat actuateci, automatc
SPUCE
Ussd to muts batt€ry Cab hamsss to iendet Produces hsat that €mits circufi to a trailer Connects ona or mora more
CHASS}S GBOUND
powsr
BOTABY SlilITCH TLAMP
REI.AY 3O AI,{P
harness the eleclrical s)€tem the electdcal system resst, protects electrical I
SWTCH) harness artifical light circuits from ovedoad

circuits that Co the same same I
ComplBtes hattery
A rnagnetic srvitcfi that function
circuit Dirscts €l€ctrical curort to dirscts €lectic (,rnBfit
one or more circtits
CONNECTORD
Cab hamess to
,
instrumefit Rear Fender \{ork LamP Wiring Canr Canopy lYork LamP lffiring
BATTESY TJNCTION BLOCK {POWEH)
hamess
224 VIOLET/DK BLUE 224 VIOLEV]DK BLUE
206 VIOLET/GMY
-
206 VIOLETIGBAY
206 206 206
& & &

russ n+ FUSE F1s ) FUSE F1s ) iAKEH
J
oq 207
@q
w
@(m
I
lrt
:f, ull
fii.l
I coNNEC'rOH D
&
g CONNECTOH D
M
I rJ cqrururrroa o CANOPY EXTENSON
HARNESS
CANOPY EXTENSON
HARNESS
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llJ:
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E l*- 207 vlolstYELrow 220 VIOLET/DK GBEI I 220 VIOLET/DK GREEN
J 5
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o o
FF
tu
JJ
trl
oo to
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CONNECTOR D -J.'l
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N 6 E coNNEgroH [,r (tF EQUTPF | ..1| coxNesron [.r (rF EeutppED)
N (\r $(o
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tr.l 6r I [c CoNNECTOR N (TF JTPPED)
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ig_ T
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2X 2n 229 V|OLETW
CONNECTOR
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t
il
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224
20 n0
-l.--
/.@ '\i,.@
,/@ /'@
q
FENDER WORK LAMP BELAY GANOPY WOBK LAMP
o
REI.AY
L H BEAR L H FRONT L H FHONT L H REAE L H REAR
o@ o@
FENDER WORK TAMP CANOPY WORK IAMP CAqOPY WORK LAMP CATOPY WOBK LAMP
FENDER WORK I.AMP
t
@@ R H REAR
FENDER I,YOHK IAMP
RHFR(
FENDERWO
R H FRONT
FENDERWORi( LAMP
@@ R H FBONT
@@
CANOPYWOBK LAMP
\
'---_.9lntoPY
i!
HARNESS
2
o
=
4
EI
206 VIOLSVGFAY
206 VIOLEVGRAY
*-,
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kaukazz@yahoo.co.uk
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Don 8-85M2
Issued 3-92 Printed in England ued 3-92 Printed in England I I CHASSIS GOUND
i/.//t
4mi-i10
AUXILIAHY POWER CONNECTOR, CIGARETTE LIGHTER AND
ELECTRIC SEAT MOTOR
Sectional lndex
Auxiliary Power Connector Circuit Test .......,.... .............. 111
Don &850a2 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001 -1 1 1
WIRING CODE
TO WIRE
REF COLOR FROM GAUGE
13
Chassis Ground
140 Brown Cigarelte Lighter
Fuse F3 11
232 Fed/Yellow Battery Junction Block
Connector A (Pln B) 11
232 Fed/Yellow Fuse F3
Conncctor E (Pin B) 11
232 Fed/Ye llow Connector A (Pin B) 11
Connector E (Pin B) Cigarette Lighter
232 Red/Yellow
Auxiliary Power Connector (Term 2) 11
232 Red/Yellow Crgar Lighter
1) Chassis Ground 13
233 Brown nuxlllary Power Connector flerm 11
FUSC i_J
234 Keyed Power Junction Block
I
Hed/Black
Connector A (Pin G) 11
235 Red/Orange Fuse F31
Connector E (Pin G) 1l
235 Red/Orange Connector A (Pin G)
Auxiliary Powcr Connector (Term 3) 11
235 Bed/Orangc Connector E (Pin G) 15
Fuse F31
Connector D (Pin P)
235* Red/Orange Splice 15
235* Bed/Orange Connector D (Pin P)
t5
Electric Seat Motor fl-erm A)
235" Red/Orange Spiice
Connector N (Pin G) 15
235" Red/Orange Splice
Trailer Connector (Pin 7) l5
235 Red/Orange Connector N (Pin G) 16
Electric Seat Motor (Term B) Chassis Ground
236 Brown
NOTE: Wie code reterences marked (*) are for cab tractars up to Cab Serla/ No JK546968'
235* Bed ('133)
235- Orange (810)
CIRCUIT TESTING
testrng use a multimeter
NorE: The batterres must be at fu, charge and art connection must be crean and tight before
lor lhe tests.
Auxiliary Power Connector Circuit Test

NOTE: Check Fuses F3 and F31 '
Reading Possible cause of Bad Reading

Check Points
ContinuttY Check wire 233 and the chassis ground
ferminalfor wire 233 Brown to ground
Q connection.
i 2 volts Bad circuit between the battery junction

Terminalfor wire 232 Yellow/Red to ground block and the auxiliary power connector
O
terminal 2. Also check the battery power
junciion block connection.
NOTE: Turn the key to the ON posrtton'

12 volts Bad circull between the keyed power
Gl terminalforwire 235 Red/Orange to ground power
lunction block and the auxiliary
connecior terminal 3 Also check the keyed
power circuit
kaukazz@yahoo.co.uk
4001-112
Cigarette Lighter Circuit Test
@ ferminal for wire 140 Brown to ground Continuity Check wire 140 and the chassis ground
connection.
@ terminal for wire 232 Red/Yellow to ground 12 Volts Bad circuit betvveen the battery .iunction
block and the cigarette lighter. Also check
the battery junction block connection,
Electric Seat Motor Circuit Test

NOTE: Disconnect the electric seat from the harness and turn the key to the ON position.
Check Points Reading Possible Cause of Bad Fleading
Terminal for wire 235 Red/Orange or l2Volts Bad circuit between the keyed power
Orange (810) to ground junction block and the electric seat motor
connector terminalA. Also check the keyed
power circuit.
connection.
NOTE: lf the readings are correct check the electric seat motol
kaukazz@yahoo.co.uk
4001. 4001-1 13
powrquadplus www.thebestworkshopmanuals.co.uk Schematic Circuit {

FUSE
KEYED POViTEB
il
BATTEFY Protscts the eleo'trical
W7 JUNCTION BLOCK
Used to route battery
systsm lrom hlgh
output or a ground In
CIGARETTE UGHTER
H€at operaiad slement
JUNSEON BLOCK
Used b roule keyed
MO
Art
MOTOR (SFAT)
THAILER CONNECTOB
Connects th€ tractor €lscrtrical
CHASSIS GROUND polYer An electric motor circuit lo a lrailer
polrYer ths electrical system
Completes battery
circuit
CONNECTORA
Transmisslon hamess
CONNECTOR D
Cab harnssg to insbument
CONNECTOR E
Transmission hamess b right Cigarette Lighter Wiring Auxiliary Connector Wiring Electric Seat Motor Seat Motor Wiring
hamess hand corsole harness BATTERY JUNCNON BLOCK {POWEN}
lo lnstrument hamess
n2 234 RED/BI.ACK
SFUCE
Connects one or morg
circuits lhat do lhe same
function
AUKLr6iifpoNNEcroR
Connebts lthe
,eblqicdglcircut
tractor
to an
Cab hamess to lender
FUSE
l
F3 ) FUSE F3
@( @
t_ 232 REDffELLOW
CONNECTOR A
t:\
ji i
CONNECTOR D
rORD IPI
tr
'rl{-
I
a a
ti
Ê | ,r. ,,=oro*NcE oR RED (103)
.-------{\ t
li
-\ \ lilt
o.),l,
lltl
----='- Ir
\\ ti 232 REDTYELTOW
.-\ li
\II
232 REDTYELLOW
ClGAHETTE H H
\.\-
\ \
@ ELECTRIC SEAT MOTOH (*)JA[ M
T
"o**ECroRN
otEourPPED) i
r\
\ \- \\\ {
c ...r.\
".
,\1IBlI@ / 235
l]---.--.
\\
\\ \\ \.
z
o
=
CE
CB
c,
(lt
(\t jt
fr iffiN**
*= 235 BEDToFANGE
@
@
(t
d
CHP.SSIS GROUND
Don 8-85042 lssued 3-92 Printed in Er 92 Printed in England
kaukazz@yahoo.co.uk
4001-'114
RADIO, RADIO CLOCK AND INTERIOR LAMP
Sectional lndex
Left Hand lnterior Lamp Circuit Test ............ .................. 116

Right Hand lnterior Lamp Circuit Test ........... ................ i17
kaukazz@yahoo.co.uk
4001-1 15
WIRING CODE
REF COLOR FROM TO WIBE
6 Red Battery Junction Block Key switch (BAT-[)
GAUGE
64 RedAVhite Key switch (ACC) Fuse F19
13
64 Red,Ailhrte Fuse F19 Accessory Power Relay (Term g6) '18
o
68 Brown Accessory Power Belay [Term g5) Transmission Control Relay fierm g5)
68 Brown Transmission Control Relay fl-erm 85) Chassis Ground
18
94 Red/Dark Btue Battery Junctio"r Blocr< Fuse F] 7
tb
94 Eed/Dark Blue Fuse F1 7 Accessory Power Relay fl-erm 30)
13
95 Red/'/iolet IJ
Accessory Power Relay fl-erm 87) Frrco !',1',
95 Fedl/iolet Fuse F32 Fuse F20
t5
95 Bed/r'iolet Fuse F20 Fuse F30
16
95 Redl/iolet Fuse F30 Fuse F29
11
232 Redffettow Battery Junction Block Fuse F3

18
232 Red/Yetiow Fuse F3 Connector D (Pin K)

13
232* Red/Yellow Connector D (Pin K) Radio

1B
'18
232* Red/Yellow Radio Left Hand lnterior Lamp Assembly
232* Redffeliow Lett Hand lnterior Lamp Assembly Right Hand lnterior Lamp Assembly
1B
237 Brown Rrght Hand Interior Lamp Assembly Left Hand lnterior Lamp Assembly
18
237 Brown Lelt Hand lnterior Lamp Assembly Radio

18
tb
237 Brown Radio Chassis Ground
238 Orange Fuse F29 Connector D (Pin L)
1B
.18
238 Orange ConnectorD(PinL) Fadio 18
240 Gray Radio Left Hand Speaker 1n
241 Brown/Gray Leit Hand Speaker Fadio 18
242 Yellow Radio Rrght Hand Speaker 18
243 Brownffeliow Right Hand Speaker Radio 18
NOTE: V/ire code references marked

O are for Cab traclors up to Sertal No Jl(J46g6g
?32 Red (71s) Z4O Orange (873) 242
Orange (872)
238 Red (870) 241
Brown (873) 243
Srowi lOze;
CIRCUIT TESTING
NOTE: The batteries must be atfull charge and atl connections must be clean and
tlght beforetesr/rg. LJse a mult6eter
lor the tesfs.
Radio Circuit Test

NOTE: Check luses F3 and F29
NOTE: Make sure the radio antenna chassrs ground connection is clean and tight. Also
check the antenna cable for
damage.
NOTE: Disconnect the radio from the harness.
Check Points Reading Possible cause of Bad Reading

@ Continuit Check wire 239 and the chassis ground
connection.
Dor B-85042 lssued 3-92 Prnted in Engtand
kaukazz@yahoo.co.uk
4001 -1 1 6
NOTE: Turn the key ta the ON position
Terminal for wire 238 Orange or Red (870) to 1 2 Volts Bad circuit between the accessory power
ground relay and the radio. Also check the
accessory power relay.
Terminal for wire 232 Red/Yellow or Bed 12 Volts Bad circuit between the battery junction
(715) to ground block and the radio. Also check the battery
lunction block connection
Radio Speaker Circuit Test

NOTE: Disconnect the radio and radio speaker from the harness.
@ ferminalsforwire Z4OGrayorOrange (873) Continuity Check wire 240
o Terminals forwire 241 Brown/Gray or

(873)
Brown Continuity Check wire 241 .
o Terminals for wire 242 Yellow or

(872)
Orange Continuity Check wire 242
o Terminals for wire 243 BrownNellow

Brown (872)
or Continuity Check wire 243.
Left Hand lnterior Lamp Circuit Test

NOTE: Check Fuse F3 and the left hand interior lamp bulb.
NOTE: Disconnect the lelt hand interior lamp assembly from fhe harness.
Terminal for wire 232 RedYellow or Red '12 Volts Bad circuit between the battery junction
(715) to ground block and the interior lamp. Also check the
battery junction block connection.
@ Termrnal for wire 237 Brown to ground Continuiry Check wire 237 and the chassis ground
connection.
Termlnals for wire 237 Brown Continuity Check wire 237 between the chassis ground
{il terminals of the lamP assemblY.
NOTE: lf the readings are correct check the interior lamp assembly
kaukazz@yahoo.co.uk
4001 -1 1 7
RightHandlnteriorLampCircuitTest(lfEquipped)
NOTE: Check Fuse F3 and the right hand interior lamp bulb'
NoTE:Disconnecttherighthandinteriorlampassemblyfromtheharness.
Check Pornts Reading Possible Cause ol Bad Reading
Red 12 Volts Check wie232 between the left hand and

Terminal for wire 232 RedNellow or
right hand interior lamps'
(715) to ground
Continuity Check wtre 237 between the left hand and

Terminalfor wire 237 Brown to ground
t) right hand interior IamPs'
Continuity Checkwire 237 between the chassis ground

(Fl Terminal for wire 237
terminals of the lamP assemblY'
the readings are correct check the interior lamp

lf assembly'
NOTE:

Don B-85042
kaukazz@yahoo.co.uk
400r-1 rB
Dor) ts-85042 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
Schematic Circuit
400'l-119
KEYSI'{ITCH
4001-119
#$
KEYS,I'flTCH
FUSE
Protec{s the electrical
system from
ouFut or a ground
high
the electrical systsrn

in
ANTENNA
Recieves
radio waves
or transmits
ANTENNA
Fecieves
radio wavgs
or transmits
vl
r or
ves
transmits I
J
RADIO
LAMP
Produces h€at lhat emits
arfficel light
ConnecGordisct Gonvsrts radio warres into sound
ConnecG or disconnects Powsr to
D;D the elec{riaal circuit
CHASSIS GAOUND
Complstss batt€ry : lnterior Lamp Wiring
BATTERY
ckcuil Radio Wit
a- _
JUN TION BLOGK
BATTERY JUNCTION BLOCK (POWEH)
Used to rol,e bett8ry BATTEHY JUNCTION BLOCK (POWEH)
pow€r
cl
UI
82
I
E
KEY SWTCH
HH
o
Jd,-"*}[:;
@( c( ot 6"f
I
@t "Lri.o
HB:.-ft0,fr
,H coNNEcroB D El
or'
'fr UJ
3
lo
Y
tct t-',
o 88
(873)
4.\l;lffil'
o F 2,m GBAY OR ORANGE oR oRANGE I- (872)
tH uJ lu
J oHANGE
& o \ I -)
;42:rowoR
R H INTERIOB
/ Gr-- A
+ I u) LAMP ASSEMBLY
&t C" E
o N (lF EOUIPPED) z
ul o
lrJ*,-HIl*,,,*o-
A o
=
-{\r e
lt
FUSE F.Ig
ro
cn ( cc
&
o
rr
.o
|-
@--
t'J
lrl
$r'*^-;;K
GI
-1 $i[l H
n
o
=
J
J
ul
to
Y OE SBOYVN (873) ? E B l- rIr*o**nrLLow oR BBowN (872) I u.l
6Eal
aYol
6
N
@ ffiffi 237 BBOWN
oNNEcroRD
c)
(\l
TRANSMISSION
CONTROL BEIA] ffiJU.fl?I., - EEilp
tEEF4L
CAB HARNESS
\.
CAB HARNESS
\-\,
ffiC,6ffi'H8,1î
vr
Eg M',
\-*
I
lsl,
BRowN
3fi$
-:$
232 BED/YELLOW OR RED r/15)
L H INTERIOB
IAMP ASSEMBLY
i\i \ I
c
RADIOEADIO
\\'....,
N- --?- 237 BRQWN
CHASSIS GROUND
CHASSIS GROUND
kaukazz@yahoo.co.uk lssued 3-92 Printed in England
4001-120
FRONT AND REAR WINDSHIELD WIPER/WASHERS

Sectional lnddx
121
wrRrNG coDE ......".
122
122
Front Windshield Wiper Motor Circuit Test ..'- ......
Front Wndshield Washer Motor Circuit Test ....,'..... 122
Front Windshield WiperAilasher Switch Circuit lest ..'......... 123
Rear Windshield Wiper Motor Circuit Test ............ 124
Rear Windshield Washer Motor Circuit Test .......,.'.. 124
Flear Windshield WiperAilasher Switch Circuit Test 125
Schematic Circuit .....,.. 127
kaukazz@yahoo.co.uk
Don &85042 tssued 3.92 Printec, in England
4001-121
WIRING CODE
REF COTOB FROM TO WIRE
GAUGE
Fuse F8
244 Red/Gray Keyed Power Junction Block
13
244 Red/Gray Fuse F8 Fuse F2 15
245Gray/RedFuseFSConnectorD(PinN)15 Front Windshield WrperMasher Switch 15

245* Gray/Red Connector D (pin N)
flerm B)
245* Gray/Red Front Windshietd Wiper,&Vasher Switch Front Windshield Wiper Motor (Term C) '15
flerm B)
246* Gray ironi windshield wiper/lVasher switch Front wiper Motor fierm B) 15
fTerm L)
Green Front windshield wiperAVasher Switch Front windshield wiper Motor fferm A) 15
247* Gray/Dark
[Term H)
248* Gray/Black Front Windshield wiperAilasher Switch Front Windshield wiper Motor fTerm D) 15
ft-erm P)
24gBrownFrontWindshieldWiperMotorFrontWindshieldWiperMotorGround15
Connector A) fl-erm
24g Brown Front Wrndshield Wiper Motor Ground Ground
Chassis 15
Connector fi'erm A)
250- Gray/Black Front Windshield WiperAVasher Switch Connector R (]-erm A) 16
fT-erm Vt/)
Front Windshield Washer Motor
2s0 Gray/Black i)onnector B (l-erm A)
16
25lBrownHearWindshie|dWasherMotorFrontWindshieldWasherMotor16
Chassrs Ground
Front Windshield Washer Motor
16
251 Brown C) 15
252 Gray,&Vhrte Fuse F2 onnector D (Pin
Switch 15
252* GrayMhite connector D (Pin c) Bear Windshreld wiperMasher
6) flerm
Switch Rear windshield Wiper Motor fierm B) 16
z5z, Grayryhite Eear Wlndshietd WiperMasher
fl-erm 6) c) 16
switch Rear windshield wiper Motor O'erm
253* Gray/Dark Blue Bear windsh erd wiperMasher
ft-erm 2) A) 16
Switch Rcar Windshield Wiper Motor fl-erm
254* Gray Rear Windshreld Wiper,&Vashcr
fI-erm 7)
255ErownRearWindshieldWiperMotorfiermD)RearWindshre|dWiperAVasherSwitchl6
5) fl-erm '16
255 Brown Fear Windshield WiperAVasher Switch Ground
Chassis
fl-erm 5)
256* Gray/Dark Green Rear Windshield wiper,&Vasher Switch connector R fl-erm B) 16
(Term 3)
256 Gray/Dark Green bonn""ior B (T"erm B) Rear Windshield washer Motor 16
NOTE: Wire code references marked (*) are for tractors up to

cab serial No JKJ4696B'
245*orange(830)248*orange(832)253*orange(842)
246* Orange (833) 250* Orange (835) 254* Orange
(841)
247* Orange (834) 252" Orange (840) 256* Orange (845)
lssued 3-92 Printeo in England

Don 8-85042
kaukazz@yahoo.co.uk
4001-122
CIRCUIT TESTING
NOTE: The battery must be attullchargeand allconnections mustbe clean and tight before testing. Use a multimeterfor
the tests.
Front Windshield Wiper Motor Circuit Test

NOTE: Disconnect the front windshield wiper motor from the harness and turn the key to the ON position
Terminalfor wire 245 GraylRed or Orange 12 Volts Bad circuit between the front windshield
(830) to ground wiper motor connector terminal C and the
keyed power junction block Also check the
keyed power lunction block circuit.
NOTE: Turn the lront windshield wiper swtch to the LOW (l) position.
ferminal for wire 246 Gray or Orange (833) 12 Volts Check wire 246 and the front windshield
to ground wiper,Arasher switch.
NOTE: Turn the windshield wiperlwasher switch to the HIGH (ll) position.
Terminal for wire 247 GraylDark Green or 12 Volts Check wire 247 and the front windshield
Orange (834) to ground wiper/washer switch
NOTE; Turn the key and the windshteld wiperlwasher switch lo the OFF position.
connection.
Between terminals B and D of the front Continuity Check wire 248 and the front windshield
windshield wiper motor connector (harness wiperfivasher switch
side)
NOTE: ll the readings are correct check the front windshield wiper motor.
Front Windshield Washer Motor Circuit test

NOTE: Turn the key to the OFF position and disconnect the front wtndshield washer motor lrom the harness
@ terminal for wire 251 Brown to ground Continurty Check wire 251 and the chassis ground
connection.
Don 8-85042 lssued 3-92 Printed in Engla.d
kaukazz@yahoo.co.uk
4001 -1 23
NOTE: Turn the key to the ON position and hotd the front windshield wiperlwasher swlch in the WASH position.
check Points !sgg,!g Possibte cause of Bad Reading
(l Terminal for wire 250 Gray/Btack to ground 12 Volts Bad circuit belween the front windshield
wiper/washer switch terminal W and the
tront windshield washer motor.
NOTE: lf the readings are correct replace the front windshield washer motor
Front Windshield WiperMasher Switch Test

NOTE: Disconnect the front windshield wiperlwasher switch from the harness and turn the key ta the ON position
Terminal for wire 245 Gray/Red or Orange 12 Volts Bad circuit between the keyed power
(830) to ground junction block and the front windshield
wiper/washer swrtch terminal B. Also check
tl-e keyed power circuir
NOTE: Turn the front wtndshield wiperlwasher switch to the LOW (l) position
Between terminals B and L of the front Continuity Bad front wjndshield wiper/washer switch
windshield wiper/washer switch
NOTE: Turn the tront windshield wiper/washer switch to the HIGH (ll) posrtion.
Between terminals B and H of t'he tront Continuity Bad front windshield wiper/washer switch
NOTE: Turn the front windshield wiperlwasher swltch ta the OFF position.
Between terminals L and P of the front Continuity Bad front windshield wiper/washer switch
windshie.ld wiper/washer switch
NOTE: Hold the lront windshield wiper washer switch tn the WASH positron.
Between terminals B and W of the froni Continuity Bad front windshield wiper/washer switch
windshleld wiper/washer switch
Don 8-85042 lssueo 3'92 Prinred i. Enoland
kaukazz@yahoo.co.uk
40a1-124
Rear Windshield Wiper Motor Circuit Test
NOTE: Disconnect the rear windshield wiper motor from the harness and turn the key to the ON position.
Terminal for wire 252 GrayAVhrte or Orange 12 Volts Bad circuit between the keyed power
(840) to ground junction block and terminal B of the rear
windshield wiper motor connector.
NOTE: Turn the rear wtndshreld vriperlwasher swltch ro the ON pasition
Terminal for wire 253 Gray/Dark Blue or 12 Volts Check wire 253 and the rear windshield
Orange (BaA b ground wiper/washer switch.
NOTE: Turn the key and the rear windshteld wiperlwasher switches ta the OFF position
Iti) Terminal for wire 255 Brown to ground Continuity Bad circuit Detween lhe rear windshield
wiper motor connector terminal D and the
Between terminals A and D of the rear Contrnuity Check wire 254 and the rear windshield
wrndshield wiper motor connector (harness wiper/washer switch.
sLde)
Rear Windshield Washer Motor Circuit Test

NOTE; Turn the key to the OFF positton and disconnect the rear vrindshield washer motor from the harness
Term,nal for wire 251 Brown to ground Continuity Bad circuit belween the rear windshield
O washer motor and the chassis ground
connection.
NOTE: Turn the key to the ON position and hold the rear windshield wiperlwasher switch in the WASH positlon
lD Terminal for wire 256 GraylDark Green to 12 Volts Bad circuit between the rear windshield
grouno wiper/washer switch terminal 3 and the rear
windshield washer motor. Also check the
rear windshield wiper/washer switch.
Don 8-85042 tssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4001-12s
Rear Windshield WiperMasher Switch Test
NOTE: Drsconnect the rear windshield wiper/washer switch from the harness
and turn the kev to the oN oositjon.
Check Points Reading Possjble Cause of Bad Readinq
Gl Terminalfor wire 252 GrayNVhite to ground 12 Volts Bad circuit between the keyed power
lunctron block and the rear windshield
wrperiwasher Swttch.
NorE: Turn the rear windshield wiperlwasher switch to the oN position.
Between terminals 6 and 2 of the rear Continuity Bad rear windshield wiper/washer switch
NOTE: Turn the rear windshietd wiperlwasher switch to the oFF position.
Between terminals 5 and 7 of the rear Continuity Bad rear windshield wiper/washer switch
NorE: Hold the rear wtndshield v.tiperfuasher switch in the wASH pasttian
Belween terminals 3 and 6 of the rear Conttnuity Bad rear windshield wiper/washer switch.
Don 8-85042 issued 3-92 Prinied ilr Enqland
kaukazz@yahoo.co.uk
4001 -1 26
Dor B-85042 lssueo 3-92 Printed in England
kaukazz@yahoo.co.uk
4AOl127
40a1-127
Schematic Circuit
DLDD"}D
(m=q MNNECTOR H
Cab hamess b *asher
MOTOR (WIPEF TOn $iPEH) WIPEFVWASHER SI.YITCH motor hamess
MOTOR (WASHEB}
CHASSIS GROUND 7r+7Dr7F IVIPEB/WASHER SWITCH
iFRONT) An slsctric rnotor
An eledic mot( elecfic motor FEAB}
FUSE
KEYED POWEH Completes battery CHASSIS GROUND Controls more than ong
Protects the eleclrical Controls mors lhan one
JUNCTION BLOCK circuil Completes battery
circuit
system from chcuit
high
Used to roule keyed o{nput or a ground in the electrical circuit
porYer
the electrical system lrom high
CONNECTOR D r a ground in
Cab harness to iflstrumsnt ical system
Circuit \{iring Front and Rear Windshield Washer Motor WirirU Flear Windshield Wiper Circuit Wiring
hamess Front \trlindshield Wiper Circuit 1
KEYED POWEB JUNCTION BLOCK
244 REO/GHAY
FUSE F8 :GBAY/YYHITE
/
2s0 GRAY/BLACK CA OMNGE (835) CONNECTOH D
€)(
\\\\] -=KEKF-asa
245 GHAY/T1ED
-'}- a
i
254 GHAY OH ORANGE (841)
CoNNEC;OB R
9 252 GFAY/WHITE OB ORANGE t84O)
CONNECTOR D ll
GHAY,ELACK 256 GHAYDK GREEN z
rc
245 GRAY/RED OR OBAI oB oBANGE {83o}
\ rc
245 GRAY/HED oB oHANGE (832)
248 GEAY/BTACK OB Of
f f
L-'\. oH oMNGE (830) zE
onANGE (833) BEAB WINDSHIELD
246 GFAY OR OBANGE
cfrEEN OR OBAITGE (834
rlt WIPERMASHER SWITCH
o
FRONT WNDSHIELD 247 GHAY/DK GHEEN O'
WiPEB/WASHEB SWITCH x
tr
E
:j
l---\ l_. (__ wlPERMoron
c E
c
t
----s i=====ii--ttt= FRONT
.. !..-- \
l/INDSHIELD
! -)>-.. WASHEH MOTOR
J---- -\ 255 BRO'TYN
\:A l'ttr' \ 244

2s1 BBOWN "53
GHAY/DK BLUE OR OHANGE {842)
\ ----i' 246
--_\
\-r 247
:
t+\\i $j \:r-
-\'*-il i',t
\ \\
1\i\
i ii t
\
i
,N:
uffi3H'nS3,35'5H, $lt1B- H
T--n
@
\o
Don 8-85042 kaukazz@yahoo.co.uk lssued 3-92 Printed in engtanJ i..
lssued 3-92 Printed in EngtanJ
4001 -1 28
BLOWER MOTOR AND AIR CONDITIONER FOR TRACTORS
FBOM CAB SERIAL NO JKJ46968
Sectional lndex
Blower Motor Relay Circuit Test flractors Up To Cab Serial No JKJ49144) . .. . . .. 131
Air Conditioner Compressor Circuit Test........... ..'........ 133

Air Conditioner Test
Control Switch Circuit ........... ..... 133
Air Conditioner ...,.......
Lockout Relay Circuit Test . ..' ... 133
Air Conditioner ......,.....
lndicator Lamp Circuit Test ..... 134
Don 8-85M2 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk 4001-129
WIRING CODE
REF COLOR FNOM TO WIRE
GAUGE
257 Red/Brown Keyed Power Junctron Biock 30 Amp Circuit Breaker 11
258 Gray 30 Amp Circuit Breaker Connector D (Pin E) 11
258 Gray Connector D (Pin E) Blower Motor Relay fi-erm 30) 11
lf Equipped
258 Gray 30 Amp Circuit Breaker Connector D (Pin G) 11
258 Gray Connector D (Pin G) Blower Switch fl-erm B) 11
259 Brown Blower Motor Connector 1/
259 Brown Connector Resistor Board Connector 14
259 Brown Resistor Board Connector Chassis Ground 11
260 Gray/Dark Blue Blower Switch [T-erm L) Resistor Board Connector t5
261 White Resistor Board Connector 0 56 OHM Resistor 1A
262 Gray/Black Blower Switch ['erm M) Resistor Board Connector 1a
]J
263 Red Besistor Board Connector 0 16 OHM Resrstor 1A
264 Gray/Red Blowcr Swrtch ft-erm H) Blower Motor Relay fl-erm 86) tb
lf Equlpped
265 Brown Blower Motor Belay flerm 85) Chassis Ground lCl
lf Equipped
266 Gray/White Blower Motor Relay flerm 87) Besisto' Boaro Connector I I
lf Equrpped
2664 GrayMhrte Blower Switch fTerm H) Besjstor Board Connector 1'l
267 Black Resistor Board Connector Connector t+
267 Black Conncctor Connector 1A
267 Black Connector Blower Motor 14
268 Gray/Dark Green Blower Motor Switch lTerm C) Air Conditioner Control Switch 1E
IJ
269 Grayl/iolet Air Conditioner Control Switch Air Conditioner Lockout Reiay fferm 30) 16
269 Grayl/iolet Air Conditioner Lockout Relay fl-erm 30) Connector S fierm B) 16
269 Grayl'/iolet connector s (]'erm B) Air conditloner Hrgh pressure switch 16
fierm 8)
269 Grayl/iolel Air Conditioner Switch Air Conditioner Low Pressure Switch i6
0-erm B)
27A Gray/Yellow Air Conditioner Low Pressure Switch Air Conditioner lndicator Lamo 16
fl-erm A)
270 Gray/Yellow Air Conditioner lndicator Lamp Air Conditioner Lockout Relay flerm 87) 16
270 Gray/Yellow Air Conditioner Lockout Relay flerm 87) Air Conditroner Lockout Relay |[erm 86) 16
270 Gray/Yellow Air Conditioner Lockout Relay fTerm 86) Connector S fl-erm A) t6
270 Gray/Yellow Connector S ferm A) Air Conditioner High Pressure Switch 16
[erm A)
271 Brown Air Conditionei Lockout Relay Chassis Ground lf)
fTerm 85)
272 GrayiDark Blue Arr Conditioner Lockout Relay flerm 87A) Connector D (Pin M) l5
272 Gray/Dark Blue Connector D (Pin M) Connector B (Pin F) 15

272 Gray/Dark Blue Connector B (Pin F) Air Conditioner Compressor Clutch 15
273 Brown Air Conditioner lndicator Lamp Chassis Ground 16
NOTE: Wire code relerences marked 'A' are for tractars from cab serla/ No JKJ49144.
Don 8-85042 lssued 3-92 Priniec rr Englan0
kaukazz@yahoo.co.uk
4001 -1 30
CIRCUIT TESTING
NOTE: Thebatterymustbeatfull chargeandall connections,nustbe cleanandtightbefore testmg. Useamultimeterfor
Blower Motor Circuit Test

NOTE: lf the blower motor fails to operate when the blower swrtch ls in LOW (l) and MEDIUM (ll) positons check the
resisfor board, and the blower switch. Nso check the thermal cut-in switch.
NOTE: lf the blower motor fails to aperate when the blower switch rs in LOW (l),MEDIUM (ll), or HIGH (lll) position, check
the circuit breaker, blower motor and the blower switch.
Q ferminal for wire 259 Brown to ground Continurty Check wirc 259 and the chassis ground
connection
NOTE: Turn the key to the ON position and the blower swltch to the LOW (l) position.
Terminai for wire 260 Gray/Dark Blue to 12 Volts Check wire 260 between the blower motor
ground switch terminal L and the resistor board
connector Also check the blower motor
switch
NOTE: Turn the blower switch to the MEDIUM (ll) position
O Terminal for wire 262 Gra'ylSlack to ground "12 Volts Check wire 262 between the blower motor
switch terminal M and the resistor board
connector Also check the blower motor
switch
NOTE: Turn the blower swi166 1o the H|GH (lll) pasitron
Terminal ior wire 266 Gray/White or 2664 12 Volts Bad circuit between the blower switch
GrayAVhite to ground terminal H and the resistor board connector.
Also check the blower motor switch and the
blower motor relay (if equipped).
Circuit Breaker Test

Terminalfor wire 257 RedlBrown to ground '12 Volts Check wire 257 and the keyed power
junction block ccnnection.
Dcr 8-85042 issued 3-92 Prinled in England
kaukazz@yahoo.co.uk
4001 -1 31
Between the terminals of the circuit breaker Continuify Bad circuit breaker
NOTE: Turn the key to the ON positron.
O Termlnal for wire 258 Gray to ground 12 Volts Blower motor circuit shorted to ground
Blower Motor Relay Circuit Test

Tractors Up To Cab Serial No JKJ49144 Only
NOTE: Turn the blower switch to the OFF positton.
@ Terminal for wire 265 Brown to ground Continuity Check wrre 265 and the chassis ground
connection.
NOTE: Turn the key to the ON pasitton
rerminal for wire 258 Gray to ground 12 Volts Bad circuit between the circuit breaker and
{l the blower motor relay terminal 30
NOTE: Turn the blower switch to the HIGH (lll) posttion
Terminalfor wire 264 Gray/Red to ground 12 Volts Check wtre 264 belween the blower switch
Q terminal H and the blower relay terminal 86
Also check the blower switch.
llil Terminatfor wire 266 Gray,&Vhite to ground l2 Volts Bad blower motor relay
Blower Switch Test

NOTE: Disconnect the blower switch from the harness and turn the key to the ON position
Check Points Reading Possible Cause of Bad ryCqlg
@ ferminal for wire 258 Gray to ground ;; *offi,uno

the blower switch terrninal B Also check the
circuit breaker
NOTE: Turn the blower switch to the LOW (l) positron.
Between terminals B and L of the blower Continuity Bad blower Switch

switch
Between terminals B and C ot thc blower ContinuibT Bad blower Switch

switch
Do.r 8-85042 issued 3-92 Prinled in Englanc
kaukazz@yahoo.co.uk
4001 -1 32
NOTE: Turn the blower switch to the MEDIUM (ll) pasition
Behryeen terminals B and M of the blower ContinuiV Bad blower switch

switch
Between terminals B and C of the blower Continuity Bad blower switch

switch
Between terminals B and H of the blower Continuiiy Bad blower switch

switch
Between termrnals B and C of the blower Continuity BaO blowcr switch

switch
Resistor Board Test

NOTE: Connecttheresistorboardtothecircuitatlheresis/orbaardconnectoranddisconnecttheblowermotor.fromthe
resistor board.
NOTE: Turn the key ta the aN position and turn the blcwer switch to the HIGH (lll) positron.
Termlnal for wire 267 Black to ground 12 Volts Check wtre 267
fi)
NOTE: Turn the key to the OFF position and disconnect the reslslor board from lhe harness.
Belween the terminals for wires 261 White 0 72 OHMS Bad resistor board.
and 267 Black
Between the terminals for wires 263 Red 016 OHMS Bad resistor board.
and 267 Black
Between the terminals for wires 261 Whte 0 56 OHMS Bad resistor board.
and 263 Red
NOTE: Use a piece o.f wood or plastic and hold the contacts of the thermal cut-in switch closed.
Between the terminals for wires 261 Whrte Continuity Bad thermal cut-in switch
and 267 Black
NOTE: The thermal cut-in switch protects lhe reslslors from over heating. lf the atr flow around the resistors becomes
restricted,Ihe reslslors will over heat and the thermal cut-tn switch conlacts will close and the blower motorwill goto
HIGH speed.
Dor 8-35042 lssued 3-92 Printed i': Engiald
kaukazz@yahoo.co.uk
4001 -1 33
Air Conditioner Compressor Circuit Test
NOTE: Before any resfs are carried out on the air conditioner
circuit, refer to Section gOO2.
NOIE, Turn the keytdthe oN position, the blower switch tothe Low (t), MEDtt)M (il) or H|GH (ilt) positions
conditioner control swilc.h to MAXTMUM cootinq. and setthe air
Check Points Reading possible

Qause of Bad Heading
Terminal for wire 272 Gray/Dark Biue to l2Volts Bad circuit between the blower switch
ground terminal C and the ai conditioner
compressor. Also check the blower motor,
the air conditioner control switch and
lockout relay, refer to Section 9002 and
check the pressure switches.
Air Conditioner Control Switch Circuit Test

NOTE: Before any tes/s are canied out on the air conditioner circuit,
refer to Section gao2.
NOTE: Turn the keytothe oN position, the blower switch to the Low (t), MEDtuM (il) or H|GH'\"'/
-(til) positions and setthe air
conditioner control switch to MAXTMUM cooting.
Check Points Reading po,ssible Cause of Bad
Reading
Terminal for wire 268 GrayiDark Green to 12 Volts check wire 26g between the biower switch
ground terminal C and the air conditioner control
switch.
@ rermlnal for wire 269 Gray//iolet to ground 12 Volts Bad air conditioner controi switch
Air Conditioner Lockout Relay Circuit Test

NOTE: Before any tests are canied out on the conditioner circuit, refer
atir to Section g002.
NOTE: Turn the key to the aFF position.
Check Points Reading Possibie Cause of Bad Reading
Te'minal forwire 271 Brownto ground Continuity check wire 271 and the chassis ground
connection.
Between terminals 86 and 87 of the air Continuity Checkwire2T0betweentheairconditioner

coditioner lockout relay lockout relay terminals g6 and 87
fcn 8-85042
kaukazz@yahoo.co.uk
4001 -1 34
NOTE: Disconnect the air conditioner high and low pressure swtches from the harness.
NOTE: Turn the keyto the ON position, the blower switch to the LOW (l), MEDIUM (ll), or HIGH (lll) position and setthe air
conditioner controlswrtch to the MAXIMUM cooling position.
ferminalfor wire 269 GrayNiolet to ground 12 Volts Check wire 269 between the air conditioner
@ switch and the lockout relay.
Terminal for wire 272 GraylDark Blue to 12 Volts Bad air conditioner lockout relay
ground
NOTE: lnstall a suitable jumper lead between terminals A and B of the air conditioner high pressure swfch connectot
(harness side)
lGl Terminal for wire 270 GrayN ellow to ground 12 Volts Bad circuit between terminals 30 and 86 of
the air conditioner lockout relay.
Terminal for wire 272 GraylDark Blue to 0 Volts Bad air conditioner lockout relay.
ground
NOTE: Remove the iumper lead from the air conditioner high pressure switch connector
ilh terminalforwire 2T0GrayNellowtoground 12 Volts Bad air conditioner lockout relay.
Ct) Terminal{or wire 270 GrayNellow to ground 12 Volts Checkwire2T0betweenterminalSTandthe

air conditioner indicator lamp.
NOTE: lnstall a suitable jumper lead between terminals A and B of the air conditioner low pressure switch connector
(harness side) and turn the key to the ON position.
€l Terminal for wire 27 0 GrayN ellow to ground i2 Volts Bad circuit between the air conditioner
control switch and the indicator lamp.
Air Conditioner lndicator Lamp Circuit Test

NOTE: Check the air conditioner indicator lamp bulb,
@ Terminal for wire 273 Brown to ground Continuity Check wire 273 and the chassis ground
connection.
NOTE: lf the reading is correct check the air conditioner lockout relay circuit
kaukazz@yahoo.co.uk
400.1-135
4001-135
q.1jr
+rZfi \P
Schematic Circuit
"/Itl
^rGUij+€ KEYED PO$IER
JUNCNON BLOCK U ljMP CIRCUIT BREAKER
PRESSURE SWITCH (LOW
W DLID HESISTOB BOARD
Controls ths amount ol
MOTOH
An slec,kic motor
PRESSUHE SWITGH
(HrGH)
MOTOR
An electric motor
PffESSURE SWTCH
(HrGH) ROTABY SWTCH
Used
power
to route kelied
RELAY3O AMP
Pr
el
Produc€s h€at that emits
artifical ligl*
Heat actuatsd, automalic
reset, protBcts €lecticz,l Pressure actuatsd, conlact
points opsn when Pressure
CHASSIS GROUND CHASSIS GHOUND electrical current to an Direc{s electrical current to circuibs lrom ovedoad
Completes battery Compl€tss battery electric motor Pressure actuated, codact Pressure acluated, corltact one or more circuits
A magnetic switch is too low
polnts close when Pressure polnls close when Pressure dkecls electric ckcuit
circuit ELECTFDC CLUTCH
circuit
ELECTEC CLUTCH is too high is too high
AIH CONDITIONER CONTROL (ooMPHESSOR)', {coMPRESSCIR)',
SWTCH
A magrretic field coit on A magnetic field coil on
CONNECTOH D A switch with a tamPerature compressor pulleY. When compressor PulleY, When
energized allows rotation oI Blower Motor Wiring Blower Motor Wiring Air Conditioner Wiring
Cab harness to lnstrument sonsing probe. The switch is energized allows rotation of
compressor
harnoss
pre-set by the opsrator. Ths compressff crankshafl. crankshafl.
GONNECTOR S
probe senses evaporator core When rrt energized PulleY
CONNECTOR S When rrt energizad PulleY
tompsratura, The switch also free wheels , Controlled bY Engine harness to free wheets . Conkolled bY Engine harness to
KEYED FOWER JUNCNON BLOCK
controls currant to the elgctric switches cab harness switches cab harness
clutch.
q
J
tr (y;
5 n
-{ -t- ---o \- 257 HEDiBRow-
30 AMP CIRCUIT BBEAKER
\o
THERMAL CUT]N SWTCH
BEI.AY 75 AMP
THERMAL CUT.IN SWITGH
Protects tho r€sisto.s from Prolgc'ts ths r€sisto.s from
@ .BHEAKER
A magnetic switch that overheating overheating

CONNECTOR D
ffisg
directs electric circuii AIR GONDTNI AIR CONDITIONER
CONTROL 51 CONTROL SWITCH
s
o
260 GBAYiDK BLUE
V;r:ilffiT:: -1-t; -t - I
\ra
H
269 GBAYNIOLET
l44l+l4l RESrsroR B.ARD

l^l^.1/\1,^l CoNNECTOR
Ih
II
ln
ts
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IE
ls
=
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CONNE TOB D
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268 GHAY/DK GREEN .]
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{,1,4",
GI I
ID
CONNEGTOR S
v I
o AIH CONDITIOIIEH
I {,:." COMPRESSOR CIIJTCH ET
\U
MoroF BLOWER MOTOR t(,
I ".o**
nEuv RELAY AIR CONDMONEH
E
o
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lrupro cAB sEBu (UPTO CAB HIGH PRESSUHE e N

1\
ol
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l' xo .ttcttooastaal Flo JK,lff49144) SWITCH E
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,ao*r* roro* o
lo @
BLOWER MOTOR
ot
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,* -KEKF"- .l
. CONNECTOHS
CONNECTOR D
@
tO
(c'
ot
CHASSIS GROUND
kaukazz@yahoo.co.uk 3-92
Don 8-85042
lssued 3-92 Printed in England lssued Printed in England
BLOWER MOTOR AND AIR CONDITIONER FOR TRACTORS
UP TO CAB SERIAL NO JKJ46967
Sectional lndex
Resistor Board and Thermal Cut-ln Switch Test ........... 140

'141
Air Conditioner Compressor Circuit Test ...........
Air Conditioner Control Switch Circuit Test ............ 141
Air Conditioner Lockout Belay Circuit Test ........... 141
Air Conditioner lndicator Lamp Circuit Test ............ 142
Schematic Circuit 143
Don 8-85042 lssued 3-92 Printed in Englanc
kaukazz@yahoo.co.uk
400'1-137
WIRING CODE
WIRE
TO
BEF COLOBNVIRE No FBOM GAUGE
11
30 AmP Circuit Breaker
257 Red/Brown Keyed Power Junction Block 11
Connector D (Pin E)
258 GraY 30 AmP Circuit Breaker 11
Splice
258 Orange (821) Connector D (Pin E) 11
Blower Motor RelaY fl-erm 30)
258 Orange (821) Splice
Besistor Board fl-erm 8)
13
258 Orange (821) Splice
Connector D (Pin G)
11
258 GraY 30 AmP Circuit Breaker 11

Blower Switch fl-erm B)
258 Orange (B2r A) Connector P (Pin G) 11
Chassis Ground
259 Brown (827) Blower Motor
L) Resistor Board fl-erm 5)
15
260 Orange (822) Blower Switch fl-erm 13
Resistor Board fl-erm 7)
262 Orange (823) Blower Switch (1-erm M) tb
Blower Motor RelaY fl-erm 86)
264 Orange (825) Blower Switch ft-erm H) 16
Chassrs Ground
265 Brown (827) Blower Motor RelaY f-erm 85) 11
Splice
266 Orange (824) Blower Motor RelaY fl-crm 87) IJ
Splice
266 Orange (824) Resistor Board flerm 6) 11
Blower Motor
256 Orange (824) Spltce
Air Conditioner Control Switch
t5
268 Red (801) Blower Switch (I-erm C) 16
Air Conditioner Lockout RelaY
269 Orange (802) Air Conditioner Control Switch
(Tern" 30)
bonn".to, S fl-erm B) 16
269 Orange (802) Air Conditioner Lockout BelaY
fi-erm 30) Air Conditioner High Pressure 16
269 Orange (802) Connector- S (Term B)
Swrtch (1'-erm B)
Rir ConOitioner Low Pressure
16
269 Orange (802) Air Conditioner Switch
Switch (-T-erm B)
Rir ConOitioner lndicator LamP
16
270 Orange (804) Alr Conditioner Low Pressure
Switch [t-erm A) RelaY 16
Air Conditioner Lockout
270 Orange (804) Air Conditioner lndicator LamP
fl-erm 87)
ii, ConOitioner Lockout RelaY 16
270 Orange (804) Air Conditioner Lockout BelaY
(l-erm 86)
(lerrn 6/l A) 16
bonnector S (Term
27A Orange (804) Air Conditroner Lockout RelaY
fl-erm 86) Air Conditioner High Pressure 16
270 Orange (804) Connector S ft-erm A)
Switch fTerm A)
16
Chassis Ground
271 Brown Air Conditioner Lockout ReiaY
flerm 85)
Connector D (Pin M) 15
272 Orange (803) Air Conditroner Lockout RelaY

[Term 87A) Conneclor B (Pin F)
15
272 GraY/Dark Blue Conreclo' D (Pin M)

Clutch 15
Air Conditioner Compressor
272 GraY/Dark Connector B (Pin F) 16
Blue Cnass's Ground
273 Brown Air Conditioner lndicator Lamo
lssueo 3-92 Prinled rn Englanc

Don 8-85042
kaukazz@yahoo.co.uk
4001 -1 38
CIRCUIT TESTING
NOTE; The battery must be at f ull charge and all connections must be clean and tight before festlng Use a multimeter for
lhe lests

NOTE: lf the blower motor farls to operate whert the blower swttch is tn LOW (l) MEDIUM (ll), or HIGH (lll) position, check
the circuit breaker. blower motar and the blower svr'tlcn.
NOTE: lf the blower motor runs at high speed when the switch is in LOW (l) or MEDIUM (ll) position check the air flow
through the blower fan. Nso check the resr'slor board thermal cut-tn switch.
NOTE: Disconnect the blower motor from lhe harness.
@ Terminalforwire 259 Brown (827)loground Continuity Check wire 259 and the chassis ground
conneclion.
NOTE; Turn the key to the ON positron and the blower switch to the LOW (l) position.
ror wire 266 oransc (824) to 12 Volts Bad circuit belween the resistor board
@ J:;n:'r terminal 6 and the blower motor. Aiso check
the resistor board and the blower switch.
NOTE: Turn the blower motor switch to the HIGH (lll) positron
Terminal for wire 266 Orange (824) to 12 Volts Bad circuit between the blower relay
ground terminal 87 and the blower motor. Also
check the blower relay and the blower
switch
NOTE: fftheblowermotorfailstooperatewhentheblowerswitchisinLOW(l),orMEDlUM(ll)positionschecktheresistor
board.

NOTE: Turn the key to the ON posttian
Check Points iggglg Possible Cause of Bad Reading
fcrrninal for wire 257 ?edlSrown to ground 12 Volts Check wie 237 and the key power lunction
@ block connection.
NOTE: Turn the key to the aFF position
Bel,veen the terrrinals of thc circuii breaker Continuity Bad circuit breaker
NOTE. Turn the key ta the ON positron
Gl Terminal for wire 258 Gray io ground

'1
2 Volts Blower motor c rcuit shorted to ground
3or 8'85C42 lsslec 3-92 Printed rn Englano
kaukazz@yahoo.co.uk
4001 -1 39
Blower Motor RelaY Circuit Test'
NOTE: Turn the key to the OFF positran.
Check Points Readino Possible Cause of Bad Reading
terminalforwire 265 Brown (827) to ground a".^n Check wire 265 and the chassis ground
@ connection.
NOTE: Turn the key to the ON Posltion
Terminal for wire 258 orange (821) to 12 Volts Bad circurt betr'veen the circuit breaker and
ground the blower motor relay terminal 30
NOTE: Turn the key to'the HIGH (lll) posttton.
Terminal for wire 264 orange (825) to 12 Volts check wire264 between the blower switch
sround x'J:iL:-"[r"'[ili:I:;',flav
terminar86
Terminal for wire 266 Orange (824) to l2Volts Bad blower motor relay'
ground
Blower Switch Test

the harness anc turn the key to the oN positton'
NoTE: Disconnectthe blower switch from
Check Points Req!'ng Possible Cause of Bad Reading
\-- /
v ". Yv (821A)
Terminal for wire 258 orange to 12Volts Badcircuitbetweenthecircuitbreakerand
ground the blower switch terminal B. Also check the
circuit breaker.
NOTE: Turn the blower swlch to the LOW (l) positron'
Beiween termrnals B and L of the blower Continuily Bad blower switch'

switch
Berween termrnais B and c of the brower continurry Bad blower switch

switch
(ll) position'
NOTE: Turn the blower switch to the MEDIUM
Betvveen terminals B and M of the blower Continuily Bad [rlower switch

swttch
Between terminals B and C of the blower Continuity Bad blower switch

switch
NOTE: Turn the blower switch to the HIGH (lll) position
Between terminals B and H of the blower Continuiry Bad [:lower swttch

switch
Between tcrmrnals B and C of the blower Continuity Bad blower switch

switch
lssrec 3-92 Prrn:eo in E'glanc
Don 8,85042
kaukazz@yahoo.co.uk
Resistor Board and Thermal Cut-ln Switch Circuit Test
NOTE: Disconnect lhe resislor board from the harness and turn the key to the ON position.

Terminal for wire 258 Orange (821) to 12 Volts Check wire 258 between the splice and the
ground resistor board terminal 8.
NOTE: Turn the blower swrlch fo the LOW (l) position
Terminal for wire 260 Orange (822) to 12 Volts Check wire 260 between the blower switch
ground rerminal L and the resrstor board terminal 5.
NOTE: Turn the blower switch to the MEDIUM (ll) posrtion
Terminal for wire 262 Orange (823) to 12 Volts Check wie 262 between the blower switch
ground terminal M and the resistor board terminal 7
Between terminals 5 and 7 of the resistor Continuity Bad resistor board.

board
Between terminals 6 and 7 of the resistor Continuity Bad resistor board.

board
Between terminals 6 and 8 oi the resistor No Continuity Bad thermal cut-in switch.
board
NOTE: Use a piece of wood or plastic and hold the contacts of the thermal cut-in switch in the closed position.
Between terminals 6 and 8 of the resistor Continuity Bad thermal cut-in switch,
board
NOTE: The thermal cut-in switch protects the resrstors from over heating. lf the atr flow around the resistor board
becomes restricted, fhe res/slors will over heat and the thermal cut-in switch contacts w// c/ose a nd the blower motor will
go to HIGH speed.
Don 8-85042 lssued 3-92 Prinlec in England
kaukazz@yahoo.co.uk
4001,1 41
NOTE: Before any tests are carried out on the air conditianer circuit. Refer to Section g002.
NOTE: Turn the key to the ONpos ition, the blower switch tathe LOw (l), MEDIUM (il) or HtGH (lll) positions
and setthe air
conditioner control switch fo MMTMUM coaling.
@ ;ron:'l ror wire 272 GraY/Dark Biue to 12 Volts Bad circuit between the blower switch
terminal C and the ai conditioner
compressor Also check the blower motor,
the air conditioner control switch and the
lockout relay, refer to Section 9002 and
check the pressure switches.

NOTE: Before any lests are carried out on the air conditioner circuit. Refer to Section gOA2
NOTE: Turn the keytothe ON position, the blower switch to the LOW (t), MED|UM (il) or H)GH (ilt) positions and setthe air
conditioner contral switch to MMIMUM cooling.
Check Points Readino Posslble Cause of Bad Readino
(h Terminal for wire 268 Red (801) to ground 12 Volts Check wire 268 between the blower switch
terminal C and the air conditioner control
switch.
Terminal for wire 269 Orange (BO2) to '1

2 Volts Bad air conditioner control switch
ground

NOTE: Before ary tests are caried out on the air conditioner circuit. Refer to Section gOO2.
Check Points Beading Possible Cause of Bad Beading
@ ferminal forwire 271 Srown to ground Continuty Check wire 271 and the chassis ground
connectron
Between terminals 86 and 87 of the air Continuity Check wire 270 belween the air conditioner
coditioner lockout relay lockout relay terminals 86 and 87.
Don 8-85042 lssued 3-92 Printed in Engtand
kaukazz@yahoo.co.uk
4041 -1 42
NOTE: Disconnect the air conditioner high and low pressure swilches from the harness.
NOTE:TurnthekeytotheONpositian,theblowerswitchtotheLAW(l) MEDIUM(ll),orHlGH(lll)positionandsettheair
conditianer control swtch to the MMIMUM cooling position.
Terminal for wire 269 Orange (802) io 12 Volts Check wire 269 between the air conditioner
ground switch and the lockout relay
Terminal for wire 272 arange (803) :o 12 Volts Bad air conditioner lockout relay.
ground
NOTE: lnstall a suitable jumper lead beNveen lermrnals A and B cf the air conditioner high pressure swttch connector
(harness srde).
Terminal for wire 27A Orange (804) to 12 Volts Bad circuit between terminals 30 and 86 of
ground lhe air conditioner lockout relay.
Terminal for wire 272 Orange (803) io 0 Volts Bad air conditioner lockout reiay.
ground
NOTE: Remove the jumper lead from the air conditioner high pressure switch cannectar
Terminal for wire 27a Orange (804) :o 12 Volts Bad air conditioner lockout relay.
ground
Termrnal for wire 270 Orange (804) to 12 Volts Checkwire2T0betweenterminal STandthe

ground air condrtioner indicator lamp
NOTE: Turn the key to the OFF positian.
NOTE: lnstalt a suitabte jumper lead betvveen terminals A and B of the arr conditioner low pressure switch connector
(harness side) and turn the key to the ON positron
Terminal for wire 270 Oranqe (804) to 12 Volts Bad circuit between the air conditioner
ground control switch and the indicator lamp

NOTE: Check the air condrtioner indlcator lamp bulb.
NOTE; Turn the key to the OFF position.
fF Terminal for wrre 273 Brown to ground Contrnuity Check wire 273 and the chassis ground
connection.
NOTE: lf the reading is correct check the air conditioner lockout relay ctrcutt
Don 8-85042 lssuec 3-92 Printed in England
kaukazz@yahoo.co.uk
4001-143 4001-143 q
Schematic Circuit
powrquadplus www.thebestworkshopmanuals.co.uk )uit
)
.-\.-
tr
f
-o c
---.-\- *Hc* -61
IA
,,7;"D D'D
\1
MOTOR
An elestric motor
BESISTOR BOARD
Controls th6 amount sf
THERMAL CUT.IN SWTCH
Protects ths resistors trom
ovefieating
\,
IARD
mount
THEBMAL CUT.IN SWTCH
Protecis the resistors lrom tI "
PBES$URE SWTCH
LT
M
CIRCUIT EfrEAKER
Hsat actuated, automatic PRESSUBE SWTTCH {LOW}
KEYED POWER
JUNCTION BLOCK
U$ed to routo ksyed
@
CHASSIS GROUND overheating ROTARY SWITCH
CHASSIS GROUND ":, electrical cunent io ari lnt to (HrGHl HEIAY$ N resst, prot8c'ts eleclrical Pressura actuatod, contast powBr
l Directs electrical cunenl to
Gompletes battery electric motor points open when pressure
circuit
Compl8tes battery
\o one or more circuits
Pressure actuated, contact A magnetir circuits from overload
ELECTRIC CLUTCH circuit points close wh€n prsssure ls too low
AIR CON DITIONER CONTHOL
SWTTCH
(coMPRESSOn)
A magnaHc field coilon
ELECTRIC CLUTCH
(c0MPRESSOR)
A magnetic field coll on
l- ls too high
direcb elscfi
CONNECTOB D A switch with a tsmPerature comprassor pulley. When compr€ssor Pulley. Whan I
sensing Probe' The switch is energized allows rotation of

Cab harnsss to instrumer*
compressor crankshaft.
energized allows rotation of
Blower Mot< Blower Motor Wiring
+
pre-set bY tte oPerator. The compressor crankshaft,
hemess
probe senses evaporalor cors VVhsn not energized PulleY
CONNECTOR S CONNECTOR S Air Conditioner Wiring
Whan nol energized pulleY
frea wheels . Controlled bY Engine harness to Engine harness to
t€mperature, The switch also free whsels , Controlled bY
switches cab harness cab harness
controls cunsnt to lhe electric switches
KEYED POWEB JUNCIION BLOGK
clutch.
SPUCE
Connects ono or more 257 RED/BROWN
\o
chctits that do thg samo 30 AMP CIRCU.Ir BREAKEF
furrtion
CONNECTOR D
AIB CONDMONER
258 ORANGE (821A) CONTROL SWITCH
AIR CONDITIONETI AIR CONDITIONER
INDICATOR I.AMP LOW PRESSURE SWTCH
tr
g,
i @
I u,
AI
i 269 OHANGE (802)
I
(\l BLOWER SWITCH

to
%@
I
u.t GONNECTOR D
i
o
z !t (, ot
N
o z o
to +
!\ d.
o
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(9
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o
z
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@
ut
CONNECTOR B
zo
u) l.)
t\l 28+ OBANGE (82s N oBANGE (825)
EC !E
i'. o 2s8 o &,
ct o!
( o
it @
d \ ( c,
t-
nl
268 HED (801)
ENGINE
258 OHANGE (821)
r--{EKl-270
CONNECTOR S
AIR CONNITIONEH
@AIR GONDT
COMPRESSOR CLUTCH
BLOWEB MOTOR REI-AY lf LOO<OUT
,{9t66{- @q *@Q
\o
266 OBANGE {824)
E
Ybo
AIR CONDMONEB
HIGH PBESSURE
i -D S { SWTTCH
--a***-1----- -fi[[ -ffP-zzz

BLO$IER MOTOR
r:
VER MOTOR
/-: zm -fiffif em
ezz
' coNNEgt
- ezz
.
I
{ \y \v . CONNECTORS
CONNECTORD
I
+ 2s9 BBOWN (824 2s9 BBOWN (824 +- 265 BflOWN (824
I CHASSIS GBOUND CHASSIS GBOUND
kaukazz@yahoo.co.uk 3-92 Printed in England CHASSIS GROUND
-L
Don &85042
lssued lssued 3-92 Prinled ln England
I
4001-144
TRAILER CONNECTOR
Sectional lndex
Trailer Connector Chassis Ground Circuit Test ............ .........,...,........ 145

Trailer Connector Keyed Power Circuit Test .......... .,....., 145
Trailer Connector Tail Lamp Circuit Test........... ............ 146
Trailer Connector Tum SignalAilarning Lamp CircuitTest ................. 146
Trailer Connector Work Lamp Circuit Test ............ ......... 146
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk 4001 -t 45
WIRING CODE
REF COLOR FROM
TO
WIRE
178 PinkMhite Tail Lamp Circuit Spiice GAUGE
188 pink Trailer Connector (pin 6) 1B
R H Turn SignalAVarning Lamp Circuit Trailer Connector (pin 5) It)
Splice
192 PinVDark L H Turn SignalMarning Lamp Circuit
Trailer Connector (prn 3) t6
Green SpIce
2A7 VioleVyellow Rear Fendcr Work Lamp Circuit Splice
234 Fed/Btack Trailer Connector (pin 2) 16
Keyed Power Junction Block Fuse F31
235 Fed/Orange Fuse F31 11
235 Red/Orange Connector D (Pin p) 1C
IJ
Connector D (Pin p) Splice
235 Red/Orange Splice 15
235 Red/Orange Electric Seat Connector fl-erm A) 1q
Splice
235 Red/Orange Connector N (pin G) 15
Conneclor N (pin G) Trailer Connector (pin 7)
235 Bed/Orange Trailer Connector (pin 7) IJ
274 Brown Traiier Connector (pin 4) 16
Trailer Connector (prn I ) Chassis Ground l3
CIRCUIT TESTING
must be at fult charge and alt connection must be ctean and tight before testing
#;:'rl:l'atteries usea muttimeter
NorE: lf all the Trailer connector circuits fail to operate check the traibr connector chassis ground circuit.
Trailer Connector Chassis Ground Circuit Test

Check points Reading possible cause of
Bad Beadrng
tcrminal for wjre 274 Brown to ground
Q Continuity Check wire 274 and the chassis qround
connection.
Trailer Connector Keyed power Circuit Test

Check points Reading Possib,e cause of Bad Reading

ferminai for wire 235 Red/Orange ground
@ 12 Volts Bad circuit between the keyed power
lunction block and the trailer connector pin
7 Also ckeck the keyed power circuit.
Terminal for wire 235 Red/Orange ground
O 12 Volts Che ck wire 235 between the trailer
connector pin 7 and pin 4.
Dcf B-85042
lssued 3-92 Pr.inied in Ergtans
kaukazz@yahoo.co.uk
4001 -1 46
Trailer Connector Tail Lamp Circuit Test
NOTE: For the trailer connectar tail lamp circuit test see page 78 for cab tractors ar page 90 for tractors without cab.
Trailer Connector Turn SignalMarning Lamp Circuit Test

NOTE: ForthetrailerconnectorTurnSignallWarninglampcrcultfestseepageTSforcabtractorsorpage90fortractors
without cab.

NOTE: Forthetraiterconnectorworklampcircuitteslsee pageg5forcabtractorsorpagel03fortractorswithoutcab.
kaukazz@yahoo.co.uk
4AAt147
Schematic Circuit
TBAITER CO$E{rcTOH
SPUCE Corrlecis tE tactor electical
Connects one or m(re circrlb aHer
FUSE
circuits that do the sane
KEYEO POWER Protects llp electical func{ion
JUNCNON BLOCK system trrrn high CONNEfiOB N
Used to route keyed output or a ground in Cab hamess to iender E
power the elecfical system harn€ss
CONNECTOR D
Cab hamess to inslrument
hamess Trailer Connector Wring
KEYED P( KEYED POWEB JUNCNON BLOC(
(
+- 234 REDIBI-AIC'(
FUSI FUSE F31
\.. :
\ri
(
c FMI TAiL I.AMP CIRCUIT
FROU 8 H YURN SIGNAT/I^/ARNING I.AMP CIBCUTT

!:
.i:
..: :
FRO$ L H IURN SIGNAL/WARNING L.AMP CIRCUTT
i: : FEOM REAR FENDER WORK I.AMP
r
CONNECTC lEi
---:i:.
I ----ri
_---'----'.L
EQE
-ar
! : <.---:l:-t 23s BEDIOBA,.tr =gH
ro:<J
cD:ZO
oH RED {133} -E=
6rl\
(Do
CONNECTO* N -C\l
235 RED/OFAI{GE
ORORA'{GEF o)
TRAILER
c
\
\ \.t-t
ELECI ELECTRIC SEAT CONNECIOR
--.----
-----=-l-\-.*- 235 RED/OHA}IGE
--:--:.-.. ---.-*-
\i
,'rl*r*-*t-**\\-..*-- Z
3
o
cc
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t
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kaukazz@yahoo.co.uk
Don &85042 lssued 3-92 Printed in England
-
Section
4001
ELECTRICAL TROUBLESHOOTING AND SCHEMATICS

(For Tractors From Pin No JJF1 015046)
Copyright @ 1992
September 1992
kaukazz@yahoo.co.uk
4001-2 powrquadplus www.thebestworkshopmanuals.co.uk
TABLE OF CONTENTS
....,.. 3
SHOP EQUIPMENT TOOLS .,...,..."
GENEBAL INFORMATION''"..."'".."'
LOCATION ''""""""""" 6
ELECTRICAL COMPONENT
BULKHEAD CONNECTORS AND
7
AND ETHER START "'""""'"""'''"""'
STARTER, KEY SWITCH, KEYED POWER' FUEL SHUT'OFF
CLUSTER """"""'"'14
ALTERNATOR AND INSTRUMENT
ACCESSOHY POWER BEI-AY,
" .,...".,.,...."..,...28
FORWARD/REVERSE AND TRANSMISSION
CONTROL"'
"""""""""""""40
SENS-O-DRAULIC (sHB) HITCH
CoNTROL
...'"'""''56
DIFF LOCK AND MFD
HEADLAMPSANDTAILLAMPSFoRTRACTORSWITHCAB.'.,.............,,.66
HEADLAMPSANDTAILLAMPSFoRTHACTORSWITHOUTCAB,.'...'.....76
TURNSIGNAIJWARNINGLAMPSFoRTRACToRSWITHCAB.....'..,.,'','..',.,.,..'.'.''..'.'..86
TUBNSIGNAL^/VARNINGLAMPSFoBTBACTOFSWITHOUTCAB,',.......'.'.''.''..'..,,..'''96
WITH CAB"""'""""""""""""'106
WORK LAMPS FOB TRACTOFS
REAR CAB
REAF FENDER, FBONT CAB AND
FOB TMCTORS WITHOUT CAB"""'"""""""114
REAR FENDER, FRONT FENDER
AND CANOPY WORK LAMPS
......122
T;;JiEN COI'INECTOR POWEB CIRCUIT"'"""
RIGHTHANDCONSoLEAUXILIARYPo}VEHCONNECToF,INSTEUMENTPANELAUXILIARY
SEAT AND
POWER CONNECTOR, ELECTRIC
coNsoLE LAMP AND INSTRUMENT

RADIO, INTEFIOR LAMP, BIGHTllND
.......128
CLUSTEB ILLUMINATION (DIMMER)
..,.,. , l JZ
FRONT AND REAR WINDSHIELD

WIPER/WASHERS """""""
BLOWEF MOTOF AND AIR CONDITIONING

""'""" "'
6A08'
NOTE: For Powershift, Refer to Section
lssucd 9-92 Prlntcd in England
Don 7-38440
kaukazz@yahoo.co.uk
, .:!i!
aaa*-.
tffiill
ilrrr l
ilffit
:IXffilE$iffiEl
::EffiiffiIffiT
::TMI
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1. SIGNAL GENEBATOR/COUNTEH OEM 13364
s
iit
,:,:i1i:
, !rq{:l
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sT27
2, MULTIMETEH OEM 1428
GENERAL INFORMATION
WARNING: Never operate the engine in a closed building, proper ventilation is required under all
circumstances .
NOTE: Nt etectrical checks must be made with the tractor parked on hard level ground with the parking brake engaged
and the engine OFF unless otherwise sfated.
NOTE: All componenls, wires and connectors disconnected during any electrical checks must be connected when the
checks are complete.
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4001,4
FUSES
FUSE AMPS CIRCUIT FUSE AMPS CIRCUIT
F1 15 Front Work Lamps (Cab) tt/ 15 Horn, Flasher
F2 10 Rear Wipcr F18 7.5 Forurard Solenoid
tr? 30 Auxiliary Power, Cigarette F19 10 Forward/Reverse Relay
Lighter lnterior Lamp F20 7C
Powersh ft
F4 t5 Rear Work Lamps F21 7.5 Revcrse Solenoid
F5 15 Turn Signal F22 I5 Ether Start
F6 5 Warning Lamps F23 l0 MFD Diff Lock
F7 5 lmplcment Auxiliary Connector F24 7.5 lnstrument Cluster 1
FB 15 Front Windshield WiperAVasher faE
taJ 5 Powershift Solenoid j
F9 Tail Lamps
5 rto tr
Powershift Solenoid 2
F10 15 Headlamp High Bcam F27 5 Powershift Solenoid 3
F.t 1 t.l Headlamp Low Beam F28 5 Powershift Solenoid 4
r tt 30 lmpiement Auxiliary Connector F29 7.5 Radio, lnstrument Cluster 2
F13 5 lnstrument Cluster lllum ination, F30 10 Front PTO
Fl-1 Console Lamp T,1 I 30 Keyed Auxiliary Power, Seat
F14 15 Rear Fcnder Work Lamps r3t 7.5 Sens-O-Draulic (SHR) Hitch
F15 l5 Front Fcndcr Work Lamps (Non Cab) Control
F16 10 Fuel Shut-Off
SCHEMATIC SYMBOLS
20wry1ts1 Schcmatic wirc Refercnce Number (20) color code (W//) wire Gauge (1g)
-
*re A -
Connector Wiih ldentification Numbcrs or Letters For Example Connector A pin or
Terminal A
-U".eel Component Connector With ldentifrcation Numbers or Letters
_{Otr Component Connector With ldcntificaiion Number or Letter Secured to the Component
by
a Screw or Nut
Conncctor Without Identification Numbcrs or Letters
ir-t
Io o-t- Circuits Grounded Direct to thc Battcry Negative Terminal
777v Circuits Groundcd to Tractor Chassis
o Check Point
o Component ldentification and Location
A Connector ldcntification and Location,
tr Chassis Ground Conncction Location.
Sec Page -
Uon 7-38440
lssued 9-92 Printed ln England
kaukazz@yahoo.co.uk
400 1 -5
FUSE AND RETAY LOCATION
LEFT HAND FUSE RELAY BLOCK RIGHT HAND FUSE REI-AY BLOCK
TRACTORS WITH CAB

1, FEAR FENDER WORK LAMP RELAY
2, FRONT CAB WOBK LAMP RELAY
3. OPEN
4. REAR CAB WORK LAMP RELAY
5, FUSES 1 TO 16
6. FTJSES 17 TO 32
7, FORWARD/HEVERSE BELAY (DIODE SUPPBESSED)
8, ACCESSORY POWER BELAY
9, WABNING IAMP TEST RELAY
10, TRANSMISSION CONTROL RELAY (DIODE SUPPRESSED)

1, REAR FENDER WORK LAMP RELAY
2. OPEN
3. CANOPY WORK LAMPS
4. OPEN
5, FUSES 1 TO 16
6. FUSES 17 10 32
7, FORWARD/REVERSE RETAY (DIODE SUPPRESSED)
S. ACCESSORY POWER RELAY
9, WARNING LAMP TEST RELAY
10. TRANSMISSION CONTROL RELAY (DIODE SUPPRESSED)
Don 7-38440
kaukazz@yahoo.co.uk
urua^HEAD
ooot powrquadplus www.thebestworkshopmanuals.co.uk LAYour
coNNEcro*s AND ELEcrFtlcAL coMPoNENT
H P1
Viewed From The Engine
P2
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ffi r-
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Seat
Viewed From The OPerators
--0.,*O*.,,.,ION
CONNECTORS
PANEL
COMPONENTS HARNESS TO INSTRUMENT
1. STABTER BELAY HARNESS
TO INSTRUMENT PANEL
-2, HEADLAMP DIMMER RELAY PIN No JJF1017717)
To
B. ENGINE HARNESS
ct*olioot wlrH cAB LJPUP TO PIN NO JJF1017821)
HARNESS
OR TRACTORS WITHOUT CAB TO INSTBUMENT PANEL
C. POWERSHIFT HARNESS
3. CHASSIS POWER RELAY HARNESS
4, CANOPY WORK IAMP OR
AIR CONDITIONEB
CAB OR PTATFORMHAFINESS TO INSTRUMENT
D,
CIRCUIT BREAKER PANEL HARNESS
HABNESS
5. FLASHER RELAY H RADAR HARNESS
TO INSTBUMENT PANEL
6. AUDIBLE ALARM P1 BATTERY POWER JUNCTION BLOCK

BLOCK
7. LEFT HAND FUSE/RELAY BLOCK P2 KEYED POWER JUNCTION
8. RIGHT HAND FUSE/RELAY
BLOCK lssued 9'92 Printed in England
7,38440
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4001-7
STARTER, KEY SWITCH, KEYED POWER, FUEL SHUT-OFF
AND ETHER START
Sectional Index
Forward/leverse Neutral Start Switch Circuit Tcst.............. ......................9

Starter Flelay Diode Module Circuit Tcst............. ...............10
Chassis Power Relay Circuit Test (Keyed Power) .......... . 11
Don 7-38440 lssucd 9-92 Printed in England
kaukazz@yahoo.co.uk
4001-8
CIRCUIT TESTING
multimeter for
be crean and tight before testing. LJse a
NOTE: The battery mustbe at fu, charge anda, connections must
the fests.
the starter motor, see section 4oo3

in this service manual'
NoTE: For testing and repair of

lever in forward, disengage the PTo and hold the key in the
NoTE: Put the range lever in neutral, the foryvardlreyarse
SIABI Position.
Reading
Check Points
12 Volts Chcck the battery cables befwccn the
$ terminalfor cable 2 Red to ground starter motor solenoid terminal B and
the
positive terminal of the battery'
relay
12 Volts Chcck wire 5 and check the starter
@ terminal for wire 5 White to ground circuits.
NOTE:tfthereadingsareCorrectseesectlbn4Oa3andcheckthestartermotorsolenoid.
Stafter RelaY Circuit Test

NorE: puttherangereverinneutrar,thefowardreversereverinforvvard,disengagetheproandturnthekeytotheoFF
position.
Reading Possible Cause of Bad Reading

Check Points
ContinuitY Bad chassis ground circuit
Terminal for wirc 10 Brown/Orange to
ground
NOTE: lf the rcading is not corrcct ga to check point 7.
NOTE: Hold the key in the SIAFI positton'

junctlon
12 Volts Chcck wire 4 and battery power
@ le,minalfor wire 4 Fled to ground block conncction.
Bad circuit between the key switch and

.12 the
Volts
O terminalfor wire 9 Whitc to ground relay. Check the key switch and the
=Utt",
toiarolreierse switch ncutral stafi circuit'
Atso chect< the starter relay diode module'
12 Volts Bad startcr rclaY

fntrinrl for wirc 5 Whitc to ground
Gl
to ContinuitY Bad chassis ground circuit

lor wire 1o Brown/oranse
o l::n:'l
NOTE: lf the reading rs conecl checkwire 10'
lssucd 9-92 Printcd in England

Don 7-38440
kaukazz@yahoo.co.uk
4001-9
Gl Tcrminal for wire 1 1 BrownAVhite to ground Continuity Bad chassis ground circuit.
NOTE: ll the reading rb conecf check wire 11 and the 3rd/4th range switch.
Gl Terminal for wire 12 Brown to ground Continuity Check wire '12 and the chassis ground
connections.
NOTE: lf the reading is correct check the lstl2nd nnge swttch.
Range Switch Test

(Neutral Start Circuit)
NOTE: The procedure for checking the nnge swrtches is the same for both lstl2nd and 3rdl4th range switches.
NOTE: Disconnect the nnge swtch lrom the harness and put the nnge lever in the NETJTRAL position.
IMPORTANT:ONLYUSEa highimpedcnccmuftimeterlotestthe mngeswlches, DONOTUSEatestlampordamagc

to the switch may occur.
Betwcen terminals A and B of thc rangc 0 to 5.9 Ohms Bad range switch. Adjust or replace switch
switch as necessary, refer to Section 9001.
Between terminals C and D of thc rangc No Continuity Bad range switch. Adjust or replace switch
switch as necessary, refer to Section 9001.
NOTE: Put the nnge levcr in 1st or 2nd range (for the l stl2nd nnge switch) or 3rd or 4th range (for the 3rdl4th nnge
switch).
Between terminals A and B of the rangc No Continuity Bad range switch. Adjust or replace switch
switch as nccessary, refer to Section 900'l .
Between terminals C and D of the range 0 to 5.9 Ohms Bad range switch, Adjust or replacc switch
switch as nccessary, refcr to Section 9001.
Forward/Reverse Neutral Start Switch Circuit Test

NOTE: Disconnect the foruvardlreyerse swtch lrom thc harness at conncctor F and hold the key in the STMT position.
Check Points Reading Possible Causq of Bad Beading
@ terminal for wire 7 White to ground 12 Volts Bad circuit betwecn the key switch and
connector F. Also chcck the key switch.
NOTE: Turn the key to the OFF position and put the forvvardlreversc swttch in the FORWMD position.
Between terminals 7 and 8 of connector F Continuity Bad forward/reverse switch. Also chcck
(switch side) for wires 7 White and 8 wires 7 and B ol the forward/reverse switch.
White/Pink
NOTE: tf the readings are correct chcck wire I and the stafter relay diode module.
Don 7-38440 lssucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001-10
Starter Relay Diode Module Circuit Test
NOTE: Turn the key to the OFF position and disconnect the diode module from the harness.
NOTE: Pd the forwardlreverse lever in the FORWARD position and hold the key in the START position.
Check Points Reading Possibte Cru.u_qj l"d Realjng
(P fnr.rninrl for wire I Whitc/Pink to ground 12 Volts Bad circuit between the key switch terminal
50A and the diode module terminal A.
Check the key switch and the lorvvardl
reverse switch neutral start circuit.
NOTE: The positive lead of the multimeter must go to terminal A of thc diode module.
Betwecn terminals A and C of the diode Continuity Bad diode module,

module
NOTE: Change the leads of the muftimeter over so the positrve lead of the muftimeter goes to terminal C of the diode
module.
Between terminals A and C of thc diode No Continuity Bad diode module

module
Key Switch Test

NOTE: Turn the key to the OFF positian
Chcck Points Rcadlng Possible Causc of Bad Reading
(D terminal for wire 6 Red to ground 12 volts Bad connection at the battery Power
junction block. Also check wire 6.
NOTE: Disconnect the key switch from the hamess, and turn the key to the ON position.
Bctwccn tcrminals BATT and IGN Continuity Bad key switch.
Between terminals BATT and ACC Continuity Bad kcy switch.
NOTE: Hold the key in the SIA,qf position.
Betwcen terminals BATT and START Continuity Bad kcy switch.
NOTE: Turn the key to the ACCESSOAy position.
Bc$vecn tcrminals BATT and ACC Continuity Bad key switch.
Don 7-38440 lssued 9-92 Prjnted in England
kaukazz@yahoo.co.uk
400'l -1 1
Chassis Power Relay Circuit Test (Keyed Power)
NOTE: Tum the key to the OFF Position.
Check Points Reading Possible Cause of Bad Fieading
@ terminal for wire l5 Brown to ground Continuity Check wire 15 and the chassis ground
connection.
NOTE: Tum the key to the ON Position.
@ terminal for wire

.14
Red to ground 12 Volts Bad connection at the battery power
junction block. Also check wire 14.
@ terminal for wire '13 Red/Orange to ground 12 Volts Chcck wirc 13. AIso check thc kcy switch.
terminal for wire 16 RedAilhitc to ground 12 Volts Bad chassis power relay.
@
terminal for wire i6 RedAVhitc to ground 12 Votts Check wire 16
@
NOTE: Check Fuse F1b.
NOTE: Tum the key to the ON position
Check Points Reading Possible Cause of Bad Heading
Terminal for wire '18 Dark Bluc/Iled to

.l2Volts Bad circuit between the kcy switch IGN
ground terminal and the fuel shut-off solcnoid.
NOTE: lf the reading is correct check the fuet shut-off solenoid connectjon or replace the fuel shttt-off solenoid as
necessaly'.
Ether Start Circuit Test

NOTE: Disconnect the ether start solenoid from the harness.
@ Terminal for wirc 22 Brown to ground Continuity Check wtre 22 and the chassis ground
conncction.
NOTE: Turn the key to the ON position and hotd the ether start swrtch in the ENERGIZED position.
Terminal for wire 21 Dark BlucrlVhite to 12 Volts Bad circuit between the ether start solenoid
ground and thc ether start switch
NOTE: lf the readings are correct replace the ether staft solenoid.
Terminal for wire 20 Dark Bluc/Gray to 12 Volts Bad circuit between the kcy switch and the
ground ethcr start switch.
for wire 21 Dark BrueflVhite to 12 Volts Bad ether start switch

@ I:;n:'r
NOTE: lf the readings are corecl check wire 21 betvveen the ether start swilch and the ether start solenoid.
Don 7-38440 lssued 9-92 Printcd ln England
kaukazz@yahoo.co.uk
4001-12
kaukazz@yahoo.co.uk
4001-13 Starier Motor Wiring Neutral Start Wirirg Key Svfich Wiring Ether Start Wiring Keyed Power Wiring
$chematic Circuit
14
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.:hAV
................. oHANGE
COMFONENTS
@rir€gruls
:k NOre: rca rRlcTogswlTr{ cAE uP TA PIN No. JJF|017717 MO
I 9. 1ST/2N0 BANG* SWITCH
1. BATIEBY 9. fEACTOffS ltttTHOUT CAB Up r0 PIN &o &|fiA17821 Aal
2. STAIIEB UO'IOR It0- f 10. rusE F1s A TqTIGTGSPiI HARNES TC} INSI?UMENT PANEL HARNESS FqCM THE rOsW4fiOlsEVrASt SW,?CH rO rHE INSTRUM€NI '?/RES
3. STASTER RELAY 11. F
11. FUSE F22 a SBr€ i*R.\ESS IO laSrRUMEilT PANEL HAFNESS HIfiNTSSN,qE BLACX-
4. KryS!$ICH 1-IAI 11A. FUSE F16 F, PANEL HAAI.ESS TO -ORWARD/REYERSE SWTCH
5. WAENING IAMP ]EST RELAY tzl 12. E HERSTARTSWTTCH PI,'SFLTENT
BATTER| FOV'IER JUTiCTION BLOCK
6. T0EWARO/EEVERSE SWICH (* ) 13. ! 13. ETHER START SOLENOID P2- KFIED PqJTER JUNCBCil BLOCK
7. STARTAR HETAY DIODE MODI,jLE t4. ( 14- CHASSIS POWEN RELAY
B,3RDI4]H BANGE SWITCH ts Fl I5 FUEL SHUT-OFF SOLENCIO
Don 7-38440 lssued +gZ Printed in Enlland
kaukazz@yahoo.co.uk
4001-.14
ACCESSORY POWEH RELAY, ALTERNATOR AND INSTRUMENT CLUSTER
Sectional lndex
lnstrument Clustcr Powcr and Chassis Ground Circuit Test,............ .............,............15
lnstrument Cluster Engine HPM Display Circuit Test..,.......... ..............,. 16

Hydraulic Filter Restriction Warning Lamp Circuit Test ........... ..,.......... 17
...........
Air Filter Flestriction Warning Lamp Circuit Tcst ......................... 17
Parking Brake Warning Lamp Circuit Tcst .......,.... ........... 18
Warning Lamp Test Relay Circuit Test ........... ............,.... 18

Warning Lamp and Audiblc Alarm Diode Tcst..........,.. .'.,,. 19
Ground Speed Radar Circuit Test (Dehxc Clustcr Only)....,..... ..".'..... 19
Ground Speed Sensor Circuit Test (Delrxc Clustcr OnV)......... .......... 20
Don 7-38440 lssucd 9-92 Printcd in Engiand
kaukazz@yahoo.co.uk
400'l -1 5
CIRCUIT TESTING
NorE: Thebatterymustbeatfuttchargeandartconnectionsmustbecreanandtightbeforetesting.tJseamurtimeterfor
the test.
Test
lnstrument cluster Power and chassis Ground circuit
NOTE: Checktuse F24.
and turn the key to the aFF position'
NoTE: Disconnect the instrument cluster from thc harness
Check Point
eoariino Possible Cause of Bad Reading
chcck wire 52 and the clean ground

pin 31 of the lnstrumcnt clustcr connector Continuity terminal'
connection at the battery negative
and the battery negative terminal (clean (clean ground)'
ground)
NOTE: Tum the keY to the ON Position'
12Volts Check wires 33 and 34' Also check the
'ruolvr vv'|
Pin2of theinstrumentclusterconnectorto keycd power junction block.
ground
uu
uuolv connector
Pin 'l 5 of the instrument cluster to 12 Volts Bad circuit between the accessory power
sround :*:"#TL:',"i::JHJ:::',"['fi?:*::
relaY.

NOTE: Turn the key to the OFF positian'
Rcading Possible Cause of Bad Fleading
Chcck Points
Continuity Bad circuit betwccn tcrminal 85 of the
ferminal for wire 36 Brown and ground acccssory powcr rclay and the chassis
O
ground connection' Also check the chassis
ground connection'
NOTE: Turn the key to the ON posrtion'
Terminal reu/usto
for wire 35 BedA)ark Blue 12 Volts Chcck wire 35 between the battery power
sround ',:H::,."!i::l'fJ'^1ff ff""""iT3 J,'#".:

Power junction block connection'
12 Volts Bad circuit between the key switch and the

Gl Terminalfor wire 19 RedMhite to ground
acccssory powcr relay terminal 86 Also
chcck thc kcY switch'
ferminal for wirc 37 FcdNiolct to ground

12 Volts Bad acccssory Powcr relaY'
@
l2Volts Chcck wire 37 bctwcen the accessory
Terminal lor wire 37 RedNiolct to grouno powcr relay terminal 87 and fuse F32'
O
lssucd 9-92 Printed in England
Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 6
NOTE: Check the aftemator warning lamp bulb.
Check Point Reading Possible Cause of Bad Realling
Terminal for wire 30 Red to ground 12 Volts Check wire 30.

O
NOTE: Disconnect wires 31 and 32 from the alternatar.
NOTE: Tum the key to the ON Position.
(lil Terminal for wire 31 Yellow to ground 12 Volts Bad circuit between the instrument cluster
and the altcrnator D + terminal. Aiso check
the instrument cluster power circuit.
NOTE: lf thc readings are correct check the alternator see Section 4008.
NOTE: Turn the key to the OFF position and disconnect the instrument cluster from the harness.
Pin 30 of the instrumcnt clustcr conncctor Continuity Chcck wire 31.

and thc terminal for wirc 31 Ycllow
Instrument Cluster Engine RPM Display

NOTE: tJse the signal genemtorlcounter for thc following tcst, reler to Page 3.
NOTE: Disconnect w1e 32 Ye1owlBrown from the alternator W terminal. Connect a signal generator to wire 32 and
programme the signal generator to genemte a signal as shown in the table below (see manufacturers instructions) ' Turn
the-keyto the ON position and press the engine rpm function button on the instrument cluster (deluxe clusters only) and
check the rpm display on the instrument cluster with the table belaw.
SIGNAL FROM SIGNAL INSTRUMENT CLUSTER POSSIBLE CAUSE OF

GENERATOR BPM DISPLAY BAD READING
Hz BPM
302.9 '1040 to 1 160 BAO INSTBUMENT

CLUSTEB
CHECK WIRE 32 SEE
605.8 1940 to 2260
CHECK POINT 7
NOTE: tf the readings are correct repair or replace the altemator, refer to Section 40A8.
NOTE: Turn the key to the OFF position, disconnect the instrument cluster from the harness
Pin 27 ol the instrument clustcrconnccior Continuity Check wire 32.

and the terminal for wire 32 Yellow8rown
NOTE: lf the readings is conect check the instrument c/uster power and chassis ground circuits.
kaukazz@yahoo.co.uk
4001-17
Hydraulic Filter Restriction warning Lamp circuit Test
NOTE: Check the hydmulic filter restriction warning lamp bulb'
(above l oc F) and the hydraulic filter must be free
NOTE: Ihe transmiss ion oit must be at normal operating temperuture
and restrictian swrtch from the harness. Turn the key to the
from restrictions. Disconne ct the hydrautic filter tempeiature
ON position.
to ground'
IMPORTANT: Do not allow the disconnected terminal for wire 44 to short circuit
Check Point Rcadino Possible Cause of Bad Reading
Terminalfor wire 44 YcllowArVhite to ground llio- Bad circuit between the instrument cluster
G) conncctor (pin 21) and the hydraulic filter
temPcrature switch.
NOTE: lf the reading is correct go to check point 15'
cluster from the harness'

NOTE: Tum the key to the OFF position and disconnect the instrument
Terminalforwire 44YellowflVirite and pin 21 Continuity Check wire 44'

of the instrument cluster connector
NOTE: Connect the hydraulic tempemture switch fo fhe harness'
Terminalforwire 45 Yellow/Brown to ground 12 Volts Bad hydraulic f ilter temperature switch' Also
@ check wire 45 between the hydraulic filter
temperature and restriction switches'
NOTE: Tum the key to the OFF positron-
Terminal for the hydraulic filter rcstriction No Continuity Bad hydraulic filtcr restriction switch'
switch to ground
Air Filter Flestriction warning Lamp circuit Test

NOTE: Check the air filter restiction warning lamp bulb'
the air fifter restriction swtch from the harness and turn the
NOTE: The air fifter must be f ree from restrictions. Disconnect
key to the AN Position.
Check Point Rozrlinn Possible Cause of Bad Reading
ferminalfor wirc 46 Dark Green to ground *ts Bad circuit between the air filter restriction -
@ " switch and the instrument cluster'
NOTE: tf the readingis conect go to check point 19'
the OFF position and disconnect the instrument cluster

from the harness'
NOTE: Tum the key to
Tcrminal for wirc 46 Dark Green and pin 29 Continuity Check wire 46
of thc instrument clustcr
(E) Terminal for wirc 47 Brown to ground Continuity Check wire 47 and the chassis ground
connection.
Bctwcen the terminals of thc air filter No continuity Bad air filtcr restriction switch'
restriction switch

Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 I
NOTE: Check the parking bnke warning lamp bulb,
NOTE: Engage the parking bmke, put blocks in lront and behind the rearwheels and turn the key to the ON position,
Chcck Points Bggqlng Possible Causc of Bad Reading
6IJl Terminalfor wire 49 Yellow/Black to ground '12 Volts Bad circuit between the parking brake
switch and thc instrument cluster
conncctor.
Between terminal A of thc parking brake Continuity Bad parking brake switch. Adlust or replace
switch to ground the switch as necessary. Refer to Section
9001.
NOTE: Disengage the parking brake.

Betwcen terminal A of thc parking brake No Continuity Bad parking brake switch. Adjust or replace
switch to ground the switch as necessary. Refer to Section
9001.
NOTE: Tum the key to the OFF position and disconnect the instrument cluster from the harness.
Tcrminal for wire 49 Yellow/Black and pin 17 Continuity Check wire 49.
of thc instrumcnt cluster connector.

NOTE: Engagetheparkingbmkeanddisconnecttheaudiblealarmfromtheharness.Putthemngeleverinlst,2nd,3rd
or 4th range and turn the key to the ON position.
Chcck Points Reading Possible Cause of Bad Reading
Terminal for wire 47 White/Dark Bluc and 12 Volts Check wire 47 between the transmission
ground control relay terminal 86 and the audible
alarm.
6) terminalforwire 48 Yellow/Brown to ground Continuity Bad circuit between the audible alarm and
the parking brake switch chassis ground
conncction. Also check the parking brake
switch.
NOTE: lf the readings are correct replace the audible alarm,

NOTE: Remove the warning lamp test relay.
NOTE: PtLt the range lever in lst, 2nd, 3rd or 4th runge and hotd the key in the STMT position
Chcck Points lgg{nS PossiPle Cause of Bad Reading
fr} Termlnal for wire 7 Whitc to ground 12 Volts Bad circuit bctween the key switch and the
warning lamp test relay. Also check the key
switch.
0B
Y
Terminal for wirc 43 Brown/Dark Blue to 12 Volts Bad circuit between the warning lamp tcst
grouno diodcs and the warning lamp test relay.
kaukazz@yahoo.co.uk
4001-1 I
NOTE: Tum the keY to the OFF Posilion'
Check Poinls lrg,ns

check the
ContinuitY Bad chassis ground circuit' Also
f1) Terminalfor wire 36 Brown to ground chassis ground connection'
and 85
ContinuitY Checkwire 36 betwcen terminals 87
6I) Terminalfor wire 36 Brown to ground of the warning IamP test relay'
waming lamp test relay'

NOTE: lf the readings are corect replace the
posrion
;;;i parxinii**
stitr ra, ta
*x,,ii,iE;;;i;;:il;!,!';;;;;in,en on checkthe.warning tamp test diodes'
ciii
NorE: rfanyofthewarningrampsfa,tocomeonwhenthemngereuerisrnTst,2nd,3rdor4thmngeandthekeyisinthe
ii check the warning lamp test
theair fitter waming ramp ,"*"Ji;
srarr ine
"n""rrr*
Nsoif for exampre "ngaged
diode.
Diode Test
Warning Larnp and Audible Alarm
NOTE: Theprocedureforcheckingthcwamingtampandaudiblealarmdiodesisthesameforeachdiode.
from the harness'
posnion and disconnect the diode
NOTE: Tum the key to the OFF
NOTE: Thepositiveteadofthemultimetermustgotothefemaletermina|ofthediode,
R"eqgq
Check Points
No ContinuitY Bad diode'
Bctween thc terminals of the diode
b the male terminal of the
NoTE:Changetheleadsofthemuttimeteroversothepositiveteadofthemultimetergoes
diode.
ContinuitY Bad diode.
Between the terminals of the diode
Test (Deluxe lnstrument cluster onty)

Ground speed Radar circuit
radar from the
cruster and the ground speed
position and disconnect the instrument
NorE: Turn the keyto the aFF
harness.
ContinuitY Chcck wire 39.
to pin 3
Terminallorwirc 39 Light Grecn/Rcd
of the instrument clustcr
ContinuitY Chcck wirc 40.
Terminal for wire 40 Browry'Light
Grccn to
pin 26 of the instrument clustcr
ContinuitY Check wire 41'

pin 33 of
Tcrminal for wire 4'l Light Green to
thc instrument cluster
to ContinuitY Chcck wire 42.
Terminal for wirc 42 Light Green'lYcllow
Don 7-38440
kaukazz@yahoo.co.uk
4001-20
Ground Speed Sensor Gircuit Test (Deluxe lnstrument Cluster only)
NOTE: Disconnect the ground speed sensor from the hamess.
Check Polnts Reading Possible Cause of Bad Reading
6P terminal for wire 51 Brown ground Continuity Check wire 51 and the chassis ground
connection.
Between terminals A and B of the ground 3575

2925 to Bad ground speed sensor
speed sensor Ohms
NOTE: Disconnect the instrument cluster from the harness.
Terminal for wire 50 Yellow/Dark Blue to pin Continuity Check wire 50 between the ground sensor
28 of the instrument cluster connector and the instrument cluster connector.
NOTE: lf the readings are correct adiust or replace the ground speed sensor.
Don 7-38440
Issued 9-92 Prinled in England
kaukazz@yahoo.co.uk
-
r Power Wiring !nstrument Cluster Wiring

4001'21 Alternator Wiring Accessory Power I
Schematic Circuit
E 3
i !l-- sr v ner _
Et,G
oc
{*-* 31 Y (16)
@
YER (18) 32 YER (18)
d- 32
34 YIB (15)
s4YlR i16)
19 ruw (16)
37
F/u
.;I?T"?.f, 38 O (18)
39 LGi q (18)
40 BRILG {18}
41 LG (18)
051
{or 'rsr al LGfv (18)
R
{r3) 1_*.ur. =&s
os ,
I
rl
44
44Y
YI,r'
Ytrt
(rtl
\ n .s
45 DG
oG (it
0t
flfi
,+9
YF DG
(1E (18)
1eryw{rE. I
I I
""-G
[9*
l+lsEr
ffiJ
47 wiBB {18t
4&lt-s
T
{}
YiB
o8)
O.\t iB,P
rr---t
sffi;
ffi I
Ivtvl I
(Wire Color Code) l-l-l I
,zEF
a
...,.,'...,,.. .'..''''RED
..'.".,.,..',.,....'.,., TAN Ld-I-U
\..\2,/
.I
BR
{ oor<s
35 AR (J6) Q,r \,e,
AD
...........................8UOWN ( , {JOMPONENTS
1. STA'TTER MOTOR 4F, FUSE F24
-
8. PARKING BRA(E S1MICH
9. AIR FILJEA HESIEEII\'N SflITCH
I @..t{EgroRs
A TRANSMISSION HARNESS TO INSTBUMENI PANEL IIAHNESS
2. ALIEENATON CWEP RETAY 10, TiYDRAUUC FIL''ER BESTENON SICH A El.lGlN= HABNaSS TO INSIfiUMENT PANEi- HARNESS
5, ACCESSORY POWER RELA'I
PTEST NELAY 11. }ryDEAULIC FIL]ER IEIIPERATUE S'ICH H. BIDT1A HAR,IESS TO INS'TPUMENT PANEL HARNESg
3. K3l SWTTCH 5A. WARNING IAMP TEST Rg.!
{ CONTROL iEI"AY t2. WHSEL SPEED SENSOA r. RtoAR To nADAR HAHhEss
4. FU$E F19 58. IRANSMISSION CONTROL T
rER BESTRICTION DIODE i3, INSTffUMENT CIU$'ER Pl. BATIEFY PO}VEF JUNCTiON BLOCK
,!A. FUSE F17 & HYORAULIC FIL-TEB RESIAI(
48. FUSE Fg? 6A. AIR FILTEH RESTRICT]ON O(
DiODE n KEYED POY'/ER JUNCTION 6LOCK (BEHiNt INSTSUMENT CLUSTER)
,IC.
'IEtcfiON
ATTP TEST DIODS
FUSI F3O 58. PARK EBANE IAMP TEST T'
,ID, FUSE FzO 6C. AUDIBLE ATARM OIODE 0l orooE
Don 7-38440
lss€d 9-92 Printed in !.€lmd 4E. FUSE F29 7, AUD]BLS AL.ANM
u
kaukazz@yahoo.co.uk
4001-22
INSTRUMENT CLUSTER
Sectional lndex
4th Bange/Reverse Warning Lamp (Master Flasher) Circuit Tcst ....,...... ..,................ 23
lnstrument Cluster 1000 RPM PTO Display .........,,.......,.,. 24
Engine Coolant Temperature Gauge Circuit Test ............ ,.:.,...,.........,,...,...,............. 25
Engine Oil Pressure Warning Lamp Circuit Test ..,..,..... ....................... 25
Don 7-38440 lssucd 9-92 Printcd in Enqland
kaukazz@yahoo.co.uk
4001 -23
CIRCUIT TESTING
NOTE: Thebatterymustbeatfull chargeandall connectionsmustbeclcanandtightbeforetestrng. Useamultimeterfor
the test.
Fuel Level Sender Circuit Test

NOTE: Disconnect the fuet level sender from the harness and tum the key to the ON position.
Check Points Reading Possiblc Cause of Bad Reading
ror wire 60 Yerlowaisht BIue to 9 Volts Check wire 60 between the fuel level sendcr
O l::nfl Approximately and the instrument cluster connector.
Gl Terminal for wire 61 Brown to ground Contlnuity Check wire 6,1.
NOTE: Disconnect the instrument cluster from the hamess.
Terminal for wire 60 Yellow/Light Blue to pin Continuity Check wire 60'
23 of the instrument cluster connector
NOTE: lf the readings are conect check the fuel levcl scnder refer to Sccllon 3005. Also check the instrument cluster
pawer and chassr.s ground circuits, (referto Page 15) or replace the fuel level if necessav'
4th Range/Reverse Warning Lamp (Master Flasher) Circuit Test

NOTE: Disconnect the 4th mnge switch from the hamess and put the nnge lever in neutral, 1st, 2nd or 3rd mnge.
tMpORTANT: ONLy |JSE a high impedance muftimeterta testthe 4th nngc switch, DO NOT USE atest lamp or damage
ta the switch may occur,
Possible Cause of Bad Reading

Check Points lgggqg
Bctween tcrminals A and B of the 4th range No Continuity Check the 4th range switch. Adjust or
switch replace the switch as necessary
Between terminals C and D of the 4th range 0 to 5.9 Ohms Check the 4th range switch. Adjust or
switch replace the switch as neccssary. Rcfer to
Section 9001.
NOTE: Put the mnge lever in 4th nnge.
Between terminals A and B of the 4lh range 0 to 5.9 Ohms Check the 4th range switch. Adjust or
switch rcplace the switch as necessary. Refer to
Section 9001.
Between tcrminals C and D of the 4th range No Continuity Check thc 4th range switch. Adiust or
switch replacc thc switch as necessary. Refer to
Section 9001.
NOTE: Tum the key switch to the ON position.
terminal for wire 62 PinlVFcd to ground 12 Volts Bad circuit bctween the 4th range switch
? and the instrument cluster.
NOTE: lf the reading is correct go to test point 6.
Don 7-38440 lssued 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001-24www.thebestworkshopmanuals.co.uk
powrquadplus
NOTE: Tum the key to the OFF position and disconncct the instrument cluster from the harness.
Chcck Points Reading Possible Cause of Bad Readtng
Terminal for wire 62 PinVRcd to pin 4 of the Continuity Checkwire 62 between the 4th range switch
instrument cluster connector and the instrument cluster connector.
NOTE: lf the reading is correct check the instrument cluster power and chassis ground circuits, (refer to Page 15).
NOTE: Connect the 4th range switch to the harness. Disconnectthe forwardlreverse swifch from the harness , turn the
key to the ON position and put the mnge lever in 4th range.
Volts Bad circuit between the 4th range switch

G) Terminal for wire 63 Brown/Pink to ground 12
and the forward/rcversc switch.
@ terminal for wire 64 Brown to ground Continuity Check wire 15 and the chassis ground
connection,
NOTE: Put the forwardlrevcrsc switch in thc REIERSEpositron.
Bctwcen tcrminals 5 and 6 of conncctor G Continuity Bad torwardlreverse switch.

(switch side) forwires 63 Brown/Pink and 64
Brown
NOTE: Put the forwardlreverse switch in the FORWMD positton.
Between termjnals 5 and 6 of conncctor G No Continuity 1ad torwardlreverse switch.

(switch side) forwires 63 Brown/Pink and 64
Brown

NOTE: Turn the key to thc OFF position and disconnect thc 1000 rpm PTO switch from the harness
Gl Terminal for wirc 66 BrownMhitc to ground Continuity Check wire 66 and the battery negative
tcrminal connection.
NOTE: Put the PTO output shaft in the 1A00 rpm pasition.
Bctwcen the icrminats of thc '1000 rpm PTO Continuity Bad 1000 rpm PTO switch.
switch
NOTE: Put the PTO output shaft in the 540 rpm position.
Bctwecn the tcrminals of thc 1000 rpm PTO No Continuity Bad 1000 rpm PTO switch.
switch
NOTE: Disconnect the instrument clustcr from the harness.
Terminalfor wirc 65 YcllowrDark Grccn and Continuity Check wire 65 betwcen the 1000 rpm PTO
Pin 22 of thc instrumcnt clustcr conncctor switch and the instrument clustcr
connector.
NOTE: tf ke reading is corrcct check the instnLmcnt c/uster pawcr and chassis ground circuits, (refer to Page 15)
Don 7-38440 lssued 9-92 Prjntcd in England
kaukazz@yahoo.co.uk
4001-25
NOTE: Disconnect the engine coolant sender from the hamess and tum the key to the ON position
Terminal for wire 67 Dark Green/Black to Approximately Bad circuit between the engine temperature
ground 9 Volts sender and the instrument cluster,
NOTE: lf the reading rb correct replace the engine coalant tempenture sender.
Terminal forwire 67 DarkGreen/Black to pin Continuity Check wire 67 between coolant

16 of the instrument cluster connector tcmpcrature sender and the instrument
clustcr connector.
NOTE: lf the readings are correct check the instrument cluster pawer and chassls ground circuits.

NOTE: Disconnect the ail pressure switch from the harness.
NOTE: Tum the key to the ON position.
#) Terminal for wire 68 Light Blue to ground l2 Volts Bad circuit belween the oil pressure switch
and the instrument cluster connector.
NOTE: lf the reading is correct check the oil pressure switch.
NOTE: Turn the kcy to the OFF position and check the oil pressure warning lamp bulb.
Terminalfor wire 68 Light Blue to pin 34 of Continuity Check wire 68.

the instrument cluster connector
NOTE: tf he readings are correct chcck the instrument cluster power and chassis ground circurt
kaukazz@yahoo.co.uk
4001-26
Check Points lgeqlg Possible Cause of Bad Reading
Between the terminal of the oil pressure Continuity Bad engine oil pressure switch.
switch to ground
NOTE: Staft and run the engine at 150A rpm.
Between the terminal of the oil pressure No Continuity Bad engine oil pressure switch or no oil
switch to ground pressure.
WARNING: Never operate the engine in a closed building, proper ventilation is required under all
circumstances .
kaukazz@yahoo.co.uk
4001-27 lnstrument Cluster Wiring

Schematic Gircuit
//
/,\
6
19 PrVl.{16i..- I R/W.{l6)
(r3)
60 Y/LB fl8) 60 Y&B (18)

62 P/R (18)
d*,
6 F {13)
0s) _
.tr .{ +oor . ,g, ,u, as, sE
65 I/UU {r6'
67 DG/B t18)
68 LB i18)
,tl'
,V
- 1s Bnr,/ (18)
3s FyDB {l:
r- 3s tuDB (13) _
r- 37
L-s7&v(1s)
I
llr-
I loi,
lo H
I
,60
ffiH 4*'
r\(16)
tt
52
BRIW
vtE
lo loru
\r {ooor - se
--I
I
/@@ I
{13}
I
;,i,
t15) tAt o frl
l^l
ffi
,m
q {*
il"4&-
@( I
I
<( +oor - zs, es
4001 - 39
L&-"{"o 8Mil
\o
36 BR n6) 03)
fl
a BR BR
(16) 6) 66 B&{.V 08)
A (1
COMPONENTS
1. Kry 30. FUSE F2O
m coNNECroRs
S\^/ITCH 30. rusE F20 8, ENGJNE COOTANT $ENOEN A. TRANSMISSION HABNESS TO TNSTRUMENT PANEL HAFNESS
2. TRANSMISSION CONTOL RELAY 3E. FUSE F29 'EMPERATURE
S. ENGINE OIL PRESSURE SWITCH B, ENCINE HARNESS TO INSTqUMENT HPANEL AFNESS
2A- ACCESSOHY POWEfi HEiAY 3F, FUSE F24 3F, TUSE F24 10. INSTRUMENT CLUSTER G. INSTRUMENT HARNESS 10 FORWAADIREVERSE SWITCH
- LIGHT GREEN
3. FUSE F19 4. FUEL LEVEL 4. FUEL LEVEL SENDER pt. gerrrnv iowEH JUNcrioN aLocK"
34, FUSE F17 5, FORWABDIH 5. FORVUARDIREVERSE SWjTCH( * P2. KEYEO POWEB JUNCTION BLOCK
)
38. FUSE F32 6,4TH BANGE 8.4TH BANGE SWITCH }K NOTE: FOR IRACTAfrS W\H CAA UP fO PN NA, JJF1017717 AND
7. 1000 RPM Pl 7. IOOO RPM FTO SwlTCH IEACTSSS WTHOUT CAB UP TO PN NC JJF1017812 AIJ \\INES
Oon 7-38440 Prinied jn FSAM WE FO8!1'AR'II16Y€FST SMICH IO THE INSTRUMENT
lssued 9"92 englild
iiIfi,VFSS AFE BI^CK
kaukazz@yahoo.co.uk
4001 -28
FORWARD/REVERSE AND TRANSMISSION CONTFIOL
Sectional lndex
Synchromcsh Neutral Switch Circuit Test (For Tractors Equippcd With Synchromcsh Transrnissions) .........,....29
Transmission Control and Forward/Rcvcrsc Rclay Circuit Tcst ............ ................... 30
Forward and Reversc Prcssurc Switch Test ........... ..,.... 35
Forward Diode Module Circuit Tcst 36

Rcvcrse Diode Module Circuit Test
Clutch Disengage Lamp Circuit Tcst
Rcvcrse lndicator Lamp Circuit Tcst ao
3B
39
i )on 7'3844(l lssLrcd 9'92 Prinlcd in Inaian,:]
kaukazz@yahoo.co.uk
4001-29
CIRCUIT TESTING
NorE: Thebatterymustbeatfult chargeandailconncctionsmustbecteanandttghtbeforetesting.useamultimeterfor
the tests.
1sV2nd and 3rd/4th Range Switch Circuit Test

NoTE: Disconnect the lstl2nd and 3rdl4th range switches from the harness and turn the key to the oN position.
tMPoRTANT:ONLyL)sEahighimpedencemuftimetertotesttherangeswitches,Do NOTUSEatestlampordamage
Check Points Rcading Possible Cause of Bad Reading
Terminal for wire 80 White/Rcd to ground 12 Volts Bad circuit between the key switch terminal
@ 58 and thc forward/reverse relay terminal
30. Also check the keY switch.
Terminal for wires 80 Whitc/Rcd to ground 12 Volts Check wire B0 between the forward/reverse
@ rclay terminal 30 and the top inching pedal
switch.
Terminal for wire B0 Whitc/trcd to ground 12 Volts Check wire B0 between the 1sV2nd range
@ switch and the top inching pedal switch'
7l Terminal for wire 80 White/Rcd to ground 12 Volts Check wire 80 betwcen the 3rdl4th range
switch and thc sPlicc.
NOTE: Turn the key to the OFF position and put the range lever in 1st or 2nd range.
Between terminals C and D of the
.lsU2nd 0 to 5'9 Ohms Bad 1sV2nd range switch. Adjust or replace
rangc switch. thc switch as necessary. Rcfer to Section
s001.
Botwccn terminals A and B of thc lsV2nci No ContinuitY Bad l sV2nd rangc switch. Adjust or replacc
range switch. thc switch as neccssary. Refcr to Section
9001.
NOTE: Put the range lever in 3rd or 4th nnge.

Bctwecn lerminals C and D o{ thc 3rd/4th 0 to 5'9 Ohms Bad 3rdl4th Rangc switch. Adjust or rcplacc
rangc switch thc switch as ncccssary. Rcfcr to Scction
9001.
Betwcen terminals A and B of the 3rd/4th No Continuity Bad 3rd/4th Range switch. Adjust or replacc
range switch thc switch as necessary. Rcfer to Section
9001.
Synchromesh Neutral Switch Circuit Test

(For Tractors Equipped With Synchromesh Transmissions)
NoTE: put the speed seleclor lever in NEUTRAL and disconnect the synchromesh neutral switch from the harness
NOTE: PtLt the range lever /n 7SI RANGE and turn the key to the ON position.
Chcck Points Rcading Possiblc Causc of Bad Reading
Gl Tcrminal for wirc 81 WhitciBlack to ground 12 Volts Chcck wirc 81 bclwccn thc rangc switch
and the synchromcsh ncutral switch. Also
chcck thc range switches.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -30
NOTE: Repeat check 5 with the range lever in 3rd RANGE
Between terminals A and B of the No Continuity Bad synchromesh neutral switch. Adjust or
synchromesh neutral switch replace the switch as necessary. Refcr to
Section 9001.
NOTE: Move the speed selector lever into gear.

Between terminals A and B of the Continuily Bad synchromesh neutral switch. Adjust or
synchromesh neutral switch replace the switch as necessary. Refer to
Section 9001.

