Repair Manual: 6820, 6920 and 6920S Tractors Repair

John Deere Agriculture
6820, 6920 and 6920S Tractors Repair
REPAIR MANUAL
6820, 6920, 6920S
TM4756, August 2010

TM4756-REPAIR MANUAL (g) by Belgreen
Table of contents
FOREWORD
VERSION DATE
Section 05 - SAFETY
Group 05 - Safety Information
Section 10 - GENERAL INFORMATION
Group 05 - Specifications
Group 10 - Tune-Up
Group 15 - Predelivery Inspection
Section 20 - ENGINE
Group 00 - Removal and Installation of Components
Section 30 - FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS
Group 05 - Speed Control
Group 10 - Fuel System
Group 15 - Air Intake System
Group 20 - Cooling System
Group 25 - Cold-Weather Starting Aids
Group 30 - Exhaust System
Section 40 - ELECTRICAL SYSTEM
Group 05 - Electrical Connectors
Group 10 - Wiring Harnesses
Group 15 - Charging Circuit
Group 20 - Starter Motor Circuit
Group 25 - Fuses, Relays and Switches
Group 30 - Monitoring Systems
Group 40 - Electrical Components
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00 - Removal and Installation of AutoPowr/IVT Transmission
Group 05 - Transmission Shift Controls
Group 10 - Input Housing
Group 15 - Output Housing
Group 20 - Differential Drive Shaft Assembly
Section 55 - POWRQUAD PLUS, AUTOQUAD AND AUTOQUAD PLUS TRANSMISSIONS
Group 10 - PowrQuad Module
Group 15 - Creeper Transmission
Group 20 - Range Transmission
Section 56 - DRIVE SYSTEMS
Group 05 - U-Jointed Shafts and Torsion Damper
Group 10 - Front-Wheel Drive Clutch
Group 15 - Differential
Group 20 - Hydraulic Pump Drive
Group 25 - Final Drives
Group 30 - Rear PTO
Group 35 - Front PTO
Group 40 - Front Implement Drive
Section 60 - STEERING AND BRAKES
<- Go to Global Table of contents TM4756-REPAIR MANUAL

Group 05 - Hydrostatic Steering

Group 10 - Brake Valve
Group 15 - Rear Wheel Brakes
Group 20 - Handbrake
Group 25 - Hydraulic Trailer Brake
Group 30 - Air Brakes up to Serial No. 398655
Group 31 - Air Brakes from Serial No. 398656
Group 40 - AutoTrac
Section 70 - HYDRAULIC SYSTEM
Group 05 - Controls
Group 10 - Hydraulic Pump and Charge Oil Pump
Group 15 - Valves
Group 20 - Hitch
Group 25 - Selective Control Valves and Couplers
Group 30 - Independent Selective Control Valve
Section 80 - MISCELLANEOUS
Group 05 - Main Frame
Group 10 - Front Wheels, Rear Wheels and Fenders
Group 15 - Trailer Mounting and Swinging Drawbar
Group 20 - Triple Link Suspension (TLS) of Front-Wheel Drive Axle
Group 25 - Pick-Up Hitch
Section 90 - OPERATOR′S CAB
Group 05 - Controls and Instruments
Group 10 - Air-Conditioning System
Group 11 - ClimaTrak
Group 15 - Heating System
Group 20 - Seats
Group 25 - Operator′s Cab
Group 30 - Cab Suspension
Section 99 - SPECIAL TOOLS (DEALER-FABRICATED)
Group 05 - Special Tools (Dealer-Fabricated)
Group 10 - Special Tools (Available from the Dealer)

Foreword
This repair manual is valid for the following tractor types:
6820, 6920 and 6920S.
The manual is written for experienced customer service personnel. Essential tools required in
performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the
cautions presented throughout the text of the manual.
CAUTION:
This is the safety-alert symbol. It indicates that there is danger of injury.
Technical Manuals are concise service guides for specific machines. They are on-the-job
guides containing only the vital information needed for diagnosis, analysis, testing, and
repair.
Fundamental service information is available from other sources covering basic theory of
operation, fundamentals of troubleshooting, general maintenance, and basic type of failures
and their causes.

SAFETY (g) by Belgreen
Version Date
01 December 2005

Section 05 - SAFETY
Table of contents
Group 05 - Safety Information ................................................................................................. 1
Recognize Safety Information ................................................................................................ 1
”Important” Information ......................................................................................................... 1
”Note” Information ................................................................................................................. 1
Prevent Machine Runaway ..................................................................................................... 1
Handle Fluids Safely—Avoid Fires .......................................................................................... 2
Prevent Battery Explosions .................................................................................................... 3
Prepare for Emergencies ........................................................................................................ 3
Prevent Acid Burns ................................................................................................................. 5
Avoid High-Pressure Fluids ..................................................................................................... 6
Service Cooling System Safely ............................................................................................... 6
Remove Paint Before Welding or Heating .............................................................................. 7
Avoid Heating Near Pressurized Fluid Lines ........................................................................... 8
Work In Ventilated Area ......................................................................................................... 8
Wear Protective Clothing ....................................................................................................... 9
Practice Safe Maintenance ................................................................................................... 10
Park Machine Safely ............................................................................................................. 11
Use Proper Lifting Equipment ............................................................................................... 11
Construct Dealer-Made Tools Safely .................................................................................... 12
Support Machine Properly .................................................................................................... 12
Work in Clean Area .............................................................................................................. 13
Illuminate Work Area Safely ................................................................................................. 14
Service Machines Safely ....................................................................................................... 14
Use Proper Tools .................................................................................................................. 15
Service Tires Safely .............................................................................................................. 15
Service Front-Wheel Drive Tractor Safely ............................................................................ 17
Safety Information - Air Brake System ................................................................................. 17
Avoid Eye Contact With Radar ............................................................................................. 18
Keep ROPS Installed Properly ............................................................................................... 19
Replace Safety Signs ............................................................................................................ 19
Dispose of Waste Properly ................................................................................................... 20
Live With Safety ................................................................................................................... 21
Safety Measures on Electronic Control Units ........................................................................ 21

Section 05 - SAFETY Group 05: Safety Information
Group 05 - Safety Information

Recognize Safety Information
This is a safety-alert symbol. When you see this symbol on your machine or in this manual,
be alert to the potential for personal injury.
Follow recommended precautions and safe operating practices.
”Important” Information
Information marked as IMPORTANT points out problems that may lead to machine damage.
By following the directions given, these problems can be avoided.
”Note” Information
When marked with NOTE the information given is more detailed or contains restrictions to
directions given previously. On the other hand useful information may be given belonging to
certain instructions without being directly connected to them.
Prevent Machine Runaway
<- Go to Section TOC Section 05 page 1 TM4756-REPAIR MANUAL

Avoid possible injury or death from machinery runaway.
Do not start engine by shorting across starter terminals. Machine will start in gear if normal
circuitry is bypassed.
NEVER start engine while standing on ground. Start engine only from operator’s seat, with
transmission in neutral or park.
Handle Fluids Safely—Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Prepare for Emergencies
Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
your telephone.

Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).
3. Get medical attention immediately.
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be
surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this
type of injury should reference a knowledgeable medical source. Such information is
available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by
calling 1-800-822-8262 or +1 309-748-5636.
Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure before removing completely.
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a
torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint
cannot be removed, wear an approved respirator before heating or welding.

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before
welding. Remove solvent or paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes before welding or heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near pressurized fluid lines, resulting in
severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally
burst when heat goes beyond the immediate flame area.
Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an
enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the
area.
Wear Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or
music headphones while operating machine.
Practice Safe Maintenance
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing
from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower

equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace
worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments
on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical
system components or welding on machine.
Park Machine Safely
Before working on the machine:
Lower all equipment to the ground.

Stop the engine and remove the key.
Disconnect the battery ground strap.
Hang a "DO NOT OPERATE" tag in operator station.
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When constructing tools, use proper,
quality materials, and good workmanship.
Do not weld tools unless you have the proper equipment and experience to perform the job.
Support Machine Properly

Always lower the attachment or implement to the ground before you work on the machine. If
the work requires that the machine or attachment be lifted, provide secure support for them.
If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under
continuous load. Do not work under a machine that is supported solely by a jack. Follow
recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions
listed in the implement or attachment operator′s manual.
Work in Clean Area
Before starting a job:
Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.
Read all instructions thoroughly; do not attempt shortcuts.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside
or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when
you work near machine tools or moving parts. If these items were to get caught, severe injury
could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving
parts.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
Service Tires Safely

Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to
perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in
air pressure resulting in a tire explosion. Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to
stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Service Front-Wheel Drive Tractor Safely
When servicing front-wheel drive tractor with the rear wheels supported off the ground and
rotating wheels by engine power, always support front wheels in a similar manner. Loss of
electrical power or transmission/ hydraulic system pressure will engage the front driving
wheels, pulling the rear wheels off the support if front wheels are not raised. Under these
conditions, front drive wheels can engage even with switch in disengaged position.
Safety Information - Air Brake System

CAUTION:
Compressed air tank is pressurized!
Always relieve pressure before working on the air brake system. Do not carry out any welding
jobs on the air brake system.
Avoid Eye Contact With Radar

Radar ground speed sensor emits a very low intensity microwave signal. It will not cause any
ill effects during normal use. Although intensity is low, DO NOT look directly into face of
sensor while in operation, to avoid any possible eye damage.
Keep ROPS Installed Properly
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten mounting bolts to proper torque.
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way altered by welding, bending, drilling, or
cutting. A damaged ROPS should be replaced, not reused.

Replace Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct
safety sign placement.
Dispose of Waste Properly
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid,
filters, and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that
may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere.
Government regulations may require a certified air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environmental or
recycling center, or from your John Deere dealer.
Live With Safety
Before returning machine to customer, make sure machine is functioning properly, especially
the safety systems. Install all guards and shields.
Safety Measures on Electronic Control Units

GENERAL INFORMATION (g) by Belgreen
CAUTION:
Before installing test equipment on tractor, always shut off the engine and
turn off key switch.
CAUTION:
Always engage the park lock when performing tests with the engine
running.
CAUTION:
When testing is performed with the engine running, there is a risk of injury
from rotating parts.
IMPORTANT:
Do not use a test lamp on any control unit. Only use a multimeter
(JT05791A/JDG1478).
IMPORTANT:
To protect electronic circuits, disconnect the battery and alternator before

performing any welding on the tractor.

Section 10 - GENERAL INFORMATION

Table of contents
Group 05 - Specifications ......................................................................................................... 1
Specifications (Summary of References) ............................................................................... 1
Engine Specifications ............................................................................................................. 3
Cooling System ...................................................................................................................... 3
Injection Pump (Bosch VP44) ................................................................................................. 4
Level 11 Electronic Fuel System with HPCR (Denso) .............................................................. 4
Air Intake System ................................................................................................................... 4
Electrical system .................................................................................................................... 4
Hydrostatic Steering System .................................................................................................. 4
AutoTrac ................................................................................................................................. 4
Clutch ..................................................................................................................................... 4
AutoPowr/IVT transmission ..................................................................................................... 4
PowrQuad Plus transmission .................................................................................................. 5
AutoQuad II transmission ....................................................................................................... 5
Creeper transmission ............................................................................................................. 5
Rear PTO ................................................................................................................................ 5
Front PTO ............................................................................................................................... 5
Differential assembly ............................................................................................................. 6
Differential lock ...................................................................................................................... 6
Final drives ............................................................................................................................. 6
Front-Wheel Drive .................................................................................................................. 6
FWD Axle with TLS ................................................................................................................. 6
Cab Suspension: ..................................................................................................................... 6
Hydraulic Brakes .................................................................................................................... 6
Handbrake ............................................................................................................................. 6
Parking Lock ........................................................................................................................... 6
Hydraulic System with Axial Piston Pump (PFC System) ........................................................ 6
Rockshaft ............................................................................................................................... 7
Front Hitch ............................................................................................................................. 7
Ground Speeds ....................................................................................................................... 7
Front and Rear Wheels ........................................................................................................... 7
Dimensions and Weights ........................................................................................................ 7
Capacities .............................................................................................................................. 8
Handling and Storing Diesel Fuel ........................................................................................... 9
Diesel Fuel ........................................................................................................................... 11
Lubricity of Diesel Fuel ......................................................................................................... 11
Diesel Engine Break-In Oil .................................................................................................... 13
Diesel Engine Oil (Engine Serial Number up to 799999) ...................................................... 15
Diesel Engine Oil (Engine Serial Number from 800000) ....................................................... 17
Transmission and Hydraulic Oil ............................................................................................ 19
Front-Wheel Drive Axle Oil ................................................................................................... 21
Diesel Engine Coolant .......................................................................................................... 23
Supplemental Coolant Additives .......................................................................................... 24
Grease .................................................................................................................................. 24
Oil Filters .............................................................................................................................. 25
Mixing of Lubricants ............................................................................................................. 26

Lubricant Storage ................................................................................................................. 26

Operating in Warm Temperature Climates .......................................................................... 26
Alternative and Synthetic Lubricants ................................................................................... 27
Unified Inch Bolt and Screw Torque Values .......................................................................... 28
Metric Bolt and Screw Torque Values ................................................................................... 29
Hydraulic system inch fitting torques .................................................................................. 30
Hydraulic system metric fitting torques ............................................................................... 31
Product identification and component serial numbers ......................................................... 32
Engine Serial Number .......................................................................................................... 34
Transmission serial number ................................................................................................. 34
Front wheel drive axle serial number ................................................................................... 35
Operator′s cab serial number ............................................................................................... 35
Operator′s seat serial number .............................................................................................. 36
Sub-assembly serial numbers .............................................................................................. 37
Group 10 - Tune-Up ................................................................................................................. 38
Tune-Up (Summary of References) ...................................................................................... 38
Specifications ....................................................................................................................... 39
Using High-Pressure Washers .............................................................................................. 39
Preliminary Engine Test ....................................................................................................... 40
Tractor Tune-Up ................................................................................................................... 41
Removing and Cleaning the Primary Air Cleaner Element ................................................... 43
Checking the Air Cleaner Safety Element ............................................................................ 43
Installing the Primary Filter Element .................................................................................... 44
Checking the Air Intake System Connections for Leaks ....................................................... 44
Checking the Crankcase Vent Hose for Clogging ................................................................. 45
Cleaning Dirt from Radiator Screen ..................................................................................... 45
Keeping the Radiator Screen Clean ...................................................................................... 46
Checking the Caps on the Expansion Tank .......................................................................... 46
Checking the Radiator for Leaks .......................................................................................... 47
Checking the engine′s thermostat ....................................................................................... 47
Checking the Fuel Transfer Pump Operation ........................................................................ 47
Bleeding the fuel system (with Bosch VP44 injection pump) ............................................... 49
Checking the fuel filter (with Bosch VP44 injection pump) ................................................... 52
Cleaning the water trap ....................................................................................................... 52
Checking the Fuel Filter (with Denso/Stanadyne Injection Pump; Stage II Engines According to
97/68/EC) ...................................................................................................................... 54
Bleeding the Fuel System (with Stanadyne Injection Pump; Stage II Engines According to
97/68/EC) ...................................................................................................................... 55
Bleeding the Fuel System (with Denso Injection Pump; Stage II Engines According to
97/68/EC) ...................................................................................................................... 55
Run Engine until it is Warm and Check Engine Speeds ........................................................ 56
Checking Setting of Fuel Injection Pump .............................................................................. 56
Cleaning the Battery, Cables and Battery Box with a Clean Cloth ....................................... 56
Check the Neutral Start Circuit ............................................................................................ 58
Checking operation of starter motor .................................................................................... 60
Checking the lighting circuit ................................................................................................ 60
Final Engine Check ............................................................................................................... 61
Tractor Operation Check ...................................................................................................... 61
Group 15 - Predelivery Inspection ........................................................................................ 63
Predelivery Inspection .......................................................................................................... 63

Section 10 - GENERAL INFORMATION Group 05: Specifications
Group 05 - Specifications
Specifications (Summary of References)
”Engine specifications”
”Cooling system”
”Bosch VP44 injection pump”
”Level 11 electronic fuel system with HPCR (Denso)”
”Air intake system”
”Electrical system”
”Hydrostatic steering”
”AutoTrac”
”Clutch”
”AutoPowr/IVT transmission”
”PowrQuad Plus transmission”
”AutoQuad II transmission”
”Creeper transmission”
”Rear PTO”
”Front PTO”
”Differential”
”Differential lock”
”Final drives”
”Front-wheel drive”
”Front-wheel drive axle with TLS”
”Cab suspension”
”Hydraulic brakes”
”Handbrake”
”Park lock”
”Hydraulic system with axial piston pump”
”Hitch”
”Front hitch”
”Ground speeds”
”Front and rear wheels”
”Dimensions and weights”
”Capacities”
”Handling and storing diesel fuel”
”Diesel fuel”
”Lubricity of diesel fuel”
”Diesel engine break-in oil”
”Diesel engine oil (engine serial number up to 799.999)”
”Diesel engine oil (engine serial number from 800.000)”
”Transmission and hydraulic oil”
”Front-wheel drive axle oil”
”Diesel engine coolant”
”Coolant additives”
”Grease”

”Oil filter”
”Mixing of lubricants”
”Lubricant storage”
”Operating in warm temperature climates”
”Alternative and synthetic lubricants”
”Unified inch bolt and cap screw torque values”
”Metric bolt and cap screw torque values”
”Hydraulic system inch fitting torques”
”Hydraulic system metric fitting torques”
”Product identification and sub-assembly serial numbers”
”Engine serial number”
”Transmission serial number”
”Front-wheel drive axle serial number”
”Operator′s cab serial number”
”Operator′s seat serial number”
”Sub-assembly serial numbers”

Engine Specifications
Type
- 6820
with Bosch VP-44 injection pump .......... 6068HLA71
with Denso HPCR injection pump .......... 6068HL472
- 6920
- 6920S
Engine power according to ECE-R24 at rated engine speed

with viscous fan
- 6820 .......... 99 kW (135 hp)
- 6920 .......... 110 kW (150 hp)
- 6920S .......... 118 kW (160 hp)
Max. torque at 1500 rpm engine speed

with Bosch VP44 injection pump (on Stage II engines according to 97/68/EC)
- 6820 .......... 611 N˙m (450 lb-ft)
- 6920 .......... 699 N˙m (515 lb-ft)
- 6920S .......... 699 N˙m (515 lb-ft)
Max. torque at 1400 rpm engine speed

with Denso/Stanadyne injection pump (on Stage II engines according to 97/68/EC)
- 6820 .......... 620 N˙m (457 lb-ft)
- 6920 .......... 688 N˙m (507 lb-ft)
- 6920S .......... 685N˙m (505 lb-ft)
Max. PTO power at rated PTO speed (factory measured, with 1000 rpm at PTO)
- 6820 .......... 90 kW (122 hp)
- 6920 .......... 99 kW (134 hp)
- 6920S
when driving .......... 104 kW (141 hp)
when stationary .......... 100 kW (136 hp)
Bore .......... 106.5 mm (4.19 in.)
Stroke .......... 127.0 mm (5.00 in.)
Displacement .......... 6790 cm 3 (414 cu.in.)

Firing order .......... 1-5-3-6-2-4
Compression ratio .......... 16.8:1
Valve clearance (engine hot or cold)

- intake valves .......... 0.35 mm (0.014 in.)
- exhaust valves .......... 0.45 mm (0.018 in.)
Slow idle
- electronic actuation at an ambient temperature
above 20°C (68°F) .......... 850±10 rpm
between 0°C (32°F) and 20°C (68°F) .......... 875±50 rpm
below 0°C (32°F) .......... 1050±10 rpm
Fast idle
- electronic actuation .......... 2250-10/+20 rpm
with AutoQuad activated .......... max. 2100 rpm
Rated engine speed .......... 2100 rpm
Operating speeds .......... 1300 - 2100 rpm

Cooling System
Type .......... pressurized system with two cooling circuits (high- and low-temperature circuits) with centrifugal pump and
expansion tank.
Temperature control .......... thermostat and viscous fan drive
Injection Pump (Bosch VP44)

Pump type .......... solenoid valve-controlled radial piston distributor pump, regulated electronically and giving direct
injection
Number of pistons .......... four
Injection pressure .......... approx. 700 bar (70000 kPa; 10150 psi)
Automatic switching off .......... electrical
Level 11 Electronic Fuel System with HPCR (Denso)

Type .......... Common rail
Injection pressure .......... up to approx. 1450 bar (120000 kPa; 17400 psi)
Air Intake System

Engine air cleaner .......... dry-type air cleaner, self-cleaned by pressure from the fan blade; with safety element
Electrical system
Battery .......... 12 V, 154 Ah or 12 V, 174 Ah
Alternator with overvoltage protection .......... 14 V, 90 A or 14 V, 115 A
Starter motor .......... 12 V, 3.0 kW (4.0 hp)
Battery terminal grounded .......... negative
Hydrostatic Steering System

Type .......... fully hydraulic
AutoTrac
→NOTE:
Applies only to 6430 - 6630 tractors with operator′s cab.
Type .......... satellite-supported steering system
Control .......... electro-hydraulic
Clutch
Type .......... hydraulically controlled wet disk clutch
Operation .......... mechanical / hydraulic with pre-tensioned Belleville springs

AutoPowr/IVT transmission
Type .......... infinitely variable mechanical/hydraulic transmission
Forward/reverse speed range .......... 0.1 km/h (0.06 mph)—40 km/h (25 mph)
Forward/reverse speed range .......... 0.1 km/h (0.06 mph)—50 km/h (31 mph)
[ If equipped ]
Shifting the reverse drive lever .......... electrical, under load, without operating clutch
Shifting the speed control lever .......... increases and decreases in speed are infinitely variable and take place without
interrupting the power flow or actuating the clutch
PowrQuad Plus transmission

Type .......... synchronized hydraulic transmission
Range shifting .......... mechanically, synchronized
-Tractors with 40 km/h (25 mph) transmission .......... 5 ranges
Shifting of the 4 gears .......... mechanical/hydraulic, under load, without actuating the clutch
Reverse gear shifting .......... mechanical/hydraulic, under load, without actuating the clutch
Shifting the F-N-R lever .......... mechanical-hydraulic or electrical-hydraulic, under load, without operating clutch
AutoQuad II transmission
Type .......... synchronized hydraulic transmission
Range shifting .......... mechanically, synchronized
-Tractors with 40 km/h (25 mph) transmission .......... 5 ranges

-Tracors with 50 km/h (31 mph) transmission .......... 5 ranges
Shifting of the 4 gears .......... electrical-hydraulic, under load, without operating clutch
Reverse gear shifting .......... electrical-hydraulic, under load, without operating clutch
Shifting the F-N-R lever .......... mechanical-hydraulic or electrical-hydraulic, under load, without operating clutch
Creeper transmission
Type .......... non-synchronized reduction gear
Reduction of ground speed in ranges A, B and C as well as in the reverse range .......... approx. 90 %
Shifting the two creeper speeds .......... mechanically, non-synchronized
Rear PTO
Type .......... independent, engaging/disengaging under load
Engine speed for PTO operation
- 540 rpm rear PTO (reversible or shiftable) .......... 1995 rpm
- 540E rpm rear PTO .......... 1743 rpm
- 1000 rpm rear PTO .......... 1995 rpm
Front PTO

Type .......... engaging/disengaging under load
Engine speed for 1000 rpm front PTO (viewed in direction of travel)
- clockwise rotating (6 splines) .......... 1995 rpm
- counterclockwise rotating (21 splines) .......... 1995 rpm
Differential assembly
Type .......... helical bevel gear drive
Differential lock
Operation .......... electrical/hydraulic, pedal operated
Disengaging .......... electrical/hydraulic, after traction has equalized
Final drives
Type .......... planetary reduction gear
Front-Wheel Drive
Type .......... operated under load, hydraulically controlled drive with wet disk clutch
Control .......... solenoid valve, electrical-hydraulic
Engagement .......... with pre-tensioned Belleville springs
Disengagement .......... hydraulically
FWD Axle with TLS

Type .......... active spring system with levelling control
Control .......... electro/hydro/pneumatic
Cab Suspension:
Type .......... active spring system with levelling control
Control .......... electro/hydro/pneumatic
Hydraulic Brakes
Type .......... self-adjusting, hydraulically operated wet disk brakes, individually acting in field operation
Handbrake
Type .......... mechanically operated brake band acting on differential
Parking Lock
Type .......... mechanically operated locking pawl, acting on front wheel drive gear