NOTE: Put the runge lever in NEUTRN and turn the key ta the ON position.
'12 Volts Bad circuit between the key switch terminal

to ground
G) Terminal for wire B0 Whitc/Rcd 58 and thc top inchlng pedal switch. Also
Gl Terminal for wirc 84 White8lack to ground 0 Volts Bad top inching pedal. Adjust or replace the
switch as necessary. Refer to Section 9001.
'12 Bad top inching pedal. Adlust or replace the

Terminal for wire 84 White/Black to ground Volts
O switch as necessary. Refer to Section 9001 .
Terminal for wire 86 WhiteErown to ground 12 Volts Bad circuit belween the top and bottom
@ inching pedal switches through the
transmission control relay. AIso chcck the
transmlssion control and forward/rcvcrsc
rclay circuits.
NOTE: Tum the kcy to thc OFF position and rclease the inching pedal to half travel.
Bctween the switch tcrminals for wire 85 Continuity Bad boltom inching pedalswitch. Adjust or
White/Gray/Black and wire 86 White/Brown replace the switch as necessary. Refer to
Section 9001.
NOTE: Fully release the inching pedal.
Bctween thc switch terminals for wirc 85 No Continuity Bad bottom inching pedalswitch. Adjust or
White/Gray/Black and wire 86 Whitc/Brown replace the switch as necessary. Rcfer to
Scction 9001,
Transmission Control and Forward/Reverse Relay Circuit Test

NOTE: Tum the key to the OFF position and remove the forwardlrcverse relay.
Chcck Points Heading Possible Cause of Bad Reading
Terminal for wire 36 Brown to ground Continuity Check wirc 36 and the chassis ground
O connection.
NOTE: Put the mnge lever in NEUTRAL. Tum the key to the ON position and hold the inching pedal DOWN.
kaukazz@yahoo.co.uk
4001-31
(fi) '12 Volts Check wire 84 between the transmission

Terminal for wire 84 Whitc/Black to ground
control relay terminal 87A and the top
inching pedal switch. Also check the
inching pedal switch circuit.
ferminal for wire 86 White/Brown to ground 12 Volts Bad transmission control relay,
@
Terminal for wire g5 Whitc/Gray/Black to 12 Volts Check wire 85 between the transmission
ground control relay terminal 87 and the boftom
Inching pedal switch, Also check the
inching pedal switch circuit.
NOTE: putthenngeleverinlstor2ndrangeandtheforwardlreverscleverinthe FORWARDposition.Turnthekeytothe
ON position.
NOTE: For tractors with synchromesh tnnsmisslons move the speed selector lever into gear'
Terminal for wirc 83 White/Dark Bluc to 12 Volts Bad circuit betwcen thc key switch and thc
ground transmission control relay terminal 87. Also
check the key switch, 1sV2nd and 3rdl4th
rangc switch circuit and the synchromcsh
neutral switch (if equipped).
NOTE: Repeat check 13 with the range lever in the 3rd or 4th nnge'
NOTE: Release the inching pedal and turn the key to the OFF position'
(E Terminalforwire 87 Brown/Yellow to ground Continuity Bad circuit between the forward/rcvcrse

relay terminal 85 and ground. Also check
the forward/reverse switch and the chassis
ground connection.
ground
NOTE: When the forwardlreverse lever is in the forward position and the range lever is in 4th range the chassrs
connection for the foruvardlreverse relay is made through the forwardlreverse swrtch terminals 4 and 5.
NOTE: Put the forwardlreverse lcver in the reverse position.

NOTE: Use the muftimeter diode test function.
(f) Terminalforwirc 87 Brown/Ycllowto ground Continuity Bad circuit between the fonvardlreverse
relay terminal 85 and ground. Also check
the 4th range diode, the 4th range switch
and the chassis ground connection.
NOTE: lnstallthe relay, putthe range lever in NEUTRAL, the fonward reverse lever in FaRWMD and turn the key to the ON
position.
Terminal for wire B0 White6ed to ground 12 Volts Bad circuit between the key switch and the
forward/reverse relay terminal 30' Also
check the keY switch.
Terminal for wire g9 Yellow/Dark Bluc to 12 Volts Bad forward reverse relay'
ground
NOTE: Hold the inching pedal DOWN.

Terminal for wire 85 Whitc/Gray8lack to .12
Volts Chcckwire 85 between the forward/reverse
ground rclay terminal BO and the boltom inching
pedal swich. Also check the inching pcdal
switch circuit.
Don 7-38440 lssucd 9-92 Prinlcd in England
kaukazz@yahoo.co.uk
4001-32
@ terminal for wire 86 White/Brown to ground 12 Volts Bad forward reverse relay.
NOTE: Tum the key to the OFF position.
NOTE: Tum the key to the ON position. Hold the inching pedal fully DOWN and put the range lever in 1st nnge then
relcase the inching pedal.
NOTE: For tractors equipped with synchramesh lransmrssians, before the inching pedal is released move the speed
se/ector lever into gear.
Terminal for wire 85 White/Gray/Black to 12 Volts Bad transmission control rclay.

ground
NOTE: Hold the inching pedal down at half travel then put the nnge lever in NEUTRAL.
Terminal for wire 85 Whitc/Gray/Black to 12 Volts Check the inching pedal switch circuit.
ground
4th Range Diode Test
NOTE: Turn the key to the OFF posrtion and disconnect the diode from the harness.
NOTE: The positive lead of he multimeter must go to the female terminal of the diode.
Check Points Readlng Possiblc Cause of Bad Reading
Between the tcrminals of thc diodc No Continuity Bad 4th range diode.
NOTE: Change the leads of the multimeter over so the positive lead goes to the male terminal of the diode.
Between the terminals of thc diodc Continuity Bad 4th rangc diode.

NOTE: Turn the key to the OFF position and disconnect thc 4th nnge switch from the harness.
IMPORTANT: ONLY USEa high impedance multimeter ta testthe 4th range switch , DO NOT use atest lamp or damage
(!l Terminal for wirc 89 Brown to ground Continuity Check wire 89 and the chassis ground
connection.
NOTE: Pd the mnge lever in the NEUTRAL position.
Between terminals D and C of the 4th rangc 0 to 5,9 Ohms Bad 4th range switch. Adiust or replace thc
switch switch as neccssary.
Bctwecn terminals A and B of thc 4th rangc No Continuity Bad 4th range switch. Adjust or rcplace thc
NOTE: Pa the nnge lever in the 4TH RANGE position.
Between terminals D and C of thc 4th range No Continuily Bad 4th range switch. Adjust or replace the
Don 7-38440 lssued 9-92 Prjntcd in England
kaukazz@yahoo.co.uk
4001-33
Check Points Rcading Possible Ceqlg !LEgg!94!9
Between terminals A and B of the 4th rangc 0 to 5.9 Ohms Bad 4th rangc switch. Adjust or replace the
NOTE: puttheforvvardlreverseleverintheRNERsEposition,tumthekeytotheONpositionandholdtheinchingpedal
DOWN.
Terminal for wire gg Brown/Dark Grccn to 12 Volts Bad circuit between the forward/reverse
ground relay and the 4th range switch.
ForwardiReverse Switch Circuit Test

NOTE: Turn the key to the OFF position and disconnect the forwardlreverse switch from the harness at connector G.
6ll Terminal for wire 64 Brown to ground Continuity Check wire 64 and the chassis ground
connection.
NOTE: Turn the key to the ON position, hotd the inching pedal fully DowN and put the range lever in 4th range.
For tractors equipped with synchromesh transmrssions put the specd sclector lever in gear'
6rI Terminalforwires 86 White/Brown to ground 12 Volts Bad circult between the key switch and the
Iorward/reverse switch. Also check the key
switch and the inching pedal circuit'
Tcrminal for wires g7 BrownA/ellow to l2Volts Bad circuit between the forward/reverse
ground rclay and thc forward/revcrse switch. Also
chcck thc transmission control and
f orward/reverse relaY circuit.
NOTE: Tum the key to the OFF position and putthe forwardlreverse lever in FORWARD position.
Between tcrminals 1 and 2 of conncctor G Continuity Bad lorwardlreverse switch.

(switch side) for wires 86 White8rown and
90 Rcd/Gray
Bctween lcrminals 4 and 5 of connector G Continuity Bad torwardlreverse switch'

(switch side) for wires 87 Brown//ellow and
64 Brown
NOTE: Put the forwardlreverse lever in the RNERSE positron.
Between terminals 2 and 3 of connector G Continuity B,ad lowardlreverse switch.

(switch side) for wires 86 White8rown and
94 Red/Yellow
Betwggn all terminals of conncctor G to No Continuity Forwardlreverse switch wircs shortcd to

ground (switch sidc) oround.
Don 7-3B440 lssucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -34
NOTE: Turn the key to the OFF position and disconnect the forvvard solenoid from the hamess.
61 termlnal for wire 93 Brown Io ground Continuity Chcck wirc g3 and the chassis ground
connection.
Terminal for wire 92 Dark Blue/Black to No Continuity Badforwarddiodemodule.Alsocheckwire

oround 92.
Between terminals A and B of the forward 5.6 Ohms Bad forward solenoid.
solenoid connector * 107"
at room temperature
NOTE: Putthe nnge lever in the NEUTRALposition. Putthe forward/reverse lever in the FORWMD position, turn the key
to the ON position and hold the inching pedal DOWN.
Tcrminal for wire 92 Dark BIuc/BIack to 12 Volts Bad circuit bctwccn thc forward/rcvcrse
ground switch and the forward solenoid
NOTE: Turn the key to the OFF position and disconnect the reverse pressure switch from the harness.
Between terminals A and B of revcrse Continuity Bad reverse pressure switch.
pressure switch
NOTE; Put the for,vardlrcverse lever in the FORWMD position, turn thc key to the ON position and hold the inching pedal
DOWN.
Terminal for wire 91 Light Blue/Black to 12Volts Bad circuit between the forward/reverse
oround switch and the reverse pressure switch
Also check the forward/reverse switch.
NOTE: lf the readings are correct, chcck the rcvcrse pressure switch, refer to farward/reverse pressure swrfch fest
Page 35.

NOTE: Turn the key to the OFF position and disconnect the reverse solenoid from the harness.
f1} Terminal for wire 97 Brown to ground Continuity Check wire 97 and the chassis ground
connection.
Qil Terminal for wire 96 Dark Blue to ground No Continuity Bad reverse diode module. Also check wire g6
Between terminals A and B of rcvcrsc 5.6 'r 10% Bad reverse solenoid.
solcnoid connector Ohms
at room tcmperature
NOTE: Put the nnge lever in the NEUTR4t|- posrtion. Put the forwardlreverse lever in the REIERSE position, turn the key
to the ON position and hold the inching pedal DOWN.
Qil Terminal for wire 96 Dark Blue to ground 12 Volts Bad circuit bctween the forward/revcrse
switch and the rcvcrse solcnoid.
Don 7-38440 lssued 9-92 Prjnted in England
kaukazz@yahoo.co.uk
4001 -35
NOTE: Tum the key to the OFF position and disconnect the forvvard pressure swtch from the hamess.
NOTE: puttheforwardlreverseleverintheRNERsEposition,tumthekeytotheONpositionandholdtheinchingpedal
DAWN.
Check Polnts Reading Possible Cau"e pf Eg9 l"g9j'g
Terminal for wire 95 Light Blue to ground 12 Volts Bad circuit between the forward/reverse
4:1 switchand the forward pressure switch' Also
check the forward/reverse switch
NOTE: lf the readings are conect, check the forward pressure switch, refer to forward/reverss pressure swtfch test
bclow.
Modulation Solenoid Circuit Test

NOTE: Turn the key to the OFF position and disconnect the modulation solenoid lrom the harness.
fD Tcrminalfor wire 101 Brown to ground Continuity Check wire 101 and the chassis ground
connection.
Between terminals A and B of modulation 7.2 +' 1OY" Bad modulation solenoid.
solenoid connector Ohms
at room tcmperature
NOTE: Tum the key to the ON Position
Terminal for wire 100 Dark Blue/ycllow to l2Volts Bad circuit between the forward/revcrse
ground relay terminal 87A and the modulation
solcnoid. Also check the forward/reverse
relay and the modulation diode.
NOTE: put the forwardlreverse lever in the FORWARD position and cycle the inching
pcdal.
ror wirc 100 Dark Bluc/Ycllow to l2Volts Bad circuit between the forward diode
@ I:;n:'l module tcrminal B and the modulation
solcnoid. Also check the forward diode
modulc.
NOTE: Prtt the forwardlreverse lever in the REVERSE posifion'
Terminal for wirc 100 Dark Blue/Yellow to 12Volts Bad circuit belween the reverse diode
ara,nA
vruurru modulc terminal B and the modulation
solcnold. Also check the reverse diode
module.
Forward and Reverse Pressure Switch Test

NOTE: Tum the key to the oFF position and disconnect the pressure swtch from the harness.
Check Points Beading Possiblc Cause of Bad Reading
Betwecn terminals A and B of thc foruyard continuity Bad forward pressure switch'
NOTE: Apply the parking brake and start and run the engine at 1500 rpm'
position (to check the forward

NOTE: put the nnge tever in NEL)TRAL and the forwardlreverse lever in the F)RWMD
pressure switch) oltne ngVgAsEposrtion (to checkthe reverse pressure switch)'
Don 7-38440
lssucd 9-92 Print€d in England
kaukazz@yahoo.co.uk
unecK Holnls Heaolng rosslole-uause oI t,ao Heaolng
Between terminals A and B of the forward No Continuity Bad forward pressure switch.
WABNING: Never operate the engine in a closed building, proper ventilation is required under all
circumstances .
Modulation Diode Test

NOTE: Turn the key to the OFF position and disconnect the modulation diode from the harness.
NOTE: The positive lead ol the multimeter must go lo the female terminal of the diode.
Between the terminals of the diode No Continuity Bad modulation diode
NOTE: Change the leads of the multimeter over so the positive lead goes to the male terminal of the diode.
Belween the tcrminals of the diode Continuiry Bad modulation diode
Forward Diode Module Circuit Test

NOTE: Tum the key to the OFF position and disconnect the forward module and the modulation solenoid from the
harness.
6jfl Terminal for wire 98 Brown to ground Continuity Check wire g8 and the chassis ground
connection.
NOTE: Turn the key to the aN position.
Terminal for wirc 100 Dark Blue/Ycllow to 12 Volts Chcck wire 100.
ground
NOTE: Pfi the foruvardlreverse lever in the FORWARD position and hold the inching pedal tully DOWN.
Terminal for wire 92 Dark Blue/Black to l2Volts Checkwire 100.

ground

NOTE: The positive lead of the multimeter must go to terminal C of the foruvard diode module.
Between terminals C and A of thc diode No Continuity Bad forward diode module.
modulg
Betwecn terminals C and B of thc diodc Continuity Bad forward diode module.
module
kaukazz@yahoo.co.uk
4001 -37
NOTE: Change The leads of the muftimeler so the negative lead goes to terminal C of the forward diode module.
Between terminals C and A of thc diodc Continuity Bad forward diode module.
module
Between terminals C and B ol the diode No Continuity Bad forward diode module.
modulc
Reverse Diode Module Circuit Test

NOTE: Turn the key to the OFF position and disconnect the reverse module and the modulation solenoid from the
harncss.
Chcck Points Rcading Possible Cause of Bad Reading
6D Terminal for wire 103 Brown to ground Continuity Check wire 103 and the chassis ground
connection.
Terminal for wire 100 Dark Blucffellow to 12 Volts Check wire 100.
ground
NOTE: Pgt the forwardlreverse lever in the REVERSE and hold the inching pcdal fully DOWN
6h Terminal for wire 96 Dark Bluc to ground '12 Volts Check wire g6.
NOTE: The positive tead of the multimeter must go terminal C of the reverse diode module.
Betwcen terminals C and A of thc diode No Continuity Bad rcversc diode module.
module
Bctwccn tcrminals C and B of thc diode Continuity Bad revcrse diode module.
modulc
NOTE: Change the teads of the multimeter over so the negative lead goes to terminal C of the reverse diode module
Between terminals C and A of the diodc Continuity Bad revcrse diode module.
module
Betwcen terminals C and B of thc diodc No Continuity Bad rcvcrsc diodc modulc.
module
Clutch Disengage Lamp Circuit Test

NOTE: Check the clutch disengage lamp bulb.
Chcck Points Rcading Possible Cause of Bad Bcading
Terminal for wirc 99 Ycllow/Dark Blue to l2Volts Bad circuit betwccn the forward/rcvcrse
ground rclay and the clutch disengage lamp.
(D Tcrminal for wire 102 Brown to ground Continuity Chcck wirc 102 and the chassis ground
conncction.
Don 7-38440 lssued 6992 Printcd in England
kaukazz@yahoo.co.uk
powrquadplus
4001 -38www.thebestworkshopmanuals.co.uk
Reverse Indicator Lamp Circuit Test

NOTE: Check the reverse indicator lamp bulb.
NOTE: Turn the key to the ON posllron, put the forwardlreverse lever tn reverse and hold the inching pedal fully down.
Check polnts Rcading Possible Cause of Bad Rgqq,ng
69 terminal for wire 95 Light Blue lo ground 12 Volls Bad circuit bretween the forward/reverse
switch and the reverse indicator lamp.
lermlnal for wire 102 Brown to ground Continuity Check wire 102 and the chassis ground
@ connection.
Forward/Fleverse Valve Block

REVFRSE soLENolD
1,,/ @
rF1 /
K
@
REVERSE PRESSU
o.l .* l'
,/
FORWARD PBESSURE SWITCH
@ ,o**oo'
Uon 7-38440 lssued 9-92 Printed in England
kaukazz@yahoo.co.uk
40i 1-39 40i.1-39 Transmission Control Wiring ForwardlReverse Switch Wiring Forward Solenoid Wiring I Wiring Reverse Salenoid Wiring
Schematic Circuit
9s LB (16) 95 LB (161
g+ RIr (16)
95 LB {16)
;r
ttl : @
[': 6008
I AA
\
81
ffil
ffiffi1
WBR
(16)
.----.1
,@ WIB
{1 8)
ffi 87 es LB 06)
I
BR/Y
t--{ (J8) e1 LB/B t',ul

{IEEIE- rtto){fEEFm-r
i-i { +oor-to @ E*I E}iE
Mru. I
s1 LB/B (16)- .91 trol
I
I
\ LB/B
19
I
'19
{ +oor-rs
*@ 94 R/r (16)
90 R/G {16}
r_
I
10o DB\
BAV FI,ryv
(1 6) -L
BRfr (18)
.\\ 81
WB I
A_
84 84 Idm
**
il
WB WB Fl
-T'
-. \ (18)
{ 'l-
--1,
L ooo,-r, & '100
-m
BR 88 BBry
87
1t (16) BR/DG (1 6)
BR/Y
(1 6) 100 DBry {16) 96 DB (16)
(18)
|{ +oor-re
",1
kt:::- Y
I
t_ ml:::- 80 wH {16)
| ,, *,r,'
sowR (16)
86
WBR
4**-r,
(16)
Iffi
102
a4
BR
wlB 4001 - 65 (16)
(1 8)
85 BBI
ryG/B
86
c6 (16)
\@
/V/BR
(18) (16) -
{aoor.ez
93 BR (16)
\@
{ +oor-zr wBR (16)
s9 Y/DB (16)
{+oor-ss, ss
87 BHry (18)
Ot COMPONENTS
1. KEY SWTCH 6. SYNCHROMESH NEUTRAL SWTCH I:K T 1 12. REVEF 12. REVEBSE PRESSSUHE SWITCH 17, MODULATION SOLENOID
CONNECTORS
A. TMNSMISSION HARNESS TO INSTRUMENTPANEL FU
2. 2. FUSE F19 7, TOP INCHING PEDAL SWITCH 13. FORIA, 13. FORWABD SOLENOID 18. REVERSE SOLENOID ,ISTRUMENT PANEL HARNESS ,r 1. NOTE: FOB IRACIORS EQIJIPPEDWITH SYNCHEOMESH IBAA/SM/SS/ONS
2A 2A. FUSE F18 (ACTUATED WHEN THE PEDAL IS FULLY DOWN) 14. POWET .I4.
POWERSHIFT FAULT INDICATOR I.AMP 19. FORWARD PRESSURE SWTCH
E, TRANSMISSION HARNESS TO HIGHT HAND CONSS-E
IGHT HAND CONSOLE HARNESS fHE SyNCHROMESH NELJTRAL SWITCH lS COTVNECfED TA THE
28 28. FUSE F21 8. BOTTOM INCHING PEDAL SWTCH 14A BEVEF G. FORWARD/BEVERSE SWTCH TO INSTRUMENT PANEI rRA!SM/SS/ON HARIIESS AT CONNECTAR M.
144 REVERSE INDICATOR I-AMP O INSTRUMENT PANEL HARNESS
(ACTUATED AT THE START OF PEDAL TRAVEL) M. TRANSMISSION HARNESS TO POWERSHIFT HARNES(
3. 3. THANSMISSION CONTROL RELAY 148. CLUT( 148. CLUICH DISENGAGE WAFINING LAMP ,OWEHSHIFT HARI'{ESS ( * {) :K 2. NOTE: FOR TRACTORS WITH CAB IJP TO PIN NA JJF1017717 AND
3A 3A. FORWAHD/REVERSE RELAY 9. FORWAHD/REVEBSE SWTCH (* 2 ) 15. MODL 15. MODULATION DIODE
P1, BAfiERY POWER JUNCTION BLOCK
-ocK TRACTORSWITHOUT CAB UPTO PIN NOJJF1O17B21 ALLWIRES FROM THE
4. 4. 1ST/zND BANGE SWTCH 10.4TH RANGE SWITCH 16. FOBW 16. FORWARD DIODE MODULE 654 FORWARD/REyERSE SWTTCH ARE BLACK,
5. 5.3RD/4TH MNGE SWTCH 11.4TH MNGE DIODE --lnr-
[-: :=l]
Don 7-39440 16A. REVEI 16A. REVERSE DIODE MODULE
kaukazz@yahoo.co.uk Issucd 9-92 Printed in England 9-92 Printed in England n
ll- E :il
il
iE:o
.rt:i"^.-,r
vrEwED FHoM rHE TERMINAL s ROM THE TERMINAI- SIDE
\---r---F--Jl
321
4001 -40
sENS-O-DRAULIC (SHR) HIrCH CONTROL
Sectional lndex
Flaisc, Lower and Slow Solcnoid Circuit Test ........... ....... 4l

Baise and Lower Solenoid Suppression Diode Module Circuit Tcst ,............ '....,........44
Slow Solenoid SuppressionDiode Module Circuit Test............. ..'..'.......45
Raise Solenoid Diode Modulc Circuit Tcst ........... ...'... .. 48

Lower Solenoid Diode Module Circuit Test ........... .'. . .... 49
SIow Solenoid Diodc Modulc Circuit Test (For Tractors Equipped With Remote Switches) ....... 49
Hitch Control Flasher Flelay and Warning Lamp Circuit Test ,.,......... ..'..,...".... .".... 50
Rclay, Flasher and Warning Lamp Diode Tcst ... . . ,. .......51
Schcmatic Circuit (For Tractors Not Equipped With Remote Switches) ............ ... 53
Schcmatic Circuit (For Tractors Equipped With Remote Switches) . ... 55
Don l-38440 lssucd 9 92 Printcd in Eooland
kaukazz@yahoo.co.uk
4001 -41
CIRCUIT TESTING
NOTE: Thebatterymustbeatfult chargcandatl connectionsmustbecleanandtightbeforetesting.Useamultimeterfor
the tests.
NOTE: The hydraulic oiltempenture must be above 1A F,
NOTE: For tractors not equipped with remote swrtches, rcfer to schematic circuit Page 53. For tractors equipped with
remote swrtches, refer to schematic circuit Pagc 55.
Raise, Slow and Lower Solenoid Circuit Test

NOTE: Tractors not equipped with remote swltches are nat equipped wik slow so/enords.
NOTE: Turn the key to the OFF position. Disconnect the raise, slow, lower solenoids and suppression diode module
lrom the harness.
Chcck Points Rcading Possiblc Causc ol Bad Reading
@ Terminal for wire 1 'lB Brown to ground Continuity Bad circuit betwcen the raise solenoid
tcrminal B and the chassis ground
conncction. Also chcck the chassis ground
conncction.
O Tcrminal for wire 1 1B Brown to ground Continuity Bad circuit bctwcen the lowcr solenoid
terminal B and thc chassis ground
conncction. Also chcck thc chassis ground
connection-
Tcrminalforwirc 135 Brown to ground (fcr Continuity Chcck wire 135 and the chassis ground
tractors equippcd with rcmote switchcs) conncction.
Bctween tcrminals A and B of thc raisc 7.2 + 10% Bad raisc solcnoid.
solcnoid ohms
Belwecn terminals A and B of the lowcr 7.2 + 10% Bad lowcr solenoid'
solenoid Ohms
Betwcen tcrminals A and B of the slow 9.5 'r 10% Bad slow solcnoid'
solcnoid (for tractors equipped with rcmotc Ohms
switche s)
NOTE; Put the hitch controtswrtch in the NETJTRAL pasitian. Turn the key to the ON position and then hold the hitch
control switch in the RAISE position (position 2).
for wire 116 Dark Blue/fcllow to l2 Volts Bad circuit bctwccn the raisc solcnoid
C) ;::H:',| tcrminal A and thc hitch control switch
tcrminal 6. AIso clrcck thc hitch control
switch.
NOTE: lf the reading at chcck point S is correct check wire 1 16 betvveen the raise solenoid cannector and the splice
(f tcrminal D of the suppression diodc 12 Volts Chcck wirc 116 bctwccn the supprcssion
V mcdule for wirc 116 Dark Bluc/t/cllow to dlodc modulc tcrminal D and thc splicc.
ground
kaukazz@yahoo.co.uk
4001-42
NOTE: Put thc hitch controt switch in the NEIJTRqtL position. Tum the key to the ON position
powrquadplus www.thebestworkshopmanuals.co.uk and lock the hitch control
switch in the FUU RNSE position (position t).
Chcck Points Rcadino Possiblc Causc of Bad Rcading
Tcrminal for wirc 116 Dark Bluc/ycllow to 12 Volts Check wirc 1 '16 betwcen terminals B and 6
ground of the hitch control switch.
@ J::n:r for wirc 117 Dark Bluc/Grav to 0 Volts Chcck thc raise solenoid diode modulc and
thc hitch control switch.
NOTE: Check 7 is for tractors equipped with remote switches only.
Tcrminal for wire 134 Dark Bluc/Flcd to 0 Volts Check thc raise solenoid diode module and
ground thc hitch controi switch
NorE: Hold the hitch controt switch in the LowER position (position 4)
for wire 117 Dark Bluc/Grav to

@ I:;n:l 12 Volts Bad circuit between the lowcr solenoid
tcrminal A and thc hitch control switch
tcrminal 5. Also chcck the hitch controt
switch.
NoTE: ll the reading at check point I is conect check wire.l 17 between the lower solenoid connector and the splice.
Terminal of thc supprcssion diodc modulc '12 Volts

Chcck wic 117 between the supprcssion
for wire 117 Dark Bluc/Gray to ground diode module terminal E and the splice.
7l lcrminal for wirc 116 Dark Bluc/ycllow to 0 Volts Chcck thc lowcr solcnoid diodc modulc and
eround thc hitch control switch.
NOTE: Check 7 is for tractors equipped with remotc switches only.
Tcrminal for wirc '134 Dark Bluc/Rcd to 0 Volts Chcck thc lowcr solenoid diode module and
ground
thc hitch control switch.
NorE: Lock thc hitch controt switch in thc woRK position (position s)
Terminal for wire 116 Dark Blue//cllow to l2 Volts Bad circuit bctwcen the raise solenoid
ground tcrminalA and the hitch control switch
tcrminal A. Check the hitch control switch
and thc raisc and lowcr solcnoid diodc
modulcs.
Tcrminal for wirc 117 Dark Bluc/Gray to 12 Volts Bad circuit between the lowcr solcnoid
ground
terminal A and the hitch control switch
tcrminal A. Check the hitch control switch
and the raise and lower solenoid diode
modules.
on 7-38440
lssucd g-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -43
NOTE: The fotlowing checks are for hactors equipped with remote swltches.
NOTE: Hold the right hand raise remote swfch in the RNSE positian.
Check Points Rcading Possiblc Causc of Bad Beading
Terminal for wirc

.134
Dark Blue/Red to '12 Volts Bad clrcuit between the slow solenoid
ground tcrminalA and the raise remotc switch
terminal S. Also chcck the remote switch
and the slow solenoid diodc modulc.
NOTE: lf the reading at check point g is conect check wire 134 between the slow solenoid connector and the splice.
Tcrminal C of the slow solcnoid 12 Volts Chcck wire 134 bctwcen the slow solenoid
suppression diode modulc for wirc 134 suppression diode module tcrminal C and
Dark Blue/Red to ground thc splice
Terminal for wire 116 Dark Bluel/ellow to 12 Volts Chcck the raise solenoid diode module'
ground
Terminal for wire 117 Dark Blue/Gray to 0 Volts Chcck the raise and slow solenoid diode
v
ground modules. Also check the hitch control relay.
NOTE: Repeat check g with the left hand nise remotc switch held in the raisc position
NOTE: Hold thc ight hand lower remote swltch in the LowER position.
to l2Volts Bad circuit bctwcen thc slow solcnoid

sround
Terminal for wire 134 Dark Blue/Hed
fi:illl3i 3 iH'fr"J?T:1""[:": :wiH
and the slow solenoid diode module.
Terminal for wire 117 Dark Bluc/Gray to 12 Volts chcck the lowcr solenoid diode module.
ground
Tcrminal for wirc ]16 Dark Bluc/ycllow to 0 Volts Chcck thc lower and slow solenoid diodc
grcund modulcs, AIso check the hitch control rclay
NOTE: Repeat check 1O with the left hano nise remote switch held in the raise position
NoTE: lf all readings are correct check the suppression diode modules.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -44
Raise and Lower Solenoid Suppression Diode Module Test
NOTE: Disconnect the suppression diode module from the harness.
NOTE: Check the nise, lower and slow solenoid circuits, refer to page 41 .
Terminal C of the suppression diodc Continuity Check wire 119 and the chassis ground
module for wire 1 I9 Brown to ground connection.
NOTE: The positive lead af the multimeter must go to terminal C of the diode module.
Between terminals C and A of the diode Continuity Bad diode module,

module
Between tcrminals C and B o{ the diodc Continuity Bad diode module.

module
Bctwecn terminals C and D of thc diodc Continuity Bad diode module.

module
Betwecn terminals C and E of the diode Continuity Bad diode module.

module
Between terminals C and F of the diode Continuity Bad diode module.

module
NOTE; Change the leads of the multimeter over so the negative lead goes to terminal C of the diode module.
Bctween terminals A and C of the diodc No Continuity Bad diode module.

module
Betwcen tcrminals B and C of the diode No Continuity Bad diode module.

module
Between terminals D and C of thc diodc No Continuity Bad diode module.

modulc
Betwcen terminals E and C of the diode No Continuity Bad diode module.

modulc
Betwcen terminals F and C of the diode No Continuity Bad diode module.

module
kaukazz@yahoo.co.uk
4001 -45
SlowSolenoidSuppressionDiodeModuleTest
(For Tractors Equipped With Remote Switches)
NOTE: Disconnect fhe suppression diode module from the hamess'
NoTE: check the nise, lower and s/ow so/enold circuits, refer to page 41 .
Terminal A of the suppression diode Continuity Check wire 137 and the chassis ground
module for wire 137 Brown to ground connection'
NOTE: The negative lead of the multimeter must go to terminal C of the diode module.
Between tcrminals A and C of thc diodc Continuity Bad diode module'

module
Between terminals B and c of thc diode continuity Bad diode module'

module
NOTE: Change the leads of the mulimeter over so the positive lead goes to terminal C of the diode module'
Between terminals A and C of the diode No Continuity Bad diodc modulc'

module
Between terminals B and C of the diode No Continuity Bad diode module '
modulc
Low Temperature Switch Circuit Test

NOTE: Chock tuse F32.
NOTE: The hydmulic oittemperafitre musl be above 1trF'

from the harness'
NOTE: Tum the key to the OFF position and disconnect the SHR tow temperature swtch
Check Points Rcading Possiblc Causc of Bad Beading
Terminal B of the low temperature switch continuity check

wire 112 between the low
connector (harness side) and the battery tcmperature switch terminal B and the
negative terminar
' battery negative terminal. Arso check the
battery negative connection.
Terminal c of the low temperaturc switch continuity chcck wire 111 between the low
connector (harness side) and thc tcrminal temperature switch terminal c and the
86 of the lockout relay for wire 11 1 lockout relay terminal 86'
Yellow/Dark Blue
NOTE: Tum the keY to the ON Position.
Terminal A of the low tempcraturc switch 12 Volts check wire 110 between the low
connector (harness side) to ground tempcraturc switch and {use F32

Don 7-38440
kaukazz@yahoo.co.uk
4001 -46
NOTE: Tum the key to the OFF position,connect the SHR low tempenture switch lo the hamess
I Te rminal 86 of the lockout relay for wire 11 1 0 Volts Bad low temperature switch.
Yellow/Dark Blue to ground
NOTE: lf the hitch controlsystem opemteswhenthe hydraulic oiltempemture is below 10" F checkthe lockout relay. tf the
readings are conect replace the low temperature switch.
Hitch Control Switch Circuit Test

NOTE; Check fuse F32.
NOTE: Put the httch controlswltch in the NEUTRAL position and turn the key to the ON position.
(D torrinul for wire 113 Red/Dark Blue to 12 Volts Check wire 113 between the hitch control
ground switch terminal 'l and the hitch control relay
terminal 30. Also check the hitch control
relay.
Terminal for wire 127 Dark BlueArVhite to 12 Volts Bad hitch control switch.
ground
Terminal for wire 115 Dark Blue/Pink to 12 Volts Check wire 115 betwcen the hitch control
ground switch terminal3 and the hitch control relay
terminal 86. Also check the hitch control
relay and thc hitch control relay diode.
NOTE: Turn the key to the OFF position and disconnect the hitch control switch from the harness.
(E) Terminals for wirc 116 Dark BIue/Yellow Continuity Check wire 1.16 betwee n the hitch control
switch connectors terminals B and 6.
NOTE: Check between terminal 3 and each terminal of the hitch control switch. lf there is continuity beNveen tcrminal 3
and any of the terminals replace the hitch control switch.
NOTE: Hold the hitch control switch in the FAST RNSE position (position 2),
Bctween terminals 3 and 6 of the hitch Continuity Bad hitch control switch.
control switch
NOTE: Lockthe hitch control switch in the FUU RNSE position (position 1).
Between terminals 3 and B of the hitch Continulty Bad hitch control switch.
control switch
NOTE: Hold the hitch controlswrtch in the FAST LOWER positton (position 4).
Between terminals 3 and 5 of thc hitch Continuity Bad hitch control switch.
control switch
kaukazz@yahoo.co.uk
4001-47
NOTE: Lock the hitch controlswrtch in the WORK position (position 5)'
Between terminals 3 and A of the hitch Continuity Bad hitch control switch'
control switch
Bctwcen terminals 1 and 7 of the hitch continuity Bad hitch control switch'
control switch
(posttion 3)'
NOTE: Hold the hitch controlswrtch in the NELITRAL position
Bctwccn terminals I and 2 of thc hitch Continuity Bad hitch control swltch.
control switch
Hitch Control RelaY Circuit Test

NOTE: Turn the key to the OFF position and chcck Fuse F32'
Terminal for wire 121 Browrv'orange to continuity Bad chassis ground circuit' Also checkthe
sround f,il",:#:"S?:i::]'r
tractors equippcd
NoTE:Thefoltowingcheckisfartractarscquippedwfthremoteswltches.
NOTE: Hold in the right hand nise remote switch'
Tcrminal for wire 121 Browrr/orange to No continuity wirc 121 shorted to ground' Also checkthe
ground rcmotc switch'
lower' left hand raise and lower remote

NoTE: Releasc the nght hand nisc remate switch. Hold in the right hand have shorted to ground' Nso checkthe
wires, I zg, t so and 131
switches in turn and repeat check 21 . lf there is continutty
remote sltches.
Bctwecn tcrminals for wirc 115 Dark continuity chcck wire 115 betwecn tcrminals 86 and
Blue/Pink 87 of the hitch control relay'
the key to the oN position'

NOTE: Lock the hitch controtswltch in thc woRK position (position 5) and turn
Tcrminal for wirc 113 Bcd/Dark Bluc to 12 Volts chcck wirc 113 bctwcen the lockout rclay
ara, nA tcrminal 87A and thc hitch control relay
vrue 'u
tcrminal 30. Also chcck the lockout relay.
Tcrminal for wirc 123 Black to ground 12 Volts Bad hitch control relay'
6)
NOTE: Put the hitch control switch in thc NEUTRN position
Tcrminals for wirc 11 5 Dark Bluc/Pink to 12 Volts Bad circuit betwecn the hitch control switch
uunA
ru tcrminal 2 and the hitch control rclay
v^,a,
tcrminal 86 Also chcck the relay diodc'
NOTE:LockthehitchcontralswilchinthewoRKposition(position5)'
Tcrminals for wire 115 Dark Bluc/Pink to 12 Volts Bad hitch control rclay'
ground
Don 7-38440
kaukazz@yahoo.co.uk
4001 -48
Lockout Relay Circuit Test
NOTE: Check Fusc F32.
NOTE: The hydraulic oil must be above 10"F. Put the hitch control switch in the NEUTRAL position and turn the key to tha
ON position.
Check Points Heading Possible Cause of Bad Beading
Terminal for wire 1'1 0 Dark Blue/Rcd to 12 Volts Bad circuit between the lockout relay
ground tcrminal 30 and fuse F32.
Terminal for wirc 111 YelloMDark Bluc to 0 Volts Chcck the low temperaturc switch.
ground
Terminal for wire 1]3 Rcd/Dark Bluc to 12 Volts Bad lockout relay.
ground
Tcrminal lor wirc 124 B.own to grouno Continuily Check wire 124 and the chassis ground
@ conncction.
NOTE: DisconnectthelowtempentureswitchlromthehamessandconnectasuitablejumperleadbetweenterminalsA
and C of the low temperaturc switch connector (hamess side) and turn the key to the ON position.
.12
Terminal for wire 125 Dark BluelBlack to Volts Bad lockout relay.
ground
Terminal for wire 125 Dark Bluc/Black to 12 Volts Check wre 125 between the lockout relay
ground and the low temperature diode.
NOTE; Connect the low tcmpenturc switch ta the harncss.
Raise Solenoid Diode Module Circuit Test

NOTE: Turn the key to the OFF position, pd the hitch control switch in the NEUTRAL position and disconnect the raise
solenoid diode module from the hamess.
NOTE: Turn the key to the aN position and tock thc hitch control switch in the FULL RAISE position (position 1).
Check Points Rcading Possible Cause of Bad Rcading
Tcrminal for wire 1'16 Dark Bluc//ellow to 12 Volts Bad circuit between the hitch control switch
ground terminal B and the raise solenoid diodc
module terminal C.
NOTE: Lock the hitch controlswilch in the WORK position (posrtion 5).
'12 Volts Bad circuit between the hitch control switch
Terminal for wirc 126 Dark Blue/Light Grccn
to ground tcrminal A and the raise solenoid diode
modulc terminal B.
NOTE: For tractors equipped with remote swtches hold the right or left hand nise remote switch in the RNSE position.
Terminal for wire 132 Dark BlueNiolct to 12 Volts Bad circuit betwecn the remote switch and
ground thc raisc solcnoid diodc module tcrminal A
Also chcck the rcmote switches.
Don 7-38440 lssued 9-92 Printed in Enoland
kaukazz@yahoo.co.uk
4001 -49
Terminal for wire 126 Dark Blue/Light Green 0 Volts check the hitch control switch,hitch control
to ground relay and the remote switches.
NOTE: ll the readings are correct check the diode module. Refer to the Diode Module Test
page 50.
Lower Solenoid Diode Module Circuit Test

NOTE; Turn the key to the oFF position and put the hitch contol switch in the NELJTRAL
position. Disconnect the lower
solenoid diode module from the harness'
position (position 4).
NOTE: Turn the key to the ON position and hotd the hitch control switch in the FAST LOWER
Check Points Reading Possible Cau:s of Bad Reading
Terminal for wire 117 Dark Blue/Gray to .12

Volts Badcircuitbeilveenthelowerdiodemodule
ground terminal C and the hitch control switch
terminal 5.
NOTE: Lock the hitch controtswrlch in the woRK position (position 5)
Terminal for wire 126 Dark Bluc/Light

" 12 Volts Bad circuit between the lower diode module
Green to ground terminal A and the hitch control switch
terminal A.
in the LOWER position

NorE: For tractors equipped with remoteswrtches hold the right or teft hand lower remote swrtch
Terminal for wire 133 Dark Blue/Pink to 12 Volts Bad circuit betwcen the remote switch and
sround n?JiT: fl"_',:"Ti?,:';"::'min,
B Arso
Terminatfor wire 126DarkBlueaight Green 0 volts check the hitch control switch,hitch control
to ground telay and the remote switches'
lf the readings are correct check the diode modulc. Refer to the Diode Module Test
page 5A
NOTE:
Slow Solenoid Diode Module

NOTE; TurnthekeytotheOFFpositionandputthehitchcontrolswitchintheNEUTRALpositionanddisconnecttheslow
solcnoid diode module fram the harness.
NOTE: Turn the key to the ON position and tock the hitch controlswrtch in the WORK
NOTE: Hold the teft or right hand remate sw,tch in the LOWER position.
ror wire r33 Dark Brue/Pink to 12 Volts Bad circuit between the lower remote switch
@ I:;nfl and thc slow solenoid diode module
terminal B.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -50
NOTE: Hold the left ar ight hand remote swrtch in the RNSE position.
Terminal for wirc 132 Dark BlueNiolet to l2 Volts Bad circuit betweenthe raise remote switch
ground and the raise solenoid diode module
terminal A.

.134
4il Terminals for wire Dark Blue/Hed Continuity Chcck wire 134 belween the slow solenoid
diode module terminal C and the slow
solcnoid terminal A.
NOTE: lf the readings are correct check the diode module. Refer to the Diode Module Test below
Diode Module Test

NOTE: The test procedure for the diode module is the samc for all the hrtch control diode modules.
NOTE: Disconnect the diode module from the harness.
NOTE: The negative lead of thc multimeter must go to terminal C of the diode module.
Between terminals A and C of the diode Continuity Bad diode module.

module
Between terminals B and C of the diode Continuity Bad diode module.

module
NOTE: Change the leads of the multimeter over so the positive lead goes to terminal C of the diode module.
Between terminals A and C of thc diodc No Continuity Bad diode module.

modulc
Betwccn tcrminals B and C of the diodc No Continuity Bad diode module.

module
Hitch Control Flasher Relay and Warning Lamp Circuit Test

NOTE: Check the hitch controlwaming lamp bulb.
NOTE: Turn the key to the OFF posrtion.
Check Points Heading Possible Cause of Fad Reading
{ Terminal or wire 127 Brown to ground Continuity Chcck wie 127 and the chassis ground
connection.
NOTE: Put the hitch contral switch in the WORK positton and turn the key to the ON posrtion
d7) Terminal for wirc 123 Black to ground 12 Volts Check wire 123 between the flasher rclay
and the hitch control rclay terminal B7A.
kaukazz@yahoo.co.uk
4001-51
NOTE: Put the hitch control switch in the NEUTRAL position.
@ Tcrminal for wire 123 Black to ground 12 Volts Bad circuit between the hitch control flasher
relay and the hitch control switch terminal2.
Also check the flasher diode.
G) Tcrminal for wire 126 Violet to ground 12 Volts Bad flasher relay.
ON.OFF-ON
Tcrminal for wire 125 Dark Blue/Black to 12 Volts Check wires ]25 and 126. Also check the
ground ON-OFF-ON warning lamp diode,
Relay, Flasher and Warning Lamp Diode Test

NOTE: The procedure to test the diodes is the same for cach diode.
NOTE: Disconnect the diode from the harness.
NOTE: The positive lead ol the multimeter must go to the female terminal of the diode.
Between the terminals of the diodc No Continuity Bad diode.
NOTE: Change the leads of the multimeter over so the positive lead goes to the male terminal.
Bctween the tcrminals of the diode Continuity Bad dlode.
Remote Switch Circuit Test

NOTE: Disconnect the left hand lower remote switch from the harness.
NOTE: Ptn the hitch controlswrlch in the NEUTRAL positian and turn the key to the ON position
Te rminal for wire '12.1 Brown/Orange to 12 Volts Check wire 121 between the right hand raise
ground remotc switch terminal O1 and the hitch
control relay terminal 87A.
lh Terminal for wire 129 Brown/Rcd to ground 12 Volts Bad right hand raise remote switch.
/P Terminal for wire '129 Brown/Red to ground 12 Volts Check wire 129.
@ Ir:n:'l for wire 130 Browr/Dark Blue to 12 Volts Bad right hand lower remote switch.
@ I:;n:'l ror wire 130 Brown/Dark Bluc to

'12 Volts Check wire 130.
Ci) Terminalforwire 13'l Brown/Graytoground 12 Volts Bad left hand raise remote switch.
Don 7'38440 lssued 9-92 Printed in England
kaukazz@yahoo.co.uk
4001 -52
Chcck Points Beading Possible Cause of Bad Reading
{) terminalforwirel3l Brown/Graytoground 12 Volts Checkwire 131.
NOTE: Lock the hitch controlswltch in the WORK position (position 5).
@ J:;n:'r ror wire 128 Red/Dark Brue to 12 Volts Checkwire l2Sbetweentherighthand raisc
remote switch terminal 51 and thc hitch
control switch terminal 7.
Terminal for wire 128 Rcd/Dark Bluc to 12 Volts Checkwirel2Sbetweentherighthandraise

ground remote switch terminal 51 and the right
hand lower remote switch terminal S1.
Tcrminal for wire 128 Red/Dark Bluc to 12Volls Checkwicl29betweenthelefthandraise

ground rcmote switch terminal 51 and the splice.
Terminal for wire 128 Red/Dark Blue to 12 Volts Checkwire 128 betweenthe lefthand raisc
ground remote switch terminal S1 and the left hand
Iower remote switch terminal S1.
NOTE: Hold the right hand raise remote swrtch in the RNSE position.
Terminal for wire 132 Dark Blue/Violet to 12 Volts Bad right hand raise remote switch.
ground
Tcrminal for wire 132 Dark BlueNiolet to 12 Volts Check wire 132 between the right and left
ground hand raise remote switches,
NOTE: Releasc thc ight hand ruise remote switch and hold the lcft hand nise remote switch in the RNSE position
Terminal for wire 132 Dark BlucNiolct to 12 Volts Bad left hand raise remote switch
ground
NOTE: Release the left hand mise remote switch and hold the ight hand lower remote switch in the LaWER position.
Tcrminal for wire 133 Dark Bluc/Pink to 12 Volts Bad right hand lower remote switch,
ground
Terminal lor wire 133 Dark Bluc/Pink to 12 Volts Chcck wirc '133 betwcen the right and lcfl
ground hand lowcr rcmotc switchcs,
NOTE: Belease the ight hand lower remote switch and hold the left hand lower remote swrtch in the LOWER position.
Terminal for wirc 133 Dark Blue/Pink to 12 Volts Bad left hand lower remote switch.
ground
NOTE: Turn the key ta the OFF position and release the remote switch.
fli) Terminal for wire 1 37 Brown/r'iole t to ground Continuity Chcck wire 137 and the chassis ground
conncction.
Bctwecn tcrminals 01 and 0 of thc lcft hand Continuity Bad left hand lowcr remote switch.
lower rcmote switch
kaukazz@yahoo.co.uk
4001-53 Hitch Control {SHB) Switch Wiring Hitch Control {SHR) Solenoid Wring
NOTE: Hold the left hand lower {eficte switch in the LOWER position.
Check Points Readino Possible Cause of Bad Reading

'110 DBIrR i16)
110 DB/! {16)
111 Y/C|8 fl8) lr1 YiOB {18)
Eetween ierminals 51 and S oi the lefi hand Contlnuity Bad leit hand lower remote swiich.
t23A I 126 v (18)
lower remste switch
11? ryoB (16)
NOTE: f lhe readlngi are caffect chac& wres 132 and 1A3 between the remole swltches and the solenoid diade
modules. r'@
Schematic Circuit
R/DB
{13}
@
(For Tractors Not Equippsd With H:emote switches) I
J dI ris /
o-
I
I
I 'I
vlog
{18}
t0
t DB/B
{1a}
^T
t\l'
19 Hii/ (16)
1*o
3(1
(16)
tol-13
-
I
I
DBih
(r8)
c
t)
lb
{a
4001-21
I
127 DB/VY {18)
I 1s DB/P (16)
lzs DBiB {18)-f-
1238{18}J
125 oB'8 (18)
A
127
lo
DSILG BR
o r'17 {16)
DS/G ,
(15)
121 BFUO {18)
128 ryDS (16)
121 BtuO {18)
128 R/OB il6)
(18)
;i, ro DB/R {16} t16 132 DB J (16)

j32 DBE {16}
DB/Y I ,-- 1a3DB/P(16) 133 DB/F (16)
{16)
rir fl9 lt 124
132
R/OB Y/DB 117 DBIG (16)
OBN BR
(13) {18) (16) {1s}
tre)
aoor+s
n[ @ 127
(
h@- 1t6 Bfi
(1B)
0sfi
=ooor+s 116 (16)
37
lo@
DB/Y
"'r--\l-_- BN
{1s}
{16) DB/G
(16)
t.*
IH
T_"<
,4ii
,,..,
t:
y
ii
36 BR (16) { +oor.
,-
4001€9
,1rra* nu,
-@
-
117OB/c (1€)
116 oEtY (16)
119
117 DBrG {16)
116 DB/r (16)
'1,24
BR
d 118 SR 66)
121
BR
,,,,.Li (16) (18) {16)
(Wire Color Code)

COMPONEMT$ CONNECTOBS
1. KEY SWITCH 6, HTTCH.CONTROL SWTCH 8. HITCH CONTROL EELAY A. 1RANSMISSION HARNESS TO INgIflUMENT PANEL I|ARNESS
R fiED 2. FUSE F19 PO$NONl.FULLRAISE 9. LOCKOUT REIAY E. InANSM1SSION HARNES TO RIGHT HANO CONSOLE HARNESS
T TAIi 2A, FUSE F17 POSIIION 2. FAST RAISE 10, SUPPRESSION DIOOE MOOULE K. TRANSMI$SION HARNESS TO'IRANSMISSION HARNESS (FEIAY CROUNO}
28, FU$E F32 POSMON 3. NEUIFAL 11. FLASHEB P]. 8AfiEfrY POWER JUCTION BLOCK
t,,.,.,., .,...,.......,_. 3. ACCESSOBY POWER HELAY . POSMON 4. FAST LOWSR 'I?. RAISE SOLENOIO
a lo LIGHT BLUE 3A, TffANSMI$SION CONTBOL SEI3Y l3Y POSrION s - WOBKING 13, LOW€R SOLENOIO
.........,. GRAY 4. LOW TEMPEHATURE LOCKOUT SWfICH r $/vrlcH 7. BETAY OIODE 14. WARNINC LAMP
o..,.................... ..,...OBANGE 5" AASE SOLENOID DIODE MOOULE
ULE 7A. FLASHER oroDE 15. CIGARETTE LEHTER
5A. LOWEq $OLENOIO OIOOE MOOULE
Don 7-38440 lssugd $-92 Pdnled in England TxJLE ?8. LOW TEMPERATURE BIOOE
kaukazz@yahoo.co.uk
powrquadplus
rss.,cd
-o 9l P.nlcrl n l-nela'ld
Don 7 118440
kaukazz@yahoo.co.uk
4001 -55
Schematic Circuit
{For Tractors Equipped With Rem ote Switches) Hitch Control (SHR) Switch Wiring Hitch Control (SHR) Sr onkol (sHH) solenoid wiring Remote Switch Wiring
@
@( 6 6
t
i-----'l
t-z- B B l11Y,DB (18) 111 Y/DB (
\
{emr-re
03) (13)
1 13 R/DB {16} T-
t
126 V (18)
f
128 FyDB U6)
121 BR/O (
I
I
\ @
121
BR/O
(18)
+ +
"\i'l
!. t t_--.
eoor-rs
110
{
3s FUDB (16)
DB/R
(r6)
o (i8)-f- :z
B
ilB) @
I
- 132 DB/r' {1
13o BR/DB (18)
12s DBB
,rr, -/- 128 B/DB (16) 128 R/OB (16)
lT"
125 DB/B
\
r/, 123 B (18) J
d
I
rzz oenv (re)
\i 115 DB/P (16)
lc
'19
RV
DB/LG
117 (1 6)
121 BR/O 08)
128 RiDB (16)
r21 BR/Q (18)
r28 FyDB (1q
'*
r-
121 BR/O (18)
t2B RIDB (16)
:K
I IO 132 DBIr' (16) r32 D$r' 0q

011 OBN 132 DB/V (16)
126 DBAG (16) I 133 DB/P (16) l33 DB/P (16)
ri r (1u) I T- -
133 DB/P (16)
ta, 124
Y/DE
DBIV DB/P BA 117 DB/G (16) -
(1 8) - 117 DB/G {16)
(1 6) (16) (r8) - 132 DBI/ (16)
133 DB/P (16)
. "?i--' d +oor-ss 132
ii BR
DBIr'
(15)
133 DB/P (1
'''l sz
(18)
I nlv
I
/r
rl
tl
rrsr
r19 BB (16)
I
-@
l
117 DB/c (16)
b
117 DB/G (16)
d
-
36 BR (16) +oor-ss
1r2 BR/W (18) t@

- 1 16 DB/y (16)
119
BR
1 16 DB/r (16)
dt,,, d1,,,*,,, 136 BBr'f (16)
(16) - 118BR(16)+ )
<l 4oo1-27
t; 1. KEYSiWITCH
,ONENTS
CONNECTOHS
YSWTCH 6. HITCH CONTROL SWTCH 8. HTICH CONTBOL RELAY
2. FUSE F19 164. SLOW SOLENOID DIODE MODULE
ISE F,Ig . POSIT1ON 1 . FULL RAISE
A. TRANSMISSION HAHNESS TO INSTBUMENT PANEL HAENESS
9. LOCKOUT HELAY 17. SLOW SOLENOID
2A. FUSE F.I7 ,SE F17 E. TRANSMISSION HAHNESS TO RIGHT HAND CONSOLE HAHNESS
POSITION 2. FAST RAISE 10. SUPPHESSION DIODE MOOULE 18. RIGHT IIANO RAISE REMOTE SWTCH
28. FUSE F32 K. THANSMISSION HAHNESS TO REMOTE SWTCH HARNESS
,SE F32 POSITION 3. NEUTML 11. FLASHER 19. HIGHT HAND LOWER REMOTE SWTTCH
3. ACCESSORY POWER RE. ;CESSOBY POWER RELAY P1. BATTEHY POWEB JUNCTION BLOCK
POS{TION4-FASTLOWER 1E RAISE SOLENOID 20. LEFT HAND RAISE REi\,IOTE SWTCH
3A. TBANSMTSSION @MTRO IANSMISSION CONTBOL RETAY POSITION 5 - WOBKING 13. LOWER SOLENOID 21. LEFT HAND LOWER REMOTE SWITCH
4. LOW TEMPEFAruRE tOC
W TEMPEFATUFE LOCKOUT SWTCH 7. BELAY DIODE 14. WARNING LAMP
5. FAISE SOLENOID DIODE
.ISE SOLENOID DIODE MODULE 74. FLASHER DIODE 15. CIGABETTE LIGHTER
5A" LOWEH SOI.ENOID DIOU )WER SOLENOID DIODE MODULE 78. LOW TEMPEBATUBE OIODE 16. SLOIY SOLENOIO SUPPBESSION DIODE MODULE
Don 7-38440
lssued g-92 Printed in Eng,and
kaukazz@yahoo.co.uk
4001 -56
DIFF LOCK AND MFD
Sectional lndex
Diff Lock lndicator Lamp Circuit Test ........... .,................. 61
t)on 7-38440 lssucd 9-92 Prinlcd in England
kaukazz@yahoo.co.uk
4001 -57
GIRCUIT TESTING
NOTE: The battery must be at full charge and all connections must be clean and tight before testing. Use a multimeter for
thc tesfs.

NOTE: Release the brake pedals and putthe range lever in 1st, 2nd or 3rd runge.
NOTE: Disconnect the diff lock solenoid and suppression diode module from the harness. Turn the key to the ON
position and hold the diff lock switch in thc MOMENTMY position then release the switch to the ON position.
$ terminal for wire 158 Dark Bluc to ground "12 volts Bad circuit between the right hand brake
pedal switch and the diff lock solenoid
connector terminal A. Also check the brake
pedal switches, diff lock switch and the diff
lock relay.
@ tcrminal for wire 158 Dark Bluc to ground

.12
Volts Chcck wire 158 betwecn the suppression
diode module and the splice.
NOTE;furn the key to OFF posttion
@ ferminal for wire 159 Brown to grounci Continuity Check wire 159 and the chassis ground
connection.
Between terminals A and B of thc diff lock 7.2 Ohms Bad diff lock solenoid.
+ 10%
solcnoid
NOTE: lf the readings are correct, check the suppression diode module, refer to Page 62.

NOTE: Turn the key to the ON postition.
6 Terminal for wire 154 Light Green to ground 12 Volts Bad circuit between the keyed power
junction block and thc left hand brake pcdal
switch. Also check the kcyed powcr
lunction block connection and thc chassis
powcr relay.
@ fcrminal for wire 155 Light GrccnrlVhitc to 12 Volts Bad left hand brake pedalswitch. Adjust or
ground rcplace the switch as necessary, refer to
Section 900'1.
kaukazz@yahoo.co.uk
4001 -s8
12 Volts
.155
@ terminalfor wire 155 Light GreenMhite to Check wire between of the left hand
ground brake pcdal switch and of the right hand
brake pedal switch.
@ terminal for wire 156 Light Green/fellow to '12 Volts Bad right hand brake pedalswitch. Adlust or
ground replace the switch as necessary, refer to
Scction 9001.
NOTE: Hold the LEFT hand bnke pedal DOWN
Gl T"rrn;n"l for wire 155 Light GreenArVhite to 0 Volts Bad left hand brake pedal switch. Adjust or
ground replace the switch as necessary, reter to
Scction 900.1.
NOTE: Aelease the LEF| hand brake pedal and hold thc RIGHT hand bmke pedal DOWN.
@ terminal for wire '156 Light Green/Ycllow to 0 Volts Bad right hand brake pcdalswitch. Adjust or
ground rcplace the switch as necessary, refer to
Section 9001.

NOTE: ,9e/ease the brake pedals.
NOTE: Disconnect the diff lock switch from the harness and tum the key to the ON position,
O tcrminalforwire 156 Light Grecn/Ycllow to 12 Volts Bad circuit between the right hand brake
ground pedal switch and the diff lock switch
terminal 6.
@ terminal for wire 156 Light Grecn//ellow to 12 Volts Check wire 156 between terminals 1 and 6
ground o{ thc diff lock switch connector.
NOTE: Put the diff lock switch in the OFF Position.
Between terminals 1 and 3 of the diff lock No Continuity Bad diff lock switch.
switch
Between tcrminals 2 and 6 of the difi lock No Continuity Bad diff lock switch.
switch
NOTE: Hold the diff lock swltch in the MaMENTARY position.
Between terminals 'l and 3 of the diff lock Continuity Bad diff lock switch.
switch
Bctween terminals 2 and 6 of the diff lock Continuity Bad diff lock switch.
switch
kaukazz@yahoo.co.uk
4001 -59
NOTE: Release the diff lock switch to the ON position.
Between terminals 1 and 3 of the diff lock No Continuity Bad diff lock switch.
switch
Between terminals 2 and 6 of the diff lock Continuity Bad diff lock switch'
switch
Diff Lock RelaY Circuit Test

NOTE: Turn the key to the OFF position and put the range lever in the 1st, 2nd, or 3rd range-
Terminal for wire 160 Browry'Dark Blue to Continuity Bad circuit between the diff lock relay
ground terminal 85 and the chassis ground
connection. Also check the diff lock diode,
the 4th range switch and the chassis ground
connection.
@ t"r.minuls for wire 158 Dark BIue Continuity Check wire 158 between the diff lock relay
terminals B6 and 87.
NOTE: Tum the key to the ON position and hold thc diff lock switch in the MOMENTMY position.
@ terminal for wire 158 Dark Blue to ground 12 Volts Check wire 1 58 between the diff lock switch
tcrminal3 and the diff lock relayterminal 86.
AIso check the diff lock switch.
@ terminal for wire 157 Light Grccn/Black lo

'12
Volts Check wire 157 belween the diff lock switch
ground terminal2 and the difl lock relay terminal 30.
Also chcck thc diff lock switch.
NOTE: Release the diff lock switch to thc ON position.
@ fcrminal for wire 158 Dark Blue to ground 12 Volts Bad diff lock relay'
NOTE: Put the mnge lever in 4th nnge.
fi) tcrminat for wire 158 Dark Blue to ground 0 Volts Chcck the 4th rangc switch
Don 7-38440
lssued 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -60
4th Flange Switch Circuit Test
tange swrtch from the harness'
NOTE: Tum the key to the oFF position and disconnect the 4th
4th range switch, DO NOT USE a test lamp or damage
IMPoRTANT: ONLy USEa high impedence multimeterto fest the
to the switch maY occur.
Continuity Check the wire 89 and the chassis ground

@ ferminal for wire 89 Brown to ground
conncction.
of the muftimeter going to the terminal for wire 160

NOTE: Use /he multimeter diode test function with the positive lead
(D Continuity Bad circuit between the diff lock relay

L:'*m,';I ;J[ ?Bf '#ffi3']:;T:'"0 terminal85 and the 4th range switch
connector terminal D, AIso check the diff
lock diode.
NOTE: Pttt the 4th mnge lever in NEUTRAL ar 3RD RANGL'
c and D oi the 4th range

ru'v
Betwecn ' terminals
rv r I rrr o to 5,9 ohms Bad 4th range switch. Adjust or replace the
switch
rangc No continuity Bad 4th range switch. Adiust or replace the
Betwee n terminals A and B of thc 4th
switch as necessary' refer to Sectlon 9001
switch
NOTE: Put the mnge lever in 4TH BANGE'
Bctwccn terrninals C and D of thc 4th rangc No Continuity Bad 4th rangc switch. Adiust or replace9001
the
switch as nccessary, refer to Section
Bctwcen tcrminals A and B of thc 4th range

" 0 to 5.9 Ohms Bad 4th range switch. Adjust or replace the
switch as necessary, refer to Section 9001 .
switch
Diff Lock Diode Test

from the harness'
NOTE: Turn the key b aFF position and disconnect the diff tock diode
tead Of thc mulimcter must go to the male terminal of

the diode'
NoTE: The positive
Chcck Points Reading lg;sible Cause of Bad

Reading
Between thc terminals of thc diodc Continuity Bad diff lock diode'
teads of the muftimeter over so the positive lead of the muttimeter goes to the female terminal of the
NorE: change the
diade.
Between thc terminals of thc diode No Continuity Bad diff lock diode'

Don 7-38440
kaukazz@yahoo.co.uk
4001-61
NOTE: Check the diff lock indicator lamp bulb.
NOTE: Tum the key to the ON position and hold the diff lock switch in the MOMENTMY position.
@ terminal for wire 156 Dark Blue to ground 12 Volts Check wire 156 between the diff lock
indicator lamp and the splice.
NOTE: Turn the key to the OFF position and put the diff lock switch in the OFF position.
(D termlnal for wire 102 Brown to ground Continuity Check wire

.l02 and
the chassis ground
connection.

NOTE: Disconnect the MFD solenoid and suppressian from thc harness. Put the MFD switch in the OFF position and
turn the key to the ON position.
fcrminal for wirc 16'l Dark Blue/Dark Gre en 12 Volts Bad circuit between the MFD solcnoid,
G) to ground terminalA, and the MFD switch terminal 7.
Also check the MFD switch.
12 Volts Chcck wire 161 between the suppression

@ terminal forwire 161 Dark Blue/DarkGreen
diode modulc and the splice.
to ground
NOTE: Tum the key to the OFF posrtion.
glll Terminal'for wire 162 Brown to ground. Continuity Check wire 162 and the chassis ground
connection.
Between terminals A and B of the MFD 7.2 Ohms Bad MFD solenoid
solcnoid -+10%
NOTE: ll the readings are correct, check the suppression diode module, refer to page 62

NOTE: Put the MFD switch in the OFF position, then turn the key to the ON position.
terminal for wire 154 Light Green to ground 12 Volts Check wire 154 between the left hand brake
@ pedalswitch and the MFD switch terminal6.
Also check the brake pedal switch circuits.
kaukazz@yahoo.co.uk
4001-62
Terminal for wirc 161 Dark Blue/Dark Green 12 Volts Bad MFD switch.
to ground
NOTE: Pd the MFD switch in the ON position
Tcrminal for wirc 161 Dark Bluc/Dark Green 0 Volts Bad MFD switch.
to ground
Tcrminal wirc 160 Light Grccry'Yellow to 12 Volts Bad MFD switch.

ground
wire 160 Light Green/Yellow to 12 Volts Check wire 160 between terminals 1 and I
@ ;r:nrl of the MFD switch.
NOTE: Tum the key to the OFF position and check the MFD waming lamp bulb
4i Terminal for wire 163 Brown to ground Continuity Chcck wire 163 and the chassis ground
connection.
Suppression Diode Module Test

NOTE: Disconnect lhe suppression diode module from the harness
@ Tcrminal for wire 1 19 Brown to ground Continuity Check wire 1 19 and the chassis ground
connection.
NOTE: The positive lead of the multimeter must go to terminal C of the suppression diode.
Between terminals C and A of the Continuily Bad suppression diode module.

suppression diode modulc
Between terminals C and B of the Continuity Bad suppression diode module.

suppression diode module
Betwcen tcrminals C and D of thc Continuity Bad suppression diode module.

Between terminals C and E of the Continuity Bad suppression diode module.

suppression diodc module
Between terminals C and F of thc Continuity Bad supprcssion diode module.

suppression diodc modulc
NOTE: Changetheteadsofthemultimeteroversothenegativeteadgoestoterminal Cofthesuppressiondiodemodule.
Between terminals A and C of the No Continuity Bad suppression diode module.

suppression diode moduie
Between terminals B and C of thc No Continuity Bad suppression diode module.

kaukazz@yahoo.co.uk
4001 -63
Between terminals D and C of the No Continulty Bad suppression diode module.

Between terminals E and C of the No Continuity Bad suppression diode module.

Betwcen terminals F and C cf the No Continuity Bad suppression diode module.

Don 7-38440
lssucd 9-92 Pnnted in England
kaukazz@yahoo.co.uk
powrquadplus
kaukazz@yahoo.co.uk
4001-65
Diff Lock Wiring rrng MFD Wiring
4001-65
Schematic Circuit
*E-
Ei*tr
S*Ai$
I 154 LG (16)
46
BiDG
.I-8EEF 1s6 LGrY (1€ 156 LGIY (1 E)-EEEF 1s6 LG/t' (16)
{1s)
ffi ffi
qlr-
LG/v (16)
i
o 160 LGIr {16)
q'o \
il /
I :\
L4 iii! { +oor-zr
'158 157 158
I
t- ii i DB LG/B DB
{16) (.l6) (16)
*i
\
157 LG/B (1
{ aoor-os-
P
{ +oor-ss-.,
tr
160 BR/DB (16)
-@l I= 163
BR
,1" E
L LJ t16)
\-_ :
\:. +l \-J \--- +H Ha @

\J 'H@ DB
(16)
h
]\-.,
,J (16)- -@
102 BR
\..', .j N-.- | ,r", 158 DB (16)- 't58 DB 06)
--o
@ 1ffi 161
BR DB/DG
(16) (16)
{ +oor.se, ss
-o d
119 142
BR
(16) [3, 162 BR (16)
15S BR (18)
161 DB/DG (
7T
COMP
1, FU
COMPONENTS
1. FUSE F24 8. SUPPRESSION DIODE
I ffi coNNEcroRS
A. TRANSMISSION HARNESS TO INSTRUMENT PANEL HARNESS
1A. FL 1A. FUSE F23 9. POWEBSHIFT FAULT INDICATOR I-AMP E. TRANSMISSION HARNESS TO BIGHT HAND CONSOLE HARNESS
2. LE 2. LEFT HAND BRAK PEDAL SWTCH 9A REVERSE INDICATOR I.AMP P2. KEYED POWER JUNCTION BTOCK
3. Rl( 3. RIGHT HAND BRAK PEDAL SWITCH 98. CLUTCH DISENGAGE WAHNING I-AMP
4. D[ 4. DIFF LOCK RELAY SC. DIFF LOCK WARNING LAMP
s. Dil 5. DIFF LOCK SWTCH 10, DIFF LOCK SOLENOID
6. 4T 6. 4TH RANGE DIODE 11. MFD SWTCH
kaukazz@yahoo.co.uk 6A. DI 6A. DIFF LOCK DIODE 12. MFD SOLENOID
Don 7-38440 lssued 9-92 Printed in England 7.47 lssued 9-92 Printed in England 7.4TH HANGE SWITCH
4001 -66
HEADLAMPS AND TAIL LAMPS
FOR TRACTORS WITH CAB
Sectional lndex
67
Hand Hcadlarnp Circuit Tcst ....
L-cft 67
Right Hand Headlamp Circuit Tcst ,. 68
Hcadlamp Dimmer Relay Circuit Test (For Tractors Up To Pin No JJF 1017717 Only) ............... 68
High Bcam Warning Lamp Circuit Tcs1............. ...... ....,.....69
Dimmer/TurnAlorn Switch Tcst (For Tractors Up To PIN No JJF1017717) .,......... 70

..............,
DirnmcrffurnAiorn Switch Tcst (For Tractors From PIN No JJF 1017718) .. ................. 70
Right Hand Tail Lamp Circuit Test ........... 71

Trailer Conncctor Tail lamp Circuit Test........... ............... 72
Lamp Switch Tcst (Headlamp and Tail Lamp Circuits) ...............,..,.... 72
Schcmatic Circuit (For Traclors Up To Pin No JJF 1017717) ....... .....73
Schomatic Circuit (For Traclors From Pin No JJF 1017718) . ... ... 75
i)on 7-384,1(l lssucd 9-92 Pnnlcd ii tnglanc
kaukazz@yahoo.co.uk
4001 -67
CIRCUIT TESTING
NOTE: Thcbattcrymustbeatfu1 chargcandall connectionsmustbecleanandtightbeforetesting.Useamultimeterfor
lhe fesfs.
NOTE: FortnctorsuptopinNoJJF|OlTTlTrefertotheschematiccircuitonPageT3,andfortractorsfromPinNoJJF
1A17718 refer to the schematic circuit on Page 75.
Left Hand HeadlamP Circuit Test

NOTE: Check Fuse F10 and F11 and the left hand headlamp bulb.
NOTE: Turn the lamp switch to the HEADLAMP position (position 3) and operute the dimmer switch to the LOW BEAM
position.
Terminal for wire i77 ?ink/Dark Blue 1o 12 Volts Bad circuit between the left hand headlamp
terminal 568. Also check the headlamp
dimmer relay, dimmer/turn/horn switch and
NOTE: lf the right hand headlamp low beam works correctly, check wire 177 between fuse F1 1 and the left hand
headlamp.
NOTE: Tractors from Pin No JJF 1017718 are not equipped with headlamp dimmer relays.
NOTE: Opemte the dimmer swtch to the HIGH BFAM position'
Terminal for wire 1g0 pinuDark Green to 12 Volts Bad circuit between the left hand head lamp
ground (high beam) and the headlamp dimmer
rclay te rminal 56A. Also check the
hcadlamp dimmer relay, dimmer/turr/horn
NOTE: lf the right hand headtamp high beam works conectly, check wire 18A between tuse F10 and the left hand
headlamp .
NOTE: Tmctors from Pin No JJF 1A17718 are nat equipped with headlamp dimmer relays.
Tcrminal for wire 178 Brown to ground Continuity Chcck wire 178 and the chassis ground
Gl connection.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -68
Right Hand Headlamp Circuit Test
l.tOTE: Check Fuse fiA and F11 and the right hand headlamp bulb.
NOTE: Turn the lamp switch to the HEMUMP position (pasition 3) and opente the dimmer switch to the LOW BEAM
position.
Terminal for wire 177 Pink/Dark Blue to 12 Volts Bad circuit bctwcen the right hand
ground headlamp (low beam) and the headlamp
dimmer relay terminal 568. AIso check thc
headlamp dimmer relay, dimmer/lurn/horn
NOTE: lf the left hand headlamp low beam works conectly, check wire 177 befueen fuse F11 and the ight hand
haadlamp.
NOTE: Tructors from Pin No JJF 1A17718 are not equipped with hcadlamp dimmer rclays.
NOTE: Operate the dimmer swrtch to the HIGH BEAM position.
Terminal for wire 180 PinVDark Green to 12 Volts Bad circuit between the right hand head
ground lamp (high beam) and the headlamp
dimmer relay terminal 564. Also check the
headlamp dimmer relay, dimmerfiurn/horn
NOTE: lf the left hand headlamp high beam works correctly, check wire 180 between fuse F10 and the right hand
headlamp .
NOTE: Tractors from Pin No JJF 1017718 are nat equipped with headlamp dimmer relays.
Gl terminal for wirc 22 Brown to ground Continuity Chcck wire 22 and the chassis ground
connection.

(For Tractors Up To Pin No JJF 1017717 Only)
NOTE: Turn the lamp switch to the HEMUMP position (position 3).
Check points Rcading Possiblc Cause of Bad Reading
ferminal for wire 171 Hcd to ground 12 Volts Bad circuit belween the headlamp dimmer
@ rclay and the lamp switch. Also check the
lamp switch.
Terminal for wirc 171 Rcd to ground 12 Volts Chcck wirc 171 betwcen ierminals 30 and
O 56 of the headlamp dimmer relay.
NOTE: Turn the lamp switch to the OFF position and hold the dimmer swrtch rn the HIGH BE/ttrl position
O Terminal for wire 172 BrownlPink to ground Continuity Bad circuit betwecn the headlamp dimmer
rclay tcrminal S and the chassis ground
conncction. Also check the dimmer/turn/
conncction.
kaukazz@yahoo.co.uk
4001 -69
NOTE: Turn the lamp switch to the HEN)LAtvlP position (pasition 3) and hold the dimmer switch in the LOW BEl$tl position.
Check points Rcading Possiblc Causc of Bad Reading
@ I:;n:'l ror wire 176 Red/Dark Bruc to 12 Volts Bad dimmer relay.
NOTE: Opemte the dimmer swtch to the HIGH BEAM position.
Tcrminal for wirc 179 Rcd/Dark Grccn to 12 Volts Bad dimmer relay.
ground

NOTE: Disconnect the instrument cluster from the hamcss.
NOTE: Turn the lamp switch to the HEN)LAMP position (pasition 3) and hold the dimmer switch in the HIGH BEAM position
Pin 32 of the instrurnent clustcr conncctor to 12 Volts Chcck wire 180 between the instrument
ground clJstcr conncctor pin 32 and fuse Fl0.
NOTE: lf the reading is correct check the instrument cluster power and chassrs ground circuit, refer to Page 15.
Horn Circuit Test

NOTE: Disconnect the hom from the harness.
(F Terminalfor wire 181 Gray/Fcd to ground l2Volts Bad circuit betwcen thc battery powcr
junction block and thc horn. Also check the
baltcry powcr junction block conncction.
NOTE: Hold the horn switch in the HORN position.
Terminal for wire 182 Brown/Orangc to Continuity Bad circuit betwcen the horn and the
ground chassis ground conncction. Also chcck the
dimmcr/turn/horn switch and thc chassis
ground conncction.
kaukazz@yahoo.co.uk
4001-70
(Headlamp Dimmer and Horn Circuits)
For Tractors Up To PIN No JJf 1017717
NOTE: Disconnect the dimmerltumlhom switch from the harness at connector R.
@ Tcrminal for wire 175 Brown to ground Continuity Chcck wire 175 and thc chassis ground
connection.
NOTE: Tum the lamp switch to the HEADLAMP position (position 3).
) fermlnal for wirc 172 Brown/Pink to ground 12 Volts Check wire 172 and the headlamp dimmer
rclay.
NOTE: Opente the dimmer swrlch until a continuity reading is abtained between terminals 2 and 6 forwires 773
BrownlWhite and 174 Brown of Connector R (switch side). lf a continuity reading can not be obtained replace the
di mm erltu m I hom switch.
NOTE: Operate the dimmer switch again.
Betwcen terminals 2 and 6 of connector R No Continuity Bad dimmer/turn/horn switch.

(switch side) forwires 173 BrownAVhite and
I74 Brown
NOTE: Press and hold the hom switch in the HORN position.
Betwcen terminals 3 and 6 of connector R Continuity Bad dimmer/turn/horn switch.

(switch side) for wires 183 Black and 175
Brown
NOTE: lfthereadingsareconect,checkwirelT2befueentheheadlampdimmerrelayandthedimmerlturn/hornswitch.
Dim mer/Turn/Horn Switch Test

For Tractors From PIN No JJf 1A17718
NOTE: Tum the lamp switch to the HEADLAMP posrtion (position 3).
Terminal for wire 171 Red to ground 12 Volts Chcck wirc 171 betwcen the lamp switch
@ and connector R. Also check the lamp
switch.
(i Terminal for wire 171 Red to grouncl 12 Volts Checkwire 17'l between the te rminals 1 and
2 of connector R.
NOTE: Put the dimmer switch in the LOW BENI position
@ terminal for wire 176 Red/Dark Bluc Io ground 12 Volts Bad dimmer/turn/horn switch.
kaukazz@yahoo.co.uk
4001-71
NOTE: Putthe dimmer swifch in the HIGH BEAM position

.12
tlil
w Terminal for wire 179 Red/Dark Green to Volts Bad dimmer/turn/horn switch.
grouno
NOTE: Pd the dimmer swltch in the MOMENTMY HIGH BEAl,l position'
Terminal for wire 179 Red/Dark Green to 12 Volts Bad dimmer/turn/horn switch.
ground
NOTE: Tum the tamp switch to the OFF position and disconnect the dimm/tumlhom switch from the harness at
connector R.
NOTE: Press and hold the ham switch in the HORN position.
Between terminal 7 of connector R (switch Continuity Bad dimmerAurry'horn switch. Also checkwire
side) for wire 183 Brown/Orange to ground 64 and the chassis ground connection at the
Iorward/reverse switch, refer to Page 39.
NOTE: lf the readings are correct check wire 182 beNveen the hom and connector R.
Left Hand Tail LamP Circuit Test

NOTE: Check Fuse F9 and the left hand tail lamp bulb.
NOTE: Dr'sconnect the left hand tait lanp trom the harness and turn the lamp swfch to the HEADUMP position (position 3).
Check points Ecading Possible Cause of Bad Reading
(D Terminalfor wire 186 Pint<rAtrhite to ground 12 Volts Bad circuit between the left hand tail lamp
and the lamp switch. Also check the lamp
switch
NOTE: lf the ight hand tail lamp works conectly, check wire 1BO between the left hand tail lamp and the splice.
6li) Terminalfor wirc 187 Brown to ground Continuity Chcck wire 187 and the chassis ground
connection.
Right Hand Tail LamP Circuit Test

NOTE: Check Fuse F9 and the ight hand tail lamp bulb.
NOTE: Disconnect the 1ght hand tail tamp from the harness and turn the tamp swtch fo the HEADLAMP position (position 3).
6Il Terminalfor wire 186 PinKAffirite to ground 12 Volts Bad circuit between the right hand tail lamp
and the lamp switch. AIso check the lamp
switch
NOTE: lf the left hand tait lamp works conectly, check wire 186 between the ight hand tail lamp and the splice'
fD Terminal for wire 188 Brown to ground Continuity Check wire 1BB and the chassis ground
connection.
Don 7-38440
lssucd 9-92 Prinled in England
kaukazz@yahoo.co.uk
4001-72
Terminal 1 of the trailer conncctor for wirc Continuity Check wire 189 and the chassis oround
189 Brown to ground connectton.
NOTE: Tum the lamp switch to the HEN)LAMP position (position 3).
Terminal 6 of the trailer connector for

.186
wire 12 Volts Check wire 186 between the trailer
Pink/White to ground conncctor pin 6 and the splicc
Check points Reading Possiblc Cause of Bad Reading
es Terminal for wire 170 Red//ellow to ground l2Volts Check wire 170 and the battery power
Terminal for wire 184 Red//ellowtWhite to l2Volts Check wire 184 and the battery power
ground junctlon block connection.
NOTE: Turn the lamp switch to the W/,q,NING LAMP posilon (position 2).
€l) terminalfor wire 185 RedllVhite to ground 0 Volts Bad lamp switch.
4?l Terminalfor wire 171 Red to ground 0 Volts Bad lamp switch.
NOTE: Turn the lamp switch to the HEADLAMP position (posnion 3).
fI) Terminalfor wirc '185 RedMhite to ground 12 Volts Bad lamp switch.
fD Terminal for wire 171 Red to ground 12 Volts Bad lamp switch.
NOTE: Tum the lamp switch to the FENDER WORK LAMP position (position 4)
@ Termlnal for wirc 185 RcdlWhitc to ground 0 Volts Bad lamp swltch.
6D| Terminal for wire 171 Rcd to ground 12 Volts Bad lamp switch.
NOTE: Tum the lamp switch to the CM WORK UMP position (position 5).
6D Terminal for wire 185 RedMhite to ground 0 Volts Bad lamp switch.
6B Terminal for wire 171 Rcd to ground 12 Volts Bad lamp switch.
kaukazz@yahoo.co.uk
4001 -73 Headlamp Wiring Horn Wiring Tail Lamp Wiring
Schematic Circuit
(For Tractors Up To PIN NO JJF 1A17717) ffi
176 R/DB (15)
R/DB 219
17e B/DG (15) (1 3) R/O
w".w
(1 8)
H${q
*ffi:;E 171 R (1 171 R_.{13 e
176 179
i i--7 184 R/Y,A/V (18)
R/DB FVDG
,, €b
1r tq
(1 5) (15) d+oor-
'--J-A f__
171
:l
I I l;Th:I
- --'i 1
.-_r/.,a_
'4=';.'
I R
(tJ.l
irf
nl
176 182
RlDB BR/O
I
1
{15} (16) olollolooo

1[+oor'zs 1ao L
{a R/DG
177 177 180 180

(1 5)
_il
3
4001-
P/DB P/DB P/DG P/DG
1-: ---- (1s) (15) (15) (15)
i-""" /\li
\--Y-'
ll 185 RA/V (18)
{aoor-zs 176 F/DB (1s)

4,001-93
172 BR/P (18) 172 BF/P 08)
{ 4001-1 13
186 186
17s BH {16) P/W PM 4001-127
I (1 8) (1 8)
175 r74 BR (16)
t
BR
'll (16)
182
L
PI 180 P/DG (15) BFUO
d
(1 173 BH/W (16) {16)
\l 4[+oor- rs 183 B (16)
#
200 B/lV (16)
202 BiDG (16) <[+oor-ss
\o
1e7 BAV/DG (16)
JI\ 187 BR (18)

174 't89
BR ss BR
(15) 22 BB (15) {aoor- 188 BR (18)
3)
{1
lea
L-l
I
ffi
(\-'l J coMPor COMPONENTS 6. DIMMEB/TURNIHORN SWITCH 10. LEFT HAND TAIL LAMP ss;. cor CONNECTORS
i. FUSE
1. FUSE Fl1 7. HORN 11. BIGHT HAND TAIL LAMP B
B, ENGINE HARNESS TO INSTRUMENT PANEL HARNESS
1A. FUSI 12. TMILEA CONNEGTOR D.
1A, FUSE F1O 8. FUSE F17 D. CAB HARNESS TO INSTRUMENT PANEL HARNESS
18. RJSI 13, HEADLAMP DIMMER RELAY N.
18. FUSE F9 9. LAMP SWITCH N. CAB HARNESS TO FENDEH REAB HARNESS
R.
2. INST] 2, INSTRUMENT CLUSTER CONNECTOH POSITION 1 . OFF R, INSTHUMENT PANEL HARNESS TO DIMMERITURN/HORN SWITCH
3. LEFT P1.
3. LETT HAND HEADLAMP (LOW BEAM) POSITION 2 . WARNING LAMPS P1. BATTERY POWER JUCTION BLOCK
3A, LEFI POSITION 3. WARNING LAMPS, TAIL LAMPS, HEADLAMPS
3A. LEFT HAND HEADLAMP (HIGH BEAM)
4. ETHI 4. ETHEB START SOLENOID POSINON 4. REAR FENDER WORK LAMPS, HEADLAMPS
s. BlGl 5. BIGHT HAND HEADLAMP (LOW BEAM) POSITION 5. REAH FENDER WORK LAMPS, HEADTAMPS
5A. RIGI 5A. RIGHT HAND HEADLAMP (HIGH BEAM) OPTIONAL FRONT AND REAR CAB WOBK LAMPS
kaukazz@yahoo.co.uk
powrquadplus
Don 7 38440
lssucd 9-92 Prnlcd in IrganC
kaukazz@yahoo.co.uk
4A$-75 Headlarnp Wiring Horn Wiring Tail Lamp Wiring
Schematic Circuit
(For Tractors From PIN NO JJF 1017718)
176 R/DB {15) 3s R/DB (13)

-?- {.* 219
H/O
(1 8)
A
Ailii-.- l/o 179
2o 184 Rlrruv (1
A-
R/DB WDG
{aoot- r,
(1 s) (15)
"J-A@ 4001- 73
<[+oor-ss
181
_---i i G,R --] G/n
'181
@1ffi
Lll
(16) (1 6)
171 R (13)
oooolotlol
,uo ,lon 1ru; J
171
t-
R
(1 s)
177 180 180
ioor-trs 4001-95
{
*:
P/DB PIDB
(1 5) (1 5)
P/DG PIDG
(1s) (1s)
179
r--JF
I L*A=' I'II J
R/DG
176 186 P/VV 0 8)

R/DB
4001 -95
B (1s)
B 4001 -1 1 3
B
177 PIDB (15) 4001 -1 27
180 P/DG-(1s)
t
I t_ I
182
,Tf
1aF BR/O BR/O
177 taa 180
DBAV
I ,,,u, (1 6)
180 P/DG (15) 171
tlrl
i13)
H
(13)
/
"\f {+oor-
ts
II
@
ll
ct 178
BR
(10
G
178
BR
(1 s)
176
(1 6)
=-l
182 BR/O (16)
- | 3[+oor-ss
={**.'-,.,
r
&t
BR
*{
187 BB (18) \@
188 BR (18)
(
--+ le+ I
10. LEFT HANU IAIL LAMP CONNECTORS

) cor'apc COMPONENTS 5. DIMMEB/TUBNiHORN SWTCH . LAMP
7. HORN 1 1. BIGHT HAND TAIL LAMP IL LAMP B. ENGINE HAHNESS TO INSTHUMENT PANEL HAHNESS
1. FUS 1. FUSE F11
8. FUSE F17
12. TRAILEH CONNECTOH :CTOB D, CAB HARNESS TO INSTHUMENT PANEL HABNESS
1A. FUI 1A. FUSE F1O
N. CAB HABNESS TO FENDER HABNESS
18. FUI 18. FUSE F9 9. LAMP SW]TCH
SWITCH
POSITION 1 - OFF R. INSTBUMENT PANEL HARNESS TO DIMMERrrUBN/HOHN
2, INS 2. INSTBUMENT CLUSTER CONNECTOR
POSITION 2. WARNING LAMPS Pl. BATTEBY POWER JUCTION BLOCK
3. LEF 3, LEFT HAND HEADLAMP (LOW BEAM)
3A. LEF 3A. LEFT HAND HEADLAMP (HIGH BEAM) POSITION 3 - WARNING LAMPS, TAIL LAMPS, HEADLAMPS
POSITION 4. REAR FENDER WORK LAMPS' HEADLAMPS * NOTE: THE DIMMERITURNIHOFN SWICH tS GBOUNDED AT
4. ETF 4. ETHEB STABT SOLENOID O PAGE 39,
THE FOBW M D I REVERSE SW ITCH, B EFER T
5. EIG 5. RIGHT HAND HEADLAMP (LOW BEAM) POSITION 5 - REAR FENDER WORK LAMPS, HEADLAMPS
Don 7-38440 lssued 9-92 Plinted in England
5A. BIC 5A. RIGHT HAND HEADLAMP (HIGH BEAM)
OPTTONAL FHONT AND REAR CAB WORK LAMPS
kaukazz@yahoo.co.uk
4001 -76
HEADHMPS AND TAIL I.AMPS
FOR TRACTORS WITHOUT CAB
Sectional lndex
Lcft Hand Headlamp Circuit Test ........... ......................... 77

Right Hand Headlamp Circuit Test ........... ........................ 7g
Headlamp Dimmer Relay Circuit Test (For Tractors Up To Pin No JJF 1017821 OnV) ,......... ..... tB
High Beam Warning Lamp Circuit Test............. .................79
Dimmcr/TurnZtlorn Switch Tcst (For Tractors Up To PIN No JJf t017AZ1) .............. g0

t017BZ2l
Dimmer/l-urn/l-{orn Switch Test (For Tractors From PIN No JJf ........,...... 80
Trailer Connector Tail lamp Circuit Test ........... ............... gz

Lamp Switch Test (Headlamp and Tail Lamp Circuits) .....,.,................ 82
Schcmatic Circuit (For Tractors Up To Pin No JJF 10178211 .............. 83
Schematic Circuit (For Tractors From Pin No JJF 1Afi822) ............... 85
Don 7-38440 Issucd 9-92 Pdnlc.l in Eno{anrJ
kaukazz@yahoo.co.uk
4001-77
CIRCUIT TESTING
NOTE: The battery must be atfull charge and all connections must be clean and tight before testing. LJse a multimeter for
the lests.
NOTE: For tnctors up to Pin No JJF|017821 refer to the schematic circuit on Page 83, and for tractors from Pin No JJF
1017822 refer to the schematic circuit on Page 85.
Left Hand Headlamp Circuit Test

NOTE: Check Fuse F10 and Fl1 and the left hand headlamp bulb.
NOTE: Tum the lamp switch to the HEADIAMP position (position 3) and operate the dimmer switch to the LOW BEAM
position.
Check points Heading Possible Cause of Bad Reading
O l:;n:'l ror wirc 177 Pink/Dark Brue to I2 Volts Bad circuit between the left hand headlamp
(low beam) and the headlamp dimmer relay
tcrminal 568. Also check the headlamp
dimmer relay, dimmer/turnhorn switch and
NOTE: lf the right hand headlamp low beam works conectly, check wire 177 betvveen fuse F11 and the teft hand
headlamp.
NOTE: Iraclors trom Pin No JJF 1017822 are nat equipped with headlamp dimmer relays.
NOTE: Opemte the dimmer switch to the HIGH BEAM position.
Terminal for wirc 180 Pink/Dark Green to 12 Volts Bad circuit between the left hand head lamp
ground (high beam) and the headlamp dimmcr
rclay terminal 56A. Also check the
headlamp dimmcr rclay, dimmerfiurn/horn
NOTE: lf the right hand headlanp high beam works correctly, check wire 180 between fuse F|0 and the teft hand
headlamp .
NOTE: Tractors from Pin No JJF 1017822 are not equipped with headlamp dimmer relays.
Gl Terminal for wire 178 Brown to ground Continuity Chcck wire 78 and the chassis ground
'1
connection.
kaukazz@yahoo.co.uk
4001 -78
Bight Hand Headlamp Circuit Test
NOTE: Check Fuse F10 and F11 and the ight hand headlamp bulb.
NOTE: Tum the lamp switch to the HEADUMP position (position 3) and opemte the dimmer switch to the LOW BEAM
position.
Terminal for wire 177 Pink/Dark Blue to 12 Volts Bad circuit between the right hand
ground headlamp (low beam) and the headlamp
dimmer relay terminal 568. Also check the
headlamp dimmer relay, dimmer/turry'horn
NOTE: lf the left hand headlamp low beam works conectly, check wire 177 between tuse Fl1 and the ight hand
headlamp.
NOTE: Tnctors from Pin No JJF 1017822 are nat equipped with headlamp dimmer relays.
NOTE: Opemte the dimmer switch to the HIGH BUM position.
Terminal for wire 180 PinlVDark Green to 12 Volts Bad circuit between the right hand head
ground lamp (high beam) and the headlamp
dimmer relay terminal 56A. Also check the
headlamp dimmer relay, dimmerlturn/horn
NOTE: lf the lcft hand headlamp high beam works concctly, check wire 180 beNveen fuse Fl0 and the right hand
headlamp .
NOTE: Tnctors from Pin No JJF 1017821 are not equipped with headlamp dimmer relays.
G) -crminal for wirc 22 Brown to ground Continuity Chcck wire 22 and the chassis ground
connection.

(For Tractors Up To PIN No JJF 1017821 Only)
NOTE: Turn the lamp switch to the HEADUMP pasition (position 3).

.171
terminal for wire Red to ground 12 Volts Bad circuit between the headlamp dimmcr
@ rclay and the lamp switch. Also check the
lamp switch.
Terminalfor wire 17'l Rcd to ground 12 Volts Check wie 171 between terminals 30 and
O 56 of the hcadlamp dimmer relay.
NOTE: Turn the lamp switch to the OFF positon and hold the dimmer swtch in the HIGH BEAM position
Gl Terminal for wire 172 Brown/Pink to ground Continuity Bad circuit between the headlamp dimmer
rclay terminal S and the chassis ground
connection.
kaukazz@yahoo.co.uk
4001-79
in the LOW BFAM
NOTE: Turn the tamp switch to the HEADLAMP position (position 3) and hold the dimmer switch
position.
Check Points Rcading Possiblc Causc of Bad Reading
Terminal for wire 176 Red/Dark Blue to 12 Volts Bad dimmer relay.
ground
NOTE: Operate the dimmer swrlch to the HIGH BAM position
Terminal for wire 179 Red/Dark Grcen to 12 Volts Bad dimmer relay.
ground

NOTE: Disconnect the instrument cluster frorn the hamess'
in the HIGH BEAM
NOTE: Turn the lamp switch to the HEADLAMP position (posrtion 3) and hotd the dimmer switch
position.
the instrume nt cluster connector to 12 Volts Chcck wire 180 between the instrument
@ ;::f;r cluster connector pin 32 and fuse F10.
NOTE: tf the reading is conect check the instrument cluster power and chassis ground circuit, refer to Page 15
Horn Circuit Test

NOTE: Chcck fuse F17.
G) Terminalfor wire 181 Gray/Fed to ground 12 Volts Bad circuit between the battery power
junction block and the horn. Also check the
battcry powcr junction block connection.
NOTE: Hotd the hom swrtch in the HaRN position
fil Terminal for wire 182 BrownlOrange to Continuity Bad circuit between the horn and the
U' grouno chassis ground connection, Also check the
dimmer/turn/horn switch and the chassis
ground connection.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -80
For Tractors Up To PIN No JJF 1017821
NOTE: Disconnect the dimmerltumlhorn switch from the harness at cannector R.
(B tcrminal for wirc 175 Brown to grounci Continuity Chcck wire

.175
and the chassis ground
conncction.
NOTE: Turn the lamp switch to the HEADIAMP position (position 3).
( Terminal for wire 172 Brown/Pink to ground 12 Volts Chcck wire 172 and the headlamp dimmer
rclay.
NOTE: Operate the dimmer switch until a continuity reading is obtained between terminals 2 and 6 for wires 173
BrownlWhite and 174 Brown of Connector R (switch side). lf a continuify reading can not be obtained replace the
di mmerltu rnl horn switch.
NOTE: Opemte the dimmer switch again.
Bctwecn tcrminals 2 and 6 of conncctor R No Continuity Bad dimmer/turn/horn switch.

(switch side) forwircs 173 BrownlWhitc and
174 Brown
NOTE: Press and hold the horn switch in the HORN position.
Between terminals 3 and 6 of connector R Continuity Bad dimmcr/turn/horn switch.

(switch sidc) for wircs 183 Black and 174
Brown
NOTE: lf thereadingsarecorrect,checkwirelT2betweentheheadlampdimmerrelayandthedimmerlturnlhornswitch.
Dim mer/Turn/Horn Switch Test

For Tractors From PIN No JJF 1017822
NOTE: Turn the lamp switch to the HEADLAMP position (posrtion 3).
Chcck points Rcading Possible Cause of Bad Reading
(F Tcrminalfor wirc 171 Rcd to ground 12 Volts Chcck wirc 171 bctwccn thc lamp switch
and conncctor R, AIso chcck thc lamp
switch
(D Tcrminal for wirc 171 Rcd to ground 1 2 Volts Chcck wire 171 bctwccn thc tcrminals 1 and
2 of conncctor R.
NOTE: Put the dimmer switch in the LOW BElttrl position
fcrminal for wire

.176
Rcd,Dark Bluc to ground l2 Volts Bad dimmcr/turn/horn switch.
@
kaukazz@yahoo.co.uk
4001 -8 r
NOTE: Put the dimmer switch in the HIGH BEAM position.
Terminal for wire 179 Red/Dark Green to 12 Volts Bad dimmcr/turn/horn switch.
ground
NOTE: Pttt the dimmer swfich in the MOMENTMY HIGH BE]Jvl position.
Terminal for wire 179 Red/Dark Green to 12 Volts Bad dimmer/turn/horn switch.
ground
NOTE: Ium the lamp swrtch to the OFF position and disconnect the dimmltumlhorn switch from the harness al
connector R.
NOTE: Press and hold the hom switch in the HOBN position
Between tcrminal 7 of connector R (switch Continuity Bad dimmcrlturn/hoi'n switch. Also checkwire
side) for wire 183 Brown/Orange to ground 64 and the chassis ground connection at the
forward/reverse switch, refer to Page 39.
NOTE: tf the readings are correct check wire 182 between the hom and connector R.
Left Hand Tail Lamp Circuit Test

NOTE: Chcck Fuse F9 and the left hand tail lamp bulb.
NOTE: Disconnect the teft hand tait lamp from the harness and turn the lamp switch to the HEADUJvIP position (position 3).
(D fcrminalfor wire '186 PinkflViritc to ground 12 Volts Bad circuit between the Ieft hand tail lamp
switch
NOTE: tf the right hand tail lamp works correctly, check wire 186 between the left hand tail lamp and the splice.
terminal for wire 187 Brown to ground Continuity Chcck wire 187 and the chassis ground
@ conncction.
Right Hand Tail Lamp Circuit Test

NOTE: Check Fuse F9 and the ight hand tail lamp bulb.
NOTE: Disconnectthe right hand tait tamp from the harness and turn the lamp swrlch to the HEMUMP position (position 3)
Check points Feading Possible Cause of Bad Reading
frl Terminal for wire 186 PinkflVhite to ground 12 Volts Bad circuit between the right hand tail lamp
switch
NOTE: lf the left hand tail lamp works correctly, check wire 1 BO between the right hand tail lamp and the splice.
tcrminal for wirc l BB Brown to ground Continuity Chcck wire lBB and the chassis ground
@ conncction.
Don 7-38440 lssucd 9-92 Prjntcd in England
kaukazz@yahoo.co.uk
4001 -82
Check points Heading Possible Cause of Bad Reading
Terminal 1 of the trailer connector forwire Continuity Chcck wire 189 and the chassis ground
189 Brown to ground connection.
NOTE; Turn the lamp switch to the HEN)LAMP position (position 3).
Terminal 6 of thc trailer conncctor for wirc 12 Volts Check wire 'l
86 belween the trailer
1BG Pinl(White to ground connector pin 6 and the splice
Chcck points Rcading Possible Cause of Bad Reading
.l2Volts Check wire 170 and the battery power

0D Terminalfor wire 170 Rcd/Yellow to ground
&1i
\y Terminal for wirc 184 Red//cllowflhite to 12Volts Check wire 184 and the battery power
ground junction block conncction'
-
NOTE: Turn the lamp switch to the W/F,NING LAMP positlon (position 2).
@ Terminal for wire 185 RcdlVhite to ground 0 Volts Bad lamp switch.
6f) terminal for wire 171 Rcd to ground 0 Volts Bad lamp switch.
NOTE: Turn the lamp switch to tha HEMLAMP posttion (position 3)
(i7 Terminal for wire 185 RedMhite to ground 12 Volts Bad lamp switch.
Terminalforwirc 17.1 Bcd to ground 12 Volts Bad lamp switch.

€.)
NOTE: Tum the tamp switch to the FENDER WARK LAMP position (position 4it.
6P Tcrminal for wire 185 RcdNVhitc to ground 0 Volts Bad lamp switch.
Terminal for wire 171 Rcd to ground 12 Volts Bad lamp switch.
@
NOTE: Tum the lamp switch to the C/t|''IAPY WORK LAMP position (position 5).
Terminal for wire 185 RcdMhite to ground 0 Volts Bad lamp switch.
@
Terminal forwirc
.171
Rcd to ground 12 Volts Bad lamp switch.
6-:'l
Don 7'38440 lssucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -83 Headlamp Wiring Horn Wiring Tail Lamp Wiring
powrquadplus www.thebestworkshopmanuals.co.uk Schematic
Circuit
(For Tractors Up To PIN NO JJF 10i7821)
r76
@@- FUDB {15) ot
f
B/DB
219
(13)
R/O
r71 H (13 @ (18)
184 Rfv/W (18)
<[+oor- zr \
35
REB 1:
I Ib182 (1 3) I
R
R/DB BB/O 0
(15) (16)
(1 3)
oo ct oo
as l
{+oor- 179 l
R/DG
(1 5) l
177 177 180 180
$
I
P/DB P/DB P,DG PiDG

I
4001- 1m r
(1s) (15) (15) (15) { +oor-rzr

\ \.
18s R,ryV (1 B)
186 Pnlv (18) 186 PAV (18)

'176 R/DB (15) 182 BF/O (16)
+oor-ros
172 BRIP (18) 172 BR/P (18) {
r I
I
175 BR (16)
186
{ +oor-,e,
1[aoor-rzz
T I
BH
174 BH (16)
',#i 6b
@@ tr
t
I '189
1n (1 6)
{+oor-ros
177 180 BB
@
I
180 P/DG (15) (1s)
@il?i: oii* i',?ig 173 BRi!V (16)
\t
trl / 183 B (16)
200 BA/V (16)
202 B/DG (16)
@
eae
t
197 BA/V/DG {16)
6)M
\-/ h
178
\@ 189
BR ros
(1s) 22 BR t1s) {+oor- 188 BR (18) BR
(13)
+r I
lco
O."* 1. FUI
COMPONENTS
1. FUSE F1 1
6. DIMMER/TUHN/HORN SWITCH
7. HORN
,IO.
LEFT HAND TAIL LAMP
11. RIGHT HAND TAIL LAMP
CONNECTORS
B. ENGINE HARNESS TO INSTRUMENT PANEL HARNESS
14. FU 14. FUSE F1O B. FUSE F17 12, TRAILEB CONNECTOf,
D. PLATFORM HABNESS TO INSTRUMENT PANEL HARNESS
18- FU 18. FUSE FS 9. LAMP SWITCH 13. HEADLAMP DIMMER RELAY
R, TNSTRUMENT PANEL HAHNESS TO DIMMEB/TURN/HORN SWITCH
2. tNs 2. INSTHUMENT CLUSTEH CONNECTOR POSIT|ON 1 - OFF
P1. BATTEBY POWER JUCTION BLOCK
3. LEI 3" LEFT HAND HEADLAMP (LOW BEAM) POSITION 2. WARNING LAMPS
3A. LE 3A. LEFT HAND HEADLAMP {HIGH BEAM) POSIT|ON 3 - WABNING LAMPS, TAIL LAMPS, HEADLAMPS
4. ETl 4. ETHEH START SOLENOID POSITION 4 - REAfl FENDEH WORK LAMPS, HEADHMPS
Don 7-38440
lssued 9-92 Printed in England s. B( s. RIGHT HAND HEADLAMP (LoW BEAM) POSITION 5 - REAR FENDER WOHK LAMPS, HEADLAMPS :
5A, Rlr
5A, HIGHT HAND HEADLAMP (HIGH BEAM) OPTIONAL CANOPY WOBK LAMPS
kaukazz@yahoo.co.uk
4001-u4
[)6n /. ]944C lssucd 9-92 Prinlcd in [:nglanrJ
kaukazz@yahoo.co.uk
4001 -85 Headlamp Wiring Horn Wiring Hom Wiring Tail Lamp Wiring
Schematic Circuit
(For Tractors From ptN NO JJF 101 TBZZ)
- ttstl- { 219
ss RDB
q
aoor-zr
t-**T <[+oo:-zr Rio
(18)
,.--, q_
1{b
RiDB
(1 s) 4001 - 83
/1, 1@ 174 RN 0 184 Rfr /v (18)
{aoor ,* X-----
181
G/H
{o,--L- 181
G/B
(16)
'171 R (13)
171
R
t-
177 177 180 180
(13)
P/DB PIDB P/DG P/DG 171
(1s) (15) (15) (1s) R
't81
{ aoor-rzr
(1s) 181 \
J R
(1
64
BB
6)
G/F
(16)
G/R
(1 6) 185 FVW (18)
I /O 107 202 186 P/W (18) 186 PAV (18)

1;i:r.!l: F/DB PN P
iiBri (1s) (16) (1 6)
l/J 200 183 1[+oor-ros

GA
B,
177 PIDB (1s)
DG/B Y/DG
{ aoor-rzr
-t,
---l'l-i 180 P/DG (15) -
DB/B
(13)
174
DB/B
(16) {16)
4+oot-tzt
I t-- 177 (13) fl3) 182 t62 189
f
P/DB BR/O BRIO {+oor-r
Pll ii'P,i
177 180 (15)
180 P/DG (1s) 171 (1 6) (16)
BB
(13) @
i',?i6 R 181
ry /
03) GiR
t16)
/
@ \
176
F/DB
182 BFUO (16)
(16)
-I l-
l/o
- < 4oo1- 1os 187 BR (18)
- {aoor- tst 3 189
*{
BR
22 BR {15) m 188 BB (18) BR
05)
(It {13)
COMPONENTS 6. DIMMEMURN/HORN SWITCH 10. LEFT IiAND TAIL LAMP NTErlTf,)TAILLAMP *': CONNECTORS
1, FUSE F11 7. HORN 11. RIGHT HAND TAIL LAMP fl.E{rHt}I'TAIL LAMP B. ENGINE HARNESS TO INSTRUMENT PANEL HARNESS
1A, FUSE F1O 8. FUSE F17 12. THAILER CONNECTOR 12rt'tooltNECTOR D, PLATFORM HARNESS TO INSTRUMENT PANEL HARNESS
18. FUSE F9 9. LAMP SWITCH R. INSTHUMENT PANEL HAHNESS TO DIMMERiTURN/HOHN SWIICH
2. INSTRUMENT CLUSTEH CONNECTOR POSITION 1 - OFF P1, BATTEBY POWER JUCTION BLOCK
3. LEFT HAND HEADLAMP (LOW BEAM) POSITION 2. WARNING LAMPS
3A. LEFT HAND HEADLAMP (HIGH BEAM) POSITION 3. WARNING LAMPS, TAIL LAMPS, HEADI-AMPS * NOTE: THE DTMMERITURNIHOBNSWICHlS GROUNDED AT
4. ETHER START SOLENOID POSITION 4 - REAR FENDER WOHK LAMPS, HEADLAMPS THE FORWARD|RNERSE SWICH, REFER TO PAGE 39.
Don 7-38440 5, RIGHT HAND HEADLAMP {LOW BEAM) POSITION 5 - REAR FENDEB WORK LAMPS, HEADLAMPS
lssued g-92 Printed in England OPTIONAL CANOPY WORK LAMPS
5A. RIGHT HAND HEADLAMP {HIGH BEAM)
kaukazz@yahoo.co.uk
powrquadplus
4001 -86 www.thebestworkshopmanuals.co.uk
TURN SIGNAL/WARNING LAMPS FOR TRACTORS WITH CAB

Sectional lndex
87
Left Hand Front Turn SignalMarning Lamp Circuit Tcst ......... . 87
Left Hand Rear Turn SignalMarning Lamp Circuil Test ......,.... 87
Right Hand Front Turn SignatAvarning Lamp Circuit Test ...,...,... , . . ........... .. 88
li3iH3li.ff3t1il.'33iflf,l/1fl;il4;JSiilJii'".r :: : :
89
B8
B9
Dimmcrfl-urnAlorn Switch Tcst [urn Signal Circuit) For Tractors Up To PIN No JJF 1017717 90
Dimmcr/TurnAiorn SwitchTcst fturn Signal Circuit) ForTractors From PIN No JJF 1017718 .............. .... 90
Lamp Switch Tcst flffarning Lamp Circuit) ............... ..... . 91
Trailer Connector fTurn SignalAilarning Lamp) Circuit Test............ ........... ......... .... 91
Schematic Circuit (For Tractors Up To PIN No JJF 1017717) ,. .... ... . 93
Schcrnatic Circuit (ForTractors From PIN No JJF 1017718) .............'.. 95
{)orr 7-38440 lssr;cd 9 92 Prinlcd ir tnt.rlar,a
kaukazz@yahoo.co.uk
4001 -87
CIRCUIT TESTING
NOTE: The battery must be at full charge and all connections must be clean and tlght before testing. lJse a multimeter far
lhc tcsls.
NOTE: For tractors up to Pin No ,LlFl 017717 relcr ta the schcmatic circuit on Page g3 and for tnctors from Pin No JJF
1017718 refer to the schematic circuit on Pagc 95.
Left Hand Front Turn SignalAffarning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and Fl7. Alsacheckthe left hand lronttum signailwaming lamp bulb.
NOTE: Disconnect the left hand frant turn signallwarning lamp from the harness.
Chcck points Rcading Possiblc Cause of Bad Reading
Q fcrmlnal for wirc 204 Brown to ground Continuity Bad chassis ground circuit. Also check thc
NOTE: Turn the lamp switch to the WMNING LAMP position (position 2)
Tcrminal for wire 201 PinUDark Grccn to 12 Volts Bad circuit betwecn the f lasher relay and thc
ground ON-OFF-ON lclt hand front turn signa7warning lamp
Also check thc flashcr relay
NOTE: Turn the key ta the ON posrtion and pa the turn signal switch in thc RlGl'l'f tum position.
Terminal lor wire 201 ?ink/Dark Grccn to 12 volts Bad circuit between the flasher relay and thc
ground dimmerAurn/horn switch. AIso check thc
dimmerAurn/horn switch,
Left Hand Flear Turn SignalMarning Lamp Circuit Test

NOTE: Check Fuses F5, F6and FlT.,Alsocheckthe lefthand rearturn signallwarning lamp bulb.
NOTE: Discannect the left hand rear tum signallwaming lamp from the harness.
Chcck poinls Rcading Possiblc Causc of Bad Rcading
O Terminalfor wirc 205 Brown to ground Continuity Chcck wirc 205 and thc chassis ground
connection.
NOTE: Tum the lamp switch to the WARNING LAMP position (position 2)
O tcrminal for wirc 201 Pink/Dark Grccn to 12 Volts Bad circuit between the flasher relay and the
ground ON-OFF-ON lc{1hand rcar turn signallwarning lamp. Also
chcck thc flasher relay
NOTE: lf the left hand tront waming lamp works, check wire 2A1 between the lefl hand rear tum signallwarning lamp and
the left hand front tum signallwaming lamp.
NOTE: Turn the key ta the ON position and pul lhe turn signal switch in the RIGHT turn position.
Tcrminal for wirc 201 Pini</lfark Grccn to 12 Vr:lls Bad circuit betwccn thc flashcr relay and the
ground dimmcr/turrVhorn switch, Also chcck thc
dimmcr/turn/horn switch.
Don 7 38440 lssucd 9-91 Printcd in England
kaukazz@yahoo.co.uk
4001 -88
Right Hand Front Turn SignalMarning Lamp Circuit Test
NOTE: Check Fuses F5, F6 and F17. Also check the right hand front tum signallwaming lamp bulb.
NOTE: Disconnect the ight hand front tum signallwarning lamp from the harness.
Check points Reading Possible Cause of Ba9.Reading
Terminalfor wire 204 Brown to ground Continuity Bad chassis ground circuit. Also check the
Q chassis ground conncction.
NOTE: Turn the lamp switch to the WIF.NING LAMP position (position 2).
Terminalfor wire 203 Pink to ground 12 Volts Bad circuit between the f lasher relay and the
O ON-OFF-ON right hand front turn signal/Warning lamp.
Also check the flasher relaY
NOTE: Tum the key to the ON position and put the tum signal switch in the LEFT turn position.
Terminal for wire 203 Pink to ground

'1
2 volts Bad circuit between the flasher relay and the
O dimmer/turn/horn switch. AIso check the
Right Hand Rear Turn Signal/Warning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and F17. Also check the ight hand rear tum signallwaming lamp bulb
NOTE: Disconnect the left hand rear turn signallwaming lamp from the hamess.
tcrminal for wirc 205 Brown to ground Continuity Bad chassis ground circuit. Check the work
@ lamp and left hand rear turn signal/warning
lamp circuits.
NOTE: Turn the lamp switch to the W/F,NING LAMP position (position 2).
Terminal for wire 203 Pink to ground 12 Volts Bad circuit betwccn the flasher relay and the
Q ON-OFF-ON right hand rear turn signal/warning lamp.
NOTE: lf the right hand front waming lamp works, check wire 203 between the right hand rear turn signallwarning lamp
and the right hand frant turn signallwaming lamp.
NOTE: Tum the key to the ON position and put the turn signal switch in the LEFT turn position.
Gl Tcrminal for wirc 203 Pink to ground 12 volts Bad circuit between the flasher relay and the
dimmcrAurdhorn switch- Also check the
dimmer/turrVhorn switch.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -89
lnstrument Cluster Turn Signal Warning Lamp Circuit Test
NOTE: Check the instrument cluster turn sigrtal warning lamp bulbs'
NOTE: Disconnect the instrument cluster from the harness
Check Points Rcading Possiblc Cause of Bad Rcading
Terminalfor wire 208 PinldYcllow to Pin 1 0 ot Continuily Chcck wirc 208'

the instrumcnt clustcr connector.
Torrrinal f or wrrc 207 Pinkr/Dark Bluc tc Pir-r Continuity Chcck wirc 207.
24 of the instrumcnt clustcr conncctor.
r'in 7 of thc instrumcnt clustcr conncctor to Continuity Chcck wirc 206 between the flasher rclay
@ grouno and thc instrument clustcr connector, Also
chcck thc flashcr rclaY.
NOTE: lf the readings are correct chcck the flasher relay.
Flasher RelaY Circuit Test

NOTE: Check Fuses F5, FO and F17.
NOTE: Disconnect the flasher relay trom lhe harness
Chcck points Rcaciing Possiblc Cause of Bad Reading
(D Tcrminal for wirc 181 Gray/?cd to ground 12 Volts Bad circuit bctwccn thc battcry powcr
junction block and thc flasher relay terminal
2. Also check thc baltery power junction
block connection.
NOTE: I'urn the lamp switch to the 4ARNING LAMP position (position 2)
(E) Tcrminalfor wirc 199 Pink/Black to ground

'12 Vclts Bad circuit betwcen the lamp switch and thc
flashcr rclay tcrminal 1 . Also check thc lamp
switch.
tD Tcrminal for wirc 206 Brown to ground Continuity Chcck wire 206 and thc chassis ground
connection.
NOTE: Put the tum signalswilch in the LEFT tum position
(lF Tcrminal for wire 203 Pink to ground

'1
2 Volts Bad circuit bctwccn thc dimmcr/turr/horn
switch and thc flasher rclay tcrminal T Also
chcck thc dimmcr/turn/horn switch.
NOTE: Put the tum signalswltch tn the RlGtlf turn position
Tcrminal for wirc 201 pinMlark Grccn tc 12 Volts Bad circuit betwecn thc dimmer/turry'horn
ground switch and thc flashcr re lay terminal 5. AIso
check the dimmcr/turn/horn switch.
position'
NOTE: Connect the ftasher retay to the ha,rness and put the tum signal swrtch to the LEFT TURN
(t-\ for wirc 201 PinM)ark Grccn to 12 Volls Bad flashcr rclay'
\.7 Tcrminal
o roLlno ON_OFF_ON
oon z-Je++o lssuccj 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -90
Check points Reading Possible Cause of Ba9 Reading
Terminal for wire 207 PinktDark Bluc to 12 Volts Bad flasher relay
ground ON-OFF-ON
NOTE: Put the tum signalswtch to the RIGHT TURN position.
lF Tcrminal for wirc 203 Pink to ground 12 Volts Bad flasher relaY.
ON-OFF-ON
(l!l Tcrminal for wire 208 PintdYcltow to ground 12 Volts Bad flasher relaY.
ON-OFF-ON
Dimmer/Turn/Horn Switch Test [urn Signal Circuit)

NOTE: Disconnect the dimmerlturnlhom switch {rom the harness at connector R.
G) terminal for wire 196 PiniqYellow to ground 12 Volts Bad circuit between the baltery power
junction block and the dimmer/turrr/horn
switch. Also chcck thc battcry powcr
iunction block connection.
NOTE: Pttt the tum signalswtlch in the RIGHT TURN position-
Betwecn terminals 4 and 5 of conncctor R Continuity Bad dimmer/turn/horn switch.