Hydraulic System with Axial Piston Pump (PFC

System)
Type .......... closed-center system with load-sensing control
Pump displacement .......... 28 cm 3 (1.7 cu.in.) or 45 cm 3 (2.7 cu.in.)
System pressure:
min. (stand-by) .......... 3000 kPa (30 bar; 435 psi)
max. .......... 20000 kPa (200 bar; 2900 psi)
Pump type .......... axial piston pump, pressure- and flow-compensated
Rockshaft
Type .......... three-point hitch with two lift cylinders, activated via stepper motor and valve
Control types .......... load, depth, load-and depth control, float position
Control .......... electronic/hydraulic draft link control, draft sensor or position sensor (actual value),
.......... operation box (set-point values),
.......... electronic control unit (processor)
Front Hitch
Front Hitch .......... controlled via selective control valve
Ground Speeds
Ground Speeds .......... see Operator′s Manual
Front and Rear Wheels

Tires, wheel treads, tire pressure and ballast .......... see Operator′s Manual
Dimensions and Weights

Dimensions and Weights .......... see Operator′s Manual

Capacities
Fuel tank .......... 207 L (54.7 U.S. gal.), 250 L (66.0 US.gal) or 325 L (85.9 US.gal.)
Cooling system
- coolant change .......... 28 L (7.4 U.S. gal.)
Engine crankcase
- oil change with filter change .......... 19.5 L (5.2 US.gal.)
- oil change without filter change .......... 18.5 L (4.9 US.gal.)
Transmission/hydraulic system
AutoQuad Plus and AutoQuad II transmissions
- oil change with filter change .......... 56 L (14.8 US.gal.)
- oil change with filter change .......... 66 L (17.4 US.gal.)
Extra on tractors with

- creeper .......... 1 L (0.3 U.S. gal.)
- front-wheel drive axle .......... 3 L (0.8 U.S. gal.)
- front-wheel drive axle with TLS .......... 3 L (0.8 U.S. gal.)
→NOTE:
Due to different equipment and design, the capacities of the front-wheel

drive axles are approximate; they vary considerably. As a basic rule:
Always fill with oil up to the bottom of filler plug hole.

Front-wheel drive axle without TLS

6820 (AS 2045)
- axle housing .......... 6.6 L (1.7 U.S. gal.)
- final drive housing (each) .......... 0.8 L (0.2 U.S. gal.)
6920/6920S (AS 2060)

6920/6920S (045JD)
Front-wheel drive axle with TLS

6820 (AS 2045)
6920/6920S (AS 2060)

- axle housing .......... 9 L (2.4 U.S. gal.)
6920/6920S (045JDS20)
Front-wheel drive axle with TLS and disk brake

6820 (AS 2045)
6920/6920S (AS 2060)

6920/6920S (045JDS20)
Front PTO .......... 3.5 L (0.9 U.S. gal.)
Air-conditioning system
R134a refrigerant .......... 1450 - 1500 g (2.20 - 3.30 lb)
Oil volume (PAG oil) .......... 220 ml (7.44 fl. oz.)
Handling and Storing Diesel Fuel
CAUTION:
Handle fuel carefully. Do not fill the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or service the fuel system.
Fill the fuel tank at the end of each day′s operation to prevent water condensation and
freezing during cold weather.

Keep all storage tanks as full as practicable to minimize condensation.
Ensure that all fuel tank caps and covers are installed properly to prevent moisture from
entering.
Monitor water content of the fuel regularly.
When using bio-diesel fuel, the fuel filter may require more frequent replacement due to
premature plugging.
Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution
of the engine oil.
IMPORTANT:
The fuel tank is vented through the filler cap. If a new filler cap is required,
always replace it with an original vented cap.
When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel
conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier
for recommendations.

Diesel Fuel
Consult your local fuel distributor for properties of the diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low temperature requirements of the
geographical area in which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended.
In all cases, the fuel shall meet the following properties:
Cetane number of 40 minimum. Cetane number greater than 50 is preferred, especially

for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the expected low temperature ORCloud Point at
least 5°C (9°F) below the expected low temperature.
Fuel lubricity should pass a minimum of 3100 gram load level as measured by the BOCLE
scuffing test.
Sulfur content:
Sulfur content should not exceed 0.5%. Sulfur content less than 0.05% is preferred.
If diesel fuel with sulfur content greater than 0.5% sulfur content is used, reduce the
service interval for engine oil and filter by 50%.
DO NOT use diesel fuel with sulfur content greater than 1.0%
Bio-diesel fuels to DIN 51606 or an equivalent standard (RME) etc. should be used only after
consultation with your John Deere dealer.
→NOTE:
If the injection pump has been adapted for bio-diesel fuel (RME), the
tractor can be used in temperatures as low as -10°C. If the tractor is
operated frequently at temperatures of around -10°C or lower and the fuel
used is either bio-diesel or normal diesel, the engine oil level should be
checked every day before the engine is started. If the oil level is 10 mm
higher than the max. level, a change of oil is required. Oil change intervals
should be reduced when operating in low temperatures under the
conditions described above.
Do NOT mix used engine oil or any other type of lubricant with diesel fuel.

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Canada, and the European Union have
adequate lubricity to ensure proper operation and durability of fuel injection system
components. However, diesel fuels manufactured in some areas of the world may lack the
necessary lubricity.
IMPORTANT:
Make sure the diesel fuel used in your machine demonstrates good lubricity
characteristics.
Fuel lubricity should pass a maximum scar diameter of 0.45 mm as measured by ASTM
D6079 or ISO 12156-1.
If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL
CONDITIONER (or equivalent) at the specified concentration.
Lubricity of Biodiesel Fuel
Significant improvement in lubricity can occur with biodiesel blends up to B20. The gain in
lubricity above a 20% blend is limited.

Diesel Engine Break-In Oil

New engines are filled at the factory with either John Deere Break-In ™ or Break-In™ Plus
Engine Oil. During the break-in period, add John Deere Break-In™ or Break-In™ Plus Engine
Oil, respectively, as needed to maintain the specified oil level.
Operate the engine under various conditions, particularly heavy loads with minimal idling, to
help seat engine components properly.
Change the oil and filter at 100 hours maximum for Break-In™ Oil or 500 hours maximum for
Break-In™ Plus Oil during the initial operation of a new or rebuilt engine.
After engine overhaul, fill the engine with either John Deere Break-In™ or Break-In™ Plus
Engine Oil.
If John Deere Break-In™ or Break-In™ Plus Engine Oil is not available, use a 10W-30 diesel
engine oil meeting one of the following during the first 100 hours of operation:
API Service Classification CE

API Service Classification CD
API Service Classification CC
ACEA Oil Sequence E2
ACEA Oil Sequence E1
IMPORTANT:
Do not use Plus-50™ II, Plus-50 or engine oils meeting any of the following
for the initial break-in of a new or rebuilt engine:
API CJ-4 ACEA E9
API CI-4 PLUS ACEA E7
API CI-4 ACEA E6
API CH-4 ACEA E5
API CG-4 ACEA E4
API CF-4 ACEA E3
API CF-2
API CF
These oils will not allow the engine to break in properly.
John Deere Break-In™ Plus Engine Oil can be used for all John Deere diesel engines at all
emission certification levels.
After the break-in period, use John Deere Plus-50 ™ II, John Deere Plus-50, or other diesel

engine oil as recommended in this manual.

Diesel Engine Oil (Engine Serial Number up to

799999)
Use oil with a viscosity based on the expected air temperature range during the period
between oil changes.
The following oil is preferred:
John Deere PLUS-50 ™
The following oil is also recommended:
John Deere TORQ-GARD SUPREME ™
Other oils may be used if they meet one or more of the following:
API CG-4
API CF-4
ACEA E5
ACEA E4
ACEA E3
ACEA E2
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by
50%.

Diesel Engine Oil (Engine Serial Number from

800000)
Use oil viscosity based on the expected air temperature range during the period between oil
changes.
The following oil is recommended for 500-hour oil changes:
John Deere PLUS-50 ™
ACEA E5
ACEA E4
If none of the available oil types meet these specifications, reduce the intervals at which oil is
changed to 250 hours.
In this case, John Deere TORQ-GARD SUPREME ™ is recommended. Other oils may be used if
they meet one or more of the following:
API CG-4
API CF-4
ACEA E3
ACEA E2
Multi-viscosity diesel engine oils are preferred.
If diesel fuel with sulfur content greater than 0.5% is used, reduce the service interval by
50% also.

Transmission and Hydraulic Oil
The following oils are preferred:
John Deere HY-GARD ™

John Deere HY-GARD ™ with low viscosity
John Deere Standard JDM J20C

John Deere Standard JDM J20D
Use John Deere BIO-HY-GARD II ™
[ BIO-HY-GARD II meets or exceeds the minimum biodegradability of 80 % within 21 days according to CEC L-33-A-93 test method. BIO-HY-GARD

meets or exceeds the minimum biodegradability of 80 % within 21 days according to CEC L-33-T-82 test method. These oils should not be mixed with
mineral oils because this reduces the biodegradability and makes proper oil recycling impossible. ]
or BIO-HY-GARD ™
when a biodegradable fluid is required.
IMPORTANT:
On tractors with AutoPowr:
Do NOT use HY-GARD with low viscosity.
Do NOT use BIO-HY-GARD. On the other hand, BIO-HY-GARD II may be used.
Other types of oil used must meet John Deere Standard JDM J20C.

Front-Wheel Drive Axle Oil
The following oil is preferred.
John Deere HY-GARD ™
Other oils may be used if they meet the following:
John Deere Standard JDM J20C
Use one of the following oils when a biodegradable fluid is required:
John Deere BIO-HY-GARD II ™

or BIO-HY-GARD ™
→NOTE:
Do NOT use BIO-HY-GARD on braked axles.

Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and
cylinder liner pitting, and winter freeze protection to -37°C (-34°F).
John Deere COOL-GARD is preferred for service.
If John Deere COOL-GARD is not available, use a low silicate ethylene glycol or propylene
glycol base coolant concentrate in a 50% mixture of concentrate with quality water.
The coolant concentrate shall be of a quality that provides cavitation protection to cast iron
and aluminum parts in the cooling system. John Deere COOL-GARD meets this requirement.
Freeze protection
A 50% mixture of ethylene glycol engine coolant in water provides freeze protection to -37°C
(-34°F).
A 50% mixture of propylene glycol engine coolant in water provides freeze protection to
-33°C (-27°F).
If protection at lower temperatures is required, consult your John Deere dealer for
recommendations.
Water quality
Water quality is important to the performance of the cooling system. Distilled, deionized, or
demineralized water is recommended for mixing with ethylene glycol and propylene glycol
base engine coolant concentrate.
IMPORTANT:
Do not use cooling system sealing additives or antifreeze that contains

sealing additives.
IMPORTANT:
Do not mix ethylene glycol and propylene glycol base coolants.

Supplemental Coolant Additives

Some coolant additives will gradually deplete during engine operation. For John Deere COOL-
GARD ™ Premix, COOL-GARD Concentrate, or John Deere COOL-GARD PG Premix, replenish
coolant additives between drain intervals by adding a supplemental coolant additive as
determined necessary by coolant testing.
John Deere LIQUID COOLANT CONDITIONER is recommended as a supplemental coolant

additive for John Deere COOL-GARD Premix, COOL-GARD Concentrate, and COOL-GARD PG
Premix.
John Deere LIQUID COOLANT CONDITIONER is not designed for use with COOL-GARD II Premix
or COOL-GARD II Concentrate.
IMPORTANT:
Do not add a supplemental coolant additive when the cooling system is

drained and refilled with any of the following:
John Deere COOL-GARD II

John Deere COOL-GARD
John Deere COOL-GARD PG
If other coolants are used, consult the coolant supplier and follow the manufacturer′s
recommendation for use of supplemental coolant additives.
The use of non-recommended supplemental coolant additives may result in additive drop-out
and gelation of the coolant.
Add the manufacturer′s recommended concentration of supplemental coolant additive. DO

NOT add more than the recommended amount.
Grease

Use grease based on NLGI consistency numbers and the expected air temperature range
during the service interval.
John Deere SD POLYUREA GREASE is preferred.
The following greases are also recommended
John Deere HD LITHIUM COMPLEX GREASE

John Deere HD WATER RESISTANT GREASE
John Deere GREASE-GARD ™
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with others. Consult
your grease supplier before mixing different types of grease.
Oil Filters
Filtration of oils is critical to proper operation and lubrication.
Always change filters regularly as specified in this manual.