(switch side) for wircs 1 97 BlackNVhitc/lf ark
Grccn and 200 BlackArVhitc
NOTE: Put the turn signal swilch in the LEFT TURN position.
Betwccn terminals 4 and "l of conncctor R Continuity Bad dimmcr/turn/horn switch.

(switch side) for wircs 197 Black/Whitc/Dark
Grcen and 202 BlacVDark Grccn
Dimmerffurn/Horn Switch Test [urn Signal Circuit)

For Tractors From PIN No JJF 1017718
NOTE: Disconnect the dimmerltumlhom swtch from the harness at connector R.
Check points Rcading Possible Cause of Bad Rcading
(D Tcrminal for wirc 196 PinkrYcllow to ground 12 Volts Bad circuit betwccn thc battcry powcr
junction block and thc dimmcrAurr/horn
switch. Also check the battery powcr
junction block conncction.
NOTE: Put the tum signalswrtch in the RIGHT TURN position.
Bctwccn terminals 3 and 4 of connector R Continuity Bad dimmcr/turn/horn switch

(switch side) for wircs 197 Pinkl/cllow and
200 Ycllow/Dark Grccn
Don 7-38440
Issucd 9-92 Prinlcd in England
kaukazz@yahoo.co.uk
4001 -91
NOTE: Put the tum signal switch in the LEFT TURN positian.
Betwecn terminals 3 and 8 of conncctor R Continui! Bad dimmer/turn/horn switch.

(switch sidc) for wircs 197 Pink/Ycllow and
2O2 P\nk
Lamp $witch Test (Warning Lamp Circuit)

Chcck points Rcading Possiblc Causc of Bad Reading
Tcrminal lor wirc I84 Rod/YcllowA&hitc ro 12 Volts Check wire 184 and the battery power
ground junction block connection.
NOTE: Tum the lamp switch to the W/fi,NING LAMP position (position 2)
ffl lerminal lor wirc 198 Whilc/llcd to ground 12 Volts Bad lamp switch
NOTE: Turn the lamp switch tc the l'lF-ADLAMP position (position 3)
6I Tcrminal{or wire 198 White/Rcd to ground 12 Volts Bad lamp switch.
NOTE: Turn the lamp switch to thc FENDER WORK LAMP position (position 4).
6r| Termlnalfor wire 198 Whitcfrccl to ground 0 Volts Bad lamp switch
NOTE: Turn the lamp switch to the CAB WO?K UMP position (position 5)
fII Tcrminal for wirc 198 Whilc/Rcd to grouncl 0 Volts Bad lamp switch
Trailer Connector Turn SignalMarning Lamp Circuit Test

NOTE: Turn the lamp switch to the W/tr,NING LAMP position (position 2).
Chcck points Rcading Possible Cause of Bad Rcading
Terminal 3 of the trailcr conncctor for wirc 12 Volts Check wire 201 betwccn the trailer
201 Pink/Dark Green to ground ON-OFF-ON conncctor and thc left hand rear turn
signal,/warning lamp.
Terminal 5 of thc trailcr conncclor fcr wirc 12 Volts Chcck wire 2A3 bclwecn thc trailer
203 Pink to ground ON-OFF-ON connector and the right hand rear turn
signal./warning lamp.
Tcrminal 1 oi thc trailer conncctor for wirc Continuity Chcck wire 189 and the chassis ground
'I
89 Brown to ground conncctron
kaukazz@yahoo.co.uk
powrquadplus
t)on 7-38440
lssucd 9-92 Prinlcd in England
kaukazz@yahoo.co.uk
Schematic Circuit
(For Tractors To plN NO JJF fi1TT1Z)
Waming Larnp Turn Signal S/iring
BI!B
fi3)
|-
(c
<"*''"
I
(
{e (e
Il/@- i6r G,R(1r-----l \ {+oor.zo
;?
l- rsP,/B(l.) { aoor.zr
r''@
r
,08 P/( (18)
*_@
\o
(1ts 207 Prrs (:E
206 B8 (18f
196
"N
(r5l
28 P {ts} /'@
*@
8R
{16) 189
\@
gR
ER ll3)
{t6}
1748R
V r---r I
2A
175
gF
luf+ l--
-
tar a 301*----[
{ roor.n (ts)
{ro
Irg*i+{
i-"t -lgr<H
zooo,w6o1*-*-fl
11"1" o!-4.-
L eoe aoc pey ---{il
Ir----q- 197 B/1,!/DG tt")
--fl 208 204 204
205 BR {16} 159
BS BR BR AH
e (J6) {16} {r3}

(J3)
COIllP'NENTS :ri.j coxHecrors

3. DTMMER/TURI.&IIC,f;.iI SrtrTICll 12. Rle$T !I.{NO AEAB OAS WOqK LAMP O. CAB :.IAftNES$ TO INSTBUMENI PANEL HAFNESS
1. RJSE F5
4. FLASHER RE-LAY TRA]LEF CONNECTCR N. ClB TC REAR FENOEH TAANESS
HAHI.IESS
FUSE F6
'Iz l.rllP s9/tTcH 5. FUA6 F,'? '3. E. III3'TEUMENTPAN'L HAENESS iO OIMMEBITUiNIHOfrN SIIITCH
A NSTRUMS{T CU}SIEI P,, SATTEhY POWEfi JUI{6NON BLOCK
POSTION 1 . OFF
7. T.EFI HAiS FFG'TiUR\ SGilATA"ASTNNG LqMP
P6}fNN 2' I'{ARNING LAMPS
8. tEFjl }IANO BEAn riFl.r SGIAUI|JASN8IG LAMP
POS{T}ON 3 - WAFNtilG ljMPS, TA}L rAMpS, HiAOLAMPS
s. AIGHT HANO Fmaii IUAI{ S|GXAIJY{ARN|I+G LAlilF
ffiIBN 4 . REAR FENDER WORK LAMPS. HECOT.AMPS
POSTION 5. figAR FENDFRWORK U,ITIPS, HSADIAfuIPS,
10. RIGHI IIANDF=rF TUBN SGilAIJiYAHNING LIMP
. OPiIONAI FAONT tND fiEAE CAA W6NK L.AMF 1I. LEfi HAND HEIi CA3I/l,oAK UIP
Don 7-38440
l$€!Bd 9.9? PriqEh Eagland
kaukazz@yahoo.co.uk
l-
powrquadplus
Don 7-38440
lssLrcd 9-92 Pnnted in England
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk 4001 -95 Warning Lamp Turn Signal Wiring tal Wiring
Schematic Circuit
(For Tractors From PIN NO JJF 1017718)
19s
OE
R/DB
V/R (13)
/R
(15) 5)
f- {+oor'zr
(o
I 219
---'\'-= R/O
(1 8)
I I
I
L
;?l e,( iB1 c/R ,,r, fa { +oor-zs
:.'/i q 170 R,^/ (13)
)
/,ii.,r
,: I
il
ii nt 208 Plr (18) r''@
t"r I
ocococcfcl
2A',
nt
207 P/DB {18) "*-(B
/-/ \i
\@
196 96 206 BR (18)
Pff
?":z-t\
{=:}" (1 5) ts)
4001-127
I
ZUJ
I P 4001 -1 1 3
I
243
P
(J5)
203 P (1s)- 203 P (1s) 2ol
{ +oor-zs
r''@
P/DG (16)
*_@
t_
\o
(15) 201 PIDG {15)- 201 P/DG (15) 203 P (16)
196 Plr (15)
206 206
B8 BR
(16)
201 203
06) P/DG P 189
203 (1s) (15) BR
-a P {13)
R 4001-81 r go {1 5) zot
/./-i-- -{: P/DG
201 PIDG (15)
I
L_
r-
L
183 BR/O (16)
202 P (16) 203 P (1s)
(15)
o* 203 P (1s)
T
rAr
{+oor
.JF
DEc
2oo Y/DG (16) 201 P/DG (1s)
Ilr PN fi _ pry (jS)
.+ 197
174 D8,4t (13)
1S16
rt, 17s WR (13) tvl

lr
L_
172 F (13)
17s H/DG (13)
204 BB (16)
(13)-J
fL ,o. r*,,
20s BR (13)
206 244 205 BR 06) 189
206 204 205
BR BR BB BR BR BR
(16) (16) (16) (16) (1 3)
(1 3)
{*
COMPONE
1. FUSE F5
ENTS Ltffi courqrcrons
F5 3. DIMMER/TURN/HOBN SWITCH 12. RIGHT HAND REAB CAB WORK LAMP 12. HIGHT HAND REAB CAB WORK LAMP D, CAB HARNESS TO INSTRUMENT PANEL HAHNESS
.,A. FUSE F{
F6 4. FLASHER RELAY 13. TMILER CONNECTOfi 13. TMILER CONNECTOR N. CAB HARNESS TO fiEAR FENDER HARNESS
2. LAMP S\ SWITCH 5. FUSEFlT B. INSTBUMENT PANEL HARNESS TO DIMMER/TURNIHORN SWITCH
POSITIOI '1 - OFF 6. INSTHUMENT CLUSTER P1. BATTERY POV{ER JUNCTION BLOCK
POSmOI 2. WARNING LAMPS 7. LEFT HAND FRONT TURN SIGNAL/IVARNING LAMP
POSmOI 3 - WAHNING I3MPS, TAIL LAMPS, HEADLAMPS 8. LEFT HAND REAB TURN SIGNAL/WARNING LAMP
POSmOI
* NOTE: THE DIMMERITURNIHORN SWICH /S G ROUNDED AT
4 . HEAR FENDEB WORK LAMPS, HEADLAMPS 9, RIGHT HAND FRONT TURN SIGNALruVARNING LAMP THE FORWARD|REVEBSE SMTCH REFER TO PAGE 39
POSITIO
5 - REAR FENDER WORK LAMPS, HEADLAMPS 10. BIGHT HAND REAB TUBN SIGNALAVARNING LAMP
OPTIONAL FRONT AND REAR CAB WORK LAMPS 11- LEFT HAND REAR-CAB WORK LAMP
kaukazz@yahoo.co.uk
4001 -96
TURN SIGNAIJ}VARNING I.AMPS FOR TRACTORS WITHOUT CAB
Sectional lndex
Left Hand Fender Turn SignalAVarning Lamp Circuit Test ..,....,... ."..'.. 97
Hight Hand Fcnder Turn SignalMarning Lamp Circuit Test. ........... ....'. 97
Left Hand Front CanopyTurn SignalflVarning Lamp Circuit Test ,.......... ....."...,.'.....' 98
Left Hand Rear Canopy Turn Signal,iWarning Lamp Circuit Test ........... .".."......'.'..' 98
Hight Hand Front Canopy Turn SignatrWarning Lamp Circuit Test ........... .,.......'...'. 99
Right Hand Rear Canopy Turn SignalAVarning Lamp Circuit Tcst ........... ..,',..."..'... 99
lnstrument Cluster Turn Signal Warning Lamps Circuit Test,,........... .... 100
Dimmer/l-urnftlorn Switch Test fiurn Signal Circuit) For Tractors Up To PIN No JJF 1017821 ..................... 101
Dimmer/TurnAlorn SwitchTest fl-urn Signal Circuit) ForTractors From PIN NoJJF 1017822 ........,.............. 102
Lamp Switch Test (Warning Lamp Circuit) ...'................. 102
Trailer Connector fl-urn SignalAiVarning Lamp) Circuit Test .........,.. .... 102
Schcmatic Circuit (For Tractors Up To PIN No JJF 1017821) ......."". 103
Schematic Circuit (For Tractors From PIN No JJF 1017822) '...'....,.. 105
Don 7-38440 lssued 9-92 Pnnted in England
kaukazz@yahoo.co.uk
4001-97
CIRCUIT TESTING
NOTE: Thebatterymustbeatfull chargcandall conncctiansmustbe cleanandtightbcfore testrng. Useamultimcterlor
the tests.
NOTE: FortractorsuptoPinNoJJF|0lTB2l refertotheschematiccircuitonPagel03andfortractorsfromPinNoJJF

1017822 refer to the schematic circuit on Page 105.
Left Hand Fender Turn SignalMarning Lamp Circuit Test

NOTE: Check Fuses F5, F6 and Fl7. Also checkthe left hand fenderturn signallwaming lamp bulb.
NOTE: Disconncct the left hand fender tum signaUwaming lamp fram the harness.
Check points Rcading Possiblc Causc of Bad Rcading
Q fcrminal for wire 187 Brown to ground Continuity Chcck wire 187 and the chassis ground
connection.
NOTE: Turn the lamp swilch to thc WMNING LN'4P position (position 2)
Tcrminal for wire 201 PinkDark Grccn tc 12 Volts Bad circuit bctwccn the flashcr rclay and thc
ground ON-OFF-ON lcft hand fcndcr turn signallwarning lamp
Also chcck the flasher relay
NOTE: ll the left hand canopy waming lamps work correctly, check wire 201 beWeen the left hand fender turn
signallwaming lamp and thc sp/tce.
NOTE: Tum the key to the ON position and put the turn signal switch in the RIGHT tum position.
€) I:;n:'l ror wlrc 201 Pink/Dark Grccn to 12 volts Bad circuit bctwecn the f lasher relay and the
drmmer/turn/horn switch. AIso check the
dimmcrAurrVhorn switch.
Hight Hand Fender Turn SignalMarning Lamp Circuit Test

NOTE: Check Fuses F5, FO and F17. Also check the right hand fender tum signallwarning lamp bulb
NOTE: Disconnect the ight hand fender tum signallwaming lamp from the harness.
Chcck poinls Rcading Possible Cause of Bad Fleading
Gl Tcrminal for wirc 188 Brown to ground Continuily Chcck wire 1B8 and thc chassis ground
conncction.
NOTE: Turn the lamp swttch to the W/tr,NTNG LAMP position (position ).
(f Termlnal for wire 203 Pink to ground 2 Volts
'1
Bad circuit betwee n the flasher rclay and the
ON-OFF-ON right hand fender turn signalA,trarning lamp.
Also chcck the flashcr rclay
NOTE: lf the right hand canopy waming lamps work correctly, check wire 203 betvveen the left hand fender turn
signallwarning lamp and the splice.
Don 7'38440 lssucd 9-92 Pnntcd in England
kaukazz@yahoo.co.uk
4001 -98
NOTE: Tum the key to the ON position and put the tum signa/ swrtch in the LEFT turn position'
f-a terminal for wire 203 Pink to ground 12 Volts Bad circuit bctween the flashcr relay and the
dimmcrlturn/horn switch. Also check the
Left Hand Front Canopy Turn Signalflarning Lamp Circuit Test

NOTE: Check Fuses F5, FO and F17. Also check the left hand front canopy tum signallwarning lamp bulb
NOTE: Disconnect the left hand front canopy tum signal/waming lamp from the harness.
Check points Bcading Possiblc Causc of Bad Bcading
Terminal for wirc 204 Brown to ground Continuily Chcck wie 204 and the chassis ground
O connection.
NOTE: Turn the lamp switch to the WARNING LAMP position (position 2)'
6 Terminal for wire 201 Pinrjl,ark Grccn to Volts

12 Bad circuit bctween the flashcr relay and the
!7 orouno ON-OFF-ON lcft hand front canopy turn signalAruarning
lamP. Also check the flashcr relaY
NOTE: tf the left hand rear canopy waming lamp works, check wire 201 between the left hand front canopy tum
signallwarning lamp and the splice.
NOTE: Turn thc key to the ON position and put thc tum signal swrtch in the RIGHT turn position.
Tcrminal for wirc 201 pinVDark Grccn to 12 volts Bad circuit betwee n the flashcr rclay and thc
ground dimmer/turrr./horn swiich. Also check thc
Left Hand Rear Canopy Turn Signal/Warning Lamp Circuit Test

NOTE: Check Fuses F5, FO and F17. Atso check the left hand rear canopy turn signallwarning lamp bulb.
NOTE: Disconnect the teft hand rear canopy tum signallwarning lamp from the hamess.
Check points Rcadino Possible Cause of Bad Reading
terminal lar wire 205 Brown to ground Continuity Chcck wire 205 and the chassis ground
@ conncction.
NOTE: Turn the lamp switch to thc ryARNING LAMP position (position 2).
Terminal for wire 201 ?ink/Dark Grecn to 12 Volts Bad circuit between the flasher rclay and the
ground ON-OFF-ON left hand rear canopy turn signalA,varning
lamP. Also check the flashcr relaY
NOTE: lf the left hand front canopy waming lamp works, check wire 2Al betvveen the left hand rear canopy tum
signallwarning lamp and lhc sp/ice.
Don 7-38440
kaukazz@yahoo.co.uk
400'l-99
NOTE: Turn the key to the ON position and put the turn signal switch in the RIGHT tum position.
Chcck points Rcadinq Possiblc Cause of Bad Reading
Te rminal {or wire 201 Pink/Dark Grccn to l2 Volts Bad circuit betwcen the flasher relay and the
ground dimmer/lurry'horn switch. Also check the
dimmer/turn/l-rorn switch.
Right Hand Front Canopy Turn SignalArVarning Lamp Circuit Test

NOTE: Check Fuses F5, FO and F17. Also check the right hand front canopy tum signaUwarning lamp bulb.
NOTE: Disconnect the right hand lront canapy turn signallwaming lamp from the harness.
check points Reading Possible cuuse*sl Baq le.qjlg
Gf Tcrminal for wirc 209 Brown to ground Continuity Chcck wire 209 and thc chassis ground
conncction.
NOTE: Turn the tamp switch to the WMNING IAMP positton (position 2).
Tcrminal for wire 203 Pink to ground 12 Volts Bad circuit between the flasher relay and the
{il ON-OFF-ON right hand front canopy turn signalA,trarning
lamp. Also check the flashcr relaY
NOTE: ll the 1ght hand rear canopy warning lamp works, check wire 2A3 betvveen the right hand front anopy tum
signallwarning lamp and the sp/ice.
NOTE; Tum the key to the ON position and put the tum signal switch in the LEFT turn position.
(D) Tcrminal ior wirc 203 Pink to ground 12 volts Bad circuit betwcen the flashcr relay and the
dimmcr/turn"/horn switch. Also check thc
dimmer/turrVhorn switch.
Right Hand Rear Canopy Turn Signal/Warning Lamp Circuit Test

NOTE: Chcck Fuscs F5, F6 and F17. Also check thc right hand rcar canopy turn signallwarning lamp bulb.
NOTE: Disconnect the right hand rear canopy tLtm signal/warning lamp from the harness.
Check points Rcadinq Possible Cause of Bad Beading
@ ferminal for wire 210 Brown to ground Continuity Chcck wia 210 and the chassis ground
conncction.
NOTE: Turn thc tamp switch to the W/.qNING LAtulP position (position 2)
Tcrmlnal for wire 203 Pink to ground I2 Volts Bad circuit betwecn the flasher relay and thc
t) ON-OFF-ON right hand rcar canopy turn signal/warning
lamp. Also chcck the flashcr rclaY
NOTE: ff the right hand front canopy waming lamp works, check wire 203 betvveen the right hand rear canopy turn
signallwarning lamp and thc splice.
kaukazz@yahoo.co.uk
4001 -1 00
NOTE: Tum the key to the ON position and put the tum signal switch in the RIGHT turn position
Check points Feadlng Possible Cause of Bad Reading
(D Terminal for wire 203 Pink to ground 12 Volts Bad circuit between the flasher relay and the
dimmer/turry'horn switch. Also check the

NOTE: Check the instrument cluster tum signal waming lamp bulbs.
NOTE: Disconnect the instrument cluster fram the harness.
Chcck Points Bcading Possiblc Cause of Bad Reading
Terminalfor wirc 208 Pint<,^/cllow to Pin 10 of Continuity Chcck wire 208.

the instrument cluster connector,
Terminal for wirc 207 Pink/Dark Blue to Pin Continuity Chcck wie 207,
r - 24 ol the instrument cluster conncctor.
Pin 7 of the instrument clustcr conncclor to Continuity Chcck wire 206 betwccn thc flashcr rclay
ground and the instrument cluster connector. AIso
chcck the flasher relay.
NOTE: lf the readings are correct check the flasher relay.

NOTE: Check Fuses F5, FO and F17.
NOTE: Disconnect the flasher relay from the harness.
Chcck points Rcading Possible Cause of Bad Beading
(D Tcrminal for wire 181 GraylFcd to ground l2Volts Bad circuit between the battery powcr
junction block and the flasher relay terminal
2. Also check the battcry power junction
block connection.
NOTE: Turn the lamp swrtch to the WMNING LAMP positton (position 2),
@ Tcrminal for wire 199 Pini</Black to ground 12 Volts Bad circuit bctwecn the lamp switch and the
lashcr rclay tcrminal 1 . Also chcck thc lamp
f
switch.
t?l Terminal for wire 206 Brown to ground Continuity Chcck wve 206 and thc chassis ground
conncction.
NOTE: PtLt thev turn signal switch in the LEFT turn position.
(E) Tcrminalfor wire 203 Pink to ground 12 Volts Bad circuit bclwccn the dimmcr/turn/horn
switch and thc flashcr rclay tcrminal 7. Also
chcck the dimmcr/turn/horn swilch.
NOTE: Put the turn signal switch in the RIGH-| turn position.
Don 7-38440 Issucd 9-92 Prjnlcd in England
kaukazz@yahoo.co.uk
4001,101
Cncck pcints Bcacing Pcssiblc Causc oi Bad Rcading
\ry Tcrminal fcr wi'c 201 Pink/Dark Grccn ic

6-Ji) 12 \/clts Bad circuit Sctwccn thc dirnmcr'/turn/horn
C':J1C switch and thc f lashcr rclay tcrminal 5 AIsc
chcck thc dirnmcr/turn/horn swiich
NOTE: Connect the f tasher retay to thc harness anc pltt the lurn signal swtch in the LEFT TURN position.
Tcrrrinal fcr wirc 201 PinkDark Grccn 'io 12 Volts Bad flashcr rciay
ground ON-OFF-ON
Tcrn,i,ral for wirc 2a7 ?inx.Dark Bluc 'it-: 12 Volts BaC llashcr rclay
g'ound ON-OFF,ON
NOTE. Put the tunt signal swilch in thc RiGHI l'.)flN aostlce
(E) Tcrrlrral for wirc 203 Pink lo g'cirnc 12 Volls Bad tlashcr rcLaY
ON_OTF.ON
fiv 'r,r,.aL 'c,wr,c 2CB Pi,rkYcltow:o grcrx(l 12 \/clts Bad flashcr rclay
CN CFF,ON
Dirnmer/Turn/Horn Switch Test (Turn Signal Circuit)

NOTE: Disconnect thc dimmcrltumlhorn swlch frorn the harness at canncctcr R
Cncck pcinls Rcacrrg Possiblc Causc oi Bad Rcacrng
l"rn","ul or wirc 136 PinkYcliow to grcunc 12 Vclis Bad circui: bctwccn thc battcry powcr
6) f
Junction block and thc dimmcr/turn/horn

switcn Also cncck thc battcry powcr
NOTE: Put thc tum slgnal s:vrl.'/ r'.- t"': R:CHi lUfli'l ccstttcr
S:lryccn icrm nals 4 anc ) I' ccrroctor B Ccn:i:rurly Bad ciimmcrllurqlnorn slitch
(switch sidc) f or wircs 1 97 BlackANhr'lc/Dark
Grccn and 200 Blaci</Whitc
NOTE: Put the turn signalswilch in the LEFT TURN posrtion.
Bctwccn lcrminals 4 ano I cf ccrrcclor ti Ccnliruity Bao dimmcr/turn/horn s',vilch

(switcn sidc) fcr wircs 197 BlackANhiicrT)a:<
Grccn and 202 BlackDark Grccr
Dimmer/Turn/Horn Switch Test (Turn Signal Circuit)

For Tractors From PIN No JJF 1A17822
NOTE: DisconneCt the Cinmer,rL'dn:,,hcrn Switct [r:ir Ihs i'e,.neSS el CO.neCtCr R.
Circck r:ctnts Rcad rg Possiblc Causc oi Qad Boadrng
6i) Tcrrninal for wirc 1 36 Pinkn/cllow Io q roi.rnc

'1
2 \iclls Bao circuii bclwccn tlc baticry pcwcr
lunction Dlock ano tnc dimrrcr/turn/horn
switcn Also cncc'( thc battcry powcr
iunction block ccnncclion
lr;r 7"38,iri0 issucd 9'92 Pnnlcd n England
kaukazz@yahoo.co.uk
4001 -1 02
NOTE: Put the turn signal switch in lhe RIGHT TURN positrort
Chcck points Rcading Possiblc Causc of B?d Bcading
Bctwcen terminals 3 and 4 ol conncctor R continuity Bad dimmcr/turn/horn switch'

(switch side) for wircs 197 Pinkl/cllow and
200 Ycllow/lfark Grcen
NOTE: Put the turn signal swrtch in the LEFT TURN positron.
Bctwccn tcrminals 3 and B of conncctcr R Continuity Bad dlmrncr/turn/horn swilch.

(switch sidc) for wires 197 Pink/Ycllow ancj
202 Pink
Lamp Switch Test (Warning Lamp Circuit)

Chccx pcints Rcading Possiblc Causc of Bad Rcading
Tci.mrnal for wirc 184 Bcd/YcllowArVhitc io 'l

2 Volts Chcck wirc 184 and thc battcry powcr
g rou nd lunction block conncctron.
NOTE: Turn the lamp switch tc the WARNING UJiP position (positian 2)
6trl Tcrminalfor wire 198 Whitc,4lcd to ground 12 Volts Bad lamp switcn
NOTE: Turn the lamp switctt to the HEMLAMP position (position 3)
fS fcrminal for wirc 198 Whitc/Rcd lc grcunrj 12 Volts Bad lamp switcn
NOTE: Turn the lamp switch ta the FENDER WORK WtP posittan (pasitian 4)
Tcrminalfor wirc 198 Whitc/Fcd to grcund C Vclts Bad lamp switch

6J
NOTE: Turn the lamp switch to thc CANOPY 'NORK LAMP positicn (positicn 5)
6F Tcrminal fc: wirc 198 Whilc/Rcc ic grcrrd O Vclls Bad lamp swilch
Trailer Connector Turn Signal/Warning Lamp Circuit Test

J' NOTE: Turn the lamp switch to the WlfiN]NG LAMP pcsiuon (pcsition 2)'
Chcck pcints Rcariinc PossiDlc Causc cf Bad Bcading
Tcrminal 3 of thc trailcr conncclor fcr wirc 12 Voits Chcck wirc 2C1 bctwccn thc lrailcr
2C1 Pink/Dark Grccn 1c ground ON OFF-ON conncctor and thc lcft hand rcar iurn
signal,/warning lamP
Tcrminal 5 of thc trailcr conncctcr lor wirc 12 Vcl:s Chcck wirc 2A3 bctwccn thc trailcr
203 Pink to ground ON.OFF.ON conncctor and tho righl hand rcar iurn
signal/warning lamp.
Tcrminal 1 of ihc irailcr ccnnccior lof wi.C Ccnirnui:y Cncck wirc 189 and ihc chassts grouncl
189 Brcwn to grcunc ccnrcciion
Dcf 7-38440 iSSuCd 9-92 Pr:niCa r. En-O an:l
kaukazz@yahoo.co.uk
400.1-103
Warning Lamp Turn Signal Wiring nal Wirlng
Schematic Circuit
(For Tractors Up To PIN NO JJF 1017821) ffiY
lo< 35
R/DB
VA
(ts) {13)
+- {oocr-zr
(o
I
G
i
I
qo
r
1 70 RIr (1 3) 184 Brrlv (1
[-lo 181 G/H,,u L {+oor+s
lr
rl ,i= L,,,P/B(iB)
208 P/v (18)
207 P/DB (18)
{.,.r,-r',
@
lt? l]|Lv
(1s) 5)
oO
ol
241
n1
206 BH (18)
{ aoor-rez
I lno
P/DG
(1 s)
P/DG
{ +oor.
l<T
(1s)
243
P
201 P/DG (16) /'@
*@
I
(1 5) 203 P (16)
17s BR (16)
1s6 P/v (15) 203 P
201 P/DG
(1s)-
(1s)-
203 P
201 P/DG
(1
(1
203 P (16)
201 P/DG (16) \@
206
BR
t tbJ 201 P/DG
f
175
BR 203 P (18)-J
Itr r---t
174 BR (16)
(16)
196
PN
(15)
{ aoor+s
{ +oor+s
? { +oor-es
{ +oor-es
t['' rit
*li 173 BR/W (16)
183 B (16)
@w
r^l
J-{'
IH 202 B/DG (16)

1e7 B /v/DG ttoi&
zlo01-105
203 P (15)
1s6 p/y (15)
206
8R
(16) J* JIA o
tr
/l
e';
(18)
'1ooo'-'*-@
G15
COMPONENTS
1. FUSE F5 H*ffi CONNECTORS
FUSE F5 3. DIMMER/TURN/HORN SWITCH 11. RIGHT HAND FRONT CANOI 11. BIGHT HAND FHONT CANOPY TUBN SIGNALAIVARNING LAMP D. PLATFORM HABNESS TO INSTRUMENT PANEL HAHNESS
1A. FUSE F6 . FUSE F6 4. FLASHER BELAY 12. BIGHT HAND REAR CANOF^ 12. RIGHT HAND REAR CANOPY TURN SIGNAL/WABNING LAMP R. INSTRUMENT PANEL HAHNESS TO OIMMER/TURN/HOHN SWTCH
2. LAMP SWTC} LAMP SWITCH 5. FUSE F17 13. TMILER CONNECTOB 13. TRAILER CONNECTOR T, PLATFOBM HARNESS TO REAR CANOPY HARNESS
POSITION 1 - t
POSITION 1 . OFF 6. INSTRIJMENT CLUSTER
:: P.I. BAfiERY POWER JUNCTION BLOCK
POSTTION 2 . t
POSITION 2.
WARNING LAMPS 7, LEFT HAND FENDER TUFN SIGNALA/V'ARNING LAMP
POSTT1ON 3 -' FOSITION 3 . WARNING LAMPS, TAIL LAMPS, HEADLAMPS 8. BIGHT HAND FENDER TURN SIGNALÎVARNING IAMP
POSTflON 4 - l
POSITION 4. REAH FENDEH WORK LAMPS, HEADLAMPS
Don 7-38440 g-92 9. LEFT HAND FRONT CANOPY TUBN SIGNAL,A/VARNING LAMP
lssued Printed in England POSITION 5 -
kaukazz@yahoo.co.uk POSITION 5. REAR FEI.IDER WORK LAMPS, HEADLAMPS 10. LEFT HAND REAR CANOPY TURN SIGNAL /VAHNING LAMP
OPTIONAL CANOPY WORK IAMPS
powrquadplus
4001 -1 04www.thebestworkshopmanuals.co.uk
Don 7-38440 lssr,rcd 9-92 Pnntcd in Enqland
kaukazz@yahoo.co.uk
4001 -1 0s Warning Lamp Turn Signal Wiring rSignal Wiring
Schematic Circuit
(For Tractorspowrquadplus
From PIN NO JJF 1017822)
www.thebestworkshopmanuals.co.uk
19s
@ ViR
(1s)
195
VIR
(15)
/ 219
R/O
I (18)
t\ r-l
t(@
I
170 Hlr (13) 84 B/Y (1
@
^v
td
i.
196
PN
(10
1S6
PN
I
(15)
ooocroccoa
.!.r@
:::
WR
(1 8)
L 1es P/B (18)
-
201 241
208 P/r (18)
2o7 PIDB (18)
206 BR (18)
{ +oor-zr
{ uoor-rzz
P/DG P/DG
201 (1s) (1s) { ooor-rz,
-
PIDG n qoot-es
r''@
(1s)
203
201 P/DG (16)
203 P (16) *@
1s6 Prv (15)
P
(15)
203 P (1s)
201 PIDG (1
:r:"::.:
203 P (16)
201 P/DG (16)
201
\@
206 206
BR BR
::0,:l 203 -e
fl::v5a
"1 P/DG
'l
,[
P (1 6)
(16) (16)
201 PiDG (11 2O1 P/DG (18)
zuJ L';
(18)---l
";'' 9'l''
P 203 P
5)
I
c- lC 1;6
Pff I
{1
P/DG
2'01
{ +oor+s
{ +oor+s
aL
(18)
A
",,r-l
- riai-$ nat- y' I
183 BR/O {16)

202 P 06) 203 P (15)
(15) I (15)
@-.'s @*i5(r6)=Fi'u)# I
200 Y/DG {1 6)
197 PN (1
201 P/DG (1s)
@&@&@&l
174 DB/B (13)
H H HI
$
17s WR (13)
172 R (13)
L 17s R/DG (13)
JA {)- I
- --
o
.4
ffig 206
BR
(16)
J*, 206
BR
06)
JIA (18) (18) t18) (13)
t-' COMPONENTS
1. FUSE F5
MPONENTS
FUSE F5 3. DIMMEB/TURN/HORN SWITCH 11. RIGHT HAND FRONT CANOP 1 1, RIGHT HAND FRONT CANOPY TURN SIGNAL/IffARNJNG LAMP
CONNECTORS
D, PTATFORM HARNESS TO INSTRUMENT PANEL HAHNESS
.IA.
FUSE F6 FUSE F6 4. FUSHER RELAY 12. RIGHT HAND BEAR CANOPY 12. R|GHT HAND REAR CANOPY TUBN SIGNAL,ryVARNING LAMP B, INSTRUMENT PANEL HARNESS TO DIMMER/TURNiHOBN SWITGH
2. I-AMP S1MI TAMP SWITCH 5, FUSE F17 13. TRAILER CONNECTOR 13, TBAJLER CONNECTOR T, PLATFORM HABNESS TO REAR CANOPY HARNESS
POSMON 1 POSITION 1 . OFF 6. INSTRUMENT CLUSTER P1. BAfiERY POWER JUNCTION BLOCK
POSMON 2 POSITION 2. WAHNING LAMPS 7, LEFT HAND FENDER TURN SIGNAWJARNING LAMP ,
,POSMON 3
POSITION 3 . WARNING LAMPS, TAIL LAMPS, HEADI.AMPS 8, RIGHT HAND FENDEB TUHN SIGNAI-^/VAffNING LAMP IP * NOTE: THE DTMMERITURNIHOENSWICH lS GRAUNDED AT
POSMON THE FORWARDIREYEFSE SWITCH, REFER TO PAGE 39
1
POSITION 4 . REAfl FENDER WORK LAMPS, HEADLAMPS 9. LEFT HAND FRONT CANOPY TURN SIGNALTW'AHNING LAMP IG LAMP
POSMON 5
POSITION 5 . REAR FENDER WORK LAMPS, HEADLAMPS 10. IEFT HAND REAR CANOPY TURN SIGNALMARNING LAMP i LAMP
OPTIONAL CANOPY WOHK LAMPS
kaukazz@yahoo.co.uk
powrquadplus
4001 - 1 06www.thebestworkshopmanuals.co.uk
REAR FENDER, FRONT CAB AND REAR CAB WORK TAMPS

FOR TRACTORS WITH CAB
Sectional lndex
107
Left Hand Rear Fender Work Lamp Circuit Test ........... 107
Right Hand Rear Fender Work Lamp Circuit Test 107
Trailer Connector Work Lamp Circuit Test .,.......... 108
Rear Fender Work Lamp Relay Circuit Test ........... 108
Lcft Hand Front Cab Work Lamp Circuit Test ........... 'r0B
Fight Hand Front Cab Work Lamp Circuit Test ........... 109
Front Cab Work Lamp Relay Circuit Test .,......... 109
Left Hand Rear Cab Work Lamp Circuit Test ............ 110
Right Hand Rear Cab Work Lamp Circuit Test 110
Rear Cab Work Lamp Felay Circuit Test ............ tt
Lamp Switch Test (Work Lamp Circuits) ,.............. 11
Don /.3B440 lssucd 9-92 Prinlcd in Enqland
kaukazz@yahoo.co.uk
4001 - 1 07
CIRCUIT TESTING
\OTE: Thebatterymustbeatfutl chargeandall connectionmustbccleanandtightbeforeteslrng. Useamultimeterfor
he tesls.

NOTE: Check Fuse F14, and the left hand fcndcr work lamp bulb.
NOTE: Disconnect the teft hand lender work lamp from the harness, and turn the lamp switch to the REM FENDER
NORK UMP position (position 4).
Chcck points Rcading Possible Causc of Bad Rcading
$ fcrminal forwire ZZ YiolcVYcllowto ground 12 Volts Bad circuit bctwccn the lamp switch
tcrminal FLl and thc lcft hand fendcr work
lamp. Also chcck thc rcar fcndcr rclay and
thc lamp switch.
NOTE: tl the right hand fenderwork lamp works correctly check wire 224 between the left hand rear fenderwork lamp and '.-/
'hc splicc
Gl Tcrminal for wirc 225 Brown to ground Continuity Chcck wire 225 and thc chassis ground
conncction.
Right Hand Flear Fender Work Lamp Circuit Test
NOTE: Chcck Fuse Fl4, and the left hand lcndcr wcrk lamp bulb.
NOTE: Disconnect the right hand lender work lamp from the harness, and turn the lamp swtch to the REM FENDER
NORK WnP position (position ,t).
Check points RcaCing Possiblc Causc of Bad Flcading
Tcrmina I lor wir e 224 Yiolct/Ycllow to grcund 12 Volts Bad circuit bctwccn the lamp switch
O terminal FL1 and thc right hand fcndcr work
lamp. Also chcck thc rcar fcndcr rclay and !)
thc lamp switch.
NOTE: lf thelefthandlenderworklampworkscorrectlycheckwire224betweentherighthandrearfendcrworklampand
'he splice
tcrminal for wirc 226 Brown to ground Conlinuity Chcck wic 226 and thc chassis ground
@ conncction.
)on 7-38440 lssucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -1 0B
NOTE: Turn thc lamp switch to the REAR FENDER WORK LAMP position (position 4).
Terminal 2 of the trailcr conncctor for wire 12 Volts Chcck wirc 224 bctwccn thc trailcr
224 VoleVYellow to ground conncctor pin 2 and thc splicc.
Terminal 1 of the trailcr conncctor for wire Continuity Chcck wire 189 and the chassis ground
'I
89 Brown conncction.
Rear Fender Work Lamp Relay Circuit Test

NOTE: Turn the lamp switch to the OFF position (positian 1).
Check points Fcading Possible Causc of Bad Rcading
Terminal for wirc 222 Brown to ground Continuity Bad circuit bctwccn thc rcar fcndcr work
@ lamp rclay terminal 85 and thc chassis
qround connection. Also chcck thc chassis
ground connection.
NOTE: Turn the lamp switch to the REM FENDER WORK LAMP positian (position 4)
lor wire 220 RcdtLisht Grccn to 12 Volts Chcck wirc 220 bctwecn the lamp switch
@ I::n:"| tcrminal FL1 and thc rcar fcndcr work lamp
rclay tcrminal 86. Also chcck thc lamp
switch.
Tcrminal for wirc 221 RcdNiolct to ground 12 Volts Chcck wic 221 and thc batlcry powcr
O junction block conncction.
'12 Volts Bad rcar fcnder work lamp rclay.
Left Hand Front Cab Work Larnp Circuit Test

NOTE: Check fuse F1 and the left hand front cab work lamp bulb.
NOTE: Disconnect the left hand f ront work lamp f rom the harncss and turn the lamp switch to the CM WORK LAMP
Chcck points Rcading Possiblc Causc of Bad Rcading
Tcrminal for wirc 223ViolcLtslack to ground Bad circuil bctwccn thc lamp
@ 12 Volts switch
tcrminal FL2 and thc lcft hand front cab work
lamp. AIso check thc front cab work lamp
rclay and the Iamp switch.
NOTE: lftherighthandfrantcabworklampworkscorrectlycheckwire223betvveenthelefthandfrontcabworklampand
the splice
rcrminal for wirc 234 Brown to ground Chcck wirc 234 and thc chassis ground
ft) Continuity
conncction.
kaukazz@yahoo.co.uk
4001 -1 09
NOTE: Check fuse Fl and the right hand front cab work lamp bulb.
NOTE: Disconnect the ight hand front work lamp from the harness and tum the lamp swtch to the CAB WORK UMP
Gl Terminal for wire 223 VioleVBlack to ground 12 Volts Bad circuit between the lamp switch
tcrminal Fl2 and the right hand front cab
work lamp. Also check the front cab work
NOTE: llthelefthandfrontcabworklampworkscorrectlycheckwire223betweentherighthandfrontcabworklampand
the splice
O Terminal for wire 235 Brown to ground Continuity Chcck wire 235 and the chassis ground
conncction
Front Cab Work Lamp Relay Circuit Test

NOTE: Tum the lamp switch to the OFF position (position 1).
Chcck points Beading Possible Causc of Bad Reading
(B Tcrminal for wire 222 Brown to ground Continuity Check wire 222 and the chassis ground
connection.
NOTE: Turn the lamp swrtch to the CAB WORK UMP position (position 5).
fii Terminal for wire 227 Red/Brown to ground 12 Volts Check wie 227 bctween the lamp switch
terminal FA and thc lront cab work lamp
rclay terminal 86.
Terminal for wire 231 Rcd//ellowflVhitc to l2Volts Check wire 231 and the battery power
ground junction block connection
Terminal for wire 232VioleVDark Grcen to 12 Volts Bad fronl cab work lamp relay.
ground
kaukazz@yahoo.co.uk
4001 -1 1 0
Left Hand Rear Cab Work Lamp Circuit Test
NOTE: Check Fuse F4, and the Ieft hand rear cab work lamp bulb.
NOTE: Disconnect the teft hand rear work lamp from the harness and turn the lamp switch to the CM WORK UMP
positian (position 5).
Check points Beading PossiPle Cause of Bad Reading
(D Terminal for wirc 230 ViolctrllVhitc to ground

.12
Volts Bad circuit belwcen the lamp switch
tcrminal FL2 and the left hand rear cab work
Tcrminal for wire 205 Brown to ground Continuity Check wirc 205 and the chassis ground
@ conncction.
Right Hand Bear Cab Work Lamp Circuit Test

NOTE: Chcck Fuse F4, and the ight hand rear cab work lamp bulb.
NOTE: Disconnect thc right hand rear work lamp {rom thc harness and turn the lamp switch ta the CM WORK LAMP
Check points Rcading Possible Cause of Bad Fleading
Terminal for wire 230 ViolctrlVhitc to ground 12 Volts Bad circuit between the lamp switch
6) terminal FL2 and the right hand rear cab
work lamp. Also chcck the rcar cab work
NOTE: tf the left hand rear cab work lamp works correctly check wire 230 between the left and right hand rear cab work
lamps.
Terminal for wire 205 Brown lo ground Continuity Bad chassis ground circuit
4)
Rear Cab Work Lamp Relay Circuit Test
NOTE: Turn the lamp switch to the OFF position (position 1).
Terminalforwire 222Brown to ground Continuity Bad circuit bctwecn thc rcar cab work lamp
6) rclay tcrminal 85 and thc chassis ground
connection.
NOTE: Turn the lamp switch to the CM WORK UMP position (position s).
Terminalfor wirc 227 Rcdl}rown to ground '12 Volts Bad circult betlvce n the lamp switch
tcrminal FL2 and the rear cab work lamp
relay terminal 86. Also chcck thc lamp
switch.
kaukazz@yahoo.co.uk
4001-1 11
fs Tcrminal for wire 228 Molct/Flcd to ground 12 Volts Chcck varc 228 and thc battcry powcr
f"rrinrlfor wire z]gVrolel to ground 12 Volts Bad reu cab work lamp relay'

Tcrminaltorwire 219 Rcct/Orangc to ground 12 Volts Chcck vire 219 and the battery power
@ junction block connection.
NOTE: Tum the lamp switch to the wMNtNG UMP posilon (position 2).
Tcrminal for wire 220 Redaight Grcen to 0 volts Bad lamp switch.
ground
Tcrminalforwire 227 Rcd/}rown to ground 0 Volts Bad lamp switch'

6)
NOTE: Turn the tamp switch to the HEADLAMP position (posifon 3)'
Tcrminal for wire 220 RcdAight Grcen to 0 Volts Bad lamp switch'
ground
fcrminal for wire 227 RcdlBrown to ground 0 Volts Bad lamp switch'
4)
NOTE: Tum the tamp switch to the FENDER WORK LAI/IP position (position 4)
Terrninal for wire 220 FlcdAight Grccn to 12 Volts Bad lamp switch'
ground
Tcrminal lor wire 227 Rcd/Brown to ground 0 Volts Bad lamp switch'
6)
NOTE: Tum the lamp switch to the cM woRK LAMP position (position 5).
Tcrminal for wire 220 RcdtLight Green to '12 Volts Bad lamp switch.
ground
Tcrmlnatforwirc 227 RcdlBrown to ground 12 Volts Bad lamp switch.

6)
Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 1 2
Don 7-38440 lssucd 9-92 Pnnlcd:n England
kaukazz@yahoo.co.uk
4001-113 Optional Flear Cab Work Lamp Wring 0ptional Front Cab Work LamP Wring Rear Fender Work Lamp Wiring
Schematic Circuit
m
v/i
0s)
22O FILG (18)
f:;G-r, I -------
l7r
BIY
{r3)
o 22. R/Bn t18)
2' BIBR (18)

ffi
=3:-
2"24 V/Y(r5)
)3, 95
13,75
220
FllLG
(r8) 2?2 BR (18) 222 BR (18)
I p22 BB
I n/BR 222 BR {r8) t18)
{18}
232 V,DG (15)------l
@3
r trel--#TiTiJ-
ffih (13)---J
t-" 233 V,lr
33va(r5)_____--l
233 v/B
v/?
224
V/f
183
BR
l- 2gs VrB {151 : I I
(16) t16) {13)
4---..
:
d aoor-so, ss
20s BR (161
*2 .,,' 234 235 *6 ts9

B BR BR BR BR SR
gB
(15) (16) 6)
(1 {1 S1
fl8)
8) fl3) 11 51
coNNECl083
CSMPOilENTS
"I. 2 PEAF CAA WORX LA}P RELAY 5. LEFi tlANO iEAB CAB WOHK TAMP O. 6A8 HARNE$S TO IN TAUMEFTT PAIigL HARNESS
LAMF SWTCH
2t. FMilT CJS ItO*( LAMP SELAY 6. Rle$T HANO REAff CAB WOEN IAMP N, CAB HARilESS TO FENDER HAENESS
POSllroN ', - oFF
23. REAA FANDgl IYORK LAMP BELAY ?, IEFT IIAND THOilT C.AB WORI( LAMP Pl. tsA-TTERY POWEE JUNCTION BLOCK
POSMON2-WABNINGTAMPS
. POSMOil 3 . WATNiNG I.AMPS, TAIL LAMFS, HEADLAil AOLAMP6 3. FUSE F4 8. R|GI"IT HAND- FRONI CAB }!ORK IAMP
DLAMPS 3At RJS€ Fr S, IEFT HAND REAR FENDER WORK LAMP
POSfiON 4 . REAF FSNDER WORK LAMP$, HEADI.',}'P
POSMON S - AEAA FENDEN WONK IjMPS, HEA!i.AUP DLAMPS 38. FI'SE FI{ rO. hIGHT HAND REAR FENDER.WONK IAMP
OP'IIONAL FRONTA}.IO BEAft CAE WOFE( WONK LAMPS 4. IEFT tlAr\O BEAA TUBI{ SGNALTWABN1NG LAMP Il, IRAILEF CONNECTOR
Dm 7-38440
lsued 9-gZ *intsd h Engtand
kaukazz@yahoo.co.uk
4001-'l 14
REAR FENDER, FRONT FENDER AND CANOPY WORK LAMPS FOR
Sectional lndex
Left Hand Rcar Fcndcr Work Lamp Circuit Tcst ,.......... ....,,.............. . 115
Highl Hand Rcar FcnderWork Lamp CircuitTest ........"... ................. 115
Left Hand Front Fcndcr Work Lamp Circuit Tcst .......,... ...,.......,......... 1-16
Right Hand Front Fender Work Lamp Circuit Test ............ ..,...,,........, '116
Trailer Connector Work Lamp Circuit Test ............ ,.,....... 1 16
Fcnder Work Lamp Relay Circuit Test ............ ,...........,... 117
Left Hand Front Canopy Work Lamp Circuit Tcst ........... ..........,........ 117
Right Hand Front Canopy Work Lamp Circuit Tcst ............ 't18
Left Hand Rear Canopy Work Lamp Circuit Tcst ..,......... 118
Right Hand Rear CanopyWork Lamp Circuit Tcst ........... 119
30 AMP Circuit Breaker Circuit Test ........... 119
Canopy Work Lamp Relay Circuit Test ............ 119
Lamp Switch Test (Work Lamp Circuit) ... . 120
Don 7 38440 lssucd 9 92 Pnntcd in England
kaukazz@yahoo.co.uk
'15
4001-1
CIRCUIT TESTING
NOTE: The battery must be at futt charge and all connections must be clean and tight before testing. Use a multimeterfor
Ihc tcsfs.

NOTE: lf all the fender work lamps fail to work, chcck the fender work lamp relay.
NOTE: Check fuse Fl4 and the left hand rear lender work lamp bulb.
NOTE: Disconnect the teft hand rear fender work lamp from the hamess and tum the lamp switch to the FENDER WORK
UMP position (position 4).
Terminal for wire 224 Yiole,rJYcllow to 12 Volts Bad circuit betwcen the fender work lamp
ground. relay, and the left hand rear fender work
lamp.
NOTE: lttherighthandrearlenderlampwcrkscorrectfy,checkwire224betvveenthelefthandrearfenderlampandthe
sp/ice.
€) Terminalfor wirc 225 Brown to ground Continuity Check wke 225 and thc chassis ground
connection.

NOTE: lf all the fender work lamps fail to work, chcck the fender work lamp relay.
NOTE: Check luse Fl4 and the ight hand rear fender work lamp bulb.
NOTE: DisconnecttherighthandrearfenderworktamptromtheharnessandtumthelampswitchtotheFENDERWORK
UMP position (posituion 4).
Check Points Rcading Possiblc Causc of Bad Rcading
Tcrminal for wirc 224 YiolcllYcllow to 12 Volts Bad circuit between the fender work lamp
ground. relay, and the right hand rear fender work
lamp.
NOTE: tt the teft hand rear lender lamp works correctly, check wire 226 between the right hand rear fender lamp and the
sp/ice.
l Tcrminal for wire 226 Brown to ground Continuity Chcck wire 226 and the chassis ground
connection.
Don 7-38440 Issued 9-92 Printed in England
kaukazz@yahoo.co.uk
4001,1 1 6
Left Hand Front Fender Work Lamp Circuit Test
NOTE: lf atl the fender work lamps fail to work, check the fender work lamp relay.
NOTE: Check tuse F15 and the left hand front fender work lamp bulb.
NOTE: Disconnect the teft hand front f ender work tamp f rom the harness a nd tun the lamp switch to the FENDER WORK
LAMP position (position 4).
Check Points Reading Possible Cause of Bad Rcading
Terminal for wire 228 Yiolcl/Dark Green to 12 Volts Bad circuit between the fender work lamp
ground. relay, and the left hand front fender work
lamp.
NOTE: lf the right hand front fender lamp works carrectly, checkwire 228 betvveen the left hand frant fender lamp and the
Check wire 229 and the chassis ground

Gl Terminal for wirc 229 Brown to ground Conlinuity
conncction.
Right Hand Front Fender Work Lamp Circuit Test

NOTE: lf atl the fender work lamps fail to work, check the fender work lamp relay.
NOTE: Check fuse F15 and the right hand rear fender work lamp bulb'
NOTE: DisconnecttherighthandrearfenderworktampfromtheharnessandtumthelampswitchtotheFENDERWORK
LAMP position (position 4).
Chcck Points Re ading Possible Cause of Bad Rcading
Tcrminal for wirc 228 Vialc{Dark Grccn to 12 Volts Bad circuit bctwccn thc fcndcr work lamp
ground. rclay, and the right hand front fcndcr work
lamp.
NOTE: lfthelefthandfrontfendertampworkscorrectly,checkwire22Bbetuveentherighthandfrontfenderlampandthe
sp/ice.
Terminal for wire 230 Brown to ground Continuily Chcck wirc 230 and the chassis ground
0 conncction.

NOTE: Tum the lamp switch to the FENDER WORK LAMP position (position 4)'
Tcrminal 2 of the trailcr conncctor for wirc 12 Volts Chcck wirc 224 betwccn thc trailcr
224 \fioletNellow to ground. connector pin 2 and thc sPlice.
Terminal 'l ol thc trailcr conncctor for wirc Continuily Chcck wirc 189 and thc chassis ground
189 Brown to ground. connection.
Don 7-38440
lssucd 9-92 Prinlcd in England
kaukazz@yahoo.co.uk
4001-t17
NOTE: Tum the lamp switch to the OFF position
(position 1),
Chcck Points Bcadino
*---:l
Possiblc Cause of Bad Reading
@ Tcrminal for wire 222 Brown to ground Continuity Chcck wire 222 and the chassis ground
connection.
NOTE: Turn the lamp switch to the FENDER WORK LAMP position (position 4).
Terminal for wire 220 RcdAight Grccn to 12 Voits Check wire 220 between the lamp switch
ground terminal FLl and the fcnder work lamp rclay
tcrminal 86. Also chcck the lamp swtch.
(F) Terminal for wirc 221 Rcdlttrolct to ground 12 Volts Check wie 221 and thc battcry power
(D fermlnallar 223 ViolcVGray to ground 12 Volts Bad fender work lamp relay

NOTE: lf alt the canopy work lamps fail to work, chcck thc 30 amp circuit breaker. Refer to page 1 19.
NOTE: Check the left hand front canapy work lamp bulb.
NOTE: DisconnectthelefthandfrontcanopywarktampfromtheharnessandtumthelampswitchtotheCANOPYWORK
LAIVP position (position 5).
(D Terminal for wire 234 Violct to ground 12 Volts Bad circuit belwccn the canopy work lamp
relay and the lcft hand front canopy work
lamp. Also chcck thc canopy work lamp
relay and the circuit breakcr.
NOTE: tf the right hand tront canopy work lamp warks corrcctly check wire 234 bctween the lcft hand front canopy work
(D Tcrmlnal for wire 235 Brown to ground Continuity Chcck wire 235 and the chassis ground
connection.
kaukazz@yahoo.co.uk
4001 -'l 18
Right Hand Front Canopy Work Lamp Circuit Test
NOTE: lf all the canopy work lamps fail to work, check the 30 amp circuit breaker. Refer to page 119.
NOTE: Check the right hand front canopy work lamp bulb.
NOTE: Disconnect the ight hand front canopy work lamp from the harness and turn the key to the CANOPY WORK LAMP
Check Points Hcading P_ossible Cause of Bad Reading
terminal for wire 234 Violet to ground 12 Volts Bad circuit between the canopy work lamp
@ relay and the right hand front canopy work
lamp. Also check the canopy work lamp
rclay and the circuit breaker.
NOTE: lf the left hand front canopy work lamp works correctly check wire 234 between the right hand front canopy work
(!l Terminal for wire 236 Brown to ground Continuity Check wire 236 and the chassis ground
conncction.
Left Hand Rear Canopy Work Lamp Circuit Test

NOTE: lf all the canopy work lamps fail to wark, check the 30 amp circuit breaker. Refer to page 119.
NOTE: Check the left hand rear canopy work lamp bulb.
NOTE: Disconnectthe lelt hand rear canopy work lamp from the harness and tum the lamp swtch to the CANOPY WORK
LAMI'>
Check Points Beading Possible Cause of Bad Rcading
(P Tcrminalfor wirc 237 ViolctflVhitc to ground '1

2 Voits Bad circuit between the canopy work lamp
rclay and the lett hand rear canopy work
lamp. Also check the canopy work lamp
rclay and the circuit brcaker.
NOTE: lf the ight hand rear canopy work lamp works correctly check'wire 237 between the left hand front canopy work
@ tcrminal for wire 238 Brown to grounri Continuity Chcck wirc 238 and thc chassis ground
conncction.
kaukazz@yahoo.co.uk
4001 -1 1 I
RightHandRearCanopyWorkLampCircuitTest
NOTE: tf all the canopy wark lamps laitta wark, check the 30 amp circuit brcaker'
NOTE: Check the ight hand rear canopy work lamp bulb'
NOTE: Disconnect the right hand rear canopy work lamp from the harness and turn the lamp switch
to the CANOPY
WORK UMP position (Position 5).
Tcrminal for wire 237 VioleWVhitc to ground

'I
2 Volts Bad circuit betwcen the canopy work lamp
€l relay and the right hand rear canopy work
lamp. Also chcck the canopy work lamp
rclaY and the circuit breaker.
NOTE: tf the left hand rear canopy work lamp works concctly check wire 237 betvvecn the
right hand rear canopy work
rcrminal for wirc 239 Brown to ground Continuity Chcck wire 239 and the chassis ground
4) conncction.

NOTE: Turn the lamp switch to the GANOPY WORK LAMP posrtion (position 5).
Check Points Beadlng Possible Cause of Bad Reading
Terminal for wirc 232 VioleuDark BIuc to 12 Volts Bad circuit betwccn thc canopywork lamp
ground relay and the 30 amp circuit breakcr. Also
check thc canoPY work lamP relaY.
NOTE: Tum the lamp switch to the OFF position (postion 1)'
Bclwccn the terminals of the 30 amp circuit continuity Bad circuit breakcr'
breaker
Canopy Work Lamp Flelay Circuit Test

NOTE: Tum the tamp switch to the OFF (position l).
Chcck Poinls RoaCino Possiblc Cause of Bad Reading
Tcrminal for wirc 222 Brawn to ground Continuity Bad circuit bclwcen the canopy work lamp
relay terminal 85 and the chassis ground
conncction. Also check thc chassis ground
connection.
NOTE: Turn the tamp switch to the )ANAPY WORK LAMP position (position 5),
fB Terminal for wire 227 Rcd/Brown to ground 12 Volts Chcck wie 227 bctween thc lamp switch
tcrminal FA and the canopy work lamp
relay terminal 86. Also chcck the lamp
switch.
Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 20
Terminal for wirc 231 PintVRcd to ground l2Volts Check wire 231 and the battery powcr
6.) junction block connection.
Terminal for wire 232 Yrolc/Dark BIuc to 12 Volts Bad canopy work lamp relay.
ground

6?l Terminal iorwire 21 9 Rcd/Orangc to ground l2Volts Check wire 219 and thc battcry powcr
NOTE: Tum the lamp switch ta the WMNING LAMP position (position 2).
Tcrminal for wire 220 Rcd/Light Grccn to 0 Volts Bad lamp switch'
ground
6ti) Tcrminal for wirc 227 RcdlSrown to ground 0 Volts Bad lamp switch
NOTE: Turn the lamp switch to the HEADLNVP position (positron 3).
Terminal for wirc 220 Rcd/Light Grccn to 0 Volts Bad lamp switch.
ground
6li) Tcrminai for wirc 227 RcdlSrown to ground 0 Volts Bad lamp switch
NOTE: Turn the tamp switch to the FENDER WORK LAMP position (positian 4).
Tcrminal for wirc 220 RcdlLight Grccn to 12 Volts Bad lamp switch.
ground
(!i) Tcrminal for wirc 227 Rcd/Brown to ground 0 Volts Bad lamp switch.
NOTE: Turn the lamp switch to the C/NOPY WARK LAMP posttion (position 5
Tcrminal for wire 220 Rcd,4-ight Grccn to 12 Volts Bad lamp switch.
ground
6Ii) Tcrminal for wirc 227 Rcdl}rawn lo ground 12 Volts Bad lamp switch,
kaukazz@yahoo.co.uk
4001-121 Optional CanoPY Work LamP Wiring Fender */ork LamP Wiring
Schematic Circuit ET:
E
219
@@ R/O
(1 8) 220 R/LG (18) 22CH|LG (18) _- 221
Rl/
-(11)
227 R/BR {1B)
t6J
r_--
ffr/w
(18) @.-
{+oor-roe,rosl
3
a
Ia
o
o { o*,-*, * 4001-127
a
|
@-,
.. 222 BR (181
2228,R (181
a 4001 -1 03,1 05
o %3
. 232 2nsR(81- 22.*llgl Bs-
t G
f-- { +oorce,
J
ViDB
r__
r-
{1 1) z24VN(1
I r,3vtc
\@ @{i" 222
BFr
-
I
I
222
BB [
223 v/G (1s)-
'l'@) (1 8)
@)@
@1
t\
(16)
ll
'i
_--s\\\\\\\ fr \
,aaorrrlJ I ,,sDcN
189
BH
I
233 G (111 | 228 03)
V/DG
\ 7 vflv (16) {1s)
228vlDG (16)
\\tr 234 v (16)
234 v (1 6)
@t
235 x6 238 oeo z 230 226

BR BR BB B BH BR
BR
(16) (1 (1 6)
(16) (16) {1 6} (16)
COMPONENTS CONNECTOBS
1. LAMP SWITCH 2. CANOPY WOBK I-AMP RELAY 7. RIGHT HAND FRONT ( 7. HIGHT HAND FRONT CANOPY WORK LAMP D. PLATFORM HABNESS TO INSTRUMENT PANEL HARNESS
POSMON 1 . OFF 2A. FENDER WOHK LAMP RELAY 8. LEFT HAND REAR CAI 8. LEFT HAND REAR CANOPY WOBK LAMP T, PLATFOHM HARNESS TO CANOPY HARNESS
3. CIRCUIT BREAKEB 9. BIGHT HAND FEAR Ci 9. RIGHT HAND FEAR CANOPY WORK LAMP P1. BATTERY POWEB JUNCTION BLOCK
POSIIION 2 - WABNING I.AMPS
4. FUSE F15 10. LEFT HAND FRONT FI
POSITION 3 . WABNING TAMPS, TAIL LAMPS, HEADIAMPS 10. LEFT HAND FRO}.IT FENDER WORK LAMP
11. BIGHT HAND FRONT
4.
REAR FENDER WORK LAMPS, HEADLAMPS 4A. FUSE F14 11 , HIGHT HAND FRONT FENDER WOHK IAMP
1
POSITION
5. THAILER CONNECTOR, 12. LEFT HAND REAR FEI
POSTNON 5 - REAR FENDER WORK LAMPS, HEADHMPS 12. LEFT HAND REAR FENDER WORK LAMP
OPTIONAL CANOPY WORK LAMPS 6. LEFT HAND FRONT CANOPY WOBK LAMP 13. RIGHT HAND REAR FI
13. RIGHT HAND REAR FENDER WORK LAMP
kaukazz@yahoo.co.uk
4001,122
RIGHT HAND CONSOLE AUXILIARY POWER CONNECTOR, INSTRUMENT
PANEL AUXILIARY POWER CONNECTOR, CIGARETTE LIGHTER, ELECTRIC
SEAT AND TRAILER CONNECTOR POWER CIRCUIT
Sectional lndex
Right Hand Console Auiliary Power Connector Circuit Test ............ ........,,............ 123
Right Hand Consolc Atxiliary Powcr Conncctor Supprcssion Diode Circuit Tcst............ .,..........123
Test
lnstrumcnt Panel Alxiliary Powcr Conncctor Circuit .................. 124
lnstrument Panel Auiliary Power Conncctor Supprcssion Diode Circuit Test ............ .............,....124
Don 7-3B440 lssLrcd 9-92 Printcd in [:nolanrl
kaukazz@yahoo.co.uk
4001-123
CIRCUIT TESTING
NOTE: Thebatterymustbeatfultchargeandallconnectianmustbecteanandtightbeloretesting,Useamuftimeterfor
lhe tests.
Right Hand Console Auxiliary Power Connector Circuit Test

NOTE: Check Fuses F3 and F31
Chcck points Rcading Possible cause of Bad Reading
$ ferminal for wirc 252 Brown to ground Conlinuity Chcck wire 252 and the chassis ground
conncction.
Gl Terminal for wire 255 Red/Yellow to ground 12 Volts Bad circuit between the battery power
junction block and the auxiliary power
connector terminal 2. Also check the
battery powcr junction block connection
and thc suppression diode circuit.
NOTE: Turn the key to the aN position.
O Termlnal forwire 251 Bcd/Orange to ground l2Volts Bad circuit between the keycd power
junction block and the auxiliary powcr
conncctor tcrminal 3, Also chcck the keyed
power clrcuit and thc supprcssion diodc
circuit.
Right Hand Console Auxiliary Power Connector

Suppression Diode Circuit Test
NOTE: Disconncct thc supprcss ion diodes from the harncss and tum the key to the ON position
Check Points Rcadinq Possible Cause of Bad Reading
O Tcrminalfor wirc 255 Rcd/Ycllow to ground 12 Volts Check wirc 255 between thc splice and the
battcry Powcr suppression diode.
Tcrminalforwirc25'l Bcd/Orangcto ground 12 Volts Check wire 251 bctwccn thc splice and thc
€l kcycd powcr suPPrcssion diodc.
NOTE: Tum the key to the aFF position
(l Terminal for wirc 256 Brown to ground Continuity Check wirc 256 and thc chassis ground
conncction.
@ Tcrminal lor wirc 256 Brown to grouncl Ccntinuity Check wirc 256 bclwccn thc battcry powcr
and keycd power supprcssion diodcs.
NOTE: ll the readings are correct check the suppression diode, refer to Page 125
kaukazz@yahoo.co.uk
4001-124
lnstrument Panel Auxiliary Power Connector Circuit Test
NOTE: Check Fuses F7 and F12.
Check points !eading Possible cause of Bad Reading
Gl Terminal for wire 262 Brown to ground Continuity Chcck wire 262 and the chassis ground
connection.
Terminal for wire 258 Red/Ycllow to ground 12 Volts Bad circuit bctwcen the battery power
Q junction block and the auxiliary powcr
connector terminal 2. Also check thc
baltery power junction block connection
and the suppression diode circuit.
NOTE: Tum the key to the ON Pasition.
(fil Terminal forwirc 260 Rcd/Orangc to ground 12 Volts Bad circuit betlvecn the keyed power
junction block and the auxiliary power
connector terminal 3. Also check thc kcycd
powcr circuit and the suppression diode
circuit.
lnstrument Panel Auxiliary Power Connector

NOTE: Disconnect the suppression diodes from the harness and turn the key to the ON position'
Chcck Points Bcadinq Possible Cause of Bad Reading
lerminal for wire 258 Red/Yellow to ground 12 Volts Chcck wire 258 betwccn fuse F12 and the
@ battery power suppression diode.
(D Terminal forwire 260 Red/Orange to ground 12 Volts Check wre 260 belween fuse F7 and the
keyed power suppression diode.
NOTE: Turn the key to the OFF posrtion.
(F Terminal for wire 262 Brown to ground Continuity Check wie 262 between the battery power
suppression diode and the auxiliary powcr
connector.
(E Terminalfor wire 262 Brown to ground Continuity Check wire 262 bctwcen thc battcry power
and keyed power suppression diodcs.
NOTE: lf the readings are correct check thc suppression diode, rcfcr ta Page 125
Don 7-38440
kaukazz@yahoo.co.uk
400.1-.125
Suppression Diode Test
NOTE: The pracedurc for checking the suppression diodc is the samc for each diodc
NOTE: The positive tead of the mulimeter must go to the male terminal of the diode.
Bctwecn the terminals of the diode Continuity Bad supprcssion diode.
NOTE: Change the leads of the multimeter over so the positive lead of the multimeter goes to fhe female terminal of the
diode.
Bclwccn thc tcrminals of thc diodc No Continuity Bad suppression diode.

NOTE: Disconnect the cigarefte lighler t'rom the harness.
Check Points Rcading Possiblc Cause of Bad Reading
S Tcrminal for wire 127 Brown to ground Continuily Chcck wie 127 and the chassis ground
connection.
(TI Terminalfor wirc 255 Fcd/Ycllow to ground 12 Volts Bad circuit bctwccn the battery power
lunction block and thc cigarctte lighter. Also
check the battery power junclion block
. connection and the suppression diode
circuit

NOTE: Chcck Fuse F31.
NOTE: D[sconnect the electic seat from the harness and turn the key to the ON position.
Chcck Points Reading Possible Cause ol Bad Reading
terminal forwire 251 Rcd/Orangc to ground 12 Volts Bad circuit betwcen the keyed powcr
@ junction block and the clcctric scat motor
connector terminal A. Also check the kcycd
powcr circuit.
NOTE: Turn the key to the aFF posrlion
Tcrminal for wirc 253 Brown 1o <,'r'ound Conlinuity Chcck wirc 253 and the chassis ground
C1 conncction.
NOTE: lf the readings are correct check the electric seat motar.
kaukazz@yahoo.co.uk
4001 -1 26
Trailer Connector Power Circuit Test
Terminal Tofthetrailerconnectorforwire 12Volts Bad circuit between the keyed power

251 Red/Orange to ground junction block and the trailer connector
terminal 7. Also check the keyed power
circuit.
Terminal 4 of the trailer connector for wire 12 Volts Check wire 251 between terminals 4 and 7
251 RedlOrange to ground of the trailer connector
€l Terminal for wire 189 Brown to ground Continuity Check wire 189 and the chassis ground
connection.
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk 40c 40a1-127 Auxiliary Power Wiring Cigarette Lighter Wiring lnstrument Panel Ar 'Wiring lnstrument Panel Auxiliary Power Wlring Electric Seat Wiring
Schematic Circuit
ffi
2s1 FUO (1 2s1 ff/O (1 uffEF 2s1R/o (1 .-@
--7i--- { +oor - s3, es, 103, 1os
*@
.-/1' 257
Rlf
257
Hio aoor - rc, 7s, Bs, 85
/t'- (13i (1s) { 4001 - 113,121
\|
\,\
1 Rfr (11) 4001 - 131 251
HiO
(1q
251
Fl/O
--@
!: 251 R/O (11 tls)
,\ tl
i\ :!
:;
255
F/r I I
189
BR
il i.i
zs'(1 1) I (1 3)
\ ,i!
FUO
(1 1)
L I
P fl/o
I (15
251
1a
rl
m0 R/O 260 FUO i15F-
255
RTT
(1 1)
.:
251 258 251
F|/O Rff
.\/ (1 1)
2e BR (1
262 BR (16) (,t5)
FUO
(15)
260
it R/O
li
r'@
(1s)
.j,- I
't na i
255 Fr/Y (13)- zss ilY (13) 2s5 ilr (1

-
251
R/O
{1 1)
255
.o
'@
B/Y
(1 1)
+ -@
,!)o
BR
\o d+oor-sa,
,ilo
BB
253
BB
(15)
189
BR
(1 3) (13) 03)
CONNECTORS
COMPONENTS
.I. 4A, RIGHT HAND CONSOLE AUXLIAHY POWER AE 8. ELECTRIC SEAT MOTOR A. TMNSMISSION HABNESS TO INSTBUMENT PANEL HARNESS
F31
FUSE )NSOLE AUXILIAFY POWEH
LIGHT BLUE 9.7 D. CAB OR PLATFORM HARNESS TO INSTRUMENT PANEL HAHNESS
2. FUSE F3 BATTERY POWER SUPPRESSION DIODE R SUPPRESSION DIODE 9. TMILEB CONNECTOB
E. TMNSMISSION HARNESS TO RIGHT HAND CONSOLE HARNESS
2A. FUSE F12 5. CIGARETTE LIGHTER {TER
6. INSTRUMENT PANEL AUXLIARY N. CAB HARNESS TO REAB FENDER HARNESS (CAE TRACTORS ONLY)
28. FUSE F/ NELAUXILIARY
POWER CONNECTOR
P1. BATTERY POWER JUNCTION BLOCK
3. RIGHT HAND CONSOLE AUXLIAHY GTOR
7. INSTRUMENT PANEL AUXLI,AHY POWER P2. KEYED POWEH JUNCNON BLOCK
POWER CONNECTOR NELAUXILIARY POWER
4. RIGHT HAND CONSOIS AUXILIARY POWER BATTERY POWEH SUPPBESSION DIODE R SUPPBESSION DIODE
Don 7-38440 lssued +92 Printed i rd $92 Printed in England KEYED POWER SUPPRESSION DIODE 7A. INSTRUMENT PANEL AUXILIARY POITYER A}.IEL AUXILIARY POWER
kaukazz@yahoo.co.uk KEYED POIVER SUPPHESSION D}ODE SUPPRESSION DIODE
4001 - l 28
RADIO, INTEFIIOR I.-AMP, RIGHT HAND CONSOLE I-AMP
AND INSTHUMENT CLUSTER ILLUMINATION (DIMMER)
Sectional lndex
Bight Hand Console Lamp Circuit Test..,.......... .............., 130

Test..,..........
lnstrument Cluster lllumination (Dimmer) Circuit ..............130
Don 7-38440 lssucd 9 92 nrinlcd in Fngland
kaukazz@yahoo.co.uk
4001 -1 29
CIRCUIT TESTING
NoTE: Thebaftery mustbe at full charge and all conncctions mustbe clean and tight before testing. use a multimeter for
lhe tests.
Radio Circuit Test

the antenna cable for
NOTE: Make sure the radio antenna chassrs ground connection is clean and tight. Nso check
damage.
NOTE: Disconnect the ndio from the hamess.
Chcck Points Rcading Possiblc cause of Bad Reading
tcrminal for wirc 270 Brown to ground Continuity Check wire 270 and the chassis ground
Q connection.
NOTE: Tum the kcY to the ON Position
Volts Bad circuit bctween the acccssory power \*'/

Gl terminal for wirc 38 Orangc to ground 12
relaY and the radio' Also chcck the
acccssory Power relaY.
l2Volts Bad circuit bctween the battery powcr

Q r"rrinrl for wire 255 Rcd//cllow
to ground
junction block and thc radio. Also check the
bat1cry junction block connection.
Radio SPeaker Circuit Test

NOTE: Disconnecl the radio and ndio speaker from lhe harness'
Chcck Points Rcading Possible Causc of Bad Rcading
l terminals for wire 271 GraY Continuity Chcck wir. 271.
Tcrminals for wirc 272 Brawn/Gray Continuity Chcck wirc 272.

Q
Gl Terminals for wire 273 Ycllow Continulty Chcck wie 273.
Terminals for wire 274 Brown/Ycllow Continuity Chcck wke 274'

@
Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 30
lnterior Lamp Circuit Test
NOTE: Check Fuse F3 and the inteior lamp bulb.
NOTE: Discannect the interior lamp assembly from the harness.
O Terminal for wire 255 Hcd//ellow to ground l2Volts Bad circuit between the battery power
junction block and the interior lamp. Also
chcck the battery powcr junction block
connection.
@ terminal for wire 275 Brown to ground Continuity Bad chassis ground circuit. Also check the
(li) Tcrminals for wirc ?75 Srown Continuity Check wirc 275 bctween the chassis ground
terminals of the lamp assembly.
NOTE: lf the readings are corecf check the interior lamp assembly.
Right Hand Console Lamp Circuit Test

NOTE: Check Fuse F13 and the right hand console lamp bulb.
NOTE: Tum the lamp switch to the aFF position and disconnect the right hand conso/e lamp from the harness.
@ terminal for wirc 275 Brown to ground Continuity Bad chassis ground circuit. Also chcck thc
inte rior
lamp and chassis ground
connection.
NOTE: Tum the lamp switch to the HEMLAMP position (posilion 3).
o) Tcrminal for wirc 276 Tan to ground 12 Volts Bad circuit bctwcen the lamp switch
tcrminal HD and thc right hand consolc
lamp. Also check the lamp switch.
lnstrument cluster lllurnination (Dimmer) Circuit Test

NOTE: For tractors with deluxe instrument c/usters, when the lamp switch is in the headlamp position (position 3) the
instrument cluster digital display will dim.
NOTE: For tnctors without deluxe instrument clustens, the instrument cluster will illuminate when the lamp swrtch is in the
headlamp position (position 3).
NOTE: Discannect the instrument cluster from the harness and turn the lamp switch to the HEADUMP lamp position
(position 3). ,A/so check the instrument cluster illumination bulb for lruclors without deluxe instrument c/uslers.
Chcck Points Rcading Possiblc Causc of Bad Rcading
Pin 36 of thc instrumcnt clustcr conncctor 12 Volts Chcck wie276 bclwccn fusc F13 and thc
for wirc 276 Ian to ground instrumcnl clustcr conncctor pin 36.
NOTE: lf thc reading is correct checkthe instrument cluster chassis ground circuit, referto Page 15.
Don 7-38440 lssucd 9-92 Pnnlcd in England
kaukazz@yahoo.co.uk
400'l -131 Radio Wiring lnterior Lamp and Right Hand Console Wiring
Schematic Circuit
254 254
&rY Hlv
(1 1)
1M Rlv/w (18)
(1 1)
I I
+oor - ra I {*,
1[ I
") t I
171
6'@
254
b
254 rlGloocoSo
R
(1 3)
171
tl
(1 3)
Rl/ Rff
I
I I
01) (1 1) I
ldqoo
{ooo, -r {001 -133
oql
I
I
l"
I
{*,
255 R^/ (i8)- ,a,] tfi1
38 O (18)
171 H (1
R/1il
(16) I
r
4[>
1[+oor
ts
+oot - rs 3s
R/DB
o
/ ,r, nrr,
@ ar-
fo
273 Y (18)
I
(1
I
3)
274 BR/( (18) Oru
&t
I 38
t-\
l/ )t u"BR/G(18)
o
(1 8)
275r(16)--J
I
Ds t_: e9 6@l 35
270 BR (18)
I
L_
@
r'@
19R/V 275r {1 er-l?lEI
3t
-rt:
27sT (1 - zr
Rl/ {+oor
i -ss
(1 5) -{sl!ll
3[+oor 25s
ffi.:-- Blr
(1 8)
270
I
BR
I
(1 8) 255 H/Y 0 8) ----------'---r
"t**---l 270 BB {18)
1[aoor
-ss 270 BR (18) ) BB (18) \
270
BR
36 BH (16) BR
06) (18)
I
lesl
(--1-
) coraponer
:r,{i1l:
x,*giii CONNECTORS
\-/ COMPONENTS
D. CAB HARNESS TO INSTRUMENT PANEL HABNESS IMENT PANEL HARNESS :K I NOTE: FAR TRACTORS UP IO P/N NO JJF 1A17717
1. KEY sw 1. KEY SWITCH 5, RIGHT HAND SPEAKEE CONNECIOF B lS SECUfiED TA THE /NSLSUMENI PANEL
S$fiTI
2. THANSi R. INSTBUMENT PANEL HARNESS TO DIMMER/TURNiHORN NESS TO DIMMER/TURN/I-IORN SWITCH
2. TMNSMISSION CONTROL RELAY 6. ANTENNA HABNESS
FHOM PIN No JJFl01718 ONLY)
FRACTORS JJFl017718 oNLY)
2A. ACCSE 7. BADIO
2A. ACCSESSORY POWEB RELAY
W. INSTBUMENT PANEL HABNESS TO HFADTAMP
DIMMER RELA' INESS TO HEADI-AMP DIMMER HELAY rK e NOIE: FOR TRACTOBS FFOM PIN NO JJF 1017718
3. FUSE F 3. FUSE F32 8. FUSE F3 CONNECTOE W /S SECU8ED TO THE INSTRUMENT
PANEL
UP TO PIN No JJF 1017/17 ONLY o JJF 1017717 ONLY
ORACTOHS
3A. R]SE F
3A. FUSE F3O 8A. FUSE F13 . HAFNESS.
38. FUSE P1. BATTERY POWER JUNCTION BLOCK ON BLOCK
F
38. FUSE F2O S. LAMP SWITCH
3C, FUSE f 3C. FUSE F2S 10, INTERIOR LAMP
3D, FUSE I 3D. FUSE F19 1 1. RIGHT HAND CONSOLE LAMP
3E. R'SE T
3E. FUSE F17 12. INSTBUMENT CLUSTER CONNECTOR
4. LEFT H
Don 7-38440 kaukazz@yahoo.co.uk 4. LEFT HAND SPEAKEfl
4001 -1 32
FRONT AND REAR WINDSHIELD WIPER/VVASHERS
Sectional lndex
Front Windshicld Wipcr Motor Circuit Test ........... ......... 133

Front Windshield Washer Motor Circuit Test ........... ...... 133
Front Windshield WiperAVasher Switch Circuit Test ............ ........,...... 134
Rear Windshicld Wiper Motor Circuit Tcst .......,.... ......... 134
Rcar Windshield Washer Motor Circuit Tcst ..,."..,.,.. ...... 135
Rear Windshicld WipcrArVashcr Switch Circuii Tcst ........... ....., .......... 135
Don 7-38440 lssucd 9-92 Printcd rn England
kaukazz@yahoo.co.uk
4001 -1 33
CIRCUIT TESTING
NorE: Thebatterymustbeatfull chargean<l alt cannectionsmustbecleanandtightbeforetcsting.Useamultimeterfor
lhe lests.

NOTE: Check Fuse FB.
position.
NOTE: Disconnect the front windshield wipcr motor from thc hamess and turn the key to the ON
Check Points Rcading Possible Causc of Bad Reading
ferminal for wire 281 Gray/Hed to ground 12 Volts Bad circuit between thc front windshicld
Q wipcr motor conncctor terminal C and the
kcycd powcr junction block. Also chcck the
kcycd power junction block circuit.
NOTE: Turn the front windshield wiper swrlch to the LOW (l) position
Tcrmlnal for wirc 283 Gray to ground

'12 Volts Check wire 283 and thc front windshicld
O wiPcrAruasher switch.
NOTE: Turn thc windshield wiprtrlwashcr switch to thc HIGH (ll) positiort
Terminal for wirc 284 Gray/Dark Grccn to 12 Volts chcck wtre 284 and thc front windshicld
ground wiPerlwasher switch'
NOTE: Turn the key and the windshield wiperlwasher switch to the oFF position.
7| Tcrminal for wirc 285 Brown to ground Continuity Chcck wire 285 and the chassis ground
connection.
Tcrminals lorwircs 281 Gray/Ecd anl,2B2 continuity check v'nre 282 and the front windshicld
Gray/Black wiperlwashcr switch
NOTE: tf the readings are correct check the tront windshield wiper mator'
Front Windshield Washer Motor Circuit Test

from the harness'

NOTE: Tum the key to the aFF position and disconnect the fronl windshield washer motor
Check Points Bcading Possible Causc of Bad Rcading
Gl Tcrminal for wirc 287 Brown to ground Continuity Check wire 287 and the chassis ground
connection.
positicsn and hotd the lrant windshield wiperlwasher switch in the ryASH
positian.
NOTE: Tum the key to the oN
tcrminalfor wire 286 Gray/Black to ground 12 Volts Bad circuit betwecn the front windshicld
@ wipcrlwashcr switch tcrminal W and thc
front windshie ld washer motor.
NoTE: lf the readings are carrect replace the front windshield washer motor
Don 7-3B440
kaukazz@yahoo.co.uk
4001 -1 34
Front \Mndshield Wiper/YVasher Switch Test
position.
NOTE: Disconnect the front windshield wiperlwasher swfch from the harness and tum the key to the ON
Chcck Points Reading Possible Causq of Bad Reading
Terminal for wire 281 Gray/Red to ground 12 Volts Bad circuit belween the keyed power
0 iunction block and the front windshield
wiperlwasher switch terminal B. Also check
thc keYed Power circuit.
NOTE: Tum the front windshield wiperlwashcr switch to the LOW (l) position.
Between terminals B and L of the front Continuity Bad front windshield wiper/washcr switch.
windshield wiperlwasher switch
NOTE: Tum the front windshietd wiperlwasher switch to the HIGH (ll) position.
Bewvecn terminals B and H of thc front Continuity Bad front windshicld wiperlwashcr switch.
windshicld wipcr/washcr switch
NOTE: Tum the front windshield wiperlwasher switch to the oFF position.
Betwecn termlnals B and p of tlre front Continuity Bad front windshield wiperlwasher switch
windshield wiperlwashcr switch
NOTE: Hold the front windshietd wiper washer switch in the wAsH position.
Between terminals B and W of thc lront Continuity Bad front windshield Wperlwasher switch.
Rear Windshield Wiper Motor Circuit Test

NOTE: Disconnect the rear windshietd wiper motor from the harness and turn the key to the ON position
Check Points Rcadino Possible Cause of Bad Reading
Terminal for wirc 288 GrayMhitc to ground 12 Volts Bad circuit betwccn the kcycd powcr
Q junction block and terminal B of thc rear
windshield wiper motor connector.
NOTE: Turn the rear windshield wiperlwasher switch to the oN position.
Terminal for wire 290 GraylDark BIue to 12 Volts Check wire 290 and the rcar windshicld
ground wiPcrAruasher switch'
Don 7-38440
Issucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
4001 -1 35
NOTE: Turn the key and the rear windshield wiper/washer swtlches to the OFF position.
terminal for wire 291 Brown to ground Continuity Bad circuit betwecn the rear windshield
@ wiper motor connector terminal D and the
(D Terminals f orwires 289 Gray and 291 Brown Continuity Chcck wire 289 and the rcar windshield
wipcrlwasher switch.

NOTE: Tum the key to the AFF positian and disconnect thc rear windshield washcr motor from the harness
(E) Terminal for wire 287 Brown to ground Continuity Bad circuit between the rear windshield
washer motor and the chassis ground
connection. Also check the chassls ground
connection.
NOTE: Turn the key to the AN position and hold the rear windshield wiperlwasher switch in the WASH position.
Terminal for wire 292 GraylDark Grecn to 12 Volts Bad circuit between the rear windshield
ground wiperlwasher switch terminal 3 and the rcar
windshicld washer motor. Also chcck the
rcar windshicld wiperlruashcr switch.
Rear Windshield Wiper,&Vasher Switch Test

NOTE: Disconnect the rear windshield wiperlwashcr swilch fram the harncss and tum the key to the ON position
Chcck Points Rcading Possible Cause of Bad Rcading
(El Terminalfor wlre 288 GrayAVhite to ground 12 Volts Bad circuit between the keyed power
junction block and the rcar windshicld
wipcrlrvasher switch.
NOTE: f um the key to the OFF position.
NOTE: Turn the rear windshield wiperlwasher switch to the ON position.
Betwecn terminals 6 and 2 of thc rcar Continuity Bad rcar windshield wiperlruashcr switch.
windshicld wiper/washcr swrtch
kaukazz@yahoo.co.uk
4001 -1 36
NOTE: Tum the rear windshield wiperlwasher switch to the AFF position.
Between terminals 5 and 7 of the rear Continuity Bad rear windshield wiperlwasher switch.
windshield wiper/washer swttch
NOTE: Hold the rear windshield wiperlwasher switch in the WASH position.
Between terminals 3 and 6 of the rcar Continuity Bad rcar windshicld wiperrl,rrasher switch,
Don 7-38440 Issucd 9-92 Printcd in England
kaukazz@yahoo.co.uk
Front Windsheild Wiper Wiring Bear Windsheild Wiper Wiring
powrquadplus www.thebestworkshopmanuals.co.uk 4AOr137
Schematic Circuit
280 Fi/G
(13)
i- 280 H/c (18) 280 R/G (1O

-
(1s)
o9 ..3o
p
Y
, K--)i
j)N
281
G/R 286 GiB (16) 286 G/B (16) (1 6)
288
c^v
(15) ffi-ru
(rs) *irdtatr
iL__------
II I
W--1
iiii'
jiiii! iii
, iii
i: .288
iiiiii : i: i, i ffiEl G (16)

/
lii ^ ii I I 286
/ {
I G/B
)I( \\ o. \:::
I
281
trol
1t
:x)N$ Y
';; ,---.aa,r\ c/R
I
A B
-/
I
r-V
t- \. ".Y
/
(1s).r.1 286
G/B
82
G/DG OJ
-/,,:r:: rF-
'l7
f'
(1 6)
:.
LN\ .-i, \
o
---*r
281 G/R (1s) 6)
_ .'v'
t; t-1.--
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6
> lDl>
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292
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(1
COMPONENTS CONNECTORS
1. FUSE F8 D. CAB HARNESS TO INSTHUMENT PANEL HARNESS 'ESS
1A. RJSE F2 V. CAB HARNESS TO FENDER HARNESS
2. FRONT WPERIWASHER SWITCH P2, KEYED POWER JUNGTION BLOCK
1G................... LIGHT GHEEN 3. FRONT WINDSHIELD WPER MOTOR
4. FBONT WNDSHIELD WASHER MOTOR
5. BEAR WINDSHIELD WASHER MOTOR
6. HEAH WPEFUWASHER SWITCH
7. HEAE WNDSHIELD WIPER MOTOR
Don 7-38440 kaukazz@yahoo.co.uk lssued 9-92 Printed in England
kaukazz@yahoo.co.uk
4001 -1 38
BLOWEH MOTOR AND AIR CONDITIONER
Sectional lndex
139
CIRCUIT TESTING
139
Blower Motor Circuit Test ............
139
Circuit Breakcr Test ............
140
Blower Switch Test .....,.....
140
Resistor Board Test
141
Air Conditioner Compressor Circuit Test '.'.
141
Air Conditioner Control SWtch Circuit Tcst '.,.'.......
142
Air Conditioner Lockout Relay Circuit Tcst . .. .....'
143
Air Conditioner lndicator Lamp Circuit Tcst '..........
143
Suppression Diode Circuit Test.
145
Schematic Circuit
I)on 7-38440
lssucd 9'92 Pnnlco in EnQIand
kaukazz@yahoo.co.uk
4001 -1 39
CIHCUIT TESTING
NOTE: Thebatterymustbeatfullchargeandall connectionsmustbecleanandttghtbeforetestlng. IJseamultimeterfor

lhe tests.

NOTE: tftheblowermotorfailstooperatewhentheblowerswitchisinLOWfiorMED|UM(tt)positionschecktheresistor
board, and the blower switch'
NorE: tfthebtowermotorfailstooperatewhentheblowerswitchisinLow(t),MEDluM(l0,arH|GH(lll)position'check
the circuit breaker, blower sw"tch and the blower motor'
NOTE: Tum the key to the OFF position'
terminal for wire 308 Brown to ground Continuity Check wire 308 and the chassis ground
Q conncction.
NoTE: Tum the key to the oN position and the blowcr switch to the Law $ position'
to 12Volts checkwire302bcilveentheblowermotor
Terminal for wire 3o2 GtaylDark Blue
groundswilchterminalLandtheresistorboardconnector. Also check the blower motor
switch.
NOTE: Tum the blower swrtch to thc MEDIUM (ll) positton
Tcrminal for wirc 304 Gray/Black to ground 12 Volts Check wire 304 bctween the blower motor
O switch terminal M and the resistor board
connector, Also check the blower motor
switch.
NOTE: Turn the blower swrfch to the HIGH (lll) position'
ferminal for wire 306 GrayiWhitc to ground l2Volts Bad circuit between the blower switch
? terminal H and the resistor board connector'
Also check the blower motor switch and the
blower motor rclaY (if equiPPcd)'
blower motor
NOTE: tf the readings are correct check the resislor board and the

NOTE: Tun the keY to the ON Position'
Check Points Bcading Possible Causc of Bad Reading
l2Volts Check wire 300 and thc keycd powcr

Gl Terminal for wire 300 Rcd/Brown to ground
iunction block connection'
Bctwee n thc terminals of the circuit brcakcr Continuity Bad circuit breaker
NOTE: Tum the keY ta the ON Position'
Termlnal for wirc 301 Gray to ground 12 Volts Blower motor circuit shorted to ground
0
Don 7-38440
kaukazz@yahoo.co.uk
4001 -1 40
Blower Switch Test
NOTE: Disconnect the blower switch from the hamess and tum thc keY to the ON position.
Chcck Points Rcading Possiblc Causc of Bad Reading
@ Tcrminal for wire 301 Gray to ground 12 Volts Bad circuit between the circuit brcaker and
thc blowcr switch tcrminal B. Also check thc
circuit breakcr.
NOTE: Tum the bletwer swrfch to the LOW (l) position
Between terminals B and L of thc blcwcr Continuity Bad blower switch.
switch
Belween tcrminals B and C ol thc blowcr Continuity Bad blowcr switch.
switch
NOTE: Turn the blower swrfch to the MEDIUM (ll) position.
Bctween tcrminals B and M of thc blowcr Continuity Bad blower switch.
switch
Bctwccn tcrminals B and C of thc blowcr Continuity Bad blower switch.
switch
NOTE: Tum the blower swrlch to the HIGH (lll) position.
Bctwccn tcrminals B and H of thc blower Continuity Bad blowcr switch.
switch
Bctwecn tcrminals B and C of thc blowcr Continuity Bad blower switch.
switch
Flesistor Board Test

NOTE: The thermal cut-in swrtch protecls lhe resistors from over heating. lf the air flow around lhe reslstors becomes
resticted, the resrstors witl over heat and the thermal cut-in switch contacts will close and the blower motar will go to
HIGH speed.
NOTE: Allow the resrstors to cool before the fallowing tests are carried ottt.
NOTE: Disconnect the blawer motor from the resistor baard.
NOTE: Tum the key to the ON position and tum the blower switch to the HIGH (lll) position.
Gl Tcrminal for wire 307 Black to ground 12 Volts Bad circuit betwecn the blower motor terminal
H and the resistor board connector.
NOTE: lf the reading is conect check the blower mator.
NOTE: Tum the key to the aFF positian and connect the resistar board to the blower motor.
NOTE: Tum the key to the ON position and tum the blower switch to the LOW (l) position.
Q Icrminal for wirc 303 Whitc to ground I2 Volts Bad circuit between thc blower motor tcrminal
L and thc rcsistor board.
NOTE: lf the reading is carrect and the blower motor lals to opcrate or operatcs at high specd, replace the resistor bowd.
kaukazz@yahoo.co.uk
4001 -1 41
NOTE: Tum the blower swrtch to the MEDIUM (ll) pasition
Chcck Points Rcading Possible Cause of Bad Beading
(fil Tcrminal for wire 305 Red lo ground 12 Volts Bad circuit between the blower motor terminal
M and the resistor board.
NOTE: ltthereadingisconectandtheblowermotarfailstoopemteoroperatesathighspeedreplacetheresistorboard'

refer to Section 9002'
NOTE: Before any tests are canied out on the air conditioner circuit,
NOTE: Disconnect the suppression diode from the harncss'
NoTE: TumthekeytotheoNposition,thebtowerswitchtotheLow(l),MED||JM(ll)orHIGH(ltl)positionsandsettheair
canditioner control switch to MMIMUM cooling'
rermlnal for wire 313 Grav/Dark Bluc to 12 volts o:H""inJn"r,:'"::1.til':"J

@ ground
l"?1,|.i"i"'3
compressor. Check the blower motor, air
conditioner control switch and the lockout
relay. Also check the pressure switches,
refer to section 9002.
to Page 143'
NOTE: lf the readings are correct check the supprcssion diode, refer

refer to Section 9002'
NOTE: Before any tests are canied out on the air conditioner circuit'
r switch to thc LOW (l), MEDIUM (ll) or HIGH (llt)
positions and s.t the air
NOTE: Turn the key to the ON position, the btawe
conditioner control swltch to M/tX|MUM cooling'
Chcck Points
Rnarlinn Possible Cause of Bad Heading
@ I::n:,r ror wire 30e Grav,Dark Grcen to 12 Vorts ?."ff::*:fi:"#:'#l:i

iffii,l'8:3:
(E) tor*inrlfor wirc 310 GrayMoict to ground 12 Volts Bad air conditioner control swttch
lssucd 9-92 Pnntcd in England

I lon /-J6ccu
kaukazz@yahoo.co.uk
4001-142
NOTE: Beforc any tests are canied out on the air conditioner circuit, refer to Section 9002.
NOTE: Tum the key to the OFF position,
(F Terminal for wirc 312 Brown to ground Continuity Check wire 120 and thc chassis ground
connection.
(B Tcrminals for wire 311 Gray//ellow Continuity Chcck wirc 3'11 betwccn the air conditioner
lockout relay terminals 86 and 87.
NOTE: Disconnect the air conditioner high and low pressure swltchcs from the hamcss.
NOTE: Tum the keyto the ON position, the blower switch to the LOW (l), MEDIUM (ll), or HIGH (lll) position and setthe air
conditioner controlswttch to the MAXIMUM cooling position.
fB Terminal for wirc 310 GrayNiolet to ground '12 Volts Check wire 310 between the air conditioner
switch and the lockout relay.
Tcrminal for wirc 313 GrayiDark Bluc to 12 Volts Bad ai conditioner lockout relay.
ground
NOTE: lnstatt a suitabte jumper lead between terminals A and B of the air conditioner high pressure switch connector
(harness srde).
O Tcrminalfor wire 31 1 Gray/Yellow to ground 12 Volts Bad circuit bctwcen tcrminals 30 and 86 ol
thc air conditioner lockout relay.
Tcrminal for wire 313 Gray/Dark Bluc to O Volts Bad air conditioner lockout relay,
ground
NOTE: Remove the jumper tead from the air conditioner high pressure swtch connector.
(D Tcrminalfor wirc 31 1 Gray/Ycllow to ground 12 Volts Bad air conditioner lockout rclay.
fJi) Terminal for wiro 31 1 Gray/Yellow to ground 12 Volts Checkwire3ll betwcentcrminalETandtho

air conditioner indicator lamP,
NOTE: lnstalt a suitable jumper lead between terminals A and B of the air conditioner low pressure switch connector
(harness side) and tum the key to the ON position.
6i) Terminalfor wirc 31 1 Gray/Ycllow to ground 12 Volts Bad circuit betwccn the air conditioner
control switch and thc indicator lamp.
NOTE: lf he readings are correct check the high and low pressure swtches, refer to Section 9002.
kaukazz@yahoo.co.uk
4001 -1 43
NOTE: Check the air conditioner indicator lamp bulb'

Possible Cause of Bad Fleading
Check Points Egeg4g
ContinuitY Check wire 315 and the chassis ground
Terminal for wire 3.15 Brown to ground
6l conncction.
circuit'
NOTE: lf the readingis cOnect checkthe air conditioner lockorLt relay
SuPPression Diode Circuit Test

NOTE: Disconnect the suppression diode from the hamess'
Rcading Possible Cause of Bad Reading
Check Points
Iterminal for wire 314 Brown to ground ContinuitY Check wire 314 and the chassis ground
@ connection.
terminal of the diodc

NOTE: The positive lead of lhe mulimeter must go ta thc male
ContinuitY Bad supprcssion diode.
Betwccn thc tcrminals of thc diodc
so the positive tead of the multimeter goes to the female terminal of the
NOTE: Change the leads of the multimeter over
diode.
Bctwecn the tcrminals of the diodc No Continuity Bad suppression diode

Don 7-38440
kaukazz@yahoo.co.uk
4001 -powrquadplus
1 44 www.thebestworkshopmanuals.co.uk
Don 7-38440 Issucd 9-92 Printed in England
kaukazz@yahoo.co.uk
llower Motor Wiring Air Conditioner Wiring

4001 -1 45 Blower Mc
$chematic Circuit
30s I
:" nL- gf
{ r!i
308
,rrrrr/ 3
(1.)
315 BR (16)
I
BA Iw
l)
*,.( *
r''
11 I (r+t
30a r
snL T
g7
313 G/SB {16)
1t+l-{ I
3 I
ct.i 309
B
l1s)
J I
lYl +*-ll
lFl 'iB',ii
ffi.i:tut
-r
\
310 Gty (16)
I
I
I
ll
:Y-i
-=-Ji::
611 Gtf (16)
e/\
(le)
3!3
G8B
it6)
c
I
lr-
)"-- ( I
Itl
A
lvl
It,tl i'g'i
:'"rin;!
r:.t'-i.!$ l?l
" B;'
308 j-*;l
13 G/DB ils) _T
BR 3r0 G// {16) _GTera_ 310 Gli/ (lq I
{1 1}
I 312 315
{ta s8
I
t1 5) (16)
I
I
I I
@ CONNECTOAS
coMPoNENTS
L/l 8. AIR CONOITIOiIEB LOCKOUTWARNING IAMP B, ENGINE FTARNESS TO INSTRUMENI PANEL HARNESS
].CISCINT BREAKM 9. AIR CONDITIOI.IER COI,|PfiESSOR CLUTCH D. CAB HAFNESS TO INSTRUMENT PANEL HAEN€SS
2. BLOWES SI{ITCH r0. suPPREsslo\ otooE P2. KEYED POYJEFI JUNCTION BLOCK
3. B€SISTOS BOARO
34, BLOWEH MOTOH CONIROL SWTCH
4. AIH CONOMONER CONTROL SWN WITCH
5. H'CH PRESSURE SWTTCH LOCKOUT HELAY
Don 7-38440
8. AIR CONDITIONSR LOCKOUT REr,'
l$sued 9'9 prir{ed in Englaild
?, LO$/ PSSSSURE SWITCH
TYITCH
kaukazz@yahoo.co.uk
Section
4001
ELECTRICAL TROU BLESHOOTI NG AND SCHEMATICS

(For Maxxum Tractors From Pin No JJFl 030000)
Copyr ght O 1 993 Case Corporatron

Da1 7'392/0 Priirteo in Englard
CASE CORPORATION November 1 993
kaukazz@yahoo.co.uk
t \r
'. 't't
4001-2
TABLE OF CONTENTS
SHOP EOUIPI'/ENT TOOLS
GENERAL INFORMATION 3
SCHEMATIC SYMBOI S 4
WIRE COLOR CODE
q
FUSES AND RELAY LOCAT]ON
FUSES 5
BULKHEAD CONNECTONS AND ELECTRICAL COMPONENT LOCATION . 6
STARTEN, KIY SWITCF] KEYED POWEN, FUEL SHUT-OFF AND ETHER START ,7
ACCESSORY POWER RELAY, ALTERNATOR AND iNSTRUN/ENT CLUSTER 12
FORWAFD/NEUTRAUREVERSE (F N.R) AND TBANSMISSION CONTBOI . 24
sENS-O-DRAULTC (Sr-rR) rlrTCFr CONTROL 36
MFD LOCK AND D T LOCK

HEADLAN/PS AND TAIL LA|VPS
TURN S]GNALA,^/ARNING LAMPS 72
WORK IANIPS .84
NIGiIT HAND CONSOLE AUXILIANY POWEN CONNECTON

INSTNUN,4ENT PANEL AUXILIANY POWEN CONNECTOR
CIGARETTE LIGHTER ELECTRIC SEAT AND TRAILER CONNECTOR POWER CIRCUIT 9B
RADIO INTEBIOB LAIIP RIGHT HAND CONSOLE IAMP AND INSTRUMENT

CLUSTER II-I UN,lINATION (DIMNIER) 104
FRONT AND RIAR WINDSIIIELD WIPtN,ryVASHERS , BLOWTN MOTON AND AIR CONDITIONER 108
NOTE: For Powcrshifl, Refer to Saclton 6008
l)cn 7 -39270 lssr.rcd 11-93 Prinled in Englanc
kaukazz@yahoo.co.uk
4001-3
.q I
.&.-;
. I l,.l:'
W
'.t) \ .q#la
'
't,?2"?'
'l
,:tr
"g '-J
_l
1. SIGNAL GENERATOR/COUNTER OEM 1 336A
aTrT
2 1,,'IULTIMETER OEM 1428
GENERAL INFORMATION
closed building, proper ventiption is required under

all
A WARNING: Never operate the engine in a
/T\
U) circumsfances
parked on hard level ground with the parking brake engaged

NorE: electricalchecks musl be made with the tractar
Alt
and the engine OFF unless otherwrse staled'
diode test functron'

NoTE: Whcn testing drorjcs and cliodc mttdutcs use ii)e rrtuiltrneicr
any elcctricalchccks must be connected when thc
NorE: componenls wlres anci connectors drsconnectc(l during
All
checks are comPlete.
lssred '1 1-93 Printed in tngland

Dcn 7-392/C
kaukazz@yahoo.co.uk
4001-4
SCHEMATIC SYMBOLS
20 wrY (18) Schematic Wirc Bcfcrencc Number (20) Color Code (W//) Wire Gauge (18)
A -
Connector With ldentification Numtrers or L-etters Fr:r Example Connector A Pjn or
Terminal A
-uq Component Connector With ldentification Numbers or Letiers
Componcnt Conncctor With ldentif ication Nurnbcr or Letter Sccurcd to lhe Component by
-i@ a Screw or Nut
Conncctor WithoLrt ldcniificaiion Numbcrs or Lctters.
rr-:l Circuits Groundcd D rcct lo thc Battcry Ncgativc Tcrminal

L" -d-
77-777 Circuils Grounded to fraclor Chassis
o Check Point
o Componcnt ldcntification and Location
A Cc:nnecior lcicntiiicatron and Location.
EI Chassis Ground Conncction Location.
Qnn Pann -
WIRE COLOR CODE

R RED
T TAN
/V . . WHITE
Y .. YELLOW
o ORANGE
. VTOLET (PURPLE)
Bn.. BnowN
DB.. . DARK BLUE
LB. . .. LIGHT BLUE
DG ... DABK GREEN
ILV,....,.,..,..
r'l ..IIGHT GREEN
Dor'/-382/A ssued 1 1-92 Printed in England
kaukazz@yahoo.co.uk
4001-5
FUSE AND REI-AY LOCATION
SM0996A
RIGHT HAND FUSE BEI"AY BLOCK
LEFT I-]AND FUSE RELAY BLOCK
Tractors Without Cab

Tractors With Cab
'1
. REAR FENDER WORK LAT/P HELAY
1. REAR FENDER WORK LAMP RELAY
2. OPEN
2, FRONT CAB WORK LAMP RELAY
3. CANOPY WORK LAMPS
3, OPEN
4. OPEN
4, REAR CAB WORK LAMP RELAY
5. FUSES 1 TO 16
5, FUSES '] TO 16
6, FUSES 17 TO 32
6, FUSES 17 TO 32
7. ACCESSOBY POWER BELAY
7. ACCESSORY POWER RELAY
B. WARNING LAMP TEST RELAY
8 WARNING LAMP TEST RETAY RELAY (DIODE
(DIODE 9. FORWARD/REVERSE LATCHING
9. FORWARD/REVEBSE TATCHING RELAY SUPPRESSED)
SUPPRESSED)
10 FOHWARD SOLENOID RELAY
(DIODE SUPPRESSED)
10. FORWARD SOLENOID HELAY (DIODE SUPPRESSED)
11 REVEBSE SOLENOID RELAY (DIODE SUPPRESSED)
11 REVERSE SOLENOID RELAY (DIODE SUPPFESSED)
12 4TH RANGE REVERSE LOCKOUT RETAY
]2, 4TH RANGE REVERSE LOCKOUT HELAY (DIODE SUPPRESSED)
(DIODE SUPPRESSED)
FUSES
FUSE AMPS CIRCUIT FUSE AMPS CIRCUIT
Front Work I amPs (Cab) f17 15 l-lorn, Flasher

F1 15
FlB 5 Foru,rardlReverse Switch
F? 10 Rear WiPer
t19 10 Forward/Reverse Re laY
F3 30 Auxiirary Pcwcr, C:garcttc
F2A 75 Powershlft
Lighter lnlerior LamP
CA 15 Rcar V/ork LarnPs (Cab) F21 7.5 Radio, lstrument Cluster 2
1a
l5 Turn Signal F22 15 Ethcr Start
F5
5 Warning LamPs
tr)2 10 Nl F D Diff Lock
F6
F24 75 lnstrument Cluster 1
F7 5 lmplcmcnt AuxillarY Conncctor
15 Front Windshicld WiPcrMasher f25 5 SPare
FB tr)A 75 SPare
(Circuit Brcakcr)
tro 5 Tail LamPs F27 10 Spare
15 HeadlamP High Bearr F28 15 Spare

l- tu
15 HeacjlamP Low Beam F29 15 SPare
F11
30 lmplerrent Auxiliary Connector F30 I0 SPare
F12
5 lnstrumcntClustcrlllumination' F31 30 KeYed AuxiliarY Power, Seat
F13
r3z 75 Sens-O-Draulic (Sl'1R) Hitch
RH Consolc lamP
Control
F14 15 Fcar fcndcr Work Lamps
t-r 5 l5 l:ront Fcnccr Work LamPs
(Non Cab)
Ft6 10 Fuel Shu:-Of f
Don 7-39270
kaukazz@yahoo.co.uk
4001-6
BULKHEAD CONNECTORS AND LECTRI C OMPONENT LAYOUT
o
./
---
-' l= ]=.\
i[ ,;i \\
il\
<nty'
P1
\\
2i.,r
\, \\
\"
sM0997
Viewed From The Engine
@ @
i-t @
.t,l @ ar=-l
'rui t.-.1
i
L-
\.-2'
z'l \ e
\ :,:: --- / l
\-:, I
P1 \o
"/ SM0998B
Viewed From The Operators Seat
COt\4PONENTS CONNECTORS
1, STARTER RELAY A. TRANSMISSION HARNESS TO INSTRUIUENT PANEL
2, HEADLAMP DIMMER REI.-AY HABNESS
3. AUDIBLE ALABM B. ENGINE HARNESS TO INSTBUMENT PANEL
4. FLASHER RELAY HARNESS
5. CANOPY WORK LAMP OR AIR CONDITIONER C, CAB OR PLATFORM HARNESS TO INSTRUMENT
CIRCUIT BREAKER PANEL HARNESS
6, LEFT HAND FUSE/BELAY BLOCK P1, BATTERY POWER JUNCTION BLOCK
7. RIGHT HAND FUSE/RELAY BLOCK P2. KEYED POWEH JUNCTION BLOCK
8. CHASSIS POWEB RELAY (SECURED TO HARNESS)
Dar 7 39270 issuod 11-932 Printed in Eneland
kaukazz@yahoo.co.uk
4001-7
STARTER, KEY SWITCH, KEYED POWER, FUEL SHUT-OFF

AND ETHER START

Sectional lndex
..8
CIRCUIT TESTING I
Starter Solcnoid Circuit Test .8
Starter Belay Circuit Test . " ' o
Fon,vard/Neutral/Reverse(r.-N.R)SwitchTest(NeutralStart).... .9
Key Switch Test , .. ..
10
Chassis Power Relay Circuit Test (Kcyed Power) 10
Fuei Shut-ofl Circuit Test 1n
Ether Start Circuit Test .. . .
11
SchematicCircuit....
lssucc 11-93 Printcd in Fngland

Don 7-39274
kaukazz@yahoo.co.uk
4001-B
CIRCUIT TESTING
NOTE: The battery must be at f ull charge and all connections must be clean and tight before lesting. lJse a multimeter for
the tesfs.
NOTE: For testing and repair ol the starter motor, scc Scclion 4003 in your senrice manual.

Check Points Reading Possibie Causc of Bad Reading
Q fcrminal for cablc 2 Rcci to gr<-rund 12 Volts Check the battcry cables between the
starlcr motor solenoid terminal B and the
positrvc terminal of ihc battery
NOTE: Put the range lever and the F-N-n lever rn NEUf RAL, disengage the PTO and hold the key in the START pasition
tern,nal for wirc 5 Whitc io ground 12 Volts Check wirc 5 and thc startcr relay circuit
@
NOTE. lf thc readlngs ate correct sec Scclron 4003 and chcck thc slarter molar solcnord
Starter Relay Circuit Test

IMPOBTANT. Only use a high tmpedance multimeter Io lesl lhe starter relay. Do not use a test lamp or damage to the
l--N-R swilch may occur.
NOTE. Turn the kay to the aFF position and ramovc the startcr rclay
Chcck Points Scadrng Possible Causc of Bad Rcading
Gl Terminai for wirc B Brown,&Vhitc io grounc 3 9 OHMS Bad circuit bctwecn thc F-N-R switch
Approxrmatcly tcrminal 4 and thc starter relay terminal 85
Also check thc F-N-R switch circuit
fcrminals ior wirc 5 Whife Con:inurly Check wirc 5 bctwccn the startcr relay
@ :crrrinal 87 and ihc slarter solenord
:ormrnal S
Gl Tcrminal for wire 4 Rcd to ground 12 Volts Check wirc 4 and the battery powe r lunction
block connection
NOTE: Put the range levcr and the F-N-R lever in NEUTRAL, drscngage thc PTO and hold the key to the START position.
formrnal for wirc 7 Whrlc to groL;nr) '1

2 \rolls Bad circuit bctwccn the kcy swilch and lhc
@ startcr rclay Also check thc kcy switch
NOTE: lf the readings are correct replace the starter relay
Do. /'3927A lssucd 1l-93 Printed in England
kaukazz@yahoo.co.uk
4001-9
Forward/Neutral//Reverse (F-N-R) $witch Circuit Test
NOTE: Turn the Key to rhe OFF posltion and remove the starter relay and disconnet the F-N-R switch from the harness al
cannector E.
lMPORTANT..OntyuseahighimpedancemultimetertotesttheF-N-Rswitch. Donotuseatest/ampardamagetathe
switch may occur.
Chcck Pornls Rcadrng Possiblc Cause of Bad Reading
Terminal for wire 11 Brown to ground Continuity Chcck wire 1 1 and the chassis ground
@ connection.
Terminals for wirc 8 Brown,&Vhite Continurty Bad circuit behryeen the starter relay and
G) conncctor E Also check the starter relay
NOTE: Put the F-N-R lever tn the NEUTRAL posttton.

Betwecn terminals 4 and 5 of connccfor E 3 I OHMS Bad F-N-R switch. Also check wires 9
for wires 9 Black "5" and 10 Black 4' Approximately and 10'
NOTE: Put the F-N-R lever in the FORWARD posrtion.

Betwcen terminals 4 and 5 o{ connector E No Continuity Bad F-N-R switch'
ior wires 9 Black "5" and 10 Black "4"
NOTE: Put the F-N-R laver rn the REVERSE posrlron
Between tcrminals 4 and 5 of conncctor E No Continuity Bad F-N-R switch'
for wires 9 Black "5" and 10 Black '4"
Key Switch Test

NOTE: Turn tho kcy to the OFF posrtton
(l ferminal for wtre 6 Red to ground 12 volts Chcck wirc 6 and the batiery power junction
block
NOTE: Disconncct the key svtitch frorn lhc harness and turn thc key 1o the ACCESSORY position
Betwee n terminals BATT and Acc of thc key continuity Bad key switch
switch
Betwecn terminals BATT and IGN of the key continuity Bad key switch,
switch
Betwccn terminals BATT and ACC of lhe kcy continuity Bad key swrtch
switch
NOTE: Hatd the key in the START position.

Betwccn terminals BATT and sTART of ihc continuity Bad key swilch
key switch
Don 7-39274
lssued 1 1-93 Prinled in Englani
kaukazz@yahoo.co.uk
' .,i '; '
I .L'r*j
4001 -1 0
Chassis Power Relay Circuit Test (Keyed power)
(il lrrrlnulfor wire 14 Brown to ground Continuity Check wirc t4 and the chassis ground
conncction
NOTE: Turn the key to the ON positron
@ terminal for wire 13 Red to ground 12 Volts Bad conrrection at thc battcry powcr
junctir:n block Also chcck wirc 3. .1
(E Terminalforwirc 12Rc|lOrangc to ground 12 Volts Chcck wia 12and thc kcy switch
(D fcrminal for wire 15 Bcd/Wnrtc to ground 12 Voits Bad chassis powcr rclay
4l termlnal ior wire i5 Red,ANhrtc to ground 12 Vorrs check wirc t5

NOTE: Chcck Fuse F16.
Check Points
rcgqgg Possible Cause of Bad Reading
Terminal for wire 17 Dar.k Blue/Red to 12 Volts Bad circuit between the key switch and the
ground fuel shut-off solenoid
NOTE: lt' the rcading is correcl chack thc fuel shui-off solenord connection or replace the fuel shut-off solenoid as
oecessa4/.
Ether Staft Circuit Test

NOTE: Disconnect the ether start sotenoid from the harness
Check Pornts Rcading Possible Causc of Bad Reading
Tcrminal ior wirc 21 Brown to ground ContinuinT Check wrre 21 and the chassis ground \-/
conncctton.
NOIE: Turn the key to the ON position and hotd the ether start switch in the ENERGTZED piosition.
Termrnal for wirc 20 Dark BluclWhilc tc 12 Volts Bad circuit betwecn the ether starl solenoid
ground and the ether start switch
NOTE: lf the readings are correct replace the ether start sotenoid
@ I,ejn:"r ror wire le Dark Brue/Grav to 12 Volts Bad circutt betwecn the key switch and the
cthcr start switch
Terr-ninal lor wirc 20 Dark BiucAvhiic to 12 volts Bad cthcr start switch
ground
NOTE: lf the readings are correct check v'rire 21 bewveen the ether start switch and the ether start solenoid.
Dor 7 39270 lssued 11-g3 prinled in England
kaukazz@yahoo.co.uk
4001-1 1
Ether Slart Chassis Power Rday

4001-1 1
Schematic Circuit
Starter ilotor Neutral Start Key Switch Ether Start ll5) -i
&
r3
t9
rt'o R
o
7 W (18) OE'G DBR
(rq (1q
{ eoor-zs
{r3)
H
-T
e
2
B
{:r0)
7 w {18.)
b
DBTT
(r3)
r;;
17
DB/F
(r5)
80 B'1" {18)
'F
m
85 B "6" {18)
oB,w
(r3)
724',2',1181
,0 B "4" {18)
{ roor+.enr
tt
B
(?01
tt
BF
(t8l
X
{ aoor-sorr
COMPONENTS
t BATTERY
@ rurr- sHUT€FF soLENorD ?t
-l
-a
tl
1
@ STARTER MOTOR
@ cHessrs PowER RELAY
@ SIARTER RELAY
(4) KEY SWITCH CONNECTORS

--t
o
.
WARNING LAMP TEST RELAY iffi ENGINE HAHNESS TO INSTRUMENT PANEL HARNESS -x
t'
9E* INSTBUMENT PANEL HARNESS TO REVERSE F.N.R SWITCH

@ F-N-R SWTTCH {W!TH 3.9 OHM RESISTORS}
e ETHER START SWITCH iffi BATIEFY POWEB JUNCTION BLOCK
o ETHER STABT SOLENOID ffi KEYED POWEH JUNCIION BLOCK
o FUSE F19
* NOTE: Ihe F-lrl.F switch is magnetically actuated.
I-: I in England
@ FU$E F22
Fl5 )--
@ FUSE
kaukazz@yahoo.co.uk
Don 7-39270 Issued 11-93 Printed in Enoland

4ffi1-12
ACCESSORY POWER RELAY, ALTERNATOR AND INSTHUMENT CLUSTER

Sectional lndex
tnstument Cluster Power and Ctnssb Ground Clctit Test......."..' """"' 13
tnsrument Clusier Engine RFM Elsphy Circuit Test---.....-..- '..""","""."' 14

Parkirq Brake Warning Lamp Clun Test ..'..-..-.- ."....""'."' 15
l-lydraulic Filter Restrictbn Wnritg Lamp Circtrit Test -..'.'.... ..."....".""' 15
Ai Rner Restiction Waming Lanp C$cuit Test -----.-.- ."."". 16
Wanirg Lamp Test fleby CtoctitTest .........- ..'.'..'..."......." 16
Warritg tamp Diode Mod.deTest-..--..... """"17
qurtd-Speed Radar Circuil Test (Ddue Cluster Only) ..--.'... "."""""" 18
Engirc C@&mtTenrperatrlre Ga;gE Circuit Test ------.---. ""' 19
En6te Oil Plressure Waming Larp Ctcuit Tst ...---.- ."'.".' 19
Burtd Speed Sen$r Clcrn Test (Dduxe Cluster Only) .-....-.. """"""' 2A
rsrrment ctster l(m RPM PIO Dbptay Circtit Test.-...-.--... ..""..'...'..' 20
i,lOTE: For he 4th Frlngelfuvg,eWaming Lamp (tubter Fkshe? .Citcuit Test refer to page 24
i,lOTE: For tE High kan WillW l-amp Ckcuit IeS relbr to page 62-
NOTE: fu the Tum Sigral Wan*g lamp Cicuit Test refer to page 72.
DonT-3927A lssued 11-93 Printed in England

kaukazz@yahoo.co.uk
4001-13
CIRCUIT TESTING
useamultimeterfor
NOTE: Thebatterymustbeatfutt chargeandall connectionsmustbecleanandtightbeforetesring.
powrquadplus
the lest. www.thebestworkshopmanuals.co.uk
lnstrument Cluster Power and Chassis Ground Circuit Test

position.
NOTE: Disconnect the instrument cluster f rom the harness and turn the key to the OFF
Check Point Reading Possible Cause of Bad Readirlg
Prn 31ol the inslrumcni clustcr connectcr Continu ty Check wire 57 and the clean ground
and the battery negative tcrminal (clcan connection at thc battery negativc terminal
ground) (clean ground).
NOTE: Turn the key to the ON Positron
the instrumcnt clustcr conrrcctor to 12 Volis Check wires 33 and 34 Also check the
G) ]f":t keyed power lunction block.
Pin '1 5 of the instrumcnt cltistcr conncctor lo 12 Volls Bad circuit between the accessory power
ground relay terminal 87 and the instrument cluster
connector. Also check the accessory powcr
relay.

Check Points Reading Possible Cause o{ Bad Reading
ferminal for wirc 36 Brown and ground Continuity Check wirc 36 between terminal 85 of the
@ acccssory power relay and thc chassis
ground connection Also check the chassis
ground conncction.
NOTE: Turn the key to the ON Posrtion
for wire 35 Rcd/Dark Siuc tc 12 Volts Check wire 35 between the battery power
6 Tcrminat
lunciion block and the accessory
power
grouno
relay terminal 30 AIso check the battery
power junction block connection
fcrminal for wire 18 RedMhite to ground 12 Volts Bad circuit between the key switch and the
@ accessory power relay terminal 86 Also
Terminal for wirc 37 Rcd/Violct to ground 12 Volts Bad accessory Power relaY
@
T"tnl,nul for wire 37 Red/violet to ground 12 Volts Check wire 37 between the accessory
Gl power relay terminal 87 and fuse F32
lssur:d I l-93 Printcd in England

Don 7 39274
kaukazz@yahoo.co.uk
4001-14
NOTE: Check thc altcrnator warntnq lamp bulb.
Check Polnl Bcad ng Possiblc Causc of Bad Reading
fcrminal for wire 30 Rcd to ground l2 Volts Check wire 30,

0
NOTE: Disconnect wires 37 and 32 from [he allernalor. Make sure the w,lres do not shart ta ground
NOTE: lurn thc kcy to the ON posltion.
re|.minal for wire 31 Yellow to ground l2 Voits Bad circuit betwecn the instrument clustcr
{) and thc altcrnator D t tcrminal. Also chcck
thc inslrumcnl clustcr powcr circuit
NOTE: ll Lhe readings arc corrcct chccx tita altc'natcrscc Sccl/on 40C8 ,;t.t yo,tr Scrvtcc l'/,anual.
NOTE: Turn the kay to the OFF position ancl dtsconnect the tnstrument cluster from the harness
Pin 30 of thc instrumcnt clustcr conncctor con:inuity chcck wtrc 31

and lhc :crminal ior wire 3l Ycllow
lnstrument Cluster Engine RPM Display

NoTE: Use the signal generatarlcaunter for the foilowtng test, refer to Page 3.
NOTE: Disconnect wire 32 yellowlBrown from the alternatar W terminal. Connect a stgnal generator to wire 32 and
praqramme the signat generator to generate a srynal as shown rn the table below (sec manufacturcrs tnstructions) Turn
nekeylo the ONpos ition and press lhe cngtnc rpn luncf.bn bullon on lhe instruntcnl clustcr (dcluxc c/uslcrs only) and
check thc rpnt display an the tnstrumcnt cluslci "Nith tt:e tabla bclow
SIGNAL FROM SIGNAL INSTFUMENT CLUSTEF POSSIBLE CAUSE OF

GENEBATOR BPM DISPLAY BAD READING
Hz RPII
100 BAD INSTRUMENT

302 10ozo
CLUSTER
CHECK WIBE 32 SEE
bu) 2200 10"/"
CHECK POINT 7
NOTE: lf the readings are cofl'ect repair ar replace the alternator, refer to Seclion 4008 in your Service Manual.
NOTE: Turn the key to the OFF positron. cirsconr.ecl lhc trislrumcr'tt clusler lrom the harncss
Ptn 27 OI lhc inslrurnent ClUStCr COnnCCtor ContrnLlrty Chcck wire 32

and the terminal for wire 32 Yellow/Brown
NOTE: lf the readings are carrect check the instrument cluster power and chassis ground circuits, refer to Page 13.
1b..7-39274 lssucc 'l 1 93 'rintei rn England
kaukazz@yahoo.co.uk
4001-15
NOTE: Engage the parking brake, put blocks rn front of and behind the rear wheols.
NOTE: Removeanddisconncctthcparkingbrakeswrchtromtheharness. Makesurewire44doesnotshorltoground
Chcck Points Rcading Possi?le Cause o{, Bad Reading
Betwcen the terminal of thc parking brake Cont nuity Bad parking brake switch.
switch and the swltch Dody
NOTE: Hotd the switch rn thc discngagc pastttan (plunger rn))
Bctween thc terminal of the parking brake No Continuily Bad parking brake switch
switch and the switch body
NOTE; Turn the key to the ON position.
(B Tcrminal for wire 44 Yellow/Black to ground 12 Volts Bad circuit between the instrument clustcr
connector (pin 17) and the parking brakc
swrtch. Also check the warning lamp diodc
module
NOTE: Turn the key to the OFF position, Disconnect the instrument cluster f rom lhe harness and check the parktng brake
warninq lamp bulb.
Terminal Ior wirc 44 Ycllow/Black anC cin 1 7 Coniinurty Check wire 44

of thc ;nst'LrTrcnl clustcr colncctor
Hydraulic Filter Restriction warning Lamp Circuit Test

NOTE: Check the hydraulic ftlter restriction warnrng lamp bulb
NOTE: Ihe lransmrss ion otl must be al normal operatirtg ternperature (above 100' F) and the hydraulic f ilter must be lrcc
fron restrictions, Drsconnect the hydrauticlilter temparatura and rcstriction switchcs from the harness. Turn thc key to
thc ON posrlion
IMPORTANT. Do nor allow the disconneaed termlnal far wire 46 ta shoft ctrcuit to ground.
Check Pornt Bcading Possiblc Cause of Bad Rcading
fEi Tcrrrinal for wire 45 YcllowWiric :o g'ounci 12 \/oiis Bad circuit betwecn the instrument cluster
conncctor (pin 21) and the hydraulic filter
te mperaturc switch. Also check the warning
lamp dlode module
NOTE: lf the reading is correct go to check point 17.
NOTE: Turn the key to the OFF position and disconnect the instrument cluster from the harness
Terrrinal for wirc 45 Yellow4V'trtc a^d prn 21 Continuity Check wire 45

of the instrurnent clustcr connector
NOTE: Conncct the hydraulic temperature switch to the harness.
Terminal for wirc 46 Yellow/Brown io ground 12 Volts Bad hydraulic filter tcmperaturc swltch. Also
@ check wirc 46 between the hydraulic filter
tempcraturc and restriction switches.
Don 7-39270 lssued 11'93 Prinlr:d in England
kaukazz@yahoo.co.uk
4001 -1 6
Check Point Bcading Possible Cause of Bad Reading
Terminal for the hydraulic filtcr restriction No Continuity Bad hydraulic filter restriction switch
switch to ground
Air Filter Restriction Warning Lamp Circuit Test

NOTE. Check the air hlter rcstnction warntng lamp bulb.
NOTE: The air fitter must be f ree f rom restrictrons Disconnect the air f ilter restriction switch f rom the harness and turn the
key to the ON posrtion.
Check Po ni Beading Possible Cause of Bad Readrng
G) Terrninal for wire 47 Dark Grccn to ground 12 Volts Bad circuit betwcen ihe rnstrument cluster
conncclor (pin 29) and the air lilter
rcsiriction switch Also check the warning
lamo diodc modulc
NOTE: ll the readng rs correct go b cnecR point 21
NOTE: Turn thc kcy to tha OFF posilton and clrsconncct thc instrument cluster from the harncss
Tcrn inal for wire 47 Dark Grcen and pin 29 conlinuily chcck wie 47
of the insirument clustcr
tcrminal for wire 48 Brown to ground Continuity Chcck wrrc 48 and the chassis ground
@ conncc:ron
Bctween lhc lerminals oi the air iiltcr No Conlinurty Bad arr filter rcstrlction swilch
rcstriction switch

NOTE: Rcmovc thc lonnard and tcvcr-\a rclaYs
NOTE: Remove the warning tamp test retay. Put the F-N-R lever in FORWARD and hold the key in the START position.
Terminal for wire 7 Whrte to ground 12 Volts Bad crrcurt between the key switch and the
€) warning lamp lest relay Also check the kcy
switch
Terminal for wire 43 Brown/Dark Blue to 12 Volts Bad circuit bctwcen the warning lamp test
ground diode module and the warning lamp test
rclay. Also chcck thc warning lamp diode
module
Flll Tcrrninal for wirc 36 Brown to ground Continuily Chcck wire 36 and thc chassis ground
connection
Do.l 7 3927A lssucd 1 1 93 P:intcd in England
kaukazz@yahoo.co.uk
4001-17
powrquadplus www.thebestworkshopmanuals.co.uk Possible Cause of Bad Rqading

Check Points lselre
6 Terminal {or wire 36 Brown to ground Continuity Check wire 36 between terminals 87 and 85
of the warninq lamp test relay.
NOTE: lf the readings ara correct rcplace the warntng lamp test relay.
NOTE; lf any of the warning tamps fatl to come an, when the F-N-R lever is in forward or reverse and the key is in the start
position, check the warning lamp bulbs. lf the warning tamps still fail to come on, check the warning lamp test diode
module. Also if for example, the alr filter warning lamp comes on, when the parking brake is engaged, check the warnlng
lamp test diode module.
Warning Lamp Diode Module Test

NOTE: Dlsconnect the bulkhead cannectars'A', B'and'C.
NOTE: Disconnect the warning larnp dlode module from the harness and turn the key to the ON position.
Terminal B for wire 44 Yellow/Black of thc I2 Volts Check wire 44 between terminal B of the
module connector to oround module connector and the parking brake
circuit splicc.
Terminai C for wrre 45 YellowMhitc ol thc 12 Volts Check wire 45 between tcrminal C of thc
nrodule connector to ground module connector and the hydraulic filler
restriction switch circuit spllce.
Termina D for wirc 47 Dark Grccn oi tnc 12 Volts Chcck wrrc 47 bctween termlnal D of thc
modLrle connoctor to ground rrodulc connector and the atr filtcr
'csrricrior sw tch circ;it spl cc.
NOTE: Turn the key to the OFF posrlron
f!) nal A fo, wrc 43 Bror,vn/Dark Bluc

1"11r, o1 No Conlinuiiy Chcck lhe warning lamp test relay
tnc modutc conrcc'or lo Q'otrnd
NOTE: Put the F-N-R lever rn the FORWARD positton and hold the key in the SIARI position.
Terminal A for wirc 43 Brown/Dark Bluc of Continuity Check wire 43 between terminal A of thc
the module conneclor to ground module connector and the warning lamp
lest re ay terminal 30. Also chcck thc
warning lamp test relay
NOTE: Turn the key to the OFF pasition.
NOTE: The negative lead of the multimeter must ga to terminal A af the diode module.
Bclwcen thc lcrnrrnals 3 and A o1 thc tliodc Contrnuity Bad drodc module
nrodulc
Bctwccn the terminais C and A o'thc dtodo Continuity Baci diode module
module
Bctwecn the terminals D and A of thc dlode Continuity Bad diodc module
modulc
Don 7-39270 lssued 1l-93 Printed n Fngland
kaukazz@yahoo.co.uk
4001 1B
Bclwccn thc termrnals E and A oi thc diodc No Continuity Bad dlode module.
modulc
Bctween tho tcrminals F and A of thc diodc No Continuity Bad diode modulc.
module
NOTE: Change the leads of the multimeter over so the posrlive lead of the multimeter goes lo terminal A of the diode
nodule
Belween the tcrmtnals A ancl B of :hc diodc No Continui:y Bad diode module
rnodule
Bctwecn the tcrminals A and C of the diode No Continuity Bad diodc modulc
module
Bctwecn ihc tcrminals A and D of ihc diodc No Con:inuity Bad diodc rnodulc
moduie
Bctween thc tcrminals A and E of thc diodc No Coniinuiiy Bad diode modulc
modulc
Bchtrccn the terminals A and F oi the diodc No Continuity Bad diode module
modulc
Ground Speed Radar Circuit Test (Deluxe lnstrument Cluster only)

NOTE: Turn the key to the OFF posiion and disconnect the tnstrument cluster and the ground speed radar from the
L^--^^^
(tl) Tcrm,nal for wirc 39 Brown/Light Grccn to Continuity Bad circuit bctween thc instrumcnt cluster
Y o,t,, 2o o'tnc'ns:rLmcr': cr-s;cl connector pin 26 and thc radar conncctor
tcrn:lrlal A.
Terminai for wirc 40 l_ight Grccn to oin 33 ol Continurty Bad circuit bctwccn the instrument cluster
thc instrument clustcr conncctor pin 33 and the radar connector
terminal B
Tcrminal for wire 41 Light Green/Rcd lo pin 3 Continuiry Bad circuit betwcen the instrument clustcr
o{ thc instrurncnl clustcr conncctor pin 3 and thc radar connector
:crminai C.
@ fcr-,nal. for wjre 42 Light Grocn,Ycllow to ContinuilT Bad circuit bctwccn the instrument cluster
prn 37 oI thc inslrumc^1 cluslcr connector pin 37 and the radar conncctor
terminai D
Dor 7 39270 lssuco 11-93 Printcd in Enqland
kaukazz@yahoo.co.uk
4001 -1 I
NOTE: Disconnect the engtne coolant sender from the harness and turn the key ta the ON position.
Terminal for wire 49 Uark Green/Black to 48 Volts Bad circuit between the enqine tempcraturc
ground Approximately sendcr and the instrument cluster
NOTE: lf the reading ts correct replace the engtne caolant [emperature sender
NOTE: Disconnect the tnslrumenl cluster frorn the harness.
Tcrminal for wrrc 49 Dark GrccnlB ack to pin Continuity Check wire 49 between coolant
'1
6 of the instrumenl cluster conncctor tcmpcrature sender and the lnslrumcnl
clustcr connector.
NOTE: lf the readings are carrect checkthe tnstrument cluster pawer and chassrs ground circuits, referto Page 13.

NOTE: Disconnect the oil pressrtre switch from the harness.
NOTE: Turn the key to the ON posttian
6D Tcrminal for wrre 5O Light Bluo to ground 12 Volts Bad circuit betwee n the oil pressure switch
and thc instrumcnt cluster connector
NOTE: lf the reading ls carrect check the orl pressure swlch
NOTE: Turn the kcy tt: the OFF posttion and chcck the otl prassurc warnrng lantp bulb
NOTE: Discannect the tnstrument cluster from the harness
Tcrmrnal for wirc 50 Liqht Bluc to pin 34 of Continuity Chcck wrrc 50

lhc instrumcnt clustcr connccior
NOTE: lf the readings are carrcct chcck the instrument clustar pawcr and chassis ground ctrcuit, refer to page 13

Check Pornts Rcading Possiblc Cause of Bad Reading
Bctwccn thc terminal ol thc oil prcssurc Conlinuity Bad enginc oil pressure switch.
switch to ground
NOTE: Start and run the engine at 1500 rpm
BeNvccn thc terminar of thc oil pressurc No Continuity Bad cngine oil prcssure switch or no oil
swrtch to ground pressure
WARNING: Never operate the engine rn a closed building, proper ventilation is required under all
circumstances .
Dcn 7-3927a lssued 11'93 Printed in England
kaukazz@yahoo.co.uk
AAU-20
Ground Speed Sensor Circuit Test (Deluxe lnstrument Cluster only)
NOTE: Disconnect the ground speed sensor from the harness.
Check Points Reading Possible Causc of Bad Reading
6l!l Terminal for wire 52 Brown ground Continuity Chcck wire 52 and the chassis ground
connection.
Bctwccn tcrminals A and B of thc ground 2925 to 3575 Bad ground speed scnsor
spccd sensor Ohms at
Boom Tcmpcraiurc
NOTE: Disconnect the instrument cluster lrom the harness
Tcrminal for wirc 51 Ycllow/Dark Blue to pin Continurly Citcck wirc 51 bctwccn the ground sensor
28 ol lhc inslrumcnt clustcr conncctor and thc instrumcnt cluster connector
NOTE: ll the reaclings are correcl adltts[ or reStlace the gtrrotind speed Sensor.

NOTE: Turn the key to the OFF position and disconnect the 1000 rpm PTO switch from the harness.
Chcck Points Bcading Possible Cause of Bad Reading
Tcrminal for wire 54 Brown,Mhilc to ground Continuity Chcck wirc 54 and the battery negativc
@ terminal conncction.
NOTE: Put the PTO output shaft in the 1000 rpm postt,on.
Betwecn the tcrminals of lhc 1000 rcm PTO Continuity Bad 1000 rpm PTO switch
switch
NOTE: Put the PTO output shall rn the 540 rpm posttron
Between thc tcrminals ol thc 1000 rpm PTO No Continuity Bad 1000 rpm PTO switch
switch
NOTE: Disconnect the instrurrtent clustcr lram the harncss.
Terrninal for wrrc 53 yellow/Dark Grocn and Contrnuity Chcck wirc 53 bctwocn thc 1000 rpm PTO
Pin 22 oi thc instrumcnt clustcr conncctor switch and thc instrument cluster
connector.
NOTE: tf the reading is correct check the instrument c/usler power and chassrs ground circufts, refer to page 13.
Don i-39270 lssucd 1 1-93 Printed in England
kaukazz@yahoo.co.uk
4001-21
Fuel Level Sender Circuit Test
NOTE: Turn the key to the OFF position and disconnect the fuel level sender from the harness
rerminal for wire 56 Brown io ground Continulty Check wire 56.

@
NOTE: Turn the key to the ON Position
Tcrminal {or wirc 55 ycllow/Lrght Blue to 4.8 volts Chcck wire 55 between the fuel level sender
ground Apcroximatcly and the instrurnent cluster connectol
NOTE: Turn the key to the OFF position and disconnect the instrument cluster from the harness.
Terminal for wire 55 Yellow/Lrght Bluc to pin Continurty Check wire 55

23 o{ the instrument clustcr connector
cluster
NOTE: tf the readings are correct check the fuel level sender reler to Section 3005 Also check the instrument
power and chassl's ground circuits, ret'er to page 7 3.
Don 7-39270
kaukazz@yahoo.co.uk
Ll-)t t' -?)
n-- 7 lQrTrl lssucc I 1-93 Printed ir Englancl
kaukazz@yahoo.co.uk
4001-23
Schematic Gircuit
Altemator Accessory Power Relay lnstrument GlusterWarning Lamps and Gaugeo
*ffi
{ *oror
3r Y 06)
gt v oot---fiTFTaf- sr v (ro)
32 Y,BR (18)
szvrsnire) -{EEF 32 YiBR (
r r{t6)r r-(16l-r. 34 Y/R fi6) 34 Y/8 O6)
5o 1o )e
38 O {r8} 38 O {r8)
39 8R/LG (18)
qrb
ffi
09 BR/LG {18} 39 BR/LG 118]
40 LC (r8! 40 LC {18}
3rl 6
40 LG {'r8}
dl LG/R {18) 4'l LGi/B tr8, 41 LGUA (18)
YI R
.'rl t6)
{ aoor-roz-{ 42 LG/Y {rS} 42 LG/Y fl8} 42 LG/Y 0S)
i{E
L- rr4 Y/B {r8} 44 YrS {18}
45Y,W(18) 45 Yflu (18) 45 Ylri, {r8}
--__-{F--
4TDGirs)- 47 OG fl8) 4? OG flB)
49 OGi/B (18) 4r, DG/B (r8)
45 47 50 LB (r8) 50 LB {r8}
35 YAY DG n,
(r8)
J&
R/DA {rq ts)
{r3} R/\'
{r5)
ffig ,#im s3 Y/OG {18}
TI
I
{mor*s h s5 YILB (r8)
I
4s vna, (r8l r 55 { coor+s
l
,8 R/W ('16) I 5r
Y,LB
30
R
{n
{ oot-os
07 B
'
t15)
4? DG (18)
(D't"
t'lt I
I
15
/w
l8)
t18!
BR'W
(r3)
{ *oor.t Q. J,
{ mor.rr /l
a7
B/V
(10
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Y'B
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36 (r8)
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COMPONENTS
o STARTER MOTOR (, WARNING LAMP DIODE MODULE @ rr.rsrnuurENT cLUSTER coNNEcroR
c ALTEBNATOR (z) AUDIBLE ALABM
o KEY SWITCH (, PARKING BRAKE SWITCH

CONNECTOBS
c
.RUMENT
HYDRAULIC FILTER TEMPERATURE SWITCH ffi rnar.rslrrssoN HABNEss ro INsTRUMENT
FUSE F19
@ PANEL HARNESS
HYDRAULIC FILTER RESTRICTION SWITCH
@ FUSE F17
@ ffi eNorNe HARNEss ro INSTRUMENT T
PANEL HARNESS
GROUND SPEED RADAR CONNECTOR
@ FUSE F32
@
FUSE F3O aa AIR FILTER RESTRICTION SWITCH
ffi CeE HAHNESS TO INSTRUMENT PANEL HARNESS {NEL HARNESS
@ ro
.ffi rneNsrrusstoN HARNESS GBouND sPEED )UND SPEED
SNGINE COOLANT TEMPERATURE SENDER
@ FUSE F2O
@ RADAH HARNESS
@ FUSE F21 (9 ENGINE OIL PHESSURE SWITCH ffi BATTERY POWER JUNCTION BLOCK )K
GROUND SPEED SENSOB

@ FUSE F24
@ iGE KEYED POWER JUNCTION BLOCK
e ACCE$SOBY POWER RELAY

kaukazz@yahoo.co.uk
6B 1OOO BPM PTO SWITCH
WARNING LAMP TESI RETAY FUEL LEVELSENDER

@ @ lssued 11-93 Printed in England
Don 749274
4001-24
FORWARDIN EUTRAUHEVERSE (F-N-R)

AND TRANSMISSION CONTROL
Sectional lndex
Fonvard/Fleverse Suppression Diode Module Circuit Test............ ............26
Tes1............
Fonryard/Neutral/Reverse (F-N-H) Switch Circuit ....................28
Forward/Reverse Latching Helay CircuitTes1............. ............29
Tes1.....,.......
Forward/Reverse Latching Relay Diode Module Circuit ........30
Tes1.............
4th Range Switch (Reverse Lockout) Circuit ...........,........,....31
Audible Alarm Diode Module Circuit Test............ ..................33

kaukazz@yahoo.co.uk
4001-25
powrquadplus www.thebestworkshopmanuals.co.uk CIRCUIT TESTING

NOTE: The battery must be atf ull charge and altconnections must be clean and tight before tesllng. Use a multimete r for
the tesl.

NOTE: Check luses F1B and F19
NOTE: Turn the key to the aFF position ancl disconnect the forward solenold and the forvvardlreverse suppresston diodc
module from harness.
Check Point Re ading Possible Cause of Bad Readlng
Bctwccn tcrminals A and B ol lhc lcrward 7 to 15 Ohms Bad forward solenoid

solcnoid at Boom
Tcmpcrature
Q connection.
NOTE: Put the F-N-R lever tn the FOBWARD position and turn the key to the ON position
ferminal for wire 87 Light Blue to ground 0 Volts Check lorward relay circuit
@
NOTE: Put the F-N-R lever in the NEUTRAL position and then back rnto the FORWARD position
Terminal for wirc 87 Light Biuc to ground I2 Volts Bad circuit bctween thc forward relay and
Gl the orward solenoid Also check the
f
fonvard rclay circuit
tern,,ual 1or wirc B7 Lrght Bluc lo ground 12 Volls Bad circuit bctween thc forward/reverse
@ suppression diode module connector
terminal D and the sPlice
NOTE: lf the readinqs are Carrect check the forvvardlreverse suppress/on diode module, refer to page 26

NOTE: Check fuses F18 and F19
NOTE: Turn the key to the OFF position and disconnect the reverse solenoid and the foruard lreverse suppression diode
module from harness.
Chcck Point Rcading Possiblc Cause of Bad Rcading
Bctwcen terminals A and B of the rcvcrsc 7 to 15 Ohms Bad reversc solenord

solenoid at Room
Tempe raturc
ferminal for wirc 85 Brown io ground Ccntinuity Chcck wirc 85 and the chassis ground
O con nectton.
Dcn 7-3927C lssucd 1l-93 Prrnted rn fngland
kaukazz@yahoo.co.uk
4041-26
NOTE: Put the F-N-R lever in the REVERSE posltion and turn the key to the ON position
Terminal for wire 84 Lrght Eluc/Black to 0 Volts Check rcversc relay circuil
ground
NOTE: Put the F-N-R lever in the NEUTRAL position and then back into the REVERSE position.
Tcrminal for wrre 84 Light Bluc/Black to 12 Volts Bad circurt betwecn the reverse relay and
ground thc rcve rsc solcnoid Also che ck the
forward rclay circuit
Tcrminal for wrre 84 Light Bluc/Black to 12 Volts Bad circuit betwccn the forward/revcrse
ground supprcssion diodc module connector
tcrminal C thc splicc.
NOTE: ll the readings arc correct chack lhe lorwardlrcverse supprcssion dtodc module crrcutt.
Forward/Reverse Suppression Diode Module Circuit Test

NOTE: Turn the key to the OFF position and disconnect the lonuardlreverse suppression diode module from the harness
Check Point Rcading Possible Cause of Bad Reading
@ tcrminal for wire 89 Brown to ground Continuity Chcck wrro Bg and thc chassis ground
conncction.
NOTE: The positive lead of the multimeler must to terminal C of the diode module.
Bctwccn terrninals A and 3 oi lhc diodc Continurly Bad diodc modulc

module
Bctwcen tcrminals A and C of thc diodc Continurty Bad drodc modulc

modulc
NOTE: Chanqe the leads over so the negative /ead goes to termrnal C ot the diode module
Bclwccn Lcrminals C and A of li'rc diodc No Conlinuity Bad diodc modulc

modulc
Bctwecn tcrminais B and A of thc diode No Continuity Bad diode modulc.

module
)o.t 7-3927a lssued 11-93 Printed in Enqland
kaukazz@yahoo.co.uk
4001-27
Forward Relay Circuit Test
NOTE: Turn the key to the OFF position and check fuses F7B and F19-
Chcck Point Reading Possible Cause of Bad Readtng
Tcrmrnal for wrrc 75 Brown to ground Continurly Bad chassis ground circuit Also check the
O chassis ground connection.
NOTE: Put the F-N-B tever in the FOBWA7D posttion and turn the key ta the ON position
Volts Check the forward/reverse latching relay

O J:;n:'r ror wirc 76 white/Lisht Bruc tcr 0
and F-N-R switch circuits.
NOTE: Put lhc F-N-R lcver in ihc NEUTRAL posrtion anC then back into the FORWARD position
Terminal for wire 76 Whitcit ight Bluo to 12 Volts Bad circuit between the forward/reversc
ground latching rclay terminal 87 and the foruvard
rclay terminal 30 Also check thc
forward/revcrse latching relay,
Tcrrrinal for wire BO Rcrj/Lrght Bluc io 12 Volts Chcck wiro 86 bctween the F-N-R switch
ground terminal 6 and the forward relay terminal 86
Also check the F-N-R switch.
terminal for wirc 87 Light Blue to ground 12 Volts Bad forward rclay
@
NOTE: lf the readings are correct check tlte auclrble alarm suppression diodc module circuit, refer to page 33
Reverse Relay Circuit Test

NOTE: Turn the key lo the OFF position and put the range lever in NEUTRAL 1ST,2ND, or 3BD range.
NOTE: Check tuses F1B and F19 and rerrtove the reverse relay
Check Pornt Rcadrng Possible Cause of Bad Reading
t) Termlnal for wirc 83 Brown,4Vhitc to ground Continurty Bad chassis ground circuit. Also chcck thc
4th rangc/revcrse lockout relay and thc
NOTE: Put the range lever in 4TH RANGE. Turn the key to the ON posttion and put the F-N-R lever rn the rcverse posttton
(D Terminal for wirc 83 Brown,AlVhitc to grouncl No Coniinuity Check thc 4th range/revcrso lockoul relay
and thc 4th range switch.
NOTE: Turn the key to the OFF position then back to the aN positron
Tcrminal for wirc 76 White/Light Bluc to 0 Vo ts Chcck thc forward/reverse latching re lay
G) grouno and F-N B swich circuits
NOTE: Put thc rangc lever rn NEUTRAL
Do't 7 39270 lssued 11-93 Printed in England
kaukazz@yahoo.co.uk
4001 -28
NOTE: Put the F-N-R lever rn the NELJTRAL position and then back rnto the REVERSE positton
Tcrminal for wire 76 Whrtc/Light Bluc to 12 Volts Check wirc 76 beMeen terminals 30 of thc
ground foru,uard and reverse relays Also check thc
forward rclay circuit.
Tcrminal for wirc 79 Red/Dark Bluc tr.: 12 Volts Check wire 79 between the F-N-R switch
ground terminal 1 and the reverse relay terminal 86
AIso ohcck the F-N-R switch.
JB Terminal ior wrrc 84 t-ight Bluc/Black to 12 Volts Bad rcvcrsc rclay

Y grouno
NOTE: tl the readings are correct check the audtble alarm drode module ctrcutt, refer to page 33
Forward/NeutraliReverse (F-N-R) Switch Circuit Test

NOTE: Turn the key to the OFF positron and check fuse F1B.
NOTE: Disconnect the F-N-R switch trom the harness at connector E and turn the key to the ON position.
Chcck Poinl Rcadrnq Possiblc Causc of Bad Beading
dh Tcrmnal for wire 71 Whrtc/Rcd to ground 12 Volts Bad crrcuit betwccn the key switch and the
F-N-R switch tcrminal 2. Also check the key
switch, refcr to page 7.
NOTE: Turn the key to the OFF position and put the F-N-R switch rn the NEUTRAL position
IMPORTANI .Onlyusaalirgltrrnpcdancentullirnalcriolcs[IhcF-N'Eswtlch DONOfi,,sealestlampordamagetathe

swilch may occur.
Belween tcrminals 2 and 3 for wircs 72 39 Ohms Bad F-N-R switch.

Black "2" and 73 Black 3' of conncctor f
Betwecn tcrminais 2 and 1 for wircs 72 No Continuily Bad F-N-R swrtch
Black '2' and B0 Black "l ol conncclor E
Bctween tcrminals 2 and 6 ior wrcs 72, No Contrnuity Bad F-N-R switch.
Black "2" and 85 B ack "6' of connccior E
NOTE: Put the F-N-R switch in the FORWARD position
Between terminals 2 and 3 lor wtres 72 No Contrnuity Bad F-N-B switch.

Black r'2' and 73 Black "3" of cortncclor F
Bclwecn tcrmrnals 2 and 1 lor wircs 72 No Conlinuity Bad F-N-R switch

Black "2" and B0 Black "1" of conncctor E
Betwecn terminals 2 and 6 fot' wircs 72 39 Ohms Bad F-N-R switch.

Black '2' and 85 Black '6' o; connector E
l'.. 7 'lo)aA lssued 1 1-93 Printed in England
kaukazz@yahoo.co.uk
4001-29
powrquadplus www.thebestworkshopmanuals.co.uk posllion.

NOTE: Put the F-N-R lever in the REVERSE
Bclween terminals 2 and 3 for wircs 72 No Continulty Bad F-N-R switch

Black "2" and 73 Black "3" d1 connector E
Between tcrminals 2 and 6 for wtres 72 No Continuity Bad F-N-R switch

Black "2 and 85 Black '6 of conncctor E
Beiween terminals 2 anrl 1 for wires 72 39 Ohms Bad F-N-R switch

Black "2" and 80 Black "1" of connector E
Forward/Reverse Latching Flelay Circuit Test

NOTE: Turn the key to the OFF positton and check |use F19.
Chcck Pornt Bcadinq Possible Cause of Bad Reading
ferminal for wire 75 Brown to ground Contlnuity Bad chassis ground circuit. Also check the
@ chassis ground connectlon.
NOTE: put the F-N-R lever in the FORWARD position ancJ turn the key to the ON positlon
lD Terminal for wire z0 Whrtc/Bed to ground 12 Volts Bad circuit betwcen the key switch and thc
forward/rcvcrse latching relay terminal 30
Also chcck thc key switch, refcr to page 7.
ror wire 77 Yettow,ark BIuc ro 12 Volts Bad forward/rcvcrse latching relay.

@ ;:;n:'r
Terrninal lor wirc 74 Whilc/Dark Bluc to 0 Volis Chcck the F-N-R switch
ground
NOTE: Put the F-N-R tever rn the NEUTRAL posirion
to Volts Bad circuit between the F-N-R

ground
switch
Te rminal for wrrc 74 Whrtc/Dark Blue 12
,N."'3[3'1,1:['TJ'.|L:3
::,fi",l,:il?
switch
Termrnai for wire 76 White/L-iqht Bluc to 12 Volts Bad forward/rcverse latching relay
ground
NOTE: Put the F-N'R lever tn the FORWARD posttion
Termrnal for wirc 74 Whrte/Dark Blue to 12 Volts Bad circuit between terminals 87 and 86 ol
ground thc forward/rcverse latching relay. Also
chcck thc forward/revcrse latchlng rclay
drode module
Don'/-39270
lssued '1
1-93 Prlnted in England
kaukazz@yahoo.co.uk
4001 30
Forward/Reverse Latching Belay Diode Module Circuit Test
NOTE: Turn the key to thc OFF position and dtsconnact the lorv'tardlrcvcrsc latchrng relay diode module from lhe
harness.
NOTE: Put the F-N-R lever in the NEUTRAL positron and turn the key to the ON positron.
Tcrminal lor wire 74 White/Dark Biuc to 12Volts ChcckwireT4bciweentheforward/rcvcrsc

ground alchrng rclay lerminal 86 and lhe diodc
rnodulc connector tcrminal F
ror wirc 76 whr:c'lLrEht Biuc :o

.l
2 Volls Chccx wirc 76 bctwccn the forward/reversc
@ IXn:'l iatching rclay tcrminal 87 and the diodc
modulc conncctor terminal E. Also chcck
thc iatching relay.
NOTE: Turn the key to the OFF pcsitnn
NOTE: The positive lead of the multimeter musl go ta termtnal E of the diade module
Betwccn tcrminals E and I. of the diode Continuity Bad diode modulc.

modulc
NOTE: Changc tha lcads ovar so thc positivc laad al thc mullrrneter rnusl ga to [crminal F of tha diode module.
Bctwccn terminals F and E oi the dtodc No Conlinuity Bad drode modulc.

modulc
NOTE: Make sure there rs NO CONI/,AiUlW between termtnal E or F and any of the rematnrng terminals of the diode
rnodule.
4th Fange Reverse Lockout Relay and

4th Range Reverse Warning Lamp (Master Flasher) Circuit Test
IMPORTANT'. Only use a high impedence multimeter to check the 4th range reverse lockout relay. DO,A/Of use a lesl
o me 4th [ange s"vtrari n)ay acct:
tar)p ot ceff,age
NOTE: ttLrn the key to thc OFF pasition and rcrnovc lhc 4th range reverse lockoul and reverse relays.
NOTE: Put the range lever in the 4th rangc postltan
Chcck Poinl Rcading Possiblc Causc of Bad Reading
-l-crminal
for wire 81 PinVBrown to gror,nd 39 Onrns Bad chassis qround circuit Also chcck thc
4l Aporoximalcly 4lh rangc switch.
NOTE: Move the range lcver rnto the NEUTRAL pastuon
F]F Tcrminal for wirc B1 PinrvBrown to grcund No Con:inuity Chcck the 4tn range switch
PIi T"rr,nrl for wire 75 Brown to ground Con:inuily Chcck wirc 75 and the chassis ground
corrcclion
Dox 7-39270 lssued'l 1-93 Printed n England
kaukazz@yahoo.co.uk
4001,31
NOTE: Disconnect the instrumenl c/usler from the harness
Tcrmrnal for wirc 84 pink/Red and pin 4 of Continuity Check wire 84 between the instrument
the rnstrument cluster connector cluster connector pin 4 and the lockout relay
terminal 87.
NOTE; Turn the key to the ON positron ancl put the F-N-R lever rn the BEVERSF position
Tcrminal for wirc 79 RcdiDark Bluc to 12 Vots Bad circuit betwccn the F-N-B switch
.1
ground tcrminal and the lockout relay terminal BO
Also check the F-N-R switch.
PII rerminals for wire 83 Brown,Mhite Continuity Check wire 83.
NOTE: lnstatl the 4th range lockaut retay ancl put the range lever in the 4TH RANGE positron
(}) Terminal for wire 83 Brownryhitc to ground No Continuity Bad lockout rclay
Pln 4 of ihe Instrument cluster conncctor to Continuity Bad lockout rclay

ground
NOTE: lf the readings are corrcct chcck thc instrument cluster powcr and chassis ground circuits, refer lo page 13-
4th Range Switch (Reverse Lockout) Circuit Test

IMpORTANT.. Only use a hrgh rmpedence multimeterto checkthe 4th range switch. DO NOT use atest lamp or damage
ta the 4th range swltch maY occur
in the
NOTE. Turn thc key to tha OFF posttnn disconnect lhc 4th range switch fram thc harncss and put the range lever
4th ranqc posllion.
Check Poinl Bcading Possible Causc of Bad Reading
Term,nal for wirc 82 Brown to ground Continuity Check wire 82 and the chassis ground
@ conncction
Belween terminals i anrj 3 of the 4tir range 3.9 Ohms Bad 4th range switch . Adlust or replace the
switch switch as neccssary, refer to Section 9001
NOTE: Move the range lever into the NEUTBAL pasitian.
Betwccn lcrmrnals I and 3 of ihe 4th rangc No Continuity Bad 4th range switch . Adiust or replace the
switch switch as neccssary, refcr to Scction 9001
NOTE: lf the readings correct check the circuit bevvccn the 4th range lockout relay terminal 85 and the 4th range
ar1-
switch terminal 1. Also check the 4th range lockout relay
Dat 7 39270 lssued 11-93 Printed in England
kaukazz@yahoo.co.uk
4001 -32
Neutral lndicator Lamp Circuit Test
NOTE: Turn the key to the OFF posltion and check the neutral indicator bulb
tcrrninal for wirc 78 Brown to grouncl Continuity Bad chassis ground circuit. Also check the
O chassis ground connection.
NOTE: Put the F-N-B lever in the FORWARD positton and turn the key to the ON position
Tcrminar for wirc 77 Ycllow,tDark Bruc io 12 Volts Chcck wtrc77 betwccn the forward/reverse
qround latching rclay tcrminal B7A and the neutral
rndicator lamp. Also check thc latching
rclay.
NOTE: Put thc F N-R lever in thc NEUTRAL posrtron
Torminal lor wire 77 YallowlOark Bluc to 0 Volts Chcck thc latching relay circuit
ground
Reverse Indicator Lamp Circuit Test

NOTE: TtLrn lhc key to thc OFF positrcrt anC chcck fhc rcvcrsc indicator bulb.
Chcck Pornl RcaC ng Possiblc Causc of Bad Readrng
6E) Tcrrninal for wire 7B Brown lo ground Continuity Bad chassis ground circuit Also check thc
chassis oround connection.
NOTE: Put the F-N-R levcr tn thc NELJIRAL position and turn thc kcy lo lhc ON position
NOTE: Fut the F-N-R lever in the REVERS,s o:.s'l,or
Termrnal for wire 84 Light BluelBlack to 12 Volis Check wirc 84 bctween thc reverse rclay
ground terminal 87 and the reversc indicator lamp
Also chcck thc rcverse relay.

NOTE: Turn the key to the OFF posttron and disconnect the audible alarm f rom lhe harness. Make sure the parkrng brake
ts engaged
Chcck Poini Rcading Possiblc Causc of Bad Reading
6fl Tcrmlnal for wirc 44 Ycllow/Black to grouncl Ccntrnurtv Bad chassis ground crrcuit. Also check thc
oarking brakc switch, rcfcr io pagc '1 5
NOTE; Put the F-N-R lever rn rhe NEUTRAL positton arid turn the key to the ON positon.
NOTE: Put the F-N-R lever in rhe FORWARD posttrort.
Tcrminal lor wire 90 WhrtclDark Bluc to 12 Volts Bad crrcuit betwccn the forward relay
ground terminal B7 and thc audible alarm Also
chcck lhc audrblc alarm diodc module
l)::' ,'-3927a lssucC I 1-93 Prinled in fnglanC
kaukazz@yahoo.co.uk
4001 -33
NOTE: Put the F-N-R lever in the REVERSE posrlion
Check Poinl Reading Possjble 9ayse of Ba{Heqding
Terminal ior wire 90 White/Dark Blue to 12 Volts Bad circuit between the reverse relay
ground tcrminal 87 and the audible alarm, Also
check the audiblc alarm/auxiliary power
diode module.
NOTE: l{ the readings are correct replace the audible alarm.
Audible Alarm Diode Module Circuit Test

NOTE: Turn the key to the OFF posilion and disconnect the audrble alarm diode module from the harness
6D T"rmnrls for wire 90 Whitc/Dark Blue Continuity Check wire g0.
NOTE: Put the F-N-R lever in the NEUTRAL position and turn the key to the ON position
NOTE: Put the F-N-R lever in the FORWARD position.
@ Terminal for wire 87 Light Bluc to ground 12 Volts Bad circuit between the forward relay
terminal 87 and the diode module.
NOTE: Put the F-N-R lever in the RFVERSE oosition
@;ml'i for wire 84 Lisht Bluc/Black to 12 Volts Bad circuit betwecn the revcrse rclay
terminal 87 and the diode module,
NOTE: Turn the kcy to the aFF posilion.
NOTE: The negative lead of the multimeter must gtro to tcrminal F- of the diodc module.
Betwccn terminals D and E of ihe diodc Continuity Bad diodc module.

modulc
Between terminals F and E of the diode Continuity Bad diode module,

module
NOTE: Change the leads of the multrmeter over so the positive lead goes to terminal E of the diode module.
Between terminals E and D of thc drodc No Continuity Bad diode module

modulc
Between terminals E and F of thc drode No Conlinuity Bad diode module

module
NOTE: Make sure there ts No Conttnuity between the terminals A, B or C and termrnals D, E or F of the dioda module
Dan /-39270 lssued l1-93 Pnnted in England
kaukazz@yahoo.co.uk
Ll.n I .192i0 lSsuCC '1,93 Printcd :r Enqla.C
kaukazz@yahoo.co.uk
4001-35
powrquadplus www.thebestworkshopmanuals.co.uk Schematic Circuit

4TH Range Reverse Lockout Re:ay Fo rward/Reverse Latching BelaY
Fonrard/Reverse (F-l&R) Switch Reverse Relay and Solenoid Fonrard Belay and Solenoid
70wrn (16)
71 lrerR {16) ?1 w/8 (101
I 86 R/lA (r8) 86 FyLE {16)
6 70 7l 79 RIOS (r8) 79 n OB (1S)
?9 n DB (1e'
B w/R WR 74 R/DB (16)--:-
00t tr6) (r6l
74 A/D8 (rO 76wLB {r5) -
80 B "1' flq
{ coor-rr
75
- f4.*,.* 85 B *6"'(181
76wLA {16}
BR
72 B'2' (r8,
(18)
r0 B "4" fl8)
{ ooor-r I
eb
is d aoor-rr
E/.W ?5176 67 LE (rq ----l
Ir-:t(,)
.
)"#
-
(16) BB IW/LS 94 LsB il6) I
-BtLryB(16)---r
i. 83 BR/W (r8)
I @{* 75 BB tr8)
rbt
87 LB {18}
lY; #HEH
l9 -_-
?6 w/LB {16)
18 ljl ISffi BElil
76 lr/LB (16l
06) |
80 t18)
n il, lvl
*f-sl'1'1" - 83 ES,W t18) s4 LB/B I
(r6) 84 Lgr/B (18)
-
p/BR (.rB)
?5BBflq - 84 LAIB (r8) ooJ
(16)1
ww
75 8R tr8)
-o."
18
4oor-23 I
L71
|
I
(D(
-
87 r.a {t8} 8? LB {18) a,
LA
I
*,-ruurr-\-
@)ffi 8l PIBR {r3}
\--
{r0}
t____J
{ aoor.sr
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*&
4r*r-,0.J rn
l^1 T
75
B8
{t8} *"gqlvl lvl
- -f,-oatAuay ,,,X ffi @ "l
Hl
ff
I
I
AR 3t
{16}
6{*"*u., {16}
COMPONENTS
r.l ) KEY SWITCH

o NEUTRAL INDICATOR LAMP FORWABD/BEVERS
DIODE MODULE
ERSE SUPPRESSION
e FUSE F19
@ DIFF LOCK WARNING LAMP
@ ronwanDSoLENo
@ FUSE F18
C nevensE rNDrcAToR LAMP
c ACCESSORY POWER RELAY

@ POWERSHIFT FAULT WABNING I.AMP CONNECTOBS
@ 4TH RANGE REVERSE LOCKOUT RELAY

o LATCHING RELAY DIODE MODULE ffi TRANSMISSICN HAI
HARNESS TO INSTRUMENT PANEL HARNESS
@ FORWARDIREVERSE LATCHING RELAY

@ AUDIBLE ALABM DIODE MODULE ffi CABIPLATFOHM HA IHARNESS TO INSTRUMENT PANEL HARNESS
@ REVERSE BELAY
e FOBWARDINEUTBAUHEVERSE (F-N.R} SWITCH
WITH 8.9 OHM RESISTORS
Iffi
rtlgY
TRANSMISSION HAI
HARNESSTO RIGHT HAND CONSOLE HARNESS
INSTRUMENT PANE
@ FORWARD RELAY {NEL HARNESS TO FORWARD/
i4) 4TH RANGE SWITCH WITH 3.9 OHM BES'SIORS

@ AUDIBLE ALARM NEUTRAUREVERSE
RSE (F-N€) Sl,YlTcH HARNESS
BATTERY POWEB J
@ PARKING BRAKE SWITCH ip#i :R JUNCTION BLOCK
lr e, INSTRUMENT CLUSTER CONNECTOR

@ REVERSE SOLENOID * NOTE: Ihe F-N-Bsr R switch b magneticatly actuated.
kaukazz@yahoo.co.uk
Don 7-39270 lssued '11-93 Printed in England
4001-36 www.thebestworkshopmanuals.co.uk
powrquadplus
SENS-O-DHAULIC (SHR) HIrCH CONTROL

Sectional lndex
Haise, Lower and Slow Solenoid Circuit Test........'.. .'....'..', 37

Haise and Lower Suppression Diode Module Circuit Test ...'........ '......"." 40
Slow Suppression Diode Module Circuit Test (For Tractors Equipped With Hemote Switches) ......41
Hitch Control Relay Diode Module CircuitTest..........'.' .......'.44

Raise/Lower Diode Module Circuit Test .......... ..'....."..'."'..' 45
Slow Diode Module Circuit Test (For Tractors Equipped With RemoteSwitches) ..'.. 47
.......'.
Hitch Control Flasher Felay and Warning Lamp Circuit Test ...,..... 47
Hitch Control Warning Lamp Diode Test............. ...."....-.'....'.48
Switches)
Remote Switch Circuit Test (For Tractors Equipped With Hemote ...............48
Switches)
Schemaiic Circuit (For Tractors Not Equipped With Remote ................'.... 51
Schematic Circuit (For Tractors Equipped With Remote Switches) .....'.. 53
Don 7-39270 lssued 1'l-93 Prinled in England

kaukazz@yahoo.co.uk
4001-37
CIRCUIT TESTING
NOTE: The battery must bc at t'utl chargc and all cannecttons must be clean and trght before testing. Use a multtmeter for
NOTE: The hydraulic oil temperature must be above 10" F.
NOTE: For tractors not equipped with remote switches, refer to schematic circuit Page 51 . For tractors equrpped with
rcrnate swllches, refcr to schematic crrcult Page 53.
NOTE: lf the hitch fails to apcratc when using the hrtch control switch and the hitch control warnrng lamp flashes
continuously, check the hitch control relay chassrs ground circuit through the remote swilches or connector G
Raise, Slow and Lower Solenoid Circuit Test

NOTE: Tractors not equipped with remote swilches are not equipped with slow so/enolds.
NOTE: Turn the key to thc aFF posilion. Disconnect the raise solenoid, slow solcnotd, lower solenoid and suppression
diode module trom thc harness
Check Points Rcadrng Possiblc Cause of Bad Reading
fcrmlnal for wire 108 Brown to ground Continuity Bad circuit between the raise solenoid
@ tcrminal B and the chassis ground
conncction. Also check the chassis ground
conncct on
TerminaL for wjrc 108 Brown to ground Continuity Bad circuit between the lower solenoid
O tcrminal B and the chassis ground
connection. Aiso check ihe chassis ground
connection.
Tcrminal forwire i25 Brown to ground (fer Conlinuily Check wirc ]25 and the chassis ground
tractors equipped with rcrnote swrtches) connection
Bctwcen terrninals A and B of thc raisc 7 io 15 Bad raise solenoid

solenoid Ohms
Bctuvcen tcrminals A and B of thc lowcr 7 to 15 Bad lowcr solcnoid

solcnoid Ohms
Betwcen icrminals A and B ol the slow 10 Ohms Bad slow solenoid,

solcnoid (tor tractors cquippcd wrth rcmote at 20' C
switchcs)
NOTE: put thc hitch conlrot swilch in the NELJTRAL posrlron Turn the key to the ON position and then hold lhe
hrtch
control switch in the RAISE position (pos;tion 2)
.1
Terminal for wire 06 Dark Blue/Ycllow to 12 Voits Bad circuit between the raise solenotd
ground terminal A and the hitch control switcn
terminal 6, Also check the hitch control
switch.
Terminal D ol thc suppression dicdc 12 Volts Chcck wirc ]06 between the suppressron
module for wire 106 Dark Blucfrellow Io diode module terminal D and the splice
ground
NOTE: lf the reading at check point 5 is correct check wire 1A6 betuveen the raise solenoid connector and the splice
Don 7 -39270
kaukazz@yahoo.co.uk
4001 -38
NOTE: Put the htch control switch tn the FULL BAISE posrllon (positionl)
Terminal for wire 106 Dark Bluc/Yellow to 12 Volts Chcck wire 106 between terminals B and 6
ground of the hitch control switch.
Terminal lor wire 107 Dark Blue/Gray to 0 Volts Chcck the raise/lower diode module and the
ground hilch control switch.
NOTE: Check 7 is for tractors equipped with remote switches only.
Terminal lor wirc 124 Oark Blue/Red to 0 Volts Chcckthcraise/lowerdiodemoduleandthe

ground hitch control switch
NOTE: Hold the hitch control swrlch rn the LOWER posilron (positrcn 4)
Terminal for wrre 107 Dark Blue/Gray to 12 Volts Bad circuit betwcen the lower solenoid
ground tcrminal A and the hitch control switch
tcrminal 5. Also check the hitch control
switch.
NOTE: lf the reading at check point B is correct check wire 107 between the lower solenoid connector and the splice.
Terminal E of the supprcssion diodc 12 Volts Chcck wrrc 107 bctween the suppression
module for wire 107 Oark Bluc/Gray to diode module tcrminal E and the splicc.
ground
ror wirc 106 Dark Bruc/Ycrrow to 0 Volts Chcck lhc raisc/lowcr diode modulc and thc
@ ;::n:'l hitch contro slvitch
NOTE: Check 7 is for tractors equtpped wtth remole swrlches only
Terrninal for wirc 124 Dark Blue/Red to 0 Volts Chccklhcraisc/lowcrdiodemodulcandthe

ground hrtch control switch.
NOTE: tock the hitch control swrlch in the WORK posrtion (posrtton 5)
Tcrminal for wirc 106 Dark Blue/Ycllow to 12 Vol:s Bad circuit between the raise solenoid
ground tcrminal A and thc hitch control switch
tcrminal A. Also chcck the hitch control
switch and the raisc/lower diode module \--
(f terminal for wire 107 Dark Blue/Gray to 12 Volts Bad circuit betwecn the lower solenoid
grouno terminal A and thc hitch control switch
terminal A. Also chcck the hitch control
switch and thc raisc/lowcr diodc modulc.
NOTE: For tractors not equipped with remote swrlches, il the readings are correct check the suppression drode module,
refer to page 40
Ocr 7 39270 lssucC 1 1-93 Prinied in England
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4001-39
NOTE: The fotlowing checks are for lractors equipped wtth remote swilches.
NOTE; Hotd the right hand raise remote switch in the RAISE position
Terminal for wire 124 Dark Bluc/Red to 12 Volts Bad circuit between the slow solenoid
ground tcrminal A and the raise remote switch
terminal S. Also check the remote switch
and the slow diode module.
NOTE: Repeat check 7 with the left hand ralse remote switch held in the raise position.
NOTE: lf the reading at check pornt g is correct chack wrrc 124 betwecn the slow solenoid connector and the splice
Tcrminal C of thc slow solenoid 12 Voils Chcck wirc 1?-4 between the slow solenoid
suppression diodc module for wire 124 supprcssion diodc module termtnal C and
Dark Blue/Red to ground the splice
Terminal for wire 106 Dark Blue/Yellow to 12 Volls Check the raiscilowcr diode module.
ground
Tcrminal for wirc 107 Dark B uc/Gray lo 0 Volts Check thc raise/lower diode module. Also
ground check the hitch control relaY.
NOTE: Hatd the right hand lower remote switch in the LowER position
ror wire 124 Dark Bluc/Fed to 12 Volts Bad circuit bctween the slow solenotd
@ I:n:'r terminal A and the lower remote switch
tcrminal S Also check the remote swrtch
and the slow diode module.
NOTE: Repeat check 10 with the teft hand lower remote switch held in the LOWER position.
Tcrminal for wire 107 Dark Blue/Gray to 12 Volts Check the raise/lower diode module.
ground
Tcrminal for wire 106 Dark Bluc,{cllow to 0 Volts Check the raise/lower and slow diodc
ground modulcs AIso check the hitch control rclay.
NOTE: lf all reaclings ara correct chcck the supprcssion diode modulcs
tssueo r t-yJ Printed in Inglano

Dcn 7-39274
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4001,40
Raise and Lower Suppression Diode Module Circuit Test
NOTE: Disconnect lhe suppression diode module frorn the harness.
NOTE: Check the rarse, lower and slow solcnoid circurts, rcfcr lo paga 37.
@ rcrmrnat C of thc suoprcssion diodc Continui:y Chcck wire I09 and the chassis ground
'roouc'or wrrc 109 Browr lo 919966 cortncclron.
NOTE: The posittvc lcad of the rnultimclcr must go la lcrmtnal C ol lhe diode module.
Between tcrminals C and A of the diodc Coniinurty Bad diodc modulc

modulc
Bctwecn terminals C and B oi thc diodc Coniinuity Bad dtode module

modulc
Bctwccn tcrrninals C and D of thc diode Coniinuity Bad diode module,

modulc
Bctween tcrminals C and E of lhe diodc Continuity Bad diode module

module
Betwccn termrnals C and F of thc dtode Continuity Bad diode module.

module
NOTE: Change the leads ol thc ntultrntctcr ovcr so tha ncgative lead gocs lo lermrnal C of the diode module
Bctwcen terminals A and C of ihc diodc No Con:inuity Bad dtodc modulc

modulc
Beharecn terminals B and C of lhc diodc No Continuity Bad dtodc module

modulc
Bctwccn lcrminals D and C of thc diodr: No Continuity Bad diodc nrodulc

modulc
Between tcrminals E and C of thc diodc No Continuity Bad diode modulc

modulc
Between terminals F and C of thc diodc No Continuity Bad dtode module

modulc
Don 7-39270 lssued 1 1-93 Printed in England
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4001 -4 1
Slow Suppression Diode Module Circuit Test
NOTE: Disconnect the suppression diode module from the harness.
NOTE: Check the raise, lower and slow solenold clrcutls, refer to page 37
Chcck Points Bcading Possiblc Cause of Bad Reading
Tcrminal A of the supprcssion diodc Continui:y Chcck wre 126 and the chassis ground
module for wire 126 Brown to clround connection.
NOTE; The negatlve lead of the multlmeter must go to termlnal C of the dlode module
Between lcrntinals A anci C oi thc diodc Continuity Bad diode module

nrodulc
Belween terminals B and C o1 the dlode Continuity Bad diode module

module
NOTE: Change the teads of the mulimeter over so lire positive /ead goes to terminal C of the dlode module
Between terminals A anci C ol thc rjrotic No Continui'y Bad diodc module

module
Betwecn tcrminals B and C of thc diodc No Contrnutry Bad diodc module

module
Low Temperature Switch Circuit Test

NOTE: Check fttse F32
NOTE: The hydrautic oil temperature must be above 1A"F
NOTE: Turn the key to the OFF posltion and disconnect the SHR low temperature switch from the harness
Check Points Be adrng Possible Cause oi Bad Readtng
Tcrminal B of the low temperaturc switch Continuity Chcck wirc 102 between the low
conncctor (harncss sidc) for wirc 102 temperature switch terminal B and the
Brown/whitc ar-o lhC oaltCry rCgalvC battery negative terminal. Also chcck thc
terminal battery ncgativc conncction.
Tcrminal C of thc low tcmccralurc srvl:ch Cont nuity Check wire I01 between thc low
conncctor (harness side) and tcrmina 86 of tempcrature switch icrminal C and the
the Iockoui relay for wrrc 101 Ycllow/Dark lockout rclay terminal 86
BIue
NOTE: Turn the key to thc OiV posilion
Termrnal A of the low lcmperaturc s\/ilch 12 Volts Check wtrc 100 between the low
connector (harness side) tcr wire 100 Dark tcmperaturc switch and fuse F32.
Blue/Fcd to ground
Doa /-392/0
lssued 11-93 Prrnlec !n England
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40a1 -42
NOTE: Turn the key to the aFF position connect the SHB low temperature switch to the harness.
NOTE: Turn the key to the ON positron.

Check Points Beading Possible Cause of Bad Beading
Tcrmina 86 of thc lockout rclay for wirc 101 0 Volts Bad low temperature switch
Yellow/Dark Blue to ground
NOTE: ltthehltchcontrol systemoperatesv,thenthchydraulicoiltemperaturetsbclowl0'Fchcckthelockautrelay.lfthe

readings are correct rcplacc the lcw tcrnperalurc swrlch
Hitch Control Switch Circuit Test

NOTf : Check luse tr32
NOTE: Put the hitch controt swilch in thc NEUTRAL positian and turn lhc key to the ON position
]-erminal for wirc 103 Rcd/Dark Bluc to 12 Volts Chcck wirc 103 bctwecn the hitch control
ground switch terminal 1 and the hitch control relay
termina 30 Also check the hitch control
relay
Tcrrninal lor wrre 110 Dark Blr,crWhitc lo 12 Vots Bad hilch control switch
ground
Tcrminal for wire 105 Dark Blue/Pink to 12 Volts Chcck wirc 105 bctwcen the hitch control
G) Qro[Jno switch terminal 3 and the hitch control relay
tcrminal86 Also check the hitch control
rclay anc thc hrtch control rclay diodc
modulc.
NOTE: Turn the key to the OFF position and disconnect the hitch control switch from the harness.
.106
6fi) terminas for wire 1Cr6 Dark Blue/Ycllow Continuity Chcck wirc bctwccn the hitch control
switch conncctors tcrminals B and 6
NOTE: Check between termtnal 3 and each torrrttnd ol tllc hrlch Conlrol switch lllhere iS continuily bctwccn terminal 3
and any of the terminals rcplace thc httch conlral swi/ch
NOTE: Hotd the hitch controt switch in the FAST,EAISFposirron (posttion 2).
Between terminals 3 anci 6 of thc hitch Contrnuity Bad hitch control switch.
control switch
NOTE: Lock thc hitch controt swilch tn the FULL RAISE post,on (posrlron 1)
Bctwccn tcrminals 3 and B oi thc hitch Continuity Bad httch control switch
control switch
NOTE: t-told the hitch control swilch in the FAST LOWF-R posilicn (posrtron 4)
Bctwccn tcrminals 3 ancj 5 of tirc hitch Corrtinui:y 3ad hitch control switch.
conIro1 switch
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4001,43
NOTE: Lock the hitch control switch in the WORK posllion (positian 5)
Check Points Reading Possible Cause oj Bad Reading
Between terminals 3 and A of the hitch Continuity Bad hitch oontrol switch.
control switch
Bctwcen terminals 1 anci 7 ol the hitch Continuity Bad httch control switch.
control switch
NOTE: Hold the hitch contralswllch tn the NEUTRAL position (position 3).
Between tcrminals 1 and 2 of thc hitch Continuity Bad hitch control switch.
control sw tch
Hitch Control Relay Circuit Test

NOTE: Turn the key to the OFF position and check Fuse F32.
Tcrminal for wire 11 I Brown/Orange to Continuity Bad chassis ground circuit. Also check the
ground remote switch circuit for tractors equipped
with rcmotc switches.
NOTE: The followingl check is far tractors equipped wtth remote switches
NOTE: tlold in the ight hand raise remote swrlch.
Tcrminal for wirc 11 1 Brown/Orangc to No Continuity Wirc 1'1 1 shortcd to ground. Also check the
ground remote switch
NOTE: Belease the rpht hand raise remate switch Hold in the flght hand lower, left hand raise and lower remote
sw/ches in turn and repeat check 21 . lf there is continuity, wtres 120, 121 and 122 have shorted to ground. Also checkthe
remote sltches.
Bctween terminals for wire 105 Dark Continuity Chcck wire 105 between terminals 86 and
Bluc/Pink B7 of tnc nitch control relay
NOTE: Lock tho hilch contrcl switch in thc WORK position (position 5) and turn the key to the ON position.
Termrnal for wirc 'l 03 Red/Dark Bluc to 12 Volts Chcck wire 103 between the lockout relay
ground tcrminal 87A and the hitch control relay
tcrminal 30. Also check the lockout rclay.
Terminal for wirc 1 12 Black to ground 12 Volts Bad hitch control relay
El
NOTE. Put the hitch cantral switctt tn the NF-UTRAL position
Tcrminals for wire 105 Dark Blue/Pink to 12 Volts Bad circuit betwecn the hitch control switch
ground tcrminal 2 and the hitch control rclay
terminal B6 Also check the hitch control
relay diode modulc.
Oan 7-39270 ssued 11 -93 Printed in England
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4001-44
NOTE: Lock the hitch control switch in tha WORK position (posrtron 5)
Tcrminals for wirc 105 Dark Blue/Pink to 12 Volts Bad hitch control relay
ground
Lockout Relay Circuit Test

NOTE: Thehydraulicoil mustbeabovelO"F.Putthchitchcontrol switchtntheNEUTRALpositionandturnthekeytothe

ON posilion.
Terminal ior wire i 00 Dark Bluc/Rcd to 12 Volts Bad circuit betwcen the lockout relay
ground terminal 30 and fuse F32
Torminal for wire 101 Yellow/Dark BlL,c to 0 Volts Check the low temperature switch.
ground
Terminal for wirc 103 Rcd/Dark Bluc Io 12 Volls 3ad lockotrt rclay
ground
Cil lcrminal for wirc 104 Brown to grotrnd Contnurty Chcci< wirc 104 and thc chassis ground
corr rcclic.r,,.
NOTE Disconnect the low temperature switch from the harness and connect a suitable jumpcr lead betvveen terminals A
and C of the low temperature switch connector (harness stde) and turn the key to the ON position.
Terminal for wire 114 Dark Bluc/Black to 12 Volts Bad lockout relay,
ground
Tcrminal for wire 114 Dark Blue/Black to '1

2 Volls check wirc 114 between the lockout relay
ground and thc low tempcrature diode
NOTE: Connect the low temperature switch to lhe harness
Hitch Control Diode Module Circit Test

NOTE; Turn the kcy to the OFF postlion and dtscanncct thc hrtch control dtade module from thc harness
Check Poinls Rcading Possiblc Cause of Bad Reading
Terminals for wirc 105 Dark Bluc/Pink Continuity Check wirc 105 bctween the diode module
ierminal D and hitch control relay terminal
86
NOTE: Lock the httch control switch in the WARK position (positton 5) and turn the key to the ON position
Tcrminal for wire 11? Black to ground 12 Volts Bad circuit bctween the hitch control relay
terminal B7A and thc diode module terminal
F. Also check thc hitch control switch
UcT7-39270 lssucd 11-93 Printed in f ngianc
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400 1 -45
powrquadplus
NOTE: Putwww.thebestworkshopmanuals.co.uk
the hitch cantrcl switch tn thc NEUTRAL pasttton
Check Points Beading Possible Cause of Bad Readlng
Terminal for wire 110 Dark BluciWhiic to 12 Volts Chcck wire 1]0 between the hltch control
ground switch te rmin al2 and the hitch control drodc
modulc terminal E. Also check tne hich
control switch.
NOTE. The positive lead ol lhc multrmetcr rnust go lo lerrntnal E al thc diode module .
Bctwccn terminals E and D of thc diodo Continuity Bad diodc module

modulc
Between tcrminals E and F of thc diodc Continuity Bad diodc module

modulc
NOTE: Change the lcads of the multtmetcr ovcr so the negative lead goes to tcrmrnal E of the diode module.
Belwcen terminals D and E of ihc diode No Continuity Bad diodc module

modulc
Betwccn terminals F and E of the diodc No Continuity Bad diode module

module
NOTE; Maka sure therc ts NO CONTINUIW bctween termtnals D, E or F and termtnals A, B or C of the diode module
Raise/Lower Diode Module Circuit Test

NOTE: Turn the key to the OFF position, put the hitch control swrtch in the NEUTRAL posttion and disconnect the raisel
lower diode module from the harness.
NOTE: Turn the key to the ON posltron ancl lock the hitch controi switch rn the FULL RAISFposition (position 1)
Terminal for wire 106 Dark Blue/Yellow to 12 Volts Bad crrcuit between the hitch control switch
grounc) terminal B and the raise/lower diode modulc
terminal B.
NOTE: Lock the hitch control switch rn the WORK posrtion (position 5)
Terminal for wirc 1 16 Dark Bluc/Light Grccn 12 Volts Bad circuit between the hrtch control switch
to ground terminalA and the raise/lower diode module
tcrminal C
Terminal for wirc I 16 Dark Biue/Light Grcen 12 Volts Bad circuit bctwecn thc hitch control swrtch
to ground tcrminalA and the raise/lowcr diodc modulc
terminal F.
NOTE: Hold the hich control swtlch tn thc FASI LOWER positron (posilon 4)
@ ;|jn:'l ror wire 107 Dark Bluc/GraY to 12 Volts Bad circuit bclween the hitch control switch
tcrminal 5 and the raise/lower diode module
terminal E.
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4001-46
NOTE: For tractors equipped with remote swilches tock the hitch controlswitch in the WORK posilion (posifion 5) and
hold the left or right hand raisc rcmole switch rn the BAISE position.
Terminal for wire 106 Dark Blue/Yellow to 0 Volts Checkthehitchcontrolswitch, hitchcontrol

ground relaY and remote switches.
lcrminal for wire l18 Dark Bluc/Violct lo 12Volts Badcrrcuitbetwccnthcremoteswitchand

ground thc raise/lowcr diode module terminal A.
Also check the remotc switches.
NOTE: Hotd the left or right hand Lower remote switch in the LOWER position
Tcrminal for wire 107 Dark Bluc/Gray to

@ ground 0Volts Checkthehitchcontrolswitch,hitchcontrol
rclay and rcmote switches
(D Terminal for wire 119 Dark Bluc/Pinkt to 12 Volts Bad circuit bctwccn the remotc switch and
oround the raisc/lowcr diodo module tcrminal D
Also chock thc remotc switches.
NOTE: The negative tead o{ the multrmeler must go to terminal B ol the diode module,
Bctwecn tcrmtnals A anci B ol iirc <jiodc Conlinuity Ba<j diodc modulc
'nodulC
Bet\^/ccn torminals C and B of thc diodo ContinLrity Bad diodc modulc

module
NOTE: Change the teads of the multirneter over so the posltrve lead goes to terminal B of the diode module.
Bctwecn terminals B and A of ihi: diodc No Continuity Bad dtodc modulc

modulc
Betwecn termrnals B and C of thc diodc No Continuity Bad dtodo modulc

modulc
NOTE: Make sure there is NO CONTINUIW beween terminals A, B or C and terminals D, E or F of the diode module
NOTE: Changc the lcads ol thc rnulttrneter ovct so lhe negative lead goes Io tarminal E ol thc diode module.
Bctween tcrminals D and E of thc diodc Continr,ily Bad diode modulc

module
Belween terminals F and E of the diodc Continuity Bad diode module

modulc
NOTE: Change the leads of the multimeter over so lhcposihvc lead gocs Io terminal E of the diode module.
Bc:ween tcrminals E and D of the diodc No Continuity Bad diode module

module
Bclwccn terminals E and F of the diodc No Continuity Bad diodc module

moduie
NOTE: Make sure there is NO CAN\NUIW betuveen terminals D, E or F and terminals A, B or C of the diode module
)on 7-39270 lssued 1 1-93 Printed in England
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SIow Solenoid Diode Module
NOTE; Turn the key to the OFF position and put the hitch control switch in the NEUTRAL position and disconnect the slow
solenoid diode module from the harness.
NOTE: Turn the key to the ON position and lock the hitch control switch in the WORK position (position 4)
NOTE: Hold the left or right hand remote swttch in the LOWER position,
Check Points Beading Possiblc Cause of Bad Reading
Terminal for wirc I 19 Dark Blue/Pink to 12 Volts Bad circuit between the lower remote switch
ground and the slow diode module terminal A
NOTE: Hold the lcft or right hand remole swrtch in the RAISE posttion
Terminal for wire 1 18 Dark Bluel/iolct to 12 Volis Bad circuit bctween the raise remote switch
ground and tirc slow diode modulc terminal B
Terminals for wire 124 Dark Blue/Red Continuity Check wrre 124 between the slow solenoid
diode module terminal C and the slow
solenoid tcrminal A.
NOTE: The negattve lead of the multimeter must lJa lo termtnal C of the diode module
Betwcen terminals A and C of thc diodc Contlnuity Bad diode module.

module
Bctwcen terminals B and C of the diodc Continuity Bad diode modulc.
rnodu c
NOTE. Change the leads of lhe multimeter over so lhe posrlrve lead goes to termrnal C of the diode module
Bctwccn terminais A and C of ihc drode No Continuity Bad diodc module.
modulc
Betvrccn terminals B and C of thc diode No Continuity Bad dlode module.
module
Hitch Control Flasher Ftelay and Warning Lamp Circuit Test

NOTE: Check the hitch controlwarnrng lamp bulb.
Check Points I-leadrng Possible Cause ot Bad Reading
Terminal or wirc 1.15 Brown to ground Continuity Check wire 115 and the chassis ground
@ connection.
NOTE: Put the hitch controt switch in the WORK position and turn the key to the ON position
Tcrmlnal for wirc 112 Black to ground 12 Volts Check wire 1 12 between the flasher rclay
@ and the hitch control relay terminai B7A
Dar 7-3927A lssued 11 -93 Pflnted in Fnq{ard
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NOTE: Put the hitch contrctl switch in the NEUTRAL position
Check Points Reading Possiblc Causo of Bad Beading
Tcrminal for wirc 1 12 Black to ground 12 Volts Bad circuit betwccn the hitch control flashcr
@ rclay and the hitch control switch terminal 2
Also check the hitch control relay diode
module.
lP ferminal for wire 1 13 Violet to ground 12 Volts Bad flasher relaY.

ON-OFF.ON
Terminal for wire 114 Dark Biue/Black to 12 Volts Check wircs '113 and 114 Also check the
ground ON-OFF-ON warning lamp diodc
Hitch Control Warning Lamp Diode Test

NOTE: Disconnect the diode fram the harness.
NOTE: The positive lead ol the multimeter must go ta the lernale terminal of the diode
Check Points Readino Possiblc Causo of Bad Feading
Betwcon thc terminals of thc diodc No Continuity Bad diodc
NOTE: Change the leads ol the muttimeter aver so the positive lead goes to the male termrnal'
Bctwecn the tcrmina s of the diode continuity Bad drodc
Remote Switch Circuit Test

NOTE: Disconnect the tefl hand lower remote switch from the harness.
NOTE: put the hitch control switch in the NEUTRAL positian and turn the key to the ON positton
Chcck Poinls Rca<jino Possible Cause of Bad Reading
Terminal for wire 11 1 Brown/Orangc to 12 Volts Chcck wirc l 'l l betwcen thc right hand raise \--./
ground remote switch tcrminal O1 and thc hitch
control relay tcrminal 85.
ferminal tor wire 120 Brown/Rcd to ground 12 Volts Bad right hand raise remote switch,
@
Tcrminal for wirc 120 Brown/Red to grouncJ 12 Volts Check wire 120.
6l
Terminal for wire 121 Brown/Dark Bluc to 12 Volts Bad rrght hand lower remote swrtch
ground
Bruc to '12 Volts Chcck wirc 121

@ ;:n:"1 for wire 121 Brown/Dark
,
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4001 -49
powrquadplus www.thebestworkshopmanuals.co.uk Beadrng Possible Cause of Bad Reading

Check Points
Terminal for wire 1223rownlGray to ground 12 Volts Bad left hand raise remote switch.
Check wrre 122

6i Terminal for wire l22BrownlGray to ground 12 Volts
NOTE: Lock the hitch cantrol sv.tilch in the woRK posittort (posttion 5)
ror wirc 117 Rcd/Dark Bluc to 12 Volts Check wire 1 1 7 between the right hand raisc
@ remote swrtch terminal S1 and thc hitch
;::n:'l control switch terminal 7.
fcr wire I l7 Bcd/Dark Blt c to 12 Volts Che ck wire 1 I 7 bctween the right hand raise
Termrnal
ground rernolc swttch tcrminal S1 and the right
hand lower rernote switch term nal S1
Terminal for wire 1 17 Bcd/Dark Bluc to 12 Volts Che ck wire 1 I7 between the lcft hand raisc
ground rcmotc switch terminal S1 and the splicc
Termrnal for wire 117 Sedloark Bluc to 12 Volis Chcck wire 1 17 between the left hand raise
ground rcrylotc switch terrninal S1 and the left hand
lower rentote switch terminal S1
NOTE: Hokl the right hand raisc rernota switch in ttrc RAISE position
for wirc 1iB Dark Blucl'/iolct to 12 Volts Bad rrght hand raise rcrnotc switoh
@ Tcrminal
ground
Tcrminal for rr,rirc 1 1B Dark Blucly' olct :o .1

2 Volts Chcck wire 1 I B between the right and left
@ ground hand raise remote swilchcs,
raise remote switch in the position

NorE: Rc/case thc rrght hancl rarse remate switch and hatd the left hand
RAISE
Te rmrnal for vrirc 1 1B Dark 3llclVioir:l to 12 Volts Bad left nand raise remote swilch
ground
LOWER position
NOTE: Release the left hand raise retnotc switch ancJ hotd lhe rtght hand lowcr remote swilch in the
Terminal for wire l19 Dark Blue/Pink 1o 12 Volts Bad right hand lower remote switch
ground
Tcrminal for wirc

']19 Dark Bluc/Pink io 12 Volts Chcck wire 119 betwecn the right and lefl
ground hand lower rcrnote switchcs,
LowER position
NoTE: Release the right hand lowar remotc switch and hotd the teft hand lower remote switch in lhe
.119 to 12 Volts Bad left hand lower remote switch
Terminal for wirc Dark Bluc/Pink
ground
NOTE: Turn the key ta the OFF pcsitron and release the remote svtrtch.
f ermrnalfor wire 123 Brownlr/iolet to ground Continuity Chcck wirc 123 and thc chassis ground
@ connection
lssued 11-93 Printed in Englard

Ooa 7-39270
kaukazz@yahoo.co.uk
400 1 -50
Bclwcen tcrminals O1 ancJ O of lhc lcrl hanc Continuity Bad left hand iowcr remotc swilch
lower rcmote switch
NOTE: Hold the ilght hand lawer remate swrtch tn the LOWER posltlon.
Belwecn tcrminals Sl and S of thc lcft lancj Continuity Bad lcft hand lowcr rcrnotc swttch
ioiver rcmote switch
NOTE: lt the readings are carrcct check wtres 118 and 119 betwecn the remote swilches and the rarsellowcr diodc
module.
Do.t 7 39?70 ssucd 1 1-93 Printed ln England
kaukazz@yahoo.co.uk
4001-51
powrquadplus www.thebestworkshopmanuals.co.uk Schematic Circuit

Low Temperaturc Switch Hitch Control Swatcfi Hitch Control nehy and Low temperature Lockt
ckout Relay Hitch Control Solenoids
poq
10o oBB {16}
I rot Y/oB (16)
R t12 a
(13) 103 ilD8 (16) . lm n DB (16) -l
{ *oor.rr
-
-.1 r r1o DB/til
(r8) ol l13
v
(r8)
,L I < *0,,J
@
+
i1it, -F
R/DB (r3)
n[ ,rooorrrrr--ra
el[Yo 6@8
't05 olyP {t6)
fi2 B (r8)
@
ls @l16o
iGts
r,7 RIDB {16}

t8 3s 0sl I r16 OB/LG 06)
r19DsV (16)
FYOB I Rr/DB
(r3) I
r20 DlrP {'16)
(r6| II I
100
107 DBG (16) t04
BA
OBB tl8)
tr6!
II r0o
DE/N ,oo
I usr DtsI,
t16)
H,m l( { motor
?_l r---:
't09
BR
{16}
3? R/V fls)-
104
6F
102 BB,l\t {16}
o8)
CONNECTOHS
COMPONENTS
o KEY SWITCH e HITCH CONTBOL RELAY iffi TBANSMISSION HARNESS TO

O INSTRUMENT PANEL HARNESS
e FUSE F19 e LOW TEMPERATUBE LOCKOUT RELAY r#

i{Bi
TRANSMIsSION HABNESS TO
TRANSMISSION HABNESS TO
O BIGHT HAND CONSOLE HARNESS
SU PPRESSION DIODE MODULE

@ FUSE Fl7 @ RELAY CHASSIS GROUND W O SHR
,IRE
HITCH CONTFOL FLASHER BELAY
@ FUSE F32 @ ffi enrrenY PowER JuNcrtoN I
o ACCESSORY POWER BELAY @ HITCH CONTROLWARNING LAMP DIODE

IBLOCK
c LOWTEMPERATURE SWITCH @ HITCH CONTROL WARNING LAMP
o HITCH @NTROLSWITCH
POSITIONl-FULLRAISE
@ HAISE gOLENOID
POSITION 2. FAST RAISE @ LOWER SOLENOID

POSITION 3'NEUTRAL
POSITION 4. FAST LOWEB
@ CIGABETTE LIGHTER
POSITION 5.WORK
l@ nerser-owEn DIoDE MoDULE

irrrcn coNTRoL BELAv DtoDE MoDULE
@ kaukazz@yahoo.co.uk
Don 7-$270 lssued 1 1-93 Printed in England
4001 -52
This page has oeen left blank

kaukazz@yahoo.co.uk
4001-53
Schematic Circuit Remote Switches and Slorr Solenoid
Srritch Hitch Controt Switch Hitch Control Relay and Low temperature Lockout R{ ,ut Relay Hitch Control Solenoids
Low Temporature
0
loo oEvB (16)
1oi YIDB {16}
D@@ -11?
t1
RIDE
BR/O
(rE
(18)-
ti? R 03 (16)
n
ro3ll105)l
{ +oorar
(13)
DI 112 113
@
B v
(r8l {r8} @
@
t1a DBB {18} ------1

117 R DB (16)
r2r sR,oB (18)
;T"',]
l{rt-m. ttr@ ,l
r12 B (18)
lr')mlJ'(
l- \-/ | nnr g(9 DBTY
'rrl Bwo {r8}
'n7 R/DB {16)
118 DA/V (
l-l@ ?i
119 08,/P
{16)
-104
roo t
BR r18 DBA' (161 I r8 DA/V
DEuR I
oe)
1t9 DEirP I 119 DsP fl6)
tio) I
t10 t18 DBn'
',?3 ARiV
loa
I tt' 124 OB/B fl6,
rr9 ogP (16)
H*m I { *orct t?{ oB/B (16}
T__J r-----;
'r09
BR
o6)
37 E
'{1s}
{ +oor-za 'r25 8R ("161
COMPONENTS
(r) KEY SWITCH @ HITCH CONTBOL RELAY @ r-eri HAND RAIsE REMoTE svr SWITCH
s
e FUSE Fl9 o LOW TEMPERATURE LOCKOUT RELAY @ urr HAND LowEB REMoTE : SWITCH
ery FUSE F.I7 @ SUPPRESSION DIODE MODULE @ slow soLENolD SUPPRE$slo SION DIODE MODULE
FUSE F32 @ HITCH CONTROL FLASHER RELAY @ sr-ow DIoDE MoDULE

@
(} ACCESSORY POWER RELAY @ HITCH CONTROLWARNING LAMP DIODE @ slow soLENolD
-, Y)
@ LOW TEMPERATURE $WITCH @ HITCH CONTROL WARNING LAMP
CONNECTORS
o HITCH CONTROLSWITCH
POSITIONl.FULLBAISE
@ RAISE SOLENOID
{.#j rRANSMlsstoN HABNESSTo rO INSTRUMENT PANEL HARNESS
POSITION2-FASTRAISE @ LOWER SOLENOID
POSITION 3. NEUTRAL
POSITION 4. FAST LOWER @ CIGAREfiE LIGHTER {# rRANSMtsstoN HARNESSTo IO RIGHT HAND CONSOLE HABNESS
POSITION 5-WORK rc
@ RIGHT HAND RAISE HEMOTE SWITCH f#i TBANSMtssloN HARNESS IO REMOIE SWITCH HARNESS
ll aersvLowEB DroDE M.DULE
6 @ RIGHT HAND LOWEB REMOTE SWITCH ffi anrrenY PowER JUNCTIoN I N BLOCK
kaukazz@yahoo.co.uk
nrrcir coNTRoL BELAV DIoDE MoDULE
@
Oon 7-39270
powrquadplus
MFD AND DIFF LOCK

Sectional lndex
Diff Lock lndicator Lamp Circuit Test ........ .'.'.' 59
Oon 7-39270 lssued 11-93 Printed in Engiand

kaukazz@yahoo.co.uk
4001 -55
CIRCUIT TESTING
NOTE: The battery must bc at {ull charge ancl all conneclions must bc clean and trght be fore lesrng Use a multirnete r for
Ihe tesls.

NOTE: Turn the key to the OFF position. Disconriect the MFD solenord and suppression drode module from the
harness.
Chcck Points Rcading Possibtc Cause of Bad Rcadirg
Q tcrminai for wirc 134 Brown to ground Continuity Check wire 134 and thc chassis ground
connection.
Bctwccn tcrminals A anc B oi thc Mi:D 7 to 15 Chms Bad MFD solcnoid

solcnoid
NOTE: Put the MFD swilch in thc OFF positran and turn thc key to thc ON position
Tcrmtnai forwirc 133 Dark Bluc/Dark Grecn 12 Voiis Bad circuit bctween the MFD solenoid,
to ground icrminal A, and the MFD switch termlnal 7
Also chcck thc MFD switch.
Gl te rminal for wirc 133 Dark Bluc/Dark Grce n 12 Volts Check wirc 133 between the supprcssion
to ground diode modu c and thc sPlicc.
NOTE: lf the readings are correct, chcck thc supprcssion diodc rnodula, refer lo page 59

NOTE: Putthe MFD switch rn the oFF posilron and turn the key to the o,ry posrtron
Chcck Points Readrng Possiblc Cause of Bad Beading
f erminal for wire 130 Light Green to ground 12 Volts Bad circuit between fuse F23 and the MFD
@ switch terminal 5
@ rerm:nar for wrrc 133 Dark Bluc/Dark Grecn 12 Volts Bad MFD switch
to ground
NOTE: Put the MFD swttch tn thc ON positron
{l terminar for wirc r 33 Dark Btue/Dark Grccn 0 Votts Bad MFD swjtch
to ground
Gf tcrm,naltor wirc 131 Lighi Grecnffcllor,v io l2 Volls Bad MFD switch

ground
@ r",, nalfor wire 131 Light Grecn/Ycllcw to 12 Volts Chcck wrrc 131 between terminals 1 and 9
ground of the MFD switch
Ilo^ 7 39270 lssued 11-93 Printed in Englano
kaukazz@yahoo.co.uk
4001-56
powrquadplus
NOTE: www.thebestworkshopmanuals.co.uk
Turn the key to the OFF posttion
Check Points Reading Possibrlc Cause of Bad Reading
Gl T"rr,nrl ior wirc 132 Brown to ground. Continuily Check wirc 132 and the chassis ground
connection

NOTE: Turn the key to the OFF position and disconnect the diff lock solenord and suppressron diode module from the
harness
Check Poinis Rcading Posslble Cause of Bad Reading
@ tcrminal for wirc 139 Brown tc ground Conlinuiiy Chcck wirc 139 anci the chassis ground
conncclron
Betwccn tcrminals A and B of thc MFD 7 to 15 Ohms Bad drff lock solcnoid
solcnoid
NOTE: Turn lhe key to the ON postttcn and noid the dtf't lock svtitch in the MOMENTARY posrtton
@ frl.rn,nrl 1or wrrc 136 Dark 3luc 1,..r grouncl 12 Volls Bad circuit bctwccn the drff lock switch
terminal 3 and the diff lock solenoid. Also
check the drff lock switch
NOTE: Be/ease the drfl lock swrtch to the ON position
fi) ferminal lor wire 136 Dark Biuc io ground 12 Volts Bad circuit betwccn the diff lock rclay
terminal B7 and thc drff lock solcnoid. Also
chcck thc diff lock switch, brake pedal
switchcs and dtff lock relay.
@ r"rr,nrl forwire 136 Dark BlLrc io ground 12 Volts Check wirc 136 bctwccn the suppression
diodo module and the splicc
NOTE: lf the readings are correct, check lhc suppressron diode module, refer to page 59.

NOTE. Cneck Fuse F23.
NOTE: Disconnect the dtff lack swilch from the harness and turn the key ta the ON position
Check Points tlcading Possibie Cause of Bad Reading
(D ferminal forwjre]35 Dark BlueiOrange to 12 Volts Bad circuit between fuse F23 and the difj
ground Iock swilch terminal 6
Gl terminal for wirc 135 Dark Blue/Orange to 12 Volts Chcck wirc 135 betwccn terminals 1 and 6
ground of lhc diff lock swilch
l).:r' 7 3927A ssr,c<; I I 93 Prinlc:d in Englanc'
kaukazz@yahoo.co.uk
4001 -57
NOTE: Put the diff lock switch in the OFF Position
Check Points Rcading fg$ibre C?"se olBad Be4I9

Between terminals 1 and 3 of the diif lock No Continuity Bad dtff lock switch.
switch
Betwcen terminals 2 and 6 of lhe difi lock No Continuity Bad diff lock switch
swilch
NOTE: Hold the diff tock switch in the MOMENTARY positlon
Between tcrmrnals 1 and 3 cf thc drli Iock Continurty Bad dtff lock switch.
SWitCh
Betwcen terminals 2 and 6 oi ihe dift lock Contrnuity Bad diff lock switch
switch
NOTE: Rclease thc dttf lock sv'titch in thc ON pastttan
Bctwecn icr-mrnals I and 3 o+ if,c cl fr lock No Continui:y Bad drff lock switch.
swilch
Between terminals 2 and 6 of the diff lock Contrnuity Bad diff lock switch.
switch

NOTE: Turn tha key ta the OrVposrlion and hold ihe dt{f lock switch rn thc MOMENTARY postttan.
IMpoRTANT: Onty use a high tmpedance rnultimeter to check the brake pedat switches. Do nol use a test lamp
or
danage tc the switches maY occur
Chcck Pc r1s RcadrnQ Possiblc Cause of Bad Fleading
lB Tcr-inal for wre '136 Darx Biuc lo

llrounc 12 Volls Bad clrcuit betwcen the drff lock swilch
terminal 3 and the lelt hand brake pedal
switch Also check the diff lock switch
Terminat for wire 140 Light Grcen,Aivhilc to 12 Volts Bad left hand brake pedalswitch Adjust or
gror,nd replacc thc swrtch as necessary, refer to
Scction 9001
NOTE: Hotd the tct't hand brakc padal DaV/N
Tcrminal forwire140LrghtGrccn,A/Vhitclo 0Volts Badletthandbrakepedal switch Adlustor

as nccessarv' refer to
sround !"j"iix *?,'*'tch
NOTE: fielease the left hand brake pedai
Tcrmrnal for wirc io

i40 Lrghi Grccn,Wh;ic 12 Volis Check wrrc 140 between thc lefl and right
grounc-handbrakepedalswltches,
Terminal for wire r3g Dark BlucAVhitc to 12 Vol:s Bad right hand L:rakc pedal switch Adlust
grouncl or rcplacc thc switch as necessary, refer to
Scction 9001
\ .- : 102;1 lssu)d 1 I 93 Printod rn Fnglanc;
kaukazz@yahoo.co.uk
4001 -58
powrquadplus
Hold the left hand brakc pcdal DOWN
Tcrminal for wire 138 Dark Blue,A/Vhitc to 0 Volts Bad right hand brake pedal switch. Adjust
ground or rcplacc the switch as necessary, refer to
Scction 9001
Diff Lock Relay Circuit Test

IMPORTANT Only use a high impedence multlmeter to check the diff lock relay. Do nol use a test lamp or damage to
the 4th range switch may accur.
NOTE: Turn the key to thc OFF posilion and put the range lcver rn thc 4th rangc position.
Check Point Reading Possiblc Cause of Bad Rcading
Tcrminal for wire 137 Brown/Dark Bluc to No Continuity Check wire 137 and the 4th range switch
ground
NOTE: Move the range lever out of 4th range
@ Hn:'r lor wire 137 Brown/Dark tsrue ro circuit Arso check the
?,1',.:[:'l'-?round
^rt;i"?H;,
NOTE: Turn the key to the ON pasition and pul the dill lock switch in the ON position
Terminal for wrre 1 37 Light Grccn/Black to 12 Volts Check wirc 1 37 betwe en thc diff lock switch
ground tcrminal 2 and thc dil{ lock rclay terminal 30,
Also chcck thc drlf lock switch
Tcrminal for wirc 138 Dark BluczWhric to 0 Volts Chcck thc diff lock switch
ground
NOTE: Hold the diff lock switch in the MOMENTARY position and hold the brake pedals DaWN
Terrninal for wirc 138 Dark BlueM/hite :o 0 Volts Check thc brakc pcdal switches.
3r'OunC
.136
Tcrminal for wrre 136 Dark Bluc to grouncJ 12 Volts Chcck wirc bctween the diff lock switch
4l tcrmrnal 3 and the diff lock relay tcrminal 87.
Also check the diff lock switch.
NOTE: Release the brake pedals
Terminal for wire 138 Dark SluciWhjte to 12 Volts Bad circuit betwecn the brake pcdal
ground switches and the drf{ lock relay terminal B6
Also check the brakc pedal switches.
NOTE: Release the difl lock switch to the ON positton
4l ferminal for wire 136 Dark Bluc lo ground 12 Voils Bad drff lock rclay
Don /-39270 lssucd 11-93 Prinled in England
kaukazz@yahoo.co.uk
4001 -59
4th Range switch (Diff Lock Lockout) circuit Test

high impedence multimeter to check the 4th range switch. Do not use a tesl lamp or damage
IN4poRTANT : Only use a
to the 4th range switch may accur.
from the harness and put the range lever in the
NOTE: Turn the kcy to thc oFF posirion disconnect the 4th rangc switch
4th range positian.
Check Point Rcadrng Possible Cause of Bad Feading
Tcrninal for wirc 82 Brown to ground Continuity Check wire 82 and the chassis ground
@ cont tcction.
Bctween terminals 1 and 2 of thc 4rh rangc No Corttinuily Bad 4th range switch
switch
NOTE: Move the range lever out of 4th range'
range 39 Ohms Bad 4th rangc switch Adjust or replace thc

Bctwccn tcrminals 1 and2o{ thc 4th
switch as neccssary, refer to Section 9001
switcn
rctay tcrminat 85 and lhe 4th range switch
v NOTE: tf thc readings are corect chcck wrrc 137 betwccn lhc dilf tock
termtnal 2.

NOTE. Turn the key to the oFF posttion artd check ttte cift lock indicalor larnp bulb
Check Potnts Rcacirng Possible Cause of Bad Beadtng
Terrninal for wirc 78 Brown to ground Continuity Check wire 78 and the chassis ground
P]h conne ction
NOTE: Turn the key ta the ON Pctsrtion anC hold the drt'l lock swiich
in the MOMENTARY postilan
(10 TarminaL for wirc 136 Darr( Bluc lo grcunc 12 Volls Bad circuit betweon the dif{ lock switch
tcrmlnal 3 and the diff lock indicator lamc
SupPression Diode Module Test

NOTE: Disconnect lhe suppress ion diodc modulc lrcn'' thc harness
Rcading Possiblc Causc ot Bad Rcading

Chcck Points
.109
Brown to ground Continuity Check wire 109 and the chassis ground
rlF Tcrminal for wire
connection
'NOTE: The positrve tead of the multimeter must go to te rminat c of lhe suppression dlode'
Bctween terminals c and A ot thc coniinuity Bad suppression dlode module

Between tcrminals c anc B of the continuity Bad suppression diode module

lssue<i 1 l-93 Prinled in England

Oor 7-39270
kaukazz@yahoo.co.uk
4001 -60
Bctwccn terminals C and D of the Continuity Bad suppression diode module.

Bctwecn terminals C and E oI the Continuity Bad suppression diode module.

supprcssion diode module
Bctween terminals C and F of thc Continuity Bad suppression diode module.

NOTE: Changetheleadsof themuttimeteroversaLhenegattvclcacJgocs tolcrntinal Cof lhcsupprcssion diodemodule
Bctwecn tcrminals A and C of thc No Continuity Bad suppression diodc module

Betwecn terminals B and C of thc No Continuity Bad suppression drode module.

supprcssion diodc modulc
Bctwecn terminals D and C of thc No Continuity Bad suppression drode modulc

Bctwccn tcrminals E and C of ihe No Continuity Bad suppression diode module.

supprcssion drode module
Bctwecn torminals F and C of thc No Continuity Bad suppression diode module.

Don /-39210 issJc() I I 93 Printcd in Englanl
kaukazz@yahoo.co.uk
4001-61
Schematic Circuit
MFD Solenoid Diff Lock SWitch Dift Lock RelaY Ditt Locl Lock Solenoid Brake Pedal Switches
MFD Switch f
R/DC ffi
(r5) ETil--r38DBl (18r 138DB/1y08)
* uu*
Etrt----l '
tr-* I
I
1'o t'o
I
135 ,36 136
DB DA DB
(16) {15, (18)
{+oor-eo |tj I
(r8)
I I
136 OB {16)-
I
136 D8 06) __l
133 OB/DG {16)
I
130 :36 136 1i6 '136
LG DE/DG D3 DB DB OB
tl6l (r6, {16)
@'r fl81 {18}
I
\,*
{ noor.ss
\ttr I
{ oor+s
,AtS"
132
B8
d eoos
08) H l^l
o[ffi] oE tffit ,",*,4**.r{

tal Lcr/Y (18)
132
BR
(18)
4_
lYl
IBI
BB
r6)
{,L
txl
fr
BB
{16)
,t flE
COMPONENTS
o FUSE F24 @ orrr LocKwARNTNG LAMP
@ FUSE F23 @
@
r-rri
nrenr
HAND BBAKE PEDALSwtTcH
HAND BRAKE PEDALSwtTcH

._..\*\*li ",
@ MFD SWITCH
c MFD SOLENOID
:-- i$$lo.::i\ii lr,
c OIFF LOCK SWITCH
CONNECTOBS
i;H
)lli-.Fft"i1
'H" :illl
1:i';;;,
!.raH
j1\' -= ffi-QY^::
l:-::-rr--iTJ-\.
o DIFF LOCK RELAY

id$ THANSMISSION HABNESS TO INSTRUMENT PANEL HARNESS
I
f:*lr","',,:=-itrffE -l-- J.-1,, i-\{N'-*C'1.x-tjl,l
o
I
.ri* TRANSMISSION HARNESS TO RIGHT HAND CONSOLE HARNESS
SUPPRESSION DIODE MODULE
c 4TH RANGE SWITCH (WTH 3.9 OHM RESISTORS) i*ffi rCVEO POWER JUNCTION BLOCK
^",\F11',V-
--'/-'jir i j'tii .\ #t,,l"ll utj )
o ili-F\,r-'
r@
DIFF LOGK SOLENOID
REVERSE INDICATOR LAMP

,,i',i,,1' \\l\
t, l\\
.\_ i\,;,iiLii'fir*,
'\'\ ii- --.,7 C,\t-r-J;rr"*\ i-'\:'l iiliii*ii
POWERSHIFT FAULT INDICATOR LAMP
sf,tt0t5G

4AA1-62
HFADI.AMPS AND TAIL LAMPS

Sectional lndex
Left Hand Headlamp Circuit Test .......... .......... 63

Right Hand Headlamp Circuit Test .........,. ....... 63
Headlamp Dimmer Relay Circuit Test............ ....................... 64
High Beam Warning Lamp Circuit Tes1........... .......................65
Lef Hand Tail Lamp Circuit Test ........... .......... 66

Bight Hand Tail Lamp Circuit Test ........... ........ 66
...........
Trailer Connector Tail lamp Circuit Test ............."...... 67
Lamp Switch Test (Headlamp and Tail Lamp Circuits) ...... 67
Schematic Circuit (For Cab Tractors) .............. 69
Schematic Circuit (For Non Cab Tractors) ............... ........... 71

kaukazz@yahoo.co.uk
4001 -63
CIRCUIT TESTING
NOTE: The battery must be atfull charge and all connections ntust be ctean and tight before testing. Use a multimeter
lor
lhe fe.sls.
NOTE: For cab tractors reler to the schemattc ctrcutt on Page 69, and for non cab tractars refer to the schematic crrcuit
n^^^
^^ rdge /-1t
un
Left Hand HeadlamP Circuit Test

NOTE: Check Fuse F1O and F17 and the left hand headlamp bulb'
NOTE: Turn thc tamp swilch to the HEADLAI'IP posrtion (posrtion 3) ancl aperate the dtmmer switch to the LOW BEAM
position
Chcck points Rcading Possiblc Cause of Bad Reading
Tcrminal for wrrc 157 pu*JDark BIuc to 12 Volts Bad circuil beiween the left hand headlamp
ground (1ow beam) and the headlamp dimmer relay
tcrminal 568 Also check the headlamp
drrnmcr reiay, dimmerhctrnlhorn switch anc
:hc arp switch c,rcrits.
NOTE: lf the right hand headlamp low beam works correctly, check wire 157 betuveen fuse F11 and the lefl hand
headlantp.
NOTE. Aperate thc dimncr swlch lo thc HIGH BEAM posrtron
Tr:rminal Ior wire 60 pirUDar.k Grccn

.1
lo i2 Volts Bad circuit betwcen the left hand head lamp
ground (high bcam) and the headiamp dimmcr
NOTE: lf thc nght hand hcadlamp hrgh bcam works correctly check wire 1 60 bet'r'teen f use F 10 and the left hand
headlamp .
Conlinurty Chcck wrc 158 and the chassis ground

lcrminal Ior wirc I58 Brown to ground
@ connecl,on
Right Hand HeadlamP Circuit Test

NOTE, Check Fuse F1A and F11 ar.,C lhc rght hand headlarrtp bulb.
NOTE: Turn the lamp sv,r1ch to the HF-ADLAMP positnn (positicn 3) and operate the dimmcr switch to the LOW BEAM
position.
Jl Tcrmlnal for wirc 157 Pink/Dark Bluc :o 12 Volts Bad circuit between thc right hand
v o,ornd headlamp (low beam) and the headlamc
dirnmcr rclay terminal 568 Also chcck the
hcadlamp dimmcr relay, dirrmcr/turn/horn
switch and thc lamp swilch circuits
NOTE: lf the left hand headlamp low beamr",orks correctly check wlre 157 beNveen fuse F1 1 and the right hand
headlamp
i]c: 7 3927C lssucd 1 I -93 Printcc in England
kaukazz@yahoo.co.uk
4001-64
powrquadplus
NOTE: Operatewww.thebestworkshopmanuals.co.uk
the dimmer switch to the HIGH BEAM positon
Tcrminal for wire 160 Pink/Dark Grccn to 12 Volts Bad crrcL,il bciwce n ihe rioht hand head
ground lamp (high beam) and the neadlamp
dimmer relay termrnal 564. Also check the
headlamp dimmer rclay, dimmerllurnlharn
NOTE. lf the lelt hand headlamp hiqh beam works carrectly, check wjre l60 benween fuse FIO and the right hancl
headlamp .
Q Terminal for wjre 2l Brown to ground Conlinuity Check wire 21 and thc chassis ground
cornccl,on.