Use filters meeting John Deere performance specifications.
Mixing of Lubricants
In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in
their oils to meet certain specifications and performance requirements.
Mixing different oils can interfere with the proper functioning of these additives and degrade
lubricant performance.
Consult your John Deere dealer to obtain specific information and recommendations.
Lubricant Storage
Your equipment can operate at top efficiency only when clean lubricants are used.
Use clean containers to handle all lubricants.
Whenever possible, store lubricants and containers in an area protected from dust, moisture,
and other contamination. Store containers on their side to avoid water and dirt accumulation.
Make certain that all containers are properly marked to identify their contents.
Properly dispose of all old containers and any residual lubricant they may contain.
Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycol base engine coolants.
Always use a recommended glycol base engine coolant, even when operating in geographical
areas where freeze protection is not required.
John Deere COOL-GARD ™ II Premix is available in a concentration of 50% ethylene glycol.

However, there are situations in warm temperature climates where a coolant with lower
glycol concentration (approximately 20% ethylene glycol) has been approved. In these cases,
the low glycol formulation has been modified to provide the same level of corrosion inhibitor
as John Deere COOL-GARD II Premix (50/50).

IMPORTANT:
Water may be used as coolantin emergency situations only.
Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation
will occur when water is used as the coolant, even when coolant
conditioners are added.
Drain cooling system and refill with recommended glycol base engine
coolant as soon as possible.
Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different
from those printed in this manual.
Some John Deere brand coolants and lubricants may not be available in your location.
Synthetic lubricants may be used if they meet the performance requirements as shown in
this manual.
The temperature limits and service intervals shown in this manual apply to both conventional
and synthetic oils.
Re-refined base stock products may be used if the finished lubricant meets the performance
requirements.
Avoid mixing different brands or types of oils. Oil manufacturers blend base stock and
additives to create their oils and to meet certain specifications and performance
requirements. Mixing different oils can interfere with proper functioning of these formulations
and degrade lubricant performance.
Consult your authorized John Deere dealer to obtain specific information and
recommendations.

Unified Inch Bolt and Screw Torque Values
SAE Grade 2
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6.
Bolt in (152 mm) long. Grade 1
SAE Grade 1 SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
or applies for hex cap screws
over 6 in. (152 mm) long, and
for all other types of bolts and
screws of any length. ]
Lubricated Lubricated
Lubricated Lubricated
[ [
[ “Lubricated” [ “Lubricated”
“Lubricated” “Lubricated”
means coated means coated
means coated Dry means coated Dry Dry Dry
with a with a
with a [ “Dry” means with a [ “Dry” means [ “Dry” means [ “Dry” means
lubricant such lubricant such
lubricant such plain or zinc lubricant such plain or zinc plain or zinc plain or zinc
as engine oil, as engine oil,
as engine oil, plated without as engine oil, plated without plated without plated without
fasteners with fasteners with
fasteners with any fasteners with any any any
phosphate phosphate
Screw phosphate lubrication, or phosphate lubrication, or lubrication, or lubrication, or
and oil and oil
and oil 1/4 to 3/4 in. and oil 1/4 to 3/4 in. 1/4 to 3/4 in. 1/4 to 3/4 in.
coatings, or coatings, or
coatings, or fasteners with coatings, or fasteners with fasteners with fasteners with
7/8 in. and 7/8 in. and
7/8 in. and JDM F13B zinc 7/8 in. and JDM F13B zinc JDM F13B zinc JDM F13B zinc
larger larger
larger flake coating. larger flake coating. flake coating. flake coating.
fasteners with fasteners with
fasteners with ] fasteners with ] ] ]
JDM F13C zinc JDM F13C zinc
JDM F13C zinc JDM F13C zinc
flake coating. flake coating.
flake coating. flake coating.
] ]
] ]
Size N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N˙m lb.-ft. N˙m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N˙m lb.-ft. N˙m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N˙m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength Replace fasteners with the same or higher grade. If higher
of the bolt or screw. DO NOT use these values if a different torque grade fasteners are used, tighten these to the strength of the
value or tightening procedure is given for a specific application. For original. Make sure fastener threads are clean and that you
plastic insert or crimped steel type lock nuts, for stainless steel properly start thread engagement. When possible, lubricate
fasteners, or for nuts on U-bolts, see the tightening instructions for plain or zinc plated fasteners other than lock nuts, wheel
the specific application. Shear bolts are designed to fail under bolts or wheel nuts, unless different instructions are given for
predetermined loads. Always replace shear bolts with identical grade. the specific application.

Metric Bolt and Screw Torque Values
Bolt
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
or
Lubricated Lubricated Lubricated Lubricated

[ “Lubricated” [ “Lubricated” [ “Lubricated” [ “Lubricated”
means coated means coated means coated means coated
Dry Dry Dry Dry
with a with a with a with a
[ “Dry” means [ “Dry” means [ “Dry” means [ “Dry” means
lubricant such lubricant such lubricant such lubricant such
plain or zinc plain or zinc plain or zinc plain or zinc
as engine oil, as engine oil, as engine oil, as engine oil,
plated without plated without plated without plated without
fasteners with fasteners with fasteners with fasteners with
any any any any
phosphate phosphate phosphate phosphate
Screw lubrication, or lubrication, or lubrication, or lubrication, or
and oil and oil and oil and oil
M6 to M18 M6 to M18 M6 to M18 M6 to M18
coatings, or coatings, or coatings, or coatings, or
M20 and M20 and M20 and M20 and
JDM F13B zinc JDM F13B zinc JDM F13B zinc JDM F13B zinc
larger larger larger larger
flake coating. flake coating. flake coating. flake coating.
] ] ] ]
JDM F13C zinc JDM F13C zinc JDM F13C zinc JDM F13C zinc
flake coating. flake coating. flake coating. flake coating.
] ] ] ]
Size N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in. N˙m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N˙m lb.-ft. N˙m lb.-ft. N˙m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N˙m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the
Shear bolts are designed to fail under predetermined loads. Always
strength of the bolt or screw. DO NOT use these values if a
replace shear bolts with identical property class. Replace fasteners
different torque value or tightening procedure is given for a
with the same or higher property class. If higher property class
specific application. For stainless steel fasteners or for nuts
fasteners are used, tighten these to the strength of the original. Make
on U-bolts, see the tightening instructions for the specific
sure fastener threads are clean and that you properly start thread
application. Tighten plastic insert or crimped steel type lock
engagement. When possible, lubricate plain or zinc plated fasteners
nuts by turning the nut to the dry torque shown in the chart,
other than lock nuts, wheel bolts or wheel nuts, unless different
unless different instructions are given for the specific
instructions are given for the specific application.
application.

Hydraulic system inch fitting torques
LEGEND:
A Bulkhead fitting
B Lock nut
C Collar nut
D Collar nut
Fittings with flat-faced ring seal
Collar nut Lock nut for bulkhead fitting
Thread size N˙m lb-ft N˙m lb-ft
9/16—18 16 12 5 3.5
11/16—16 24 18 9 6.5
13/16—16 50 37 17 12.5
1—14 69 51 17 12.5
1-3/16—12 102 75 17 12.5
1-7/16—12 142 105 17 12.5
1-11/16—12 190 140 17 12.5
2—12 217 160 17 12.5
The torques in the table above are intended only as approximate values, and do NOT apply if
a different torque value is listed for specific fittings at other points in this manual. Check
fittings regularly to make sure they are seated properly.
When replacing fittings, be sure to use parts with an equal or higher grade to the parts you
are replacing. Items of hardware (e.g. collar nuts) that are of a higher grade should be
tightened to the same torque value as the parts they replace.
It is vitally important to make sure that the sealing faces are clean and that the O-rings have
been inserted properly.

Hydraulic system metric fitting torques
LEGEND:
A Stud-end fitting
B Groove for metric spec.
C Lock nut
D Adjustable stud-end fitting
Straight stud-end fitting and lock nut for adjustable stud-end fitting
Steel or grey-cast iron Aluminium
Thread size N˙m lb–ft N˙m lb–ft
M12x1.5 21 15.5 9 6.6
M14x1.5 33 24 15 11
M16x1.5 41 30 18 13
M18x1.5 50 37 21 15
M22x1.5 69 51 28 21
M27x2 102 75 46 34
M33x2 158 116 71 52
M38x2 176 130 79 58
M42x2 190 140 85 63
M48x2 217 160 98 72
The torques in the table above are intended only as approximate values, and do NOT apply if
a different torque value is listed for specific fittings at other points in this Manual. Check
fittings regularly to make sure they are seated properly.
When replacing fittings, be sure to use parts with an equal or higher grade to the parts you
are replacing. Items of hardware (e.g. union nuts) that are of a higher grade should be
tightened to the same torque value as the parts they replace.
It is vitally important to make sure that the sealing faces are clean and that the O-rings have
been inserted properly.

Product identification and component serial

numbers

LEGEND:
DT-1 PowrQuad module
DT-2 SyncroPlus module

EN-1 Motor
FA-1 Front axle
FI-1 Front PTO
FI-2 Front hitch
FI-3 Front loader
HY-1 Hydraulic pump
OS-1 Operator′s cab
OS-2 ROPS
OS-3 Seat
OS-4 Brake valve
OS-5 Steering valve
OS-6 Compressor, air conditioning
RA-1 Transmission assembly
RA-3 Transmission ratios, differential - FWD
RI-1 Inlet priority valve
RI-2 Hydraulic pick-up hitch
RI-3 Wagon hitch
RI-4 Swinging drawbar
RI-5 Holder for pick-up hitch
RI-6 Trailer brake valve
Engine Serial Number
→NOTE:
Besides the engine serial number, the plate shows the engine type as well.
When ordering spare parts for the engine, please quote all the numbers
and letters on this type plate.
The engine serial number plate is located on the right-hand side of engine block.

Transmission serial number
→NOTE:
Besides the transmission serial number and type this plate shows the
transmission ratio of differential and front wheel drive as well.
The transmission serial number plate is located on the right-hand side of differential housing.
Front wheel drive axle serial number
The front wheel drive axle serial number plate is located on the rear, right-hand side of the
axle.
Operator′s cab serial number

The operator′s cab serial number plate is located behind the operator′s seat on the hydraulic
pump cover.
Operator′s seat serial number
LEGEND:
A Designation
B Part number (needed when ordering)
Section 10 - GENERAL INFORMATION Group 10: Tune-Up
C Date of manufacture (year/week)

The serial number of the operator′s seat is located on the back of the seat.
Explanation of serial number plate field C:
The first two digits (XXxx xx) indicate the year of manufacture.
Third and fourth digits (xxXX xx) indicate the week of manufacture.
Sub-assembly serial numbers

Fuel injection pump, fuel injection nozzles, alternator, starter motor, steering unit
(hydrostatic steering system), air conditioning system compressor (if equipped) and the
hydraulic pump also have serial numbers. These numbers help to distinguish between the
different types of a sub-assembly.

Group 10 - Tune-Up
Tune-Up (Summary of References)
"Specifications"
"Using high-pressure washers"
“Preliminary engine tests”
“Tractor tune-up”
“Removing and cleaning the primary air cleaner element”
“Checking the air cleaner safety element”
“Installing the primary air cleaner element”
“Checking air intake system connections for leaks”
“Checking the crankcase vent hose for clogging”
“Cleaning the radiator grille screen”
“Cleaning radiator”
“Checking the caps on the expansion tank”
“Checking the radiator for leaks”
“Checking the engine′s thermostat”
“Checking the fuel transfer pump operation”
“Bleeding the fuel system (with Bosch VP44 injection pump)”
“Checking the fuel filter (with Bosch VP44 injection pump)”
“Cleaning the water trap”
“Checking the fuel filter (with Denso/Stanadyne injection pump; Stage II engines
according to 97/68/EC)”
”Bleeding the fuel system (with Stanadyne injection pump; Stage II engines according
to 97/68/EC)”
”Bleeding the fuel system (with Denso injection pump; Stage II engines according to
97/68/EC)”
“Running the engine until it is warm and checking engine speeds”
“Checking setting of fuel injection pump”
“Cleaning the battery, cables and battery box with a clean cloth”
“Checking the neutral start circuit”
“Checking operation of starting motor”
“Checking operation of lighting system”
“Final engine check”
“Tractor operation check”

Specifications
Thermostat
- opening temperature .......... 82°C (180°F)
- operating temperature (fully open) .......... 94°C (202°F)
Slow idle
- speed .......... 845 - 855 rpm
Fast idle
- speed .......... 2455 - 2465 rpm
Rated engine speed .......... 2300 rpm
Air cleaner restriction warning switch closes at a vacuum of .......... 5.9 to 6.9 kPa (59 to 69 mbar; 0.85 to 1.0 psi)
Radiator cap pressure valve

- opens at a pressure of .......... 70 to 90 kPa (0.70 to 0.90 bar; 10 to 13 psi)
- vacuum, max. .......... 10 kPa (100 mbar; 1.5 psi)
Cooling system test pressure .......... 50 to 60 kPa (0.5 to 0.6 bar; 7 to 8.7 psi)
Using High-Pressure Washers
IMPORTANT:
Directing pressurized water at electronic/electrical components or

connectors, bearings and hydraulic seals, fuel injection pumps or other
sensitive parts and components may cause product malfunctions. Reduce
pressure, and spray at a 45 to 90° angle.

Preliminary Engine Test

Before tuning up an engine, determine whether a tune-up will restore operating efficiency. If
there is doubt, the following preliminary test will help to determine whether the engine can
be tuned. Perform the following tests:
[1] - After engine has been stopped for several hours, carefully loosen crankcase drain plug
and watch for any water to seep out. A few drops could be due to condensation, but any
more than this would indicate problems which require engine repairs rather than just a tune-
up. Refer to the Technical Manual ”Engines” in the event of malfunctions.
[2] - With engine stopped, inspect engine coolant for an oil film. With engine running, inspect
coolant for air bubbles. Either condition would indicate problems which require engine repairs
rather than just a tune-up. Refer to the Technical Manual ”Engines” in the event of
malfunctions.
[3] - Perform a dynamometer test as instructed below. See Technical Manual ”Operation and
Tests”.
Repeat dynamometer test after tune-up so that horsepower before and after tune-up can be
compared.
[4] - Measure compression as described in the Technical Manual ”Engines”.

Tractor Tune-Up
Fuel system components (Bosch VP44)
LEGEND:
A Fuel tank
B Primary fuel filter
C Fuel filter
D Injection pump (Bosch VP-44)
E Cooling element with integrated fuel cooler
F Fuel injection nozzle
G Fuel gauge sending unit
H Fuel transfer pump
I Control unit (ECU)

Denso/Stanadyne fuel system (Stage II engines according to 97/68/EC)
LEGEND:
A Fuel tank
C Fuel filter
D Injection pump
E Fuel cooler
F Fuel transfer pump
G Fuel gauge sending unit
H Control unit
I Check valve

Inspect the entire fuel system for leaks, and put right anything that is wrong.
Removing and Cleaning the Primary Air Cleaner

Element
Open the hood, pull lug (A) forward and swing catch (B) down. Fold cover (C) up. Pull primary
filter element (D) out of the cleaner housing.
IMPORTANT:
Never run the engine without the primary filter element!
IMPORTANT:
The guide ring for the primary air cleaner element must not be damaged or
deformed.

Checking the Air Cleaner Safety Element
Check if safety element (see arrow) is properly installed.
IMPORTANT:
Always replace secondary (safety) element, do not attempt to clean it.
Installing the Primary Filter Element
With the rubber seal first (arrows on decal pointing into the filter housing), slide a serviced or
new primary filter element as far as it will go into the filter housing. Fold down the cover and
let the catch click into place.
IMPORTANT:
Never close the hood or start the engine unless the filter is locked securely.

Checking the Air Intake System Connections for

Leaks
Check restriction in air intake system by measuring vacuum, see " Testing the Air Intake
System ", Section 230, Group 15.
Checking the Crankcase Vent Hose for Clogging
LEGEND:
A Vent hose
If necessary, remove vent hose and clean it in a suitable solvent.
Cleaning Dirt from Radiator Screen

Keeping the Radiator Screen Clean
For efficient cooling, the radiator screen must be kept clean.
Pull the screen (if equipped) out to the side. Remove any dust or oil and carefully straighten
any bent fins.
Checking the Caps on the Expansion Tank
Use special tester for cap check, see " Checking the Expansion Tank Caps ", Section 230,

Group 15.
Checking the Radiator for Leaks
Clean cooling system as described under “Changing Coolant” in the Operator′s Manual.
Refer to " Checking the Cooling System for Leaks ", Section 230, Group 15 in the event of
malfunctions.
Checking the engine′s thermostat
Refer to Technical Manual “Engines”.
Checking the Fuel Transfer Pump Operation

With Bosch VP44 injection pump
Stage II engines to 97/68/EC
LEGEND:
A Fuel transfer pump
In the event of a malfunction, see " Checking the Fuel Transfer Pump Operation ", Section
230, Group 15.

Bleeding the fuel system (with Bosch VP44 injection

pump)
CAUTION:
High-pressure fluid
Escaping fluid under pressure can penetrate the skin causing serious
injury. Avoid the hazard by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the
skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference to a
knowledgeable medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.
Whenever the fuel system has been opened up for service (lines disconnected or filters
removed), it will be necessary to bleed air from the system.
This fuel system can only be bled by the electronic transfer pump or at the injection nozzles.
Bleeding should not be performed at any location on the Bosch VP44 injection pump.

Bleeding at the Fuel Transfer Pump
LEGEND:
A Bleed orifice in filter base
B Overflow valve
C Fuel return line
The bleed is automatically performed by a small orifice (A) inside the filter base connected to
the overflow valve (B) on injection pump. This system allows air to escape continually
through the fuel return line (C) when ignition is ON.
[1] - Turn key in main switch to the right as far as the first switch position so that the fuel
transfer pump is operating.
[2] - Allow 40 seconds for electric transfer pump to complete priming.
[3] - If additional system bleeding is required, bleed the circuit by loosening fuel line
connections at injection nozzles. See the next procedure, "Bleeding the Fuel System at the
Fuel Injection Nozzles".
Bleeding the Fuel System at the Fuel Injection Nozzles
Injection Line

[1] - Place throttle lever in half-throttle position.

On engines equipped with electronic fuel shut-off solenoid, energize solenoid.
[2] -
IMPORTANT:
Always use a backup wrench when loosening or tightening fuel lines at
nozzles and/or injection pump to avoid damage.
Using two open-end wrenches, loosen two fuel line connections at injection nozzles.
[3] - Crank engine over with starting motor for 15 seconds (but do not start engine) until fuel
free from bubbles flows out of loosened connection. Retighten connection to specifications.
Item Measurement Specification
Fuel injection lines Torque 27 N˙m (20 lb-ft)
[4] - Repeat procedure for remaining injection nozzles (if necessary) until all air has been
removed from fuel system.

Checking the fuel filter (with Bosch VP44 injection

pump)
LEGEND:
A Drain screw
B Plastic ring
C Drain screw (fuel tank)
Should water or sediment deposits have settled in filter, proceed as follows:
Loosen drain screw (A) and plastic ring (B).
Retighten the screw and plastic ring as soon as water and sediment deposits have drained
out.
If water was present in fuel filter, then also slacken off the drain screw (C) under the fuel tank
by one turn. After draining off any water deposits, retighten the drain screws (see table).
Drain screw (fuel tank) Torque 12 N˙m
9 lb-ft

Cleaning the water trap
LEGEND:
A Drain plug
B Breather hole

Checking the Fuel Filter (with Denso/Stanadyne

Injection Pump; Stage II Engines According to
97/68/EC)
LEGEND:
A Drain screw
B Bleed screw
C Drain plug (fuel tank)
Should water or sediment deposits have settled in filter, proceed as follows:
Loosen drain screw (A) and bleed screw (B).
Retighten drain screw (A) and bleed screw (B) as soon as water and sediment deposits have
drained out.
If water was present in fuel filter, then also slacken off the drain plug (C) under the fuel tank
by one turn. After draining off any water deposits, retighten drain plug (see table).
Drain plug (fuel tank) Torque 12 N˙m
9 lb-ft

Bleeding the Fuel System (with Stanadyne Injection

Pump; Stage II Engines According to 97/68/EC)
The fuel system must be bled whenever the fuel tank has been run dry or the fuel filters have
been replaced.
Turn key in main switch to the right as far as the first switch position so that the fuel transfer
pump is operating. Keep the pump running for approx. 40 seconds.
Bleeding the Fuel System (with Denso Injection

Pump; Stage II Engines According to 97/68/EC)
CAUTION:
Never loosen or disconnect the lines between injection pump and nozzles
as the fuel pressure there is very high!

The fuel system must be bled whenever the fuel tank has been run dry or the fuel filters have
been replaced.
Turn key in main switch to the right as far as the first switch position so that the fuel transfer
pump is operating. Keep the pump running for approx. 40 seconds.
Run Engine until it is Warm and Check Engine

Speeds
Engine speeds: See reference " Engine Specifications ", Section 10, Group 05.
Adjustment: See reference " Speed Control Linkage ", Section 30, Group 05.
For more information about the injection pump, see the Component Technical manuals for
Diesel engines.
Checking Setting of Fuel Injection Pump

Refer to the component technical manual (CTM).
Cleaning the Battery, Cables and Battery Box with a

Clean Cloth

If necessary, remove oxidation on connectors using a wire brush.
Coat battery poles and connectors with petroleum jelly.
Check electrolyte level in each battery cell.
Remove caps (A). Level of electrolyte should be above the mark. Fill with distilled water only.
→NOTE:
If water must be added to battery more often than every 200 hours of
operation, alternator may be overcharging.
See reference ”Checking the Electrical Circuits” in Section 240, Group 15.

Check the Neutral Start Circuit

Tractors with SyncroPlus transmission
[1] - Depress the clutch pedal.

[2] - Move range-shift lever (A) to neutral.
[3] - Move gear-shift lever (B) to any gear.
[4] - Turn key in main switch as far as it will go to the right. The starter motor must NOT turn
over. If it does, seeReference 240-15-001, SE01 — Starting Motor and Charging Circuit.
[5] - Repeat the test in all the other gears.
Tractors with Power Reverser transmission

[3] - Move reverse drive lever (B) to any travel direction (forward or reverse).
[5] - Repeat the test in the other direction of travel.
Tractors with PowrQuad transmission

[3] - Move reverse drive lever (B) to forward position.
[5] - Repeat the test in the reverse position.
Tractors with PowrQuad Plus or AutoQuad II transmissions
[1] - Move range-shift lever (A) and reverse drive lever (B) to neutral.
[2] - Start the engine and wait 6-7 seconds.
[3] - Move the reverse drive lever to forward or reverse and release it there.
If the reverse drive lever remains in the selected position without being held there manually,
the neutral start circuit is operating correctly.
If the reverse drive lever moves INSTANTLY by itself from forward or reverse to neutral
without being moved by hand, seeReference 240-15-001, SE01 — Starting Motor and
Charging Circuit.
Tractors with AutoPowr/IVT transmission
[1] - Move reverse drive lever (A) to forward or reverse.

Checking operation of starter motor
IMPORTANT:
Do not operate starter motor for more than 20 seconds at a time. Turn key
in main switch to “zero”. Wait at least one minute before attempting to
start again.
Refer to Technical Manual “Operation and Tests” in the event of malfunctions.

Checking the lighting circuit
Check setting of headlights, and adjust if necessary.
When equipped, check lights on cab frame and adjust, if necessary.
Refer to Technical Manual “Operation and Tests” in the event of malfunctions.
Final Engine Check
Use a dynamometer to check engine power. See Reference220-15-010, ”Dynamometer Test”

in Section 220, Group 15.
→NOTE:
Compare performance with test carried out before tune-up.
Tractor Operation Check

Check power train, steering and brakes, hydraulic system and operator′s cab as described in

Section 10 - GENERAL INFORMATION Group 15: Predelivery Inspection
the Operator′s Manual.
Refer to the relevant Group of the Technical Manual in the event of any malfunction.

ENGINE (g) by Belgreen
Group 15 - Predelivery Inspection

Predelivery Inspection
The first page in the Service Record, which is titled “Delivery Certificate”, when properly filled
out and signed by the dealer and customer, verifies that predelivery and delivery services
were satisfactorily performed.
When delivering the tractor, give the customer a “Service Record” booklet with a copy of the
plate that bears the product identification number and sub-assembly serial numbers, plus the
relevant Operator′s Manual. Be sure to explain their purposes to him.
Because of the shipping factors involved, plus extra finishing touches necessary to promote
customer satisfaction, there are certain predelivery services that must be performed by the
dealer. The page in the Service Record booklet titled “Predelivery Inspection” lists the
checks, adjustments and service jobs already performed at the factory, which the dealer has
to recheck.
Perform all the checks and service jobs listed, and tick them off on the page titled “Delivery
Check List”. When completely filled out and signed, this page certifies that the proper
delivery service has been carried out.
Make three copies of the plate that bears the product identification number and sub-
assembly serial numbers.
Thefirst copy is intended for the John Deere dealer, thesecond copy is for the servicing dealer
and thethird copy should be attached to the “Service Record” booklet.
The plate bearing the product identification number and sub-assembly serial numbers must
be attached to the left-hand side (as viewed in direction of travel; see arrow).