NOTE: Turn the lamp switch to the l'lEADUMP positron (posttion 3).
Check pornts Reading Possible Cause of Bad Reading
tcrmnal for wire 151 Red to groui-rd l2 Volts Bad circuil bctwcen the headlamp dimmer
@ rclay and thc lamp switch Also check the
lamp switch.
{l Tcrminal for wire 151 Bcd to ground 12 Volls Chcck rnrire 151 bctwccn terminals 30 and
56 ot ihc hcadlamp dimmer relay.
NOTE: Turn thc lamp switch to thc OFF positton and hold the dimmer sv,titch in the HtGH BEAM positfun
€| Terminal for wire 152 BrorvniPink to groun<j Conrrnuity Bad circurt bctween the headlamp dimmcr
rclay lcrn inal S and :he chassis ground
conncclion Also chcck thc drmrner/turni
horn switch and ihc chassis oround
connection
NOTE: Turn the lamp switch to the HEADLAMP position and hold the dlmmer switch in the LOW BEAM posltion
Tcrminal for wirc 156 Red/Darx Bluc lo 12 Volls Bad drmmcr rciav
q16ltnrj
NOTE: Operate the dlmmer switch to the HIGH BF.AM position
Tcrrninal for wire 159 Red/Dark Green to 12 Volts Bad dimmer rclay
ground
)cr t 39279 lssuec 1l-93 P.ilrtcd in England
kaukazz@yahoo.co.uk
4001 -65
NOTE: Disconnect the instrument cluster lrom thc harness
switch rn the HIGH BEAM posttton
NorE: rurn the lamp swttch ta the HFADLAMp position (position 3) and hold the dimmer
chcck points Bcading Possiblc cause of Bad Reading
to 12 Volts
the instrument cluster conneclor
Check wirc 160 between the instrume nt
Prn 32 of
groundc]usterConnectorpin32andfuseFlO.
ground circuit' refer to Page 13
NoTE. tf lhe reading is correct check the inslrumcnt cluster power and chassis
Horn Circuit Test

NOTE: Disconnect the horn f rom the harness

Rcadrng Possible Cause ol Bad Beading
Check pornts
Terminal lor wirc 161 Gray/Bcd to ground 12 Volts Bad circuit between the battery powe r
Gl junction block and the horn Also check thc

battcry powcr junction block connccl on
NOTE: Hold the horn switch tn the HORÎ positton
Term "'-"v.-
nal ior wirc 162 Brown/orangc to
'- continuiiy Bad circuit between the horn and thc
chassis ground conne ction Also check thc
ground
dimmerlturn/horn switch and the chassis
ground con'reclion

H
NOTE: Disconnect the dimrnerlturnlhorn switch from lhe harness at cannectar
Bcading Possiblc Causc of Bad Reading
Chcck potnts
Continuitv Check wire 155 and thc chassis ground

v. fcrminal for wire 155 Brown to groLrno'
Gl connection,
(posrtron 3)
NOTE: Turn the lamp switch to the HEADLAMP position
(h Volts Chcck wire 152 and the headlamp dtmmcr

Termlnal for wire 152 Brown/Pink to ground 12
rclaY
2 ancl 6 for wires 153 Black

NOTE: aperate dimner swich unti! a conitnutry readlng rs obrlrned between terminals
the
readlng Can nat be obtained replace the
154 Black,,16,,of Canneclor u (s*itcn sirle) tf a conttnuibl
,,12,,and
di m mer lturn I horn switch.
NOTE: Operate the dimmer switch again'
Bclwccn terminals 2 and 6 oi conncctor ! No Conrinurly Bad dimmcr/turn/horn switch

(swLtch sidc) for wircs 53 Black '1? anc
.1
154 Black "16"

lssued 1l-93 Printed rn Fngland
Don /'39270
kaukazz@yahoo.co.uk
4001 -66
NOTE: Press and hold the horn switch tn the HORN position
Chcck points Reading Possible Cause of Bad Reading
Sctween lcrrninals 3 and 6 oi corrncc:or i-i Contrnurly Bad dtmmeriturn/horn switch

(swilch sidc) for wires 163 Black "13" and
t55 btacK lh
NOTE: lf the readings are correct,check wire 152 betvveen the headlamp drmmer relay and the dimmerlturnlhorn switch
Left Hand Tail Lamp Circuit Test

NOTE: Chcck Fusc FS and the lett hand ial lamp bulb
NOTE: Discon nect the lefl hand tail lamp f rom the harrless and turn thc lamp switch ta thc HFADUMP posrtion (pasition 3)
Chcck poi:ris Rcadrng Possibic Cause cf Bad Rcading
tcrminal forwrrc 166 Prn(,Wnrtc io ground 12 Vc::s Bad crrcurt bctwccn thc left hand tail lamp
@
and thc lamp switch Also check the lamp
switch
NOTE. il tne rtgi"tt hand tatl lamp r'lark:; correcily, check vtire 166 between ihe lcft hand tail lanp and the splicc.
G Tcrminal ior wrrc ]67 Brown ro grounrj conlinr,riv chcck v,tuc 167 and thc chassis qround
conncctron.
Right Hand Tail Lamp Circuit Test

NOTE: Check Fuse F9 and the le{l hand tail lamp bLtlb
NOTE: Orscon neci the rlghl. ha,)C iar! iarnc tlsrr: rl'^ harrr;.s-c ato li,n ihe lamp s la lhe I :EADUMP posilion (postion 3)
^,,!ch
Chcck pcrnls Rcading Possrblc Causc ot Bad Reading
fD Tc,minal for wire 166 PnKA,A/hrtc lo oround I2 Volts Bad circuit betwcen thc right hand tail lamp
and thc lamp switch Also check the lamp
switch
NOTE: ll the left hand tail lamD,,vorks correctly, check vtire 166 berween ihe nght hand tail lamp and the spltce
6fil T.tmnul for wirc 168 Brown lo ground Continui:y Chcck wire 168 and the chassis ground
conncctron
Dc;r 7-39270 lsslr:cj 1 I 93 Plntco rn Engiand
kaukazz@yahoo.co.uk
4001-67
Trailer Connector Tail LamP Circuit Test
Termrnal 1 of thc trailcr connector ior wirc Continuity Check wirc '1 69 and the chassis ground
169 Brown to ground connection
NOTE: Turn the lattp switch to the HEADAMP posrilon (posrtron 3)
Tcrminai 6 o1 thc trailcr conncctor- for wrrc 12 Volts Check wire 166 between the trarler
166 PinkAVh te to ground connector Pin 6 and the sPtice
Lamp Switch Test (Headlamp and Tail Lamp Circuits)

Chcck points Re ading Possible Cause of Bad Heading
Turn,,r,, lor wirc 150 Rcd/Ycllow to ground 12 Voils Check wirc I50 and the battery Powe r
4l Irrnctio'r block conncctlon.
Terminal for wirc 164 Bcd,YcllowrWhrtc to 12 Volts Chcck wirc 164 and ihe battery power
ground lunction block conncction.
NOTE: Turn tha larnp switch la thc wARl\llNG UMP posrlio, (posttron 2)
Tcrminal for wirc 165 RcdrWhiic to (lroLnd 0 Volts Bad lamp switch
ffl
.l
t.tn,,nol for wrrc 51 t-lco to oroL,'rti 0 Volts Bad lamp swilch
@
NOTE: Turn thc lamp swttch to thc HEADLAI:/IP aosttron (posrtron 3)
Tcrminal {or r,virc 165 Eccl.tuVhiic to 9r'oirnd 12 Volts Bad lamp switch
@
lcc io J'curc Bad lamp switch
6h
\y ,cI.t,nar fo'wirc 151 12 Volts
(pasiilon 4)
NOTE: Turn thc lam{: sv'titch {o thc FENDER WORK iAMp pasttton
- ior wirc 165 RcdMhtte lo grounc 12 Volts Bad lamp swrtch
6R
-
\J Tcrmrnal
tcrn inal for wirc '151 8ed to ground 12 Volts Bad lamp switch
6
NOTE: Turn the tarnp swttch ta the CAB Afl CANOPY WARK itMP posttton (postlron 4)
Tcrminal for wirc 165 Rccl,Whrtc tc gror'nd 12 Voiis Bad lamp swrlch
6l
Terminal for wirc i51 Rcd 1o ground 12 Volls Bad lamp swtch
6.1
lssueC 11-93 Prinlco jn England

l)on /-392lA
kaukazz@yahoo.co.uk
.10c r -68
kaukazz@yahoo.co.uk
4001-69
Schematic Gircuit (For Gab Tractors)

Headlamps Headlamp Dimrner Relay and TurniHorn/Dimmer Switch Horn
Lamp Switch and Tail Lamps
I
159 lsl R (13)
E/DB Bloc i'
lso rvY (t3) 164 EvY t18)
$5)
{15}
.{ oor-zo I
I q
I
3[rcor.r I
) (@
R/DB
(13) I
ht\ 151
l\__
.it
R
160 P/DG {r8} {eoor.ror fl3) rtl -- lla -' e
t)
t5? l5f
I
?-r
160
'50
PiDB PIDB PiDG P/DG
fls, trs) flg fl5)
J..-. *{ +oor+r
t6-t GrR (16) __l

162 BR/O (16)
-t t66 Pi$' (18) 166 P/W {18}
ll {
r52 AR/P (14) rcorer
{ +ooros
l"l
uPl
{ +oor.roo
t5?
PIDB P/DG
tt5)
t60
flq
157
P/DB
(15)
160
P/DG
(r5) r53 B"1Z'(18)
Al
*J,
{loor-l
,55
AR
160 8"14" {16)
H
{r6) 'r80 8"r5" (i5)
{ oor-ar @00
182 8"11" {r5l
H
,58
177 8"14" (151
6l?
A 159
BB
BR {16} (131
{15)
COMPONENTS CONNECTOFS
o FUSE FI.' r8) HORN LSI ENGTNE HARNEss io tNsrRuulrNT PANEL H,l
. HARNESS
@ FUSE FlO e FUSE Fl7 liBi CAB HARNESS TO INSTRUMENT PANEL HARN
TRNESS
60-) LAMP SII,.ITCH 1.# INSTRUMENT PANEL HARNE$S TO
@ FUSE F9
DIMMER/TURNIHORN SWITCH
e LEFT HAND HEADLAMP (LOW BEAM) 6i LEFT HAND TAIL LAMP

CAB HARNESS TO REAR FENDEH HARNESS
$si
@ LEFT HAND HEADLAMP (HIGH BEAM} ri) RIGHT HAND TA'L LAMP
iS
ffi# sarrERY PowER JUNcloN BLocK
o ETHER START SOLENOID
@ 7 PIN TRAILER CONNECTOR
e RIGHT HAND HEADLAMP (LOW BEAM}
RIGHT HAND HEADLAMP {HIGH BEAM)

@
o INSTRU MENT CLUSTER CONNECTOR
\;1:;J,)!
o
(z\
HEADLAMP DIMMER RELAY 1..
t.'.-1i
-,'\
-t --,,, )- *{
_ /r i!r'^ -',\ r'
,
DIMMER/TURNIHORN SWITCH ./-.:'- -' : a

sM1016G
kaukazz@yahoo.co.uk
Don 7€9270 lssued 11-93 Prinled in England
4001-70
This page has been left blank
kaukazz@yahoo.co.uk
4001-71
Schematic Gircuit {For Non Cab Tractors)

Headlamps Headlanp Dimnrer Belay and Tum/Horn/Dimmer Switch Hom
Lamp Switch and Tail LamPs
156 R DA (15)
1s9 R/DG {r5)

I
159 rsl B (13)
E/DB B/OG
{15) (15)
q qI
{ aoor-zs
35
WDB
6 (- {r,a) I3)
\"
t-
fr
r60 P/OG (181
.ft rrl--fOa--a
\
157 tE
PIDB P/OB
160
'@
PiDG P/OG
e
(rq
i=
{r5} {r5} (1s) *{ +oor-zc
165 &W (18)

161 GvB (16)
162 BR O (16) ),,-^ !66 Ptrr{ (,t8)

1s2 ER/P (18)
;t '{?qe t6tI
,66 ,
. {
{
*oor+o
oor-sz
l,l
vPl
PAY
(181
-160P/w{ts)
P/U'
(18) { oor-ros
nrl
157
t57
PIOB
160
P/DG P/D8
t00
P/OG L*f d,oor.ao
BR
(r5l (15)
iisii a {r3}
{ noor-tt 155
BR
(!6)
{ eoor-ea
t5a 8B
BF o3)
(15,
COMPONENTS COHNECTORS
u, FUSE F1 I o HORN iffi ENGINE HARNESS TO INSTRUMENT PANEL HI

. HARNESS
@ FUSE FlO ai FUSE Fl7 -+&s PLATFORM HARNESS TO INSTBUMENT PANEL

\IEL HABNESS
itft INSTRUMENT PANEL HARNESS TO DIMMER]Tl,
@ FUSE F9
@ LAMP SWITCH VIURIYHORN SWITCH
ar) LEFT HAND HEADLAMP (LOW BEAM) ril) LEFT HAND TAIL LAMP i,igffi BATTERY POWER JUNCTION BLocK
@ LETT HAND HEADLAMP IHIGH BEAM} 6A RIGHT HAND TAIL LAMP
c ETHER STABT SOLENOID @ 7 PIN TRAILEB CONNECTOB
c RIGHT HAND HEADLAMP (LOW BEAM)
RIGHT HAND HEADLAMP (HIGH BEAM)

@
as) INSTRUMENT CLUSTER CONNECTOB
f6) HEADLAMP DIMMEB RELAY
c DIMMEB/TURNIHORN SWITCH
kaukazz@yahoo.co.uk
3il1017G

powrquadplus
TURN SIGNAIJIA/ARNING TAMPS

Sectional lndex
73
LeftHandFrontTurnSignalflVarningLampCircuitTest(CabTractorsonly)'........
IJ
Left Hand Bear Turn SignalMarning Lamp circuit Test (cab Tractors Only) .........
74
Hight Hand Front Turn Signalllffarning Lamp Ckcuit Test (Cab Tractors Only) ...'..'..
74
Rilnt XanO Rear Turn SignalArVarning Lamp Circuit Test (Cab Tractors Only)
75
Le-ft Hand Fender Turn Signal&Varning Lamp Circuit Test (Non Cab Tractors Only)
75
Right Hand Fender Turn SignaltWaming Lamp Circuit Test {Non Cab Tractors Only)
76
Le-ft Hand Front CanopyTuin Signalffiarning Lamp Circuit Test (Non Cab Tractors Only)
76
Left Hand Rear Canopy lurn SignalflVarning Lamp Circuit Test (Non Cab Tractors Only)
77
Right Hand Front Canopy Turn Signal/lVarning Lamp Circuit-Test (Non Cab Tractors Only)
nilnt HanO Hear Canopy turn Signallffarning Lamp Circuit Test (Non Cab Tractors Only) ....'.... 77
78
lnitrument Cluster Turn Signal Vfarning Lamps Circuit Test """"""
Flasher Relay Circult Test ...........
79
Dimmer/Turn/Horn Switch Test fiurn Signal Ckcuit)
Lamp Switch Test {Warning Lamp Circuit} 80
Trailer Connector fl-urn SignalMarning Lamp) Circuit Test '.""""'
80 r'
B1
Schematic Circuit (For Cab Tractors Only)
B3
Schematic Circuit (For Non Cab Tractors Only)
Don 7-39274
lssued 11-93 Ptinted in England
kaukazz@yahoo.co.uk
4001 -73
CIRCUIT TESTING
N9TE: The battery must be at fult charge and all connections must be clean and tight before testing. Use a multimeter for
the lests,
NOTE: For cab lractars refer to the schematic circuit on Page 81 and for non cab tractors refer to the schematic circuit on
Page 83.
Left Hand Front Turn signal/warning Lamp circuit Test

(Cab Tractors OnlY)
lamp bulb
NOTE: Check Fuses F5, F6 and F17. Also cheCk the left hand front turn signallwarning
NOTE: Disconnect the left hand lront turn signallwarnrng lamp from the harness.
Chcck poinls Readino Possiblc Cause o{ Bad Reading
terminal for wire 184 Brown to ground c*il, check wire 184 and the chassis ground
Q connection.
NOTE: Turn the lamp switch to the wABNlNc UMP positian (posttion 2)
Terminar for wire 181 pinldDark Grecn to 12 Volts Bad circuit between the flasher relay and the
grounri ON-OFF-ON left hand front turn signal/warning lamp
NoTE: Turn the key to the oNposrtion ancl put the turn signal switch in the RIGHT turn position
Terminal for wirc ro

1
g 2 voris Bad circuil beMeen the flasher rcray and the
1 pinuDark Grccn 1
grounddimmcr/turn/hornswitch.A|socheckthc switch dimmer/turn/horn
Left Hand Rear Turn signalruarning Lamp circuit Test

(Cab Tractors OnlY)
NOTE: Check Fuse.s F5, FO and F17 Also check the lefl hand rear turn siglnallwarning lamp bulb'
NoTE: Disconnect the left hand rear turn signallwarning lamp from the harness.
Chcck points Roariino Possible Cause of Bad Reading
ferminal for wire 185 Brown to ground a*,*, Chcck wirc 185 and the chassis ground
O connection
(posrtion 2).
NOTE: Turn the tamp switch to the 4ARNING LAMP position
rerminar for wire 1g1 prnrvDark Green to 12 Vorts Badcircuitbctweentheflasherrelayandthe

ON-OFF-ON left hand rear turn signal/warning lamp. Also
ground check lhe ilasher relaY
lamp and
NorE: ll the left hand lront warnine larTp works, check wire 1 81 beuteen the left hand rear turn signallwarning
the lefl hand front turn signallwarntng lamp
lssued 11-93 Printcd in England

Don /-39270
kaukazz@yahoo.co.uk
4001-7 4
powrquadplus
Turn the key to the aN position ancl put lhe turn stgnal switch tn the RIGHT turn position
Check points Readrng Possible Cause of Bad Reading
@ J|jn:'l ror wire lBr Pink/Dark Grccn to l2 Volts Bad circuit bctwcen lhe flasher relay and thc
drmmca'turn/horn swiich Also check the
1' r,Yl t.ncr.rlu rn,/hcrn swi toh
Right Hand Front Turn signal/warning Lamp circuit Test

(Cab Tractors Only)
NOTE: Check Fuses F5 F6 and F17 Also check the rrght hand front turn signallwarnlng tamp bulb
NoTE: Disconnect the right hand lront lurn signaliwarntng lamp front the harness.
Chcck po nls Rcading Possible Cause of Bad Beading
@ terminal for wire 184 Brown to ground Continurty Bad chassis ground circuit. Alsocheckthe
chassis ground conncction
NOTE: Turn the lamp swilch to the WARNII'lG lAlvlP post[ior) lposttron 2)
lcrminal for wirc 183 Prnk tc ground 2 Volrs

.1
Bad circuit be twee n thc f lashe r relay and the
O ON-OFF ON right hand fronl lurn srgnal/warning lamp
Also chcck thc flasher relay
NOTE: Turn the key to the ON position and aut the iLrn signal swltch tn the LEFT turn position
@ fer,minal ror wire t83 Pink io groL.)d 12 volrs 3ad crrcuii betwcen the f lashcr rclay and thc
dimmcr/turn/horn switch Also check the
dimmcr/turn/horn switch
Hight Hand Hear Turn SignalAffarning Lamp Circuit Test

(Cab Tractors Only)
NOTE: Check Fuses F5, FO ancl F17 Also check tne right ttand taar lurn stgnallwarnrng lamp bulb
NOTE: Discannect the lett hand rear lurn stqnll,rvtarninq lamp from thc harness
Chcck poinls Bcading Possiblc Causc of Bad Reading
@ ferrninal for wire 185 Brovrn to grcund Contrnr;rlv Bad chassis ground circuit. Check the work
larno and lefl hancj rcar turn srgnal/warning
lamc circuils
NOTE: Turn the lamp switch to the WARNING UMP position (posrtron 2)
(!l T"r*,nrl for wire 183 Pink to ground 12 l'olls Bad circuit between ihc flasher re lay and the
ON-OFF-ON rght hand rcar turn srgnal/warning lamp
Also chcck thc flasher rclay
NOTE: lf the rrght hand front warning lamp works, check wlre 183 betwcen ihe rrght hand rcar turn signallwarning lamp
and the right hand fronl turn srgnallwarnrng lamp
D.n 7 39?7a lssucc i I 93 Pflnteo rn Enoia.d
kaukazz@yahoo.co.uk
4001-75
NorE: Turn the key to the oN position and put the turn signal swttch in the LEFT turn Position.
Check points Readtng Possiblc Causc of Bad Rcading
Tcrminal for wirc 183 Pink to ground 12 volts Bad circuit bctween thc f lasher relay and the
O dimmcr/turn/horn switch. Also check thc
Left Hand Fender Turn signal/warning Lamp circuit Test

(Non Cab Tractors OnlY)
NOTE: Check Fuses F5, F6 and F17. Nso check the lcft hand fender turn signallwarning lamp bulb.
NOTE: Disconnect the left hand fender turn signal/warning lamp from the harness'
Qhcck points Readino Possiblc Cause of Bad Reading
fcrminal for wire 167 Brown to ground Continuity Chcck wire 167 and the chassis ground
@ connection.
NOTE: Turn the lamP swrtch to the 4ARN|NG LAMP position (positron 2).
ror wiro 181 pinl</Dark Green to 12 Volts Bad circuit between the flashcr relay and thc
G) J::n:.r ON-OFF-ON lcft hand fcnder turn signal/warning lamp'
Also check thc flasher relaY
fender turn
NOTE: ll the left hand canopy warntng lamps work correctty, check wire 181 between the left hand
srgnallwarning lamp and the sp/rce.
RIGHT turn posttton'

NOTE: Turn the key to the ON positton and put the turn signal switch in the
Gl Terminal for wrre 181 Pink/Dark Green to 12 volts Bad circuit betwccn the f lasher rclay and the
9 oinrno dimmer/turn/horn switch. Also chcck thc
Right Hand Fender Turn Signal/Warning Lamp Circuit Test

NoTE:CheckFusesFS'F6andFlT.AlsoCheckthertqhthandfenderturnsignallwarninglampbulb,
harness
NOTE: Disconnecl the right hand fender turn signatlwarning lamp from the
Rcadtng Possiblc Cause of Bad Reading

Check points
fcrminalfor wire'168 Brown to ground Continuity Check wrre 168 and thc chassis ground
(l conncctron.
NOTE: Turn the lamp switch to the 4ARNING LAMP position (positron 2)
12 Volts Bad circuit between the flasher rclay and the

ferminal for wrrc 183 Pink to ground
? ON OFF-ON right hand fendcr turn signal/warning lamp
Also check the flashcr relaY
NOTE: lf the right hand canopy warntng tamps work correctlY, check
wire 183 beNvcen the Ieft hand fender lurn
signallwarning lamp and the sp/ice
lssued 1 l-93 Printed in Engla.rd

)on 7-39270
kaukazz@yahoo.co.uk
4001-76
NOTE: Turn the key ta the ON poslllon and Pul the turn signal switch tn the LEFT turn position.
Check f:oints Re ading Possib e Cause of Bad Reading
tcrminal for wire 183 Pink to ground 12 Volts Bad circuit bctwccn the flasher relay and the
@ dimmer/turn/horn switch. Also check the
Left Hand Front Canopy Turn SignaliWarning Lamp Circuit Test

NOTE: Check Fuses F5, FO and F17. Also check the teft hand front canopy turn srgnallwarning lamp bulb
NOTE: Disconnect the left hand front canopy turn signallwarning lamp from the harness.
fcrminal for wire 184 Brown to grouncj Continurty Chcck wrrc 184 and the chassis ground
@ conncction
NOTE: Turn the lamp switch to the WARNING UMP posltton (position 2)
G) ;::n:rl ior wire 181 PinrdDark Grccn to .-l',.u.?::,..,

Bad circuit bctwecn thc f lasher relay and the
c{r hand front ca'r<,rpy lurn s,gnal/warning
lamp Also check the flasher relay
NOTE: lf the teft hand rear canopy warnrng lamp works, check wrre 181 between the left hand front canopy turn
signallwarning lamp and the splrce..
NOTE: Turn the key to the ON position and put the turn srgnal swltch in the RIGHT turn position.
Terrninai for wirc 18'1 PnlVDark Grccn to 12 volis Bad crrcuit bclwcen thc flasher relay and the
Left Hand Rear Canopy Turn Signalffiarning Lamp Circuit Test

NOTE: Chcck Fuscs F5, FO anrl F17 Atso chcck lhc lelt hanC rcar canapy turn srgnallwarning lamp bulb
NOTE: Disconnect the left hand rear canopy turn signallwarning lamp from the harness.
rerminal for wire 185 Brown to ground Continuiiy Check wire 185 and the chassis ground
@ conncction
NOTE: Turn the lamp switch ta the WARNING UMP position (position 2)
for wire 181 PinicDark Green tc 12 Volts Bad circuit between the ilasher relay and thc
G) ;:n:tl ON.OFF ON eft harrd rcar canopy turn signal/warning
amf: Also chcck ihc iiashcr rclaY
NOTE: ll the lefl hand front canapy vtarning lamp v.torks, check wire 181 betvveen the left hand rear canopy turn
signallwarning lamp and the sp/ice.
l)a,' 7-39270 issuod I I 93 Printed in Fnqland
kaukazz@yahoo.co.uk
4001-77
tn the RIGHT turn position
NOTE: Turn the key to the oN position and put thc turn signat switch
Terminal for wirc 1B l PinlVDark Grccn to 12 Volis Bad circuit bctwccn thc flasher relay and thc
ground dimmcr/turn/horn switch' Also chcck thc
Right Hand Front Canopy Turn SignalMarning Lamp Circuit Test

NoTE: check Fuses F5, F6 and F'l 7. Atso check, the rigt',| hancl front canopy turn signallwarnrng lamp bulb
NOTE: Disconnect the right hand front canopy lurn stgnallwarning lamp from lhe
harness'
ferminal for wrrc 189 Broivn to ground Continuity Check wire 189 and the chassrs ground
@ co^ncctior
NoTE: Turn thc tamp switch to the wABNING LAMP position (positron 2)
(f,il Terminal ior wire l83 Pink to ground 12Volts Bad circuit between the flashe r relay and the
ON-OFF ON right hand lront canopy turn signal/warning
lamp Also check the ilashcr rclaY
NOTE: tf the riaht hancl rear canopv warn)ng lamp works, check wire 1 83 befween the
ight hand front canapy turn
signallvtarning lamp and the sp/rce.
NOTE. Turn the key to the oN posilion and put the turn signat switch in the LEFT turn position
ftJ t"r.,nrl for wre 183 Pinx to grounc 12 volts Bad circuit between the flasher relay and the
dimmer/turn/horn swltch. Aiso check thc
dirrrner/turn/horn swilch.
Right Hand Rear Canopy Turn Signal,&Varning Lamp Circuit Test

lamp bulh
NOTE: Check Fuscs F5 F6 and F1 / Alsc check the riqht hand rear c)anopy turn signallwarnrng
! NOTE: Disconnect the right hand rear canapy turn stgnal,twarning lamp from the harness.
Chcck poinis Beading Possiblc Cause of BaC Reading
,.rr.,nrl for wirc 190 3rorvn lo grolnd Continrity Check wirc 190 and thc chassis ground
O conicc' o'
NOTE. Turn the iamp switch to the wARNtNG LAMP posttion (posrtion 2)
#) terminal for wirc 183 Pink to ground 12 Volts Bad circuit bctween the flasher relay and the
ON-OFF-ON riqht hand rear canopy turn signal/warning
larrp Also check the flasher relay
the flght hand rear canopy turn

NOTE: tf the rrght l-tand lront canopy warning lanp works, chcck wirc 183 bcNvccn
spnallwarning lamP and the sPlice
tssued 1 1,93 Printed in England

Oo: 7 -392 /0
kaukazz@yahoo.co.uk
4001 -78
powrquadplus
Turn the key to the ON position and put the turn signal switch tn the RIGHT turn position
Check poinls Beading Possible Cause of Bad Reading
(t) r.rnrinul for wirc 183 Pink to ground I2 Volts Bad circuit between thc flasher relay and the
dimmer/turn/horn switch Aiso check the

NOTE: Check the tnstrument cluster tutn signat warning larnp bulbs
NOTE: Disconnect the tnstrument cluster tram the harness.
Check Points Readinq Possrb c Cause of Bad Reading
Tcrminal lorwire 188 PrnkYcllow io Pin 10 oi ContrnL;iiy- Chcck wirc IBB

illc instrumcnt cluster connccior.
ierminal for wire IB7 Pink/Dark Bluc to Pin Contrnuity Check wirc 187
24 of thc instrument cluster conncctor
Pin 7of the instrumcnt clustcr conncctor to Contrnuity Chcck wire 186 bctwccn the flashcr rclay
qround and thc i"rstrumcnt cluster conncctor. Also
chcck ii'rc flashcr relay
NOTE: lt the readings are correct check lhe {lasher relay

NOTE: Chcck Fr,,se.s F5. F6 and F1 /
NOTE: Dtisconnect lhe t'lasher relt)v lrarn 1rr9 /ra,,,/ri-,ss
Chcck pornts Bcadrng Possrblc Cause of Bad Reading
(h icrrninal ior wirc 161 Gray/Rcd lo grounci 12 Vol:s Bad crrcurt betwccn thc battcry powcr
junction block and thc f lashcr rclay tcrminai
2 Also check thc battcry powcr junction
block conncct on
NOTE: Turn the lamp switch to the WABNiNG UMP positton (positron 2).
@ ierminal for wire 179 PinVBiack to ground 12 Volts Bad circuit belwee n thc lamp switch and lhc
flasher rclay tcrminal 1 Also check the lanrp
switch
Terminal forwire -186 Brown Io eroirnd Conlinu'lv Check wirc 186 and lhe chassis ground
t) conneciron
NOTE: Put the turn signal switch in the LEFT Turn pssltion
(E) lc,minal for wirc 183 Pink to grouncj I2 Volts Bad c rcuit bctwccn the dimmcr/turn/horn
sv/rich anC lhc f ashcr rclay tcrminal 7 Also
check lhc dinn crltrtrn/horn swrtch
Ilor 7'392/C lssucd 1 1 93 Prinled in England
kaukazz@yahoo.co.uk
40a1-79
NOTE: Put the turn signal switch in the RIGHT TURN positron
check points Rcading Possible cause of Bad Realing
Terminal for wirc 181 pink/Dark Grecn to 12 Volts Bad circuit between the dimmer/turnlhorn
ground swrtch and thc flasher relay terminal 5. Also
chcck the dimmer/turn/horn switch
in the LEFT TURN position

NOTE: connect the flasher relay rc lhe harness anrl put the turn stgnal switch
Terminal for wire 181 Pink/Dark Grcen to 12 volts Bad flashcr relay
ground ON-OFF-ON
Tcrminal for wire 187 PinvDark Blue to 12 Volts Bad Ilasher relay
ground ON.OFF-ON
NOTE: Put the turn srgnal switch in the RIGHT TURN positron
12 Volts Bad flashcr rclaY

G) Termina for wire 183 Pink to ground ON-OFF-ON
Cl) tor wire 188 Pink/Yellow to ground 12 Volts Bad flasher relaY
v f arminal ON OFF.ON

(Turn Signal Circuit)
H
NOTE: Disconnect the dimmerlturnlhorn switch from the harncss at connactor
Rcading Possible Cause of Bad Readtng

Check potnts
Terminal for wjre 176 PinlvYcllow to ground 12 Volts Bad circuit between the battery powcr
@ lunction block and the dimmer/turn/horn
switch. Also check the battery power
NOTE: Put the turn siQnal switch in the RIGHT TURN positron
Belween terminals 4 and 5 of connector H ccntrnuity Bad dimmer/lurn/horn switch

(switch side) forwires 1 77 B ack"14' Green
and 180 Black I 5 '
NOTE: Put the turn slgnal switch in the LEFT TURN posrtion
Between terminals 4 and 1 of conneclor 1."1 continuity Bad dimmer/turn/horn switch

(switch side) for wires I 77 Black " 1 4 " Green
and 182 Black "11"

Don 7-39270
kaukazz@yahoo.co.uk
400 r -80
Lamp Switch Test (Warning Lamp Circuit)
Terminal for wire 164 Red//ellowAVhitc to 12 Volts Check wire 164 and the battery power
ground lunction block connection.
NorE: Turn the lamp swltch ta the wARNING lAlvlp position (positron 2)
6 Tormnrl for wrre 178 white/Bcd to ground t2 Volts Bad lamp switch
NOTE: Turn the lamp switch to the HEADLAMp position (pcsition 3).
lF rerminal for wirc 178 whitc/Reo to ground 12 Volts Bad lamp switch
NorE: Turn the lamp switch to the FENDER woRK LAMp posittor't (position 4)
@ Tcrminai lor wirc "178 whitc/Red to grounri 0 Votts Bad lamp switch
NOTE: Turn the lamp switch to the CAB oR CANopy woRK LAMp pasirion (position 5)
@ Tcrminal Jor wire 178 whitc/Rcd to ground 0 Volts Bad tamp switch
Trailer connector Turn signal/warning Lamp circuit Test

NOTE: Turn the lamp switch to the WARNTNG UMp position (posrtton 2)
Chcck points Readrng Possible Cause of Bad Reading
Terminal 3 of the trailer connector for wirc 12 Volis Check wirc 1Bl betwecn thc lrailer
81 PinldDark Grcen to ground
'1
ON-OFF'ON conncctor and thc left hand rear turn
signal/warning lamp
Terminai 5 of the trailer conncctor for wirc 12 Voits Cneck wirc 183 between the trailer.
lB3 Pink to ground ON-OF[--ON connector and thc right hand rear turn
signal/warnrng lamp
icrminal I oi thc trailer conncctor for wrrc Con:inuity Chcck wire 169 and the chassrs ground
169 Brown to ground connection.
Dcn 7-3927A lssucc 11-93 Printed rn England
kaukazz@yahoo.co.uk
4001-81
Schernatic Circuit (For Cab Tractors)
Lamp Switch and TurrrHorr/Dimmer Switch Flasher Relay Left Hand Tum Signal/ltl ulMamirg Lanps Bight Hand Tum SignaUllllaming Lamps
200
-l
B/O
(18)
[-]o Tro*""
lr_,,. -J --lto.*,*
i'
176
P/Y
(r5)
@
ot--Orl--f
t78
w/R
tl8)
183
P
(rs)
191
P/OG
(15)
183
P
(r5)
,88PiY(18)r
187 P/DB
186
{r8)
BB {-16}
-
-
181 183 P (r5)

PIDG ,8t P/DG (15)
{ oor-ss
{ mor-ss { oor+e
('15) 186 t80
BR P
1?5 PrY {r5}
{16} (15)
189
L r&P{rq
BB
(r3)
t8t
P/DG PiI'G
t1s)
176
P/Y
(15)
183
?
q."l'-,", PIDGr P/DG fls) 160 P (15)
tr5)
X
+
,55
BB
{r6)
cm
185 BR {13}
1&4 BR {16) AR 66)
166
BA
185 Afl {1q ,€
BR --184 an
{15) (t6) {r3)
COMPONENTS
@ (il6i
o FUSE F5
o RIGHT HAND FRONT TURN SIGNAL/WAFNING LAMP
\
Y=.r*r-t-t--
@ FUSE F6
@ RIGHT HAND REAR TURN SIGNALX,VAHNING LAMP
o LAMP SWITCH
@ 7 P'N TRAILEB CONNECTOR
o DIMMER/TURI.IIHORN SWTCH
c FLASHER RELAY CONNECTOBS
o FUSE FI7 tstr CAB HARNESS TO INSTRUMENT PANEL HABNESS
o INSTRU MENT CLUSTER CONNECTOR irl#J INSTRUMENT PANEL HARNESSDIMMEBiIU RNiHOHN SWITCH
c LEFT HAND FRONT TURN SIGNAL/WARNING I-AMP wf CAB HARNESS TO REAR FENDER HARNESS
o LEF-T HAND REAR TUBN SIGNATJWABNING LAMP ffi# BATTEBY POWER JUNCTION BLOCK
o LEFT HAND BEAR WORK LAMP
RIGHT HAND REAR WORK LAMP

@
kaukazz@yahoo.co.uk
Don 7-39270 lssued 't 1-93 Prirded in England

powrquadplus
This page has been lelt blank

kaukazz@yahoo.co.uk
7
4001€3
Schematic Gircuit {For Non Gab Tractors)
Flasher Relay Fender Tum SignaU\lllar ming Lamps Canopy Tum SigmUWarning LarnPs
Lamp Switch and Turr{HordDinumer Switch
3s UDB {13}
mo
1*.
R/O
(18,
[-?,o ?"
I r_,,, 16r GrR (1s) l\4ooor-zr
%
164 R/Ynrv
i' o
-
o t7a
WR
(r8) ,88 Prr {r8}
-
fl8!-
167 P,DA
{ *oor-roo
mor+z
q . 4001.71 {
1864R{rO
176 -
?N 180 'r8, P/DG t16)
{r5l P P/OG
'81 '83
P
fls) (ts) {15} P (16) 18O P {'16)
rB P (r5)- rmp(to
t8l P/DG {tl
.{ {
lar eiio 1rq --{fffif- 18i Pioc
---DEEFtsop(16
*oor-zr
{ loor.sz noor-rr
186
BR
w ffi
1?6 PrY {15} {16}
15s EB (16)
181 PlD6 (rq-
t5{ s "1d'(16)
175
pvY
{15}
I83
P
(1s)
{ coor.rr * ,w
1Bl H
fr
155
BA ,s6 B'1f' (18) PIDG
{r6)
t63 B'13'06)
{ mor-zr {15) €
18O B' i5" (t5) r8, P/DG {15}
'ts3 P {rq
H
s'r1" (15)
17r a.14'(lq PIY {15)
186
BR
(r6) "h
(r6)
BB
(16)
169
BR
(13)
COMPONEttITS
nrexr HAND FRoNT cANoPY TURN sIGNALI JARNING LAMP

C FUSE F5 @
nrenr HAND BEAR cANoPY TUBN slcNALlrvARNlNc LAMP
@ FUSE F6 @
(e LAMP SWITCH @ z rrr.rrRArLER coNNEcroR
o DTMMERITURIYHORN SWITCH
c FLASHEB HELAY CONNECTORS
o FUSE FI7 lffi purronu HARNESS To IN$TRUMENT PANEL HARNESS
o INSTHUMENT CLUSTER CONNECTOB ffi wsrnuueNT rANEL HABNESS To DIMMER/TUBN/HoBN swlr ]H
c LEFT HAND FENDER TUBN SIGNAL/WARNING LAMP ffi pr-rrronla HARNEssro cANoPY EXTENSIoN HARNESS
o BIGHT HAND FENDER TURN SIGNAL/WARNING LAMP i,ffi ExreustoN HARNESs cANoPY HARNESS
o LEFT HAND FBONT CANOPY TURN SIGNALWARNING LAMP ffi alrrenY PowER JUNcrtoN BLocK
LEFT HAND REAR CANOPY TURN SIGNAL/WARNING LAMP

@
kaukazz@yahoo.co.uk

powrquadplus
WORK TAMPS
Sectional lndex
Left Hand Rear Fender Work Lamp Circuit Test ........... ...... B5
Hight Hand Flear Fender Work Lamp Circuit Test ........... ........................ 85
Left Hand Front Fender Work Lamp Circuit Test (Non Cab Tractors Only) .....,......... 86
.........
fiight Hand Front Fender Work Lamp Circuit Test(Non Cab tractors Only) ...... 86
Trailer Connector Work Lamp Circuit Test ........... ................ 86
Fender Work Lamp Relay Circuit Test ........... ....... .............. 87
Left Hand Front Cab Work Lamp Circuit Test (Cab Tractors Only).......... .................. 87
Right Hand Front Cab Work Lamp Circuit Test (Cab Tractors Only) ......... ...........,.... 88
Front Cab Work Lamp Relay Circuit Test (Cab Tractors Only).......... ..... 88
Only)
Left Hand Rear Cab Work Lamp Circr:it Test (Cab Tractors ......., Bg
Hight Hand Rear Cab Work Lamp Circuit Test (Cab Tractors Only) ......... ............,.... 89
Front Cab Work Lamp Helay Circuit Test (Cab Tractors Only)....... ...... 89
Left Hand Front Canopy Work Lamp Circuit Test (Non Cab Tractors Oniy) .............. 90
Right Hand Front Canopy Work Lamp Circuit Test (Non Cab Tractors Only) ........... 90
Left Hand Hear Canopy Work Lamp Circuit Test (Non Cab Tractors Only) .............. 91
Right Hand Flear Canopy Work Lamp Circuit Test (Non Cab Tractors Only) ............ 91
Canopy Work Lamp Relay Circuit Test (Non Cab Factors Only) ........... ......,............,...92
Lamp Switch Test (Work Lamp Circuits) ............... .............. 93
Schematic Circuit (Cab Tractors Only) ............ 95
Schematic Circuit (Non Cab Tractors Only) .......,. ............... 97
Don 7-39270
kaukazz@yahoo.co.uk
4001 -85

NOTE; The battery must be at full charge and all connecilans must be clean and tight before testlng. Use a multimeter far
lhe tests.
NOTE: Far cab tractors, refer to the schematic urcuil on Page 95 and for non cab tractors, refer to the schematic circult
on Page 97.

NOTE: lf all the fender work lamps farl to work, check the fender work lamp relay.
NOTE: Check fuse Fl4 and the left hand rear fender work lamp bulb.
NOTE: Disconnectthe lelt hand rear lender work lamp from the harness and turn the lamp switch to the FENDER WORK
UMP posrlton (posttion 4).
Check Poinls Rcading Possible Cause oi Bad Reading
Terminal for wire 205 Violctflcllow to 12 Volts Bad circuit bctween the fender work lamp
ground. relay, and thc left hand rear fender work
larnp.
NOTE: ll the nght hand rear lender lamp works correctly, check wire 205 beNveen the left hand rear fender lamp and the
sp/rce.
€l Tcrminal lor wire 206 Brown to ground Continuity Check wire 206 and the chassis ground
conne ction

NOTE: lf all the fender work lamps farl to work, check the fender work lamp relay.
NOTE: Check fuse F14 and the righl hand rear fender work lamp bulb.
NOTE; Disconnect the right hand rear fcncler work lanp f rom the harncss and turn the lamp switch to the FENDEB WORK
UMP podtion (position 4)
Check Points Rcading Possible Causc of Bad qead ng
vo Tcrminal
ground,
for wirc 205 Violct/Ycllow to 12 Volts Bad circuit betr,veen the fendcr work lamp
relay, and thc right hand rear iender work
lamp
NOTE: tf the teft hand rear fende r lamp works carractly, check wlre 2A4 bclween the right hand rear fender lamp and the
sp/lce
? ferminal for wire 207 Brown to ground Continuity Chcck wie 207 and the chassis ground
conncctton.
Don 7 39270 lssued 11 93 Prinled jn England
kaukazz@yahoo.co.uk
4001 86
Left Hand Front Fender Work Larnp Circuit Test
(Non Cab Tractors Only)
NOTE: ll all the fender work lamps fail to work, check tttc lendcr work lamp rclay
NOTE: Check fuse F15 and the left hand {ront fender work lamp bulb.
NOTE: Disconnect the left hand f rant fender work lamp from lhe harness and turn the lamp switch to the FENDER WORK
UMP posilion (position 4)
Check Points Rcadrrq Possiblc Cause of Bad Reading
Tcrminal for wirc 208 Violct/Dark Grccn to 12 Volts Bad circuit between the fcnder work lamp
ground rciay, and the left hand front fender work
lamp
NOTE: lf the righl hand f ront fender lamp works correclly. check wrre 208 betvteen the left hand f ront fender lamp and the
Tcrminal for wirc 209 Brown to grounci Continuity Chcck wire 209 and the chassis ground
Gl connection
Right Hand Front Fender Work Lamp Circuit Test

NOTE: lt all ihe lander work lamps latl to work, chcck lhe lendcr work lamp relay.
NOTE. Check fuse F15 and the right hand rear fender work lamp bulb.
NOTE: Disconnect the right hancl rear lender wark lama lrom the narness an<l turn lhe lamp swttch to the FENDER WORK
AMP position (posibn 4)
Chcck Points Rcading Possiblc Cause ol Bad Reading
Tcrmjnal for wire 208 Violct/Dark Grccn to 12 Volls Bad circuit bctwecn lhe fender work lamp
grour:d relay, and thc rlght hand front fender work
lamo
NOTE: lf the left hand tront fender lamp works correctly, checkwre 2AB betueen the right hand f ront fender lamp and the
sp/rce.
Tcrminal for wire 210 Brown to ground Confinuity Chcck wirc 210 and the chassis ground
O conncctron.

NOTE: Turn the lamp switch to lhe FENDEB WARK LAMP posrlion (position 4)
Chcck Poinls Rcading Possible Causc o{ Bad Reading
Tcrminal 2 of thc trailer connector lor wirc 12 Volts Chcck wirc 205 betwccn thc trailcr
205 VioletrYcllow to grcund conncctor oin 2 and thc splice
Tcrminal 1 of lhc trailer conncctor ior wirc Coniinuity Chcck wrrc 169 and the chassts ground
169 Brown to ground conne ctron
Dcr /'39270 lssued 1 1-93 Printed in England
kaukazz@yahoo.co.uk
4001-87
NOTE: Turn the lamp svtitch to the OFF positton (position 1)
@ ferminal for wirc 203 Brown to groun<j Continuity Check wire 203 and the chassis ground
connectron
NOTE: Turn the lamp switch to the FENDER WaBK UMP posrtion (position 4)
@ J::n:'r ror wire 201 Red/Lisht Grcen to 12 Volts Check wire 201 between the lamp switch
terminal FL1 and the fender work lamp relay
terminal 86. Also check the lamp switch,
lE f"rrinrl for wire 202 RedNiolct to groirnd 12 Volts Check wire 202 and the battery power
lunction block connection
@ Tcrmlnal for 204 Violet/Gray to gror,nd 12 Volts Bad fender work lamp reiay
Left Hand Front Cab Work Lamp Circuit Test

(Cab Tractors Only)
NOTE: Check fuse F1 and the left hand lront cab v.tork lamp bulb.
NOTE: Disconnect the left hand frant work lamp lrom the harness and turn the lamp switch to the CAB WORK UMP
position (position 5)
Check points Re ading Possible Cause of Bad Reading
(f{ T"rr,nul for wirc 21 7 Vrolet/Black to ground t 2 Volts Bad circuit belween the lamp switch
terminal FL2 and the left hand front cab work
Iamp Also check the front cab work lamp
rclay and the lamp switch.
NOTE: lf therighthandfrontcabworklampworkscorrectlychcckwrre2lTbetweenthclefthandfrontcabworklampand
the splice
(h terminal for wirc 218 Brown to ground Continuity Check wire 218 and thc chassis ground
connection
Don /-39270 lssued l1-93 Printcd in England
kaukazz@yahoo.co.uk
4001-88
(Cab Tractors Only)
NOTE: Check fuse F1 and thc riqht hand front cab work lamp bulb
NOTE: Disconnect the rrght hand f ront work lamp f rom the harness and turn the lamp switch to the CAB WORK UMP
Check points Rcad ng Possible Causc of Bad Reading
@ ferminal ior wirc 21 7 Vrolct/Black to ground 12 Volts Bad circuit bctwcen the lamp switch
terminal FP and the right hand front cab
work lamp Also check thc fronl cab work
NOTE; l{ the left hand frant cab work lamp works correctly check wire 21 7 befween the right hand f ront cab work lamp and
the splice
(?l Terminal for wire 219 Brown to grounrJ Continuity Chcck wirc 2]9 and thc chassis ground
connectron
Front Cab Work Lamp Relay Circuit Test

(Cab Tractors Only)
NOTE: Turn the lamp swirch to the OFF pasttton (position 1)
Check points Reading Possiblc Cause of 8ad Reading
G) Terminal for wirc 203 Brown to ground Continuity Check wire 203 and the chassis ground
conncction
NOTE: Iutn the tamp swttch to tt,e CADWORK LAMP posttton (positron 5)
flD Terminal for wire 211 Red/Brown to ground 12 Volts Chcck wire 211 betwcen the lamp switch
tcrminal FL2 and the lront cab work lamp
rclay terminal 86.
Tcrminal for wire 2-15 Rcd/Ycllow,&Vhite to 12 Volts Chcck r,virc 215 and the battery powcr
ground jrrnction blocx co^ncct or
Terminal for wire 216YioletlDark Grcen lo 12 Volts Bad front cab work lamp relay
ground
Da. 7-3927A lssucd 1 1 93 P'i1lcd ,. Fnorand
kaukazz@yahoo.co.uk
4001,89
powrquadplus www.thebestworkshopmanuals.co.uk Rear Cab Work Lamp Circuit Test

Left Hand
(Cab Tractors OnlY)
NOTE: Check Fuse F4, and the left hand rear cab work lamp bulb.
NOTE: Disconnect the left hand rear work lamp from the harness and turn the lamp switch to the CAB WORK UMP
Chcck points Bcading Possrble Cause of Bad Reading
&h T"r,r,nal for wirc 214 Vrolct,&Vhite 1o ground 12 Vo ts Bad circuit between the lamp switch
v tcrminal FL2 and the left hand rear cab work
relay and thc lamp switch.
fu Terminal for wire I85 Brown to ground Continuity Check wirc 185 and the chassis ground
connectron.
Hight Hand Rear Cab Work Lamp Circuit Test

(Cab Tractors OnlY)
NOTE: Check Fuse F4, and the right hand rear cab work lamp bulb
NOTE; Disconnect the right hand rear work lamp lrom thc harncss and lurn the lamp switch to the CAB WORK UMP
positian (posilion 5)
Chcck points Bcading Possrbie Cause of Bad Reading
flB Terminal for wire 214 Violet,&Vhite to ground 12 Volts Bad circuit bctween the lamp switch
terminal FL2 and the right hand rcar cab
work lamp Aiso check the rear cab work
iamp rclay and the lamP swrtch
NOTE: tf the left hand rear cab work lamp works correctly check wire 214 belvveen the left and right hand rear cab work
lamps.
pD Terminal for wire 185 Brown to ground Continuity Bad chassis ground circuit
Rear Cab Work Lamp Helay Circuit Test

(Cab Tractors OnlY)
NOTE: Turn the lamp switch ta the OFF position (posttion 1)
Check Points t!4!g Possible Cause of Bad Reading
Bad circuit bctwccn the rear cab work lamp

Ch T",^n,ul for wire 203 Brown to grouncj Continuity
relay tcrminal 85 and the chassis ground
connection Also check the chassis ground
connection
NOTE: Turn the lamp switch to the cAB woBK UMP pasition (positton 5)
Terminalfor wirc 2l1 Rcd/Brown Io ground I2 Volls Bad circuit betwecn thc larnp switch
E) lcrrninal FL2 and thc rear cab work lamp
rclay tcrminal 86. Also check the lamp
switch.
Dan 7-392-/A
kaukazz@yahoo.co.uk
4001 -90
points
Chcck Rcading Possiblc Causc of Bad Reading
Icrminal for wirc 212 Violot/Rcd to grouncl 12 Volts Chcck v,rue 212 and the battcry power
4) junction block connection
@ Tcrminal forwire 213 Vrolet to ground 12 Volts Bad rcar cab work lamp relay

NOTE: lf all the canopy work lamps fail to work, check the 30 amp crrcurt breaker Refer ta page 92
NOTE: Check the left hand lront canopy work lamp bulb
NOTE; Disconnect the left hand f ront canopy wcrk larna f ront tbe ha,.ness and turn the lamp swltch to the cANoPY woBK
UMP positton (posilron 5).
Chcck Points Rcading Possiblc Causc of Bad Beading
le,minal for wire 223Yiolcl to ground 12 Volts Bad circuit betwcen the canopy work lamp
rclay and the left hand front canopy work
larnp Also check the canopy work lamp
relay and iirc circuit brcakcr.
NOTE: tt lhc right hand fronl canopy work larnp works correctly check wirc 223 between the left hand f ront canopy work
lamp and lhe splicc.
lD ferminai for wlre 224 Brown to ground Continuity Chcck wie 224 and the chassis ground
co^ncc:io".
Right Hand Front Canopy Work Lamp Circuit Test

NOTE: tf att the canopy work lamps fail to work, check the 30 amp circuit breaker Refer ta page 92
NOTE: Check the right hand !roni canopy work lamo oulb
NOTE: Disconnect the right hand lrant canoDy work lamp trom the harness and turn the key to the CANaPY WORK UMP
position (posrtton 5).
Chcck Points Bcading Possiblc Causc of Bad Reading
ferminal for wirc 223 Violet io ground 12 Volts Bad circuit betwecn the canopy work lamp
@ rclay and the r ght hand front canopy work
lamp Also check the canopy work lamp
rclay and the circuit breakcr,
NOTE; tf the teft hand front canopy work lamp works correctly check wirc 223 between the right hand front canopy work
lamp and the splrce.
(t) Te,minal for wire 225 Brown ro rlrounrj Coniinrity Check wie 225 and the chassis ground
connect on.
Dct, 7 39270 lssued '1

1-93 Prinled in England
kaukazz@yahoo.co.uk
4001 -91
Left Hand Rear Canopy Work Lamp Circuit Test
NOTE: lf alt the canapy work lamps farl to work, check the 30 amp circuit breaker. Refer to Page 92.
NOTE: Check the teft hand rear canopy work lamp bulb.
NOTE: Disconnect the left hand rear canopy work lamp from the harness and lurn the lamp switch to the CANOPY WORK
UMP positron (posrtion 5).
Chcck Points Rcading Possible Causc of Bad Reading
fcrminal for wirc 226ViolclNVhitc to ground 12 Volts Bad circuit between the canopy work lamp
@ reiay and the lcft hand rear canopy work
lamp. A so check the canopy work lamp
rclay and the circuit breaker
NOTE: ll thc right hancl rcar canapy work lamp works correctly check wire 227 between the left hand front canopy work
flil Tcrminal for wire 227 Srown 1o ground Continuity Chcck wtrc 226 and the chassis ground
conncction
Right Hand Rear Canopy Work Lamp Circuit Test

NOTE: lf a1 the canopy work tamps fail to work, check the 30 amp circuit breaker Refer to Page 92.
NOTE. Chcck thc right hand rear canopy work lamp bulb.
NOTE: Disconnect the rtght hancl rear canopy work lamp from the harness and turn the lamp switch to the CANOPY
WORK UMP positian (position 5)
Chcck Points Fcading Possible Cause of Bad Reading
Term,nal lor wirc 226 Vioiel,4Vhitc to grounri I2 Volts Bad circuit betwcen thc canopy work lamp
6I rclay and thc right hand rear canopy work
lamp. Also check thc canopy work lamp
rclay and thc circuit brcaker.
work
!. NOTE: lf the left hand rear canopy work lamp works correctly check wire 226 between the rlght hand rear canopy
IerminaL for wire 228 Brown to groun<i Continuiiy Chcck wvc 228 and the chassis ground
@ connection
)c^ 7 -39274
issucd 11-93 Prlnted in Fnglano
kaukazz@yahoo.co.uk
4001 -92
NOTE: Turn the lamp switch ta the CANOPY WORK AMP position (position 5).
Chcck Points Bcading Possiblc Cause of Bad Beading
Terminal for wirc 212 YiolctlDark Blue to 12 Volts Bad circuit betwccn the canopywork lamp
ground rclay and the 30 amp cjrcuit brcaker, Also
chcck the canopy work lamp rclay.
NOTE: Turn the lamp switch to the OFF posttion (posilton 1)
Bctwee n lhe terminals of thc 30 amp circui[ Continuily Bad circuit brcakcr
brcakcr
Canopy Work Lamp Relay Circuit Test

NOTE. Turn lhe lamp switch to the OFF position
Q0 Terminal for wire 203 Brown to ground Continuity Bad circuit between the canopy work lamp
relay tcrminal 85 and the chassis ground
conncction Also check the chassis ground
conncctton.
NOTE: Turn the lamp swrtch to the CANOPY WORK UMP positton (posrtion 5)
Terminal for wire 211 Redl}rown to ground 12 Volts Chcck wire 211 between the lamp switch
terminal FL2 and thc canopy work lamp
relay tcrminal 86 Also check the lamp
switcl^
Tcrminal for wire 22O Pinl/Red to ground 12 Volts Chcck wie 220 and the battery power
junction block connector.
Terminal for wiro 212 VtalctlDark Bluc to 12 Volls Bad canopy work lamp rclay
ground
)or 7 392'i ) lssucd 11-93 Printed in England
kaukazz@yahoo.co.uk
4001 -93
@ ferminal for wire 200 Red/Orange to ground '1

2 Volts Check wire 200 and the battery power
lunction block connection.
NOTE: Turn the lamp switch to the WARNING UMP posltion (positton 2)
Terminal for wire 201 Bed/Light Green to 0 Volts Bad lamp switch
ground
6D Terminal for wire 211 RedlBrown to ground 0 Volts Bad lamp switch
NOTE: Turn the lamp switch to the HEADLAMP position (posrtion 3)
Terminal for wire 201 Rcd/Light Grecn to 0 Volts Bad lamp switch
ground
6Il Terminal for wire 211 Red/Brown to ground 0 Volts Bad lamp switch
NOTE: Turn the lamp switch to the FENDER WORK UMP position (posrtron 4)
\-_.,
,-. Terminal for wire 201 RcdiLight Grcen to '12 Volts Bad lamp switch
€El
v orouno
6t) Terminal for wire 211 Red/Brown to ground 0 Volts Bad lamp switch
NOTE: Turn the lamp switch ta the CANOPY WORK UMP position (pasition 5.
Term nal for wire 201 Rcd/Light Grccn to 12 Volts Bad lamp switch
ground
6Il Terminal for wire 21

.1
Red/Brown to ground 12 Volts Bad lamp switch
kaukazz@yahoo.co.uk
400't-94
in,s i-,;:qc has beer leil blank
i,a,. i-39214 issucd 1 1-93 Printcd in Enqland
kaukazz@yahoo.co.uk
4001-95
Schematic Circuit (For Cab Tractors)

Lamp Switch Optional Rear Cab Work Lamps Opiional Front Fender Work Lamps Rear FenderWork Lamps
212
200
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{r0)
{ts) N2
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v/oc (lsl *---t hl
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lv,s(re) J \e, llrB) T
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217 VlB {15) I I ('3r
le 205 205 I
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185 BR (r3) i35 BR (15) <[ +mtat
204
T'
,85 2la 219 206 207 I69
BR BR BR BB 3n BR BR
fl8) (r3) $9 (15)
fl6) (16) fi3)
COMPONENTS
(t LAMP SWITCH
@ r-srr HAND FRoNT cAB woBK LAMP
e BEAR CAB WOBK LAMP BELAY

@ nrenr HAND FRoNT cAB woRK LAMP
@ FRONT CAB WORK LAMP RELAY

@ r-rrr HAND REAR FENDER woRK LAMP
@ REAR FENDER WORK LAMP RELAY

@ nrcxr HAND FENDEB woRK LAMP
c FUSE F4
@ z erm TRATLER coNNEcroR
rUSE Fl
@
CONNECTOES
@ FUSE F14
(,
o LEFT HAND REAR TURN SIGNAL/IAIARNING LAMP ,{-.ffi cns HAHNESS To IN$THUMENT rANEL HARNEss
{.1
o LEFT HAND REAB CAB WORK LAMP ffi cxe HABNEssro REAR FENDEB HAHNEss
I
(J
o RIGHT HAND REAR CABWORK LAMP ffi# BATTEBY POWER JUNCTION BLOCK (i
)l
ii
(t
kaukazz@yahoo.co.uk
Don 7€9270 lssued 1't-93 Printed in England

4001-96
This page has been left blank
lssued 1.1-93 Printed in England

Don 7-39270
kaukazz@yahoo.co.uk
4001-97 4001-97
Schematic Circuit (For Non Gab Tractors) ) Tractors)
Lamp Switch Ganopylillork Lamps Front Fender lriYork Lamps Front FenderWork Lamps Bear Fender liYork Lamps
200
R/O
(181 201 R/LG n8)
150 1Bt
(r8)
N
fuY R/YAi'
{r3) (r8l f-2t1R/BB P/B
n,
ffi
271
Ni/BR
(18)
rs$,}
ffi
v vdr
(19 trs! {loor-ro
dr*
IrPi
HH
tffi -2038R{1S}
I 204
r nuBF {181 *
*3 26 vlDB
tlo)
v vnJy I vre r)
J (r5) tr
(1s) (15)
{H#
Ar& {-ro4vlc(r5}-
t zqt
v/Y
{r6l
,69
BA
(13)
+# P,*",, { -
@
{ coor.zr l,26
fls)
205 V/Y
JIfr
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ns) I
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I
@
I
I
n4
(r6)
BR
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BR
fl6'
c* 8R
{t6)
4a
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tl6)
203
BR
{18}
aI
la
151
203
BR
(r8)
e ffi 6i)
(16)
e';
(16)
@'"T
(16)
(DH
06)
lT
(r3)
COMPONENTS
(1) LAMP SWITCH

@ nreirr HAND FRoNT FENDER woRK LAMe ;ENDER WOBK LAMP
o CANOPY WOBK LAMP RELAY

@ lerr HAND REAR FENoER woRK LAMP { {DER WOBK LAMP
6A-) FENDER WORK LAMP RELAY

@ nreHr HAND REAR FENDER woRK LAMP :NDER WORK LAMP
c CIRCUIT BREAKEB
@ r erN TRATLEB coNNEcroR :CTOR
c rUSE Fl5
coNltEcToRs
FUSE F14
@
u, LETT HAND FBONTCANOPY WORK LAMP ffi er-nrronM HARNESs ro TNsTRuMENT eANEL HARNESS O INSTRUMENT PANEL HARNESS
\, BIGHT HAND FRONT CANOPY WOHK LAMP I#,J PLATFORM HAFINESS TO CANOPY EXTENSION HARNESS O CANOPY EXTENSION HABNE$S
(7\ LEFT HAND REAR CANOPY WORK LAMP I.,ffi cnuopv ExrENSroN HARNEssro cANopy HARNEss IABNESS TO CANOPY HARNESS
c RIGHT HAND REAR CANOPY WORK LAMP ffi anrrenY PowER JuNCroN BLocK .ICTION BLOCK
o LETT HAND FRONT FENDEB WOBK LAMP

kaukazz@yahoo.co.uk
Don 7-39270 lssued 11'93 Printed in England lssued I1-93 Printed in England
4001-98
RIGHT HAND CONSOLE AUXILIARY POWER CONNECTOR, INSTRUMENT

PANEL AUXILIARY POWER CONNECTOR, CIGAREITE LIGHTEFI, ELECTRIC
SEAT AND TRAILEH CONNECTOR POWEH CIRCUIT
Sectional lndex
Right Hand Console Auxiliary Power Connector Circuit Test ,........., ...;................ ... .. 99
Right Hand Console Auxiliary Power Connector Suppression Diode Module Circuit Test ....,.............................99
lnstrument PanelAuxiliary Power Connector Circuit Test .......... .........,. 100
lnstrument Panel Auxiliary Power Connector Suppression Diode Module Circuit Test ............ ......100
7 Pin Trailer Connector Power Circuit Test............. ..............fi2

kaukazz@yahoo.co.uk
4001 -99

NOTE: The baftery must be at full charge and all connection must be clean and trght before testtng. Use a multlmetar lor
the tests.
Right Hand Console Auxiliary Power Connector Circuit Test

NOTE: Check Fuses F3 and F31
Check points Rcading Possible cause of Bad Rcading
Terminal 3 of the auxrl ary powcr conncctor Conlrnuity Chcck wirc 237 and the chassis ground
for wirc 237 Brown to ground conncctron
Termrnal 2 of thc auxiliary power conncctor 12 Voits Bad circuit beiween the battery powe r
for wire 239 Rcd,rYellow to ground junction block and the auxiliary powcr
connector terminal 2. Also check the
battery power lunction block connection
and thc right hand console auxiliary powcr
suppression diode module circuit.
Tcrminal 1 of thc auxiliary powcr conne ctor 12 Volts Bad circuit between the keye d powcr
Ior wire 236 ?ed/Orange to ground junction block and the auxiliary power
connector terminal 3. AIso chcck the keycd
power circuit and the right hand conso e
auxt|ary power supprcssion diode modulc
circuit
Bight Hand Console Auxiliary Power

Suppression Diode Module Circuit Test
NOTE: Disconnect thc right hand console auxihary powcr suppressio n diode module f rom the harness and turn thc key
lo the ON position.
Terminal for wire 239 Bed,Ycllow to ground 12 Volls Chcck wire 239 betwccn the splice and the
bat:cry powcr suPpression drode
Gl Terminal f or wire 236 Red/Orange to ground 12 Volts Check wire 236 between the splice and the
keyed power suppression diode
Gl terminal for wirc 240 tsrown lo ground Con:inurty Chcck wtra 24a and the chassis ground
connectron.
NOTE. lf the readings are correct check the rrghl hand conso/e auxlliary powcr suppress/on drode module, refer to
Suppression Diode module fes/, page 141.
Dan 7-39270 lssued 'l 1-93 Printed in England
kaukazz@yahoo.co.uk
4001,1 00
Instrument Panel Auxiliary Power Connector Circuit Test
NOTE: Check Fuses F7 and Fl2.
Check points Rnarlino Possiblc causc of Bad tteading
wre 244 and the chassis ground

Tcrminal 3 of the auxiliary powcr connector Continuity Chcck
for wire 244 Brown to ground conncctton
Tcrminal 2 of the auxiliary powcr connectcr 12 Volts Bad circuit bctwccn thc baitery power
{or wire 243 Red/Yellowio g,'ouncl iunction block and the auxiliary powcr
conncctor terminal 2 Also check thc
battery power junction block connection
and thc instrumcnt panel auxiliary powcr
supprcssron dlode module clrcuit
NOTE: Turn the keY to the ON Positron
Terminal of thc auxiliary power connoctor

I 12 Volts Bad circuit bctween the keyed powcr
lunctron block and thc auxiliary
powcr
ior wirc 246 RedlOrange to ground
conncctor tcrm nal 3 Also check thc kcyed
powcr circuit and thc instrument panel
auxiliary power supprcssion diode module
circuit
lnstrument Panei AuxiliarY Power

and turn the key ta
NoTE: Disconnect the instrument panet auxiliary power suppresslo n diode madule f rom the harness
the ON position.
Rca.Jing Possibie Cause of Bad Beadrng

Chcck Poinls
12 Vo:s Chcck wire243 between fusc F12 and the

(il Tcrm,nal for rvirc 243 Red,rycllol' |e groL;nd
battery Power suPprcssion dlode
12 Volts Check wrre 246 between fuse F7 and the

Terminal forwirc 246RedlOrangc to ground
@ keYcd oowcr suPPrcssion diode
NOTE: Turn the key to thc aFF pasttron
Continurty Chcck wre 244 bctwccn the baite ry powcr

(D Terminal for wrre 244 Srown to ground
suppression diodc and the auxiliary power
connector.
panel auxilnry power suppression diode module' refer to

NOTE: ll
the readrngs are carrect check the inslrument
Suppressron Diode Module Iesl, page 101
lssucd 1 1-93 Prrnteo ir England

t)c. / 392./A
kaukazz@yahoo.co.uk
4001 -1 01
NOTE: The procedure for testing lhe suppress ion diode modules is the same for the rlght hand console auxtliary power
diode module and the tnstrument panel auxihary power diode module.
NOTE: Turn the key to the OFF posrtion and drsconnect the auxiliary power diode rnodule from the harness.
NOTE: The positive lead of thc multtmetcr must go ta lcrminal B of the diode modulc
Chcck Points Rcading Possjble Cause of Bad Reading
Betwcen tcrmrnals B and A of thc diodc Contrnuriy Bad diode module

modulc
Betwcen tcrminals B and C of the diodc Continuity Bad diode module.

modulc
NOTE: Change the leads of the multrmeter over sa the negative lead goes lo termrnal B of the drode module.
Bctween terminals A and B of thc diode No Continuity Bad diode modulc.

nrodulc
Bctween tcrmina s A and C ol thc dicde No Continuity Bad diodc module.

moduie
NOTE: Make sure there rs NO CONTINUIW beN'teen terminals A, B or C and terminals D, E or F of the diode module

NOTE; Chcck Fusc F3
NOTE: Disconnect the ctqarette ltghler from the harness
Check Points Bcading Possiblc Cause of Bad Reading
(31 Tcrn,inal for wire 109 Erown to grounC Continurty Check wire 109 and the chasss ground
connection.
tf,|
v Tcrminal for urire 2ll9 Rcd/Ycllow to ground 12 Volts Bad circuit betwccn the battcry powcr
lunctron block and the cigarette lighte r. Aiso
check the battery power junction block
connection and thc suppre sston diodc
c rcuit
Aan 7 3927A lssucd 1 I -93 Printe d in Fngland
kaukazz@yahoo.co.uk
.ii ..'i
4001 -'1 02
NOTE: Chcck Fuse F31
posllion
NOTE: Disconnect the electric seat from the harness and turn the key lo the ON
236 Rcd/Orangc to ground 12 Volts Bad circuit bctwecn the keyed power
lEl terminalforwire
iunction block and the electric seat motor
conncctor terminal A. Also check thc keyed
oowcr circu t
NOTE: Turn the key to the OFF positron
Continuity Check wrc 241 and the chassis ground

lD Terminal for wire 241 Srown to ground
conncctior
NOTE: lt the raadings arc correct chcck the alcclnc scat motor
7 Pin Trailer Connector Power Circuit Test

NOTE: Turn the key to the ON posillort
Chcck Potn:s Rcadrng Possiblc Cause o1 Bad Reading
Tcrnrinai 7 oi iho traiir:r conncclor ic' r'vrrr: 12 Volts Bad circuii frctwcen the keycd powor
junction block and the trailer connector
236 Redlorangc to ground
tcrminal 7 Also check the keyed oower
circuit
Terrninal 4 of ihc trailcr conrtcclor i6r r,virc l2 Voits Chcck wirc 236 bctlvecn terminais 4 andT
23ti Rcd/Orangc lo groLrnd of the trailer connecior
NOTE: Turn the key to the OFF pasition
Tcrn,inal ior wrrc 169 Brown to grourd Cortinuity Check wirc 169 and lhc chassis ground
G) COnnCCtrOn.
lssled 1 1 93 Prirrtcd jn England

3or^ 7-39270
kaukazz@yahoo.co.uk
4001 -1 03 -103
Schematic Circuit
Right Hand Gonsole Auxiliary Power Connector Cigarette Lighter lnstrument lnsfurnent Panel Auiliary Power Connector and Electris Seat
{trtr}- 236R'o(15}
242
236 R/O 0s) 235 R/o (15)
245 I
Rna R/O I
{r0) flq 236
B/O
(rs)
1
$T
+oor-roz
239 E/Y (11)
{
236
F
235
R/O 246 FvO (16) 246 ilO (16)
- 246 R/O fl6) F/O
(iu (r5!
2i13 R/Y (13 243 RYfl3)
Bn (lE 244 8n $6) 244 8n fl6)
/J6 eoor-srieo
R/O 3[
(11) d' eoor-esar
- < Aool+,srsl'
-
*oorasrsz
d.BR 16g
244 I 2$
anI B/O {'t3}
n?l lls) n|/o
I 243 {i5,
lsv
l,o
239 RfY {r0) I osl
4001.51/53 I,P
K
(fle
H
(") O
M
l-El
M
/rh@
244
BR
(13)
,F,
(15)
169
BR
(13)
{r3)
COMFONEI'ITS CONNECTORS
(, FUSE F31 irAb TRANSMISSION HARNESS TO INSTRUMENT INSTRUMENT PANEL HABNESS

tl
ll
rl
! ll
jiffi CAB/PLATFORM HARNESS TO INSTRUMEN-I il
@ FUSE FS INSTRUMENT PANEL HABNESS t
r
I
ll
ll
ffi_l r ll
@ FUSE F12 TRANSMISSION HARNESS RIGHT HAND COI HAND CONSOLE HARNESS
r rl
"::_
CAB HABNESS TO REAR FENDER HARNESS tr
@ FUSE F7 xiit..
HAHNESS {CAB THACTOBS ONLY}
$
c HIGHT HAND CONSOLE AUXIUABY POWER CONNECTOR
4') RIGHT HAND CONSOLE AUXILIARY POWER SUPPRESSION DIODE MODULE

isfi BATTEBY POWER JUNCTION BLOCK BLOCK
r ipft KEYED POWER JUNCTION BLOCK
e CIGABEITE LIGHTER
ail INSTBUMENT PANEL AUXILIARY POWER SUPPRESSION DIODE MODULE

,L?
c INSTRUMENT PANEL AUXILIARY POWER CONNECTOB

,l
lll e ELECTRIC SEAT MOTOR (CAB TRACIORS ONLY}
ae) 7 PIN TRAILER CONNECTOB

kaukazz@yahoo.co.uk
Don 7-39270 lssued 11-93 Printed in England in England

4001-104
RADIO, INTEHIOR I3MP, HIGHT HAND CONSOLE I.AMP

AND INSTRUMENT CLUSTER ILLUMINATION (DIMMER)
Sectional lndex
Right Hand bonsole Lamp Circuit Tesi....'....'. .....".......'.'1..' """"""""""' 106

Test.'..".......
lnitrument Cluster lllumination (Dimmer) Circuit """""""""106
DonT-39270 lssued 11-93 Printed in England

kaukazz@yahoo.co.uk
4001 - 1 05
CIRCUIT TESTING
NOTE: The battery must be at f ull charge and all cannections must be clean and tight belore testing. Use a multimeter for '
Ihe tesls.
Radio Circuit Test

NOTE: Make sure the radia antenna chassis ground connection is clean and trght. Also check the antenna cable for
damage.
NOTE: Disconnect tha radio from the harness.
Check Polnts Rcading Possible cause of Bad Reading
fcrminal for wire 254 Brown to ground Continuity Check wtre 254 and the chassis ground
@ connection.
'\J Tetminal for wirc 38 Orangc to ground

'1
2 Volts Bad circuit between the accessory power
G) relay and the radio. Also check thc
accessory power relay.
Gl Termlnal for wire 239 Rcd//cllow to ground 12 Volts Bad circuit bctwee n the battery powcr
junction block and the radio. Also chcck the
battery junction block connectron.
Radio Speaker Circuit Test

NOTE: Disconnect the radio and radio speaker from the harness
Chcck Points [ieading Poss ble Cause of Bad Reading
lcrminals ior wirc 25A Gray Con:inuily Check wirc 250

@
0 lerminals for wire 251 BrowniGray Conlinuity Check wire 251
O lerminals for wirc 252 Ycllow Contrnuity Chcck wirc 252
@ tcrminals for wire 253 Brown/Yeilow contrnuity chcck wire 253
Don 7-39270 lssued 11 .93 Printcd in Engiand
kaukazz@yahoo.co.uk
400r-106
lnterior LamP Circuit Test
NOTE: Chcck Fuse F3 and the tnterior lamp bulb'
NOTE: Disconnect the lnterior lamp assembly lron the harness

Rcadtng Possiblc Causc of Bad Reading
Chcck Poinls
f"tmnnl lor wire 239 Rcd'Yci ow lo grouno 12 Volts Bad circuit betwcen the battery powcr
0 lunction block and the inierior lamp
Also
chcck lhc baitery powcr junction block
connccilon.
Conlrnuiiy Bad chassis ground circuit Also chcck thc

Gl Tctm,nal for wirc 254 Brown lo ground
chassts ground connection
Contrnuily Check wirc 254 bciwcen thc chassis ground

Tcrminals for wirc 254 Brown
{il tcrminals of the lamP assemblY
NOTE: lf the readings are carrect cneck the tnrcr"ar lamp assembly
Right Hand Console LamP Circuit Test

NOTE. Check Fuse F13 and Lhe right hand canscle lamp bt;itt.
the harncss
NoTE: Turn the lamp SwilCh o i.t,c cFt: past!ior, ard clrsconnccl ihc tigki hand console lamP from
Rcading Possible Causc of Bad Rcading
Chcck Poinls
Conitr'lLriiy Bao chassis ground circuti, Also check thc

lct,, nnl ior vrrrc 254 Brown lo ground
@ irrrcrior lamo and chassis ground
conncction
(pttstiion 3)
NOTE: Turn iha lama svtttch to tha IIEADiAMP "'t'to'
(D Tcrminal 'cr wirc 255 Tan to grounc 12 Volts Bad circuit bctwccn the lamp switch
lcrminal HD and thc right hand consolc
iamp Also chcck thc lamP swrtch
lnstrument cluster lllumination (Dimmer) circuit Test

when ihe iamp swilch is in the headlamp positron (position 3)
the
NOTE; For tractors with deluxe instrumentc/irslers,
tnsitument cluster diglital drsplay wtll dim.
svtitch is in the
NorE: For tractars v.,rithout deluxe instrumer,t c/uslers, the instrument cluster v'tili rllumrnate when the lamp
neadlamp posttion (PosrLton 3)-
ttLrr; LhC ianip sl, /tc, Io thc HEADLAMP lamp

poSitrOn
NOTE: Dtscortfiect thc inst{ut)At)l c/Lsi0/ tiofi) ll;ci)i.ir'licss aiici instrument clusters'
withaut deluxc
(pasitian 3) Also check the instrumcnt cluster iltumination btLtb for tractors
Check Points
Qo2.i!nn Possible Cause of Bad Beading
connccicr 12 Volts Chcck wirc 255 bctwecn fusc F13 and thc
Pin 36 of thc nstrumcnt clus:cr
instrumcnt clustcr connector pin 36
for wirc 255 Tan io ground
rcfcr to Page 15
NOTE: lf the reacling is correct check the instrumenI Clusler chassrs ground ctrcutt'
lssucd I 1-93 Printec n Lngland
Don / 392711
kaukazz@yahoo.co.uk
4001-107 4001 -1 07
Schematic Circuit
BTY
{11}
3
o6 I
I
239
R/Y
tlo
{ noot-ssrsz
{oor.roe -1
,5r E {i6}
I
23S
F/Y
{16)
@
255r(i6)-_ffi-tO
d2br
77 2s5 T {16) {oo-zo
RA'
{r5) 2ss T {16}
254
I
BB
I
t18)
"39
RrY t18)
:* HfY {18)
239 F/Y OS)
239 &Y (18)
{ motao
36
37 R/v (r5) _l 254
BB
6B 254 3R (.r8) 254 BB (r8)
t't8l 254 8R {r8)
{16)
COMPOHENTS CONNECTOBS
(1) KEY SWITGH

e LEFI HAND SPEAKER ffi CAB HARNESS TO INSTRUMENT PANEL HARNESS ) INSTRUMENT PANEL HARNESS
e FUSE F19
c RIGHT HAND SPEAKER
ffi alrrenvPowEnJuNcroN BLocK ] JUNCTION BLOCK
@ FUSE F17 .8) FUSE F3
@ FUSE F32
@ FUSE F13
@ FUSE F3O
e LAMP SWITCH
HEADLAMP DIMMER BELAY

@ FUSE F2O
@
@ FUSE F2T
o INSTRUMENT CLU$TER CONNECTOB
c ACCESSORY POWER RELAY

@ INTERIOB LAMP
c HADIO 6} RIGHT HAND CONSOLE LAMP
o RADIO ANTENNA
kaukazz@yahoo.co.uk

Printed in England
4001-108
FRONT AND REAR WINDSHIELD WIPERMASHERS,

BLOWER MOTOR AND AIR CONDITIONER
Sectional lndex
CIRCUIT TESTING 109
Front Windshield Wiper Motor Circuit Test ......... ....."'..'...' 109
Front Windshield Washer Motor Circuii Test ........... '..'.'.... 109
Froni Windshield WiperlrVasher Switch Circuit Test .'......... .."...'.....'.'... 110
Rear Windshield Wiper Motor Circuit Test ........... ......'....... 111
Rear Windshield Washer Motor Circuit Test ......... '.'.'....".. 111
Rear Windshield Wiper/Washer Switch Circuit Test .......... .......'...'....'... 111
Air Conditioner Compressor Circuit Test ........... ................ 114

Air Conditioner Controlswitch Circuit Test ........... ."....'...'. 114
Air Conditioner Lockout Relay Circuit Test ........ '......"'...... 115
Air Condiiioner lndicator Lamp Circuit Test ......... .........'.... 116

kaukazz@yahoo.co.uk
4001 -1 09
CIRCUIT TESTING
NOTE: The battery must be at full charge and atl connections must be clean and tight bef ore testing. Use a multimeler for
the tcsls.

NOTE: Disconnect thc fronl windshietd wrper mator trom thc harncss and turn the key to the ON position
Chccx Points Reading Possiblc Cause of Bad Beading
ferminal for wirc 266 Gray/1cd to ground 12 Volts Bad circuit between the front windshield
Q wiper motor connector terminal C and the
kcyed power junction block. Also check the
keyed Power junction block.
NOTE: Turn the front winclshielrl wiper swilch {o the LOW (l) position
Terminal for wire 268 Gray to ground 12 Volts Check wire 268 and the front windshield
wiper/washer switch.
NOTE: Turn the windshield wiparlwashcr swllch lo the HIGH (ll) posrtion
Terminal for wire 269 GraylDark Green lo 12 Volts Chcck wirc 269 and the front windshield
ground wiper/washcr switch.
NOTE: Turn the key and the windshield wiperlwasher switch to the OFF position.
Terminal for wire 220 Brown to ground Coniinuity Chcck wue 270 and the chassis ground
connection
Tcrminals for wires 266 Gray/Rcd and 267 Continuity Chcck wia 267 and the front windshicld
Gray/Black wiperiwashcr swltch
NOTE: ff the readings are carrect check the frort wrndshield wiper rnotor
Front Windshield Washer Motor Circuit Test

the harness.
NOTE: Turn the key to the oFF positron anc disconnect the front windshield washer motor from
'fermlnal for wlrc 272 Brown to ground

Continuity Check wre 272 and the chassis ground
@ connection.
and hatd the front windshield wiperlwasher switch in the ryASH position.
NOTE: Turn the Rey to the ON positron
Volts Bad circuit between the front windshield

@ f.,, nalfor wire 271 GraylSlack io grounr) 12
wipcr/washer switch terminal W and the
front windshicld washer motor.
NOTE: lf lhe readings are correct replace the front windshield washer motor.
Doa t-3g27o
lssued 1 1-93 Printed in Eng and
kaukazz@yahoo.co.uk
4001-110
Front Windshield Wiper/Washer Switch Test
NOTE: Check Fuse F8
NOTE: Drsconrtect the front wincJshield wiperlwasher switch from the harness and turn the key to the ON position
Check Poinls Rcading Possiblc Causc of Bad Reading
Tctminal for wire 266 Gray/Rcd to ground 12 Volts BaC circuit bctwccn the keycd powcr
O junction block and the front windshield
wiper/washer switch terminal B. Also check
thc kcycd powcr circuit.
NOTE: Turn the key to the OFF podtton.
NOTE: Turn the front windshield wtperlv'tasher svtitch to the LOW (l) pasitlon
Betwccn rcrminals B and L of lhc lront Continuity Bad front windshicld wiper/washer switch
NOTE: Turn thc iront winclshield v.ttpertwasher sw'rich lo lhe HiGH (ll) postr,'on
Betwccn tcrminals B and H of lhc front Continurty Bad front windshicld wiper/washcr switch
wrndshicld wipcr/washcr switch
NOTE: Turn the front wrndshrelcl wrperlvtasher swttch to the oFF posiliott.
Betwecn terminals B and p oi thc troni CoilinLtity Bad front windshrcld wrper/washer switch
windshicld wrPcr/washcr swrich
NOTE: Hotd the front windshietd wipe|washer switch tn the wAsH pastttan
Bcfwccn tcrminals B and w of thc front Cortinuity Bad front windshicld w pe r/washer swttch
\vlroshlcld w,Pcr/washcr swl:c'l
Bear Windshield Wiper Motor Circuit Test

NOTE: Disconnect the rear windshielC wiper motor from the harness and turn the key to the ON position
Chcck Poinis Flcadirrcl Possiblc Causc of Bad Bcading
Tern-inal for wrre 273 Gray,Mhrte to ground 12 Volts Bad circuit bewccn the keycd power
@ junction block and tcrminal B of the rcar
windshield wiper motor connector,
NoTE: Turn the rear windshreld wiperlwasher switch to the aN pasttton
Tcrminal lor wirc 274 GraylOark Bluc lo 12 Volts Check wirc 274 and thc rear wrndshield
ground wipcr/washcr swttch
D<;r' /'39270
issucd 1 1-93 Prrn:ed in Eng and
kaukazz@yahoo.co.uk
4001 -1 1 1
NOTE: Turn the kcy and the rear windshicld wiparlwasher swilchcs to the OFF position
Chcck Points Beading Possible Causc of Bad Beading
ferminal for wirc 276 Brown to ground Contrnuity Bad circuit bctween the rear windshield
@ wiper motor connector terminal D and the
chass s ground connection.
ferm,nals forwires 275Gray and 276 Brown ContinL,ily Check wlrc 275 and the rear windshicld
@ wiper/washer swltch.

NOTE: Check Fuse FO
NOTE: Turn the key to the OFF posrtron anci disconnect the rea|wtndshield washer motor from lhe harness
Chcck Points llcading Possiblc Cause of Bad Reading
Terminal for wire 272 Srown to ground Continuity Bad circuit bcMcen the rear windshield
washer molor and the chassis ground
conncction. Also check the chassis ground
coancctron.
NOTE: Turn the key to the ON position and hold the rear windshteld wipedwasher switch rn the WASH position
Terminal for wire 277 Gray/Dark Grecn to 12 Volts Bad circuit bctween the rear windshield
ground wiocr/washcr switch terminal 3 and the rcar
windshicld washcr motor. Also check thc
rcar wrndshield wiper/washcr swilch
Rear Windshield Wiper/Washer Switch Test

NOTE: Drsconnect the rear v,tinclshield wipertv'tasher switch from the harness and turn the key to the ON posrtron
Chcck Pornts Reading Possible Cause of Bad Reading
lF t"rmn"lfor wire ?73 GrayWhitc to ground 12 Volts Bad circuit betwee n the keyed power
junction block and the rcar wlndshield
wiper/washer swttch.

NOTE: Turn the rear v,tlndshield wtperlvtasher swilch lo the O/V positron.
Bclween terrrinals 6 and 2 oi lhe rcar Corrtinuity Bad rcar windshield wiper/washer switch
windshrcld wiper/washcr switch
NOTE: Turn the rear wirtdshidd wiperlwasher switch to the OFF posrtion.
Betwcen tcrminals 6 and 2 of lhc raar Continuity Bad rear yindshield wiper/washcr switch
NOTE: Hold thc rear windshtald wiparlwast;er swrtcl' in lhc WASH posilion
Betwcen lcrminals 6 and 2 of ihe raar Continuity' Bad rcar windshield wiper/washcr switch
windshicld wtpcr/washer switch
ssJoo I I 93 P'inled i- gnqland
Dan 7-39?7A
kaukazz@yahoo.co.uk
4001 112
NOTE: lf the blower motor fails to operate when the btower switch is in LOW (l) or MEDtt)M (tt) positions
check theresisfor
board, and [he blower switch
NOTE: lftheblowermotorfailstooperatewhentheblowerswitchisinLaw(l),MEDluM(ll),orHlGH(ttt)position
check
the circuit breaker, blower switch and the blower motor.
NOTE: Turn thc key to the OFF pasition
Chcck Points Rcading Possible Cause of Bad Beading
(h Tcrm,nal for wire 286 Brown to grounci Coniinuity Check wirc 286 and the chassis ground
conncction
NOTE: Turn the key to the ON pcsition and the blo'war swilch to lhc LOW (l) position
tcrminal for wirc 285 Black to ground Bad circult between the blower switch
@ 9 Volts
Approximatcly terminaiL and the resistor board Also
chcck the blower switch and the resistor
boarC.
NOTE: Turn the blower switch to the MEDIUM (tt) position
fcrminal 1or wire 285 Black to grounr) Bad circuit between the blower
@ 1 1 Volls
pproxirnatcly
switch
n Ierminal M and thc resistor board . Also
chcck the blower switch and thc resistor
board
NOTE: Turn the blower switch to the HIGH (|il) posrtron
fcrminal for wire 285 Blacx io ground Bad circuit bctwccn the blowcr switch
@ 12 Volts
tcrminal H and the rcsistor board . Also
check the blower switch and the rcsistor
board
NOTE. ll lhe readtngs are coirect check wtre 2EC bt:tv,een the blower motor ancl the reststor baard

NOTE: lurn the kay rc Lhc ON posthort
Chcck Points Rcading Possible Causc of Bad Readjng
(tl tcrm nal for wirc 278 Redl}rown to ground I2 Volts Check wuc 278 and the keyed powcr
3ctwccrr lhc tcrmrnals oi thc circurt brcakcr Conlinurty Bao circuii brcakcr
NOTE: Turn the key to the ON positron
(E) Tcrminal for wirc 279 Gray to ground 12 Volts Blowcr motor circuii shorted to oround
)ct''/-392/A lssucd 11-93 Printed in England
kaukazz@yahoo.co.uk
4001 -1 1 3
powrquadplus www.thebestworkshopmanuals.co.uk Blower Switch Test

NOTE: Disconnect the blower switch from the harness and lurn tha key to the ON position
Check Polnts Rcading Possible Cause of Bad Beading
Terminal for wtre 279 Gray to ground 12 Volts Bad circuit betwcen the circuit breaker and
@ the blower switch terminal B, Also check thc
circuit breaker.
NOTE: Turn the blower switch to the LOW (l) pasttnn
Bctwecn tcrminais B and L of the blower Continuity Bad biowcr switch
switch
Betwecn terrninals B and C of the blowcr Continuity Bad biower switch
switch
NOTE: Turn the blower switch to the MEDIUM (ll) positron.
Bctween terminals B and M of the blowcr Continuily Bad blower swttch
swiich
Bctlvecn tcrmtnals B and C ol lhc blo,,vcr ConilnLlity Bad blowcr switch

swi:ch
NOTE: Turn the blower switch to the Hlcll (lll) pasttton
Belween terminals B and H of the olowcr Continuity Bad blowcr switch

switch
Bctween termina s B ancj C oi lhc blowcr Continu ty Bad blower switch
switch
Resistor Board Test

NOTE; The thermal cut-in switch protects the resistors from aver heating. lf the air flow around lhe reslstors becomes
rcstricted,lhe rcslsaors wiil over heat ancl the thermat cut-in switch conlacls will closc and the blower motor will go to
HIGH specd
NOTE: Atlow* the reslslors tO cool be{ore ihe follcwtrq lesls are carried out.
NOTE; Turn the key to the ON paslttan anC turn the blower switch to the lllGH (lll) position.
Chcck Points Rcading Possiblc Cause of Bad Rcading
terr,,nrl for wirc 285 Black lc grouncj 12 Volts Bac crrcuit betwecn the blower switch termtnal
@ H and thc blower motor Also check thc
blower swilch.
NOTE: Turn the blower swrtch to the LOW (l) positton
rcrminal for wire 281 Whitc to ground 12 Volts Bad circuit betwcen the blowcr switch terminal
€l L and thc rcsistor board Also chcck thc
blowcr switch
Dcn 7-39270 lssucd 11-93 Pri'rted in Engiand
kaukazz@yahoo.co.uk
4001-114
powrquadplus
Turn thewww.thebestworkshopmanuals.co.uk
NOTE: blower switch ro thc MEDIUM (ll) posrtton
Ch Terminai for wire 283 Red to ground 12 Volts Bad circuit between the blower switch terminal
M and thc resistor board Also check thc
b owcr switch.
NOTE: if the readings are carrect and the blower motor latls ta operate ar operates at high speed replace the resistor
board.

NOTE: Bcfore any resls are caried oul on the air conditioner crrcuit, refer to Section 9002.
NOTE: Disconnect the suppression diode t'rom the harness.
NOTE: Turn the key to the ON position, the blower switch to the LOW (l), MEDIUM (ll) or HIGH (lll) positions and setthe arr
conditioner control switch to MMIMUM coolrnq.
Check Pornis Rcading Possrble Cause of Bad Readrng
@ ;::n:'r for wirc 2eo Grav/Dark Bluc io 12 Voits Bad circuit betwccn the air conditioncr
lockout relay tcrminai B7A and the air
condrtioner comprcssor. Chcck the air
conditioner lockotrt rclay. Also check the
pressurc switches, refer to section 9002
NOTE: ll lhe readings arc ccrec! chcck the.srrppre.ss/on dtode, refer la Paqe 116

NOTE: Before any lesls are carricd oul on the air conditioner crrcurt, rcfcr lo Scctton gAA2
NOTE: Turn thc kcy to thc ON position. the blower sv'trlch to the LAV/ (l) MEDILIM (ll) or HIGH (lll) posrtions and set the air
conCrtioner contral swrtch to MAXIMUM caolinq
Check Poinis Scadinq Possiblc Causc of Bad Rcading
for wrrc 287 GravtDark Grccn io 12 Volls Check wirc 287 betwecn thc blowcr switch !-/
@ ;[n:'l tcrminai C and lhc air conditioner control
switch
PP fcrmina forwire ?BBGra,v,Ntolet io ground 12 Vclis 3ad air condi:ioncr control switch
Doo 7-39270 lssued 11-93 Printed in England
kaukazz@yahoo.co.uk
4001 -1 1 5
NOTE: Belore any tesls are carrred out on the arr condltraner circuit, rcfer to Scction 9002.
NOTE: Turn ihc kcy to thc OFF pcsiton
6h terminal for wire 291 Brown to ground Continuity Check wire 291 and the chassis ground
connection.
l"t^,nols for wrrc 289 Grayficllow Continuity Chcck wire 289 between thc air conditroncr
@ lockout relay tcrminals 86 and 87
NOTE; Disconnect the air conditioner high and low pressure swttches from the harness
NOTE: Turn the key to the ON position, the blower switch to the LOW (l), MEDIUM (ll), or HIGH (lll) position and set the air
conCitioner control switch to the MA^XIMUM cooilng posttion.
t"rr,r',nl for wirc 2BB Gray,Vrclcl lo ground 12 Volts Chcck wire 288 betwecn the air conditioncr
4!l switch and the lockout relay.
Tcrminal for wirc 290 GraylDark Bluc to 12 Volts Bad air conditioner lockout relay
ground
NOTE: tnstall a suitable jumper lead between terminals Aand B of the air condltioner high pressure switch connector
(harness side).
6li) Tcrminal lor wirc 289 GrayNcllow to ground 12 Volls Bad circuit betwecn tcrminals 30 and 86 oi
the air conditioner lockout relay
fE) Tc,r,nrl for wrrc 290 GraylDark Bluc to 0 Volts Bad air conditioner lockout relay.
Y orouno
NOTE: Reniove the juntper teacJ lrom lhe air conditrcner htgh prcssure swltch connector
terminal for wire 289 GrayNcllow to ground 12 Volts Bad ajr conditioner lockout rclay
@
6h Terminal for wirc 289 Gray/Yellow to ground l2Volts Checkwirc2BgbctweenterminalBTandthe

air conditioner indicator lamp
NOTE; Turn the key to the OFF pos!tion.
NOTE: lnstall a suitable jumper lead betwcen tcrminals A and B of the air conditioner low pressure switch connector
(harness side) and turn the key to the ON position
6rF) Terminal for wire 289 Gray/Yellow to ground 12 Voits Bad circuit between the air conditioner
control switch and thc indicator lamp
NOTE: tf the readings are correct check the hrgh and low pressure swllches, refer [o Scction 9002
kaukazz@yahoo.co.uk
. : +iii
i*.1.
4001-1 16
NOTE: Check the alr conditioner indicator lamp butb.
NOTE: Turn thc kcy to thc OFF positron.
6F Icrmlnal for wire 293 Brown to ground Continuity Chcck wirc 293 and the chassis ground
connectron
NOTE: lf thc readrng ts correct check the air condrlioncr lockout relay circuit.

NOTE; Disconnect the suppression diode from the harnes-q
Check Poinls Bcading Possiblc Causc ol Bad Reading
6D Tcrminal for wire 292 Srown lo ground Continuity Chcck wirc 292 and the chassis ground
conncclion.
NOTE: The positive lead of the mtihmeter r.ust gc lc lhe rnale termtnal cf the dtode
Betwcen the tcrminals of thc diodc Corrtinuiiy Bad supprcssion diorje.
NOTE: Change the leads ol the multtmclcr ovct'so thc positivc lead ol thc multimctergoes 10 lhc female terminal of the
drodc
Bctwcen tho lcrminals of thc diodc No Continuity Bad suporcssion diodc.
Dat 7-39270 IssueC 1 1-93 Printed in England
kaukazz@yahoo.co.uk
4001-'117
Schematic Circuit
Front lrtlindshield Wipers lilindshield Washer llotors Rear tttindshield WPers Blouer tlotor Alr Conditioner
w. I zBRlBR(ru -----r -@
28OG/D8 (rq
@@f
r- n3)
282 GilB
28a ow{1r)
R'G
{15} 286 2nc(1i) zrec{ri)
'i'r
2S'
BF 286 GilDG {r5}
-&- -f\t
t
SF
tl 1)
=r-
o( 271
",3Gi/W(r5)
27sc{rq lsnl 286

281
$
{r{
B
fl4,
sBR{16}
266 Gi/B
-J
trsl Gi,B
2rr
lfl{ **'nn
f
G/DG {16l AR
{16}
Gtrl (r5) tr.! 293
Hru 273
l*
AR
Y_: 266 Gr/B tr$l

2rlGiloc (r5) L 285 28
Gi/y
l__ (t6)
B
'"-l
A. t
{'l{) {r6)
ld M
AB
L 288Crn (16l
@l I fl;
(1.)
Gi/w
/l*"El
275 (15!
G
267 ci/B
_t
(r5l --'l (r6)
t. o n2
.g
r
BR
268 (r6)
G
(15) "[
267ats
26S G (151
(rsl
269 Gi/DG (151
I
Gi/DG
(r5)
tt6
BR
(16) o
It, r,t rlh
285
LJ".,,,$U T
BR
4l
(11)
M 293
276 3R BR
276 ('t6) {r6}
SR gR
(15)
(16)
-__J
COMPONENTS CONNECTORS
ffi ENGINE HARNESS TO INSTRUMENT PAI

t FUSE F8 @ TEMPERATURE CONTROL SWITCH iTBUMENT PANEL HARNESS
@ FUSE F2 o HIGH PRESSURE SWITCH ,ffi

fffi
CAB HARNESS TO TNSTRUMENT PANEL JMENT PANEL HARNESS
e FRONT WINDSHIELD WIPEB SWITCH @ LOW PRESSUBE SWITCH
ffi
CAB HARNESS TO HEAFI FENDER HAHNI
KEYED POWEB JUNCTION BLOCK

FENDEH HAHNESS
(3) FFIONT WINDSHIELD WIPER MOTOR

@ AIH CONDITIONER LOCKOUT RELAY V BLOCK
c FRONT WINDSHIELD WASHER MOTOR

@ AIR CONDINONER LOCKOUT WARNING LAMP
CIRCUIT BBEAKER
@ REAR WINDSHIELD WASHEB MOTOR
@
re REAH WINDSHIELD WIPER MOTOR rih SUPPRESSION DIODE
(7\ REAR WINDSHIELD WPEFI SWITCH

@ AIFI CONDITTONER COMPRESSOR
\_./
@ BLOWEB SWITCH
o BLOWEB MOTOR
RESISTOR BOARD
DanT-39274 lssued 1l-93 Printed in England

Section
4003
STARTER MOTOR
(BOSCH)
Cooyrighl o 1992
CASE CORPORATION )a" 7-4178C Priirted in England
March 1992
kaukazz@yahoo.co.uk
4003-2
TABLE OF CONTENTS
SPECIFICATIONS .
2
SPECIAL TORQUES
2
SHOP EOUIPMENT TOOLS
STARTEB l','lOIOF
Removal and installation . . .
3
J
No-Load Test Procedure tr
Understandrng No Load Tcst Results
6
Disasserrbly and AssemblY
7
inspectron
SPECIFICATIONS
Manufacturer
Lubricant tor End Cap Bushing and Splines on Armature Shaft CE siri.""" g,""=" csi-, t",?ff;:
No Load Test at 27"C (80'R

Mrnrmum
Minimum Armature
Current Draw Armature Commutator End Play
Brush Length
Part Number Voltage (Amps) Speed (rpm) Diameter mm (inch)
mm (inch)
mm (inch)
1-1 q.
425 8s 01to03
A1 861 57 130 700c (t 67) (o 34) 0.004 to 0 012
425 B5 0.1 to03

A1 861 42 23 B5 7000 (r o/l (0 34) 0.004 to 0 012
425 85 01to03
A1 87597 115 174 BOOC (1 67) (0 34) 0 004 to 0 0121
425 a( 01to0,4
A186180 115 125 7000 (1 67) (0.34) 0.004 to 0 016
SPECIAL TOHQUES
Drive Housing Nuts

45to6Nm 3to4lbft
43 Nm 32 lb f1
Starler Motor Mounting Bolts . ..