Section 20 - ENGINE
Table of contents
Group 00 - Removal and Installation of Components .......................................................... 1
Specifications ......................................................................................................................... 1
Removing the Engine ............................................................................................................. 2
Installing the Engine ............................................................................................................ 20

Section 20 - ENGINE Group 00: Removal and Installation of Components

Specifications
Engine mounting screws Torque 100 N˙m
74 lb-ft
Front engine supports to main frame, cap screws Torque 95 N˙m
70 lb-ft
U.j. shaft to input flange, cap screws Torque 135 N˙m
100 lb-ft
Mounting at rear of front frame, nuts Torque 55 N˙m
40 lb-ft
Mounting at side of front frame, screws Torque 55 N˙m
40 lb-ft
Mounting at front of front frame, screws Torque 55 N˙m
40 lb-ft

Removing the Engine
IMPORTANT:
Before disassembling the engine, mark where the cables and hoses are
connected; this will make it easier to re-assemble them.
[1] -
LEGEND:
A Battery terminal (polarity as indicated on the battery)
B Battery terminal (polarity as indicated on the battery)
C Retaining strap
Open the hood and disconnect battery terminals (A) and (B).
CAUTION:
Disconnect the negative terminal first. Always reconnect the positive
terminal first. Always pay close attention to battery terminals.
Release retaining strap (C) and lift off the battery.

[2] -

LEGEND:
A Connector
B Hinge
C Damper connecting point
D Nuts
Remove engine hood. This is done by pulling out connector (A) and disconnecting the two
gas-filled damper struts from the frame at (C). Remove hinge (B) from the front frame,
remove nuts (D) for this purpose.
→NOTE:
The hood is heavy and awkward to move; you will require the assistance of
a second person.

[3] -
LEGEND:
A Drain valve
Put one end of a suitable hose on the drain neck and put the other end of the hose in a
suitable container. Open drain valve (A) and drain the coolant.
→NOTE:
Opening the cap on the expansion tank helps the coolant to drain quicker.
See also reference ”Removing the Radiator” in Section 30, Group 20.
[4] -
LEGEND:
A Screws in floor-plate
Remove the mat from the cab floor, take out screws (A) and lift off the floor-plate.

[5] -
LEGEND:
A Input flange of transmission
Disconnect the u.j. shaft at flange (A).
[6] -
LEGEND:
A Clamps on muffler pipe
B Wiring harness
C Wiring harness
D Ground cable
E Retaining nuts at rear
Unfasten the two clamps (A) and remove the flexible muffler pipe. Disconnect wiring
harnesses (B) and (C) from the front frame. Disconnect ground cable (D) from the engine
block. At the rear, take off the two retaining nuts (E).
→NOTE:
For information on removing the muffler, refer also to Section 30, Group 30.

[7] -
LEGEND:
A Fitting on compressed-air line
B Refrigerant hose
If a compressed-air line is equipped, disconnect it at fitting (A). If refrigerant hose (B) is
equipped, take its clamp off the engine block.
CAUTION:
Before disconnecting the compressed-air line, reduce the pressure in the
system by operating the drain valve at the compressed-air tank.

[8] -
LEGEND:
A Connector
B Connector
C Bracket for fuel transfer pump
D Connector for water-in-fuel sensor
E Fuel hose
F All starting motor cables
H Fuel filter
J Ground cable
Disconnect all connectors (A), (B) and (D), and disconnect ground cable (J). See also Section
40, Group 10.
Take off fuel filter (H) and disconnect all the starting motor cables (F).
Pull off fuel hose (E) and seal the open end. Take bracket (C) off the main frame, break the
connection and let the fuel transfer pump hang on the hoses.
CAUTION:
Comply with relevant safety instructions when working on the fuel system.
→NOTE:
There may be differences depending on how the tractor is equipped.

[9] -
LEGEND:
A Air-intake hose
B Coolant hose
C Screws
Disconnect air-intake hose (A) from the turbocharger. Disconnect coolant hose (B) from the
thermostat housing.
At both sides, take out the two screws (C).
IMPORTANT:
Seal the turbocharger and air-intake hose so that no dust can penetrate.
→NOTE:
Trap the coolant as it emerges.
[10] - Disconnect all remaining wiring harness connection points on the engine. See Section
40, Group 10.
→NOTE:
Before disconnecting the wiring harness, mark each individual connection.
This will facilitate re-assembly. Remove any cable straps and brackets that
may be present.

[11] -
LEGEND:
A Air-intake hose
B Air-intake hose
C Air cleaner housing
Disconnect hoses (A) and (B) and remove air cleaner housing (C).
[12] -
From above, lift the rear part of the front frame.

[13] -
LEGEND:
A to F Coolant hoses
Disconnect coolant hoses (A), (B), (C), (D), (E) and (F).
→NOTE:
Trap the coolant as it emerges.

[14] -
LEGEND:
A Connector
B Connector
C Screw
D Nuts
Unscrew connector (A) from the cross-member and pull out connector (B). Remove screw (C)
and take off the two nuts (D).
→NOTE:
The illustration shows a tractor with a battery cut-off switch.
[15] -

LEGEND:
A Screws on the cross-member (with battery cut-off switch only)
B Screws on the bracket for the air cleaner
C Screws on the bracket for the fuel cooler
D Bracket for the fuel cooler
E Cross-member (with battery cut-off switch only)
F Fuel cooler
G Refrigerant lines
At both sides of the tractor, remove screws (A) to (C). Then lift off cross-member (E).
In the case of tractors with fuel cooler, remove bracket (D) of cooler (F) without first
disconnecting the hoses. The fuel cooler (F) must be placed on the left side of the tractor as
soon as possible.
CAUTION:
[16] - On tractors with air-conditioning, doNOT disconnect refrigerant lines (G); instead,
disassemble as follows:

a.
LEGEND:
A Retaining springs
On both sides, unhook the retaining spring (A) of the condenser.
b. Remove all the clamps on the refrigerant hoses.
c. Relieve tension on drive belt (see Section 30, Group 20).
d.
LEGEND:
A Drive belt
B Compressor attaching screws
Remove the air-conditioning compressor. Relieve tension on drive belt (A) and take it off
the compressor′s V-belt pulley. Take out screws (B).
The compressor remains in position until the front frame is removed.

e.
Remove the condenser and place it temporarily on top of the engine. Once the front
frame has been removed, move the condenser together with the compressor to the
right-hand side of the engine.
IMPORTANT:
Use suitably folded cardboard to protect the fins on the condenser
from damage. Do not bend the refrigerant hoses or subject them to
tension.
CAUTION:
If the air-conditioning sub-assemblies are not handled correctly, leaks
will result. If leaks occur, pressurized refrigerant will escape, possibly
leading to severe personal injury. Always wear appropriate safety
gear when working on the air-conditioning system.

[17] -
LEGEND:
A Screws for attaching the front frame at the side
B Plug
C Plug
At both sides of the tractor, remove screws (A). Disconnect plugs (B) and (C).
[18] -
LEGEND:
A Screws
Take screws (A) off the front attaching point of the front frame.

[19] -
Suspend the front frame as shown, and remove it.

→NOTE:
One at a time, cut through all the cable straps (number varies depending
on how tractor is equipped) before you raise the front frame.

[20] -
LEGEND:
A D01042AA
B JDG19
As shown, attach twoJDG19suspension eyes (A) to the cylinder head. Suspend the engine on
theD01042AA(A) load-positioning sling.
→NOTE:
Depending on what further work is to be done on the engine, it may be
necessary to remove the muffler.
[21] -

LEGEND:
A Attaching screws on front engine mounting
B Rear engine mounting screws
On both sides of the tractor, separate the front engine mounting from the main frame. Do
this by taking out screws (A). At both sides of the tractor, take screw (B) out of the rear
engine mountings.
CAUTION:
Before removing the engine mountings, suspend the engine properly.

[22] -
Using load-positioning slingD01042AA, lift the engine out of the main frame.
→NOTE:
Use the load-positioning sling to alter the angle of the engine as
appropriate.
[23] - Before doing further work on the engine, place it on a suitable stand.

Installing the Engine

[1] -
LEGEND:
A JDG19 suspension eyes
AttachJDG19suspension eyes (A) to the cylinder head.
Attach the lifting tackle to the suspension eyes using load-positioning slingD01042AA.
[2] -
Use load-positioning slingD01042AAto install the engine in the main frame.

→NOTE:
Make sure the u.j. shaft is positioned correctly. Use the load-positioning
sling to alter the angle of the engine as appropriate.

LEGEND:
A Engine mounting screw (rear)
B Washer
C Rubber bearing
D Rubber bearing with bushing
E Supporting cup
F Engine mounting screw (front)
G Nut
H Engine mounting screw
Locate the engine mountings as shown and tighten the engine mounting screws to the torque
prescribed.
Engine mounting screws Torque 100 N˙m
74 lb-ft
Front engine supports to main frame, cap screws Torque 95 N˙m
70 lb-ft
IMPORTANT:
Do NOT use grease or oil to make assembly of these parts easier. If a
lubricant is needed, use talcum powder or silicone spray.
[3] -
LEGEND:
A Input flange
Install u.j. shaft on input flange (A) and tighten the cap screws to the specified torque.
U.j. shaft to input flange, cap screws Torque 135 N˙m
100 lb-ft
See also ”Installing the U.J. Shaft (Engine)”, Section 56, Group 05.
IMPORTANT:
Use screws that have not been used before.
→NOTE:
To bring the holes into alignment, it may help to use flywheel turning
deviceJDG820to turn the flywheel.
[4] - Install the floor-plate of the cab or open operator′s station.

[5] -
Install rubber damper (A) and spacer bushings (B) and (C).
[6] -
Suspend the front frame as shown, and install it. Connect all the hoses to the relevant hose
fittings and lay out the engine wiring harness.
CAUTION:
Install the battery only when assembly is completed.
See Section 40, Group 10.

See also ”Installing the Radiator” in Section 30, Group 20.

[7] -
LEGEND:
A Mounting at side of front frame
Install and tighten attaching screws (A).
Mounting at side of front frame, screws Torque 55 N˙m
40 lb-ft
[8] -
LEGEND:
A Front frame attachment (at front of frame)
Install and tighten screws (A).
Mounting at front of front frame, screws Torque 55 N˙m
40 lb-ft

[9] -
LEGEND:
A Front frame attachment (at rear of frame)
Install the rear part of the front frame and tighten nuts (A) on both sides.
Mounting at rear of front frame, nuts Torque 55 N˙m
40 lb-ft
[10] - Tractors with air-conditioning:
CAUTION:
If the air-conditioning sub-assemblies are not handled correctly, leaks will
result. If leaks occur, pressurized refrigerant will escape, possibly leading
to severe personal injury. Always wear appropriate safety gear when
working on the air-conditioning system.
a. Install the compressor bracket and compressor.

b. Install the drive belt.
c. Install the condenser.
d. Install all the clamps on the refrigerant hoses, and secure all the lines/hoses.
IMPORTANT:
Lay out the hoses and lines so that they are not subject to any
mechanical or thermal forces.
[11] -
LEGEND:
A Air cleaner housing
B Strut attaching screws
C Fuel cooler
Install the strut and tighten the screws (B).
Tractors with fuel cooler: Install cooler (C) on the front frame.
Install the air filter housing (A).
CAUTION:
[12] - For further assembly, reverse disassembly procedure. See ”Removing the Engine” in
this Group.

FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS (g) by Belgreen
[13] - Then:
a. Add coolant.
b. Check the engine oil level.
c. Check the air intake and coolant hoses for leaks.
d. Check all electrical functions.
e. Check engine idle speed.
f. Check that the fuel hoses are laid out and connected correctly.
g. Check that the protective equipment (e.g. caps on electrical connections and heat-
shields on the exhaust) are all installed properly.