1, SUN ELECTRIC VAT-33 TESTER
2. HAND HELD TACHOMETER CAS 10756
3, MULTIMETEH CAS 1559
4. DIAL TEST INDICATOR CAS1006&14
MAGNTTIC BASE FOR DIAL TEST INDICATOR OEM 1O3O
6. TOROUE WRENCH OEM M79
tssLred 3-92 printed in Enqland

Dcn 7-41780
kaukazz@yahoo.co.uk
4003-3
STARTER MOTOR
STEP 1 STEP 3
Park the machine on hard level ground. Apply the Fasten identification tags to and disconnect the cables
parking brake (if equipped) and stop the engine and wires from the starter motor and solenotd. Remove
the three mounting bolts and washers and remove the
STEP 2 starler rrotor.
Turn the master disconnect switch, if equipped to the NOTE: For lnstallation, follow the same procedure rn
OFF position and remove the kcy or disconnect the reverse order and tighten the starter motor maunling
battery, negative (*) terrninal first. bolls fo a torque of 43 Nm (32 lb ft)
No-Load Test Procedure

The No-Load Test is carried out with the starter motor The No-Load Test can be carried out using a Sun
removed from the machine, Check to make sure the Electric VAT-33 Tester or an equivalent tester. A hand
drive clutch slides freely on the armature shaft and the held tachometer is required to measure the speed of
armature rotates freely. the armature shaft A remote starter switch is required
to actuate the starter motor and one (two lor a 24 voll
starter motor)fully charged '12 volt battery is required to
suppiy tne electricity to turn the starter motor.
12 Volt Starter Motor
POSIT lvE
VOLTMETER LOAD LEAO
LOAD
CONTROL
\
AMMETER
REMOTE STARTER SWITCH
NEGATIVE LOAD LEAD
BATTERY AMMETER CLAMP

TERMINAL
START TERM
HAND HELO
POSITIVE BATTERY CABLE POSTTTVE

VOLTMETER LEAO
NEGATIVE VOLTMETER LEAD
NEGATIVE
BATTERY CABLE
B8TZ54B
Don 7-41 780

lssued 3-92 Printed in Englano
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4003-4
24 powrquadplus
Volt Starterwww.thebestworkshopmanuals.co.uk
Motor
VOLTMETEH
AMMETER
REMOTE STARTEB SWITCH -+
NEGATIVE LOAD LEAD
TTERY AMMETER CLAMP

RMINAL
START TEHM
HAND HELD
TACHOMETER
\postrrvE BATTERy cABLE POSITIVE
L VOLTMETER LEAO
NEGATIVE VOLTMETEB LEAD
NEGATIVE
BATTERY CABLE
887754
STEP 4 STEP 6
r_asten the starter motor in a sof't lawed vrse . Conncct the cositive voitmeter lead of the tester to post
Connecl ',he positive bat1ery cable to the positive post (A)
(A) and tc the bat1ery terminal on the starter solenoid Connect the negative voltmeter lead of the tester to
/D\
Connect ihe negative battery cable to the negative pcst ^^^+
frUJL i Lrl.
iB) and to the mountrng flange on the starter
STEP 7
STEP 5
Connect lhe load teads of the tester as shown
Adlust ihe conlrols for thc Sun Electric VA I--33 tes:e : as
:ollovrs. STEP 8
'I [/ove the load control to the OFF cosition
2 Move the volt range control to the 10 to 30 volt Fasten the ammeter clamp around the negative battery
range cable The point of the arrow on the ammeter clamp
3 Move the amp range control to the 0 to 1000 must be toward the bat1ery
a.nperes range.
4 Move the volt lead switch to thc EXT oosiiior'
_ .. -.!-o- issued 3-92 Printed in England
kaukazz@yahoo.co.uk
4003-s
STEP 9powrquadplus www.thebestworkshopmanuals.co.uk STEP 12
Connect the leads of the remote starter switch to the Use the hand held tachometer to check the armature -
battery terminal and the switch terminal on the starter shaft speed, Make a note of the armature shaft speed,
motor solenoid,
STEP 13
NOTE: Steps 70 to 73 musl be done rapidly DO NOT
apply a load to the battery for more than 15 seconds at Release the remote starter switch and turn the load
onetime.Afterlssecondsturntheloadcontrol totheoff control to the OFF position.
position for 60 seconds to allow the tester to cool.
STEP 14
STEP 1O
Disconncct thc ncgative battery cable from the staner
Actuate the remoie starter switch and turn the load Disconnect the remainder of the tesi connections
control until the voltmeter indicates 1 1 volts (for 12 volt
starter motors) or 23 volts (for 24voll starter motors) NOfE: Refer to Specifications, Page 2, to check the
readings obtained in Steps 11 and 12.
STEP 11
Make a note of the reading on the ammeter.
Understanding No-Load Test Results

STEP 15 STEP 17
Low armature shaft speed and high current draw are lf the armature does not rotate and the current draw is
indications of too much friction. Possible causes of too zero possible causes are:
much friction are: 1. An open field circuit, disassemble the stader
l. Tight, dirty or wornbearings. motor and inspect the field coil connections.
2 A bent armature shaft 2. An open armature coil, disassemblc the starter
3. Loose pole shoes (pole shoes make coniact with motor and check for burned commutator bars Use
the armature) an armature tester to test the armature.
4 A short circuit in the armature coil. Disassemble 3 Brushes not making good contact with the
the
the starter motor. Use an armature tester to test commutator bars. Check for high insulation between
armature, the commutator bars, broken brush springs or worn
5. Damaged f eld coil, refer to the test on Pagc 8. brushes
STEP 16 STEP 18
li the armature does not rotate and the current draw is Low armature shaft speed and low current draw are
high, possible causes are: indications of:
lrame
1 . Field terminal making contact with the f ield
'1
. Dirt or corrosion on connections
lnspect the insulators for the field terminal 2 Damaged wiring
2 8
Damaged field coii, refer to the test on page 3 Dilry commutator bars,
3 Damaged bearings 4, All causes in Step 17
STEP 19
High armature shaft speed and high current draw are

indications of a short circuit in the f ield coil, install a new
field coil Repeat to the No-Load Test, Page 4, and
check the operation of the starter motor
Don 7-41 780 lssued 3-92 Printed in Engianc
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4003-6
Disassembly and Assembly
STEP 20
@so
o\:-.k-N,
$-$
4.5 TO 6 Nm
\ (3to4lba)
\ \
@
$,/@ -@
{@rNrc/
# 6s,-
-,
\
@
: -*C\@{
'nu^'*-\
AO8142A
\
NOTE: For Assembly, use Mo ilat bars or
sc'cwCrrvers to apply pressu'e Io the_p,nton stop
')8, ano .'a6r ;ns snap ;tng fizS tJtty into the
graave.
']
, SCREW 6. NUT 11, SOLENOID RETAINING SCREW 16. SHIFTER LEVER
2, END CAP 7, WASHEB 12, SOLENOID 17. SNAP RING
1 atrAl 8, END COVER 13. Nt/T 18. PINION STOP
4. CLIP 9. FIELD COIL HOUSING .I4,
SCREW 19. OVERRUNNING CLUTCH ASSEMBLY
5, SHIM 10, BRUSH HOLDER 1 5, ARMATURE 20, INTERMEDIAIE BEARING
NOTE: ltems marked * musl be repiacecl.
NOTE: ltens are numbereC in order o/ Drsasse,o:o,,.
)cr ;-,f i80 tssuco 3 92 Printed in England
kaukazz@yahoo.co.uk
4003-7
lnspection
STEP 21 STEP 25
Use a clean dry cloth to clean the drive clutch,

armature, field f ramc and starter solenoid. Use
cleaning solvent to clean the remaining parts.
STEP 22
Measure the length oi the brushes connected to the

brush holder, l1 thc length of any brush is less than 8.5
mm (0.34 inch) both brushes must be replaced
Measure the length of the brushes connected to thc
field coil. lf the length of any brush is less than 8.5 mm
(0.3a inch) both brushes must be replaced.
Place the probes ol the multimeter to two segments oi
STEP 23 the commutator lf there is no continuity the winding
has an open circuit and the armature must be replaced.
STEP 26
rolder frame and the other probe to each rnsulaled

rrush holder in turn. There musl be no ccntinuiiy
'eplace the assembly if there is continuity.
the armature with a dial indicator. The run out must not
STEP 24 be more than 0.03 mm (0.012 inch) . lf necessary, put
the armature in a lathe and remove enough material to
make the run out less than 0.03 mm (0 012 inch)
STEP 27
)lace one probe of the multimeter to a commutalor

;egment and the other probe to the armature core
lhere must be no continuity l{ there is continuity the
lrmature has a ground and musl be reolaced
Place the armature cn vee-blocks and check for
on li the arrnature is distorted it rnust be
dislorl
re0 aced
)an 7 -41780 lssued 3-92 Printed in fng and
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4003-8
powrquadplus
STEP 28 www.thebestworkshopmanuals.co.uk
STEP 30
','ifffi1''''
J^ :.'
&,:war..;*_
lf the depth of the groove beMeen the cornmr.ta:or bars

405533
Nffi#ffi
Touch one probe of the multr-neter to the field coil
rs less than 0 2 mm (0 0079 rnch) cut the insulatior: termina and the olher orobe to lhe brush connection. lf
between lhe commutator bars to a depth of 0 5 mm there is no continurh/ the field winding has an open
(0 02 inch) Use sandpaper to remove the rough edges circurl arc ilus: be 'eoiaceo
'ror. llle cornri-,llator bars. DO NOT use emerv cloth.
STEP 31
STEP 29
Checx the spiines and teeth of the overrunning clutch
for wear and damage. Make sure the drive clutch
moves freely on the armature shaft.
STEP 32
Check lhe bushrngs rn the dnve clutch, drive housing

and end cover, replace rf worn or damaged.
,in zfr;;1;t
or,clr one Drobe oi the muiiirneter to the lrerd cor

terrntnal and the otner probe to an unpatnteo area on
the surface of the frame lf there rs continurty lhe field
'v,rrdtrtg tS grCtU,tr.li.:d ar)aj rnltc' Dl reOlaCeC
lCr r-{:,'80 lssuec 3-92 Printed in Enqland
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Section
4004
BATTERY TESTING, MAINTENANCE AND
BOOSTER BATTERY CONNECTIONS
For 5100 Series Tractors
Printed in England
CASE CORPORATION December 1 989
kaukazz@yahoo.co.uk
4004 2
TABLE OF CONTENTS
SAFEry BULES .
2
SPECIFICATIONS ..
3
MAINTENANCE
Elcctrolytc Lcvc
Jrsoect,ng and Crcan ng J
3
SAITERY TEST]NG
Visual Checks .. .. .. . ,...
,4
Capacity (Load) Test 4
5
CHi\rlGlNG iHE BAT] ERy
6
CHABGING GUIDE FOB MAINTENANCE FREE BATTERIES
6
CHARGING GUIDE FOR OTHER THAN MAINTENANCE FREE
BATTERIES 7
PREPARING A DBY CHARGED BATTERY FOR USE
BOOSTTB BATERY CONNECTIONS
SAFETY RULES
i'..r" 8 i15'tl
issucd 12 89 Printcd in England
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4004-3
powrquadplus www.thebestworkshopmanuals.co.uk SPECIFICATIONS
Votage o'rhe Batlcry . 12 volts
Cold Cranking Capacity (SAE) at -18"C (0'F) 700 amps
MAINTENANCE
Electrolyte Level lnspecting and Cleaning a Battery

lf thc battery is a marntenance frcc battery, check the lf damage causes an electrolyte leak, replace the
lcvel of the electroly,te every 1000 hours of operatron or banery
six months, whichever occurs first, For all other
batterics, check thc lcvel of the clectrolytc cvcry 250 lnspect the battery at regular inlervals for dirt corrosion,
hours oi operation. and damage Elcctrolyte and dirl on the top of the
baltery can cause the battery to discharge by making a
NOTE: A maintenance free battery will have words passage for the current to fiow.
Maintenance Free on the decal on the top of the battery
lf the center part of the decal has been removed for lf the battery must be cleaned, remove the baltery from
access lo the battery caps, it r,s possrb/e that the words the battery carrier and clean the baltery, cable
Maintenance Free have bccn rcmoved fram the decal. tcrminals, and the battery carrier When available, usc
Case Bat1ery Saver and cleaner according to the
Check the level of the electrolyte more often during hot instructions on the container. Case Battery Savcr and
weather, The use of a large amount of water by the Cleaner also helps prevent corrosion. lf Case Bat1cry
baltery can be caused by high battery temperature or a Saver and Cleaner is not availablc, use baking soda
voltagc regulator setting thal is too high. Keep the and water as a cleaner DO NOT permit any type of
clectroly,te levcl above tne top of thc platcs in thc bat1cry clcaner to enter the cells of the battery
at all times to prevent damage to the battcry
lnstall the battery rn the machinc and makc surc thc
NOTE: On maintenance free batteriesit is necessa,ry ro fasteners are tight. Apply Case Baltery Saver and
remove the center part of the decal For access Io lhe Cleaner or Urethane Seal Coat to the cable terminals to
battery caps. Do not discard the center paft of the prevent corrosion. See the Parls Counter Catalog. DO
decal lnstall the center par-t of decal after the battery NOT apply grease.
caps have been inslalled
lf the level of the electrolyte is low, add distilled water or

other clean water until the electrolyte is just below the
cell opening. Do not add more water than is needed.
Too much water can cause bad performance, a short
service life, and corrosion around the battery.
NOTE: Add water only DO NOT add electrol$e
Don 8-85110 lssued 12'89 Printed in Ingland
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BATTEHY TEST
NOTE: To correctly test a battery, do each part of the

battery test until you know the condition ol the batterv
rtl _.IIS fo
t3, -.rxp
.ED :'Il2!
Visual Checks rao
rT
:;Ei-'@8
_.@ 0-
Il2r
r20
-.m 50
I Makc surc thc cablc connections arc clean and 1!0
-.Dt6
+.I,la
-. D12
01{
lrght Clean foreign material from thc top of thc battcry ro

m :6a-'m
-.ott
o* __@ 61
2 lnspect thc battery case, baitcry posts, and cablcs -IX
_-m 20-
for damagc o- -
50* -.@
-,IDl Dl2 _trra !0
{, -fi.
_ff1 -!r4
-
3 Check thc clcctroly,te level. Scc pagc 3, I
&
-
--
--m
--Ot0
o
- tr21
l0
=-6-'M
-::6--* !o
4 ._-
_ -tt[ .M
ltyou addcd water to the batte ry, the battcry must bc 0 -IEP -
chargcd tor I5 minutes at l5 to 25 ampercs to n rx thc
watcr with the electrolytc
790863A
Specific Gravity Check 1. Temperature rn 'F 2. Temperalure in 'C.
A hydromcter is used to chcck the speciiic gravity 4. Make a record of the corrected speclfic gravity
(wcrght) of lhe clcctroly,tc Thc spcciflc gravity rs an rcad ng ior cach ccll
rndication of thc level of chargc lor cach ccll
5 lf lhc drifcrcncc bctwcen thc hrgh rcading and the
Hydrometers arc madc to show the correct specific low reading is 050 or more, charge the battery and
gravitywhen thc tcmperaturc of the clectrolfc is 26 7"C check the specific gravity again. lf after charging, the
(80'F)
difference rs still .050 or more, install a new battery
\ y'hcn you check the specific gravrry, you must know thc 6 Thc corrccted specific aravity reading shows the
lcmperaturc of tho electrolyte lf your hydromcter does level of charge for thc ccll. The lcvel of charge must bc
nol have a thcrmometer, get a thermometcr io check at lcast 75% in each of the cells ln maintenance free
thc tcmperature of lhc electroiy.te. The thermomelcr batteries the level of charge is at least 75%
must rndicate a hrgh ternpcrature of at lcast 52"C it lhe
corrected specific gravity reading is 1.240 or higher. ln
(r20'F ) all other batteries the levelof charge is at least 75%rtld;re
corrected specific gravity reading is 1.230 or higher.
I Remove enough electrolyle from a cell so that the
float is frce in thc tube 7 lf thc difference between thc high reading and the
iow rcadrng is less than 050, and the level of charge is
NOTE: lf the specific graviry cannot be checked wtthout at least 757o tn alt of the cells, do the Capacity (Load)
lirst a'dding water to the cell, the battery must be Test.
charged for 1 5 minules aI 7 5 to 25 amperes to mtx thc
watcr with the clcctrolytc. fhen check the specilic 8 lf thc diffcrcnce belween the high reading and the
gravtly low reading is less than 050 but the level of charge is
less than 75"/"in any of the cells, charge the batteryand
2 Read the floar check the specliic aravity again lf after chargrng.
3 Rcad thc thcrmometer. lf thc rcading is abovc a. the level of charge is less than 15%in any of the
26 7"C (80'F ) add spccific gravity pornts to thc rcading cclls, discard the batlery
lor specifrc gravity. lf the readlng is below 26 7"C (90"F
)
sL:btract specific gravity points from thc reading for b the level of charge is at least 75% in all of the
specifrc gravity See the {oliowing illustration and add or cells, do the Capacity (Load) Test.
subtract specific gravity points as needed
Don 8-851 t0
lssucd 12-Bg Printed in England
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4004-5
Capacity (Load) Test NOTE: Never apply a load for longer than 75 seconds.
After each 75 seconds, turn lhe load control knob to OFF
This test can be done using a variable load tcster such for at least one mrnute.
as thc Sun Eiectrlc VAT-33 Othcr test equipmcnt can
be used. Connect the test equrpment according to thc 4 Apply a 15 ampere load to the battery for 15
nstructions of the manufacturer of thc cquipmcnt. seconds, Wait at least three minutes before continuing
with the test
1. The ievel of chargc of thc battery must be at least
75% Do the Specific Gravity Chcck in this section. 5. Check and make a record of the temperaturc oi the
elcctrolytc.
2 Prepare the testcr (Sun Elcclric VAT-33 shown) fc;r
the test 6. Find the correct load for this test in Soccifications
a Sclcct the voltmetcr range that wrli measurc 1 to

1 8 volts. NOTE: The correct load is half of the cold cranking
anlperes at -1B"C (0"F).
b Make surc thc ioad control xnob is in thc OFF
position 7 Iurn the load control knob until the ammetcr
rndicates thc spccified load. Keep the load for 15
c Sclcct the ammcter range thal wrll measure 0 to seconds and read the voltmeter. Turn the load control
1000 amperes. knob to OFF
d Move the volt lcad switch to the iNT, posiiion. B. Comparethe tcst rcading andthetemperature of the
clectroly4e to thc chart below.
3. Connect the testcr to the batiery as shovrn
Temperature of electrolyte Minimum Voltage
2t',c (70 tr) aro above . ..

r
ro
ô u [ou r)
/^ô-\
........ 95
o 1 0'c (s0'r) 94
.t 4-e /4n"F\ 93
s 1C(30F;
7C(20t)
12 c (10"F)
91
89
QA
QA
1B"C (0',F)
a 11 the test resuit rs equal to or more than the

voltagc shown, thc batlery is in good condition
b lf the tcst result is less than the voltagc shown,

drscard the battcry.
1. LOAD CONTROL KNOB 2. AMMETER CLAMP
Don B 851 10 lssued 12-89 Printed in England
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4004-6
CHARGING THE BATTERY
Thc charging ralc musl bc decrcased if.
1 . Too much gas causes the electroly,te to f low from the
cclls
flt:'orc you chargc thc battcry chcck thc tcvcl of ihc
cicctrolytc.
2. The tempcraturc of the electroly.tc rises above 52"C
(r 2s'F).
It rs ditficult to give an exact charging ratc because of
the f ollowing variable conditions (1 ) tcrnpcralLtrc of the
NOTE: Far the best charge, use lhe slow charging
r:locirolye, (2) level ol charqe ancj (3) condilion c,iirc
rates.
battcry. Usc the charging gurdc ior ihc corrcci chargrng
ratc and time.
The battcry is fully charged when, over a threc hour
ccriod at a ow chargtng rate, no cell is giving too much
Sco Spccifications for the rescrvc capacily of thc gas, and thc specific gravity docs not change.
battery in this machinc
CHARGING GUIDE FOR MAINTENANCE FREE BATTER|ES
Rccommendcd Rate* and Time for Fully Discharged Battery
8anery Capaciry -
See Reserve Capacity
under Specifications Slow Charge Fast Charge
B0 Minules or Lcss 10 Hours at 5 Amperes 2 5 Hours at 20 Amperes

5 Hours at 10 Amperes 1.5 Hours at 30 Amperes
Acovc 80 1c 125 Mlnurcs l5 !ours al 5 Arnocres 3.75 Hours at 20 Ampercs

al lC A,.nccrcs
7 5 Houi's 1 5 Hours at 50 Amperes
Aoovc 125 to 1 /0 lvinutcs 20 Hours ai : Ampercs 5 l-lours at 20 Amperes

10 Hours at 10 Amperes 2 Hours at 50 Amperes
Acove 170 to 250 Minutcs 30 lours al 5 Arnperes 7 5 Hours a1 20 Ampcrcs

15 Hours al 10 Ampe rcs 3 Hours at 50 Ampcres
" lnr:ral ratc ior standard laper charqer
NOTE: A rnaintenance free battery wlll have the words

Maintenance Free on the decal on the top the battery t
lhe center part of the decal has been ramoved tc get
access to the battery caps, rl is possrb/c thc worcls
Matntenance Free will have been removed from ihe
decal
Don 8-U)'l 1 0 lssued '12-89 Printcd in Engtand
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4004-7
CHARGING GUIDE FOR OTHER THAN MAINTENANCE FREE BATTERIES
Recommendcd Ratc* and lirnc tor Fuily Discharged Battery
Battery Capacity -
See Reserve Capaclty
under Specifications Slow Charge Fast Charge
80 Minutes or Lcss 10 Hours at 5 Amoeres 2 5 Hours at 20 Ampcrcs

5 Hours at 10 Amcercs 1.5 Hours at 30 Amperes
'l
Above B0 to 125 Minutcs 5 Hours al 5 Ampcres 3 75 Hours at 20 Amperes
7.5 Hours at 10 Amperes '1
5 Hours at 50 Amperes
Above 125 lo 170 Minutes 20 Hours at 5 Amperes 5 l-lours at 20 Amperes

10 Hours at 10 Ampercs 2 Hours at 50 Amperes
Above 170 1o 250 Minutcs 30 llours at 5 Amperes 7 5 Hours at 20 Amperes

I5 Hours al 10 Ampcres 3 Hours at 50 Amperes
Above 250 Minules 24 Hours at 10 Amperes 6 Hours at 40 Amperes

4 Hours at 60 Amperes
- lnitial rate for standard tapcr charqcr
PREPARING A DRY CHAHGED BATTERY FOR USE

l. Remove the caps from thc batiery 5 Chargc thc battcry at 30 amperes until the specific
gravity ls 1 250 or morc and the temperaturc of thc
2 Fill each ccll to the top of the separators with clcctrol;4c is at lcast 15 5'C (60"F)
elcctroly,te This wiii pcrmrt ihe volurne of electro y'te to
rncrease when hcatcd by charging thc bal1ery 6 lf nccessary, fill cach cell with elcctroly.le until thc
clectroly4c is lust bclow split ring at the bottom of the cell
3. lnstall rhe caps or the bartcry opcninq
4 Connect a baltery charger to thc battcn/
Don 8-851 1 0 lssued '12-89 Pnnted in England
kaukazz@yahoo.co.uk
4004 8
BOOSTER BATTERY CONNECTIONS
STARTING TF]E ENGINE I ll .r't :i.it ({),",,i\^,,icli .l.rc

iL) S,A[]T OOSitiOn RCleaSe
'; \r"
:rit[)r :is ll]it ctr!rTtr._. 3L-clrns lo !,jn l{ lhe
.1:r
NOTE: Iv,,o Oer.sor;s a!'e .Cei.)t,eci iot it.:: {),a)(),,;(:t),(,
a.rQrnC OCqrnS lit r.,i 2i5 ihr.n.,,.pq dO nOl Cngagi:
liti:
s:aricr a'olor r.,rl r tno {)frgrnc l as sloppccl runi,ng Do
1 \,4a(c surc lho iorwarc,/i.cvc.so an(j [)- () l1,ygr5: ;.1i'i; r1: rtc: aciLtslO ifrc slaricr {or .r.61g lhan 30
r'!l itiiinl scconds al one
tirr-(' Al,.,w :itc slarlcr moior to cool for 3 mtnutcs
I ^;i,t-. :t.,ra lha 33rki11q i;..-.ri".r' br:icrc vou orrgagc iirc s:arlcr again
j)t;1.1;;;_,. .,
I i Wi:cn 1ir(_. cnqtnc rs runnrng havc iflc othcr pcrson

3 iurn ihc xeyswitch to the ON ccs iio!
d sccnncct :hc ncgatrve lrrmpcr cable and thcn the
positivc lumpcr cablc
CONNECTING THE BOOSTER BATTERIES
.1
2 lnstall thc bailery ji-irrpcr stud proteclive covcr.
9 Have the other Derson rlo thc {ollowing
:lC.nOvC 1-C p.OlCCl;v(r

l ll Chcck lhc followinq warning lamps and make surc
a LO\'C. ,.Orn :.rC Da::C-V lhc lamps arc not illuminaterj lf any of thc followrng
j-rnpcr sluo rvarnrng larnps arc illuminatcd, stop the engine and
chcck for thc problem
b Conncci lhc posilivc ( i I lulr.ccr c.jbic .(.)
tir(l
baltcry lLrmpcr slud
a Allcrraior rvarnrng lantp
c Connecl the ncgativc ( r jurnocr c.,rbic :o a gocd b Enqirc oil orcssLtrc warning lamo
chassrs Eround
.1" 14 Rl-rr :irc cngir.c al .,i, throille until tne cngrnc

$i lcrni)cralurc s warrri Do not run thc enginc al low
j tJ cr)ernc sDCCds 1or long periods of trmc. Low cngrne
1 BATTERY JUI'IPER STUD sDCC(js will causc acids ancj ocposits in thc cngine otl
BAN-ERY CONNECTIONS
6 2 POSTT|VE
t-+- JUMPIR ,/ *;:L% 1 POSITIVE
CABLT ' ;:
n z. -*
i)on B B)1 10
lssur:o 12 89 Prrnlco in Fnglano
kaukazz@yahoo.co.uk
Section
4008
ALTERNATOR
(BOSCH)
Copyright @ 1992
;ORPORATION Printed in England
March 1992
kaukazz@yahoo.co.uk
4008-2
TABLE OF CONTENTS
SP:CIFICA-IONS a
SDSC|A. TORQUES .2
SHOP EQUIPMENT TOOLS .2
ALTEBNATOR
Testing on :he Machrne J
Voliage Test at the Alternator Termrnals J
Alternalor and Voltage Regulator Test. . 4
Removal and Installation .. . 5
Disassembly and Assembly . 6
lrspection 7
SPECIFICATIONS
Manufaciurer Bosch
Resistance oi Resistance of Maximum Rotor

Pafi Number Output Curren
Stator Winding Botor Winding Shaft Run-Out
A186.125 65 amps, 14 volis 0.05 mm
A1 87873 at 6000 rorn
0 10 ohrr t 10o/" 28onrr'* 10o/o
(0.002 inch)
45 amOS. 24 volis 005mm
24
90ohm *
A1 861
A1 8791 6 al 6000 rorn
0 22 ohff :: 10"k 107"
(0 002 inch)
45 amcs, 24 volts * + 005mm

1964860C'1 0 10 ohm 10"k 2.8 ohm 10"k
at 6000 rpnr (0.002 inch)
95 amps, l4 volts * + 0.05 mm
A1 87623 0 055 ohm 107" 3.0 ohm 10o/"
at 6000 rom (0.002 inch)
SPECIAL TORQUES
Alternalor Mounting Bolts 24 Nm 18tbft
Pultey Retairinq Nut 68 Nm s0 lb ir

1. MULTIMETER CAS 1559 3, SOLDEBING IRON OEM 6156
2. SUN ELECTRIC VAT,33 TESTER 4 TOROUE WBENCH OEM 6479
Jo^ l-d I790 lssued 3-92 Printed in England
kaukazz@yahoo.co.uk
4008-3
Testing on the Machine
STEP 1 STEP 4
Park the machine on hard level ground Apply the Check the operaiion of the battery warning lamp Steps
parking brake (if equipped) and stop the engine 2 and 3 may have corrected the fault.
STEP 2 STEP 5
Make sure that all electrical connections are tight and Tes: the bratleries, each battery must bre fuily charged
iree of corrosion. and have a voltage of at least 12 volts.
STEP 3
Make sure that the alternator drive belt is trght and rs

free of or or grease that would cause the Delt to siip
Voltage Test at the Alternator Terminals

Carry out Steps 1 to 5 before doing this test. Use a STEP 7
nrultimeter set to read volts for the tesi
Connecr the positive multrmeter lead to the battery
terminal of the starter solenoid.
Connect the negaiive multimeter lead to a good ground
connection on the engine.
11 the multimeter indicates rated voltage (126 or 25.2
$+
.I'ERN/INAL volts), repair or replace the wire between the alternator
and the starter solenoid
lf the multimeter does not indicate rated voltage (12 6 or
25 2 volts) replace the positive battery cable
STEP 8
Turn the starter key switch to the ON position

Disconnect the connector from the D + terminal ol the
alternalor. Connect the positive multimeter lead to the
terminal in the connector and the negative multimeter
lead to a good ground connection on the engine
TERM]NAL lf the multimeter indicates rated voltage (12 6 or 25.2
volts), connect the connector to the alternator and reier
to the Alternator and Voltage Regulator Test, Page 4.
STEP &51 746 Fefer to Section 4001 if the multimeter does nol
indicate rated voltage (12.6 or 25.2 volts)
Connect the positive multimeter lead to the B + termina
of the alternator
Connect the negatrve multimeter lead to a good ground
connection on the engine.
lf ihe multimeter indicates less than rated voltage (12.6
cr 25.2 volts) or indicates zero, reter to Step 7
lf the multimeter indicates rated voltage (12.6 or 25.2
vots), refer to Step 9
lssued 3,92 printed in EnOland

)or 7-41 790
kaukazz@yahoo.co.uk
4008-4
Alternator and Voltage Regulator Test
1. SUN ELECTFIC VAT-A3 TESTER

oo
Ooo
5, AMMETER CLAMP LEAD
4, NEGATTVE (_) VoLTMETEB
3. POSiT|VE (+) VOLTMETEF LEAD
2. 12 VOLT BATTERY
790499M
|'JOTE; Refer to Steps 7 to B, page
3, before carrying out STEP 11
thls lesa Use a Sun Etectric ief_SS
o, otii, suitabte
equipment to carry out the lollowing test.
Connect the positive voltmeter lead of the tester
to the
B + terminal on the alternator.
STEP 9
Connecl the negatlve voltrneter lead of the tester
to a
good ground connection on the engine.
AdJUSt the conlrols for the Sun Electric VAT_33
as
foliows:
l Put the load control to the OFF position. STEP 12
2 Select the volt range that will measure.l
B to 40
volts
Connect the ammeter clamp around the wire
that
fastens the B -r- terminal on the allernator
3. Select the ampere range that will measure to the battery
0 to I00 terminal of the starter. The clamp must be
amperes at least
50 mm (1 97 ir:ch) from the ajternator The poinl
4. Put the volt lead select switch to
the EXT position, of the
arrow on the ammeter clamp must be pointing
away
lrom the alternator
STEP 1O
Connecl lhe positive load lead of tire lestcr to the

oosrtive posl of one of the bafteries
Connect the negative load leacl of the
tester to the
neeative post of the same bat1ery.
Don 7-4179A
rssued 3-92 Printed in England
kaukazz@yahoo.co.uk
1008-5
STEP 13powrquadplus www.thebestworkshopmanuals.co.uk STEP 15
Start and run the engine at 3/4 throttle. Slowly decrease the engine speed and stop the engine.
STEP 16
rhe ammeter reading in Step 14 must be more than the
rated output (45 65 or 95 amperes). The voltmeter
NOTE: Carry out Steps 14 and 7 5 rapidly. Do not apply a reading in Step 14 must be;
load at the battery for more than 15 seconds at a time.
After 1 5 seconds turn the load control to the OFF position A. 13 to 15 volts (12 volt system).
/or 60 seconds before applying the laad again
B 25 to 29 volts (24 volt system).
STEP 14
lf the ammeter and voltmeter readings are correct the
Adjust the load control of the tester to get the maximum alternator and voltage regulator are good.
ammeter indication, make a note of the ammeter and lf the ammeter and voltmeter readings are not correct
voltmeter readings. replace the voltage regulator and brush holder then
Turn the load control to the OFF position. repeat the test.
lf the ammeter and voltmeter readings are still not
correct repair the alternator,

STEP 1 STEP 4
Park the machine on hard level ground Apply the Fasten identification tags to and disconnect the wires
parking brake (if equipped) and stop the engine from the alternator Remove the top and bottom
alternator mounting bolts and rernove the alternator.
STEP 2
NOTE: For lnstallatian, follow the same procedure in
Turn the master disconnect switch, if equipped, to the reverse order and tighten the alternator mounting bolts
OFF position and remove the key or disconnect the to a torque of 24 Nm (18 lb ft).
battery negative (-) terminal tirst
STEP 3
lnstall a 13 mm (1/2 inch) drive lever into the tension

pulley oracket, use the lever to release the tension and
removc the drive bell.
Don 7-4'1790 lssued 3-92 Prinled ir England
kaukazz@yahoo.co.uk
4008-6
DisassemblY and AssernblY
/-eD
f -\"-" -@
I
rl \t
@/ \ \/
d
@@,ro
(E\
/.o
\
*2@n
:v 6 ***
NOTE: ltems marked * must be replaced
\*-@ */ 861 586A
NOTE: ltems are numbered in order of Disassembly
12, CAPACITOB 18. scBEW
1, NUT 7, SCREW
13. SCREW 19. RECTIFIER BRIDGE
2 WASHER 8. VOLTAGE REGULATOR
14. covER 20. STATOR
ANO BHUSH HOLDER
3 PULLEY RETAINER
15. scREw 21. HOUSING
4 PTJLLEY 9, NUT
16. ROTOR 22. INSULATOR
5. FAN 10, FIBER WASHER
17. O-RING
6. KEY 11. SCREW
Dor 7-41 790
kaukazz@yahoo.co.uk
4008-7
powrquadplus www.thebestworkshopmanuals.co.uk lnspection

NOTE: Use a multimeler sel to read ohms for the STEP B
I
inspectton.
STEP 6 ,
g
t I
I
I
t
Check the positive diodes in the rectifier bridge.

a. Connect the negatrve lead of the multimeter to the
oulput (B+) terminal Connect the positive lead of
Check the stator resistance. The resistance tn each cotl the multlrneter to one of the leads for the positive
must be 0.22 ohms. lf the resistance in a coil is not 0,22 diodes. The positive diodes are the three diodes that
ohms, reier to Siep 10 and install a new stator are closest to the output (B + ) termina . Read the
multimeter
STEP 7 b Reversc the rrlltimeter leads Re ad thc
multimeter
c. There must De a high reading and a low reading lf
the readings are the same, replace the rectifier
bridge
d Repeat this procedure for the other two positive
diodes
STEP 9
Check the stator for a short circuit. Make sure the

recitifer bridge does not touch the stator. Connect one
lead of the multimeter to the housing o1 the stator.
Connect the other lead of the multimeler to each of the
three leads irom thc stator lf the porntcr of lhe
mullimeter moved, ihcrc rs a shorl circuit tn the stator.
Reier to Step 10 ano irslall a new stator.
Check the negative diodes in the rectifier bridge,

a Connect the negative lead of the multimeter to the
surface ol the diode plate that is not parnted
Connect the posiiive lead of the multimeter to one of
the leads for the negative diodes Read the
multimeter.
b Reverse the mullimeter leads. Read the
multimeter.
c. Therc must be a high reading and a low reading lf
the readLngs are the same, rePlace the reciifier
bridge
d. Repeat this procedure for the other two negatrve
oiodes
Don 7-4 1 790 ssued 3-92 Printed i1 Enqland
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4008-B
powrquadplus
STEP 1O www.thebestworkshopmanuals.co.uk STEP 13
Check the bearings on the rotor for wear or damage and

replace tf necessary.
STEP 14
1f any of the diodes are damaged or the stator winding is

iaulty, use a soldering rror to seperale ihe rectifier
bridge from the stator Disconnecl :he wri-es cLrrck,y:c
Drevent oamage to tne Ciooes iieplacr.. tne iaulV
rectrfier briOge or stator
-I1
Check for continurty befween the capacitor mounting
STEP tab and the lead. lf there rs continuity, the capacitor rs
faulV and rnusi be replaced
STEP 15
Measure the length of each brush, this must be more

than 4 mm (0.55 rnch) lf the length of a brush is less
"1
than 14mm (0 55 inch) replace the voltage regulator

and brush holder.
STEP 16
,:/ 517902
Use the mult,meter to check the resistance of the rotor
winding The resistance must be 9 0 ohms lf tne
resistance is not 9 0 ohms the rotor is iaLitiy and r:rL;sl
Lre r'eolaccd
STEP 12
!
ft Check for contrnuity LreMeen each brush and the brush
lerrninal lf there rs no continuity, replace the voltage
regulator and brush holder.
HoLd one lead o1 the multir-neler on the sito rinq anc :rre
other lead of the mulirmeter on the nousing lf :he
pornier moved ihere is a short cii'cu i oorween :l-,e
lrous..lg ard I.e roior C C . 'Cplace ":,.: ,'tt- '
bcr i -41-!9C
lssuec 3-92 Prlnted in Enaland
kaukazz@yahoo.co.uk
Sectional lndex
STEERING SECTION NO.
Front Axle 2WD

Frone Axle King Pins 5003
Removal and lnstallation 5003
Toe-ln Adjt stment . ,
5003
Whcel Bearing 5003
Steering Cylinder 2WD

Removal and Disassembly 5002
Steering Cylinder MFD
Hydraulic Schematic 8001
Removal and Disassembly 5004
Steering Hand Pump
Hydraulic Schematic 8001
Removal and Disassembly ... 5001

February 1990
CASE CORPORATION
kaukazz@yahoo.co.uk
ection
5001
STEERING HAND PUMP
CASE CORPORATION Printed in England

December 1989
kaukazz@yahoo.co.uk
500r -2
TABLE OF CONTENTS
SPECIFICATIONS . .
2
SPF-CrAl TOROJFS
,
SPECIAL TOOLS .. .. .
?
STEENING I]AND PUIV1P

Removal
3
Drsasscmbly
7
lnspection
12
Assembly
14
Cross Sectional Drawing of The Stccrlng Hand pump . .
21
Installation
22
SPECIFICATIONS
fypc
Danfoss
Modcl
21,'D
OSPC lOO LSR
VFD
Ralccl trlow
. OSPC 160 LS
2WD
lu t/mln
[/FD
Rolo, - Slator wcar linit
?Z,:fTil 16|/min
Rotor - Stator thickness differcnce "' 0.005 inch
0 002 inch
SPECIAL TORQUES
Stecring Column Plvot Boll 32 to 37 Nm 23 to 27 lb tt
Steering Pumo End Cover Bolts 30 to 35 Nm 22to26 lbft
SPECIAL TOOLS
1. ASSEMBLY TOOL
CAS 1238-3 2, TORQUE WRENCH
cAS 10037
NOTE: Any ret'erence to left and right hand is rnadc from thc aperalors seat looking forward
Don 8 85130
ssued 12 89 Printed in England
kaukazz@yahoo.co.uk
5001-3
STEERING HAND PUMP
Removal
STEP 1 STEP 4
Apply thc parking brake and block thc whecls Remove the cab floor cover
STEP 2 STEP 5
ffi
-,".jrJais*
Drsconncct thc battcry tcrminais. nr:gative (-) tcir'' nar Rcmovc tnc lwo slccring column side covers
.frrst
STEP 3
throtllc pedal
Don B-851 30 lssuec 12-89 Prinled in England
kaukazz@yahoo.co.uk
STEP B
Ir"T)oVC Ir c slccr,.tg cotur,ln stdc covcrs
STEP 9
flffii
". :,s'.
*1 &N:l
Bcmove fhe stcenng colurnn adlust& .JfLt t"",rr
STEP 7
STEP 1O
ffi.w
Remove the rrghrhand sirre r,;i:;,1^ffiffii(,ffi,
llon B B5i3O
rssucd 12-89 pnnted in England
kaukazz@yahoo.co.uk
5001-5

STEP 1 1
fgu*',.,',
/
@//
,.uvE i
{thisrff<
REMOVE
v,'"
,:itrii
Removc the stecring column rght hanC motlnttng Remove the hruo remainrng mounting brackct bolts and
bracket bolts rernove the steering hand pump
STEP 12 STEP 15
@'b,1 ,
Y#!;?;:
Bcmovc the right hand mounting brackei lnstall protective caps to all the hydraulic connections
to prcvcnt forergn matcrial trom entcring the system
STEP 13
NOTE : The steertng column has been removed for
photog raph ic p u rpo se s on ly
Rcmovc the roll pin from thc coL;pling
,SS-co I 2 89 P'j11s6 ir E -gla^cl

Don B'85130
kaukazz@yahoo.co.uk
5001 6
DisassemblY
STEP 19
STEP 16
,"4
$af
6
sd"
ls} c1m19
c 1srs1 I
and brackol
tOr Removc lne slccring shaft asscmb'ly
i)l:t A r-:'a'k:r'i,'tl s::cct'llc hanC OLImO
las cr assCti.orr
STEP 20
STEP 17
&
I
s.Ei I .
.\& -dr
\
h
c 1991 3 i'1olC tfrestccring hand pump ;t' a vice f lttcd with solt law
,r(..'. .i ra.,;'1.'11r:61 i.iifC llaics Rcmove thc orotocirvc caos from the fittings
.,r, - llt, )i,r'(i aii)lIr:] |
r,.t !racki::
STEP 21
sirl' '18
'*,1+,y
M
^,1
.&,
''.\tr"i
w,
r,qz@.tPfr a::Y:@rryww|
c199ii itcmovc ano drsCard :hc o-r n<;s f ron' thc flttings
Lla' tr2'na:
::s.,c,1 '2 8,9 f)'r'rlcd rn EnglanC
kaukazz@yahoo.co.uk
5001 -7
STEP 22powrquadplus www.thebestworkshopmanuals.co.uk
BO3Bl 2
Pui a rnark on the puntp body, slator and cnd cover Rcrnovc thc end cover
fhcsc marks musl bc aligned rvhcn thc pump is
asscmbled. STEP 26
STEP 23
Bcmovc the stator
Removc thc six bolts and :italrnq w.iitirors fron'ihc cnd STEP 27
covcr. Drscaro the scaitCri rvciilll(litj
STEP 24
80331 6
Rcmove and discard the two o-rings from the stator
:ff.ffiTrl:Try B&B1o
Bemove the special bolt and sealing washer from the

chcck ball bore. Discard the sealing washer
Don B 85130
rSS_Cd 12-89 o.,ilco - Eagla.C
kaukazz@yahoo.co.uk
5001-8
STEP 28 STEP 31
80331 I
Rc.move thc rotor []t-.rrcvc the drrvc shafl
STEP 29 STEP 32
[ir.:.novc the spacer (rf equrpped) Remove and discard thc o-ring from the groove in the
pump body.
STEP 30
STEP 33
,ff;,,r;,4>
iloi'rovc :he valve piate

Use a screwdrivcr to remove the threaded bush
Do. B-85130 lssucd 12-89 Printed in EnOland
kaukazz@yahoo.co.uk
5001,9
powrquadplus
STEP 34 www.thebestworkshopmanuals.co.uk STEP 37
i,ts'
il
l?&e
tiiar' -
s*q ti
s-
s!+q
% Pusl'r thc spool and slceve from thc pump body

Removc thc chcck bail
STEP 35 STEP 38
'!. t.
803S3,{
Bemove the pump body trom the vice Shakc out the Remove the thrust washer, needle brearing and
tr,vo suctron valve prrs ancj stect balls chamfcred washer from the spool.
STEP 36 STEP 39
*'
o
t
,*' o
\"\e;;#_ l,
brunT
Look inside the pump body rhg pin through the spool Rcmovc thc pin from thc spool and slccvc
and sleeve is loostt Thc Jrrr-r r:.itst be horizontal when
you remove the spooi attc sli:cvc lo prevent danrage to
ihe pump body bore
Dorr B-851 30 ssucd 12 89 Prtnlccj tn England
kaukazz@yahoo.co.uk
5001 -1 0
powrquadplus
STEP 43
Bep{xl
Bemove the retainer ring for the centering springs from Bemovc and ciscard the lip scal frorn lhc thc pump
lhe sleevc, body
STEP 41 STEP 44
Remove thc spool frorn the sleeve Remove and discard the dust seal from the pump body
#
STEP 42 STEP 45
Remove and discard the centcnnq sprinc;s f rom the slot

,n the spooi
Two shock vaivcs are fitiecl and arc a non servtcable

rlern [lgrn6yg for crcan,ng ourDoscs only.
Ilon B 85130 lssucd l2-89 Printcd in England
kaukazz@yahoo.co.uk
5001 -l I
STEP 46 STEP 47
,i.
-d
"*.&
r""] z:1*Z * x
d **w. : *\
?T1;xi
"**w:., 'll:-^*a.'-
80321 9
ihc nlct port (P) ot

A mechanrcal chcck valve s f it:cd in if a Jiilrng has been movcd during thc steering hand
thc stoering pump Thc chcck valvc is fitied during pump romoval or disasscmbly procedure, removc the
assembly al the faclory anc ;s hcld rn r')osrtrr:n by a frtting Remove and discard the litting o rrng
scaling compoLrnd DO NOT rcmova lnc ;hcck va,vc
Scrvicc oarts arc n^ avliJabl:-'
lnspection
STEP 48 STEP 50
t
\ @,
Bt2&5r BO32l 1
Clcan thc parts in kr:roscrrc or lucl oi and dry wrih air

alr Chi:ck thc ormp borc {or darr:agc or wear 11 dar-nagc
DO NOT use a cloth lo dry the parts or wcar is {oLrnd, rr-.olacc the stcclng hand pump
STEP 49
ffiffilt; *).i,.,..,:t
a r-Y#a
^-
STEP 51
ru
& /e
litiiitt:
KI{
Rffi,I&
: " {''F
The pump spooi and slecve arc a matchcd set lf thr:rc

85'2850
d!
@
@
Chcck thc rotor and stator for damagc or wear if ihc
8+2854
is wear or damage to cither pari inslall a ncw siccrrnQ damagc or wcar s found replace the steenng hand
hand pump
Don I t'15130 lssued 12 89 l)rrnled tn EnQland
kaukazz@yahoo.co.uk
5001-12
STEP 52 STEP 54
2. STATOB
1. ROTOR
8r2a45
Measurc the thickness of rotor (A) and the stator (B) as Check the thrust washer, needle bearing and chamfer
shown lf the rotor (A) is 0 002 rnch (0.051 mm) less washer lor damagc or wear. lnstall new parts if
than thc stator (B) install a new steering hand pump. nccessary.
STEP 53
1. STATOR
Mcasure thc gap bcMeen the rotor and the stator with
lhc parts aligned as shown lr ihe gao is 0 005 inch
10 12l mm) or largcr rnstall a ncw slecring hand purnp
tlon B-85 I 30 lssued 12-89 Printed in Fngland
kaukazz@yahoo.co.uk
5001 -1 3
powrquadplus www.thebestworkshopmanuals.co.uk Assembly
23. DUST SEAI
20 STEEL BALLS
-#r)h \
1/
@ . re. LrP sEAL / 18 sucroN vALVE prNS
X%^ @
ASSEMBLY
\\) =\
f .)\l "\'//
7^t)L \ 14 THRUST*ASHEHS
21 CHECK VALVE \ N^ ,..
\=*^\ yYy(flffir^/ ""/"u'
\
&)
A/ Y'so*J ,)'*
/
.'Î\EEDLEBEABING
\\Sb5-{d"'/A'=-
,opN
^
16 BUSHTNC
<2-.-, \ -!.
-@'.
8. DRIVE SHAFT
I
I
"\ [ro,*r*o,*o\ ^","h
l.CENTERING 9. SPOOL
/-*w
-r\{ / .. o-* ING
t
\'/
7)
,rr:'0n '/<& .^/ lrV
Vr,
o,
n ' 3. o-RING
\ -.
,/"
6. VALVE
/
/
PLATE
5. R(
fQ@
P06""
,r.R
4. I Iq0*
srAro' .-F.NG 3.
,%
*.,.
/
2. SPECIAL BOLT
Don 8-85'130 lssued 12-89 Printed jn England
kaukazz@yahoo.co.uk
5001-14
powrquadplus
STEP 55 www.thebestworkshopmanuals.co.uk STEP
-4ri1!.,i:,i:ti!j,,
K
&.
:i;*r
'*?Eq**
?s*.
lqr|ti
.,,.fr.1t..
B$2908
Lubricaic a ncw ip sca lvith clcan transmission fluid
and install it on to Special Tool CAS l238-3 Refcr to
Spccral Toois Pagc 2
rwo shock valvcs are fiitr,'d and arc a non scrvicable STEP 59
rtem Bemovc for clcaning purposes only
IMPORTANT Be{orc assernbty, lubticate ail parts with

cl{:an transmtsston fluid ol the correct :;pectftcatro.
STEP 56
-/-6--:.-* '\
{*:@;,'
w8 .#$Br, 46C
Make sure the lip seal iits on to the Special Tool CAS
1238-3 as shown
ST EP 60
"@,i)
{
ffi:t
jf rcmoved, instali a new o-ring onto the {itiing. lnstall
anri tighten the fitiing to the cL:mp bod,v
STEP 57
='*--**?.
*
lnstall tho spccial tooi and lip scai into the pump body
Push lhc spccral rool against thc shouider insidc the
bore then turn it through 180 degrees to makc sure the
lip seal rs in position
Hold the assembly tool in positjon then prcss in the
small end until you feel the lip seal drsengage from thc
Bttutt7 special tool. Carefully rcmove thc special tool from the
irstar a rcw dust scal wllr :h(r o[)C. ltidc facing pump body
outward
Don 8-85130 ssued 12-89 Printed in England
kaukazz@yahoo.co.uk
5001 -1 5
STEP 61 STEP 64
. ::'.i::.:, t:....:'t'
w
. r1i:. . ':' r.:j:'
@
-*q*;
nj'i.tt:t
M I
.rD
t-
'Q
o aa f
,
\i --l-*-"tr-, ./
8r2g15
lnstall hvo ncw flat ccntering spr ngs rnto lne slct ln thc lnstall lhc rctaincr ring ovcr thc centering spnngs
spool Hoid two ncw curvcd ccnlcrng scrings logcther Chcck that thc retainer ring will rotate easily on thc
so that thcir centcrs arc toucning sleevc.
STEP 62 STEP 65
a
C,
$$i
ti*
au812
lnstallthe curvcd springs behryce n thc wo f lat springs in lnstall the pin through the spool and slcevc
Ihc slol
STEP 66
STEP 63
2, CENTERING SPHI
W
8t2343
95'.291 4 Install thc chamfer washcr, ncedle bearing and thrust
Movc thc centcring springs so thal the r cnds are level, washer onto the spool. Make sure thal the chamfer on
thcn install thc spool ontc the sleevc rr,ake sure the the first washer is towards the retainer ring
sprinqs are posrtioned in thc slol oi :rle sleevc
Don 8-85130 ssued 12,89 Printed rr FnqLand
kaukazz@yahoo.co.uk
5001-16
STEP 67 STEP 69
#
.r/ \
il
-q
rf{
.,s{*
BO€34
Pul the pump body on lhe workbe nch so that the ittings
f lnstall the two steel balls and suction valve pins into the
are ai thc too Hold thc soool and slet-'vc asscmbly so pump body
that thc oin is horizontal Carcfliiy lithc arsscmb'ly into
the pump body DO NOT tL;rn il-rc slccvc during lhrs STEP 70
operation.
NOTE: llthe sleevewill nolIit tnto tlie pump body easily'

cool the sleeve in dry tce then rcpsea! Ihe asscmb/y
proced;.)re. Heal fram your hancls cot;lci t:xpand thr:
sleeve maktng tt difficult to tnstall
STEP 68
2. FITTINGS
Hold the pump body in a vice f lned with soft iaw plates
lnstall the check ball into the largest hole with threads
STEP 71
Check that the pin through the slecve anC spool is at 90

degrees io thc fittings
lnstall the threadecj bush so that its top edge lust

bciolv the facc of thc PLrmP bodY.
Don B-85 I 30
lssuori 12 89 Prinled irr England
kaukazz@yahoo.co.uk
5001 I 7

STEP 72
q:
,:L
Brvrpg
Lubricate the thinncst new o-ring with clean

transmission oil lnstall the o-ring into thc groovc in the
pump body.
STEP 73
lnslall ihe drive shafl
STEP 74 lnstall thc rotor onto thc drivc shaft so that the curve
bctwee n two of thc teeth is aligned with the pin through
the sleeve and spool. lf the rotor is in the correct
position, one of the teeth will be in the direction of the
fittrngs in the pump body
STEP 76
Put the valve platc into position on thc

lv4akc surc that thc marks align.
lnslail the spacer,
Don B-851 30 lssued 12-89 Printed in England
kaukazz@yahoo.co.uk
5001 -1 B
powrquadplus www.thebestworkshopmanuals.co.uk STEP BO
STEP 77
ttg3}"'
tVYTWT'.,,,,, 8033 1 0
installthe special bolt and a new sealing washer into the

holc for thc check ball and bush do not tighten at this
siagc
STEP B1
BO33l4
tns:ali thc stator onto the pump body then align thc B{fiO8
:-rit,ks
Tighlcn all sevcn bolts evenly to a toroue of 30 to 35 Nm

STEP 79
(22 to 26 lb f1)
STEP 82
8(rI31 2
lnstall the end cover and align lire: marks
lnstall new o-rings to the fitlings and install the caps
lqsuod 12 89 Printed in England

llon B 85130
kaukazz@yahoo.co.uk
5001 -1 I
B3 STEP 85
;.!::aa- -:'.
.\. "..re,".,**
. t::
*,.. iil
c1 991 I c1s13
Check the stcering shaft asse mbly for damage or wear lnstall and tighten the steering pump mounting bracket
It damage or wear is found install a new assembly bolts
f ngage thc splincs on thc steering shafl with thc splrnes
rn thc spool STEP 86
STEP 84 Check the condition of the rubbcr mountings Replacc

the mountings if necessary.
,*#.i;',,
c1 891 7
lnstall the mounl rlq r,,n.i", as rrarked on

oisassemL:ly.
Don 8-85130 lssued l2-89 Prrnled rn Ingland
kaukazz@yahoo.co.uk
500 r -20
powrquadplus
CROSSwww.thebestworkshopmanuals.co.uk
SECTIONAL DRAWING OF THE STEERING HAND PUMP
12, CENTERING
SPRINGS
9. THRUST WASHER
10. NEEDLE BEARING
13. DUST SEAL
14 SHOCK VALVE
ASSEMBLY v THRUST
WASHER
15, HETAINER RING
16. PIN
8. CHECK
BALL
]7 SPOOL
1 B SLEEVE
1S, PUMP BODY

6. CHECK VALVE
22. SPACEF
7 DRIVE SHAFT
lssued '12-89 Prinled in Enqland

Don 8-85 1 30
kaukazz@yahoo.co.uk
5001 2 1
lnstallation
STEP 87 STEP
8t
,1,i
Rernove protcctive caps ironr iho iiitrngs lnstall the slecring colurnn right hand nrounting brackel
STEP BB STEP 91
r INSTALL aNof u
TTGHTEN f q;
lnstall the stee ring hand pLrmp. lnstaii lhc lwo c:.i hand lnstall and trghten the stcering hand pump mountrng
moLrntrng bolts, do not lignten. bo ts and the steering column right hand mountrnq
bolts.
STEP 89
STEP 92
d,,,@
Align the holes in the input shaft arrd universal jorni and
install thc roll pin lnstall and lighlcn the stecring column pivot boll
Don 8-85130 lssued 12-89 Prnieo in Engla.c
kaukazz@yahoo.co.uk
5001 22
powrquadplus
STEP 93 www.thebestworkshopmanuals.co.uk STEP 96
,;t'Barto
lnstall and tighten the steerinq lral.;r Di,.li, : i.oc f litrcs l.lsta:hc lce rrng Ot,|Tro s Ljo covers and tighten the
as markcd or rerrjova' :)olls
STEP 94 STEP 97
lnstall the stecring column centcr panel and tightcn the

SCTCWS
STEP 95
STEP 98
!liarl ihc Cngrr)e and Chock fOr' ca,rS l,-r, | :rrc :::ccr !g
wfl(-'ol rrom 'ull Rl-l lOCk iO Iuil I il li--i:ii l;,,vit.ijl ifi-i)S lO
rcrnovc arr from the hydraulrc stcelnq slysierrl &r
IMPORTANT. lf the steeflng hand pump has been

tncorrectly serviced it could operate hke a hydraultc
motor when tnstalled in the tractor
With the engtne running the steertng wheel wrll rolale
corttinuously- Keep hands clear of the steerinq 'tti.at:l lnstal the stccring column tilt control levcr and tighten
t,:tltl lhc slccrtne operatton tS no,r,t;il S/r.rtr ,.trn ()r,;)..o lhe allon sorcws
rv/)i;,r (tfieck.s are compteted
i)or' 8-85 I 30 lssucc l2-89 Printed in Fngland
kaukazz@yahoo.co.uk
5001 -23
powrquadplus
99 STEP 101
lnstall the cab floor covering and guide thc throttlc

pedal through thc slol in thc covcr
STEP 1OO
I
I
I
I
":i
W
1:/
:'f,
: :.j'1,a-',._
Chcck thc transmission oil lcvel, add oil i{ ncccssary
Use only CASE HY-TRAN PLUS flutd
Align the holes in thc throttle pedal and shatl and install
the roll otn STEP 102
Removc the biocks from thc rcar whecls
Don I 85130 lssued 12-89 Prinled in Fngland
kaukazz@yahoo.co.uk
Section
5001
STEERING HAND PUMP (EATON)
o 1993 Casc Corporation

Printed in England
CASE CORPORATION
Febuary 1993
kaukazz@yahoo.co.uk
5001 -3
powrquadplus www.thebestworkshopmanuals.co.uk TABLE OF CONTENTS

SPECIFICATIONS 3
SPECIAL TOBOUES Ja
STEERING HAND PUMP
SPECIFICATIONS
Displacement. .. . . . ... ... 96 ml/rev 5 9 in3/rev

Ratcd Systcm Pressurc 1 73 bar 2500 psi
Gerotor Thickness,...... 13.26 mm 0.522 inch
SPECIAL TORQUES
End Cover Cap Screws (First Siage) 17 Nm 150 lb in
End Cover Cap Screws (Final Stage) 25 to 30 Nm 225 lo 275 lb in
Check Ball PIug.. .. 11 Nm 97 lb tn
SPECIAL TOOLS
1 Spring lnstaller CAS 1239
First Uscd On Pagc 6
Dc.t 7-38774 lssued 02-93 Printed in England
kaukazz@yahoo.co.uk
5001 4
STEERING HAND PUMP
Removal and Installation
STEP 5
STEP 1
Park the machrne on hard ievel ground

Apply the
parking brake and stop the enginel
STEP 2
Disconncctthe battcrytcrminals ncgaiivc (_

) tcrrninat
lirs t
NOTE; For lnstallation, lnstall an(j tighten

the positive
i -)terminal first
STEP 3
STEP 6
Cr,rn0
STEP 7
t *,i.
i rl::.
ii:l:lji':
::
J;8..
\ 'r,:r*
i.,'
Remove the steering cotumn ufffiffirrJi

tou"r
ffi
Remove the screws and the s:eering colurnn 'i':'".:rrrri:rr':::'::i:j.r:)-&{:twffi }t*-}Ilw&..\$i.r"iimi*
centcr Remove the righl hand side steerrno cffi-n pilot Ooft.
)a^ i-381'7A
Issucd 02-93 Printed in Enotand
kaukazz@yahoo.co.uk
5001-s
STEP B STEP 1O
Femove :he bolts and remove thc right ranci srde Remove the two remain ng mounting bracket bolts and
mounting bracket rer.ove the steerng hand pump. lnstall dust caps to
the hydraulic tubes and fittings
NOTE; Far installation follow the same procedure rn

reverse order.
Remove the roll pin from the couplrng
kaukazz@yahoo.co.uk
500i -6
Disassembly STEP 1 1
STEP 1 v:
Put thc assembly on a clcan work bench' Remove the ct:
mounting brackct from thc steering hand pump
STEP 2
u
Remove the bolts (1) and the column (2)
STEP 3
llcmove items (3 to 11) Shake oul iiems (12 to 14)
STEP 4
Remove items (15 lo 24)' sM045s
lnstall the Special Tool CAS 1239 through the sprtng
STEP 5
qcrnovc the sPool/sleeve assemblY (25) and rcr'.rove slots in the spool/sleeve assembly Position six springs
'i:,r-:126 to (28) on a Donch so that the exiended edge is down and
28) install
ine'arched centers are together, ln this position
the springs into tne Special Tool as shown'
STEP 6
Remove items (29 to 34) lnstall a # 10-24 machine
screw into the check ball seat (30) and pull out the
STEP 12
push
Compress the extended end of the spring set and
chcck ball seat,
gently into the spool/sleeve asssembly Centcr the
ipring set so that they push down evenly and level with
STEP 7
the uiper surface of the spool/sleeve assembly'
Clean all components in kcroscnc or lucl oii and dry
wth compressed air.
DO NOT use a cloth to dry the cornoonents
STEP 13
lnstall thc pin (26) through the spool/sleevc asscmbly
into the
untll level on lloth sides lnstall thc asscmbly
Wear safety glasses when cleaning with ^9
comprcssed air, Compressed air can propcl
s:cering hand o;rro nous
rlirt dust, ctc into lhc air which can bc
in,nznr
rnlerousc S\'19 4 NOTE; Heat from your hand could expand lhe sleeve
assemb/y making rt drfftcult to rnstall'
STEP
f
Assembly
STEP 8
lnspect all mating surfaces Rcolace any part that may
P
have scratches or burrs that may cause leakage
STEP 9
lnstall items (34 to 29). Make sure item (34) is installed
straight into the housrng, Tighten the plug (29) to
a
torque of 11 Nm (97 Ib in)

\@
STEP 1O
Carefuily install the spool (27) into thc slccvc
(25) The
spool must rotate freely in the sleeve'
(A)'
NOTE; The spoot and s/eeve have alignment marks
Ihese must be aligned on assemblY'
Instaii riems (24 to 15)

Don i'-38770
kaukazz@yahoo.co.uk
3tJ1.J l- /
eo 4
o€;;
I
) I
,{
).N,N)'"b: J*a
\SJ-"*..ffi\-@-
,"
y, b,{e.6 9 ,
0
-' D f.ffi n<
(97 lb in) .,,
,''
,' (
25 to 30 Nm
(2251o 275 lb in)
WM
( \
I
I \o"
I
I
P*\\-@
sM0930
NOTE; ltems are numbered in order of disassembly

NOTE; ltems marked ),must be replaced.
1, BOLT 10. SPACER PLATE 19. TEFLON SEAL 28. SPRINGS

2. COLUMN 11. o - RING 20, O - RING 29. PLUG
3. BOLT 12. SFRING 21. BACK UP RING 30, CHECK BALL SEAT
4, END COVER 13. RETAINING PLUG 22. BEARING RACE 31. o - RING
s. o - RjNG 14. BALL 23. NEEDLE BEARING 32. O - RING
6. SPACER 15. BETAINING RING 24, BEARING RACE 33. BALL
7, GEROTOR SET 16. SEAL GLAND BUSHING 25. SLEEVE 34. CHECK BALL RETAINEB
8. DRIVE SHAFT 17. o - RING 26. PrN
9. O - R|NG 18. SEAL 27, sPooL
Do.l 7 -3877A lssued O2-93 Printed n EnEland
kaukazz@yahoo.co.uk
5001-8
powrquadplus
STEP 17
B
@@
$fl\o o@
f T-, Qo9 SHP2
ii"--@
l\
lnstall itcms (6 to 3). Tighten thc bolts (3) cvcnly to a
(-\ torquc of 17 Nm (150 lb in) and then in the sequencc
shown to a torqLrc of 25 to 30 Nm (2ZS to 275 lb in)
STEP 18
Install itcms (2 and 1).
lnstall items (14 to
STEP 16
lnstall the Gerotor (7) onto the drive shafl (B) so that the
curvc bctween two of the teclh are aligncd with thc pin
(26) through the sleeve and spool. lf thc rotor is in thc
correct position, onc of thc teclh wrll be ir inc diroction
of the fittings rn the pumo body
NOTE; Pin (26) must be paraltet to the hydrautic fiftings.
)oo 7 3877A lssucd 02-93 Printed in England
kaukazz@yahoo.co.uk
500'1-9
eo ,,, 1
a"
,,6
I
/'/o* I
fk*r l
/L b3 ) l
,,,
,,,
a"
,t@
@
il< 25 to 30 Nm
,"
fro \
(22s to 27s lb in)
(
i^.@ @\
D)t\)tn, \
u\\L-\\\tl
1
I
B l-\J
\o.
I
sM0930
I
L'
-@
NOTE; ltems are numbered in order of dtsassembly
NOTE; ltems marked *must be replaced.
1. BOLT 10, SPACER PL-ATE 19, TEFLON SEAL 28, SPRINGS

2. COLUMN 11. o - BrNG 20 0 - RING 29. PLUG
3, BOLT 12. SPRING 21 . BACK UP RING 30. CHECK BALL SEAT
4. END COVER I3. RETAINING PLUG 22- BEARING RACE 31 0 - HING
s. o - R|NG 14. BALL 23, NEEDLE BEARING 32. o - B|NG
6. SPACEH 15. BETAINING RING 24. BEARING BACE 33, BALL
7. GEROTOR SET 16, SEAL GLAND BUSHING 25, SLEEVE 34. CHECK BALL RETAINEB
8. DBIVE SHAFT 17. O , RING 26, PIN
9. O - R|NG 18, SEAL 27. sPooL
Don 7-38774 Issued 02-93 Printed n England
kaukazz@yahoo.co.uk
Section
5002
STEERING CYLINDER 2WD TRACTORS
Ccpyrighi o 1991
CASE CORPORATION Printcd r. [i S.A
Oclober 1991
kaukazz@yahoo.co.uk
5AA?-2

SPFC AI 'OROL,FS
SPIC AL 'OOLS
Si]OP EQUIPMENT TOOLS
SILTH|NG CYLINDER
Rernoval anci Installation ... ..
3
Drsasscmbly and Asscmbly
4
llemoving Air rrom the Steering Cylinder
6
Cross Seclional Draw ng of thc Sreerrng Cylinricr
7
SPECIAL TORQUES
S:r:crrng Cylindcr io Mountrng Brackc: 380 Io 420 Nm 280 to 310 lb fl
Slccring C;rlindcr Mountrng Brackct Bolis 330 Nrrr 243 rb f1
q'.'oring CylrncJcr
Ball Jr.rint (L H Sirjc) 295 lb ft
CylinCer Mouniing Brackct to Ax c Bolts . ],]. ],-,...,'.]..'.'.,'...'..;ss 340 tb ft
Siccrrng Nut (R H Side) ,,,,,.'.'. ffi 148 Ib tt
SPECIAL TOOLS
''..*s
81 3016
1. GLAND SEAL RETA|NING WIRE

REMOVAL AND INSTALLATION TOOL
CAS 3461
(First Used on Paqe 4)
IOROUE WBENCH 3. LOCTITE R,T,V, SEALANT 595

oEM 6476
2, LOCTITE 270
Don 8'85141 lssued O-9l

'1
Printed in England
kaukazz@yahoo.co.uk
5002-3
STEERING CYLINDER
STEP 1
App y :he parking brake and put blocks in lront ol and

bcnind thc rear whcels
STEP 2
i
c1B80S
Rcrcvc ihc cottcr pin and looscn thc steering cylindcr
ba I 1c n: nu: DO NOr rcmovc thc nut
STEP 5
[ooscn lhc ba I tornt to slccrng cy{rndci' jarr nrit
NOTE: For lnstallatton ttghte n rhe iam nul ia a toreue al

2a0Nn (148 lb lt.)
STEP 3
' 802107
acn ove ihr: collcr prn and ihc nul irom the stccr .q
cylinder ball lornt Rcmovc :hc stocr nq ball joint
NOTE, For lnstallatron tighlen the steenng cyllnder ball

jotni ,tut la a [arque ol a)A Nn Q95 lb ft)
STEP 6
c1 8804
D;i a surfablc containcr undcr the stccnnq cylindcr
lrsconncct and cao the hydrau ic frltings D scard lhc
o-rincl,s
NOTE: For lnstallatton, tnstt:ll riew o-itngs.
802122
Rcmove thc bal loint nrrl and thc siocnnq cylinrler
NOTE FoT lnstallatton ilghlcn ihc sleering cyhnder ball

jolnt nut [a a torque ot 380 to 42A Nm (28A rc 31C ]b ft)
lnstall a .e\r'i collat 'Jiil
IJo. [] 8r I ,1 l ssuco 10 91 Plnlod 't E,rgla:rd
kaukazz@yahoo.co.uk
5002-4
Disassembly and Assembly STEP 9
STEP 7
sM0s75
i&.k Bemovc tlc.rrs (9 io 11)
NOTE: For Assembly, lubricate items (g to 11) with

clean hydraultc oil
803805 STEP 1O
irLt lirc s:ccr nq cylinder on a clcan work bench and
rcr.ovc 1tc lliil loin1 and lam nLt Removc itcn (12)
STEP B NOTE: For Assentbly, apply Loctite 2lO to the thread of

pint (12) and tphten to a torque of aA) Nn (295
the ball
tb ft)
STEP 1 1
,i'*
& .a,t
#,
s'
B03B 1 5
St\40576
sM0574
[]cmovc thc ring (1) Usrng a surtablc dr t cush the seal
f Usrng the gland sca rclarn ng rarirc ioo CAS 3461
gland (4) rnward lo ga I acccss to llrc i'ciarrrng ring (2) romovc the rclarn,rcl wiro ,'13\ Rcmovc items ('1 4 to
Ilcrrovc itcrrs (2 to 8) 18)
NOTE: For Assembly lLtbricale iterns i2 to 81 wrth clean NOTE: Fcr Assembly lubncate rtems (15 to 1B) vtith
hvdraulic oil. clean hydraulb oil
NOTE: For Assemblv. apply sealant 817575 to the seal

g12nj rglg n ..q ,vttc slot.
NOTE: For Asscmbly, follow lhe sa,,ne procedure rn

)o'8 85141 reverse order issucd 10-91 Printed in England
kaukazz@yahoo.co.uk
5002-s
powrquadplus www.thebestworkshopmanuals.co.uk Disassemb/y

NOTE: ltems are numbered in order of
P
.r9g {L@. I
\1
!
@.
(-.@.
.@*'C tr)*- --
,{ ----
*O*
CYL2
NOTE: ltems marked (") must be replaced
B, RING SEAL 14. INNER SEAL GLAND

1, RING
9 WEAR RING 15. o-BING
2. RETAINING RING
]O SEAL 16. BACKUP RING
3. PISTON ROD
11, WEAR RING 17. BACKUP RING
4. SEAL GLAND
12, BAIL JOINT 18. RING SEAL
5, BACKUP RING
13, BETAINING BING 19. CYLINDER
6. O-RING
7. WIPER SEAL
lssued 10-9'1 Pr nled in [nglard

Don 8-85141
kaukazz@yahoo.co.uk
ri002-6
Removing Air from the Steering Cylinder
STEP 12 STEP 15
Pul all thc control levers tn neutral then start
and run the
cngine at low idle spccd
STEP 13
-.., . r^r. ,.O.
:,r,,1OC:S lrCff ,..rl f,Ul:. ,ock io 1uil cfl loc< ;:
,il;ls: ;Our t,rrCS tC rer:fOvC all air ir"om thC SySiCrl
Chccx ihc transmissicn orl lcvcl. nOO oiioiifie-correo
scccilicaticn to thc t-ULL rnark on thc diostick
STEP 16
Ci.i:ck :hr: stccrrng alignrrcnt, rcicr lo Secircn :OrJlJ
STEP 14
'ry.":,.,ffi
-l
,t' c1 8802
Turn thc stccring jrom lock to lock and chcck :hc
hycrauiic stcering iubes arc corrcclly routed and
,-irmnni
D:rr, I 35 l4l
rssJod l0 91 Pr nlolj rr] E"rcllanrj
kaukazz@yahoo.co.uk
5002-7
Cross Sectional Drawing of the Steering Cylinder
1. EING 6. O-RING 11. WEAR RING 16, BACKUP BING

2 HETAINING RING 7. WIPEF SEAL 12. BALL JOINT I7, BACKUP RING
3, PISTON ROD B, FiING SEAL 13 BETAINING RING 18. RING SEAL
4 SEAL GLAND 9, WEAR EING 14, INNEB SEAL GLAND 19 CYLINDER
5, BACKUP RING 10, SEAL 1s, O-BING
Don 8-85141 ssucC l0-91 Prinled in Fngland
kaukazz@yahoo.co.uk
Section
5003
FRONT AXLE 2WD TRACTORS
For 5.1 00 Series Tractors
CASE CORPORATIOttT
Printed in fnqlanC
Ileccmber 1989
kaukazz@yahoo.co.uk
5003 2
TABLE OF CONTENTS
SPECIFiCATIONS 3
.)
SPFCIAL TORQUES
-OOIS
SPt-CIAL
WHEEL BEARING
AdJUSlmCnt ,..'.-.'',,,.'' 4
rlcrnoval . .6
lrslaltatior .., '. B
FRONT AXIE KING PINS

llc.noval ..
12
13
lnstallatior
FBONT AXLE
Fe'noval .16
19
lnslallatron
)a
TOE IN ADJUST\4ENTS
Don B'851 6C
lssued 12 89 Printed n England
kaukazz@yahoo.co.uk
5003-3
SPECIFICATIONS
Lubricatron
Ambient temperatures above 0'C (32"F) . . CASE Wearguard Super Lithium or Moly-Disulphrde No 2 Grease
Ambient temperaturcs brelow 0'C (32"F) Lithium Base Greasc to N LG I No. 1 Consistency
Toe-in Adjustment. 2to8mm 0 314 to 0.79 inch
SPECIAL TORQUES
Wheel Bearing Retaining Nul 100 Nm 74 lb t1
Front Wheel Nurs . .. ., . 300 Nm 220 tb t1
Stccring Arm Clamping Bolt.. . .. .. . .280 Nm 206 tb fl
Axlc Pivot Pin Retaining Nut and Bolt 150 Nm 110 tb fl
SPECIAL TOOLS
1. TOHAUE WRENCH LB F.T (Nm) 3, SLIDE HAMMER

(cAS 100s7) (cAS 10s81)
.&&drf 1+,##diu-+&+&;i}*r*&"{&!*+!i!4 c
,!,{85ffi{
M*ffi.r-;l;;A*.:itiiiii;il;=ffi*aildiEadr
::#:;:;*iii;-l;;.iri!!a@tsffi t
E,
ffi 4. ADAPTEB
ffi (cAS 2014)
effi
ffi i
ALIGNMENT STUD SET

CAS 1995
5, BEARING OVEN
cAS 10133
Don 8-851 60 lssued 12-Bg Printed in England
kaukazz@yahoo.co.uk
1003 4
WHEEL BEARING
Adjustment
STEP 1 STEP 4
Engaqc lhc parking brake Check thc whccl bearing cnd PlaY
STEP 2 STEP 5
BOO318
Sorn the v;heel and check for noisy dry wheel

bca:ings
STEP 3
STEP 6
;,L
.t
$
. ..;'.." ,,.'.-
.:r:,!f *''&',
,,@
,:i;J
t]ax'3r 6
Ba sc ihe f ront of the tractor and put an axlc siand irndcr

rhe axlc Usc a suilablc spanncr lo remov€ the dust cover
Don 8 85160
tssued 12'89 Printed in EnqLand
kaukazz@yahoo.co.uk
5003-s
STEP 7 :M
/ . \q*
f
rlu6,,;i.'',:i:.::,,
Y
:ll
i"l l.;l',r:.&
&
,18
rl*
i*
\
.k
B@#
Remove the cotter pLn lnstall a ncw cottcr prn
prn rn position
STEP B
.f
p STEP 1O
l@
in"
\ d' rlt b*
t xr,,
.,*.. -..'-
,a
'ryffiitii;.:i','l'l:. ,f.9*^ W
i-tuiaic ihc whcel and ttgittcrr ilrr r)ul io a torquc oi 100
Nrn (74 lb ft), thcn back oii lltc nui to the nex: s or lnstall and tightcn thc dust covcr
Uon 8-851 60 lssuccj 12-89 Prinled in Fngland
kaukazz@yahoo.co.uk
5003 6
Removal
STEP 1 1 STEP 14
q.
8{(,)31 6
lli: sc inc iront ol inc ,,ractor and pLrt an axle s:and r.r'rocr' Rcmovc the nr-r
thc axlc ani rcrovc tho whcc

,I5
STEP
STEP 12
ii, I
_d(*
E
'41
t
EOO39 Rcrnovc the washcr

l-r,cc a surfable soanner Io rcn-ovc tire dusi covcr.
STEP 16
STEP 13
. *.{ee&
80@36 Rcmovc thc ouier bearing

Rcrrovc thc cotlcr pin
Dr)'r I 8516i) lssucd l2 89 Printed in England
kaukazz@yahoo.co.uk
5003-7
STEP STEP 20
,:ili:i;rr'
,:itiir.
i1;'i
!t:
Bomovc thc wncci irLrb Rcmove thc hub scal and clamping ring
STEP 18 STEP 21
Fcmove thc inncr bcarino Bemove thc inner bcaring cup
STEP 19
*-1 ;
-a
'a
$_*',4
Bcmovc the outcr bcarincl cuc
Dor 8'85 60 1 lssLted 12-89 Printed in Eng and
kaukazz@yahoo.co.uk
5003-8
lnstallation
2. SEAL
\
,A' \-
6. WASHER
v@@ / /B
NUr
.-o*o,( r.o.
/
3, INNER BEARING
@6h
*\
^t,
7, COTTEB PIN
9. CAP
50033
STEP 22 STEP 23
lnsiail ihc outer bcar ng 0uo l1S:all :nc ,n.cr bca'rng cuc
Don I 85160
kaukazz@yahoo.co.uk
5003-9
STEP 24 STEP 27
1, CLAMPING
RING
t{i:;/
?
lnstall thc hrb scal anci clamp ng lng lnstall the wher:l hub
STEP 25 STEP 28
:ft
c274o3
Hcai thc inncr wlreci Dca:irtg in i: l;i:arrng ovcn , CAS Apply greasc and insta i thc oule r bearing
10133. alo r^sa: r( tr r''!l
STEP 29
STEP 26
lnslall thc washer
iill thc hub wrih lithiLrrn l-,asCti qrcasc
Uon 8-85 I 60 ssr,eo r2 89 P,r.rtcd in fncla.C
kaukazz@yahoo.co.uk
)003- 1 0
STEP
STEP 30
lnstall and tightcn thc dust cover

lnstall the nut
STEP 34
STEP 31
ff
{1
Fd
\, ,rn
@ eo1m4 xa,;w
lnstall thc whccl onlo lilc hub Bcmovc thc
axlc stand
r.rul"o lorquc r:i 100 Nrtl
Rotatc the hub anC :rgntcn 1i1g of 300 Nm (220 lb f1)
oi'lllr: rri-: io
'l
ifrc I'oxi colicr !tn siol ir.c liqhic'n ll'c n[rts to a iorquc
tZA tO tti Ihcn back
STEP 32
-q&
80636
lnslall a new cottcr 0ln Bcnci Ovr:r fhc orlC:i

lo o(l( ''rc
pin in position
lssued 1 2-89 Printed in England

Ilo. B 85160
kaukazz@yahoo.co.uk
5003-1 1
FRONT AXLE KING PIN
Removal
STEP 35 STEP 38
I
k
q I
c
s
-- 800316
laise the iront of thc traclor high cnough to a ow thc Bcrnovc thc shrms
emoval of ihc krng pin :rrC oLrl ar, axlc sianC uroer thc
lx c anc rcrovc 'rc "\^ccl STEP 39
,,7
STEP 36
.M@
w
sieffi
,,::M
"fffi
--,M
,,W
, ,' , ,, ,-*....*.*,.,, ,}
':rffi
..'i, . :8/
k"h, rl..j':&
@'H)
-*
Yr,-;
': :'
ffi
'W",;%, -w
!: W
.'%i;:t.M
'W
80,612
Bcrnove thc k ng pin assembly

h",{o, f#i.
lcn-ovc lnc ero.cct'r' ' '.r\ -'' '',,' STEP 40
) acc suitablc
ltltirc cqrr otlrorli
luPPori the Kinq Prn !11''r6'Yn
:lamprng nut and boll
STEP 37
ao1 61 5
Remove the steerinq arr"t
lss-co 12 b9 P'nlco r^ frgla"c

f on B-85 i (10
kaukazz@yahoo.co.uk
STEP 43
. | :.
ry
:'::r.,iirj.+::
'
ti,jtir:il!i;:iiii'lli.:i:
Bcnovc thc upoer king pin bushing Remove thc thrust bearing
STEP 42 STEP 44
%
&
Rcrrovc tirc lowcr king prn busntng nspect the bushings for wear or damage
tf on B-85160
lssucd 1 2-89 Printed in England
kaukazz@yahoo.co.uk
5003-1 3
lnstallation
2. WASHEB
B, SUSHING \
\ l'
\^\
U
m\
[.Q-,
10 BLAR'NG
.'
II
KINC PIN AND
'-,UB---* I
d\
I
\eh
\K-)
\f ,t:z\
STEP 45 STEP 46
ry
lnstall a ncw thrust be arrng lrstall a rew rowc. btrsh onto the krng pir
Uon 8 85i60 SsLrCo

.2.89 n.intcd i" Elqta^d
kaukazz@yahoo.co.uk
, . i', i-t\-:4F
I.
5003- 1 4
STEP 47 STEP 50
BG1 61 7 'AM**,
lns;tall the rc\,^/ uppcr king pin bush lnstall and tightcn Ihe nut and bolt
STEP 48 STEP 51
, .?.tt,' ih,::-.r*''
:'W
-=:-'-.t:
aol 61 2
Usrrg suitablc lifting cquipmcnt, install thc krng prn Mcasure the spacc between the steering arm and the
assCmilly krng pin housing of thc axle to detcrmine the thickness
of ll'rc shims rcqurrcd
STEP 49
STEP 52
Subtract 0 1 mm (0 03 inch) from the measurement

notcd in Stcp 51 Thrs will givc ihc requircd thickness of
shims to give an end play of 0 1 mm (0.03 inch)
With lhe king prn supportcd on thc lrftinq qear, rnslall lhe
slocr nq arm.
NOTE : Make sure tne cut-out in the krng ptn ts altgrted

\vilh the ball hole tn the steering arn)
Dor:8.85160 lssued 12-89 Prinled in England
kaukazz@yahoo.co.uk
5003 r5
STEP 56
'.!i; I '
'B;.t.;:
t!r,1i!::l::4,: 801233
Supporl thc king ptn asscrrb,ly anri rc'ill;t'i.' lllc stccrrng lnstall and trghten thc nut and bolt to the correct torquc
arrn. of 280 Nm (206 lb ft) .lnstall thc protective covcr onto
the stccring arm nLr:
STEP 54
STEP 57
, r:rl
' i iilr
'ti:,
a:l
ll tfrc fclt seal and the correct amcLtnl ir

Apply lithlum based grease to the krng prn
DtrE
,I JJ
STEP 58
Align thc cut-out in the king pin with tnc bol: tho
stccrrng arm
whcel nurs to a torquc of 300 Nm (220 lb ft)
Don B 85160 lssucd 12 89 Pr nlcd in Englan.i
kaukazz@yahoo.co.uk
'.'Y'iri'ttt
5003 r6
FRONT AXLE
Removal
STEP 59 STEP 63
Engaqc :frc parkrnq brakc lnstall two 16r-,m CAS 1995 alrgnmenl studs
STEP 60 STEP 64
Bemovc thc rcrnainrng bolts and carcfully lifl

i r.r rl wr,.irlh i f)rackct
STEP 61
Rcrrove ihe tracicr' lvcLqfrls (it cqutppcd)
STEP 62
ili:,i,ovc :r'rr-' :r/o bolts irom lhe frcrll wc llirl brachcl
Dcn 8'851 60
lssLrcd 1 2 89 Prinlod in England
kaukazz@yahoo.co.uk
5003-l 7
STEP 65 STEP 68
1a i
.ir,-#,-#
C 1 BBO4 801 009
Pirt a suilablc conta ner undcr the stecring cyirndcr Looscn lhc locK nLrf ar'rd rcn"ovc thc Allcn screw
Disconncct thc stccrrng cylindcr tube c amp and tubes
from thc cylindcr and disconncct thc o-ring se als lnslall STEP 69
caps lo the f ttings lo prcvent foreign maicria f rorll
entcrine thc system
STEP 66
{ Put surtablc lifl ng e qurcn'cnt undcr the lront axle. lnstall

i
a slidc hammer pullcr (CAS-10670) and adaptcr (CAS
l; 2014) and romovc ihc rrvot Pin.
PL,l su lablc lrfting equiprnt:"1 undcr :l-'c i1'or'rlaxic Farsc STEP 70

tht iral'lor high cnough 'lr, thc front axlc io De rcnrovcd
and orri slands undcr ll,c sidc tramcs
STEP 67
llcrnovc thc shims trorr thc {ront and rear of lhe ax c

p vot
rle'nove l\c a'lu: pra Drcteclrvc cc\/cl
ssucd 12 89 Prinlcd ir E'rglarrl

Doq B-8i:160
kaukazz@yahoo.co.uk
STEP 73
i ;"
Carcfully lowcr thc axle :o lne ground Use a suitacic long drifl lo remove the rear plvot
bushinq
STEP 74
ffi+.
ffi,:i%r
Bffi."
1*:'ii::.:;.
!
F*,.',' ._o
''''W;!;!'
Use a suitable long drift to remove the front pivot

bushing
801 C24
lvlovt: lhc axlc clcar oi ihc lractor and pui it on axle

slanos
!)or.[r 85160
lssucci r2 89 Prrnlr;d in England
kaukazz@yahoo.co.uk
5003-1 I
lnstallation
1, PROTFCTIVE COVER\
4. NUr 2. Prvor PrN\ ) a

/ e conE' prN \ a/ ;
/ ,/ ,tta" 3 ALLEN scREw
@2 ,","/
(/// ^r/
$ \
--u
2r4'\ /
// 7. Prvor BUSHING
PIVOT BUSHTNG \\
- €j.-+NU
€j1_+. NUr
.\^- \ \ \, \ Glr"/ 4
Yo.
-i.l\ -\ ,/
)r \
14\
(1 r I
NUr
9. COTTER 6, SHIM
ptN
rur-.J@4\.=-==.- ^
\ #N*<
o-+4
u*.*uXb*\
*<a\ \-
x
l,-- " "'"'- \
'
-
\\ \ \
N;;.;;
10. BOLT
18. TIE BOD
9, COTTER PIN
16, BUSHING
/p)\ ''";l'-'#I" \ tz
"\ 17. AXLE
\E . 4, NUT
,. uo) JorNr ' EXTENSION
20, KING PIN P\ 19, BEARING
\
22. SEAL
23. HUB
-/
/ar-\' ,/ 5 wASHER
Wg^'j^"u'
;*gud
1S. BEARING
4, NUT
9. COTTER PIN 24. CAP
kaukazz@yahoo.co.uk
5003 20
STEP 75 STEP 78
lnstal' a acw ircnl Oivot Dusntng Baisc thc a(lc inlo positron and rnstall a 0 019 inch (0 5
rnm) shrm at ihc rcar of thc arx c pivot and the required
STEP 76 a.nount a1 rho front The cnd play must be 0 1 to 0 3
ffi mm (0 003 to 0 011 inch)
STEP 79
,
s"
&
illl a NCW rcar p vo: brrsn
EP 17
Mark ihc r:nd oi llrc axlc orvot pin rn linc wrirr thc locatrng
j. lr. 1 'or 'n,.' Al,cr s( ro*
!
&"#
ii*; s STEP BO
fiu f* ,i
^-d J
da,{-ifJ
.,, "&
,w
.-t|:d
' ifi,i
BO10"oA
Rcrnovc iirc ax c lr'crr lirc axlc siarcls i.ir'r(.1 rnovc I
c;.i(-.illly lowards lllo :'tlclcr
Usc a sofl hanmor and rnsta I the axle pivot pin
ssueo 12-89 Prlnled in England
kaukazz@yahoo.co.uk
5003,22
STEP 87 STEP 90
f
Turn thc front wheel from full right lock to full left lock at
east four timcs to remove all air from the system.
STEP 91
Check thc transmission oil ievcl. Add transmission oil oI

the correct specification to correct level if necessary.
lrg
lr)L:lall an.i tlqhlen lhO rc.rarnine holls lo th'r corrCCt
torouc'
STEP BB
lnstall thc tractor wcrQhts (ti cqutppcd) ancJ tlqhtcn thc

clampinq bolts to the correct torque
STEP 89
Put all the control levers in ncutrai thcn start and run
the engine at low idle spccd.
kaukazz@yahoo.co.uk
5003-23
Toe-in Adjustment
FRONT
+
LOOKING DOWN ON THE FRONT AXLE
STEP 92 STEP 94
I-o set the ioe-in oi thc front whccl use thc following
:rocedure
I Put a mark at the horizontal ccntcr of each whecl rim.
2 Measure the distance betwecn thc whcel rims at the

ront.
I Rolate the wheels 180' and measure the distance

letween the wheel rims at the rear.
I Thc measurement at the front oi the wheel rims must

:e 2 to 8 mm (0079 to 0314 inch) less than the Looscn the clamping bolt on the Right Hand side of the
neasurcment at thc rcar of thc wheel rtms tie rod
) lf the toe-in is not within thrs drmension do lhe STEP 95

ollowing step
Turn the tic rod in or out to get thc corrccl toe-in
STEP 93
STEP 96
Tighten the Fight Hand and Left Hand clamping bolts

and install the pin in the Left Hand side of the tie rod
STEP 97
Chcck thc toe-in Adlust if necessary
2 PIN
c\4227A
pin f rom
-oosen the two clamping bolts and remove lhe
he Left Hand side of the tie rod
)on 8'85 60
1
lssued 12 89 Prinled in England
kaukazz@yahoo.co.uk
ection
5004
MFD STEERING CYLINDER
Copyrignt @ 1991
CASE CORPORA"IiON Pr,n:eSinUSA
October 1991
kaukazz@yahoo.co.uk
5004 2
SPFCIAI TOBQT]ES
SI]OP TOUIPN4ENTTOOLS . .. .
I,Ii:I STEENING CYLINDER

3
i-iiyl-p6yrt r.,j trig{3llatrOn (
Disassc;rot,v and Assembly .
6
Cross Sr;cticnal Drawing of the Steering Cylinder
7
Rernovii're A : from the Stcerlng Cylinder
SPECIAL TORQUES
230 Nm
lrack Rod Betaining Nut , .. . ..
Siccring Cylinder Retaining Nuts .

. 90Nm
. 300 Nm
Ball Joint to Stcering Cylinder Retaining Nuts

1 TOBOUE WEENCH OEM 6475
lssled 1O-9'1 Prlnled in [nglani

{lcn [] []: l :> l
kaukazz@yahoo.co.uk
5004 3
MFD STEERING CYLINDER
Hemoval and lnstallation STEP 3
STEP 1
b'rew
E02807
whec nuis PL;t a sLrtablc lacx lnder
'ffi Loose n thc iront
ihc ccnter of lhe front axle Baise and support the
[)Ltt ino l'aCtOr On haird ground ald aPrr Y ir)c l'ac:cr on :wo 5200 kg ax c stands as shown Removc
oarkrrî: Dra<t: lnc iront uvhccls
STEP 2 NOTE : For lnstallatron, tghten thc front whcel nuts to a

torque of 3AA Nrn
q
STEP 4
"4 . 4',I:rl...j:i
6
}di
"-;#
80fi35A
PLrt blocks rn front of and bch ttrl ll'c ra:it'v"''rc(tls
rew
Eo281 3
NOTE : For lnstallation. cf,eck tho lra,'s,'.'sriia : ori ieve!
ancl add orl to the cartca[ /c.,ei rl ,'-ccr:ssa,y A/so check Rcrncve ihc irali iornis :rom thc swivel housrngs (oolh
and aclJUst the lront vinoci :)e-tr rclr.,:r i{.t Saci,or' 6C21 S OOS]
NOTE . Ljt lrtstallattat) t'."' .'. :'t. -t'i :al(l'I)a-) NOTE tot tnstaliatto.,. ttghten the ball./ornl nli ls l.) ;l
::vitttJt:' tt:lar la Pagc i la'aLe a\l 23C Nrrt and tr,stall naw cotter ptns
ss-cc lU.9' i"rte c '' F ^.;.,^c

[-r:r^ l] 85'r1
kaukazz@yahoo.co.uk
WWffixE,N
#*'ri" '"'
;-, a^ ,T 1.,'
t''
"+i - *1., l{, '" Br)2907
' : .i..
track roO ''Lt- "(' SICC'in!l []c'rcvc thc stccr ng cylindcr mounting bolts (1) and
s:i)c"rg lubc clarr:c crackel (2)
NOTE For lnslallatton, ttclhten the irar:k rod ball jotnt ta NOTE Ftr lnstailattctn tighten the steering cyllnder
3A0 Nnt r'!.1Ljr't'ie bo/ts :o p rgreue of 9A Nm Make sure lhe
sr)--(ia." is betwe r:n the steertng tube bracket and
'îasher
STEP 6 ,i r, 5issrine cyltrder
.: ""S
l;., "1,,.,'i
lMs STEP 8
llcrrovc iht_. Stccrtng Clarnp reta nrnq bOii (l ) and c arrl.

'i: J,sconncct anC cap thr: sir:i'r'inq tur;c (3) (bcih
s cos) Rcmove:hc rrqhl harri t-'i'.iw',1'ril i4) disi:ard Rc:novc :r,a: :.r.tar 1g 3yltndC.
:nC o-r'ri'rgS
NOTE . ['cr tnstalteilon, t'olior, Inc sanit prccedure rn
,r':",(:,se 2rder
NOTE : For lnstal at,on lnsaaii '(;'\' o-riirgs.
D.). 8-85151 issucc l0 91 P'irlec lrr Ertgtanc
kaukazz@yahoo.co.uk
5004-5
Disassembly and Assembly STEP 12
STEP 9
,'@
Fcn'ove the end cap (1) and 1nr: p ston rod asscrnbly
(2) from ihe cylindcr (13) *-o
STEP 1O
Rerrove and discard inc glarld scal (3) ar)c ^ca r'|r
ES
-@
(4) irom ihe prston rod assorrtbly i2)
ilemove and d scard the scraper seal (B) back t p
STEP 11 washcr (9) and piston rod seal (10) from the end cap
(r )
STEP 13
NW
Bcrrrove and discard the o-ring (11) and back up
wasircr (12) from thc cylinder cnd cap (1)
NOTE: For Assembly follow the same procedure tn

reverse order.
Re,.novc and cirscard tnc scrapcr sc.tl ir) ,:f:t,

washcr (6) and piston rod seal (7) irorY'' lrlc cylrndcr
(1 3)
.o
o/
/'@
d
NOTE , ltems are nurnbcrcd tn orde:r ol ,lisasscrnb/y
r'.o.
NOTE : ltanis rriarked (*) rttusL bc rcplitcacl
rss-Co O o' D' nlÔ n F^g a' ::

Dol ii-85151
kaukazz@yahoo.co.uk
5004-6
Cross Sectional Drawing of the Steering Cylinder
O-
@*
\''
\,\
r'
/)
\o
ENI] CAP
2. PISTON ROD ASSEMBLY
3, GLAND SEAL
4 SEAL RING
\u
5, SCRAPEN SEAL
6 BACK UP WASHEB
7. P]STON ROD SEAL
8 SCMPEH SEAL
9, BACK UP WASHER
10. PISTON HOD SEAL
1 1. BACK UP WASHER
12. o-RrNG O220MSA
13, CYLINDER
Dor B-i151 5 l
lssued 1 0-91 Printed in Eng and
kaukazz@yahoo.co.uk
;044-7
Removing Air from the Steering Cylinder
STEP 1 STEP 3
1l
Put a sLritable contarner under the steering cylinder and
looscn the RH steel tube at the steering cylinder
STEP 4
Rarse the flH side of thc axle until it is fully against the
axle osc ltatron stop
"rorfr&;f:fl STEP 5
.\. \rij'
t Turn the front wheel to the full LH lock unlil the cylindcr
E02830 prston is fuliy extendcd on the RH side. Tightcn thc
Put a suitable jack undcr thc ccnter of the front axlc steerrng cylindcr tube.
Raisc artd support the tractor, ort two 5200 kg axle
stands, under the EH and LH sidc {rarrres. as shown STEP 6
NOTE: The f ront whaal has been removed lor Start ihe e ngine and turn the stcering whcel from lull L H
photographic purposes only lock to full RH lock sevcral times
STEP 2 STEP 7
Remove thc stee ring stops from lhe RH and LH swivcl Rcpeat Steps 3 to 6 for removing air from the LH side of
housings of itrc axlc the siccring cylindcr
Don B-85151 lssued 10-91 Plnlcd rn England
kaukazz@yahoo.co.uk
Sectional lndex
TRANSMISSION SECTION NO.
Creep Transmission
Removal and Disassembly ... .. .. ........... 6011
Diiferential and Differential Lock

Removal and Disassembly 601 2
Hydraulic PTO
Removal and Disassembly . . .. 6019
M MFD Axle Differential 602 1
Powershift Valve 6009

PTO Clutch 601 I
.6019
PTO Valve .6019
Rear Axles and Planetaries .6018
,............
Servicing the Powershift Transmission ....6006
Servicing the Range Transmission ..... 6007
Servicing the Synchromesh Transmission ............ ...6005
Separating thc Tractor
Engine from Speed Transmission . 6002
Speed Transmission from Bange Transmission . 6003
Torque Limiter

CASF CORPORATICN
February 1990
kaukazz@yahoo.co.uk
Section
6002
SEPARATING THE TRACTOR
ENGINE FROM SPEED BOX
For 5.1 00 Series Tractors
Don 8'850 1 0 Prrnted in England

CASE CORPORATION
January 1 990
kaukazz@yahoo.co.uk
6A02-2
TABLE OF CONTENTS
SPECIAL TORQUES
SPECIAl TOOLS
SEPARATING IHE TRACTOR (Engrne from SPeedbox)

Rcmoval ....... J
10
lnstallatron .....
SPECIAL TORQUES
Iront Cab/Platform Mounting Bolts , . 310 to 380 Nm 230 to 280 lb ft
Rcar Cab/Platform Mounting Bolts .. . 310 to 380 Nm 230 to 280 lb ft
Enginc to Transmission Mounting Bolts
'I
6 mm ... 3ss to 375 Nm 247 to 277 lb 11
Enginc to Transmlssion Mounting Bolts

'l
2mm.. 1e,A to 151 Nm 99 to 111 lb fl
SPECIAL TOOLs
2. TOBOUE WBENCH
1 817s55 rLocTlTE s1s)
ffi
ffi
ffi
m
ffi
3. ALIGNMENT STUDS
CAS 1995

Don 8-85010
kaukazz@yahoo.co.uk
6002-3
Removal
STEP 1 STEP 4
2ul the machinr-- on levcl ground and apply thc parking

)rakc
STEP 2
r.!
,-J$&
l,:l{#.1: .in
';riiiffi1'
ffi',',,
.r'. .l,ft&.,,
,.,:::a:',;;a':,:,tt:-.t:.:.::'t.ii'l:!!l:r,'aili.ia:'ririii:,;,::'!::
?, ,.'Y' *rrro
i,lrl#h Fcr-ove thc MFD drivc shaft (rf equippcd) nefer to
)ut blocks rn front oi an<l bc:rrircl lirc i'car whccls Scclron 6014
}TEP 3 STEP 6
lemove 'he Danery box Rcre' to Sec'ion 9020 Instali a container with a capacity of at leasl 76 lrtres (2C
US galls) undcr thc iransmission drain plug Removc
thc plug and drain thc oil After dra,ning, insta I and
lighlcn lhc drarn p uq
on 8-85010 lssucd 1-90 Prinled rn Enqlarc
kaukazz@yahoo.co.uk
Raisc the hood Aemoue the clevis pin from the hood release cable and
lcver
STEP B
STEP 1 1
Loose" tlre eifraust clamp bolt and remove the exhaust

t ooscn rhe hood rclcase cable adlusting nuts and
exlension tube
move the cable out of the waY
STEP 9
STEP 12
Bemove the hood rear cover

Do. 8-850 1 0
kaukazz@yahoo.co.uk
6002-5
STEPpowrquadplus
13 www.thebestworkshopmanuals.co.uk
STEP 16
Loosen thc right hand steer nca hosc .r'rountrn,:l l'r!1 and rubber it oot and disconneot the battcry
rrove thc hosc oLr: o1 the r^r:ry ro.n thc siarlcr motor
STEP ]4
i.t6'. :
-:1f;!dlNiii; a:,:4.
Disconnccl and caD the or coolcr suoply arri rciLlrr eci thC solcnord SWI
tubes
rc)
IU
STEP 15
Disconncct the qround cable

Disconncct thc oil cooier tube brackct
ilon 8-850 I 0 lssued 1-90 Prinled in Enaland
kaukazz@yahoo.co.uk
l@waa
(,:i--4\
16& drl
-,,r;:'),:ai
tl':ral:al:. :::l::t:','
:.:.,
iii,';i1|iit ;:1,'
ffi'
##twW.
' ,.'4'.P R
n
,,) Disconnccl and rcnnovc the heatcr supply tube

Turn thc neatcr shui ofl tap to lhc cioscd Posrtron
STEP 20 STEP 23
fie.
{ ..ta ',i',4.
w q.,'*
:q. ,,DH
du
'*'i -
.
q$$
::'B
"kq
fu..*?
ffiu,t:i,/lW
Pui a sLritabJc contarner undcr thc heater Disconnccl and rcrnovc the heater return tube
D sconnccl thc ncater itoscs
STEP 24
STEP 21
i,fo",.-n i
: rl':i tr:
,, l'I ?:ou
I fl
I I {',,1
B
B
lfil:l:i"m''
panel mountrng bracket nut and the
Remove the side
\ffivs'.:ww
s de rail bolt
Femovc inc fealer lubc mounting i:r-acket bolt
r)..r,1.85010
lssucd 1-90 Printed in Enqland
kaukazz@yahoo.co.uk
6002 i
powrquadplus
25 STEP 28
"$i ,$
a:
Iit
;*
$.
ra \ :P
'l'
.&
'r.
t:.
.'\
ai,
,i'
i:
s{r . ': 1r,..
i ',:
.i)o:iirn l,rt: it:1' 'rilrt0 !ti.tcrin0 hosc mounttng arruTt
rcrno\1C lf lc ir()sc 'r'orn thc brac(ct
STEP 29
,x
!,
i
:j?t
ffi
gfls35
Looscn thc clamlr arld renlovc lhc brakc rclurn hosc
from thc hoL;sing adaotor
STEP 30
ojx h
Drsconnecr anc caD lho left hancl stecrirg tr.;bc rf,i

Disconnecl thc cnginc harncss bulkhead conncctor
lro,r- iirc irro rvalr
t-run 8 8501C Ssu.o i-90 n'i"lco '!':ta^c
kaukazz@yahoo.co.uk
6002 il
STEP 31 STEP 34
SIEP:]2
.t
'i
T
r*l
&tr'/ ,$ (larc'L;il)
1jl w-4 : i1 lirc ,-rao/itlaiiorry' and ,nstallwoodr:r irior:i^rs
qx$r - 4X
ffi,3
$ffii#Yffi
-q&& tr{-.ffit',
,Bfu" r^t's
'#i ',. ,'.1
'
rr l)(_,lwalo,. :,,rr ..-alt/olaii(lrrroLtniing lran.l artrr lf C
:.i1.'.
#W,#ffi''il"jx,' S TEP 36
irrtr't'O\,i) "10 'rirn: :ia.tC:ot !v(ltiJTls; i,: (,f;t,rn')t'fll
*ffi81 * I STEP 37
.tJnd:l On :t(j....1..J),", .j-( j"
' . .,"f'.
ffihWi
a] ,
:.)r ir.'a)it: cor, 3ri-'rs.
*& t*a *Gf8r..aVr; I
T*-.:W q#t;1dl.!tl
EP 33
{\ t? r{rJ
)rr.iraa ,r f'r) ;l
kaukazz@yahoo.co.uk
6002-9
STEP 38 STEP 41
'i4r1t:" '"''*:''
-4.
io.&
*t1)
.
1:11 ;:, 1:
r1:''
$:;1,;1,;1:r.1'
Pul wooden wcdgcs in bclwr--r-.n thr-. bolstcr arrC thr:

fronl axle
STEP 39
Rcrrrovc thc re nrarning transmissron to cngine housrng

rc'a ni.]g bolts
Remove the four STEP 42

retaining bolts
CarofL,il:y scparaie thc engine from thc [ransrn,ssion
STEP 40
NOTE : Check and make sure all harnesses, cables
and tubes have been dtsconnected.
Rerrclve the lefl hand outer srde r;lil boli
Don I-85010 lssued 1'90 Pnntcd in Englanrt
kaukazz@yahoo.co.uk
6002 1 0
lnstallation
STEP 43 STEP 45
Carefully push [f]c cngine towards the transmission

Make surc thc input shaft is aligned with the torque
lrmiler
STEP 46
STEP 44
lnsil-ri, :i',o l6 rnrr alignrrrcnt studs, CAS 1995 into the

a'let.ro itgus nq
i)rr:lC,J rn L nCianC
kaukazz@yahoo.co.uk
powrquadplus
46 STEP 48
lnstali and ticthtcn lhc lctl hand side rail boit
SIEP 49
" \ .n.?,|
Ek'A
gnment sli,rcs and install
thc cnginc lo transmissron rrtour)lrng boiis Trghten the m14
6 mm bolts to a torqLjc of 335 to 375 Nm (247 ',a ?77 \b Rr-.rrr:ve the froni tractor splitting stand, CAS 10852
.1
ir) arrr'i r()movL' :frc r.r ocks from under thc tr ansmission
STEP 47 S]EP 50
ffi,
&-mi.
ffli_r3{tl',' .:':: i
lnstall and tighten lhe l2 mrn bolis lo a t flc:nrive tne wooden wedges lrom rn DeNvecn thc
151 Nm (99 to 111 lb ft) boister and lront axle
lssued 1_90 prinleC jIl Engiand

Dc': 8-85010
kaukazz@yahoo.co.uk
6002 1 2
STEP 51
etr
.,.....,;}
STEP 54
I RiTUFN cotlPLER
Carr:fLtily raise the front of the cab and 'r"tr''r''

.^.;r .,11gr' blo,;k:;
a' ;:;l Li,

UIL' JL
2- SUPPLY COUPLER
ConrrcL;i an(i ll0hlo.' :lrr' .1rf cotl(lltionrnq sLlpi.rly antl

retUrn C,.tiCk dr:t(:(,r'tn0Ci l.tOUplCrS
STEP 55
(lijrrl]cr-: ll , ' rrll.L\ .ltrrj (llo

M( )ill'.il iN(.1
STEP 56
t),i::t'lr,' " :'rri!:l arl(l lrlllll io .t lrltCL.tt-

r,r'ir I rr I .rili, ,' I r:,
(,Or)ri{1, I "l.
kaukazz@yahoo.co.uk
6002 r 3
iil
*dp,:il
,it
li
.ki
Mi:.
[ :lS
:l'
807835
install thc brakc rc:urn hose anO trehicn thc clamf)
STEP 58
.'*^: ! :
r$l lnstall the throitlc cabic into the brackct Conneci ihc
i.6) soT8ol cablc to the nloction pump Bcfcr to Scction 900 j for
lnstall the lcf: hano slccr rre hos(-i 'ric ihc Drackcl af d ac uslrncnl
ljLlfrtc! ihc n.Ou.l1,,rq lu1
STEP 61
.,.rWn,
i
t
br" ,:, I
1
. )-.
-.,i
c3001 0
lnsrali and t ghtcn thc sidc oanc mounttng brackct nu1

and lhc SrCC rar bolt
i,o 8 83i10 lssLr<ro I 90 Prinico ,n f nQ aorl
kaukazz@yahoo.co.uk
p':;iu"g :rn|r",4,
".r:,&
Wu
^ - tal'
&i' "
a 2ti,
'nj
ii
1l
t
t;4.41
1r:slali ihr clarrl ps

l' rsiiill :rnC liQillci r lir(,"rei,il(l'
STEP 63
t@wma
i'i'e'6,
,..'.*4i:itl::,.in
ir-:jlall allli
STEP 64
' rwiffitt
it{.ffq-q'lt',
1r.,
i l
.I I
tr :,1'.,:@&
.lrr(i l(jitlorr thc hr:a1cr lubo nroi.lnirrrg brackct
r ''tcc r F-l'1 anr
kaukazz@yahoo.co.uk
6002 1 5

r.il
flT
Hfl
trrq
st
EX
Ei*
;n
iti
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na
d&
);il
.t{s
,jI^
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r1:.t
t.i,It,
#${,:
d-.s
t:ri.- ER SUPPL'
!crrove lile cacs and inslall and tightcr the oil cooler
rciurn anc supply tubes
STEP 72
61. ryre*'1
ffiM
€nrry
@'
ffi
efff;
lnstall and lighlcn thc starlcr motor cac c arrd lnstall lhc
protectivc nrbber bool lnsialt thc rtghi lrand s:ccrrnq hosc a^d rtgh'c1 '^,--
mor-r|iing ni,:.
STEP 70
STEP 73
lnstall ano tightcn thc oil cooicr tuoc brackcl

lnstal anrl tighten thc right hand steering tubc
Don I 85010
lssuco l -90 Pri.rled ir: f nE ;lrrll
kaukazz@yahoo.co.uk
6002 1t)
STEP 74 STEP 77
#
v:n
.
\ffi -.*q"*"* ffil
ffi
.:tl4#XMi:f,. ffi.
', "BEf/r4
:'i: _:t:tt : iir
-ffi
'_1a;F:q.
Inslaii thC t-.xhairs:' r'ifrS,, )rl fubC ald llqhiCn
STEP 78
,w:
',,,,,1t'
HI.
,1' .1.W,,';:::,, sfr171rA
irl:;l;:, thi-' MFD sr-ra1: (if r:quipped) [icfo, lo

'.1,':: trii)'lr' :c Sooi crr g00B '{rr :nclrsirttcn: !-lcclron 6014
STEP 78 STEP 79
'€ I
i-,ll
.":.d8tif _rd-.1
ai D' ,t,'.,qr:r*."-4
tr
d
:$'.Q
B&a 7(X
Qr-.fur 1o Sr:ction 300:r
I ,- i-Elanc
kaukazz@yahoo.co.uk
STEP 83
.1,:..:4..t:::i1,:1.:11,, ..
lnstall :hc tlattcrv box Refer lo Scclrort 9020 Chcck coolant lcvc and top up if neccssary.
STEP 81 STEP 84
lnstall thc tractor werghls (if couippcd) Starl thc cng;ine and check lhe operation of the stcering
cab healcr anC air condilioning systeri rs
STEP 82
[-ill ihC tra.)SrniSSron wriir l-1Y IRA\ i)l ..rS lO lf ri] itorr(-rcl
lr-.vci c,n lnc droslit:k
Don I 85010 lssued 1-90 Prinled rn England
kaukazz@yahoo.co.uk
Section
6002
Engine From Speedbox
(For Maxxum Tractors From PIN JJFl 030000)
IMPOBTANTT DO NOT discard Section 6A02 (8-85010), it is to be used

to Service older machines prior to PIN JJF1030000.
Copyright O 1994 Case Corporat on

CASE CORPORATION Printed in U,S.A
August 1 994
kaukazz@yahoo.co.uk
X]IFI
' fl
rl
6002-2
TABLE OF CONTENTS
SPECIFICATIONS
SPECIAL TOFQUES
SPECIAL TOO1S........

Removal and Installation ...
FILLING THE COOLING SYSTEM
SPE.CIFICATIONS
Cooling System
Coolant ...... CAS CC 2801 Ethylene Glycol
17.6 lrtres 4.6 U.S gal
Syslem CaPacity 5220 (With Cab). .1
5.7 litres 4.2 U.S gal
System Capacity 5220 (Without Cab) ...... ..
20.8 litres 5.5 U.S gal
System Capacity 5230-40'50 (With Cab)
System Capacity 5230-40-50 (Withoui Cab) .. " 18.9 litres 5 U.S gal
SPECIAL TORQUES
....... ' "" 285 Nm 210|b f1
Front Cab/Platform Mounting Bolts '..
Bolts......- 285 Nm 210|b fl
Rear Cab/Platform Mounting
1621o 184.5lb fl
Side Flail Mounting Nu1s.........,... 2201o 250 Nm
Transmission Felaining Bolts
134 to 151 Nm 99 to 111 lb ft
12 mm 8o11s............
.t 335 lo 375 Nm 247 lo 277 lb 11'
6 mm 8o1ts............
SPECIAL TOOLS
1. SPLITTING STAND, CAS 10852
2. HYORAULIC JACKS, CAS 10855
3. ALIGNMENT STUDS, CAS 1995
lssued 8-94
Dcr 7'692 1 0
kaukazz@yahoo.co.uk
6002-3
SEPARATING THE THACTOR
Before separating the engine from the transmission it is necessary to carry out the following
. Flemove the Battery Box, refer to Section 9020.
. Remove the Fuel Tank, reler to Section 3005.
. lnstall the left hand rear wheel after the {uel tank has been removed.
. Remove the MFD Drive Shaft, refer to Seclion 601 4 (for M FD tractors on ly).
STEP 1
Put blocks in fronl of and behind the rear wheeis
STEP 2
Put a suitable container under the transmission and

drain the oil. Alter dralning the oil install and tighten
the drain plugs.
NOTE: For lnstallation lnstall clean HY-TRAN PLUS

@ into the transmission to the correct level.
Disconnect the throttle cable retaining clip (1) Loosen
STEP 3 tne adjuster nut (2) and remove the cable from the
bracket.
Raise the hood and remove the engine side panels
NOTE: For lnstallation, adjust the throtlle cable, reler
lt, Seclton 9001 .
STEP 4
STEP 6
Remove the right and lefl hand front cab/platlorm

mountrng nuls (1)
Put alignment marks on the rear hood panel (l)
mounting brackets. Loosen the exhaust tube clamp
NOTE: For lnstallation, tighten the cab mcunltng nuls
(2) and remove the exhaust tube (3). Bemove the rear
to a torque of 285 Nm (210 lb ft)
hood panel mc:Lrnting nLrts (4) and washers, remove
the rear hood panel
NOTE: For lnslallation, align the marks and make

sure the hood closes correctly.
Don 7-6921 0 lssued B-91
kaukazz@yahoo.co.uk
'- -'!q,
6102 4
STEP 7 Tractors Prior PIN JJF1034500 STEP g
For lrectors with air cOnclrtrorrrrl(l PIN D sr;or:r'ret.l iilc t;lt:t:rrlt.i tirbc) l1; arrJ ri'::car(i ll're li
1i: self ,ittal I -,i ,i:i ii't., .j1 , i il tar:Tl0,,re tfii: l":: ..:, .i'lrr,r
,.1 1tl3.15r0it, disconni:t;i rii
:irr,tiing couplirrqs (i ) arlcl t, , the f)r:ic(i.rl Rerrrove :'le tit: slraP: lro'tl the lra'e
retui'n hoso i-1 ,, lOl:,'' :' :11:)ll ilili.j i.i;:;i.:,rlnCat lir[;
[)rake fe) sr:]r,'orr tplttrrt lt(,:r .rl 1l,e | :,ii), ir.lli:S i1litl
t,iEVF R lout:l"t.Ii lrlltitlls. i:i(;rrl(;,t' irl r r,lr" ,rijtl tlitl lrf;ll i .11 l
A.J,i,!) ott V(ttt ;;.itt ri. ill./1t:'-ir:'I,r'rr.'.1';r.l
rcfil.lv[r ilt(.]:irl,lu 1.:'ap i[i) lrorrt lht: l]occl SL.rppor'i
l--\,,tt;:!:ti froslttt!,-'. /tlw'av:; wi:i1t ptolac!i'''':
Irrac;i'.ill
NOTE: For lnslailattort. tttlh!en lhe side raii boll to a

tarque ol 134 to l5i Nrn (99 to 11l lb ft)
ALWAYS waar 5;lr.)l) goelql€;:; ;aihr rt
warkrrtq wilh ittlL;it': relrtqi.:tarti irtiL;;ii
NOTE: t()t lnslalteitart, iUbt'tr:allt: and tnslall a new a-
tairiqeranl irt Iotit' .rytr; :;tir;ii rr.'it/.sc
nnq io lhe :;it,:a:rtrit,l liDc itt:;!ali new Cablc sl/aps /0
!':!iniJn ess.
t;ect;r'a lhe !ran:;rnt.;:;tOtt harr'itlss to llte hooo StJpp(.)rl
bracket and lo sec!tre the transmissian harrtess and
brake reservoir return hose to the steering tuhe.
STEP B Tractors From FIN JJF1034500
STEP 1O ,:ili
ffqsivi,i'{g ,r:
Fi)r iraclors; lvrlh ilrr ,ii(lriri'/rl" ) lti')'t Pil'l

.l.ii'tl1,li;{10 r'r:filr lrt lli:,r''i .' (1irii:) ,^.,r ('-,i1,j 1 i rlr
(-)orllponetlls Slrrp Awi.lv ') l(r rp'l1r rv'- ll ' l rlrr
. .
,)' trjri ic rter cor--ll,or")u I I ts
Discolnr 1l
kaukazz@yahoo.co.uk
6002-5
STEP 11 STEP 13
Disconnect the st.,i11er solenoid celble (1), battery Loosen the clamps and disconnect the oil cooler
cable (2) and alternalor cable (3) from the staner hoses (1) and (2) Bemove the tube bracket retaining
rrrotor. Renrove ilre outt:r side rarl iioll (4) ano lne srde bolt (:l) Cap the lroses and tubes.
pancl hrackel r'etaininq nul (5)
STEP 14
NOTE: f ar lnstallalion, lighten lhe stde ratl holt to a
torque ol 134 to 151 Nm (99 to 111 lb fl ). Make sure
there are two washers between the side panel bracket
and the starter motar rnaunting flange.
STEP 12
Drsconnect the steerir-irl lube (1) irn,:i 11':ci.ltd ihe o-

ring. Looscn the nul (2) and rerTrove tlr(t irr.lsi (li) irort
the bracket. Fernr:ve the cat.rle :,irap i':ll llaD tne
hose and tube.
NOTE: For lnstallattttn, lubricale artd nsittii a tlet// a-

ing to lhe steertnq luDe. lnstaii a r:tw t:able:ilrap lo
secure the brake reservatI su;tS:ly httst: artd Datlety
power harness to the stee(ing1 lube. PLrt a riritable container under the heater hoses (1)
irr,l i.l) Turn tlrr-. itealer +,ap (2) to the OFF pc,siirr:n
ar''ri-l iiislonnect tile lle;rter hoses ('1 ) and (3).
Don ;/-6921 0 ssued 8 9,1
kaukazz@yahoo.co.uk
6002-6
STEP 15 STEP 18
i or):,,.ri' llrfi ,.:iir .ilL l-.iliOr i'r.,,. rri,l ,.i:,(lr ,;'ii.,. ll .t , .lCAli liriitri- i,lljir,ya.aultctacks,
( ,^.:.i I t:.:.r--r L li', rWn A...i.ri:il llte Siand JUSt eOOUgfl
IIOTE: !:t)r l:..:,tit;tltOn. 'rti'i, ' l' :i'i : I ' i.r,.",r.\! :'r';l lrl,'"r'1)rSup[)1jr1 lilelrorll Of
t,)()Unltnq 1,,11-s 11 a lOrqir() i ,; 'r;r; furrlr ",'
'rlt /' lfr,1 lf;-lnqan,qf:, r)ll i)ll (i,lrl,ti,,,, :liOCK:l
STEP 16 STEP 1g
Pui r,vlro<ir:n ctor;<r,, belvrt:en 1le f ront Solster and the

lrortt atxle
STEP 20
Clref ult', 1r11 ihe C.'ttli SlatfOr.n arlC rr

|,. .1,, l;, ,,... ,.1r lhe ciil;,.Jiati(.)r.r. ilroi
i;.&te--. "\ ,r''*; ,

Uzr"-qY'
''l;1"$,) a;ek${:,
sTt-*P 17 -
B08St0
Remove tne irpl)til lr'ansmrLsron re larnrlq bcrlts 11 I
lr,. ,. 1,.,1r trrri l/(1'rr lra(.lOf Wolalillst ,i r.(lLIfI,i..f j)

NOTE: F::r it'
!Ni:',.t,: 't
lssJea S-9.l1
kaukazz@yahoo.co.uk
6002-7
STEP 21 STEP 23
Care{ully separate the engine and transmission.
IMPQRTANT: Check and make sure all harnesses,

tubes, hoses and cables have been disconnected.
NOTE: For lnstallation, follow the same procedure in

reverse order. Ref er lo Steo 24 for the correct sealant
application.
NOTE: After lnstallation, add coolant to the radiator.

Refer to Filling The Cooling System, page 8.
Remove the side rail nuts NOTE: After lnstallation, remove the air from the
braking system. Refer to Section 9001.
NOTE: For lnstallation. iultricale lhe lhreacls of lhe
stde ratl studs with orl and ttghten !he retatt)tng t)Llts Io STEP 24
a torque of 22A b 250 Nm (162 to 184.5 ib tl).
STEP 22
,P
sM1196
Rr:rrovc the lower lransmissior. retarninq bolts (1) Clean the engine and transmission mounting faces.
Apply Loctite 515 to the engine mounting face as
NOTE: Far lnstallation, tiqhten the lower transrnrssion shown. lnstall two alignment studs, CAS 1995, into
retaininq bolts to a tareue ol 335 to 375 Nrn 1247 lo the threaded holes (A) and (B)
277 lb ft).
NOTE: After connecting the engine and transmission,
remave the alignment sluds.
Don 7-692 1 0 lssued 8-94
kaukazz@yahoo.co.uk
6002 I
FILLING THE COOLING SYSTEM
STEP 1 STEP 4
Start and run the engine al LOW IDLE {or 1 minute.

Stop the enqine and add coolant to the radiator and
recovery reservoir as necessary. lnstall the radiator
and recovery reservoir caPS.
Never operate lhe engrne in a closed

builcling proper ventilation ts requtred under
ell circumslances.
STEP 5
Start and rurr ihe eng ne at HIGH IDLE without load

l; r.:,:.tli:r rirlitlr valVe (1 ) 1O lfr,r (-)l-i I o:;rtrOrt until the engine reaches its normal working
to run the engine {or 3
lenlperature. Continue
.fhe minutes.
NOTE: lieelet relurn valve r.s i/r l,l.:.' OFF;:t':"!""t
v.1';,,' fl'r;i val'/€) aonlrai is al 90' lr-' l,'r' ' ':i 'te
NOTE: The enqirte i:; at normai working temperature
vthen the lhernosiatl ls aperl and the hose betwee.:n
STEP 2 lhe engine and radtalor top tank is hot.
Fiernove the radiator frller call an(i fill lhe raclia:cr
corr0lelely wrth coolant SolLltiorr
Ncver operate the engine in a closed
buitding proper ventilation is required under
a minifiturn (rI lri,,,r (:itryiPne all circumslances.
NOTE: Always have
qll(.:oi (:o()lanl rrt lhr:.sy-sle/, al all !eolperalittre rAnQes'
1)i' r;rrl inslalt rnorc tlttttt '159c t)li)Yietla qi','ctti tt: !lte STEP 6
,^, r, rirtlQ SySfenr i/n/e.SS thF air)t'.tt(\ttl iCnlpetatittt' t\tii
ail/e..;s !han -iJ,/" C , reler lO.SytrtL:i'. '.,ttrOn PaqC il. Alter 5 m nules stop tfre enqrne and allow to cool
Remove the radrator an<l recovery reservoir caps. Fi 1
NOTE: The maximunt fill rale ol the t;ooiintl sy.slertl is

the radialor completely and fill the recovery reservoir
13 5 titres G.5 U.S gal) Per minute. to the maxintum mark. lnstall the radiator and
reCOv0'y /9s0rVOrr r ;;'t0S
STEP 3
Bernove the coolant recovery rcservorr cap and fill the

re(lovery reservoir tO the maximL,jm mark lnsl;l' ii'e
recovsry reservoir cap.
lssued 8-v.
i)r -, i '69210
kaukazz@yahoo.co.uk
Section
6003
SEPARATING THE SPEED AND
FIANGE TRANSMISSION
Prrnted in England
CASE CORPORATION
Fobruary 1 990
kaukazz@yahoo.co.uk
6003-3
TABLE OF CONTENTS
SPECIAL TORQUES 3
SPECIAL TOOLS
REMOVAL AND INSTALLATION
SPECIAL TORQUES
Speed Housing to Rangc Housing Bolts 312 Nm 230 lb fr
Cao Molnting Nuts . 310 to 380 Nm 230 to 280 lb ft
Bear Wheel Nuts 434 to 515 Nm 320 to 350 Ib tt
SPECIAL TOOLS
'/f \
\-"/
\/ t
\'-l
3. LOCTITE 515
B1 755s
TRANSMISSION SPLITTING RAIt
cAS 1 08s3
Don 8-8521 0 lssued 2-90 Printed ,n Englan0
kaukazz@yahoo.co.uk
6003 4
REMOVAL AND I NSTALLATION
,}/
WPOSB
lssi.]cd 2'90 Prrntcd rn England
kaukazz@yahoo.co.uk
6003,5
STEP 1
STEP 4
BO7 I 05
Put blocks in front of and bchind rhc front vrheels. rriri a contatncr wiilr a capacily of at least 76 litres (20
US galls\ r.inior :hc lransmisston and drain the oil
STEP 2
l.iOTf : Fo, lrstallalton rnstall 76 litres (20 US gallsl ol
clear': l-iy-l'tat: [)ius /rarisn]/ss/o, otl. Check the level on
the dtpsitck
STEP 5
lnstallwedges tn between the bolster and tire iront axie
STEP 3
,,r!,H
c11531
[]crnove the seal rc:alning screws and spaccrs
Rr:movc thc scat irorn the machine
STEP 6
Disconncct the bat1ery terminals, neeative (,) terminai

f irst
NOTE: Far lnstallatron tiehtr,r't lhe postlr.rc t r ) letit) r)ei.:,

first
Pul icJcnlification rnarks on the eleclncal conneclrons

ancl clrsconnect thc sl.rutlle valvc solcnoids, pressurc
S\,v lCnes arrtj eroi;rrcj lcads
Don 8-852 0 1
lssucd 2 90 Prrnrcd 1 Eng and
kaukazz@yahoo.co.uk
6003 6
o@@
lssLrccl 2.90 Printed in England
kaukazz@yahoo.co.uk
6003 7
STEP 7 STEP 1O
.,wi 4
4 Y:3
Y,W,#?:1
ff,, ,;*:;ffi;, ffir;"€' c: i:iiiG]':i. $
i.r-_,ffi,?.i,W.W
't .. , .."::,,,:q 4]r^risii":' ..".:..ffi\
,,i,,-,' i:dfu$":; 7::' %;
,6,*i1,;;l;Wm
Disconncct and cao thc hydraulic iubes Disconnect the parking brake clevis Removc rhe
ari Lrslrng nut and C sconnect the caf:le frorn :re
STEP 8 b'ai:k c:
NOTE, For lnstallation Refer to Secllon 9001 to adpsl

the parfung brake cable.
STEP 1 1
Drsconnect lhe clutch cai:]e
NOTE: For lnstallal on. Re:ler /r: .'ir:c,,ar ii')f-jr ii,, ;-i,.i:i.r.,,1
ttte r:lulch cable
STEP g flcrnovc the fuel tank. Fefer to Scction 11005
STEP 12
Bcrnr:ve ihe bolt from thc pari<.rr'rg brakc citblc c ,trrrt

,^? .:.'id* WaA
Remove thc three bolts from the bottom oi lhe

transmission lnstall thc transmissron spli'lling ra CAlj
I Cll53 i;ncjer ihe r.l'rqc transm ssic.rn lrslall a surtablc
bi0ck r.,trcier' :he sr;i-.r:l.l lra|r"srrrrSS on Flcfriovc li^rc rrclht
hi:nd rr:ai rruirr-.c lrrsltr I cail stands CAS 11389 unrli:r
lnc cab franrc
Don 8-85210 lssJed 2'90 Pr r-1co rn Erq arg
kaukazz@yahoo.co.uk
tr(F Y' rr{r
dl,fF:lI t't x
i1
ilit
tl,
6003-B
'r,
,l)4
Dor 8-852i0 lssued 2-90 Printed rn England
kaukazz@yahoo.co.uk
6003 I
STEPpowrquadplus
13 www.thebestworkshopmanuals.co.uk STEP 17
DISCONNECT
t:{<#Y#^ .' 1}lati:1itltt :,:.,1::tiXi,,,,*itlt2*.

=+'?-
clips and remove the remote valve
and removc thc cabic and swrtch irom thc brackct
STEP 14
ffi 4, - ,'#Y&.. 1. DrscoNNEcr

.tffiffiu',
DISCONNECT
t::4.:
:!ffi,
=i;" rt
'Et'ffi+ , -i'&i'^'
:i: i:..:i:.lti
d lilt$
.iffii
:lw.'
Rcmovc thc mounting i:olts and removc tlc trailer
e.'
cap the brake hoses
electncal sockct.
NOTE: For lnstallattan. Reler ro Seclion 9A01 b adjust

the PTO cable
STEP 15
Disconneci the qround specci scnsor e ectrical

conneclor (i' eou ooco;.
STEP 16
., ab_. :M
us€# *)y1r'Y/.|-at:t ::. | -: ; :t ::a' M ,Y*carraoe

ection shield rctaining bolt and spacer
tion shicld
Rernove the rentolc '.,alvr-: control rod rr:li'rrnitrq r,lrps

Ilemove lhe ri.:r"n(llr-r virlvL' conlro r|-'dS
llon B. 852 t 0 lssucc 2-9C P.irlco n Frglanct
kaukazz@yahoo.co.uk
6003- 1 0
t
l:4
/:
'i
't "';)11
, -,
/
, 'r.
"/z-.
@
@@ @
kaukazz@yahoo.co.uk
6003-r 1
STEP 20
-',e.
DrSCOnnr:ct
connector
,n , ;&&!w-
the Steerirrg
i
pr(;SStir a Swi:a-i'
k
Rei'nove the retaining cirps and rernove the ranqe
sr:lector rods
STEP 21 STEP 24
/;
kw,w
*.i &".-.fu
zJ '{ W'
Disconneci tne drail conlrol soief r( .: i:iL.:clr'cal Disconnecl the MFD solenoid electrical connector
connector equrpped)
STEP 22 STEP 25
*qn*ffi
-ffi, Er-b\tdP-l* 'W
ffi
i
2. BETAINING PIN
,l
DISCONNECT
1, ADJUSTING NU
Disconnect the range swiiL:h elcclrical c:c,rrncciors Lor:sen the creep cable adlusting nuts and remclve :rrt:
reirtir'ro! prrr Rcmovc ihe crcep cablc from the bra(r((r:
(ii coLrrpped)
NOTE: for lnstallation Refer Io Section 9007 lo;iii,r,'::l

the creeo cab!':.
Don 8-8521 0
kaukazz@yahoo.co.uk
i'lr,,.i.il['
6003- 1 2
:ssucd 2-90 Prlnted in Englano

Dcn 8 85210
kaukazz@yahoo.co.uk
6003-1 3
STEP 26 STEP 29
.*
'*L
i),5, and (:i{t.: 'r rr ' r.l

q r'111' 1 Disconnect the ground cables on both sides oi the cat)
valve (rf equippcd)
STEP 30
STEP 27
1. DISCONNECT
ilornove ther rear cab rnounting nuts from both sroes c'
Disconncct and cap lnc iydraL'llic lt'i: 'i r:: I
compcnsaior valvu
NOTE. l:or lrt:;ralti;tron itqtlrcn lhe cab mounting ntils la
STEP 28 a totoue ol 310 to 380 Nm (230 to 280 lb lt).
STEP 31
Rarsc thc hood Removc lhe: exhaust cxtenslon tube

and remove the rear hood panei
Loosen lhe front cab rnounting nuts on both sides of :hc
cab
NOTE: Fo' lnsiatiattor' ltghlen lhe cab mounttrq rrlrl:; io

tb fl)
;) !)ttlt){: c:l 1lC ltt:jiJ? l''ln1 (230 to 28A
Don I'8521 0
lssued 2,90 Printco in E:Q ard
kaukazz@yahoo.co.uk
:/
kaukazz@yahoo.co.uk
bUUJ- I )
STEP 32 STEP 33
Remove the speeo Io rangc [ransmission rnountrng Carefully seoarate thc range transmission lrom the
bolls speed lransrnission
NO-IE: /f is rlecessary lo use the three cab supporling

sfand.s vthen removtnq the range transmtsston.
NOTE; Far lnstallatian clean fhe sudaces of the range

ar,d speed l,'ansmlssion and apply sealant 817555
LACTITE 515
NOTE: For lnstallation follaw the same procedure tn

reverse order, installing new o-nngs where required.
Don 8-8521 0 lssucd 2-90 Printed in Englano
kaukazz@yahoo.co.uk
Section
6004
TORQUE LIMITER
Copyrighl @ 1992,
Prinled rn Englanc
CASE CORPORATION
May 1992
kaukazz@yahoo.co.uk
)!, li;!! ,; ' I 1.,,'-
6004-2
TABLE OF CONTENTS
2
SPECIFICATIONS ....
2
SPECIAL TOROUES ..
SPECIAI- TOOLS 2
SHOP EOUIPMENT TOOLS . . .... 2
TOROUE LIMITER
Removal .......... J
4
lnstallation
6
Cross Sectional Drawing of ihe Torquc l-rmrier
SPECIFICATIONS
Belleville Sprrng Free Height (A)

25 mm Wrde Spring .10.82 to'1133 mm
40 mm Wioe Sprinq .11 27 to 11 78 mrn
SPECIAL TORQUES
Torque Limilcr Betaining Bolts 134 to 151 Nm 99to111lbft
SPECIAL TOOLS
sM0615
1 , FRICTION PLATE ALIGNMENT TOOL CAS 1991

FIRST USED ON PAGE 4

1 TOROUE WBENCH
cAS 10033
Don 2 396a2 lssued 5-92 Pflnted ln Englanc
kaukazz@yahoo.co.uk
6004-3
powrquadplus www.thebestworkshopmanuals.co.uk TORQUE LIMITER

Removal STEP 3
STEP 1 Bemove all of the retaining bolts (3) and spacers (4)
except the two bottom bolts and spacers,
Separate the engine from the transmisston refer to
Scction 6002. NOTE: The tvvo lower retaining bolls and spacers will
support the torque limiter assembly dunng assemb/y
STEP 2
STEP 4
Turn the flyvheel until lwo retaining bolts (3) are at the
bottom. Loosen but do not remove the retarntng bolts. Remove items (5 to 7). Bemove the two remaining bolts
(3) and spacers (4).
o\
Q-"-*en I
)
o
\
@
6$
\d-q" rE. Latermachines have a 12 point rinure
sM061 3
NOTE: ltems are numbered tn order of Removal
1. BOLT 4 SPACER 6 STEEL PLATE
5 BELLEMT I F SPRING a FRICTION PLATE

2. BAFFLE PLATE
3, BOLT
Don 7-30842 lssued 5'92 Prinled rn England
kaukazz@yahoo.co.uk
6004-4
lnstallation
STEP 5
lnstall items (6 and s)
NOTE: Make sure that the bellevrlle sPring (5) rs
installed behind the spacers (4), as shown
STEP B
/'o lnstall the remaining spacers (4) and bolts (3)
STEP 9
.FFSET HUB
a
,/2
't' ,/.,'
Preveni the fly,wheel lrorr iurning Evenly tighten the

51?244 retaininq bolts to a torquL- of I 34 lo 1 51 Nm (99 to 1 1 1 lb
lnslall thc two spacers (3) anri bolls (a) Using the t1)
nclron plate aligning tool CAli 1gg I , install the riclion

f
f
NOTE. Laler macltrttes have a 12 [)Ott1l ltrture.
plale (7)
NOTE: Make sure that the oflsel hub rs lactng the STEP 1O
Iransmrssion.
Remove the lrictrcn plalc alrgning tool CAS 1 991 lnstall
items (2 a^d 1)
STEP 6
STEP 1 1
Connect the engine to the transmission, rcfcr to Sectton

6002
60047
(51, refer
Ci-reck the f ree height (A) of the belleville spring
to Speci{ications, Page 2, and replace il necessary
lssucc 5 9? Prlnlcd rn Englar(l
Don 7-30842
kaukazz@yahoo.co.uk
6004-5
o\
@*orn I
.)
$q" rE: Later,,",,":;:',1,,,,, point rixture
1 BOLT 4 SPACER 6 STEEL PLATE

t BELLEVILLE SPRING 7 FRICTION PLATE
2 BAFFLE PLATE
a BOLT
Don 7-30842 lssued 5-92 Printed ln England
kaukazz@yahoo.co.uk
Drawing of the Torque Limiter
Cross Sectional
/.@
r''@
sM0612
6, STEEL PLATE
3. BOLT
7, FRICTION PI-ATE
4. SPACER
s,BELLEVII IFWASHEB
lssued 5-92 Prrnled rn Englanc
kaukazz@yahoo.co.uk
Section
6005
SERV]CING THE SYNCHROMESH TRANSMISSION
v Jpv 19'
^^^.,,i^Fr va I OO,
p.isieo In Erglanc
CASE CORPORATION )c^ 3-8a192
113161. 1992
kaukazz@yahoo.co.uk
6[i05 2
TABLE OF CONTENTS
2
SPiCiA. .'OROU''S
srfclA- -oo-s
2
S,,Op :CUTPVEN- -OO-S
3
PrC IORIAL IND;X
-iRA\SMISSI'\
SERVICING THE SYNCHBOIVES' 4
Inorrl Shaft and Dropshafl Fen oval
l\;r,.r i SFAFI
.,r';ss Secirona D'at'ving C: :he irrOUi S''i'i'
[)rsassernbly and Asscmbiv
:lqOPSr,/rFT
B
Cross Sectional Drawing ol the Dror:sharl a
Jisassernf,lv ano Asser.blv 10
!,'r'chronrzer Shimming Procedur'e
11': ' gr-rAFl AND DROPSHAF-

12
lr-slal a:ron
SPECIAL TORQUES
ln:..: Sha'i anc Droosnal 3s3rrn! Covt'll 80 lb 'n

y'rrlho,,.l Shrrns to Seal Bcarttlcs I Nrrt
.,8 \ i,r 25 lc in
\\',iac-: $nrmS to Meas.lrc Sr r' 'ia: 20 io 34 lb i1
40 lc 46 Nrn
\('rl. Sl-,tms \rynen lns:a leC
75 lo 83 lb i1
Sroosnail D'ive Gear Reiarning Bor:s '']d:J ;3 r\l 52 rc 58 lb f1
i'or:: Searing Carrrer Plale Feiaining 30l:s
SPECIAL TOOLS
1 TJNLL DETENI RETAINERS

CAS 1 994
FINST USED ON PAGE 5

I)AOUI WRENCH
1 LOCI'ITE 515
oEM 6474
TOROUE WRENCI.l
oEM &77
.-rsr?: 3-32 Prrrieo rn Erglar:c
kaukazz@yahoo.co.uk
bUUS-J
PICTORIAL INDEX
INPUT SHAFT
INPUT SHAFT
Removal . ,
',,4
Drsassembiy.. ..7 Front Bearing
Assembly. 7 Adlustment 13
Instaliation 12
DROPSHATT
DROPSHAFT
Front Bearing
DRIVE GEAR SYNCHRONIZER
Adjustment 14
Shrmming Shimming
Procedure. ... ..1 4 Procedure 10
Lr3. d-d5 I 92 ssued 3-92 Prr^tec ' E'E a::
kaukazz@yahoo.co.uk
f'f)Cr5.1
SERVICING THE SYNCHROMESH TRANSMISSION
lnput Shaft and DroPshaft Removal STEP 5
I ,: lii *t
! 11. r
STEP 1
llelaraie ln? lractor reler lo Secl on 6ij02
STEP 2
*
E
q
*
?ry
ilt:.r-CVe the Siee'rng i,.1111 5r;1i-.kei

r)\
-$- a
#
6.-
STEP 6
Fpx #
iii:t- r';i-' Il-lc '(iiaIiIiIrl(i Cr i.-]S aiIir:l dI:'L
1 r:a 1s: 'l)rtil 2l ('laAr sc:r( t')r'
SIEP 3
( iEL; 7
UILI
STEP 4
$JI
P.'
j&_
**fu k
rcalror lJfie
*&
, 1..&
kaukazz@yahoo.co.uk
6005 5
STEP 8 STEP 11
Repeat Step 10 for the I sv2nd gear selector fork
$TEP 12
ffi
F esf
Remove the retaining screws and renrovc Ih(.'df opslra'1
cearirc ccver (1) ano shm cack Miit \l
.2
STEP 9
#
B@E
Bemove thc front bear,ng retarrrrng bolts
STEP
*
x:
$h
#*
ffi
ffi
*9ft.
ili:l: rr
iaTr
lemovc the reiatninc scif)ws and ren'rove lflr.l 'll)r..

I :rril sirrrn '';ac<
sia:: Dearrnq co,,,l'
SIEP 1O rnstall two I2 rrn' cowels (1) Put the 1sV2nd gear
selector rn tirc n'utral position lnstall the Ball Detcn:
Retarner, CAS 1994 with the f at facing up and pusl- l.e
gaar shiL rarl iror:r the frcnt bearrrrg r:arrrer plale il.'r-:
.1
the Ball Dr:rent Retarrcr through B0'.
STEP 14
*ffi
b C*
ffi
ffi
Loosen locknut (1) arro scisCrcw (2) llrc 3r(i,'41l'

"trtil
gear seleclor fork car';;11 rroved on ihe l]car si'li:'.r,
l-r.: lilc 3r'r; 4''' .li]it' :t3iCC:or tn the neuli-al pCSri or^
i'r;l:rlr lir: :ic:r.r'r(l i:i;,r l)a'lerl Bctainer CAS 199.1 wr:r:
ri,r,'iai 'a0'C ato,.",r, ai"ilpr.,sh ine gear shrfl rai iro'n l-r;
lrrrri bear a() .')t)t. f)' :r ilic
i,.rr 8'85'3: ,,.-: j', ; ^:ccr^F-:,
kaukazz@yahoo.co.uk
aiL)0a
STEP 17
%
STE
F
!
,j{
1t
d
B
v If
"ag
,i,
t.:.tl
t il.
ri?rnove lire ironl bearing carrrer cralc iicrr':ove thc:

drcf:shan and tnpL.tl sha* froni bear rr,t -Lri-3'rorlr illc
r;;-iir er ola:c
l.:1li-)vtl ltr;''.'tl;,1i'
ru
STEP 16
STEP I 9
'1,, :ls 1I ' i ."1,1 l,l
,ffi
-.t'
./:'. .,
Ir STEP 20
*g#
I ;".
ttr +:
Bf,)oo6
1i,;r',r,ryc iiie r,ti, Sitetf: alSSCrrtiJl\
kaukazz@yahoo.co.uk
6005-7
INPUT SHAFT
Cross Sectional Drawing of the lnput Shaft
o /.@
\ /
\

NOTE: ltems are numbered in crder of Disassembly o
/
o\ \
o\ ,/o
@\
o.*
sM0604
NOTE: For Assembty, heat bearinEr cones (1 and 3) in a bearlng cven to a temperature of 150"C
7. DRIVE GEAR (3RD)
1, BEARING CONE 4. DBIVE G:AH (2ND) 8. SPACER
2. SNAP RING 5 SPACER 9 DRIVE GEAB (4TH)

3. BEARING CONE 6, DRIVE GEAR ilST) 10. INPUT SHAFT
Dor 8-85'l 92 ssuec 3-92 Pri.lec in Ergand
kaukazz@yahoo.co.uk
i t', ,t' !'1,:r:i$;'i{i
lcs-8
DROPSHAFT
Cross Sectional Drawing of the Dropshaft
sM060s
DRIVEN GEAR (1ST)

1. BEARING CONE
24 SYNCHHONIZER
5 DB]VEN GEAR (4TH)
?1 DRIVEN GEAR (2ND)
9 SYNCHI]ONIZEB
40 DBOPSHAFT
]4 DRIVEN GEAR (3HD)
iss.rcd 3-92 P.!nlec ir EnoianC

lrr 8-35t 92
kaukazz@yahoo.co.uk
6005 I
NOTE: ttems are numbereC tn oroer ol Drsassemb/y
s%q;
-@-" oo.=,.--
-/ 1---,\' -i
-l-%'a:-'JY"\
,r ,aB)'( i^.aA.
:'@i =(D \
,.d-a_ffi)
_\i,A\
-\/A{a.-!
;,--:.\( \'(a
.- g-rA\
-" @ i\m
rNrki\V
\to'Jl
\\sr',
\ \_r/ \-ni>.-'7 lE, //
'6-
,.'
(il\re)..':'
/
\,=\l \t1\' , I
/'l--' '\\-
i
\
/-\ts\ I \// / o
';€Fu'ie - -@- B).se7a
,/j'
N\';\-;/ z /
d .7,-- @:-'.-ffi.$rt
--'g-
@ P
--{\ffi9'9
1'[6'r.\
(N"'']'Y:Y
r
-o'W-t^b ,--.-[ r-.,N
\
s-\\\t \\
NN\S4 ]-
O
r\lr \\'
\--,
f-.'.\'\ \ \
:\
'' r 1\r
k\ ')--- \
1 --\
\Y7:-,/
o
NOTE: ForAssemb/y, follow
'-# fia saile pi.)ceClre ir: teverse aroel
sM0580
IMPORTANT'. For iractors eQdtt)oeo wrlh snrms (/ 1? 22 a'C 2/) reier tc page 10 before Asse,.nbly
1. BEARING CONE 11. CUP 21. THRUST BEARING 31. DRIVEN GF}R (2ND)
2. SNAP HING 12. SHIM (lF EOUIPPED) 22, SHIM (IF EOUIPPED) 32. SPACEF
13 I|IRUST BEARING ,a nl tp 33. BEARING
3. THRUST WASI-]ER
4, THRUST BEARING 14 DRTVEN GFIR (3RD) 24, SYNCHRONIZER 34. SPACER
5 DRIVEN GEAH (4TH) 15 THRUST BEARING 25, BUB 35. EEAR]NG
6 THRUST BEABING 15 THRUST WASHER 26- CUP 36. THRUST WASHEII
7" SHrM (lF EOUIPPED) 17 SNAP RING 27. SllrM (rF EOUTPPED) 37. TTRUST BEARING
8. CUP 18. THRUST WASHER 28, THRUST BEARING 38, BEARING CONE
S. SYNCHRONIZER 19, THFUSI BEABING 29, THEUST WASHER 39, WASHER
10, HUB 20 DRTVEN GCAR (1STl 30, SNAP HING 40, OROPSHAFT
lc:8-85192 lsS ,ec J.9. n'-:lC ^ Elq,ai:
kaukazz@yahoo.co.uk
6005-1 0
Synchronizer Shimming Procedure
STEP 21
Assemble iterns (40 to 17)
NOTE: Shim (27) MUST be 0 5 mm thrckness
NOTE: Shrm (22) MUST be 0 5 mm rhlckness
STEP 22
STEP 23
Use the table below to deterrnine the total shirr Pack

required at (A) and (B)
;M0595
Total Shim Pack Total Shim Pack

X
t-ift the lst gear (20) up against the snap rrng (17) and required at (A) required at (B)
take three evenly spaceo measurenlenls ai (A) (mm) (mm) (mm)
between the synchronizer cup (213) and s:lir: t22) \'1akr:
a note of the average reading (X)
upto050 05 NONE
051 io080 075 NONF
i81 to130 05 05
'.Jl 1o : :r0 t0 AC
151 to200 r25 05
more lhan
200 10 10
:,c^ 8 35'92
kaukazz@yahoo.co.uk
6005,1 I
STEP 24
Assemble items ('16 to 2)
NOTE: Shim (12) MUST be 0.5 mm thickness
NOTE: Shim fi MUST be 0.5 mm thtckness
STEP 25
STEP 26
t-,se ihe table b,eloiv to determine the total shim pack
rcrtL,rred al (C) ano (D)

required at (C) required at (D)
(mm) (mm)
(mm)
sM0596
i;p to C 50 05 NONE
Litt the 4tn aear (5) up againsl ihe snap rrnq (2) and take
three evenly spaced measurements at (C) between the 051 lo0B0 075 NONE
synchronizer cup (B) and shim (7). Make a note of the a<
average reading f/). 081 to130 C5
131 :o150 10 05
Il1to200 125 Cr i)
rrrore lhan
200 10 10
STEP 27
lnstail beanng cone (1) cnto tne droPsna'1 (40)
Dor 8-85r92 rss-cc 3 9l P'r1teo n l'ga^:
kaukazz@yahoo.co.uk
6005 12
INPUT SHAFT AND DROPSHAFT
lnstallation STEP 31
STEP 28
+-uSd
,j
e*,ffi
lnsl all the in put shafl assembly
,. .t1a , 'r. . l . ; ,' r.' .lsc'( j:lbrv ST EP 32

ffi
SIEP 29 ff
,w
ffi
tu
,s
ry
#
,r 'l
&:!
lnslall new [:earing ciups intc the 'rorrt beartng carrter
piaie and install the plaie onto lwo 12 r''i'rrr dowels
llstali :hr,: lsl.i2rrC gear seieclor fork and 5;5 | lsrl. :at1
STEP
l.,lOrE fC llCi ttr"rftit,t i/r? !ear ,:,::,r'C1.. 1.'r", li€l &
&!
:,'i,fiiL'.,'k t:,ttI::: at lr't. :tlilitarl '&
STEP 30
#qr
sw
is
Beceai lllr;;: ,:19 fcr- fhe 3rdi4th ,fear i;i'lli,,':'(jr i')I;. ::ilc
ffi
shifl iork rail
Dull the lsL'.)rrc qear selecfor shali (1] rnlo the it-''^"
OuSh ng []rlil :r:r:l nli:l',,.rCk Orn OrOIS rnlt lhe groOve :'
(-
i'lt-. Snit !111, ':-, ii;r'r1'r,"'o l',ir'[]all Lle'::rl'i'igt3119r 1 '1
l y94
l:- ll r.::'92
kaukazz@yahoo.co.uk
6005-1 3
STEP 34 STEP 37
Repeal Step 36 for the l st/2nd gear selector fork
STEP
&s
Turn ihe Ball Detent Rciarner, CAS 1994 through 180'

counterclockwise Puli tire 3rd/4th gear selector shafl
(1) into the same position as the 1sV2nd gear selector
shali Remove the Baii Deteni Belainer CAS 1994
lnstall the dropshafl bearing cover (1) and retaining
STEP 35 bolls; without shims.
NOTE: DO NOT tighten the retaining bolts at thrs stage
STEP 39
the front bearing carrrer relaining bolts to a torque ol 70

:o 79 \lm (52 ro 58 ,o fl)
STEP 36 lnstall the input shaft bearing cover without shims

g
{ lnstall and tighten the retaining bolts to a torque of 9 I'lm
{
A
(80 lb in) while rotatrng the input shafl to seat the
! bearing cone into the beanng cup Loosen the re:arning
d
bcils
{r
Trghten the setscrew (1) in lhe 3rd/4th gear selector

fcrks onlo ihe gear sh h rar Trohlen lhe rocknut (2)
NOTE: Maxe -\t.ite lha! tne selea{or loc:ates in tne detent

,'r l/rc gea.' S/.,11 ra;.'
D11 6-851 g2 sSued 3-92 pr.leC rr E.qlalC
kaukazz@yahoo.co.uk
6005 I4
STEP 40 STEP 43
lnstall tne snrm oac(s and beaflng covers Tighten the

relarr 'rq tlcils to A rcrotr.i oi 'lC lo 46 Nm (20 to 34 1b ft)
STEP 44
lrglr','rr lhe retainlng bolts to a l,-)r'(.iir(l oi 2 8l''jrrr i25 lt'

,r,' .'''.' roia:inq :l'lc shall l-jr ;t '€:tlle' "lat-!(l :c)
-l: ''r'l' ar-rci lll{.
mila :l'e c)a0
, r i-)clwtlfin ff
'r' lr('all'lrlil
-'l'l :( " 11: rr -:
l:i." :.'.lrnq,-:.1,,!'i l,rialiil
I ' 'r :v1ake r fi-:a' rl' ina '; i '' ' ifril
1 r.'J i'qhieTr rhe oro[,t:
lirr:..rijc )ei\^,,ecr lne lnre(-i' .
i';:i' r) C5 rnn' take an avcra(.'

ar"ro;trjc] C 36 mm lC deterrrin('' I r'l(-lrr i!il 'rlii'
lor l, .]Otr: shal: cear'ln(l 'li:r:irir 'i'(l r^ri'rl: STEP 45
f...art' i l.r.1r"p' lt'):i:llll'r'Q ba l:
llO'l-[: ll !l^'e Crllerence l'i:iiv''' :'''ee

,,1t . .r,,,?enfs is qrealer ihar it (:
t)eat;t)(l caver. reseat the beattt'rt
' it ''' t:. ! ,.'ii!
Slelrs 38 lo 40
0.-.._1r,i
I
Lf,.
.t.1
/-'
lL +
pzfrq.i
i,.:tliit i'r(.' t)']vL (.1()ali' ('l I oi l':, il')c (lroSshafi Measi''t:

SILP 42]
:re drsiance (E) jron-r i't-'e t)i':)At hr'lr iace to:he end oi iric
Croosnah Srlbtraci 0 0i: rrm 'r(:n fhls meastlrernenl
r]r 1 .,' :)ra'l salf'-o ilrccc(jtjrt) a:, {or lhe oro)s')ar:
:c celer.^'1,'i "lc '-r{.ll,,r'i' I s"' rrll.l:i'
, ..'," D.,i adc ii 28 - rrr (0 111
.1
t:.,t
"
rjrrv€ Q€&r
(rrr,r:,i,,It-t'€fl ,'g 6jotg:1',11il3 :na Oil r
1,. ,r1;35na'l l"lOTE.('r,r'
,- tr.;) !:;l
kaukazz@yahoo.co.uk
6005-1 5
STEP 46 STEP 49
lnstall the shim pack washer (1) ar)o retaining bolt (2) Remove the caps Conncct and tighten lhe creePer
and tighten the bolt tc a torque of 101 to 1 '1 3 Nm (74 to iubrication tube.
83 rb fl)
STEP 50
STEP 47
E,sl.
*
,&jtl,,
:-:htr'-
-J *t'
i'Er}:,,
4r'-tt *,M:
II
s ii
f*_ C2a826 lnstail the steering tube clamp (1) . lnstall and trghten
Clean the surfaces ci the iransrllissiorr and access the retarning screw
plate Appiy a continuous bcad o1 :c)cl 'r 5l: to il"r'
face cf the transmisslon housirtq lnsiail irre aicco:;il STEP 51
plate and install and trqhlen :he relaining screws
STEP 48
);i3:ilr
&ri*"
and retarnrng cltPS.
lnstall the steering tube mounting bracket (1). lnstall STEP 52

arrd tighten the retaining screu/s
Ccnnect thc transm ssron 10 thc cngine teler io Seclro')
6002
Don I 85192
issued 3-92 Pr'rried ln Er:g anc
kaukazz@yahoo.co.uk
Section
6006
SERVICING THE POWERSHIFT TRANSMISSION
Copyright O 1992
Printed in Engiand
CASE CORPORATION
March 1992
kaukazz@yahoo.co.uk
UVUU-'
TABLE OF CONTENTS
SPECIFICATTOI\S
powrquadplus
SPECIAL www.thebestworkshopmanuals.co.uk
TOROUES
SPECIAL TOOLS
SHOP EOUIPN4EN T TOOLS
orC-ORTAL INDEX

Removal
IN]UT SHAT
Disassemcty 8
Accomh,rr ,, 10
-oo9rrrvy____
DFOP SHAtrT
Disassembly 12
Assembtv

Cross Sectional Draw ng of the lrrpul Shaft and Dropshaft tb
lnstallation t/
f rgrl $s3plrg Adlustmen: 18
SPECIFICATIONS
Fricfion Piale Thickness . . 2 45 to 2.60 mm 0 096 to 0 102 inch
Steei Separaior Plate Thickness 2.'t1 lo 2 31 rnm 0 083 to 0.091 inch
lnout Shafl Diameter 44 99 to 45 00 mm 1 772 lo 1 773 inch
1sl Gear lnside Diameter .. 50 009 to 50 02 mm 1 970 to '1 971 inch
3rci Gear lnside Diameter . 50 009 to 50 025 mrn 1 970 to '1 97'1 incn
Dropshatt Diamcler (2nd Gear) 44 389 to 44 404 mm 1.748 to 1 749 inch
Dropshaft Diameter (4th Gear) .. 39 985 to 40,000 mm 1 575 to 1 576 tnch
2nd Gear lnside Diameter . . . . . . 57 117 to 57 137 mn', 2 250 to 2 251 inch
4rh Gear lnside Diameter 45 009 to 45 025 mr. 1 773 lo 1 774 toci)
SPECIAL TOHQUES
Sceed lnput and Dropshafl Bearing Cove's
Wilhout Shims to Seat Bearings I Nrrt 80 lb in
Wrlh Shrms to Measure Shim GaP 28Nm 25 lb in
\^/i:h Shirns vrhen lnstallcd .
40 to 46 Nm 20 to 34 lb ft
101 to 113 Nm 75 to 83 lb f1
Llropshaft Retaining Bolt
Front Bearing Carrier Plate Retaining Bolts 70 io 79 Nm 52 to 58 lb ft
0ce B-85202
lssucc 3 92 Pttlec r f :g arc
kaukazz@yahoo.co.uk
6006-3
SPECIAL TOOLS
1. SPFING COMPHESSOR 3. SEAL EXPANDER/PROTECTOR

CASl 992 CAS 2OO2
FIRST USED ON PAGE B FIRST USEO ON PAGE 1O
2. SFNL COMPRESSOB
cAS 2005-4
FIRST USED ON PAGE 10
TOROUE WRENCH 3. LOCT]TE 515

oEM 6478 B1 7555
TOROUE WRENCH TRACTOR SPLITTING STAND

oEM 54aO cASl 08s2
Ocn 8-85202 lssled 3-92 Prrnleo in Erglanc
kaukazz@yahoo.co.uk
6006-4
PICTORIAL INDEX
INPUT SHAFT
Front Bearing
Adlustmenl - Paae 18
SROP SHAil
cr6nl Bearrng
Ad,usirrenl -Pagc 18
D:- 8-85202
kaukazz@yahoo.co.uk
6006-5
Removal
STEP I S
Scpar-ate the tractor between the engrne and the specd \

transmission housing Befcr to Section 6002
S is t' '1:
i)rsconnecl and cap ll-le areeper lubricatton tube (rf
equipped)
STEP 6
lemove and cap the InoLti sl'ral arlcj drcpshal I :lr -:
':brrca:ion tubes ! I [1
}r#a|
STEP 3
&lr,g,-
HY*
,w,
Remove the retaining screws and remove lhc steerlnQ

mcurrtrng tube bracket (1)
D
a#M
sconnect and cap ihe cowershifi clutcl'r r{.jilli
STEP 7
i*--* 7'
STEP 4
bai$1r 'wff\ !- C24426

Eerncve il-,e retatn ng screws anO rerlov( l'i) Sci,css
BemOve the sCre,,^,' (l:rfrla

"r)('1
iLrbes
Dcn 8-85202
kaukazz@yahoo.co.uk
STEP
a-,
a)
!,
a
'1, 'r assen:bly t:.r :;tc;l ii fror'- :ll"'ng

' '.jrolsi.afl
:i.-r"'ov€t lhe diive qear reia ninr; 3lll: i1) and v"as::i" i2)
NOTE:
[-*ffi I#
Bemove thr ironl bear-ir:; cover and rernove the shrrns
!'t:.,.1;t lfis shirr5 16gs16er for assembly

STEP 9
STEP 12
,-ii rr I '.1r,( :r li)o drive gear and shtt'rr:

Remove ihe dropshaft fronl Dearrng cover retalnlng
\iOTF (r,.C .he \htr.< t.-,qr,i! ; bolis:
SIEP 10 STEP l:i
ililr,' Ov1:lire'ror'rl Lrarrrrg Cover and rcrrlovc lile sf)rrrll-
NOTE r;t:tp lhz sl;irris ioeeliiai lar assentbly.
r q2 P.r-,t.rc
kaukazz@yahoo.co.uk
bUUb-,,
STEP 17
$
.$""
,$I g
fiil
H*
st tiB B1*,1t9
Bemove lhc fror:i bearing carrier slale retainlng Dolts Remove the nput shaft assemblY
STEP 15 STEP 1B
ffi :ri
,,:,t
,.,lC
lnstail two 12 mm dowel bolis through lhe f roni bear ng Pul a prece of wood under the dropshafl assembly 10
carr,cr p a:e n:o the I'ansn-lss o1 hoJs n0 prevent damage to the gears. Remove the dropshail
assemblY
STEP 16
Dc.r I 85202
kaukazz@yahoo.co.uk
6006-8
INPUT SHAFT
Disassembly STEP 5
STEP 1 Removc itcms (12 io 20)
Re,nove items (1 and 2) STEP 6
STEP 2 Remove the 'l st gear (?1) and remove items (22 to 32)
STEP 7
j!.
it {:
lt
!r
;l I ttg 4,
tl iii .l .! ;l
r.I 4i
X
Bl 1129
Belease ihe srap rrnq (l5) {rorn the 2nd gear clut:t'
ho;-q ng (5)
Put the tnpul shaft asserrrr',, cn a hydraulrc press Use
STEP 3 the sp,inq compressor ( ,A:i 1992 to cornpress lhe
OiSlO. rCiurn spring Rsn.''r'7i' thQ snaC ring (33)
STEP 8
Remove items (34 io 44) lrorri ihct lnpLt shail r45)
STEP 9
Checx all rlerns 'or wea: or Carnage anc replacc as

NECESSATY
;Lr-)OVe r:e-S r3 lo 5) ;'..: i ,,
! llCril.: C :)ri;SS [,';'

'1
9J2l .r.t ilorncri:rs:r ilrii :
-e ra . 'tn ;F,
STEP 4
i(_'.r,Cve ilerrs i7 to I1l
: L lrJla-ra
kaukazz@yahoo.co.uk
6006-9
NOTE: ltems are numbered rn order of disassembly
,.,i
"@\ e3\-
-g. o9r ffi- \@
-")u-( $9 )o
/*
)o-
\o- )
@-
,iSAN
@\
mel ---\o.
-o
,J-'\
\8.
-@
sM0579
NOTE: ltems marked (.) must be replaced
1. SEAL RINGS IO. SEAL 19. THRUST WASHER 28, BEARING BACKING PLATE
2. BEARING 11 0-RtNG 20 THRUST BEARING 29 SPACEH 38. FRICTION PLATE
3. BEARING 12. SEPAMTOR PLATE 2r . 1ST GfnR 30 BEARING JY, SEPARATOR PLATE
4. o-RtNG 13, FBICTION PLATE 22. BEARING 31. THRUSTWASHER 40. PISTON
5, 2ND GEAR 14. BACKING PLATE 23. SPACER 32. THBUST BEARING SEAL
6, SNAP RING 15. SNAP RING 24. BEAEING 33. SNAP RING O.FING
7, PISTON 16, SPRING 25 THRUST WASHER 34, RETAINER +J. O.RING
8, SEAL 17 RETAINER 26, THRUST BF}RING 35, SPRING SEAL
9. O-RING 18- SNAP BING 27 3RD GEAF 36 SNAP RING 45. INPUT SHAFT
Don 8-85202
rssucc 3-92 Pr.ied n E|]clarc
kaukazz@yahoo.co.uk
6006-1 0
Assembly STEP 16
STEP 1O
lns:al rtems (44 to 40) io the rnprri sha'i (45\
STEP ] 1
hry
c2c825
: len- s (5 i(, ,1 ; a'ill 1l
.rng (15)rnio th,.-:
. .: Clear,.liL,iai'r "o.,s,ii'ii
STEP 17
i-1(ral :)Car'ngs (2 ard :j .r i,:larirg oven :l a
l^:rt;rl1 ,lerns (35 to 33) l.t.tl a llyrir;,r,.,1 , irrrl-ir(.'ri1li,rc of 15C'(l (1102'i- r ;ino 'nsiali onlo the 'npu:
spr .rq comresscr CAS rlt ) io (orf :lrtll:
.,i "
-r
'1c, I :irt(j raSiall SnaD rrni:

'1,) inlit ile l:,
STEP 12
.:i)lli<. il'-r{l irlClrOl i)l,l:uS . ):l ST EP 19

insiall i1e.ns r.l!.r lo 3ij,
STEP 13
7
rrsiall rtems ;32'.a 28t lrlakc l.;;tc iirc rLr 'r". :il!l
lhrr,sl bcariirg (31)are lowards ihaj lflrLrsl v\'il'| ' ,;2 )
STEP 14 '"q\q
! i. 6. ,.- J {
i't1.r'3 .1 l6) Man.e S-ra "".r '. lflr:

i ,;,il: :
., ,\^ ,/,,.,.
\,
,)f
>,r. ' t..,,ri j:: llf., lll,
\'-! ''
...
irr'al lrlc rcl ers o'lhe thrLsi 0oarlrg (20) :ir,,: llr\','il l
i:.rr.sl wasrict (19) ,)\. 1 ',23
STEP 15
\'t'
$ll'f
Br I l23A
,;br a,, . '' , r 'll'iilli l

,tl)Ljl Sira" it 1; ir.1 S, 1, ,'r)' : iS :OC:.
lrstall iier-s (17 to 6r l-Jsi: i i'iflr'3i;lrr: irrr)!,. I
rJortprrr.ss :rli' siaii:l i'f i)(' r'ir!ll 'r-
comDrcssor CAS1992 '' a),lrT'OreSS :he lll
.....1 .,-c sqac.r^g rr " li.(. :j6:r 13:t l):a' .:;.,r .,,ASl frl)(.':r''i
r,r) gf ()o'''.
: -,:: i E5l3i
kaukazz@yahoo.co.uk
6006-1 1
-*---9"
.@\
-g. o9:. &@-
\@
@2
-o-o @\ \^
l} '-6i
,,-
O,--.@--*
@\
,N Yz
@-
qg-e
4<
)@-
l.-\o.
-(a
.@\
.(D J-\ --@.
\ sM0579
E
1. SEAL RINGS 10. SEAL 19 THRUST WASHER 28, BEARING 37. BACKING PLATE
2. BEARING 11. o RrNG 20, TF]RUST BEARING 29, SPACER 38, FRICTION PLATE
3. BEARING 12, SEPAMTOR PLATE 21 1ST GEAR 30, BEARING 39, SEPABATOR PLAIE
4. o-RrNG 13, FBICTION PLATE 22 BEARING 31, THRUST WASHEB 40, PISTON
.14, 23 SPACER 32, THRUST BE}RING 41, SEAL
5. zND GEAR BACKING PLATE
6. SNAP RING 15, SNAP RING 24. BEARING 33, SNAP RING 42. O-RING
7. PISTON 16 SPRING 25 THRUST WASHER 34 RETAINER 43. O-RING
8, SEAL 17, RETAINER 26 THRUST BEARING 35 SPRING 44, SEAL
3. O-BrNG 18, SNAP RING 27 3RD GEAR 36 SNAP FING 45. INPUT SHAFT
SS-uC 3 92 n'rll?C r^:n.l.a^:

Don 8-852C2
kaukazz@yahoo.co.uk
6006- 1 2
DROPSHAFT
Disassembly STEP 5
STEP 1
Rercve rierns (1 to 9)
STEP 2
B1+704
Use a hvdraultc Dress ,,.'r:.1 ::oring cornprr::;scr CAS
1 992 lC CorirCf CS: i' l:,:,'r- :: return S..,r 'rO i35)
Flenrovr: iirc s':ai: ','', r i.l
STEP 6
Br1426
i..lse a nvdraulic oress ano sprinq compressor CAS Bemove items (34 io 44r from shafi (45)
1992 tc ccrrcre ss the scrino I l2) and remove ihe snao
STEP 7
STEP 3 CrreCk all ,:e.n:i "l' wara: OI CaTaOal arl,.1 'trf aCe r'
NECCSSATV
Re.r',ove rtems (1 1 to 2l)
STEP 4
^.^ t-'432c? sS.rC. 3-92 P'r.icaj r' :nglanc
kaukazz@yahoo.co.uk
ai()c6 14
Assembly STEP 14
STEP B Soak the lriction Ciaies ii:r) r', ciean tsY -RAN ,. i-ls
lnstall items (.1 6:o 13)
l"slall items (44 to 40) to the shari (45)
STEP 15
ST[-P I
lnstall iterrs l'9 :o :il \4ake sLrre :ne rotlcrs of thc :n.lr:;
Dearrng (B) are :cwards :he ihrust washer l9)
STEP 16
[,:;rn!.] a Lrcarir ,t :;, rrlis '2 aaa'l2i 'o

",'.rl;:lia.ri:rr a-
larrrlr.)rall:,rt o '..1 .irrr'l '.:;i:i:l 'te br:zl:inl,'
{-
\ STEP 1B
- .lr 11..c
rmr,rocc., ,ÂC-
I v't
l'35' :O rrrSiail sraC ring
:iTEP 1O
i
:rlai(:il.r:rrclrc:r plates (38) in crcan i/ -iiAN Pl ii:i

i{
t
','iir, lcn-rS (39 to 36)
STEP 1 1
.r!liail riems (32 lf 23) I't,iaki: surr: lli.r ('l;ri-rr:t Cl ir'tt)

"l' r:i' Dearrn(-l (.J11 are loward:: :hi' lir.ilsl: wlt:;hi:r i,lll,
STEP 1 2
l'rstall r:c'rrs (21 to lB) ar',d ca'rgiullv rnSiaii :fre c,sion

"l
ii:i:li:r'l lfll'y/ ( 7)
STEP 1 3
R 1 1 1i?3/,
-l : ,i(: r ) 1 i'ii i'l' ,:: ,)t', '. l'

./\:l :)0f ):, ' j:a1r. :tre Stoa.ils, i){'rlO '' , ltOl': ,liai'l
[,i-:t]]i)res:, rfl;t iq,.lil1ia: .ltl,'-,r, tro()!,.r:. .,1,' .t I'r(r :lti-:
iicrr"r:)r'ussl-'-i i)rir 2001.l .1
B1 r426
ll slii I rle.ns (1 2, 1 I anrl t l .: ii
:;:,rr' :,r COfnOreSSO" (lAS 1 ,
' :"a'r lhe :1tt
f.-f,- i'1ii _
kaukazz@yahoo.co.uk
buub- l 5
'-,@ @.-
\@ "@-'.1 :-@.
@* 5r^ -@ - )o.
-@Y- ,/
a @-.
@u :-J-;u.---- (D\
@1 -@ @\- t@"
-@
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a
a\
'g-
l
\: ar
\-;)
@--.rxgxz*r to
lv'-|o -9,
hsto$re
(D
sM0584
1, SEALS 10, SNAP RING 19 0-RING 28. SPACER 37. BACKING PLATE
2. BEARING 11. RETAINEN 20 SEAL 29 NEEDLE BEARING 38. FHICTION PLATE
3- THBUST WASHER 12, SPRING 2r O-RING 30 THBUST WASHER 39, SEPAMTOR PI-ATE
4- THHUST BEARING 13, SNAP NING 2:.] BEARING 31. THRUST BEARING 40, PISTON
5. 4TH GEAR 14, BACKING PLATE 23. IHRI]S1 WASHER 32. THRUST WASHER 41. o-RtNG
6. NEEDLE EEARING 15. FRICTION PLATE 24 THRUST SEAFING 33. SNAP RING 42, SEAL
7. NEEDLE EEARING 16. SEPAMTOR PLATE 25, THRUST WASHER 34. RETAINER 43. o-RING
B, THRUST BEARING 17. PISTON 26, 2ND GEAR 35 SPRING 44. SEAL
9, THRUST WASHER 18. SEAI 27 NEEDLE BEARING 36. SNAP RING
alc. 8-85232
kaukazz@yahoo.co.uk
6006 16
Cross Sectional Drawing of the lnput Shaft and Dropshafi
5, 3ND GEAR (DBIVE)
7, 2ND GEAR (DPJVE)

6 iST GEATI IDRIVE)
I
_r Jl.
4 4TH GEAR (DRIVE)
kaukazz@yahoo.co.uk
6006-1 7
lnstallation
STEP 1
lnstall the dropshaft assemblv
STEP 2
lnstall ihe rnput shafl assemblY

Remove the lwo 12 mm dowel bolts
STEP 3
STEP 6
tr
!&"
s'* B1o41o $F
lnstall the input shafl and ciropshaft front bearing cups
81 fr*r
reta rning
into the iront bearirrg carrier olate.
bft)
Dcn 8-85202
issccc 3'92 PriniDd '. f .Ela:xi
kaukazz@yahoo.co.uk
6006 1 8
Front Bearing Adjustment
STEP 1O
a
l
,C
?
t
t
;e' ()3r.129
,ns:.ril tllc droosha'f1 bearino cover,r"(i :,rliirn[]q il()lls l]se t.
,^.,it:3Jl shirns DO NOT :ighler'r-,':, :(r::ir' t i,''-
STEP 8 f,1,t r
:
;)1 , :1. ,t i.1:.,., ,' i. . , r
:-jp',,.ftir,r, '-i1 . ,tir- t. : l. 'r}CKreSS l' :he Olrlirf ;:.ri;,

t oet\i/ee'r :l')0 l'-rr?e' i-.:1: .lre,rtartis rs cieaier [la:0 i.i)
:nr.. (C,l( iil â:- rO'-'(t'./a.t ifril rlTal.C r.l)Ver artc (li,€t(,(
t
ific Ir6-,3',6^ fOr COrr.eCl Sealrrg
{r
a STEP 1 1
r^rdrl ii .l(i rrm i0 (i 1 .i rr iClr) io if,e averaQe meas!reil- err:

"\ :aken rrr S:ep 10 lor lhe required shrm pack 1or the rr-tDLri
i.,' siafl bea.''rQ Lcosen ihe inpui shaft bearinq cover
s
.sii.t ' .r rno;l shafl bearrng
ietarnrric boils.
l:rs1o1, ,..,',,, irghlen the retarnrnO boli' '

t',i l',,.t STEP 12
l. l. "\,,tile ra':alritq Ine tr];.Ill i:,t i
'-,,.'3: itl :.riti) t).r" '

, ,.1!l i ,. .:
STEP 9
t*
fr
ff4.
I t,jt , L,t .)
,i ,,\ ,. .
) t[) rl ] lvr e ll:al :
kaukazz@yahoo.co.uk
6006-1 9
STEP STEP 15
b
il
O
Q;
)'*',
q* 3
r;
Xft*.*
Tighten the bearing cover retaining bolts lo a lorcue ol
2 8 Nm (25 lb in) while rotaling the sha'l
STEP 14
Remove the input shaft and dropshafl bearing cover

retaining bolts and remove the bearing covers
Repeal Step 10 on Page 18 io Ceterrnr.c lhc averagc STEP 16

rl-easurement for thc drooshitl sirim pilt-'k thickness
Add 0.28 mm (0 01 1 inch) fo ihe average
n'easurement. This ts the shim pac;k reQurrec for ihe
drcpshaft bearing
lnstail the dropshaft bearing cover and snlms lnstall

and tighten the reta ning bolts to a torque of 40 to 46 Nm
(3rr to 3a lb rr)
Don 6-85202 lssued 3-92 Pr'.ted ^ :.q a'3
kaukazz@yahoo.co.uk
o006-20
STEP 17 STEP 19
a;}i$ffi:'J -'--
":w
-3%ffi
#;
,tst
"
f*ffifuIM
inS:all tf ,r,, ltlr.lt Snal
il'rtl tigfriirl llle retatning
tlr:arrnr; r)r,1. nrr(i sf rp3
Col:S ii.) il ::rf oi..i) Ol '10 til
i"1 :;'.111
<1ir i"ri:l
l'.,:ll;r : ctrivar
)i, iiii.,j,a)l_.S,: J'' r:
cl(lar 1ar'r::irlql)()r' ' and v723ir'r'
r"ri)iv iaSlr)i '''Orr'Urn.' ,
i30 iC 3i:'i lL) f1) irt, ,. .,.,1.1 .. ' ',.,., tral a. lC' i'.)
6.: it, '
S iL'P 18
SlEP :?O
*F*
.a11
*j* :
3!}.-."'t t "
i
I
'l
I , : .:lla i.: )l)L! :)r
,'.1:i '"r,:r llarlSlrrli;-S
).: L
I
/Y ' -.- 1 1"---:

' ii a.to :rc' I
sltt_F,21
ri j $',-,e*,:
I
*
!Yv
llt-.rl [ .n1J':< et? a/A.!;ii.',t:.

', ),i : .,i I '1'7 ,T/1a
kaukazz@yahoo.co.uk
6006-2i

STEP 22
Eemove the caps Clcnrrect arrd irghien the luDrrcatlon Rerncvc ihc caps lnstall and tighlen the lubricatlon
tube (if equipped) tubes onlo lhe inpul shat and dropshaft frorrt bearing
COVCTS
STEP 23
STEP 26
Connect the transmissron 10 the engine. Beler to

Sectior 6002
lnstall the steering lube Ctanrl, (' : rrrsla ane iighle'

the retaining screw
w
STEP 24
c:
r?
/f.r1
a
Remove the caps. lnstall new o-rlrlgsj orrio tne
powershift clutch {eed lubes Connect arrd :rcjhtlrn the
lubes onto the rnDt,i srraf.i art.,j cl'.-ltlslail lra)ni llilarli(l
CCVETS,
Dcn E-85202
ssued 3,92 Prinlec rn Engla.c
kaukazz@yahoo.co.uk
Section
6007
RANGE TRANSMISSION SERVICING
Cooy.iqht O 1991
CASE CORPORATIO,\ P.inIcC nUSA
Oclober 1991
kaukazz@yahoo.co.uk
TABLE OF CONTENTS
. . 'ri, : 5i-/\-
.l ..-l!lsr:rro',
i\ajstltr.Otv
,)'.;,:s Sci:l 6rt3 Jr2ry1ri) (; i" ' )1". "'t ,.'.:',1,:-'t: ':.':' .i''
: :-Lii-i
..
:.) .v
- l)r'. i .rrl
^
.:, :: i-"1-' l-' ,
-,a-t-c
SCI'l Crral Dra!^/iaC t)i i-a, ili, ",. 'l-rA':
',it ) \l :) I '/r'
':r':l a''Oi
''j '11.'".." 1''l'
:- t; : r S-rArj i
i15)'al ai on
_' -
-a
''.':i :i)' Cl'--
' '; ii^,/:-i)iAi'* Sl-rA:i'A\rl ilL,\i:r\.iG r-.,\il:.' ' ''1r.,::l)l-l

'lSla a rO'l
.)I1 .,: Sitc:rcnal Drawinit l-r: li, i:'it':alir I'211;" ,,.,,'
S PECI FI CATI O N S
.ilr :la:i: 'lal Ol

r ', '. r(J'lr'o Si:i:i: !'rrj -',r',' . i):)
: . . ,tia,, - l:.'
i:l l. : i.l i,
.r q.j
: :' :' ': .t l \' - ' ."
kaukazz@yahoo.co.uk
6007 3
SPECIAL TORQUES
Bcarrng Carrier Mounling Elolts 235 to 265 Nm 174 la 195 lb ll

P nror Srafl Bol: 3ll5 to 375 Nm 247 Io 27 7 1b li
SPECIAL TOOLS
51OO SERIES TFANSMISSION SPECIAL TOOL KIT

CAS 1990
CLUTCH PACK SPBING COMPRESSOR

CAS 1992 SEAL EXPANDEB PROTECTOR
FIRST USED ON PAGE 23 CAS 1999
F1BST USED ON PAGE 32
3. SEAI COMPRESSOR
cAS 2005,1
FIRST USED ON PAGE 33 4- LIFTING BRACKET
CAS 1 993
FIRST T,JSED ON PAGE 7
Don 8-8522 1 lssucd '0.91 Prinled rn F|g a'tr:
kaukazz@yahoo.co.uk
SPECIAL- TOOLS (Cont )
,.\+rd + rqlpt,@jffiSt-r<ffiS*
1. ,!;i. .
a$nryeffi3&di@d,s$.@
''w::i.'1 _'
riiiusd**v...w
i::@. :..
'ûi&:ir6+w"*
.1:1{qlnP!s61siM
PINION S'.AI I 9:iIJ 1)4,- iJETTING WASHEF

c1.t"t9: tJ
-A:- 198
:, i iililr :ii:: 'r i'r\ l'AGL 18
Al lcr't\!'1f \l i : -
cAS r 3i)5
FIFST USEI O\r li\lli fr
/'/'
-4-->-\\
'i ---.l
,/ frlir:lli:H {ltAllrNG CONI.

rir\S 2021.i
;'r:i:iI J:ii:il L)\j PAC! ,Jl;
SHOP EQUIPI'/ENT TOOLS
f('):lo.li ,,,iir '. .: i.r Af ll\(; L.)'!/: \

(,,1.r1 1],)l' CA:i 'a,33
2 Pl.,l I i:[] l:iF I 5 iJ[]il.!li^.lLl ili A;til'ii.' A'r-) l:iEAL DRIVEF Kll
OEI 424:) )f f,4 b.l.l'
3 MllL flMEl[:!r ri'r L.i)r I'lIE 515

(lAS 1:,:,:l
kaukazz@yahoo.co.uk
6007-5
PICTORIAL INDEX
SHUTTLE SHAFT
Removal Sec Page 12
Disassembiy See Page 23
Assembly See Page 27
lnstallation See Page 42
INTER[/EDIATE SHAFT
Removal See Paqe 6
Disassembly See Page 18
Assembly See Page 20
Installatron See Page 50
PINION SHAFI
Bemova See Page15
lnstallation See Page 35
60073 1
Don I 85221 ssrjco ]C 91 Prlnlec rn Er'rgialrc
kaukazz@yahoo.co.uk
0c_r7 6
BEAFIING CARRIER HOUSING AND INTERMEDIATE SHAFT
Removal
STEP 1 SIEP 5
d-Si:K
E#. '!"ii'. a,
r-u$& t$
.:!q"
.,J
'\.'4,, .'
)r
1i
-*
@- ,--^.
Fr
(& *6"
*
. S,i'?*S
;i;t,"(_rir.
I l..r'a:].(l ,"!' !::)i)OC arU':jrlljil ,'
i:,),.. I
STEP 6
STEP 2
'' _a\, ""_'''r41"\: l'ir'
STEP 3 For 2WD Tractors
'1
'?
rI&r.
"Wffia -t
b*
i""d rc4&& ss
Fwdfld;
,ts I 'hn ri.c
$m$ 5l P7
tr
ET
&-
# ,li
t'-rr .',
.L i'
'&',.' N,
STEP 4 For 2WD Tractors B
"*
, .'
q
"r**E
'*i*- ., -:& B
ffiimi
'* *i
f, #
c
' '@,x: t' 'l' t #,
r1
\,,ei
&.
:ii/-
.! l #,i
- s-- c'
M*" 3,; t)084
ar'!i. ,,
w
i-ra 1it_ralrl(.1
"\*
M cxo37
1.1 i q!: ll
kaukazz@yahoo.co.uk
6407,7
STEP 8 STEP 1 1
*-,*;ff -#
,
l;t ':"'*' ': '*a1
..,.'g&;
:r -*ry.% ffffi
.:' * ^ffi.ffi)r
c2362 1
Insiair li{lrrrg brackel CAS -]993 tnto the parking brako

Tnour':rng holcs Connccl sLtitable iiftrng cqurpn cnt lo
'\:w*'\ the riitrng bracket
.ks&a\
" R:t. w1'
*iffi STEP 12
is.Frd
It
ta'
{ii: { r
s
E
,, 1i] \
:k '\
c23628
:-lCrTrO\'O ,5.311;i.11h S DACCI'
:r:)rin() a'r .ba *r,kYP
STEP g
i:siall a siliiablc orllc.'. rh. lftinQ brackci CAS 1993
rlcoc:a: Slcp B 1or 'a ot,i fhc bcarnrl carr ar irouslno ofi the pin on si-ai:
STEP 1O STEP 13
Idil
11:& l,r,,tlil:
lREN/OVE H&
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sd
iic''r'(;','a 'rrc bcaring cariicr housrng
il;^ t ti:212
kaukazz@yahoo.co.uk
A' r' -/ ,l

STEP 14
.!P%: 1
4
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ttrcr.-'c'it-' ihc nlc'rcdialc Sl'aii enr. .; .r, 3:1l . -1
NOTE ,'1.r, ,r.ie'rt:Ctate S,':iill :, 'i'.1 " l'... :... - .'

bea r ; "t 11 :: a r ri e r h a u s tn g. Re rtl c'ie i n e r' i e' r) e d e i C
i r
iJ 6rr', " 2,: 5Jr,, 951;r' h395ln{r' .tu'' a' r:e' i:' i l' ; i,( : :.i'' ) ..
.
r:.,c li] S /(^,.'-a., l'f t'O. ;' ; :,i'- .. ;, : '.. '.:

the
'ntermeCirig 5naft
STEP 16
#tr:tt:@ \$
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',,. ,- *r, "1.
ttt.
&
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lc^ I 3):'2
kaukazz@yahoo.co.uk
6007-9
powrquadplus www.thebestworkshopmanuals.co.uk GEAR SHIFTERS

Flemoval
STEP 1 STEP 4
Makc sure the gear shiilers arc rn i'rcLlral and put

idcntification marks on thc sclcctor forks for easy
assembly
STEP 2
&
1. LOCK NUT
I
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IB
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Looscn thc shift fork al en screrl lcck nuts ar(l .f.Tovi
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thc allcn screws
fut
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\."
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&
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il c23g1d
& STEP 6
W'.-.."''$,.wfw
Rcmovc the 3rd/4lir (Tc.tp) sirif: rai 1. INTERLOCK HOUSING
&
Rr-.rrovc iic ntcriock ;in rom lhc interlock hoL.sirrl
Ar 6 :\?t': isslec 1J 91 Pr::cC rr' [:,:q ar,o
kaukazz@yahoo.co.uk
r ]i
powrquadplus www.thebestworkshopmanuals.co.uk STEP

STEP 7 1O
e
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flr:rlol,l; anir .lr: ' .,,r | '..ii
STEP 13
O,8ING
\
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tn^ '
C26905
kaukazz@yahoo.co.uk
6007 1 l
STEP 14 STEP 16
Check a oarts for wcar or darnarlc ancj reolace as
nccossary
STEP 15
\
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if" ." \,
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BUSHING tr
\ /r li thc bushrngs arc [o bc rcplaced use a bushinO C.rvc.
and rcmovc thc bushings
ls
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Chcck the shrll rarl birshings in thc bcarinq carricr
housrnq for wear or damagc
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kaukazz@yahoo.co.uk
SHUTTLE SHAFT
Hemoval
ST EPl STEP 4
;
ri
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s
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kaukazz@yahoo.co.uk
6007- r 3
powrquadplus
STEP www.thebestworkshopmanuals.co.uk
7 STEP 1O
r:;
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Rcmovc ihc jourth gcar anc scaccr Rcrovc lhc svnclrol zcr ftub
STEP 1 1
d,
Rcn ovc thc synchronizer asscr''it1y ancl shrms (if Bcrrovc inc snap rrng
cquiopco)
STEP 12
NOTE: K.aap lra. sh,,z:.s ir.r:.,a,,ihcr ior t:.tallattOr it/
pt1' t-t)t..;
STEP 9 r, THRUST BEARING
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Do', 8 !1522 I
0-9r P'rr166 1 i ^g ai':i
kaukazz@yahoo.co.uk
(i[_r),.1,i
powrquadplus
SIEP 13 www.thebestworkshopmanuals.co.uk STEP 16
#:r ffi
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kaukazz@yahoo.co.uk
6007 15
powrquadplus www.thebestworkshopmanuals.co.uk PINION SHAFT
Removal
STEP 4
-4.
@
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I
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1. PINION SHAFT
**,
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Rcn ovi: ihc Crf{crcnlrr-t aSSClrr0i,y, Flc,it, ll; c . ."-.. SccLrrc ihc p nron shafl rn position with blocks of wood
6012
STEP 5
STEP 2
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I-UBNICATION
TL] BE
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. 1. LUBRICATION
i TUBE
ilcmovc Inc lst/2nd synchronrzer assenrbly and sh rns

(r1 cquLppcd)
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Do,, 8 8522'
kaukazz@yahoo.co.uk
fill ' Ia
STEP 7 STEP 1O
.s sffi ffiffi
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STEP 9
v STEP 12
TtsRtrST !/ASHERS
THSUSI WASHEBS
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BEARING
kaukazz@yahoo.co.uk
6007 -17
13 STEP 15
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bcaring cL.rO frorr the bearing carricr hoi.rsino
Uso a busir,r'rLJ .Jr vcr anC fct'l,,vl .o [r

r\]on l:carrnt.t
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t o- 8-E522
kaukazz@yahoo.co.uk
INTERMEDIATE SHAFT
Disassembly
STEP 1 STEP 4
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irrS sl)ac..,f 'r'I
kaukazz@yahoo.co.uk
6007-1 I
powrquadplus
STEP www.thebestworkshopmanuals.co.uk
7 STEP B
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kaukazz@yahoo.co.uk
.li)
INTERMEDIATE SI-iAFT
Assembly
CONE
,, NA anovlr sf)ACFI:i
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ks
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2 WIDE .l NAIIROW
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1 :,ll:lS f)lo :
NOTE: Tle 4ik ilL)a' "' .:ii :j "l lbc iapoco l-,6112 27,1 1',r
:t)e I ', ie r't)e O talc' sh.;i:
kaukazz@yahoo.co.uk
6007 21
STEP 3
,r&,,,,f{M$,,,",,'
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sirffiYr4fffiEl{}
ccarirtg conc Makc si.rrc ai :hc carls arc ln cO rlrlci and bcarrnc carrrrlr hr)i-rs:-rQ uSi) a bcarng olvcr;-t::11 rr51;r I
tf-o spaccrs cannot bc :r,rncd a nCvi bCarrr.tq Cr.lO
STEP 4 STEP 6
-/ \
1 BEABI NG CUP 2, SNAP RlNG
r SHOULDER 2 EFAFING CUF)
3, BEARING
CARBIEFi HOUSING
600722 60072s
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ir:rirsnrrs':i ol iloris,nq Usc:t bcarrng dt r'c'a'iti irlsiatla sa rr,s srrms can only oc rnstalled whcn :hc bcarrng
itt-.rv boar'rnq cuD Mai<c si.t'c iitc cu0 rs aqarnsl ihc g;;.11r.:1 i-gggrrlg i,35 [g6;'r rnslallcd and the 'nferr:edrStc
:lr'f-'., alCf sr a{: crrd p a),rJ,.r.Crft ::'i)d Vakc SurC:hC bcartrlg cuc
scaccr anc Sir"ilr) lnq airL' In corltaci
l,).r' I 8122
kaukazz@yahoo.co.uk
6007-22
powrquadplus www.thebestworkshopmanuals.co.uk of the lntermediate Shaft
Cross Sectional Drawing
6. FOUR TH GEAR
5. tH IRD GEAR
\
\
b HAUtr 11
I INTERMEDIATE SHAFT
3. FIBST GEAR
/
COND GE
600731 B
Don 8-8522 1
kaukazz@yahoo.co.uk
6007 23
powrquadplus www.thebestworkshopmanuals.co.uk SHUTTLE SHAFT
Disassembly
STEP 4
!lli{r
't tsfirj
c25425 t': c26921

Rcrnovc and discard tlrc lorwa,ri gcar//hub scal Bernove the lriclicr a,rd sc;;ara'cr ciatcs
STEP 2 STEP 5
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Rcmovc lhe forwaro c r ci rack snap rrnq Pr,i the shuitlc sha:i or'- a i:ydraur,c prcss l,srr]l; .rtI
C/iS 1 992 sDrrng con'D,esstr' cor.prcss n{' l, sll',
STEP 3 rc:urr spring and rcmovc '^c snac r:ncl f rol' :hc Croovc
Bclcasc the oressurc Rcn'ovc l"lc shitillc shar'ir')'v.''r'
nyoraL rC prr-'SS Ani "TCr' :n( clâ3 :,n;
STEP 6
Rcmovo the backinq oia:c
Rcrrovc the sprinq rc:a ncr ::"c scrinq
Don E-85221
kaukazz@yahoo.co.uk
6007-24
powrquadplus www.thebestworkshopmanuals.co.uk STEP 1O
STEP 7
t
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c25427
I r-j-t:l
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Remove the lubrication sleeve. Usc a sharp knife and remove the four sealing rings
STEP B STEP 1 1
ijii:t, qr F.N' it6 c26831

c26929
L ":i:;. ,e"' .#
Use a surtable puller and remove the reverse clutch
Remove the spacer(s) (if cquipped)
pack bearing
STEP 9
W
STEP 12
c2681 9
c27017
Use a block of wood and shock the forward piston out
D^-n',a
J turrruvu
iho
rr rv
of the clutch housing.
lssucd 1O-91 Prinled in England

Don 8-85221
kaukazz@yahoo.co.uk
600 7 , 2::
powrquadplus
13 STEP 16
c27019 ' ':'t:l c27027

Remove the thrust washcr and lirrusi bear rq Rcmovc lhc rollcr bcarings and spaccr
STEP 14 STEP 1 7
\L
:,$.ft:$ixA.i,,
ri:T:!:lil; r;t;f
r.f.._,ii- iir
':1:I:i;:.9;$:r' c27o2s
Rcrnove the rcvcrsc gcar'lrt,b Rcmovc the ihrusl bcarnq and ihrusl wasner
STEP 15 STEP 1B
:i.u
Rcpcat Steps 2 10 4 and rcrno!,c thc rcvcrsc clutcir
oack
)-)
STEP 19
ilcoca: Stcps 5 io I and rcrrove thc reversc clutch

cistcn
c27036
llcr'rovc ard discaro l',c ' ',ar':ic gca'ihuD :.aai
[)on B iJ5221 iss"oc 1C E1
kaukazz@yahoo.co.uk
6007-26
powrquadplus
20 www.thebestworkshopmanuals.co.uk STEP 21
STEP
ffi
tffi's'
1, SEAL HING
''t ' *\,,
,%
1.
SEAL BING
2, O-RING
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Bemove and discard the piston outer seal ring and Remove and discard the inner seal rino and o-ring
o-ring
lnspection
STEP 22 STEP 24
Clean all parts in cleaning solvent and dry with

compressed air DO NOT permit the bearings to rotate
when drying with compressed air ,;1n..,1ir1,1:,r.:,,,
:i,],1'
+, li...l;:,t",i,..,,t.,.&
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STEP 23 '::a:a.i':'l
.:.i:q
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t4,: ,,, l::,
ar:
F*
B08t 1 I
Check the steel separator plates for wear or damage
Replace the plates if the thickness is less than 2.10 mm
(0 082 inch)
STEP 25
8081 16 Itlairy*
Check the friction plates for wear or damage, Replace
the plates if the thickness is less than 2.40 mm (0 094
inch)
Check the shuttle shaft wear sleeve in the transmlssron

housing for wear or damage Beplace it the bore size is
more than 36.07 mm (1 42 inch)
NOTE: lf the sleeve has to be removed use a blind hole

puller.
Don 8-8522.1
lssJcd 10-91 Printed in England
kaukazz@yahoo.co.uk
6407 2/
SHUTTLE SHAFT
Assembly
I. SNAP RING
qrNG *
ian rr_rnus,
I BtAntNc
i 8. THRUST
WASHEB
,,
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,/ Ut ,., .- rsBAcl
BACKTNG
14 r:RrcroN ,i \r:i'
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PL-ArE
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22 REVEBSE \ 1
{*.^N){'r , \ \ 18 LUBRT.AT.N
'NAPR,NG
10 ,(ffi)Y).
'PACER
B i-,HUSf wAs"rER\*--R.-,"4Y \ \ \ \ \ 17 SPRING
. sLEtvE
-' -{<iNr'--z-
s BLAFNG---------),ISY{ \ \ ErHRusrwASHEq
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\t, ,,,*ur'.11t:;,*u'"""
ElNc 1 SNAP Rr\G
-/
6 CIJP
ll.- o c.-aal
kaukazz@yahoo.co.uk
6007-28
NOTE; Eefore assem blinq the shuft/e shaft, make sure
the oit passage ptugs are correctly installed tn the ends
of the shaft. Use compressed air to make sure the oil
passages are clear.
NOTE: Lubricate alt pafts with clean Hy-Tran Plus

lransmission oil before assembty. Put the seal rings for
the pislons and shuttle shalt tn warm Hy-Tran Plus
transmission oil for several mtnutes to prevent damage
during assembly
NOTE: Lubricate the friction p/ates in clean Hy'Tran

P/us transmis sion oil before assembly i']:'r::
" ,d3;,,',
4. t',
STEP 1
ffi,:.lHr -
1, SEAL RING
' î:
,%
\ ,ff:;
2. O.RING
}t+
o10
new lnstall the fon.vard pislon into the forward clutch
Lubricate and install a new rnner o-ring and then a
pistons housing. Make sure the grooved side of the piston is
inncr seal ring onto the clutch
facing iutward. Carefully push the piston into lhc
nousing using even prcssure lf thc piston iocks up
STEP 2
during installation, remove lhc prt;lon and install again
Nevei use {orce to correct wrong allgnmeni of the
piston.
2, SEAL RING
srEp o
1. o-RlN
/ i',i,
011
Lubricate and install a new oute r o-ring and then a new f,

ti
inner seal ring onto the clutch pistons 3,'
t{ r$"
#
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lnstall the lubrication slccvc
lssrod 1C-91 Prinied in England

Don 8-85221
kaukazz@yahoo.co.uk
0C07 2!r
powrquadplus
5 STEP 7
ry
LUBRICAT]ON
SLti FVE
5. TAPEREi)
SEAT
n T* *
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60076
r'
Rcrnovc ihc lubrrcalron s/ccvc and install thc sf:,.:
#,, c,2atll2ii
.,
PISTON
dclcrrrincd rn Sti : (i
tolc :ho lubrication !: ccvc rrt"i'\. ai!ar.si :hc iapcrcd
sCal on l"rc shafl I'lcasLrrl trc C't: i)aiwac- '' c it,slor) STEP B
and slcevc io cclct'^ '.a ia'c..'. i r' .,or ";t',. . ::, .CVC
spaccrisi 'rrckncss 'llii
STEP 6
USC ihC Char: br:lOr^r ii.; i r-1r 't.i oorrccl sDaccrisl

].CCU Cd
llr-ASl-lil. ) i;: ir ;jl l-

GAP sjPACaR(Sr
TFiCKNESS
lvllv1 INCI i INCi-

445 1.c467 0 17 :o C lU:i .tr aa: ) : '67 irsiall thc lubr cairor: sr'cvc anc ,Jccai Si,,,. .,t:n:t,'
41:9 \a442 0 165 :o 0 179 I l.lI .. 157
39,ii0.;17 0 !5: ',; , le-,1 -) NOTE -ite Eaa " r . .'. :,.
3 68 io 3 9l 0 l4o 1o O 154 ., )[.r ., ;3il A 0C27 lo 0 032 tnct .' l' (., .l.rl-l
343ic365 0 13o lo 0la4 325 0 .28 I'lt- t'-Pr';r11',t, .',:t'.' : ' j '- <t :
318io340 012c io O 134 300 0 i 18 aro 6

2 92 rc 3 15 01li)rc0l:24 0 l,l8
26/'c?90
241 'c:;264
0 10.: 'r
0 09: 'r: 0 ii'l
f) : 1,1 :)r
.,2:r
' r r1)u
i'08sl
srEP e
,iitli
216ic2ll9 0 ()ll'r 'a (l r):: i I7ar
191 :o213
165:c188
0 07:
0 065
'o 0 rl6a
lc 0 074 :50 0 059 .dffi
.e, ffi
l38to163 0 054 to 0 064 1?a 0 049
121 ta137 0 048 to 0 053 100 0 039
084ic119 0 033 io 0 042 '.7a 0 02!l
0{i7re083 0 002 to 0 0lJ2 \O SPACEC
NOTE: Soacers are avarlaDle,o .s zcs o/ ii nn', ' A(')

mm 12tmnand225mm
o26933
.ll(j s'.)rrno r(li:l ",1'
D.i I 85221
kaukazz@yahoo.co.uk
6007-30
STEP 1O STEP 13
:M::i$,:
i.-,.
,$i.r.t11
i[ t B{+t
,,{
,.ii'u'
A
t*
$i*
c26936 c2691 I
install the snac r lnstall a frictio orward clutch hoLtsinq
STEP 11 STEP 14
Repeat Steps 1 2 arx) 13 urriii six separator plates and

six friction plates havc been installed
NOTE: The last ptate installeci must be a frictlon plate.
STEP 15
1992 and compress the 0iston return spring until the

bI
snap ring can be installcd rio lhc groovc bT
i-
i
.$r t.m
ffi
STEP 12 i$
t*
Bl E:$li
n"tl- EE
t,
lnstall the backinq plat
STEP 16
c2691 6
fonarard clutch
.. -i,,
-;
p!1
'. i c2691 0
I )
lnstall the snap rin0 rnto thc groove
lssued 10-91 Prilted in Lnglano

Don 8-85221
kaukazz@yahoo.co.uk
6007,3 1
STEP powrquadplus
17
STEP 20
l?cpeat Stcps
STEP 18
1 to 16 lor thc r'cvcrsc ciuich pack
ru
c27cr36
Inslall and lubricate a new rcverse gear/hub scal
STEP 21
c27A31
lnstall the thrust washer 1 ,1;
'#
STEP 19
;ik
a:),
2. SPACEI] 'i, 1, ROLLER BEARINGS
2, \EEDLE BEARING SIDE (OPEN)

c27027
lnstall thc rollcr second rolier
bearinq
STEP 22
1, THRUSI BEARING
\*
,}i"d
h
\1"
lnslall thc thrust bcarrng l,/akc surc thc opr:n srdc c1

'nc DCaring 'aCCS lowa'Cs 'f'C l'rrJSi waSnC.
Align the iriction platcs and inslall the reversc gcar/hub
Make surc ail the frictron olalcs engagc onto thc
gear/hub splincs
Don 8-8522 1 issucd 10-91 Prinl0d in Enolarrd
kaukazz@yahoo.co.uk
6047-32
STEP 23 STEP 26
LZ tttJ
lnstall the thrust bearrng Make sure the open stde ot Heat the reverse clutch 5;ack bearing in a beartng oven
the bearing faccs towards ihe thrust washer to a temperature o{ 150'C (302' F).
STEP 24
'
.
,
STEP 27
T#iipF#j:,
i''l#:r:iil: :
'::'"r
\l1.:rl,i:.,;
c27A19
c2701 4
lnstall the bearing onto the shuttle shaft Make sure the
beari^q rs against tnc snaP rrÊ
STEP 28
2. SEAL RING
i*d'
;x,! ...
, INNEF GROOVE
iv
"1 # S$#
I .; It:
llt I
c27017 @i
lnstall the snap
SEAL EXPANDER CAS 1999
c25431
lubrcate a new seal ring wilh clean transmrssion oil
Use the seal expande r CAS 1999 and install the seal
ring into the tnner groove on the shuttle shatt.
Don 8-85221 ,ssued '10

91 Prinled rn England
kaukazz@yahoo.co.uk
600 i :l.J
STEP 29 STEP 30
{,;
,k
9r-"
sl
.\
't '&' -/
1. SEAL COM PFESSOR
1 cAs 2005 1 cAS 2005-1
600726
c25437
Turn thC SLlaiCorrlli'cs:;c'round and push ihc Cii'cr cnC
ol il"e ccmc.csscr ovcr :hc scal agatn and 'cn'ovc l"rc
scal corlprt:ssc,'
STEP 31
Heocai Stcos 28 'l 30 'or ihc rcmainrng sc^r r'':ii'i
NOTE : (.nsil,1, |i't21 new sea/s are no! lrt,stt t1 :;'

danagei A.o ate frei: io ttrn tr ihe gea/e-<
SEAL COMPRESSOR
cAS 2005-1
c25437
Coi'rrprcss thc scat by irand in lo the shuitlc shaft
r':r'rg
qroovc, thcn insla I ih6 i;931 comcrcssor. CLS 2005 1
onto lhe shrrillc shaft Pi;sh thc scal comorcsscr over

:hc scal ring wrth lhc icng chamfer lovrards lnc scal ring
NOTE ; Only by usinq the seal compressor CAS 2005-1

can the seals be cornprcssed to the correct working
S:Ze
Don 8.85221
kaukazz@yahoo.co.uk
)4
Cross Sectional Drawing of the Shuttle Shaft
1. SHUTTLE SHAFT
13. SNAP RING
4. FORWARD GEAR
14. THRUST
5. THRUST WASHEE
13. SNAP RING
5, SPRING RETAINEB
7, LUBRICATION SLEEVE
8. PISTON
9. SEAL BING
9. SEAL RING
10. o-RrNG
sEALRINGGRoovES
),,
11, SEAL RING GROOVES
kaukazz@yahoo.co.uk
600i 35
PINION SHAFT
lnstallation
4. BOLT
6. PARK
BRAKE
HU8 5 GEAR (4WD)
8,CUP
12. 4T11 10, THRUST

GEAB WASHEF
.1
1. THBUST
BEABING
15 HUB
10. THRUST
WASHER 7, BEARING I
I
1.1 . THRUST
BEARING
r ] THRUST
-\ .BEARING
10, THRUST 13, SPACEE
WASHER\ I 7 2ND GEAR
14 SYNCRONIZER
9. SNAP R,\G
r 4 SYNCRONIZER
\ 16 3RD GEAR 15 HUB

\
9 SNAP RING ,]
10. THRUSI
18, ST
uc WASHER
19 NEEDLE {triJ-\1 '.
BE AR|NG l-\) 1 1. THRUST BEAFING
Mfl
1 1 THRUST
BEARING
2- SHIMS
tu*ooo''o
\*\ .-
1 1. THRUST BEARING
13. SPACER
1O THqUST WAS'IER
\ - BCUP
7 BEARING
20, PINION SHAFT
Dcn 8-8522 l
kaukazz@yahoo.co.uk
6007-36
IMPORTANT: lf the original pinion shaft and crown STEP 2
wheel are to be installed, use the origlnal pinion beartng
shims removed in Step 3.
STEP 1
1, DI MENSION
ST AMPED HERE
\-
lf -
"- ;;-.)
l,/
lnstall the required shim pack deternrined in Step 1 and
,", [] install the prnion bcaring cup into thc transmission
'\-=Jr housing
STEP 3
ffi
s
c26719 ,.-g|?6t24
To calculate the correcl prnion mounlrng orslancc shinl lnstall thc prnron shaft into thc transmission housing
pack. sLrbtract the din ens on clchcd on the crown and block thc pinron shaft rn positron w th blocks of
wheel from the dimension stampcd on the transmission wood
housing and then subtracl the bearing groMh constant
of004mm STEP 4
Example,
Stamped transnrtssion
housing dimension 181 46 mm
Etched crown wheel dimenston 179 86 mm
Bearing groMh constant . .. 004mm
] SHOULDER 2. BEARING CUP
?equ,red shirr pack 156mm
a BEARING
<rn\
N\S CARRIER HOUSING
rs\\N//
t\l
Is,_-sr 6|fr7 12
l{ the pinion bearing cup has been removed from the

bearinq carrier housing install a ncw cup into thc
bearrng carrier housrnq Makc sure the bearrng is
against the shoulder
Don 8-8522 1
lssucd 10 91 Prrntod in Ergland
kaukazz@yahoo.co.uk
6t)CZ 3 /
powrquadplus
5 STEP B
',&e'
$
'"4$c
:ft- rr
Ni
,,i.l.i
.. 1'&
,' {
- i"*4"" *.u. &
"".,
-&n
,& '.#
"\ \ ffi qBffiffi
d '@ .'.,,,
..i
f
i
&
,iitr^ &t &.* ffi
ffi* czscos
lnslall two I6rnm ajign-rent stuCs, CAS '1995 r.to ihc Instalr thc rnasicr bcar rq cc"c CAS 2a24 ::,t' 'r,i1
transrnissioi' rousing lnSiail tnc liftrng brac<c:. (.;îirr Drnrorr shafi
1993 and surlablc lr'i rg cqL, orrcrrt nslali :iri: i-r(:i,r, :
carrrc.l. nouslng STEP 9

eq.
..- #l1I :.
STEP 6 ffi #i,ii,,r
tc.
p l!.e t
eM.i
il i;s{
'& ffi-e
:rri
dFB.qe.*-s
@s.
p&
&
&
a::i
'ile :'
J
/ ts&,
v
lrc.:t .rn rt).1.\.\l\1 ,' r)-,

c?p201
Insla I ihe .nounling i-rr,'l1s and hardc.nec vr AS NCTS
STEP 1O
.i
STEP 7
=i t s\l
p
in
't o
. MOU\TING
/e AnlT
s.*4 I, /"&&*^\
.{'iq
-.
+
ft
&
'6
fff$n,%
'i* r lj
w
t.,, &
&
e\1 dBffi
.w.ff e
ffi' 66 , %
j
-$*r,
$ C2A334 lnslali lhc s0:t. :t',/,'asâ)' IAS 1998 a.C .roi.rnirng scrcyi
Bcrovc:hc lrfiinq br.rl<ci []Ail '!l!13 .l"il trgi':,.r'r:r1l artll lorqLtC :i a: ,rc,,,.1 " j S(lrrl\r :l-'lCr(1,.;. :l'20 \:-' lB0
:h.aa.rc.,nlrnoi_.o11s.... j ]a.r).ti_..,?ll5 lCt.)05 \lr^ ,1.1.1 i: :.)
:o r95 ;b it)
kaukazz@yahoo.co.uk
6007-38

STEP 11
Remove the block of wood from the pinion shaft. Rotate Remove the bearing carrier housing
the pinion shaft one revolution and check the mounting
screw torque. STEP 17
STEP 12
Bepeat Step 10 until the torque remalns conslanl
STEP 13
2. SPACER
1Pl NION 3 SET UP WASHER

SHAFT
CAS 1998
/
ct3a15
lnstall thc ih ck thrust washer thrust bearing and
5. MOUNTING
second thick :hrust washcr
BOLT CAS 1998
STEP 18
L 60071 3
Using a depth gauge, measure the distance from the

face of the setup washer to the pinion shaft through
both holes in the setup washer to calculate the shim
pack thickness.
NOTE: lf the measurement beM/een the Nvo holes rs

mm (0.002 inch)or /ess, lrse lhe average ol the Nvo
A.O5
measurements. lf the distance is greater than 0.05 mm
@ 0A2 inch) drsassemb/e the pinion shaft and check
the beailng seals and check for burrs or foretgn
fo 70.
material, then repeat Steps 2
lnstail lirc :uro necdle roller bearings and
STEP 14 spacer to thc crnion shaft
Subtract the set up washer thickness from the average STEP 19

measurement obtained in Step 13, then add 0 043 mm #ffi
,F W.i ",
(O 0017 inch) This will give the required shim pack

thickness to give the correct pinion shaft bcaring
preload. Make a note of the shims required.
STEP 15
Block the pinion shaft in position with blocks of wood

Remove the set up washer, spacer or MFD drive gear
and park brake gear hub
j'i.a,',oa&
Install the first gear
Don 8-85221
lssucd l0-91 Prinled n England
kaukazz@yahoo.co.uk
6007 :t!l
powrquadplus
20 STEP 22
i, Ti.,1RUST
wASHHTtS 1 I']TCFSS
rn-s:;ll a:hin
wffi
<.t:. '//'
iirusi \vasthcr "I:.s:

s$s#F-
.
*MM
-tsBti!l fla
:rcar:
,.ir'. .: $ ffi
ffiffi #ffi
"q llic'T :,1 s caor:l
:nrn:niusl \.iashcr
STEP
,S ffi
21
i1!i;,*1i
ry
l.1r';1 lhir i ,'.,-'rl
s,.,Ii-'a.'aar
:rslall itc srap lnc STEP 23
ili)" rrrr):'.. : l',-)"' " i. ' -.:' ,rlra'i
STEP 24
$s.'r
',1
" l
LUBRICATION TUBE
tr*
I LUBFICAiIO\ Iiitir
l.'
STEP 25
'1. ,:
Oc1 t'E522' t:ti,aa ll !l
kaukazz@yahoo.co.uk
6007-40
Synchronizer $himming Procedure (lf Equipped).
STEP 7
STEP 1
Using feeler gauges take three evenly spaced

lnstall items (1 to 16) Refer to pinion shaft installation
,"rlur*rn.nts (B) between the synchronizer assembly
Steps 1 to 25
(32) and the shim (33) Use the table below to
(31) and (33)'
determine the tolal shim pack required at
STEP 2
lnstall items ('17 to 23) B
required at (31) required at (33)
(mm) (mm)
(mm)
NOTE : tnstatlO.5 mm (0.020 inch) shims (17 and 19)'
STEP 3 upto050 05 NONE
the
Push the second gear (20) rearwards to elimrnate 051 to0B0 075 NONE
space between tne tst gear (10) and the-sy.nchrinizer
assembly (18) then putitne 2nd gear (20) forwards 081 1o130 05 0.5
STEP 4 131 1o150 10 0.5
Using feeler gauges take thre e evenly spaced

151 to200 125 05
*nrirrur*nts (n) Oetween the synchronizer assembly
(18) anrj the shim (19) Use the table belovr to detemine more than
totrt shim pack required at (17) and (19)
it-," 200 10
'1.0
fotal Shim Pack Total Shim Pack STEP B

required at (17) required at (19)
(mm) (mm)
(mm)
Remove rtems (39 to 17)
up to 0.50 05 NONE lnstallation
051 to080 075 NONE STEP 9

* iffi
081 to 130 05 05 #;i
131 to150 10 05
#&
L
I r st to 2oo 05
I
I more than
10
I zoo 10
STEP 5 fl *d +CIzs83z
lnstall the synchronizer assembly with the shrms

(i1
lnstall items (24 to 39)

equrpped) determined in SteP 4
NOTE: tnstall0 5 mm @.020 inch) shims (31 and 33)' shtms were
NOTE: Only rnstatlshims rl rn disassembly
removed.
STEP 6
Push the 4th gear (36) rearwards to eliminate the space

betrrveen tne SrO gear (26) and the synchronizer
assembly (32) then pull the 4th gear (36) forwards
lssued 1 O-91 Pr nled in England

Dor B-85221
kaukazz@yahoo.co.uk
6007-41
SHUTTLE SHAFT
@.-\6a
@-1^@P) 4
@- q.Wft. 'fr @
@
\J|N%)}{Y
GW
.\
-_,-"-,@-
\)@-,,"2P'-\,ffi
.'u)\
:\'-' ---@
/
\@
@ .^l
\b_
o.* \o
I
l/
sM0s89
1, PINION SHAFT 1.] . THRUST WASHER 21, THRUST BEARING 3.1 , SHIM
2. BEARING 12. THBUST BEARING 22 THRUST WASHER 32. SYNCHRONIZER
3, BEARING CUP 13. THFUST WASHER 23 SNAP RING ASSEMBLY
4.,SHIM 14, SNAP RING 24, THRUST WASHER 33, SHIM
S IRUST WASHER 15. HUB 25. THRUST BEARING 34. THRUST BEAEING
6. THRUST BEAFING 16, IHF]UST BE,AFiNG 26, 3RO GEAR 35, SPACER
7. THRUST WASHER 17 sHt[.,l 27. THRUST BEARING 36. 4TH GEAB
8. NEEDLE BEARING 1 B, SYNCI.]RONIZER ASSEi/BLY 28. THRUST WASHEB 37. THRUST BEABING
9, SPACEB 19. sl-llM 29. SNAP RING 38 THRUST WASHER
10. lST GEAR 20 2ND GEAR :i0 HU8 39 SNAP RING
Dorr B 85221
kaukazz@yahoo.co.uk
6007-42
STEP 1O
ffi-
f;
B ..1
ffiti
ffi
iiil
OIL GALLERIES
2 WEAR SLEEVE
/
60071 1
11 the shuttle shaft wear sleeve has been removed,

install a new wear sleeve. Make sure the holes in the slide the second gear along the pinion shaft until tl
wear sleeve are aligned with the oil galleries in the locates wtth the l st and 2nd synchron zet geat
transmission housing.
STEP 14
STEP 1 1
4 TRANSMISSION
l,@ sx
HOUSING
urourrr
rT# ;aiiit:
1. THBUST WASHER
2, WEAR SLEEVE
3. BEARING CUP
-a/D// 2.THRUST BEARING
,e238:18
"/l 600724
tiili:* ii;im:!'Ti1i::'l:r'r ::i:ri7,r$,wB?,
lnstall a thrust washer Ihcn a thrust bearrng onlo the

l{ the shuttle shaft rear be aring cup has been removed,
pinion shatl
install a new bealng cup Make sure the cup is against
the shoulder STEP 15
STEP 12
& Wr
1, GROOVE
,,6hgatr
@t1. .w
lnsta I the snap ring into the groove
lnstali the second gear halfway on the pinion shaft as

shown
1sslcc 1O-91 P'ntcd lr England

Don 8-85221
kaukazz@yahoo.co.uk
6i
STEP 19
,--,.-^"s
1 :HRUST WASHER d$$wr\
:qe ,.ffi
;*i-
.w .ffigr*
,,:rf, t:*:' #
2 THRUST BEARING
r-# ,-ti
>iB
r3:*@#(* -#
STEP 17
!?6.-*
&
&.
ffi
srr'
':isF
ci3812
sIf t,2l
rr"iit' SEAnl\c
.i'ffi"
fcn il 85221
kaukazz@yahoo.co.uk
6407-44

STEP 22
i{
&r
t\
lnstall the synchronizer assembly with shlms (if lnstall thc snap rinq
equrpped) determinied in Step 7 on page 40.
STEP 26
NOTE: anly install shims if in disassemb/y shims were s': ..1;
remaved 1. THRUST WASHER 2. THRUST BEARING

ffi-r:i. tiw: .;r
3. NEEDLE &
STEP 23 BEARING
::s
*
I r:i:
{,!A
ffi
ffi
,ffi
(t:: )l'
lnstall the shuillc shaft thrust washer, thrust bearing,

ncedle roller bearing, spacer, then a second needle
bcaring
lnsiall the {ourth gear and spacer NOTE : Make sure the open srde (rollers) of the thrust
bearing gc towards towards the thrust washer
STEP 24
STEP 27
.,,t,ffi.
.r"l:ij".,..:x^f;. ,..:. : ,,.
t: :ii,,i,,,.i.Wit: ;j:.r
y1.,:,,,,
. t-.i - ji :i!ari'
,: :1,. .
"''1.'' : :'ir"1'gr
."k
l
'a
4^
d,
^/&
TH RUS T
q '"^d
F,:.
s .ffi F,, C23532

lnstal us1 bcaring and I'rcn ath rust washer
lnstall a new forward gear hub seal
Don 8-8522 l lssued 1O'91 Prlnted i'r England
kaukazz@yahoo.co.uk
>t
it
l,/
I
Iti
t)
lj
. Y-
I - ----:-'
o'"-----! .l
t
\r\t---
&
.t:r i?6
A rl, ' :ti-ral'r a)..laf DCar nq rr
i :.., ln, :
NOT{_
on lat :" "',:
STEP 29
2 i HiUST V\'ASli!irl STEP 32
.M.;
{W'!s^ffi
W
?*l' o 'o*\ , .+'t KW'
-/-*
1 THRUST BEARINC
t
,, &;{,.
lr'a.:ii . r
NOTE
[t€;;'' :
STEP 30
#-
" R}l
.T
,.1
instiat i ,
Dor u rj:rl<
kaukazz@yahoo.co.uk
6007-46
Cross Sectional Drawing of the Pinion Shaft
FIRST
4. SECOND GEAF
/ 5. THIRD GEAR
/ 6 FOUHTH GEAR
(*ft* / [- PINION
\ \
2. SY NCHR ONIZER SYNC HRONIZEH
600731 A
lssued 1O'91 Prinled in England

Don B-85221
kaukazz@yahoo.co.uk
600/ -4 t
GEAR SHIFTERS
lnstallation
t- S'IAFILEVER
,!\ -." ,'1-y'
\_., i\\ so.RrNG
,o ,*ren,-5cx tJ"-.-
) i'f
. les
aranr,rc \
o6,i*;'.'u*
\(.)^
,t)\\ 28 sNA, qt\G ^ )
'/ ]O NUl
;U4?{
HOUSING
.18,
l STi 2ND
SHIFT FOFK
39 NUT
38. SHIFT LEVEB
Don B'8522 t lss,rrr; r0.91 ).rnlOc 1[rgard
kaukazz@yahoo.co.uk
6007-48
STEP 1
3, BUSHING
2. LOCK NUT
1. o-RING I
I
I t
1. DETENT HOLE
/
BUSHING
\ /
I
+
,,1=
\ss#rrt
, q
ffi
//,/////
.,/7ttt ,,
W 600727
Lubricate new o-rings with petroleum lelly Inslall

the
c27135
lock nuis and o-rlngs onto the pivot shaft bushings
e'" EP4
!irt,
l.:w
C27210
from the
lf the shift rail bushings have becn removed
driver and install
bearing carrier housirrg usc a bushinq
new bish ngs Make sure thc holcs rr^ :hc bL'shtrgs c2ffi
align with ih" d"l"nt holes in ihc bearrng carr cr '"'lnc'- v.
lnsial, Gt/Zno pivol shaft bushing rnto the

housing no
transmtssion hoLlsrng Turn the bushing clockwtse
n orc :'a- Iwo fLll i.,rrs
STEP 2
STEP 5
.\
tr
_ffi
""w
c26904
J
i
i. ..
I ubricate the new o-rings with pctroleum lelly lnstall
the o-rings onto the Pivot shafts lnslall lhc 1st/2nd p voi shait rnto the bushtng
10 91 Prinlcd in Englano
Don 8-85221
kaukazz@yahoo.co.uk
ii( jal: r1{ri

STEP 6
ffi
1
q
l/
'r/
rtf
?1 qEEAl) ry
t';
lrw
I
I
I
)
3 BIJSHING 00c7?'A
i.L,,l. :ftt: i)t,:jntr:(; (- . i.tk!'",:j(l llri.t ::'. (,1:j Oi :'l(. rl:.i:.1 l,rL
l)r.ril'lg '.)(r!,rlS, i(l :r'rir'v !ri ll: iilr) ilr.; (-,' ItlL
:rarlsrlSsr(lai flOirs|rir lila-'':.il , l_ I STEP 1O
oi,sirinr.l lvr I bC mAar{r r. S1i:o i:r
STEP 7
;l1l1t;tl S i;t_tS .l :1; ai 'i_.

,t . .\r..,
'.'l'r 3: ;'._'r
1
'() a)l
U|VO' S|ai'
STEP B
1 sl Jtrl SAtL
& *,"t 'cl#s*$d' lr ts',, "-,il l] :ri

w#
{*
"1- // STEP 1 1
2 ]ETENT
"#
c27 134
' rlC'"! Sh li ,arlS a'rc (1.:rlorri!l ilrC l() [)r] 'rl::allcd ..lsal a.i
Oarr Cl Snar) rrnq lr t(1)'(: il'l,l r''r: I {ii' 'r'', r)r':(--, I'l{'
shr:t rai s
NOTE: DO tttat ,,ock i::r,: ::a')tCr.is ).1

i.)-r: t)(: ad, .:,!(.;o i/n(. 1'
36,fgr)fS
,i)or.si,'r g'.s r.lslal/c-(J.
SuDpr:l 1t:c shrrl tcrks n t)o.-srlion anC lns'2 'l-' 1
sf i rari Makc sL;r'r: ll-16 5.'i 'ot<s aro I .'
/a.i,. aj!::ia':.
kaukazz@yahoo.co.uk
6007-50
STEP 12
2. SHIFT FORK
1, INTERLOCK PIN PIVOT SHAFT
. ',/
tVt/,/,/)
,/,.1
,/,/,/
1
)
p
!
lL-,'\
3. BUSHIN
l"
.OCK NUT
TOl .O MM
TO0 04 rNcH) ll_ 600721
lnstall the interlock pin into the interlock houslng Turn the 1st/2nd pivot shaft bushing clockwise until the
bushings, pivot shaft and shift fork are in contact
STEP Turn the pivot shaft bushing counter clockwise unttl a
gap of 0 5 to 1 0 mm (0 02 to 0 0a inch) can be
measured i:etween the pivot shaft and shift fork
T ghten the lock nut
STEP 16
Repeat Step 15 for the 3rd/4th pivot shaft.
&. STEP 17
Install the 3rd/4th shiit ratl
NOTE: Make sure the allcn screw delonts cn lhe sh/f

/clces tA"^/atdS tre 'oD lr fhe I?rS- ss lr
IOrr
l&r
ST EP 14 u
l:r I
,|)
?
g, 2. LOCK NU ,:
q' i , l&E;j ''.'''

+#
,
?
:ir1
lnsrall rhe shift levers onto the 0ivot shafts align the
ffi
I
!
marks made rn Removal. lnstall and tlghten the
.\ r4
clarnoinq bolts and nuts
#l
1
*
2. LOCK NUT
1, ALLEN SCREW
&Iffiwffil @i"f:l:
Alrgn the allen screw detents on the shift rails wrth the
holes in the shrft forks lnstall and tighten lhc al en
screws and tlghien the lock nLlts.
Dcn 8-85221
lssucd 1o 91 Prntcd in England
kaukazz@yahoo.co.uk
powrquadplus INTE
RM ED IATE SHAFT AND BEARING CARRIER HOUSING
lnstallation
STEP 1 STEP 4
#
j,-..d d -
,,. ,:i*
d*
ffi
ri'll:::rs
iliii+''
15
Clean thc iaces oi rf'r hc 600729
bearinq carrrcr ho,,s -rr-l
STEP 2
rffirB
M,w
.w
# m
&
,#i
Acl;iy a Coalrirr,!i..:j bcar.i O'iociric Claskcl [:]r,' rr,r'r.
31 7555 :o ir{_i :riir:SrT. itlt(_.r ' , , . )',-,a,. .,
1o8405
lnslal at .rciv scal ring STEP 5
STEP 3
tr
s
.,i
I
#
W e:{ry
W,r, Fr PoFr i
3 LUBAIC]A ]'iON PU[,l']

, ,
.J
,'ds
s:'.a
lnslalL a nCV. :- "'! ,.ia lirr rrlDr 0;i:rCf- t...i'-f :
l-DIiCatC ihc i-r-',r :; \.\,tl irclj':) i)1.,'r' Ll
ll.n 8 E52:r1 ', i I i
kaukazz@yahoo.co.uk
6007-52
STEP 6
'' 't:i 7:=i\.

'1;
1r,i
t..1.
t
l\m1a1 :::i ]te *q'},ll
lnstall the intermediate shaft lnstall the bear ng carrier mounting bolts and new
hardened washcrs Tighten the bolts to a torque of 235
STEP 7 to 265 Nm (17 4 to 1 95 lb ft) Remove the lifting bracket.
STEP 9
' " *; , ili.",

lili"r+iiil;rl:i
q
*9
lnslall two 16 mm alignmcnt studs, CAS 1995, to the
transmrssion housing lnstall the lifting bracket CAS
'1993, and suitable lifting equipment and lnstall the
Heat the pinion shaft bearing in a bearing oven to a
bearing carrier housing Make sure the chargc/PTO terilperature of 150"C (302'F)
shaft coupling is installed to the lubrrcalion pump J''vc
shaft
IMPORTANT'. Make sure lhc lubncation pump inlet

tube locates correctly into the charge pump tnlet port
lssued 1O-91 Prinled !n England

Ilon 8-85221
kaukazz@yahoo.co.uk
600 / i)3

{ tr-" 'q
,;a.i-u:li'
a"
q
>r**
, ts /tr-"r )\
"
,8_ -r
-.ro -,.'-\
{ .r
_ t'-^ "t"f
a "ff. .\
,:j
I
lrXe
'*r' r*:i' r
* 'q'r I
&qht
,:)?r*
lnslall thc Diiion shaii bcarrnc; onio ihc prnion shafl

#*.{h
&;66r#
d
ffir*
Inslall ihc sirirrrs iCctcrri. ni,'d in S:co 14 p ^ 66 $1-3r: ir
stailalron) orrrior sira'i washcr and oolt I3i1r1;r' 'r

.)/,/ rh;tr
SIEP 1 1 Doil to a lcrcir l;'335:o 3/5 Nm (247 io
NOIE: Sreps l.l lo 21 wrii nol be necessarr / lne <n,tlt';

iI r:! rvrced
snalt haC been se
STEP 14
${i r'rr
""S-_**e^.
CI i \,.:::1/
i,ti::t. )
I
\ i$f ry
p
{
.P*
I ;fr
lnstall :hc park ng Drakc qtlar hub, wiih lhc chan'icr
iacing oL';i
'G ..*S1'
"Y.'
,,"}
STEP 12
R r*t ''- $h c2661,1
Ls -l-s:'g
,
$,.
r ffigs';f lns:all a dra gaLigc io:he ceartng carrer ar-r-i
w&i
'iffin
' oosit,on the c,ungcr on :he end of lhe sirLii:e sfraF:
Push the shafi iowarcs tne rear oi thc iran:;'rrss o' ,ir'r(.'
&
$mi'
d?--'..''\--i
J' t--
toro,hr,.l,,t fl2 ,ri Q.r.ai! a,td OUI rl,lc girliri ;. .
arrO r'rO:C lirC '^',1,.0 gr: ihC rjai,g(l
.
--
ie1;"*-- t''''*
.s "&T& -r r ; STEP 15
h,,, : Sr..,btraci 0 CB rrrr (0 C02.1 ;rrch) irom :hc cn.: pt;.,

.t j s * n casurcd n Slep
oack
l4 lo oclcrrnrnc :hc rcqu,'cd sir :r'
";
insta I lne spacer cr Vr[)
ffi
tir r.'c qcar
c,.os7
fon 8-8522 SSrC.i 'C-9
kaukazz@yahoo.co.uk
b
it
7,$::\ x
l: PI
\'!b
%"r
fl1 \.'"
\\ *.
'5
i --{6&r-
4 "&
,'@, .'C26818 & ."&
lnstall the sPacer
#*ffi\
Rcmove the snaP ring
STEP 20
\
.s?. c
.ffit
'iffi.
-w*l r
'9*s I
Bif I
\
, \. -- "s
"Remove'sthe sPaccr"rf.ffi
,/dFh c26620
lnstall the snaP rlnq
NOTE It may be nece ssa0/ 10 use a beartng driver to

STEP 18
Y::.. push the bearing cup furlher tnta the houstng to enable
& & the snap ring to be instalted anp push the beartng cup
into the housing far enough to install the snap ring'
km
w':\
Y{ STEP 21
".,,1
:fu dE
Bepeat Step 14 and check the shuttle shaft end play
The ond play must be 0022 to 0102 mm (0001 to
e,v' 0 004 inch ).
t\
NOTE: Steps 22 to 30 witl not be necessary tf the
_& inlermediate shaft has not been serurced
NOTE . Hotd the shirns ln position with petroleum

plly to
prevent lhe shims dropptng rnto the snap rtng qroove
lssueC 1O-91 Prinled 1n England

Don 8-85221
kaukazz@yahoo.co.uk
60L);':)
STEP 22
w"
STEP 26
u.#ffi
-',"
'-.!.
j.
.::-".. .
' "6;y'
tNils
qb
.Wffi#i
_,,,^^,ll{M^
pssffir
.\
I
WN]],,
'''S\ss\j r: \'
nLl: rnlo thc

ffi&zq
cld ol
ffi
Hor'r,,'vo :irc sDacr-'r
lnstall a I0 mm bolt anC thc
.ticr':-cCiaic shafl
STEP 27
STEP 23 ,?
on
lml*: '1r.
dille\++.''1q))S'. - \.-** \ t,
t
\
' u*-'mB'*\.-
't' 't
z{
acs&f)
A
q _ tlqFF t:10( i.lcl, ""'-acl . Slc0 :).1

.,
rnsiail a clar gaLgo lil ii'lt: ilc;lr' 'lq :li.irrri
"ti-':
ihc olurrclt:' 3r 1n11 1'111 fl(l3fl l)i,s'' .1r'(l De"
,n pO.S,i,On Wtln , t'
..i-
:Owarf;S :,'C rcar .jl :'lC :'!ir'srilrSlij a)ll , l ,t. i \J
tha a-r.
gaugC rurr: lhc nr: ;t r:t.o1;ia a:c r)i.l :h

and no'o 'he rcadirrc or '-,' .lar.cl
STEP 24
Subirac: 0 06 nrr. 'i 4,

reasurcd rn Slcc ,?'.
%.
OACK &,
W.* -
.n |
t{!" "
STEP 25
&w
s1
s-.
,* _wke-
lns:a ihc s;accr
E
s
i
(e \ffi7,;
E:I
5!\ ...
b
,:J,
..i:- , .
'::iii',i\
_E)
I
ffi.rffi
4,"!ff\W c2g2u
[]ci-novc :i:c snac rtr.g
.) !
[)cr B 85221
kaukazz@yahoo.co.uk
6007-56
STEP 29 2, BEARING
1 1ST/2ND SHIFT RAIL
CAAAIEA HOUSING
/,/
3. BUSHING
F;t 'lj
&
tq
rl'ld
{1
i
. ,b*ffit,,,:,,
4. DETENT HOLE
& Align the groove on the 1st/2nd detent wlth the bottom
CWoa detent hole in the bearlng carrier housing Use a pair of
lnstall the snap ilng snap ring pliers and turn the detent until the groove is
centered with the dctent hole.
NOTE: lt may be necessary lo use a suitable drtfl to
push the bearing cup f urther into the housing to enable STEP 33
thc snap ring to be installed Only push the beanng cup
into the housrng enough to install the snap ring.
njolr;fu
STEP 30 rnt
Rcpeat Steps 23 and 24 and check the intermediatc

tl
:P.' fiwrd
shaft e nd play The end play must be between 0 022 to :
0 102 mm (0.001 to O 004 inch)
NOTE: Stcps 37 to 32 and Slcp u are not necessary if

the shift rail detents are nat to be adjusted
;;4L:
Yry ,E B: ,'ri' ,@Ô8P,i
STEP 31 BEARING
^
lnstall thc 3rd/4th dclcnt bal , sprrng and spacer,
CARRIER HOUSING
1.3RDi4TH SHlFI RAIL
3, BUSHIN STEP 34 .--an-:
%
'{**
j!,
B:"
-:s
1 #@
il
600733 .,*::; @."

effi
/\/\
4. DETENT HOLE s. 4TH RANGE swtTCH HOLE
Put the gear shtfters in neutral. Align thc groovc on thc

3rd/4th dctent through the top dctcnt hole in the bearing
carrier housing Use a pair of snap rlng plie rs and turn
the dctent until the groove is ccntered with the dctent lrstall and lLoilcatc a new
hole lnstall anr-t lghicn tl'le 0lug
NOTE: The 4th range swilch ,ztusl show a parltal STEP 35

qroove.
Rcr;cat Stcps 33 anc 34 lor lne 1st/2nd detent ball
S'TEP 36
Oheck lhc oocratron of the gcar shilters
ss,ed lO-91 Prrnted ln England

Don 8'8522 1
kaukazz@yahoo.co.uk
STEP 37
d.
Fq
i.i:
M a-
,?
&
ffi:ry*W
#.- &
"a"-&
h. & @
..*r'i
&;lit,r;,rW
a Sri!:abiC dr fl ard loc(
P38
t. :,: I
g .ri Wu ##-
mffi;;
qBim:
ffi
'.yF' $
I
L# .c *,
#
"'W- *
&&" n
"o ,.ffit. ! t
.tS [r
rtu ,t ""$
sd- '":.a4s
#
&ln"- -1 f,
i}:v, i6
tf
d
\;.'"s
I
M4 ,r c2921'2
l.lia ihc .1ia rangc swiici- |lo..,i:'ir,
I jrC,l' ' ' :',, rrsia ihc ,ai' '
'.) '-(-. :lrc r:i'roe 30s i.oil ,lVCj cn2;:<l
NOTE : -. 4tb tAaO? :,v.;i:C.' 'al) ,.i"r' t! ',.ta' !a.) Sl,t'!,1,' STEP 45
i)c I
STEP 39
'dB6"q!S, -
B-.-,
hi
;
,
s
.d
r@
E t i
sl
, kd",
,''tt'4;-, r.S.a 'tr.1 .... ,.rl"a a.;". 'tciio'ola'c
,*i" ,;
*c29206
llcrrc,,,t: 1tlg gl qrrrr.gli Sl;CS CAS f 995
STEP 40 For 4WD Tractors OnlY
QC-:';i) :.C VFD C.,.,.: :lat:1. n,t:j :'1"' r-
NOTE. Keap thc snr/n.s l:r:'cl'2' tr':' 2<;'-:6;1nll'1
kaukazz@yahoo.co.uk
6007-58
STEP 46 STEP 49
a}**.]'lrirt::it . ,.: i o1,.;?
5l,,,,&
I, I', @
:, :,;; e..itrlli
: , *F :.1''
lc ,, .i
*&i
c20701 B
lnstall the backing plate, lnstall the range transmtss on to the tractor Befer to
Section 6003
STEP 47
Reoeat Stcps 44 to 46 lo install the Lcli l'land sr'. gear

shaft and brakes
STEP 48
E$"
ffi,
. i, l:iiilrli,
lssucd 1O-91 Printed in England

Don 8-85221
kaukazz@yahoo.co.uk
Cross Sectional Drawing of the Range Transrnission
T )
2. INTERIVEDIATf SI.]ATT
6 END PLAY
0.025 TO 0.i02 r"4M
f-l [. -tr I io oo, ro o oo4 rNCF
i -l[) i, |1l ] n=re n ro pACE i2
1il
/-L-.# ', I
^ t -J
i i
'--l
t ENsPLA\
'
I
<- o 025 Io o '02 \4r'4
:--1
- io oo' ro
o ooa rNcil
r .r: :r : .-,i-l REFEB TO PAGE 54
-J+*_a]*
ti
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\
I t ',., ' ^ssEvrt\
'
-:)-, fl [i5:21
kaukazz@yahoo.co.uk
kaukazz@yahoo.co.uk
Section
6008
POWERSHIFT TROUBLESHOOTING AND SCHEMATICS
For Tractors Up To PIN No JJF1015046
kaukazz@yahoo.co.uk
6008-2
TABLE OF CONTENTS
INTRODUCTION 2
GENERAL INFORMATION 3
SPECIAL TOOLS 3
SHOP EQUIPIUENT TOOLS 4
TOOLS TO BE N4ADE . 4
POWERSHIFT SYSTEM COMPONENTS. .. . 5
POWERSHIFT FAULT INDICAIOR LAMP. .. 6
POWERSHIFT TROUBLESHOOTI NG GUIDE 7
POWERSHIFT ELECTRICAL TNOUBLESHOOTING ..8

Circuit TestinS o
11
Powershift Pressure Switch Circuit Test 12
Transmission Oil Temperature Sender Circuit Test..........,.. 14
Powershift Shift Lever Switch Circuit Test 1a
Powershift Fault lndicator Lamp Circuit Test .. . 15
lnching Pedal Circuit Test 16
Creep Circuit Test 16
Wiring Code 19
POWERSHIFT PRESSURE OPERATING TEST aa
FIVE POSITION HITCH CONTBOL SWITCH FEEDBACK TEST 25
CLUTCH PACK LEAKAGE TEST 26
TEST RECORD SHEETS 28
INTRODUCTION
The powershrft is the system used to change gears 1 to 4 without needing to cycle the inching pedal.
The movements of the powershift transmission lever are converted into electrical signals at the shifter assembly and
transmitted to the powershitt control module. The powershrft control module receives electrical signals both from the
shifter assembly and from the pressure switches in the powershift manifold. Dependant upon the electrical signals
received, the powershift control module operates solenoids in the powershift manifold The solenoids operate the
hydraulic circuits that control the clutches of gears 1 to 4.
Faults in the powershift system may be hydraulic or electrical. Hydraulic faults in other systems may also prevent correct
operation of the powershift system. lf a fault occurs in the powershift system the powershift control module will detect
thefaultandselectalail mode Therearetwotail modes(Drive) and(Stop),intheDrivefail modethemodulewill remain
in the current speed (A) after a change is made to the selected speed (B), this will allow the tractor to be driven to a place
of repair. lf the module detects a fault that will cause damage to the transmission the module will select the Stop mode
and the tractor cannot be driven.
a^^ o ooraa lssued 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
h l''1"
INTRODUCTION (Cont)
FaultsinihepowershitsysternareinoicaiedbvineOolversnrfiia;lt rdica:cr cr'-t- cCCir'rln:i-o.slr.rrre|ica1{r
-'
indicator lamp shoulcl illuminate rvh?n:hi: siarir:'kt:','.,.vrlcl'- rs:.r'neC ic::,i.'CN cosr:!ln lr l-,ere r'-s:r:.'at-rl '
powershifisystern tnclarrowrll ecoiri w''r.r:i)i'i)rJnlt,, slariijd.iorirac:cr9',!.1 :',.racu:lcPl\ i\o'CC,565, '
inching Cedal must bc-. iuli;,C'taicc iC lalcr',:hc crocOCr":i.rysi il :hsr.l S al'a-l: 'r.:i'r) l)ovrcrsiril svslerr'. :fu i.ir:': i"'l
remain illurlinated or will ilash aier ihe enctine rs staried a gear selected and :he rnching pedal iuily cvclec
When the powershifl fault indicaior lamp rndrcaies a iauli in the Dowershi{l sysiem, Jse the appropnate Powe:shr'
Troubieshooting Guide to locate and repair lhe lauii f f.c Pcwcrs:it Troi:blr:s-oc:rnlt G:.i:de Cces rrcl ccalc :r,.: '.'-.; '
the fault may bc ouisrde tnc porvershi'i :tvs:(:,'r
GENERAL INFORMATION
NOTE: Nl electrtcal Checks ,'nus: be nada ,t"'tli- !f,e iraclo' aatt<e': a? hari ie',e: grcurc a'rtft the oarktng brake enQa::r:,
arici the engtne aFF unless othervvlse slale!'
NOTE. Nl c;orriponenls v"'/Ir:s ar:,a.l '.' :r::"r '' ": ' ')t " .''.lt '':..1
(t,"ecx.s are corn r>le-!t:
SPECIAL TOOLS
1 BnEAKr.)UT 3OX . r" ) ADAPTEN. HARNESS CAS 218!