Section 30 - FUEL, AIR INTAKE, COOLING AND

EXHAUST SYSTEMS
Table of contents
Group 05 - Speed Control ......................................................................................................... 1
Speed Control (Summary of References) ............................................................................... 1
General Information ............................................................................................................... 1
Specifications ......................................................................................................................... 1
Accelerator Pedal, with Mechanical Speed Control ................................................................ 2
Replacing the Accelerator Pedal Assembly (AutoPowr/IVT) .................................................... 4
Removing the Accelerator Pedal′s Potentiometer .................................................................. 5
Removing the Hand Throttle′s Potentiometer ........................................................................ 9
Group 10 - Fuel System .......................................................................................................... 11
Fuel System (Summary of References) ................................................................................ 11
General Information ............................................................................................................. 11
Removing the Fuel Tank ...................................................................................................... 12
Installing the Fuel Tank ........................................................................................................ 13
Replacing the fuel gauge sender ......................................................................................... 14
Replace the Fuel Transfer Pump .......................................................................................... 16
Changing the Fuel Filter ....................................................................................................... 19
Bleeding the Fuel System .................................................................................................... 20
Bleeding Air from the Fuel System (with Bosch VP44 Injection Pump and Denso/Stanadyne)
....................................................................................................................................... 20
Installing Check Valve in Fuel System .................................................................................. 21
Install the Check Valve in the Fuel System (with Denso/Stanadyne injection pump; Stage II
engines to 97/68/EC) ..................................................................................................... 21
Group 15 - Air Intake System ................................................................................................ 24
Air Intake System (Summary of References) ....................................................................... 24
Air filter - Exploded view ...................................................................................................... 24
Replacing the Sending Unit for Air Cleaner Restriction (B02) ............................................... 25
Group 20 - Cooling System .................................................................................................... 26
Cooling System (Summary of References) ........................................................................... 26
Specifications ....................................................................................................................... 26
Removing and Installing the Ring-Shaped Cooler ................................................................ 26
Remove the Radiator ........................................................................................................... 28
Change the Fan or the Viscous Fan Drive ............................................................................ 36
Remove and Install the Intercooler ...................................................................................... 38
Remove and Install the Intercooler (Stage II engines to 97/68/EC) ...................................... 40
Removing and Installing the Expansion Tank ....................................................................... 41
Removing and Installing the Thermostat Valve .................................................................... 43
Installing the Radiator .......................................................................................................... 45
Filling the Cooling System with Coolant ............................................................................... 46
Relieve the Tension on the Drive Belt .................................................................................. 50
Replacing the Drive Belt ...................................................................................................... 52
Replacing the Drive Belt Tensioner ...................................................................................... 53
Repairing the Fan Console ................................................................................................... 55
Remove and Install Fan Console (with Mechanical Coolant Pump) ...................................... 56

Group 25 - Cold-Weather Starting Aids ............................................................................... 58

Fuel Preheater ...................................................................................................................... 58
Electrical Starting Aid ........................................................................................................... 59
Coolant Heater ..................................................................................................................... 60
Group 30 - Exhaust System .................................................................................................... 62
Exhaust System (Summary of References) .......................................................................... 62
Specifications ....................................................................................................................... 62
Installing the Muffler ............................................................................................................ 63
Exhaust Pipe or Intermediate Exhaust Pipe ......................................................................... 66
Exhaust Pipe or Intermediate Exhaust Pipe —Upright .......................................................... 67

Group 05: Speed Control
EXHAUST SYSTEMS
Group 05 - Speed Control

Speed Control (Summary of References)
“General information”
“Specifications”
“Accelerator pedal, with mechanical speed control”
“Replacing the accelerator pedal assembly (AutoPowr/IVT)”
“Removing the accelerator pedal′s potentiometer”
“Removing the hand throttle′s potentiometer”
General Information
→NOTE:
Replace the potentiometers as complete assemblies only.
On tractors with electronic speed control ("cruise control"), calibration takes place
automatically when the tractor is started.
Specifications
Voltage output of hand throttle sensor and accelerator pedal

Voltage 0.5 to 4.5 volts (over entire range)
sensor (electronic speed control)

EXHAUST SYSTEMS
Accelerator Pedal, with Mechanical Speed Control
LEGEND:
1 Pedal plate
2 Bushing
3 Spring
4 M6x16 self-tapping screw (3 used)
5 Stop
6 Lever
7 Snap ring (5 used)
8 Hex. nut (6 used)
9 Spring pin (4 used)
10 Ball socket
11 Pivot (2 used)
12 Retaining wire

EXHAUST SYSTEMS
13 Threaded rod
14 Bushing (4 used)
15 Lever
16 Lever
17 Spring
18 Lever
19 Shaft
20 Lever
Checking the Linkage
Dimension “a” must be 78 mm (3.07 in); check the dimension, and adjust if necessary.
→NOTE:
The ball sockets must be on the same side.

EXHAUST SYSTEMS
Replacing the Accelerator Pedal Assembly

(AutoPowr/IVT)
LEGEND:
A Accelerator pedal assembly
B Hex. socket screws (3 used)
C Plug connection
[1] - Fold back the floor-mat.

[2] - Take out hex. socket screws (B).
[3] - Take off the accelerator pedal assembly and disconnect plug (C).
[4] - For installation, follow removal procedure in reverse order.
→NOTE:
A new assembly does NOT require calibration.

EXHAUST SYSTEMS
Removing the Accelerator Pedal′s Potentiometer
[1] - Take out hex. socket screws (A).

[2] - Remove potentiometer (B) together with holder (C) and the toothed segment.
Installing the Accelerator Pedal′s Potentiometer
[1] -
Remove stopper (A) from the housing.

EXHAUST SYSTEMS
[2] -
Move the accelerator pedal far enough to allow a punch with a diameter of 5 mm (0.2 in.) to
pass through the holes in housing (A) and toothed segment (B).

EXHAUST SYSTEMS
[3] -
LEGEND:
A Potentiometer with holder
B Toothed segment with spring
C Accelerator pedal housing
D Punch
E Hole in toothed segment aligned with hole in potentiometer
Use a punch to install potentiometer (A) with its holder and (pretensioned) toothed segment
(B) on housing (C).

EXHAUST SYSTEMS
[4] -
Install hex. socket screws (A) on the housing.

→NOTE:
Install the stopper on the housing.

EXHAUST SYSTEMS
Removing the Hand Throttle′s Potentiometer
[1] - Take out hex. socket screws (A) and lift off operation unit (B).
[2] - Mark the plug connections and then disconnect them.
[3] -
Disconnect plug connection (A) and remove potentiometer (B).
Installing the hand throttle′s potentiometer

Group 10: Fuel System
EXHAUST SYSTEMS
[1] -
When the segment is installed properly, the two arrows (A) are in perfect alignment.

EXHAUST SYSTEMS
Group 10 - Fuel System

Fuel System (Summary of References)
”General information”
”Removing the fuel tank”
”Installing the fuel tank”
”Replacing the fuel gauge sender”
”Replacing the fuel transfer pump”
”Changing the fuel filter”
”Bleeding air from the fuel system (with Bosch VP44 injection pump and
Denso/Stanadyne)”
”Installing the check valve in fuel system”
”Installing the check valve in the fuel system (with Denso/Stanadyne injection pump;
Stage II engines to 97/68/EC)”
General Information
CAUTION:
Do not smoke or permit live sparks or fire of any nature in the vicinity
while repairing the fuel system.
→NOTE:
For instructions on how to repair the injection pump and nozzles, see the
relevant Component Technical Manual for “Engines”.
CAUTION:
Never under any circumstances disconnect or open the lines between the
injection pump and injection nozzles. Even with the engine shut off, the
fuel pressure is still very high.
Any work on the Common Rail fuel injection system (HPCR) must ONLY be
carried out by trained personnel familiar with this type of systems.
If an accident occurs, immediately see a doctor who is familiar with this

type of injury. Any fluid injected into the skin must be surgically removed
within a few hours or gangrene may result.

EXHAUST SYSTEMS
Removing the Fuel Tank
Remove drain plug (see arrow) and drain the fuel.
For capacity of fuel tank, see “Capacities” in Section 10, Group 05.
Tractors with Cab
→NOTE:
Mark the fuel hoses before disconnecting them.
LEGEND:
A Cover
B Plug connection
C Fuel hoses
D Mounting plate
Take off cover (A), disconnect fuel lines (C) and pull off plug (B).

EXHAUST SYSTEMS
Support the tractor securely and remove the rear left wheel.
Remove the step by taking out screws (A) and hex. socket screw (B). Take cap screws (C) out
of the tensioning straps.
Take fuel tank out of support.
Installing the Fuel Tank

Install fuel tank by following the removal procedure in reverse order. The tensioning straps
must be hooked to the holders at the main frame. Make sure the fuel tank does not rub
against other parts.
Add fuel and bleed the fuel system.

EXHAUST SYSTEMS
Replacing the fuel gauge sender

Sender with retaining plate
When exchanging the fuel level sender, take action to prevent dirt from getting into the tank.
On tractors with cab, remove floor mat and cover (A). Disconnect cable (B) and fuel line
connections (C) through opening in cab floor.
Take out the four Phillips-head screws and lift off plate (D).
Carefully pull the sender upwards and tilt it to avoid damaging the float system linkage.
Install the fuel transfer pump on the new sender. See “Replacing the fuel transfer pump” ,
section 30, group 10.
Correctly position the O-ring before installation. Insert the sender and fuel transfer pump in
such a way that the pump fits into the recess in the base of the tank, and the connections
face in the direction of forward travel.
Connect the cables and install the fuel lines.

EXHAUST SYSTEMS
IMPORTANT:
Do not mix up connections!
Install the retaining plate.
Bleed fuel system.

EXHAUST SYSTEMS
Replace the Fuel Transfer Pump
LEGEND:
B Screen
C Connecting hose
D Hose clip
E Fuel level sending unit and float system linkage
F Connector
The fuel transfer pump is located inside the tank together with the fuel gauge sending unit,
so proceed as instructed at Reference ”Replace the Fuel Gauge Sender” .
Open hose clamp (D) and pull out fuel transfer pump (A), screen (B) and connecting hose (C).
IMPORTANT:
When repairing the fuel level sending unit or transfer pump, always use
new hose clamps on the connecting hose.
Make sure the connecting hose and fuel transfer pump are seated
correctly.
Clean screen (B).
Tractors with Bosch VP44 injection pump

EXHAUST SYSTEMS
LEGEND:
For information on how to replace the fuel transfer pump, refer to the Technical Manual for
Stage 4 electronic fuel systems with Bosch VP44 pump, Section 02, Group 090,”Remove and
Install the Electronic Fuel Transfer Pump - 12-Volt System”.
Tractors with Denso/Stanadyne injection pump
LEGEND:
A Cap screw
B Retainer
C Fuel hose
EXHAUST SYSTEMS
D Fuel hose
E Fuel transfer pump
F Connector
G Clamp
Remove cap screws (A) and pull off retainer (B).
Take off fuel hoses (C) and (D), and remove connector (F).
Remove clamp (G) and lift off fuel transfer pump (E).
For installation, follow removal procedure in reverse order.

EXHAUST SYSTEMS
Changing the Fuel Filter
LEGEND:
A Retaining ring
B Filter element
C Second filter (tractors with Bosch VP44 injection pump only)
[1] - Unfasten filter retaining ring (A) and remove filter (B). Seal old filter with cover of the
new one.
[2] - Remove water trap and install it on new filter.
[3] - On tractors with Bosch VP44 injection pump, also replace second filter (C).
[4] - Attach new filter. The marks on the filter must be aligned with those on the housing.
[5] - Tighten retaining ring (A) until it can be heard to engage.
[6] - Turn key in main switch to the right as far as the first switch position so that the fuel
transfer pump is operating. Keep the pump running for approx. 20 seconds.

EXHAUST SYSTEMS
Bleeding the Fuel System
→NOTE:
Before bleeding, check the system for leaks.
In order to prevent the engine from starting, move gear lever or reverse drive lever to any
position other than neutral. Turn ignition key fully to the right (to first position or as far as it
will go) to make the fuel transfer pump operate. Keep the pump running for approx. 20
seconds.
If fuel injection nozzles or lines have been replaced in the area behind fuel injection pump,
bleed fuel system as described previously. If engine will not start, proceed as follows:
[1] -
CAUTION:
Escaping fuel under pressure can have sufficient force to penetrate the
skin causing serious personal injury. If injured by escaping fuel see a
doctor immediately as otherwise serious infections may be the result.
Loosen lines at injection nozzles.