Ftri)- [jS{}O a,n i)ili)(' Frrst []s€rd On Paoe 8
S
3 FOUP EXTENSION TUBES 4 AHL-SSURF. GAI]GE BAR
(From tho hycralrlic test kd 1or lho 510O St-'rros lrac'ltrl rlAS I 0U95
OAS ?C)o!i ; -li, rSe., ,.,t, ;,aqe ,'
F rsl Usod ()n t',rec
Don 8-88a22
kaukazz@yahoo.co.uk
6008-4
1. MULTIMETER OEM 1049 2. FLOWMETER CAS 10280
3. HAND PUI\,1P CAS 10090
SPECIAL TOOL TO BE MADE
. ia"9fqlm-_r
= ._'\
/./
CONNECT TO 3. CONNECT TO
POWERSHIFI CONTROL MODULE POWEHSH IFT SHIFTEB ASSEMBLY
CONNECTOR COMPRISES: CONNECTOR COMPRISES:
CONNECTOR CASE PART NO. 245489C1 CONNECTOB CASE PART NO. 24S88C1
TERMINALS CASE PART NO. 225120C1 TERMINALS CASE PART NO. 225123C1
CABLE SEALS CASE PART NO.225124C1 CABLE SEALS CASE PART NO.225124C1
WIRE GAUGE CONNECTOR COLOUR

PIN OUT
ltl BROWN
,n B RED I
20 ORANGE I 4. MAKE MULTI-METEH CONNECTIONS HERE

cn D YELLOW -_t
r* -/-/ CONNECTOR COMPRISES:
20 E GREEN )q,./ CONNECTOR CASE PART NO. 245488C1
IERMINALS CASE PART NO, 225123C1
20 tr LT, BLUE
-l CABLE SEALS CASE PART NO, 225124C1
1, WIRING ADAPTER TEE HARNESS
Don 8-88422 .ssLeo 2-92 Printeo in U.S A
kaukazz@yahoo.co.uk
6008-5
POWERSHIFT SYSTEM MAJOR COMPONENTS
2. POWERSHIFT
SHIFTER ASSEMBL Y
3. POWERSHIFT
CONTHOL MODULE
I)
*,-4
tfz
4, CONNECTOR L
5 CONNECTOR J
1. POWERSHIFT SHIFTER ASSEMBLY AND CONTROL MODULE

I-OCATED IN THE RIGPT HAND CONSOLE
POWERSHIFT
MANIFOLD \
\
\ 10, TEST PORT NUMBER 3
14. PBESSURE SWITCH NUMBER 3

6, SOLENOID
NUMBER 3 ,,4,,
TEST PORT NUMBER 1
I5. PRESSURE SWITCH NUMBER 1

7. SOLENOID
NUMBER 1
12. TEST PORT NUMBER 2
8. SOLENOID 16. PRESSURE SWITCH NUMBER 2

NUMBER 2
13. TEST PORT I.iUMBER 4
17 PRESSURE SWITCH NUMBER 4
9. SOLENOID
NUMAER 4
4, POWERSHIi:T MANIFOLD
LOCATED ON TrlE RTGHT-HAND SIDE OF THE TRANSMISSION
Dcn B-88a22
lsSueo 2-92 Pnntec rn u S A
kaukazz@yahoo.co.uk
6008-6
POWERSHIFT FAULT INDICATOR I-AMP
The check powershift fault indicator lamp is amber and will illuminate if there is a fault in the powershift system
The powershift module controls the operation of the powershift transmission. When a fault occurs the
powershift fault
indicator lamp will illuminate. Also the module will give an indication to the nature of the fault by flashing diagnostic
codes on the fault indicator lamP.
When the powershiit indicator lamp rs illuminated, hold the inching pedal f ully down and count the number of flashes on
tne fault indicator larnp.
NOTE: For tractors with creep up to plN No 1005652 the creep lever must be held in the intermediafe posltion (A). Refer to
fig 2 Page 7 while holding the inching pedal fully down'
The Diagnostic Codes are discribed as follows
I,AMP FI-ASHING CODE POSSIBLE FAULT
ONE FLASH lndicates the module is receiving none or multiple shift lever signals
TWO FLASHES lndicates the ofi going pressure switch circuit has failed
THREE FLASHES lndicates the temperature sensor circuit has failed open or shorted to ground
FOUR FLASHES lndicates that one or more of the powershift solenoids is shorted to ground
FIVE FLASHES lndicates the on coming clutch pressure switch circuit failure
SIX FLASHES lndlcates none or multiple clutch pressures detected by the module
MORE THAN SIX FI.ASHES, Tractor still moves, indicates clutch pedal switch circuit iailure
TRACTOR DRIVES
lndicates the module has received none or multiple shift lever signals
I-AMP ON STEADY
TRACTOR DRIVES Should read one flash when the inching pedal is held down
refer to Five
NOTE: lf the powershift module will not reset without turning the engine off , then restafting the engine,
Position Switch Feedback fest Page 25.
NOTE: The modute is not equipped with a diagnostic code memory, therefore the flashes must be counted as
they
cycling the rnciing pedal (with the creep lever held in the intermediate position (A) for
occur. Turning off the engine'
"ef'l
or
tractors with creep up to No l'oososz, refer to fig 2 Page 7) wilt reset the module code and the fault code will be lost.
X-.1
Don 8-88422
lssued 2-92 Printed in U,S.A
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6008-7 600&7
POWERSHIFT TROUBLESHOOTING GUIDE iGUIDE
FORWARD/REVERSE FORWARD/RFUEHSE RETAY

CREEP ENGAGED
CREEP LB/ER
Flemove the forwardlfieverse Relay. Refer to Fig.1 POSSIBLE CAUSES :S
- Check the Powershifi Fault xrershifi Fault
lndicator Lamp Circuit, Circuit,
Turn the key to the ON position - Flefer to Page I Tests 1 to 3. Tests 1 to 3.
Did the powershift fault indicator
- Check the Powershift module ershift module
CREEP DISENGAGED
Power and Chassis ground hassis ground
lamp illuminate ?
Circuits
RIGHT HAND F RIGHT HAND FUSE/REI3Y BLOCK CREEP LE'\/ER GATE
lnstallthe pressure gauges to the Flc FIGURE 1 FIGURE 2

powershift manifold test ports,
Refer to Page 5.
Start the Engine and Cycle the

lnching Pedal
Shift the Powershift Lever through
ls the powershift fault indicator allgears
Heat the transmi: Heat the transmission oil to a
lamp on steady or flashing ?
Did the powershift fault indicator temperature of 1l temperature of 150" F (65' C).
lamp illuminate ? Shift through all E Shift through all gears again. or lault
lntermittant iault not
Did the powershifl Did the powershift fault indicator duplicated. Check for loose and
larnp illuminate ? lamp illuminate ? poor ground connectkns
NOTE: lf the speed sfiifred in too is

ls there pressure on one of the pressure gar4es ? known when the fault occured check
the pressure switch circuit of that speed
only. Refer rc Pressure Swtch Circuit
YES NO Test Page 12.
(DRME FAULT} (sToP FAULD Example: lf the fault occured from
Shift the creep Shift the creep lever (if equipped) into the speed 2 ta s?eed 3 check the 3rd
intermediate posil intermediate position 'A', refer to fig 2. Hold the speed pressure switch circuit.
ls the powershift fault indicator inching pedaltulty inching pedal fully down and count the number of
lamp on steady or flashing ? flashes. flashes.
Check the inching pedal switch hing pedalswitch

circuit. Reter to Powershift r to Powershiit
Troubleshooting, Circuit rng, Circuit
Testing and Tests 13 to 16. NOTE: lf the speed shh Tests 13 to 16. NOTE: lf the speed shifted Check the solenoid circuits Check the solenoid and
Shift the creep lever (if equipped) into the Reler to Pages 8, 9, 10. For out of is knawn when ps 8, 9, '10. For out of is known when the Flefer to the Powershift pressure switch circuits. Refer
intermediate position 'A'. Flefer to fig 2. Hold
the tractors with creep up to P.l.N lault occured check creep up to P.l.N hult accured check the Troubleshooting and Circuit to Powershift Troubleshooting
inching pedal fully down and count the number of No. 1@5652, Tests 17 to 20. pressure switch circuil pressure sw?ch circuit of Testing Pages B and 9Tests and Circuit Testing Pages I
, Tests 17 lo 20.
flashes that speed only. Refet lhaf speed only. Reler to 5to8. and gTests 5 to 12 Also carry
Pressure Swlch Circuit i Pressure Swlch Circuit Test out "rhe ctutch pack leakage
Page 12. Page 12. test Fage 25.
Check the temperature sensor nperature sensor
circuit. Hefer to
Powershift Example: lf the 1 r to Powershift Example: lf the fault
Troubleshooting and Circuit accured from speed 2 ing and Circuit occured from speed 2 to
Testing Pages 8 and 9 Test 4. speed 3 check the s 8 and I Test 4. speed 3
check the 2nd
Check the powershift lever
speed pressure sw speed pressure swlch
circuit. circuit.
kaukazz@yahoo.co.ukswitch cireuit,
refer to Page 14.
Don 8-88422 lssued 2-92 Printed in U S"A lssued 2-92 Pfinted in U S.A
powrquadplus
POWEHSHIFT ELECTRICAL TROUBLESHOONNG

STEP 1 STEP 3
Park the tractor on hard level ground ard apply the Connect the adapter harness CAS 2183 to the
parking brake. powershift harness (1). Do not connect the adapter
harness to the module.
STEP 2
STEP? -'
/n Connect the breakout box CAS 2110 to the adapter

harness CAS 2183 and connect the ground lead of the
breakout box to the negative ( - ) terminal cf the battery.
NOTE: Nl checks are to be made atthe breakout bax

from the opercfors seat using a multimeter unless
ofiersse srafed.
STEP 5
Flemove the Forward/Reverse Relay. Refer io Fig 1.

Page 7.
Disconnect the powershift harness (1) from the module NOTE: Afier a// ciecks have been completed insfall the
(2) at connector (J), Fa*vard / Reve rse relay.
CAS 2110
,@
.@' -@
_@"
@"
BREAKOUT BOX CAS 2110
NOTE: The letters an the breakout boxAtoXconespond with the idenification letterc an the pins of conneclors C and J,
refer to Schemalics, Pages 2? and 23.
Dan 8-884?2. Issued 2-92 P.inted in U S.A
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6008-9
Circuit Testing
NOTE: The battery must be at full charge and all connecttons musr be clean and ttght before testing. Use a multrmeter f or
fhe fesfs.
NOTE; Conne ct the breakout box CAS 21 1O ta the powershifl harness, refer ta Page B, DO NaT connectthe breakol't ba)
tc the module.
NOTE: Refer to Schematic Circuit 1 for tractors wtthout creep an,7 tractors with creep from PIN No JJF1aa5653
NOTE: Refer to Schematic Circuit 2 for tractars with creep up to PIN No JJF1005652
NOTE: Check luses F2A, F25, F26 F27 and F2B
NOTE: furn the kev to the ON posrrtan.
Breakout Box (CAS 2110) Check Points Beading Possible Cause of Bad Reading
Power Supply and Chassis Ground TesI
@ Sut*"un 2 (B) and 38 (ground) 12 Voits Bad cjrcurl beiween the accessory power
relay and the cowershifi module connccior
(P n B) A so check the accessory power
relay reier ic Section 400 1
@ a"*""n 7 (G) and 38 (grounc) Contrnuiry Bad crrcurt between the module conneclor
(Prn G) and the batlerv negative (- )
terninal
Powershift Fault lndicator Lamp Test
NOTE: furn the key ta the ON positron
Connect the pos tive jumper lead between 2 Powershilt Check the powershrtl fault indicator lamo
(B) and 1B (U) Lamp
Fault crrcuir, refer to Page 15
illLrminated
Temperature Sensor Test (3 Flashes)
NnTE: Iurn the key to the OFF position
A"tr."n 12 to 1 787 Ohms Check the :er-,perature sender crrcur:, refer

e 12 (M) and 38 (ground) 1
(Refer to table on to )age 14

Page 1 4)
Solenoid Test (2, 4, 5 and 6 Flashes)
NOTE: Iests 5 ta I must be carried out at a temperaturc of 70'F QA'C.)
@ a"t*u.n 13 (N) and 38 (ground) 5 tc 7 Ohms Check the cowershift solenord circurl, reier
Approxrmately to Dage 1 1
@ a"*"nn 1a (P) and 38 (ground) 5 to 7 Onms Check the powershiit solenord circuit refer
Approxrmately to cage I 1
@ a"w""n 16 (S) and 38 (ground) 5 io 7 Ohn s Check the oowershift solenoid circuit. re'er
Approxrmately :o Page I 1
@ au*"un 17 [) and 38 (ground) 5 to 7 Onfi-rs Checx lhe povrcrshrfi soleno d c rcuti rc'er
Approxirnatelv tc Page 11
Do'8-88422 lssL;cl 2'92 Pr nlec n i.t S ri
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6008-1 0
Breakout Box (CAS 2110) Check Pornts Reading Possible Cause of Bad Reading
Pressure Switch Test (2, 5 or 6 Flashes)
@ A"*""n 19 (rf and 6 (F) Cont nuity Check 1ne powershift pressure switch
circuit, refer to Page 12.
@ a.*".n 21 (X) and 20 (W) Contrnuity Check the powershift pressure switch
circuit, refer to Page 12
@ au*""n 9 (J) and B (ts) Continuity Check the powershift pressure switch
crrcuit, refer to Page 12
@ au*""n 11 (L) and 10 (K) Continuity Check the powershlft pressure switch
NOTE: lf the readings to check pornfs 9 ta 12 are correct, check the pressure switch operation, refer to Page 24
lnching Pedal Switch Test (Continuous Flashing)

NOTE: festponts 13 to 16 are lor tractors without creep and tractors with creep from PIN No JJF1005652.
Gl g.t*..n 3 (C) and 15 (R) Continuity Check the inching pedal position switch
l?l aeueen 3 (C) and 1 (A) No Conlinuity Check the inch ng pedal position swltch
NOTE: Hold the inchinq pedal DOWN
G autr..n 3 (C) and 1 (A) Continuity Check the inching pedal position swtch
circurt, re{er to Page 16.
(D s.t*.rn 3 (C) and 15 (!) No ContinuiirT Check the rnch ng pedal positton swttch
Creep Circuit Test (Continuous Flashing)

NOTE: restpornts 17 rc 2a are lor tractors with creep up to PIN No JJF10a5652.
NOTE: Turn the key to the ONposition and putthe creep lever in the engaged or disengaged position (DO NOT cycle the
inching pedal).
@ e.uu.n 3 (C) and 1 (A) Continuity Bad creep relay 2. Also check the creep
() a"u.tn 3 (C) and 15 (B) No Continuity Bad creep relay 2 Also check ihe creep
NOTE: Hold ihe rnchinq pedal DOWN
(E) a"t*u.n 3 (C) and 15 (F) Continuiry Bad creep relay 2. Also check the creep
s"t*..n 3 (C) and r (A) No Continurty Bad creep relay 2. Also check the creep
4ll crrcuit. refer to Page 'l 6
)o. 8-88122 issued 2-92 Printed in U.S.A
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6008-1 1
Powershift Solenoid Circuit Testing
NOTE: Connect the breakout box, CAS 21 10 to the powershift harness, refer ta Page 3. DO NOT connect the breakau:
box to the module.
Breakout Box (CAS 2110) Check Pornts ileadinc Possible Cause of Bad Reading
1st Speed Powershift Solenoid
NOTE: Disconnecfihe 7sl speed oowershilt sclenotd from the harness
@ A"w"un check point 13 (N) and terminal A Cont nurty Bad circuit between connector J (Pin N)
of the solenoid connector (Harness srde) and the 1st speed solenoid1ermrna A Also
check cclnnector C (Pins A and N)
a.*uun check point 38 (ground) and

@ terminal Continuily Bad chassis ground circuit Also check t.re
B of the solenoid connector chassis ground connections at ine
(Harness side) powershri't rranitold.
Between termrnals A and B of the soleno c 5 to 7 Ohms Bad soieno d

Aporoximately
NOTE: lf the readings are correct, connect the solenaid ta the herness and connect the pasitive jumper lead befweer
check points 2 (B) and 13 (N) at the breakout box. Turr the key to the ON position ll the solenord does not lurn ON clicx
repeat rests 21 and 22.
2nd Speed Powershift Solenoid
NOTE: Disconnect the 2nd speed powershift solenoid from the harness Turn the key to the ON positron
Between check coint 14 (P) and termrnal A Contrnuity Bad crrcurt between connector J (Pin o) an<i
of the solenoid connector (Harness side) the 2nd speed solenoid terminal A Alsc
check connector C (Pins A and e)
dl B"t*".n check point 38 (ground) anc Continuity Bad chassrs ground circuit Also check tnc
termrnal B of the solenoid connector chassis ground connections at ine
(Harness srde) powersh tt 'naniiold.
Between terminals A and B o{ the soienoic 5 io 7 Ohms Bad soleno d

Aporoximately
NOTE: lf the readings are corr'ect, cannect the solenoid ta the harness and connecl the posltive jumper lead beNveer
check points 2 (B) and 14 (P) of the breakout box. Turn the key to the ON positton i the solenoid does nol turn ON click
repeal lesfs 23 and 24.
3rd Speed Powershift Solenoid
NOTE: Ct eck fuse F27
NOTE; Disconnect the 3rd speed powershitl solenotd from the harness lurn the key o the ON position
Bad crrcL,it belveen connector i (Pin S) and
Between check ooint 16 (S) anc terrn nal A Soni nu:y lle 2nC speed soienoid te.m ra, A Alsc
of the solenoid connec:or' (Harness side) check co"êctcr C (Pirs A and S)
Oot S-88422 ssue:2-92 P'i:iec r'ri S
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6008-1 2
Breakout Box (CAS 2110) Check Points Reading Possible Cause of Bad Reading
e"*""n check point 38 (ground) and

@ terminal Continuily Bad chassls ground circuit. Also check the
B of the solenoid connector chassis ground connections at the
(Harness side) powershift manifold.
Between terminals A and B oi the solenoid 5 to 7 Ohms Bad solenoid.

Approximately
NOTE: lf the readings are correct. Connect the solenoid to the harness and connect the positive jumper lead betvveen
check points 2 (B) and 16 (S) of the breakout box. Turn the key to the ON position if the solenoid does not turn ON 'click
repeat lests 25 and 26.
4th Speed Powershift Solenoid

NOTE: Disconnect the 4th speed powershitt solenoid from the harness.
@ a.wuun check point 17 [) and terminal A Continuity Bad circult between connector J (Pin T) and
of the solenord connector (Harness side) the 4th speed solenoid terminal A AIso
check connector C (Pins A and T).
dll g.*""n check point 38 (ground) and Continuity Bad chassis ground circurt. Also check the
terminal B of the solenoid connector chassis ground connections at ihe
(Harness side) powershift manifold.
Between terminals A and B o.f the solenoid 5 to 7 Ohms Bad solenoid.

Approximately
NOTE: lf the readings are correct. Connect the solenoid to the harness and connect the positive iumper lead between
check points 2 (B) aLnd 17 (T) at the breakout box. Turn the key to the ON position if the solenaid does not turn ON
'click'
repeat lests 27 and 28
Powershift Pressure Switch Circuit Test

NOTE: Connectthebreakoutbox,CAS2ll0,tothepowersiftharness,refertoPageS.DONOTconnectthebreakautbox
to the module.
'1st Speed Pressure Switch
NOTE: Disconnect the 1st speed pressure switch from the harness.
Breakout Box (CAS 2110) Check Points Rea{L9 Possible Cause of Bad Reading
Beh.veen check point 19 ft) and terminal A Continulty Bad circuit between connector J (Pin \.f and
of the pressure switch connector (Harness the l st speed pressure switch
srde)
Belween check point 6 (F) and terminal B of Continuily Bad circuit between connectorJ (Pin F) and
the pressure swrtch connector (Harness the 1st speed pressure switch.
srde)
Between terminals A and B of the pressure Continuity Bad pressure switch.

switch
NOTE: tf the readings are correct, refer ta pressure switch operation Page 24
Dot, 8-88422 lssued 2-92 Printed ln U.S.A.
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600E- 1 3
Breakout Box (CAS 2110) Check Points Beading Possible Cause of Baci Readrng
2nd Speed Pressure Switch

NOTE: Disconnect the 2nd speed pressure switch from the harness
Breakout Box (CAS 2110) Check Points Reading Possible Cause of 3ad Readrng
@ A"*""n check point 21 (X) and terminal A Continuiry Bad crrcuit between connector J (Prn X) and
pressure
of the (Harness
switch connector the 2nd speed pressure switch
side)
6D A"t*."n check point 20 (W) and terminal B Continu ly Bao circuit between connector J (Pin W)
of the pressure swtch connector (Harness and the 2nd speed pressure svri:cr
side)
Belween termlnals A and B o'i the pressure Continuity Bad pressure switch
swilch
NOTE; lf the readings are correct, refet to oressure swttch operation Page 24
r 3rd Speed Pressure Switch

NOTE: Disconnect the 3rd speed pressure swilch from the harness
@ U"*"un check pornt g (J) and terminalA of Continurty Bad circuit between conneclor J (Pin J) and
pressure
the switcl connector
(Harness the 3rd speed pressure sw tch.
side)
A.*."n check point B (H) and terminai B or

@ the Continuitlv Bad circuit between connector J (Prn Hi
pressure switcn connector (Harness and :he 3rd speed pressure switch
side)
Between terminais A and B o'the cressure Conlinurly Bad pressure swilch

switch
NOTE; lt the readrngs are correct, rcfer to pressure sw,'!ch operailon Page 24.
4th Speed Pressure Switch

NOTE. Disconnect the 4th speed pressure swtich fram the narness.
Belween check porni 1 1 (L) and terminai A Contrnuity Bad crrcuit beNveen connector J (Prn :) anc
of the pressure switch connector (Harness the 4th speed pressure sv/ilch
side)
Between check poini 10 (K) and terminal B Cortrnuiry Bad crrcurl benveen connector J (Prr K) anc
cf the pressure swi:ch connector (Harness lhe 4th soeed cressure swrich
srde)
Between terminals A and B o'the pressur-e Continuity Bad pressure switch

swrtch
NOTE; tf the readtngs are correct. reter lo pressure sw;tch operation Page 24.
D.r 8-88422
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6008-1 4
Transmission oil Temperature sender circuit Test
NOTE: Connect the breakautbox, cAs 2110, to the powershift harness, refer to Page 8. DO NOT connect the breakout
box to the module.
Breakout Box (CAS 2110) Check Points Beading Possible Cause of Bad Reading
.-. Continuity Bad circuit between connector J (Pin M)
Setween check point 12 (M) and the
Qp temDerature sender and the temPerature sender.
Between the temperature sender and See Table Below Bad temperature sender
chassis ground
OIL TEMPERATUBE oll TEI,iPERATURE RESTSTANCE OHMS

RESISTANCE OHMS
* .8
17 0.0 1 519 to 2055 26.7 80.0 413 to 599
-12.2 10.0 1305 to 1765 32.2 90.0 378 to 510

*6] 2O.O 1074 to 1453 37.8 100.0 331 to 448
*3.9 25.0 981 to 1327 €.3 110.0 292 to 395
48.9 120.0 253 to 343
- 1 .1 30.0 912 to 1234
0.0 32.O 906 to 1226 *.4 130.0 225 to 305
4.4 40.0 770 to 1040 65.5 150.0 178 to 240
10.0 50.0 871 to 908 76.2 170.0 141 to 191
s.6
1 60 0 575 1o 778 a7.a 190.0 11510155
21 .1 70.o 506 to 684 98.9 210.0 95 to 129
Powershift Shift Lever Switch Circuit Test

NOTE: Ta test the powershilt shift lever circuit it wiil be necessary ta make and use the special tool shown on Page 4 of
this sectlon.
powershift shift lever assembly

NorE: Connect the powershift module to the harness at connector J and disconnect the
from the powershift module at connectar L.
BetweenterminalsAand B o{connector L 45 to56Volts Bad powershift module

(Module side)
BetweenterminalsAand Cof connectorL 3I tc 46Volts Bad powershiftmodule'

(Module side)
Between terminals A and D of connector L 3 8 to 4 6 Volts Bad powershitt module

(Module side)
Between terminalsA and E of connectorL 3 8 to 46Volts Bad powershift module

(Module side)
BetweenterminalsAand F of connectorL 3B to 46Volts Bad powershiftmodule

(Module side)
Harness, refet'to Toots to be Made, Page 4, belveen the Nva terminal blocks of connector L
NOTE: Cannect the Tee
NOTE; Put the powershift shift lever in the 1st speed positton
Don 8-88422 Issued 2-92 Printed in U.S'A
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6008 1 5
Between terminals A and B of the open 4 5 tc 5 6 Volts Bad powershift speed select levet
connectcr of the Tee Harness assembly
Between terminals A and C of the open 0 io 0 5 Volts Bad powershift speed select levet
connector of the Tee Harness assembly
NOTE: Move the powershift shift lever out of 1st speed
Between terminals A and C of the open 3 B to 4 6 Volts Bad powershift speed select lever
connector of the Tee Harness assernbly
NOTE: Put the powershift shrft lever to the 2nC speed posttion.
Between terminals A and D of the ooen 0 to 0 5 Volts Bad powershift speed select lever
connector of the Tee -larness assembly
NOTE: Move the powershift shift lever out of 2nd speed
Between terminals A and D of the open 3 8 to 4 6 Volts Bad powershift speed select lever
NOTE: Put the powershift shift lever in 3rd speed
Between terminals A and E of the open 0 to 0 5 Volts Bad powershift speed select lever
connector of the Tee Harness assembly'
NOTE: Move the powershift shift lever out of 3rd speed.
Between terr-ninals A and E of the ooen 3 8 to 4 6 Volts Bad powershifl speed select lever
NOTE; Put the powershift shilt lever in the 4th speed pasttton
BeNveen terminals A and F of the ooen 0 to 0 5 Volts Bad powershift speed select lever
connector of the Tee Harness asserr biy.
NOTE: Move the powershilt shift lever out ol 4th speed
Between terminals A and F of the ooen 3 I to 4 6 Volts Bad powershift speed select lever
connector of the Tee Harness assembly.
Powershift Fault lndicator Lamp Circuit Test

NOTE: Check the powershift fault indicator lamp bulb.
NOTE: Turn the key to the ON posltlon.
Terminal forwire g7 White/Brown to grouno 9 to 14 Volts Bad circuit between the fault indicator lighl
Approximaieiy and the powershifl module, also check thc
Powershrft module
6Ef terminal for wire 91 Brown to ground Continuity Cneck wire 91 and the chassis ground
ccnnectron
Don 8-88422
lssuec 2-92 Plnled rn i SA
kaukazz@yahoo.co.uk
6008-1 6
NOTE: Refer to Schematic Circuit 1.
NOTE: Connect the breakout box, CAS 21 10, to the powershift harness, refer ta Page 8. DO NOT connect the breakoul
box to the module.
NOTE: Disconnect the inching pedal from the harness
Breako;t Box (CAS 21 10) Checx Points Reading Possible Cause of Bad Reading
Between check point 1 (A) and terminal C of Continuily Bad circult between connector J (Pin A) and
the inching pedal connector (Harness side) the inching pedal
Bad circuit beNveen connector J (Pin C)

@ eu**.n check point 3 (C) and terminal B of
inching pedal connector (Harness side)
Continuity
and the inching pedal
the
Bad circuit between connector J (Pin R) and

@ e.*".nrnching
check point 15 (R) and terminal A
pedal connector (Harness
Continuity
the inching pedal,
of the
side)
Between terminals A and B of the inching Continuity Bad inching pedal switch.
pedal switch
NOTE: Hold the inching Pedal DOw-N.
Between terminals B and C of the inching Continuily Bad inching pedal switch
pedal switch
CreeP Circuit Test

(For Tractors With Creep Up To PIN No 1005652)
NOTE: Refer to Schematic Circuit 2
NOTE: Checkthe ln-lLne creep harness fuse (located behind the instrument clustel.
NOTE: Connect the breakout box, CAS 21 10, to the powershift harness, refer to Page B. DO NOT connect the breakout
box to the module.
NOTE. Remove the creep relay 1, refer to Page 23
Breakout Box (CAS 21'10) C-feck Points Beading Possible Cause of Bad Reading
Continuity Bad circuit between connector J (Pin A) and

@ fff;; iffij Point 1 (A) and terminarror
the creep relay 1 .
au*u919neck_.point 3 (C) and terminal for Continutty Bad circuit belween connector J (Pin C)
@ wire 126 Lrgnt B,uel/ellow and the creep relay 1.
Au*..n checkpoint 15 (R) and terminalfor Continuity Bad circuit between connector J (Pin B) and
@ wue 127 WhiteAellow the creep relay 1
Itrl a"t*u.n check point 38 (ground) and Continuity Bad chassis ground circuit.
tern inat for w're 133 Browr
au*.un check point 38 (ground) and contrnuity Check wire 133 between the creep relays 1
@ terminat for wire T33 Brown and 2.

Don 8-88422
lssued 2-E2 Printed in U.S.A
kaukazz@yahoo.co.uk
6008- 1 7
NOTE: Put the creep lever in the engaged or disengageC posrtion Turn the key to the on position and hold the rnchtng
pedalDOWN.
Breakout Box (CAS 2110) Check Points Reading Possrble,Cause of Bad Reading
A.*u"n check point 38 (ground) and

@ terminal 12 Volts Bad circuil behryeen the creep relay 2
for wire 131 Light BlueZVVhite tern:inal 86 and the creep relay I terminai
86 Go to test ooint 50
NOTE: lf the readings are correct, replace creep relay 1
@ A.*uun check point 38 (ground) ano 12 Volts Bad circuit between the keyed oower
terminal for wire 129 Red tunctron block and the creep reay 2
iermrnai 30 Also check the keyed power
circuit. refer to Section 4001
eur*un check point 38 (ground) and

@ ternina 12 Volts Bad circurt between the creep relay 2
lor wrrc 131 Lrght Bl,c/Wr-itc terminal 86 and the inching pedal switch
Go to test ooint 52
6{l g.t*r.n check point 38 (ground) and 12 Volts Bad creep relay 2
- rern nal 'or wr.e 132 Ligrt B -e
@ Au*"un check point 38 (ground) and 12 Volts Bad circuit between the creep relay ?.
[erminal for wire 129 Red terminal 30 and the inching pedal switch
.l
Su*""n check point 38 (ground) and
@ re'rrinal 2 Volts Bad inching pedal switch Adlust or replace
for wire 130 BruelBiack
-ignt the switch as necessary reier to Sectror
9001
@ Au*".n check point 38 (ground) and .1

2 Volts Bad crrcuit between the incning peda
- terminal for wire 131 Lrqht BlueAVhite swrch and the creep lever switci- Go lo tesi
pornt 57.
@ A"**"nforcheck point 38 (ground) and

wirc 132 Lrght Blue
Z VUIIS Bad circuit befureen the creep relay
terminal 87 and the inching pedal swilch
2
termina
NOTE: Belease the inchlng pedal.
^-. Belween check point 38 (ground) and 12 Volls Bad inching peda switcl^r Adlust or rcplacc
Qp
- the switch as necessary refer to Sec: on
rermrnal for wire 131 L oht Blue/Wh,:e
9001
Don 8-88422 ssued 2-92 P'rnled ' .-i -i r
kaukazz@yahoo.co.uk
6008-1 B
NOTE: Hold the inching pedal DOWN.
Breakout Box (CAS 21.10) Check Points Reading Possible Cause of Bad Reading
aut*""n check point 38 (ground) and 12 Volts Bad circuit between the inching pedal
@ te.minal for w,re 130 Light Blue/Black swich and the creep lever switch
12 Volts Bad creep lever switch. Adjust or replace

@,?:x::i,":ffi5, ???lnii.lnJil,lil "o the switch as necessary, refer to Sectton
9001.
NOTE: Hold the creep lever switch in the intermediate position
0 Volts Bad creep lever switch. Adjust or replace

@ r":m:i,":ffi:,3? T.;:,lnJiilil'"0 the switch as necessary, refer to Section
9001
NOTE: lf the readings are correct, check wire 131 befween the inching pedal switch and the creep lever swlch
Don 8-88a22
lssrec 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
powrquadplus www.thebestworkshopmanuals.co.uk 6008- 1 I
WIRING CODE
REF COLOR FROM TO WIBE
GALGE
(mm2)
6 Red Battery Junction Biock Key Swrtch flerm 30) (Batt) 13 (2 5)
64 RedMhite Key Switch (l"errn 58) (Acc) Fuse F19 16 (1 0)
64 RedMhite Fuse Fl9 Accessory Power Relay fl'erm 86) 18 (0 75)
68 Brown Accessory Power Relay fierm 85) Transmission Control Relay fl-erm 85) 16 (1 0)
68 Brown Transmission Control Relay (Term B5) Ground
Chassis 16 (1 0)
9l Brown Powershift Fault lndicator Lamo Ground
Chassis 18 (0.75)
94 Bed/Dark Blue Battery Junction Block 7
Fuse Fl 13 (2 5)
94 Red/Dark Blue Fuse F1 7 Accessory Power Relay (Term 30) 13 (2 5)
95 Hed/r'iolet Accessory Power Belay flerm 87) Fuse F32 15 (r 5)
95 Redl/iolet Fuse F32 Fuse F20 16 (1.0)
96 Dark BluetuVhiie Fuse F20 B)
Connector C (Pin 15 (r 5)
96 Dark BlueMhite Connector C (Pin B) B)
Connector J (Pin 15 (r 5)
97 White/Brown Connector J (Pin U) U)
Connector C (Pin 18 (0.75)
97 White/Brown Connector C (Pin U) Powcrsh ft Fault lndicator Lamp 18 (0 75)
98 Brown Powershift Solenoid 1 (Term B) Splice 18 (0 75)
98 Brown Powershift Solenoid 2 (Term B) Splice 1 I (0.75)
98 Brown Powershiit Solenoid 3 (Term B) Splice 18 (0 75)
98 Brown Powershift Solenoid 4 fl'erm B) Splice 1 I (0.75)
98 Brown Splice Chassis Ground 15 (1 5)
99 White/Pink Connector J(Pin N) Connector C (Pin N) 18 (0.75)
99 White/Pink Connector C (Pin N) Fuse F25 18 (0 75)
100 Dark Blue/Pink Fuse F25 Connector C (Pin H) 18 (0 75)
100 Dark Blue/Pink Connector C (Pin H1 Powershifl Solenoid 1 fl-erm A) 18 (0 75)
101 White/Black Connector J (Pin P) Connector C (Pin P) 18 (0 75)
.101 White/Black Fuse F26 18 (0
Connector C (Pin P) 75)
102 Dark Blue/Black Fuse F26 Connector C (Pin J) 18 (0 75)
102 Dark Blue/Black Connector C (Pin J) Powershift Soienorc 2 fTerm A) 18 (0.75)
103 White/Yellow Connector J (Pin S) Connector C (Pin S) 18 (0 75)
103 Whitel/ellow Connector C (Pin S) Fuse F27 18 (0 75)
104 Dai'k Blue/Yeiiow Fuse F27 Connector C (Pin K) 18 (0 75)
104 Dark Bluer/eltow Connector C (Pin K) Powershilt Solenoid 3 fl-erm A) 18 (0 75)
105 White/DarkGreen Connector J (Pin I connector c (Pin T) 18 (0 75)
105 White/DarkGreen Connector C (Pin T) Fuse F28 18 (0 75)
106 Dark Blue/Dar< Fusc F28 Connector C (Pin L) 18 (0 75)
Green
106 Dark Blue/Dari< Connector C (Pin L) Powershift Solenoid 4 (1-erm A) 18 (0 75)
Green
107 Light BlueiPink Connector J (Prn \,f Powersnift Pressure Switch 1 fi'ermA) 18 (0 75)
108 Brown/Pink Powershift Pressure Switch t (Term B) Connector J (Pin F) 18 (0 75)
109 Light Blue/Black Connector J (Pin X) Powershrft Pressure Switch 2 fl-ermA) 18 (0 75)
1 10 Brown/Black Powershift Pressure Switch 2 (Term B) Connector J (Pin \Al) 18 (0 75)
111 Light Blue/Yellow Connector J (Pin ") Powershift Pressure Switch 3 Clerm A) 18 (0 75)
112 Brown//ellow Powershift Pressure Switch 3 fierm B) Connector J (Prn H) 18 (0 75)
1 13 Light Blue/Dark Connector (Pin l) Powershifl Pressure Switch 4 fierm A) 1B (0 75)
Green
114 Brown/Dark Powershift Pressure Switch 4 fl-erm B) Connector J (Prn K) 18 (0 75)
Grccn
1 15 Yellow Connector J (Prn M) Transmission Oil Temperature Sender 18 (0 751
'1'16 BrownMhite Connector J (Prn G) Battery Negatrve Terminal 15 (1 5)
117 Black Powershift Module Connector L ft-erm A) 18 (0 75)
117 B ack Connector L (Term A) Powershrn Lever Assembly 18 (0 751
1 18 Red Powcrshift Module Connccior L (Term B) 18 (C 75)
1 18 Red Connector L (Term B) Powershrtl Lever Assembly 18 (0 75)
tssued 2-92 p.rn:ec i. :l S A
Don 8-88422
kaukazz@yahoo.co.uk
6008-20

GAUGE
(mm')
19 Powershift Module Connector L fl-erm C) 18 (0 75)

Powershift Lever Assembly
1 Orange 18 (0 75)
1 19 Connector L (l'erm C)
Connector L (i-erm D)
Orange 18 (0 75)
120 Yellow Powershift Module
L (T-erm D) Powershift Lever Assembly 18 (0 75)
120 Yellow Connector
Module Connector L (ierm E) 18 (0 75)
121 Gray Powershift
Powershift Lever Assembiy 18 (0 75)
121 Connector L fli-erm E)
Connector L fl-erm F)
Gray 18 (0 75)
122 Light Blue Powershift Module
L (1-erm F) Powershift Lever AssemblY 18 (0 75)
122 Lrght Blue Connector
Connector C (Pin R) 18 (0 75)
123 White/Dark Blue Connector J (Pin R)
lnching Pedal Position Switch fl"erm A) 1B (0 75)
123 White/Dark Blue Connector C (Pin R)
Refer to Schematic Circuit 1
lnstrument Harness Connector ft-erm A) 18 (0 75)
123 Whrte/Dark Blue Connector C (Pin R)
124 White Connector J (Pin A) Connector C (Pin A) 18 (0 75)
Connector C (Pin A) lnching Pedal Position Switch fl"erm C) 1B (0 75)

124 White
Befer to Schematic Circuit 1
Connector C (Pin A) lnstrument Harness Connector fl'erm C) 1B (0 75)
124 White
125 Light Blue Connector J (Pin C) Connector C (Pin C) 18 (0 75)
lnching Pedal Position Switch fl-erm B) 18 (0 75)
125 Light Blue Connector C (Pin C)
C (Pin lnstrument Harness Connector (T-erm B) 18 (0 75)

125 Light Blue Connector C)
1 (l"erm 30) 1B (0.75)
126 Lrght Blue/Yellow lnstrument Harness Connector ferm B) Creep RelaY
1 87) 1B (0.75)
127 Whrte/Yellow lnstrument Harness Connector fl-erm A) Creep RelaY flerm 18 (0.75)
lnstrument Harness Connector fl-erm C) Creep RelaY
1 (-l-erm 87 A)
128 Whrte Creep Harness Fuse 16 (1.0)
129 Red Keyed Power Junction Block 16 (1 0)
Creep Harness Fuse
2
Creep RelaY fT-erm 30)
129 Red Creep lnching Pedal Switch flt-erm 6) 16 (1 0)
1 29 Red Creep RelaY 2 fl-erm 30) 16 (1 .0)
Connector M (Pin A)
130 Lrght Blue/BIack Creep lnching Pedal Switch fl-erm 5) 16 (1 .0)
Connector M (Pin A) Connector B (Pin A)
130 Light Blue/Black
Connecior H (Pin C) 16 (1.0)
'130 Lrght Blue/Black Connector B (Pin A)
Connector E (Pin L) 16 (1 .0)
130 Lrghi Blue/Black Connector H (Pin C) 16 (1.0)
Creep Lever Switch flt-erm A)
130 Lrght Blue/Black Connector E (Pin L) 18 (0.7s)
Connector E (Pin M)
131 Lrght Blue,ryVhile CreeP Lever Swrtch fl-erm B) 18 (0 7s)
Connector E (Pin M) Connector H (Pin D)
131 LLght BlueAVhite Connector B (Pin C) 18 (o 7s)
131 Light Blue,&Vhite Connector H (Pin D) 18 (0.7s)
Connector B (Pin C) Connector M (Pin B)
131 Light BlueflVhite Creep lnching Pedal Switch fl-erm t1 18 (0.7s)
131 Light Blue,Mhite Connector M (Pin B) 16 (1 0)
2
Creep RelaY fl-erm 86)
131 Lrght BlueAVhite Creep lnching Pedal Switch (Ierm 1) 'l 16 (1.0)
Creep RelaY fTerm 86)
131 Lrght Blue,&Vhite Creep RelaY 2 (Term 86) 16(1 0)
CreeP Inching Pedal Switch fierm 2) Creep Relay 2 f-erm 87)
132 Lrght Blue Creep Relay 1 fi'erm 85) r8(07s)
133 Brown CreeP FelaY 2 (l-erm 85) '18 (0.75)
CreeP RelaY 2 fl-erm 85) Chassis Ground
133 Brown
lssued 2-92 Printed in U.S A

Dcr B-BB1?2
kaukazz@yahoo.co.uk
6( 6008-21
powrquadplus www.thebestworkshopmanuals.co.uk o
Schematic Circuit 1
\!
o*(/ CONNECTOH L
, BATTEBY
JUNCTION BLOCK 1}
"d LAMP SoLENOID (POWERSHFT)
{tn} PRESSURE SWITCH
Contacts closed by low oil TfA}'*llSStON OIL POWEHSHIFT I.EVEH
Powershift modde to
powershift lever assembly
DD Used
polfier
io routs battery
ffELAY 30 AMP
Produces heat thal emitts
artifcal light IFICHING PEDAL POSMON actuat€s a hydraulic vahe
CONNECTOR C
pressura TEMFqATURE SENDEH
CONNECTOR J
ASSEMBTY
:HSHIFT TEVEH
I.ll8LY POWEHSHIFT MODUL€
CTTASSIS GROUND Connects or disconnecls power to rat
s'wrTcH
Powefshilt hamess to instrumenl Fesisr $pq switch Powershift hamess to powershift Actuates nge tlran dr€ ies more lhan one Elec{ronic monilor (sensor), lhal
FUSE A magnetic switch that Csdacts open or closed bY actrcd by a probs thal is switch to cond maetran
CompHes batt€ry the eleclrical circuii
dlrecls eleclric cunent
'1t hamess module rto cond morgthan ongag€s or disengages lhe
Protects the ebcti=l pedal action imersd h bansrnission oil one circuit J
circuit kcuit powershilt clutches.
SPUCE system lrom high
Co*n€cts ons or mor€
circu*s that do th6 samg
funclion
ouFrrt or a ground in
lhe electrical system F, Powershift Solenoid Wiring Powershift Pressure Switch Wiring Powershift Lever and Powershift Module Wiring
BATTERY JUNCTION SLOCK
:96 DK BLUE1TYHITE
eHe
u#="*"#ll5Tl[#,r@6 IGN
H
f ,-,,. - 123 WHITE4]K BLUE
124WHm
1. BULKHEAD CONNECTORS
VIEWED FBOM THE ENGINE
KEY SWTCH
MI
*0':
*hIBATT
tG 1
ut r 125 LT BLUE INSTALL
ADAPTOR HARNESS
POWER SHIFT LEVEB ASSEMBLY
16-}@
I\-o-, ,t\ :) 37 WHTTEBROWN
w
tl\, 1t , @
I
J
at) gg Wl-lllEPlNK
96 cAs 2183
HERE
Y
r
CONNECTOH.C
it o
Ml t{0-A ,.0 o I 101 101
t-J o-,t t)l

i1 IU
103 -99 1ffi WHTEffELLOIY
i i\iI lcN d,4 L

b M
tq
r+
ct) H
q z z r
I l-'1Gs
,0s -
-
10s WHITE/DK GBEEN
18 123
*"'rft 69 *'='rp6 f--'ou

3 124
o
--! M CONNECTOR C -
Is=i\.---
= tl
ii
f CONNECTOTi C
ACCI )rg STAH
E
P
{D
to
D *.='rp 1Xi. 125
64 ut
F
F
t
FUSE F2
6y POWER SHIFT PSESSURE
SWrICH 1
s7 97 INSTALL THE TEE HARNESS HERE
\-*6\ ,..;fJ
Fls ) I;J-.37
-
=
F
.D
3
t-
O) o ,O2DKBLUE \
/BLACK *04
\
DK BLUEIfE,,-o*l
? 111
99
101 --99
11/
FUSE ac FUSEFl ul
3 1OO DK BLUEPINK . - 1Gr
-_ 103 CONNECTOR L
@(l t_ | GFIEtrN J
I 't(5 d
\i lo6 @il
(D 106 DK ELUE/DK 10s
Y
@' IrJ o UJ
ul lrl fJ
107 LT BLUE/PINK /?INK
lr| fJ € F ts @ 108 BROWN/PINK PINK
L * r.o**,r.. E tI a f
I CONNECTOR C POWER SHIFT P POt/VER SHiFT P BESSUEE
\i J
o 5 =
5
= rfl @ SY/TTCH SWTCH 3 POWEH SHIFT PRESSURE
\l:.-
lr.l
+ ()
=
(r1
6I N <! SWTCH 2 3
(5 tu
POWER z o
\ \
o
=
l,rJ
E
$, T FAULT INDICATOR
LAMP
104 DK BLUE/YELLOW
106 DK BLUSDK GREEN
@ 109 LT BLU'BLACK
I1O BROWN/BLACK
lr*"* o J
ul f, t! (,
d o
J E
=
J
F
TD
POWSH SHIFT MODULE
J
\\ ro TBANSMISSION
o, .I11
/Bl3CK ct 6) o cr
E ol €v
-\r- CONTBOL LT BL
102 DK BLUE /BLACK
\- RELAY
\rt
--=---_.-r\__\_\ r.
____r
o 113 LT BLUSDK
---i-.-
ii -\ \ !
68 BROWN
POWER SHIFT
SOLENOID 2
POWER SHIFT
SOLEN otD 4
1'I4 BHOWNfl]K
115
------1-
t--.. \--\:
.-\:
\\;\\
\i,'
@ POWER SHIFT PRESSU8E
SMTCH 4
tU
ts
r
ll,
ts
t
CONNECTOR J
i. ::::>\ i.. \ ,.. -\-* \ \-\ i ;

z= z
=
3
HARNESS
POWERSHIFT :RsHrFT HARNESS i ij o
= o
-----'-- \--t i .' i
;'--'--- i ---.-;' ,; EI (E
to
b
(o
r
G}
I
.t
CLEAN GHOUND {BATTERY NEGATIE TERUiT'TNI.i

CLEAN GROUND (BATTERY NEGATWE TERMINAL}
kaukazz@yahoo.co.uk CHASSIS GFOUND

CHASSIS GFOUND
CHASSIS GR(
Don 8-88422 lssued 2-92 Printer lssued 2-92 Printed in U.S-A. ,/ ,/ ,/ ,/ ,/
-
powrquadplus
Don 8-88422 lssued 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
I
rffil
..\# 6-
n\
6008-23
*Hc* "^--l CONNECTOB L

Powershift module to
\\,
\o-
Schematic Circuit 2
7r,r77r.
CHASSIS GF
2
j77jr77,r;
CHASSIS GROUND
BATTERY
JUNCTION BLOCK
Used
power
to route battery
INCHING PEDAL SWITCII
CONNECTOR M
lnstrumsfit hamess to
optional cre,:p hamgss
CONNECTOR M
lnstumer* hamess to
optional cre'-.p hamesg
KEYSWiTCH
"rytr
CONNECT(f'I H
Engine hamess to
transmissicrn hamess
CREEP LEVEB SWITCH
(omoNAiJ
Conlacts op€n or closed bY
lever action
RELAY 30 AMP
A magnetic switch that
ffi1
r3oAMP
tnetic switch that
I
LAMP
Produces hea that smitts
artifical ligil
SPUCE
Connects on€ or more
circuits thal do the same
function
soLENolD (PowERSHlFr)
actuates a hYdraulic vafue
CONNECTOH C
Powershit harness lo instrument
lI **
Press
PHESSURE S1MTCH
Contacts closed bY low oil
pressur€r
THANSMISSION OIL
TEMPEBATURE SENDER
Besistor tYPa switch
acnrated by a Prob€ that i3
cor{r.rECTO8 J
Powershifi hamess to Powershifi
porrershift lever assembly
POWERSHIFT
ASSEIJBLY
Actuatos mor€
l
switchto contr(
POWERSHIFT LEVEH
ASSEMBLY
Actuatos more than one
switch to contol more thaa
POWERSHIFT MODUT-E
Elscfonic monitor isensor)' that
engages or disengages the
Completes bi Connects or disrcnneds Powarto I
hamsss module one citcuit
FUSE Completes battery Cordacts op€n or closed by directs electric cuff ent s electric current imersed iil tansmission cril one citcr:it powsrshift clutch€.
circuit the electrical circuit I
Prote;B ths al€crrical circuit pedal action
svst€m kom [*] Powershifl
high
Powershift Pressure Switch Wiring Powershift Lever and Powershift Module Wiring
output or a ground in Powershift Solenoid lMring
the electical system
CONNECTOR E
CONNECTOR B
Transrnission hamess to right Creep Wiring
to inst'ument CREEP BELAYS BATTERY JUNCTION 8LOCK (PO\ilEF)
Engine hamess hand console hamess CREEP BELAYS
hamass
-T-
96 DK BLUEAVHITE
g 125 LT BLUE
I 123 WHTTE/DK BLUE INSTALL POWEH SI
INSTALL POWEB SHIFT LEVER ASSEMBLY
=''*: KH*b
B
ll \g/.A\ A
124wHrrE
s7wHngBROWN
ADAPTOR HARNESS.
cAS 2183 *o?ffrffi.us- f(6\--.} @
c .+-6\Y fic I u HEflE
$Bht&-
2. coNNEcroR HERE
(POWEBSHIFT HARNESS) \g/ ls&4 Ol
N g ECTOR C
101 101
LEFT HAND FUSSRE /
-&"M
LEFT HAND FUSE/RELAY BLO(:K
1. BUIXHEAD CONNECTORS
o-,N0r*\
l!11 B
to3 '103
VIEWED FROM THE ENGINE

I
dllo los -
I/ rGN E 105wHrrE/DKGREEN 't25
- 1X
CBEEP
i
UJ
HARNESS E
f,-'ou CONNECTOR C - 12!
O
I
FUSE
rcc[pJ srARr
<:
tu
=
f,
J
E
I
lt I
7T*tl €
FUSE F
o
'.*E"?O POWER SHIFT PBESSURE
swficH 1
97
oo
101
INSTALL THE TEE HARNESS HEBE
CONNECTOR L
\-i CONNECTOR H
*,,:r-l
''77 *.=,,,{ lnisE rs;1 FUSE F2o )
I
| ] DK BLUSPINK
J
103
105
€) b I o( I@( oq_J
'129 DK BLuuoK t07 LT BLUE/?INK
t---.! "*.=*
EL @
108 BROWN/PINK
rer
,,l.
l.'rlrzl
I
mTl CONNECIOR E
L-* - g
a
o
lg .. 186l I3d
/
1
/
POWER SHIFT PBE SSUHE
SWITCH 3
SSUHE
POWER SHIFT PRESSUBE
SWITCH 2 LU
ul POIVEB SH1FT MODULE
H
POWERSHIFT POWERSHIFT
@ @ 109 LT BLUE/EI3CK z oJ :f
N
J
t-----l--l
lV'rl ,ld 161 FAULT INDICATOI
LAMP
FAULT INDICATOR
LAMP
106 DK BLUE/DK
110 EROWN/€IACK (r Jtrl
o
I9
o T
----a-
131 LT BLUE/WH I .'.0
TFANSMISSION 111 LT o o (\,1 ol ct
!:
i! \ CONTBOL
BEIAY @ 112
6l
\i-
\
I
\ \$-.\J"
-+ I
ul
:)
J
I 6', o T13 LT SLUE/OK
114 BROWN/DK
11s
CREEP RELAY 1 126 CBEEP BEIAY2 (o
=\=-f
-=-:{- \x-. \\\ 5 POWEH SHIFT
POWER SHIFT
lro*r..",.,
--='
l6
POWERSHI FT SOLENO1D 4
*-/ , ]
6l SOLENOID 2 I SOLENOID 4 trl CONNECTOB J
\\ (t
@ z SOLENOIO 1 F CONNESTOR J
---L ]--'-.---
@
B
o
G,
o
@ POWEH SHIFI PHESSURE
SWITCH 4 =
Z
=
_\=\-::=
3
o-
{D Ir
t-:: TRANSMISSION OIL
TEUPEFATURE SENDER
ro
@l
126 LT BLUE/YELLOY'I
i ;\) -\-
127 S/HITE.TYELLOW
CLEAN GROUND {BATTERY NE NEGATTVE TEBMINAL)
.'- .l>>l'-=r=-='.
.
12A CLEAN GBOUND (BATTERY
_i
;) -i PowERSHtFT i
J!.,\ HARNESS -\..
ii
i..t
rBANSMlssoN
HARNESS CLFAN GROUND (BATTERY NEGATTV€ TENUIHAI'
CHASSIS GROUND
kaukazz@yahoo.co.uk
t
lssued 2-32
Don 8{8422
lssued 2-92 Printed in U.SA
6008-24
POWERSHIFT PRESSURE SWITCH OPERATING TEST
STEP 1 STEP 8
Apply the parking brake Connect the positive jumper lead between check points
2 (B) and 1a (P) of the breakout box, CAS 21'10, to
STEP 2 energize the 2nd speed solenoid. Check the 2nd speed
pressure gauge. lf there is no pressure reading the 2nd
Connect the breakout box, CAS 21 10, to the powershift speed solenoid ls failed closed.
harness, refer to Page 8. DO NOT connect the breakoul
box to the module. NOTE; lf there ls pressure on any of the other gauges
STOP the engine and check the manifold gaskets.
STEP 3
STEP 9
lnstallthe extension tubes, CAS 2009, to the powershift
manifold test ports and connect the pressure gauge Check between check points 21 (X) and 20 (W) of the
bar, CAS 10895, to the extension tubes, refer to Page 5. breakout box CAS 2110 lor continuity. lf there is
continuity then the 2nd speed pressure switch is failed
STEP 4 closed. Go to Step 14 Page 25.
Put the range lever in neutral and start the engine. Heat STEP 1O
the transmission oil to 150' F (65'C)
Connect the positive jumper lead between check points
2 (B) and 16 (S) of the breakout box, CAS 2110, to
energize the 3rd speed solenoid Check the 3rd speed
pressure gauge. lf there is no pressure reading the 3rd
speed solenoid is failed closed.
STEP 5
NOTE; lf there ls pressure on any of the other gauges
Check the pressure gauges. lf there is pressure on one STOP the engine and check the manifold gaskets.
or more of the gauges STOP the engine and check the
solenoid valve. STEP 11
Example, Check between check points g (J) and B (H) of thc

breakoul box CAS 2110 for continuity lf there is
It there is pressure on the 1st speed pressure gauge continuity then the 3rd speed pressure switch is tailed
check the 1st speed solenoid has not mechantcally closed. Go to Step 14 Page 25.
failed open.
STEP 12
STEP 6
Connect the positive JUmper lead between check points
Connect the positive jumper lead between check points 2 (B) and 17 fl-) of the breakout box CAS 2110, to
2 (B) and 13 (N) oi the breakout box CAS 2110, to energize the 4th speed solenoid. Check the 4th speed
energize the 1st speed solenoid. Check the 1st speed pressure gauge. lf there is no pressure reading the 4th
pressure gauge. lf there is no pressure reading the l st speed solenoid is failed closed
speed solenoid is tarled closed.
NOTEI lf there ls pressure on any of the other gauges
NOTE; lf there rs pressure on any ol the other gauges SfOP|,he engine and check the manitold gaskets.
SIOP the engine and check the manilold gaskers.
STEP 7
Check bctween check points 19 (VJ and 6 (F) of the

breakout box CAS 2110 tor continuity. ll there is
continuity then the 1st speed pressure swrtch is failed
closed. Go to Step 14 Page 25.
Don 8-88{22 lssued 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
6008-25
STEP 13 STEP 15
Check between check points 11 (L) and 12 (M) ol the Connect the pressure swrtcir to a hydraulic hand pumc
breakout box CAS 2110 for continulty lf there ts and connect a mullimeler ic the terminals oj lhc
continuity then the 4th speed pressure swltch is failed pressure swrtch.
closed Go to Step 14 Page 25
STEP 16
NOTE: lf the solenotds orpressu,re swttch reaction tirne
rs slow due to a sticking so/enold or pressure switch the Pressurize the switch The switch should open lNo
powershift module will detect a faull and will give Nvo, continuity) on rncreasing pressure before 120 pst (8 3
five or six dragnostic f/ashes. Refer ta Page 6. bar) Replace lhe svr:ch i necessary
STEP 14 STEP 17
Stop the engine and removc thc pressure switch from Belease the pressure on the switch The switch should
thc powershr't mani'olc c ose (Continuity) between 107 io 93 psi (7 4 to 6 4 bar)
Replace the swrtch r' necessary
FIVE POSITION HITCH CONTROL SWITCH FEEDBACK TEST

NOTE: The tollowing procedure is far tractors when the STEP 5
powershifl module will only reset when the engine has
been turned off and then restarted, refer ta Page b
STEP 1
Stop the engine and disconnect the I st speed pressure

switch from the harness.
STEP 2
Put the powershilt shrlt lever in the 1st spccd position

and start the engine
li the powershrit module resets, pu1 identifcation rnarks

on the hitch solenoid connectors and dtsconncct trre
solenoids from the harness lnstall a drode aoarlor
(1987587C1) between each or the sotenoids ana the
l'arness.
STEP 3
NOTE; For tractors equrpped wrth drode adaptc;rs Test
Cycle the inching pedal and check the powersril !aul: the diodes, refer to Srep 6
indicalor lamp The lamp should turn OFF lf lhe lamp
does ncl turn ofl checK tne rncnrr-g cedar l,'a-)t', tl STEP 6
creep crrcuit lefer ic Pagc 16
Connect the multimeter posrttve lead to termrnal B and
STEP 4 the negative lead to terrrinal A of the diode adaptor and
check for continuily. lf there rs NO CONTINUITY
Shrft the powershrft shifl lever into the 2nd speed replace the diode adator
position and cycle the inching pedal to reset ihe
powershift module l1 the rnoouie v,rtll nol resei aillst STEP 7
the lnchrng pedal positiorl swr:ch and creep lev(:r' swricn
(rl equrpped) refer tc Scclron 900 1
Connect the multrmeler positive lead to termrnal A aro
the negatrve lead to tern'rnal B o{ the diode adaptor and
check for contrnuity l{ there is CONTINUITY'eplace the
diode adator
Don I 88422
kaukazz@yahoo.co.uk
6008-26powrquadplus www.thebestworkshopmanuals.co.uk
POWERSHIFT CLUTCH PACK LEAKAGE TEST

STEP 1 STEP 7
Set the engine throttle at 1000 rpm Make a note of the

Apply the parking brake.
flow rate, the flow should be approximately 4 U.S gpm
STEP 2 15.1 Umin).
Connect the breakout box CAS 21 10, to the powershift STEP 8

harness, refer to Page 8 DO NOT connect the breakout
box to the module. Connect the positive jumper lead between check points
2 (B) and 13 (N) of the breakout box CAS 2110, to
STEP 3 energize the 1st sPeed solenoid.
STEP 9
Make a note of the clutch pack pressures and the fiow

rate.
NOTE: Use the chart on Page 27 to record the

readings.
NOTE: lf there are pressure readings on the 2nd, 3rd or

4th speed pressure gauges check the powershift valve
b/ock gaskets and solenords-
STEP 1O
Connect the positive lumper lead between check points

2 (B) and 1a (P) of the breakout box CAS 2'1'10' to
energrze the 2nd sPeed soienoid
Connect the flowmeter, CAS 1 0280 to the remote valve
block STEP 11
STEP 4 Make a note of the clutch pack pressures and the flow
rate.
lnstallthe extension tubes CAS 2009 to the powershift
valve tesl ports and connect the pressure gauge bar, NOTE: lf there are pressure readings on the 1st, srd or
CAS 10895 to the extension tubes, refer to Page 5' 4th speed pressure gauges check the powershift valve
b/ock gaskels and solenoids.
STEP 5
STEP 12
Put the range lever in neutral and start the engine Heat
the transmisslon oil to 150'F (65" C) and set the Connect the positive iumper lead between check points
flowmeter pressure to 1000 psi (69 bar). 2 (B) and 16 (S) cf the breakout box CAS 2110 to
energize the 3rd sPeed solenoid
STEP 13
Make a note of the clutch pack pressures and the flow

rate
STEP 6
NOTE: tf there are pressure readings an the 1st, 2nd or
qh speed pressure gauge s check the powershift valve
For tractors equipped with MFD put the MFD switch in
block gaskets and so/enoids.
the ON position
lssued 2-92 printed in U.S.A

nta A-AAA))
kaukazz@yahoo.co.uk
6008-27
STEP 12
Connect the positive jumper lead betrveen check points

2 (B) and 17 fI) of the breakout box, CAS 2110, to
energize the 4th speed solenoid.
STEP 11

rate.
NOTE: lf there are pressure readings on the 1st, 2nd or

3rd speed pressfre gauges check the powershift valve
b/ock gaskefs and solenoids.
CLUTCH PACK PRESSUBE
tst
SPEED 2nd SPEED 3rd SPEED 4Ih SPEEO FLOW RATE
CLUTCH CLUTCH CLUTCH CLUTCH
1st SPEED CLUTCH TEST
2nd SPEED CLUTCH TEST
3rd SPEED CLUTCH TEST
4th SPEED CLUTCH TEST
pack
NOTE: lf there are pressure readings on any ol the pressu re gauges other than the pressure gauge for the clutch
being tested check the powershift valve block and the so/enoids.
NOTE: ThereshcutdnotbemorethanO.SlJSgpm(0.44U.Kgatlmin,2.0Llmin)differenceintheflowratesrecordedfor
the clutch packs and the tlow rate noted in Step 5 Page 26.
Don 8-88422
lssued 2-92 P.rlled rn J S A
kaukazz@yahoo.co.uk
6008-28
TEST RECORD SHEETS
CLUTCH PACK PRESSURE
ffils,osrEgol+rnseeeo FLOW RATE

cLUrcHlclurcrilclurculclurcx
FLOW RATE
cLUrcHlclurcrlcLUrcHtcL!I9!-
1st SPEED 2nd SPEED 3rd SPEED 4th SPEED FLOW RATE
Ist SPEED CLUTCH TEST
CLUTCH PACK PRESSUBE
FLOW RATE
cLUrcH I crurcH I clurcr _[ cuurcr
lst SPEED CLUTCH TEST
Don 8-88422
lssued 2-92 Printed in U.S.A
kaukazz@yahoo.co.uk
6008
POWERSHIFT TROUBLESHOOTING AND SCHEMATICS
For Tractors From PIN No JJF1 015046
To Be Used With Section 4001
Copyrigrt q 1992
Prrnted ln Engiano
May 1992
kaukazz@yahoo.co.uk
6008-2
TABLE OF CONTENTS
2
INTNODUCTION .. .
3
GENERAL INFORMATION .
3
SPECIAL TOOLS
4
SHOP EQUIPI/ENT TOOLS. . ... .
4
TOOLS TO BE MADE.
5
POWERSHIFT SYSTEM CON/PONENTS
o
POWERSHIFT FAULT INDICATOR LAMP
7
POWERSHIFT TROUBLESHOOTING GUIDE
B
POWERSHIFT ELECTRICAL TROUBLESHOOTING I
CircuitTesting .. . .
11
Powershift Solenoid Circuit Test.,... . ' tz
Powershilt Pressure Switch Circuit Test 14
Transmission Oil Temperature Sender Circuit Test 14
Powershift Shift Lever Switch Circuit Test ' "
'
15
Powershift Fault lndicator Lamp Circuit Test 16
lnching Pedal Positron Circuit Test "" 17
Schematic Circuit . ......,
18
POWERSHIFT PRESSURE OPEBATING TEST
19
CTUTCH PACK LEAKAGE TEST
INTRODUCTION
4 without needing to cycle the inching pedal
The powershift is the systern used to change gears 1 to
into electrical signals at the shifter assembly and
The movements of the powershift transmission lever are converted
control module receives electrical signals both from the
transmitted to the powershift control mocjule, The powershift
powershift mani{old Dependant upon the electrical signals
shifter assembly and from the pressUre switches in the
in the powershift manifold The solenoids operate the
received, the powershift control module operates solenoids
hydraulic circuits that control the clutches of gears 1 to
4
l-lydraulic faults in other systerns may also prevent correct

Faults in the powershift system may be hydraulic or electrical.
powLrshift system the powershift control module will detect
operation of the powershift system. lf a fault occurs in the will rematn
(Drive) and (Stop) in the Drive fail mode the module
the fault and select a fait mode There are wo faiimodes placc
in the current speed (A) after a change is made to the selected
specd (B) thrs will aliow the tractor to be drrven to a
the transmission thc modulc will select thc Stop mode
of repair lf the module detects a tautt that will cause damage to
and the traclor cannot be driven
fault indicator lamp located on the instrument
panel The
Faults in the powershift system are indicated by the powershift fault in the
is turned to the oN position f there is no
incjtcator. lamp should illuminate when the starter key switch the lamp will
there is a fault in the cowershift sysiem,
powershift system, the lamp willgo outwhen the engine is started. lf
gear selected and the inching pedal fully cycled
remain illuminated or will flash after the engine rs"started a
powcrshift system, usc the appropriaie Powershift
when the powershift fault rndicator lamp indicatcs a fau t irr thc does not locate the fauit
Powershift Troubleshooting Guide
Troubleshooting Guide to locate and repair the faLrlt lf the
the fault may be outside the powershift system
lssuccl 5-92 Prinled rn England

Don 7-37470
kaukazz@yahoo.co.uk
6008 3
GENERAL INFORMATION
NOTE: All electricalchecks musl be rnade wtth tha ltacta!: parkt)cl on harC leval ground wlth the parktng brake engage:l
and the engtne OFF unless olire,'vvise s/aled
NOTE: All comDoncrrl.s 'v/re.s an:l :.ctr''ect:':,

checks Aic cai.tAietr)
SPECIAL TOOLS
BRFAKOUI BOX CAS 211C O\,'f ziA/ CAS 2187 2 ADAPTFR HARNESS CAS 2186
trrr:ll ,iseci a)r'It:](lc t Firsl Usod On Page I
s 3, FOUN EXTENSION TUBES

(From the hydrauLrc test krl for ihc 5100 Ser os traclor)
4 PRESSURE GAUGE BAR
cAS 1 0895
CAS 2OO9 First Used On Page 7
Frrsl Used On Page z
Don'/'374/a ss-rd ) 92 ;)'n'c' [^ga^:
kaukazz@yahoo.co.uk
6008-4
2. FLOWMETER CAS 10280

1 MULTIMETER
3, HAND PUI/P CAS 1OO9O
SPECIAL TOOL TO BE MADE
9i''9j-[=1;1fr-
-
,, ---
CONNECT TO
3 CONNECT TO
POWERSHIFT SHIFTER ASSEMBLY
POWERSHIFT CONTROL MODULE
CONNECTOR COMPRISES:
CONNECTOR COMPRISES:
CONNECTOR CASE PART NO. 245488C1
CONNECTOR CASE PART NO, 245489C1
TERMINALS CASE PART NO. 225123C1
TERMINALS CASE PAHT NO. 225120C1
CABLE SEALS CASE PART NO- 225124C1
CABLE SEALS CASE PART NO. 225124C1
l
WIEE GAUGE CONNECTOR COLOUR
(mm') PIN OUT I
I
20 (0.8) A BHOWN
20 (0.8) B RED I
20 (0.8) ORANGE I MAKE MULTI-METER CONNECTIONS HERE

20 (0.8) D YELLOW CONNECTOR COMPRISES.
20 (0.8) E GREEN =
.._:. CONNECTOR CASE PART NO' 245488C1
TEBMINALS CASE PART NO. 225123C1
20 (0.8) F LT- BLUE CABLE SEALS CASE PART NO.225124C1
l.
WIRING ADAPTEH TEE HARNESS
lssued 5_g2 printed rn England

Don 7 -37 47O
kaukazz@yahoo.co.uk
6008-s
POWERSHIFI SYSTEM MAJOR COMPONENTS
Iol
,/v
(8) \' L
l
-\ \./ /'.'
--d
n'.
..t
/i---'---- : /\-n-' \
I ----/
I" tL-'
'; :-\- .-
,/
-'-- t'
/r--i-"
t_!
\-,
F-1 \- \-
\,
COMPONENTS CONNECTOqS
6, 1ST SPEED SOLENOID J POWERSHIET HARNESS TO POWERSHIFT MODULE
6A, 2ND SPEED SOLENOID L. POWERSHIFT MODULE TO POWERSHIFT SPEED
68. 3RD SPEED SOLENOID SELECTOR LEVER SWITCH
6C,4TH SPEED SOLENOID

6D, 1ST SPEED PRESSURE SWITCH PRESSUBE TEST PORTS
68, 2ND SPEED PRESSURE SWITCH 1 1ST SPEED TEST PORT
6F 3RD SPEED PRESSURE SWITCH 2 2ND SPEED TEST PORT
6G, 4TH SPEED PBESSURE SWITCH 3 3RD SPEED TEST PORT
8. POWERSHIFI MODULE 4 4TH SPEED TEST PORT
9, POWERSHIFT SPEED SELECTOB LEVER SWITCH
1 O, POWERSiiIFI MANIFOLD
,.. | a) ).'.,'rr' 'f ' 't'

I)an 7-3747C) ^^
kaukazz@yahoo.co.uk
6008-6
POWERSHTFT FAULT INDICATOR LAMP
The check powershift fault indicator lamp is arnber and will illuminate if thci'c is a fault in the powershift system
The powershift module controls the operation of the powershift transmission When a fault occurs the
powershift fault
rault by flashing diagnostic
indicator lamp will illumrnate Also the module will give an indication to the nature of ihe
codes on the fauli tndicator lamP.
When the powersh ft indicator lamp is rlluminated hold the rnching pedal fully down and count the number of f lashes on
the iault ,16igslor lanp
The Diagnostic Codes are described as follows
LAMP FLASHING CODE POSSIBLE FAUTT
ONE FLASH lndicares the module is recerving none or mulliple sh ft lever signals
TWO FLASHES lndicates the off gorng pressure swtch circuit has failed
THREE FLASHES Indicates ihe lemperature sensor crrcuit has failed open or shorted to ground
FOUR FLASHES lndicates tnat one or more of tne powershitt solenords is shorted to ground
FIVE FLASHES lndicates the on coming clutch pressLirc switcn circuit failurc
SIX FLASHES lndicates none or multiOle clutch pressui'es detected by the module
MORE THAN SIX FLASHES, Tractor still moves, incjicates clutch pedal switch circurt failure
TRACTOR DRIVES
Indicates the rnodule has received none or multrple shift lever signals
LAMP ON STEADY
TRACTOR DRIVES Should rcad one flash when the inching pedai is hcld down
lhe SHF
NOTE; tf the powershift mociule vyitl not reset without turning the engine off , then restarting the engtne Check
suporession diode module, refer to Sectron 4001 -
NOTE: The module is not equipped with therefore lhe //ashes must be counted as they
a diagnostic code memory,
occur. Turning oft' the engine or cycltng the inching pedal witl reset the rnodule and the lault code will be lost.
POWERSHIFT FAULT
INDICATOR LAMP
7Ft 7E-it
.:- i r r:'ll
(@)))
Dar 7 -37 470 lssued 5-92 Prlntcd in England
kaukazz@yahoo.co.uk
6008-7
POWERSH IFT TROUBLESHOOTING GUIDE
FORWARDIHEVERSE ERse Reuv
Remove the forward/Reverse Flelay. Refer to Fig.1 POSSIBLE CAUSES

- Check the Powershift Fault
lndicator Lamp Circuit,
Turn the key to the ON position - Reier to Pages 5, 8 and 9 Tests t
to 3.
Did the powershift fault indicator - Check the Powershift module
lamp illuminate ?
Power and Chassis ground
Circuits RIGHT HAND I IND FUSE/RELAY BLOCK
I
lnstall the pressure gauges to the Fr( FIGURE 1

powershift manifold test ports,
Refer to Page 5.
Start the Engine and Cycle the

lnching Pedal
Shift the Powershift Lever through
ls the powershift fault indicator all gears
Heat the transmi ion oil to a
lamp on steady or flashing ?
Did the powershift fault rndicator temperature of 1
lamp illuminate ? Shift through ali gr
lnlermittant fault or fault not
Did the powershifl ishift fault indicator duplicated. Check for loose and
lamp illuminate ? poor ground conneclions
NOTE: ff ttle sqeed shifted in foo is

ls there pressure on one of the pressure gauges ? knawn, when the fault accured check
the pressure sw'fch ci rcuit of thatspeed
FIVE TLASHES
only. Refer fo Pressure Swtch Circuit
YES NO Test Page i2.
(DRTVE FAULT) (sToP FAULT) Example: lf the fault occured fram
speed 2 to sPeed 3 check the 3rd
speed pressure swfch circuit.
ls the powershift fault indicator Hold the inching ; pedal fully down and count the
lamp on steady or flashing ? number of flashes
Check the inching pedal switch ial

iJI FOUR FLASHES
circuit. Refer to Powershift ]I
,
Electrcal Troubleshooting on
Page B. Circuit Testing, Tests NOTE: tf the speed shil shifted Check the solenoid circuits. Check the solenoid and
out of is known, when hen the Hefer to Powershift Electrcal pressure switch circuits. Refer
Tests 13 to 16 on Pages 9 and
Hotd the inching pedal tully down and count the 10. fault occured check ick the Troubleshooting on Page I. to Powershift Electrical
number of flashes pressure swtch crrcuit lcuit ot Circuit Testing, Tests 5 to B Troubleshootingon Page 8.
that speed anly. Refer lefer to on Page 9. Circuit Testing ,Tests 5 to 12 on
Pressure Swfch Circuit 1 lull Iesf Pages I to 10, Also carry out
Page 12. the ciutch pack leakage test on
check the temperature sensor Page't9.
circuit. Reter toPowershift Example: lf the fi fault
Elecircal Troubleshooting on occured kam speed 2 2to
Page B. Circuit Testing, Tests speed 3 check the i 2nd
Check the powershift speed
13 to 16 on Pages 9 and 10. speed pressure sw, switct't
circuit.
kaukazz@yahoo.co.uk selector lever switch circuit,
refer to Page 14,
Don 7-37470 issued 5-92 Printed in England
6008-8
POWEHSHIFT ELECTHICAL THOUBLESHOOTING

STEP 1 STEP 3
Park the tractor on hard, level ground and apply the Connect the adapter harness CAS 2'1e6 to the
parking brake powershift harness (1) Do not connect the adaPter
harness to the module
STEP 2
STEP 4
1r-1 Connect the breakout box CAS 2'110 to the adapter

harness CAS 2186 and connect the ground lead of the
L) breakout box to the negative ( - ) terminal of the battery

lnstall the overlay CAS 2187 onto the breakout box,
CAS 21 1O
IMPORTANT: Nl checks are fo be made at the

breakout boxfrom the operalors seat using a rnultirneter
unless otherwr'se stated.
STEP 5
Remove the ForuardlReverse Helay Refer to Fig 1
Disconnect the powershift harness (1) from the module Page 7

(2) at connector U)
NOTE: After all checks have been made install the
ForwardlReverse relay
CAS 2110
GRoUND
"*Î'.@
BREAKOUT BOX CAS 21'10 AND OVERLAY CAS 2187
NOTE: The tetters on the breakout box AtoW carrespond with the idenification lefters on the pins of cannectars C ancl
J
rcfer ta the Schematic on Page 17
Don 7-3747C
issued 5-92 Printcd in Engiand
kaukazz@yahoo.co.uk
6008 9
Circuit Testing
NOTE: Thebatterymustbealfult chargeandallconnecllonsmuslbecleanandtightbeforetesttng.Useamulttmeterfor
Ihe fests
NOTE: fesl 7 to 16 are made at the breakaut box ONLY
NOTE: Connect the breakout box CAS 21 10 rc ne pa\,lershift harness 'e[er to Paqe B, DO NOT connect the breako,Lt box
to the module.
NOTE: Check /uses F20 F25. F26, F27 and F2B
NOTE: Turn the key to the ON Posttlon

Breakout Box (CAS 2110) Check Points Beading Possrble Cause o.f Bad Bead nq
Power Supply and Chassis Ground Test

3"nruor 3 arc Cnassrs Grourc+ 12 Volts Bad circurt between the accessory powcr
Q of rlre breakout box relay and the powershift module connector
(Pin B) Also check the accessory powor
rclay, rcfcr lo Scction 4001
G) frru":-?,:? ctass s Ground $ Contrnu ti; Bad crrcLrit tletween the module connector
G' ard lhc batlcry negarrvc /
rPrn I
teIminai
Powershift Fault lndicator Lamp Test
NOTE: Turn the key to the ON Posrtion
reacl bcrwecn Powcrshrf t Chcck tnc powershilt fault rndicator lan'p

G) 3rur:,'["ff:::l",i1rnPer ts
-auii uamP Jrrcu I rc cr 'o Pagc 15
lilr rrr rnair:d
Temperature Sensor Test (3 Flashes)
NOTE: Turn the key to tne OFF posttron
() GroLrnd * 112 io I /8/ Ohrrs Check thc temperature sender circuit rcier
rlil:r":-l:ichassis iRcier :o taDle on :o Page 14
Pagc I 4)
Solenoid Test (2, 4, 5 and 6 Flashes)
NOTE: Iurn thc kay io lhc OFF postlton
56 Cnn's ' Chec< thc powershif: solcnord clrcurt. rctc'

Aut*."n N and Chassis
@ ol Ground =*- 1A%
:o Pagc 11
tHc brcal"out box
Gl g.t*""n P and Chassrs Grouncl $ c 6 Ohrqs ' 1O/" Check thc powcr-shift solenoid circui[, refer
v of thc brca(out Lrox
.1
io Page I
Between S and Chassrs Ground $ 56Ohms t 10% Chcck the powersniit solcnoid crrcutt refcr
of the irreakout box 1oPage 11
Between I and Chassis Ground { 5 6 Ohms :: 10"/" Chcck tne powershiit solenoid clrcult. refcr
of the breakout box :o Pag;e 11
ss-Crl 5 g2 ;). nlCC r^ E rqlaac
f)',^ i JiAlC
kaukazz@yahoo.co.uk
6008- 1 0
Pressure Switch Test (2, 5 or 6 Flashes)
a"t*uun V and F ot the breakout box Continuily Check the powershilt pressure switch
@ circuit, refer to Page 12
aut*u"n E and W of the breakout box Continuity Check the powcrshif t pressurc switch
@ circuit, refer lo Page 12
A**uun J and H of the breakout box Cont nuity Check the powershift pressure switch
@ circuit refer to Page 12
A.*"un L and K of the breakout box Cont nuity Check the powershift pressure switch
@ ctrcuit, re{er to Pagc 12
NOTE: tf thereadingstofestpornlsg tol2arecorrect,checkthepressure switchoperation,refertoPagelS'

lnching Pedal Switch Test (Continuous Flashing)
aut*""n C and R of the breakout box Contrnuity Check the inching pcdal position switch
Gl crrcuit, refer to Page 16
aet*"en C and A of the breakout box No Continuity Check the inching pedal position switch
Gl circuit refer to Page 16.
NOTE: Hold the inching Pedal DOWN
Between c and A of the brcakout box continuity check the inching pedal posit on switch
circuit refer to Page 16
Continuity Check the inching pedal position swttch

llil g.w."n C and R of the breakout box No
circuit refer to Page 16,
lssucd 5-92 Printcd in Enqland

Don 7-37470
kaukazz@yahoo.co.uk
5008-r 1
Fowershift Solenoid Circuit Testing
NOTE: Connect the breakout box, CAS 21 10, ta the powe rshifl harness, reler lo Page 8. DO NOT connect the brea\aut
box to the module.
Breakoul Box (CAS 2110) Chcck Points ileading Pcssrble Causc of Bad ileadtng
1st Speed Powershift Solenoid
NOTE: Disconnect the 1st speed powershit solenoid ltom the harness
@ Aut*""n chcck Dorrt N and termirral A oi thc Con:rnurtv Bad circui: beuccn connector J (Pin N)
solenord connector (Harness s de) and tne lsl soee d soicnord lerminal A Als<l
check connector C (Pin N)
CEI Bu,*..n chccK oornr Chass s Ground == Continuity Bad chassrs ground circuil Also chec( lne
and termrnal B of the solenoid connector chassis ground connectrons at inc
(Harness side) powershift manifold
Between lerrrinals A and B ol the solenotd 5 6 Ohrns : 10"A Bad scicnc O
NOTE: lf the readings are correci, connect the solenold ta the harness and cannecl the positlve jumper lead betweer'
check points I and N at the breakout box. Turn the key lo the ON pos itan tf the salerotd does nol turn ON
'clrck repca:
Iesls 77 and 18
2nd Speed Powershift Solenoid

NOTE: Cl.eck luse F26
NOTE: Discannect the Znd speed powershrfl solenotd from the ha'ness.
@ a*,*""n check pornt P anci terminal4 6f lire ContinLlry Bad circur: betr.vecn conncclcr J (Prn P) anc
solcnoid Connector (Harness Stde) lhe 2nd speed solenoid terrninal A Also
citcck conncctor C (Prn P)
fi) R"*""n cncck Do'nr Urassrs Grolrno -! ContrnL;ity Bad chassrs ground circurt Also cneck thc
-- and termrnal B of the soleno d connector chass s qrolnd connections at th{.
powcrshift manifold
(Harness side)
Br:tween lcrrninals A and B o1 thg solet'rotd 56 Onms :. 10'/" Bad solenoid
NOTE: tf the readings are carrect, connect the solenoid to the harness and connect the posrtive iumper lead betutaen
chcck points B and P of ihe breakout box. Turn the key to the ON position rt' the solenord ips5 not lurn ON cl:ck' repeat
lests 79 and 20
3rd Speed Powershift Solenoid

NOTE: Check tuse F2/
NOTE: Disconnect the 3rd speed powershrll solenard from [he harness.
A.t*."n check point S ancj terminal A oi thc

@ solcno,o Continui:y 3ad c,rcuit between conneclor J (Prn S) anO
co^ncclo' sidc)
lFrarncss :f'c 2nd spocd soicnr: cJ terrninal A Also
chcck conncctor C (Prn S)
Dar / 37470 Ssit(xl 5 92 Pr^la(r,^ [ -ei,ti..
kaukazz@yahoo.co.uk
6008-1 2
@ au*"un check point Chassis Ground * Continuity Bad chassis ground circuit. Also check the
and terminal B of the solenoid connector chassis ground connections at the
(Harness side) powershift manifold
Between terminals A and B of the solenoid 5.6 Ohms -' 1A7o Bad solenoid
NOTE: lf the readings are correct. Connect the solenoid to th€) harness and connect the positive jumper lead between
check points B and S of the breakout box. Turn the key to the ON positron if the solenord does not turn ON 'click' repeat
tests 27 and 22.
4th Speed Powershift Solenoid

NOTE: Check tuse F28
NOTE: Disconnect the 4th speed powershift solenoid from the harness.
@ a*u9n check pointT anrj terminal A of the Continuity Bad circuit between connector J (Pin T) and
solenord connector (Harness side) the 4th speed solenoid terminal A Also
check connector C (Pin T)
Between check point Chassrs Ground * Contrnuity Bad chassis grouncl circuit. Also check the
and terminal B of the solenoid conncctor chassis ground connectrons at the
(Harness side) powershifi manifold
Between termrnals A and B of the solenoid 5 6 Ohms * 1A7o Bad solenoid
NOTE: tf the readings are correct. Connect the solenoid to the harness and connect the positive iumper lead befween
'click' re peat
check points B and T at the breakout box. Turn the key to the ON pos itron if the solenotd does nol turn ON
fests 23 and 24
Powershift Pressure Switch Circuit Test

NOTE: Connect the breakout box, CAS 21 10, to the powershill harness, refer to Page 8. DO NOT connect the breakout
box to the module.
1st Speed Pressure Switch
NOTE: Disconnect the 1st speed pressure switch from the harness
Breakout Box (CAS 2110) Check Points Readrng Possible Cause of Bad Beading
.-, Continuity Bad circuit betwce n connector J (Ptn V) and
Qp Acueen check pointV and terminalA of the
pressure swrtch connector (Harness side) the 1st sPeed Pressure switch.
@ a.m".n check point F and terminal B of the contlnuity Bad circuit between connector J (Pin F) and
pressure switch connector (Harness side) the 1st sPeed Pressure switch
Between termrnals A and ts of the pressure Continuity Bad pressure switch

switch
NOTE: lf the readings are correct, refer to pressure switch operation Page 18
f)on7'37470 lssued 5-92 Printed in England
kaukazz@yahoo.co.uk
6008 1 3
Breakout Box (CAS 2110) Check Potnts Bcading Possible Cause of Bad Rcadrng
2nd Speed Pressure Switch

NOTE: Disconnecl the Znd speed pressura swttch from lhe narnes.s
Breakout Box (CAS 2110) Check Points Readtng Possible Cause of Bad ReadinE;
a.*u.n cireck pornl E anrj tcrminal A 01 thc

@ pressure Continuity bclwr:cn connccior J (PLn E) and
Baci ctrcurt
switch corrnector (Harness side) the 2nd speed pressure swrtch
Between check Oornt W anrj terminal B of Continuity Bad crrcuit Oelween connector J (Pin W)
the pressure switch connector (llarncss and the 2nd speed oressure switch
s ide)
Belwee n terrn nals A and B of the pTCSSUTC Ccntinuily Bacl prcssurc switch
switch
NOTE, lt the reacltn.qs are carrect. refer to pressure svtttch operatrcn Page 18
3rd Speed Pressure Switch

NOTE Disconnacl the 3rd spced FrressL,re swi(cti tront the ha,'ness
@ nour""n checn point J and terminal A of the Continurly Bad oircuit belween connector J (Pin .J) anct
pressrlre swrtch connector (Harness sidc) the 3rd soeed cressure swiich
6lil 3",*""n clrcck pornt E and tcrrrinal B of trre Conlinurly Bad circuit betwcen conncctor J (Pirr rl)
otcssure swrlcl connccior iHarncss Srdc) and iho 3rd sPccd PrcssLro swrlch
Betrveen fe rmlna s A and B of the Dressurc Contini' tv Bad pressu.e slvrlch

switch
NOTE: tf the readrngs are ccrrect reler io pressurer svtrtch operalton Page 18.
4th Speed Pressure Switch

NOTE: Disconnect the 4th speed presstrre sv'titch fron the harness.
6I) Au*""n check point L and terminalA of the Continuiry Bad crrcurt betr,veen connecior J (Pin L) ano
pressure swttcl'r connector (Harness sice) tirc 4th sPeed Pressure switch
Ao*."n check point K and termrnal B of the

@ pressure Continurry Bad circurt betvveen connector J (Ptn K) and
switch connector (Harness srde) lhe 4li' sPeed Pressurc sivrtch
BeMeen tcrrninais A and B of thc pressurc Contirturiy Bad pressure swltch

swLtch
NOTE: lf the reaclings are carrect, refer to pressure switch operation Page 1B
Ocn l-374lC lss,rcd 5 92 Prlr'1c(l rrr F-glant:
kaukazz@yahoo.co.uk
6008-1 4
Transmission oil Temperature sender circuit Test
NOTE: Connect the breakout box, CAS 21 1A, b the powershift harness, refer to Page 8. DO NOT connect the breakout
box to the madule.
Breakout Box (cAS 2110) check Points Reading Possible cause of Bad Reading
Between check point M and the Continuity Bad circuit belween connector J (Pin M)
temperature sender and the temperature sender
Between the temperature sender and See Table Below Bad temperature sender'
chassis ground
OIL TEMPERATURE OIL TEMPERATURE RESISTANCE OHMS

RFSISTANCE OHMS
.C 'F 'C "F
- 17.8 0.0 1519 to 2055 267 80.0 413 to 599
- 12.2 10 O 1305 to 1765 32.2 90,0 378 to 510

20.0 to 1 453 37 8 100 0 331 to 448
- 6.7 1 074
43.3 1 1O.O 292 to 395
'-3 9 25.O 981 lo 1327
48.9 120 0 253 to 343
-11 3OO 9121'01234
0.0 320 906 to 1226 54.4 130.0 225 to 305
4.4 4O.O 770 to 1040 65.5 150.0 17810 240
10.0 50.0 871 to 908 76.7 170.0 141 to 191
15.6 60.0 575 to 778 87 .B 190.0 1 15 to 155
21 .1 70 0 506 10 684 98.9 210.0 95 to 129
Powershift speed selector Lever switch circuit Test

to make ancl use the specral tool shown
NOTE: Io test fhe powershif/ shr// s peed .selector lever circuit it wilt be necessary
on Page 4 af thts section.
modute to the harness at connector J and cJisconrtect the powershift shtft

speed selector
NoTE: Connect the powershift
/ever assernbly from the powershill module at connector L'
check points Reading Possible cause of Bad Reading
BetweenterminalsAand Bof connector L 45 to 56Volts Bad powershift module

(Module side)
Between terminals A and c of connector t- 3 B to 4 6 Volts Bad powershift module

(Module side)
BetweenterminalsAand Dof connector L 3B to 46Volts Bad powershiftmodule

(Module side)
Between terminals Aand Eof connector L 3B to 46Volts Bad powcrshift module

(Module stde)
Between terrninalsAand Fof connector L 3B to 46Volts Bad powershift module'

(Module side)
to fools lo be Made, Page 4, betvveen the tvva terminal btacks of connector

L
NOTE: Connect the Tee Harness, refer
NOTE: Put the powershift shitl lever in the 1st speed positton.
lssued 5'92 Printcd ln England
r)an 7 37110
kaukazz@yahoo.co.uk
6008 1 5
Betvveen terminals A and B of the open 4 5 to 5 6 Volts Bad powershift speed select lever
connector of the Tee Harnoss assembly
Betvveen terminals A and C of the open 0 io 0 5 Volts Bad powershrft speed select lever
NOTE: Mave the powershrlt shitt lever aul of 1sl spesd.
Belween ierminals A and C of thc open ll B to 4 6 Vol:s Bad powersh ft speed select lcvcr
connector of thc Tee Harness assembly
NOTE: Put the powershift shitt lever to the 2nd speed position'
Between terminals A and D of the open O to 0 5 Volls Baci powershifl spccd sc ect lcvcr
connector of the Tec Harness assembly
NOTE: Move the powershtft shift tever out of 2nd speed
Belween terminals A and D of the ooen 3 B to 4 6 Volts Bad powershift speed select levcr
connector of thc Tec Harness assembly
NOTE: Put the powershrft shifl lever in 3rd spced
Between terminals A and F o1 ihe opcn 0 1o 0 5 VoltS Bad powcrsh'il speed select rcvcr
connector of the ice [ ]arness assemb y
NOTE: Move the powershift shift lever oul cf 3rd speeo
Between terminais A and E of ihc open 3 8 to 4 6 Volts tsad powcrshrfl speed select lcvr:r
connector of thc Toe Harncss assembly
NOTE: Put the powershifl shit tever in the 4th speed posrlror
BeMeen terrninals A and F 01 lhe open o to 0 5 Volts Bad powershift speed selecl lever
conneclor cI thc Tee Harness assembly
NOTE: Mr:ve the powcrsl-tll shtlt teve r oul al 4tn specd
Between te.rnrnas A and F of lhc ooen 38to46Volls Bad oowershrlt soeed selec[ lcvot
conneclo!- of the Tcc Harness assernb y
Powershift Fault lndicator Lamp Circuit Test

NOTE: Chec:k thc ;:owershifl faull indicalor lamp bult-t
NOTE: Turn the ke'/ tc lha ON Pcsrlron
Peadinc Possrble Cause of Bad Readrng
Terrrrinal ior wire 32g White/Brown to 9 to 14 Volls Bad circurt bctween the fault indicator l'ghl
grounrl Approximatcly anc the powershitl rlodulc aiso chcck thc
cowershrtt rnodule
NOTE: Turn the key to the aFF pos"t;cn
ru|,* nal for wrrc 102 3rown to ground Conlrnurty Checx wirc 102 a1d the chassis ground
€i connecl!on
Dot' 7 3i41C
kaukazz@yahoo.co.uk
6008-1 6
lnching Pedal Position Switch Circuit Test
NOTE: Connect the breakoutbox, CAS 21 10, to the powershirt harness, refer to Page 8. DO NAT connect the breakout
box to the module.
NOTE: Disconnect the inchtng pedal frorn the harness
Po,ntt Beading Possible Cause of Bad Beading

Breakout Box (CAS 2110) Check
Continuity Bad circuit betwe en connector J (Pin A) anc

@ a"*".n check point A ano terrninal C of ihe
position switch conneclor the inching Pedal Position switch
- inchinq pedal
(Harness side)
Continuity Bad circuit betwcen connector J (Pin C)

Bctween check point C and terrlrnal B o1 thc
inching pedal position switch conneclor and the inchrnQ pedal position switch
(Harness side)
Continurty Bad circuit between connector J (Pin B) and

6l!l
v got**"n check point R and termrnal A of ihe the inching pedal position switch
- tnchinq cedal position switch connecior
(Harness side)
BetwecnterminalsAandBofthctnchlngContrnuityBarlrnchingpedalpositionswitch
pedai posiiion switch
NOTE: Hold the inching Pedal DOWN
c o{ the inching continuity Bad inching pedal position switch

Between terminals B and
Positron Pedal switch
lssued 5-92 Printed in Englano

Don 7-37470
kaukazz@yahoo.co.uk
6008 -1 7 6008 -1 7
Schematic Circuit
{ aoor-rs
325 DB/w 0.s) 325 DBnl/ (1.s)

iil 2A
DB/11/
325
326 WDB {0.7{
327 W {0.7s)
-
_ 326 WDB {0.7s)
327 W (0.7s)
32s DB/W (1.s)-
326 WDB {0.75}
(2.5)
DBiVV
327 W (0.75i-
(1.5) 328 LB (0.75) - 328 LB (0.7s)
il 32s wBR {0.75 - 32s WBR {0.75)
328 LB (0.75)
:i 35 326 328 - 330 WP (1
329 V\{AR {0.7s)
(1.0)-
330 t4l,P
-
\---i !ii
ii ti
B,fiB
(2.s)
WDB
(0,75)
LB
(0.7s)
I r--
332 W8 {1
l,J4 wrr
334 yylY (1
{r
332W€(1.0)-
gUW{ {1.0)-
-
lii I I
)rbb@)@5 i-336
327
j*-.- -\\ S \-
:.
\- 19
I
w
(0.75)
3*
ffr6 $r.oc (1.0)
- '/{n'
I I
FUW WIBR
{0.7s) (0.75)
')>-. I
I
L.,,,
'.' { +oor-ror
i ffi
{ -_ \ -::--:-
\-*x
I
\ -sesDery(. (1.0)-
t\
33i! DE/B
--....1 331 DB/P (1.0)
{*,
tl
re \3 324 331 DE/P (1.0)
339 LB/P (o.75)
340 BH/P (0.75)
331 DB/P (1.0) 351
LB 341 LBiB (0.75) o
,H,O (0"7s) 3€r3 DB/B (1.0) 342 BR/B (0.7s)
/'A
i0.8)
34il LB/v (0.75) 3S
001-71 344 BRrY {0.75) LB
345 LB/DG (0.75)
@\
(0.8)
346 BR/DG {0.75}
347 Y (0.75)
@
37
346
/
*i'o(
Rlu 346
BR/DG
{1.5) BR/DG
(0.7s)
142 v2 I
348
\@{
BB IR BR/W
I
(1.0) .0) I (1^s)
I __l
I
d
36 SH (1 338 BE (1.0) 338 BR (1
(1 0)
COMPONENTS CONNECTOFS
1. KEYSWTCH 2G. FUSE F27 (7.5A) 6C. 4TH SPEEB SOTENOID D SOLENOID C. POWERSHIFT HAFNESS TO INSTRI.,'MENT PANEL HARNESS mm2 Wire Gauge
2. FUSE F19 {10A) 2H. FUSE F28 (7.5A) 6D- lST SPEED PRESSURE SWITCT D PHESSURE SWTCH J. POWERSHIFT HARNESS TO POWERSHIF' MODULE
2.5 o
2A. FUSE F17 (104) 3, ACCESSOHY POWEB RETAY 6E.2ND SPEED PflESSURE SWITG D PRESSURE SWITCH L, POWERSHIFT MODULE TO POWERSHIFT SPEED SELECTOR LEVER SWTCH
1.s 5
28. FUSE F32 r.sA) 4. POWEHSHIFT FAULT INDICATOR LAtI,tP 6F. 3RD SPEED PRESSURE SWTTCT D PRESSLJHE SWITCH P1. BATIEHY POWER JUNCTION BLOCK
1.0 b
2G. FUSE F30 (10A) 5, INCHING PEDAL POSITION SWITCH 6G.4TH SPEED PHESSURE SWITO D PHESSURE SWITCH
0.8 I
2D. FUSE F20 (7.5A) 6. 1ST SP=ED SOLENOID 7. TEMPEBA?URE SENSOR ruRE SENSOR * r NorE; coNNEcrrHEffiApTER HAFNESS cAS 2186HERE. 0.75 I
2E. FUSE F25 (7.54) 6A. 2ND SPEED SOLENOID E. PO$/ERSHIFT MODULE IFT MODULE
2F. FUSE F26 (7.s4) 68. 3RD SPEED SOLENOID S. POWERSHIFT SPEED SELECTO IFT SPEED SELECTOR LEVER SWTCH :t e ruotg: coNNEcr rHE TEE HrcNEss HERE (REFER To zAGE 4).
Don 7-37470 lssued 3-92 Printed in England issued S92 Printed in England
kaukazz@yahoo.co.uk
6008-1 B www.thebestworkshopmanuals.co.uk
powrquadplus
POWERSHIFT PRESSURE SWITCH OPERATING TEST

STEP 1
STEP 8
Apply the parking brake and put blocks in front and Connecl the positive jumper lead between check points
B and P of the breakout box, CAS 21 10, to energize the
behind the rear wheels.
2nd speed solenoid. Check the 2nd speed oressure
STEP 2 gauge lf there is no pressure reading the 2nd speed
solenoid is faibdffi
Connect the breakout box, CAS 2110, to the powershift
harness, refer to Page 8 Steps 1 to 5 DO NOT connect NOTE: lf there ls pressure on any af the other gauges
the breakout box to the module. SIOP the engine and check the manifold gaskers.
STEP 3 STEP 9
lnstall the extension tubes, CAS 2009, to the powershift Check between check points E and W of lhe breakout
manifold test ports and connect the pressure gauge box CAS 21 10 for continuity' lf there is continuity then
bar, CAS 10895, to the extension tubes' refer to Page 5 the 2nd speed pressure switch is failed closed. Go to
Step 14 Page 19.
STEP 4
STEP 1O
Put the forward/neutral/reverse (F-N-R) and range
levers in neutral and stari the engine. Heat the Connect ihe positive jum per lead between check poinls
B and S of the breakout box, CAS 21 10, to energize the
transmission oil to 150" F {65"C).
3rd speed solenoid Check the 3rd speed pressure
WARNING: Never operate the engine in a gauge. lf there is no pressure reading the 3rd speed
closed building. Properventilatian is required solenoid is failed closed.
un d e r al I c i rcurnsfarces.
NOTE: lf there is pressure an any of the other gauges
STEP 5 STaP the engine and check the manifold gaskels'
Check the pressure gauges. lf there is pressure on one STEP 11

or more of ihe gauges STOP the engine and check ihe
solenoid valve, Check between check points J and H of the breakoui
box CAS 2'l 10 for contrnuity lf there is continuiiy then
Example: the 3rd speed pressure switch is failed closed' Go io
Step 14 Page 19
lf there is pressure on the 1st speed pressure gauge
check the'"lst speed solenoid has not mechanically STEP 12
failed open.
STEP 6 B and T ol the breakout box, CAS 21 10, to energize the
4th speed solenoid. Check the 4th speed pressure
Connect the positive iumper lead belween check points
gauge. lf there is no pressure reading the 41h speed
B and N of the breakout box, CAS 21 10, to energize the solenoid is failed closed.
1st speed solenoid. Check the 1st speed pressure
gauge. lf there is no pressure reading ihe 1st speed NOTE: lf there is pressure an any af the other gauges
solenoid is failed closed. SfOP the engine and check the manifold gaskels'
NOTE: lf there ts pressure on any of the other gauges

STOP the engine and check the manifald gaskels'
STEP 7
Check between check points V and F of the breakout

box CAS 21 10 for continuity. lf there is continuity then
the 1st speed pressure switch is failed closed' Go to
Step 14 Page 19.
Don 7-39460
kaukazz@yahoo.co.uk
6008- 1 I
STEP 13 STEP 15
Check betrveen check points L and M of the breakout Connect ihe pressure switch to a hydraulic hand oui'.n;l
box CAS 2110 for continuity lf there is continuity then and connect a multimeter to the terrnrnals oi thc
the 4th speed pressure swilch is failed closed Go to pressure switch
Step 14 Page 19
STEP 16
NOTE: ll the sotenatds o/ Pressr,re swtlcr' teacttan ttme
rs siow due to a slicking solenotd or pressr./re swirch lhe Pi'cssirrzc the swrtoh The switch should open (No
powershift module will detect a fault and will give two, coniinurty) on increasing pressure before 120 ps (B 3
five or six diagnosttc f/ashes. Refer to Page 6 bar) Replace the switch if necessary
STEP 14 STEP 17
Stop lhe engine and remove thr-- presstrre sr,vllch from Rcle ase thc oressurc on the swttch Thc switch should
the powershifl mani{o d close (Continurly) belwecn I07 to 93 psi (7 4 to 6 4 bar)
aeplacc thc swrlch if recessary
POWERSHIFT CLUTCH PACK LEAKAGE TEST

STEP 1 STEP 5
Apply the parking brakc Pui ihe rBnQe rcver rn NEUTRAL and stari Ihe e ngtnc
ilcat lhc iransmissron oil to 150'F (65'C) and scl lhc
STEP 2 fiowmeicr cressure to 1000 psr (69 bar)
Conncct the brcakout b<;x CAS 21 10, to the powershrft

harness refer to Pagc 8 DO NOT connecl lhc breakoul
box io ihe rnodule
STEP 3 STEP 6
f or :ractors eqLrrcDeci wrlh MFD. pul lhe MFD switcn 'r

ihc ON oositron
STEP 7
Sc: inc engine lhrottle at 1000 rDrr" Makc a notc o1 thc

llow rate, :hc flow should be approximately 4 U S gpn-
t15 1 .imrn)
STEP B
51213X i.,.t,rni;r;:ina 0c)sil vc lrtraocr lead betwccn chcck Irrri"c

i3 aô N oi inc brcakor;i box, CAS 2110 io errerg zc ihc
FLOWI"4ETEH CASl O2BO l sr scced sole noid
Connect the flowmeter CAS I0280 to thc rcmctc valvc

block
STEP 4
lnslall thc cxtcns on lubcs. CAS 2009 to the powersh fl

valve test ports and connccl thc prcssure gauge bar,
CAS 10895 to the extension tubes, reier to Page 5
lssrcc:'92 l)'rlac I l-rq;:-rl
Aa1 7 -37 4"70
kaukazz@yahoo.co.uk
6008-20
STEP 9 STEP 12
Make a note of the clutch pack pressures and the flow Connect the positive lumper lead between check points
rate. B and S of the breakout box, CAS 21 10, to energize the
3rd speed solenoid
NOTE: Use lhe chart below to make a note of the
readings. STEP 13
NOTE: lf there are pressure readings on the 2nd, 3rd or Make a note of the clutch pack pressures and the flow
4th speed pressure gauges check the powershtft valve rate
NOTE: lf there are pressure readings on the 1st, 2nd or
STEP 1O 4th speed pressure gauges check the powershilt valve
btock qaskets and so/enotds.
B and P of the breakout box, CAS 21 10, to energize the STEP 12
2nd speed solenoid.
Connect the posittve jumper lead between check points
STEP 1 1
B and T of the breakout box, CAS 21 10, to energize the
4th speed solenoid
rate STEP 11
NOTE: lf there are pressure readings on the 1st, 3rd or Make a note oi the clutch pack pressures and the flow
4lh speed pressure gauges check the powershift valve rate.
NOTE, lf there are pressure readings on the 1st' 2nd or
3rc1 speecl pressure gauges check the powershift valve
block gaskets and solenoids.
2nd SPEED 3rd SPEED 4th SPEED FLOW RATE

1st SPEED
1sl SPEED CLUTCH TEST
3Td SPEED CLUTCH TEST
lhe pressure gauge f or the clutch pack

NOTE: tt thereare pressure readings on any ol lhe pressu re gauges other than
belng tested check the powershilt valve btock gaskels and the so/enoids
packs
NorE: There shoupl not be more than 0.s l-.)S gpm (2 o Llmin) difference in the flow rates recorded for the clutch
and the flow rate noted in Step 7 Page 19

Oon 7-37470
kaukazz@yahoo.co.uk

Case Ih 5100 Maxxum WSM Vol1

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Copyright @ 1994 Case Corporation

Separating the Tractor - Engine from Speed Transmission

Don 7-32936 lssued 9-94

Air Conditioning - Gauges and Testing

Don 7-32936 lssued 9-94

cab Removal (for Tractors prior to PtN JJFl030000) ..9006 8-85550

Don 7-32936 lssued 9-94

1 GENEML SECTION NO.

E Electrical System Specificaions .. .....1002

tar' Hydraulic Fittings SpecialTorques .................... 1001

CASE CORPORATION Copyight @ 1992

SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

STANDARD TORQUE DATA FOR NUTS AND BOLTS .. .. ,...,..,. .. 6

TORQUE DATA FOR HYDRAULIC FITTINGS

Don 8-86530 lssued 6-89 Printed in England

To prevent injury always follow the Warning, Caution

See Other Side Reason

Don 8-86530 lssued &89 Printed in England

Always install genuine Case service parts, when

Don 8-84$0 lssued 6-89 Prinled in England

TOROUE SPECIFICATIONS .r 1O%

GRADE 8.8 GMDE 10.9 GRADE 12.9

5mm 4 5.5 0.56 5.5 7.5 0.76 b.b I 0.92

6mm 6.6 o 0.92 9.2 12.5 1.27 11 15 1.s3

8mm 'r6.5 22.5 2.3 31 5 3.2 26.5 JO 3.67

10 mm 32 44 4.5 45 ol 6.3 55 75 7.65

12 mm 57 77.5 7.9 81 110 11.2 95 130 13.2

'14 mm 88 120 12.2 125 170 17.3 155 210 21.4

16 mm 'r40 190 19.4 195 265 27 236 320 32.6

18 mm 192 260 26.5 269 365 37.2 320 435 44.3

20 mm 273 370 37.7 383 s20 53 457 620 63.2

ca 516 700 71.4 619 840 85.6

24 mm 471 640 65.2 665 900 92 796 1 080 110

27 mm 702 9s0 ooA 1 3s0 137.7 1 195 1620 165.2

1328 '1800 183.6 593 60 220.3

Don 8-86530 lssued &89 Printed in England

TORQUE DATA FOR HYDRAULIC FITTINGS

FITTINGS CONNECTIONS AND PLUGS

Diameter x Pitch Newton / Metres Pounds / Feet Kilogram / Metres

14 mm x 1.5 45 33.2 4.6

22 mm x 1.5 100 t3 10.2

27 mmx2 200 147 20.4

NUTS TOR TUBES AND HOSES

Diameter x Pitch Newton I Metres Pounds / Feel Kilogram / Metres

20 mm x 1,45 45 22C 4.6

Diameter x Pitch Newton / Metres Pounds / Feet Kilogram / Metres

14mmx2 145 107 14.8

16mmx2 230 170 23.5

lssued 6-89 Printed in England

Don 7-30801 Printed in U.S.A.

GEN ERAL SPECI FICATIONS

Electri cal Specif ications

No-Load Test at 27"C (80.6"F)

Output (Part No A187623) 14 Volts At 95 Amperes

Brush Length Wear Limit 14 mm 0.55 inch

Don 7-30801 lssued 10'91 Printed in England

Steering Hand Pump

Transm ission Specifications

Dilferential Plate Thickness

Differential and Ditferential Lock

Differential Lock C lutch Plate Thickness