[2] - Place throttle lever in full load position.
[3] - Start engine until fuel flows free from bubbles out of loosened fuel nozzle connections.
[4] - Retighten connections.
Bleeding Air from the Fuel System (with Bosch VP44

Injection Pump and Denso/Stanadyne)
Before bleeding, check the system for leaks.
Turn ignition key to the right (to first position) to make the fuel transfer pump operate. Keep
the pump running for approx. 40 seconds.
EXHAUST SYSTEMS
CAUTION:
With Denso injection pumps, never under any circumstances disconnect or

open the lines between the pump and the injector nozzles. Pressure is very
high!
Any work on the Common Rail fuel injection system (HPCR) must ONLY be
carried out by trained personnel familiar with this type of system.
Refer to the relevant Technical Manuals.
If an accident occurs, immediately see a doctor who is familiar with this

type of injury. Any fluid injected into the skin must be surgically removed
within a few hours or gangrene may result.
Installing Check Valve in Fuel System
Use two clips (B) to install the check valve (A) approx. 100 mm (4 in.) in front of the fuel filter.
IMPORTANT:
The arrow on the valve must point towards the fuel filter!
Install the Check Valve in the Fuel System (with

Denso/Stanadyne injection pump; Stage II engines

EXHAUST SYSTEMS
to 97/68/EC)
LEGEND:
A Fuel tank
C Fuel filter
D Injection pump
E Fuel cooler
F Fuel transfer pump
G Fuel gauge sender
H Control unit
I Check valve
Use two clips (B) to install the check valve (I) approx. 100 mm (4 in.) in front of the fuel filter.

Group 15: Air Intake System
EXHAUST SYSTEMS
IMPORTANT:
The arrow on the valve must point towards the fuel filter!

Group 15: Air Intake System
EXHAUST SYSTEMS
Group 15 - Air Intake System

Air Intake System (Summary of References)
Air filter - Exploded view
Replacing the Sending Unit for Air Cleaner Restriction (B02)
General Information
IMPORTANT:
Never run the engine without the primary filter element, secondary (safety)
filter element and the dust unloading valve all in place.
→NOTE:
For instructions on how to repair the turbocharger, see relevant

Component Technical Manual for “Engines”.
Air filter - Exploded view
LEGEND:

Group 20: Cooling System
EXHAUST SYSTEMS
A Air intake openings

B Air filter housing
C Outlet
D Primary filter element
E Secondary (safety) filter element
F Outlet support
G Sender for air filter restriction
Replacing the Sending Unit for Air Cleaner

Restriction (B02)
LEGEND:
A Sending unit for air cleaner restriction indicator (B02)
B Plug
The sending unit for the air cleaner restriction indicator is located between the air cleaner
housing and expansion tank.
Open the hood.
Disconnect plug (B).
Unscrew the sending unit for air cleaner restriction (A) and replace it with a new one.
Assemble in reverse order.
IMPORTANT:
If you replace the sending unit for air cleaner restriction, you should check
the basic informator (BIF) for diagnostic trouble codes. See reference
“245-05-002 , Calling up Addresses and Diagnostic Trouble Codes”.

EXHAUST SYSTEMS
Group 20 - Cooling System

Cooling System (Summary of References)
”Removing and installing the ring-shaped cooler”
”Removing the radiator”
”Changing the fan or the viscous fan drive”
”Remove and install the intercooler”
”Remove and install the intercooler (Stage II engines to 97/68/EC)”
”Removing and installing the expansion tank”
”Removing and installing the thermostat valve”
”Installing the radiator”
”Filling the cooling system with coolant”
”Relieving tension on the drive belt”
”Replacing the drive belt”
”Replacing the drive belt tensioner”
”Reconditioning the fan console”
”Remove and install fan console (with mechanical coolant pump)”
General Information
→NOTE:
For information about repairing the coolant pump and thermostat, refer to
relevant Component Technical Manual for “Engines”.
Specifications
Drive belt tensioner to engine front plate, cap screw Torque 50 N˙m (37 lb-ft)
Deflection roll to plate, cap screw Torque 75 N˙m (55 lb-ft)
Fan console to engine

M10 cap screw Torque 50 N˙m (37 lb-ft)
M12 cap screw Torque 90 N˙m (65 lb-ft)
Fan to viscous fan drive, M10 hex. nut Torque 50 N˙m (37 lb-ft)
Viscous fan drive to hub, M10 hex. nut Torque 50 N˙m (37 lb-ft)
Cap screws at fan console with integrated coolant pump Torque 70 N˙m
52 lb-ft
Coolant drain plug Torque 4 – 5 N˙m
3 – 3.7 lb-ft

EXHAUST SYSTEMS
Removing and Installing the Ring-Shaped Cooler

See reference ”Removing and Installing the Ring-Shaped Cooler” in Section 56, Group 05.

EXHAUST SYSTEMS
Remove the Radiator

[1] - Draining the coolant ontractors up to serial no. 425328 .
Illustration shows a tractor up to serial no. 425328

LEGEND:
A Drain plug
B Filler cap
C Connect/disconnect control

EXHAUST SYSTEMS
IMPORTANT:
Radiator repairs should be carried out only by experienced mechanics or in
specialist workshops.
Drain the coolant and trap it in a suitable container.

Slacken off drain plug (A) half-way and open the filler cap (B) on the expansion tank.
3 – 3.7 lb-ft
Turn the connect/disconnect control (C) as far as it will go in direction ”b” (open).
→NOTE:
Connect/disconnect control (C) is used to connect or disconnect chambers
within the radiator.
On tractors with cab, fully open heater control.

[2] -

EXHAUST SYSTEMS
LEGEND:
A Drain plug
B Filler cap
Draining the coolant ontractors from serial no. 425329 .
IMPORTANT:
Drain the coolant and trap it in a suitable container.

Slacken off drain plug (A) half-way and open the filler cap (B) on the expansion tank.
3 – 3.7 lb-ft
→NOTE:
The connect/disconnect control is used to connect or disconnect chambers
On tractors with cab, fully open heater control.

EXHAUST SYSTEMS
[3] -
Remove the air cleaner.

Take off clamps (A) and (B) and disconnect plug (C).
Tilt air cleaner housing (D) up in the direction indicated by the arrow.
Pull the air cleaner housing out from the front.

EXHAUST SYSTEMS
[4] - Remove engine hood.
IMPORTANT:
a second person.
Disconnect safety cable (A) at the screw.

Disconnect the gas-filled cylinder (C) at the bottom.
Take off hex. nuts (D) and lift off the engine hood assembly.
[5] -
Disconnect ground cable (A) from the radiator.

EXHAUST SYSTEMS
[6] -
Take out cap screws (A) and lift off the mounting for the main fuse and horn.
[7] -
Take off rubber seal (A), feed cables (B) through the slits and slacken off clamp (C).
[8] -
Disconnect hoses (A), (B) and (C).

[9] -

EXHAUST SYSTEMS
Take out attaching screws (A), (B) and (E).

Take off retainer (C) and pull out dust screen (D).

EXHAUST SYSTEMS
Take off the two frame parts and use a cable binder to secure condenser (A) to the side of
the engine.

EXHAUST SYSTEMS
Change the Fan or the Viscous Fan Drive
→NOTE:
If equipped
Remove the radiator; see ”Remove the Radiator” in Section 30, Group 20.
To remove the fan, take out the four hex. nuts (A).
To remove the viscous fan drive, take out the four cap screws (B).
IMPORTANT:
Thermal coil on viscous fan drive can be easily damaged. Handle assembly
carefully.
Inspect drive for damage. Make sure thermal coil (D) is not bent or damaged.

EXHAUST SYSTEMS
→NOTE:
Viscous fan drive is factory balanced and is not repairable. Small nicks or
chips in fins are permissible.
Inspect fins (E) for damage.
IMPORTANT:
Replace viscous drive if more than one complete fin has been lost.
Improper balance could cause viscous drive or fan failure.
When installing, tighten the hex. nuts to the appropriate torque (see below).
Securing the drive to the pulley Torque 50 N˙m
37 lb-ft
Securing the drive to the fan Torque 50 N˙m
37 lb-ft

EXHAUST SYSTEMS
Remove and Install the Intercooler
LEGEND:
A Hose clamp
B Air intake hose
C Intercooler
D Hose clamp
E Air intake hose
F Flanged screw
G Console
H Gasket
I Retainer
J Cap screw, 45—55 N˙m (33—41 lb-ft)
K Flanged screw, 13—17 N˙m (10—12 lb-ft)
L Ground strap
M Flange nut

EXHAUST SYSTEMS
N Rubber buffer
Disconnect the inlet and return hoses (see arrows) from the intercooler.
→NOTE:
Before disconnecting coolant hoses, always put a suitable container

underneath to trap coolant as it emerges.
Loosen hose clamps (A) and (D) and remove air intake hoses (B) and (E).
Take out flanged screw (K) and remove intercooler (C).
When installing, tighten to the appropriate torque (see below):
Ground strap to intercooler Torque 13—17 N˙m
10—12 lb-ft

EXHAUST SYSTEMS
Remove and Install the Intercooler (Stage II engines

to 97/68/EC)

EXHAUST SYSTEMS
LEGEND:
A Hose clamp
B Air-intake hose
C Cap screw (3 used)
D Bushing
E Intercooler
F Insulating pad
G Seal
H Contact plate
I Plug for injection valves
Disconnect the inlet and return hoses (see arrows) from the intercooler.
→NOTE:
Before disconnecting coolant hoses, always put a suitable container

underneath to trap coolant as it emerges.
Remove air intake hose (B) and cap screws (C).
→NOTE:
Be careful when taking off the intercooler, as you may damage the injection
valve plug (I; to the right of the cylinder head).
Take off intercooler (E).
Intercooler to engine block attaching screw Torque 16 - 20 N˙m
11.5 - 14.5 lb-ft
Removing and Installing the Expansion Tank

EXHAUST SYSTEMS
Carefully press the two plastic lugs (A) and slide expansion tank (B) in the direction indicated
by the arrow.
Installation
Make sure that O-ring (A) is seated correctly.
→NOTE:
Carefully slide the expansion tank onto the radiator, making sure that it is
straight and that O-ring (A) does not become damaged.
Slide the expansion tank onto the radiator in reverse order to the procedure described above.

EXHAUST SYSTEMS
Removing and Installing the Thermostat Valve
→NOTE:
Applies only to tractors without AutoPowr
On tractors up to serial no. 425328
Removal:
Carefully lift up both lugs on the thermostat valve (A) and completely remove the thermostat
valve from its seat.
Installation:
→NOTE:
Make sure the valve seat is clean.
To install the thermostat valve (A), reverse the removal procedure.

EXHAUST SYSTEMS
On tractors from serial no. 425329
Removal:
LEGEND:
A Hose (inlet from radiator)
B Hose clamp
C Hose (return to radiator)
Take off clamps (B) and remove hose (C).
LEGEND:
A Thermostat valve
Unscrew the low-temperature thermostat (A).
Installation:
→NOTE:
Make sure the valve seat is clean.
To install the thermostat valve (A), reverse the removal procedure and comply with the

EXHAUST SYSTEMS
following specification.
Thermostat Torque 27 N˙m
20 lb-ft
Installing the Radiator

Install the radiator in reverse order (with regard to the procedure described under "Removing
the Radiator"). See reference “Removing the Radiator” .

EXHAUST SYSTEMS
Filling the Cooling System with Coolant

On tractors up to serial no. 425328
LEGEND:
A Drain plug
B Connect/disconnect control
C Filler cap
D Relief valve cap

EXHAUST SYSTEMS
IMPORTANT:

[1] - Tighten coolant drain plug (A) to the torque value quoted below, and remove filler cap
(C) from the expansion tank.
Coolant drain plug Torque 4—5 N˙m
3—3.7 lb-ft
Turn the connect/disconnect control (B) as far as it will go in direction ”b” (open).
→NOTE:
Connect/disconnect control (B) is used to connect or disconnect chambers
[2] - On tractors withAutoPowr/IVT , the upper hose must also be removed from the
intercooler.
[3] - Add coolant up to the "max." mark.
[4] - On tractors withAutoPowr/IVT : As soon as coolant emerges from the intercooler hose,
connect the hose to the intercooler and secure it with a clamp.
[5] - Start the engine and run it for 5 minutes.
[6] - Shut down the engine and add coolant up to the "max." mark.
[7] - Start the engine and bring it up to operating temperature.
[9] - Turn the connect/disconnect control (B) to the right to position ”a” (closed).
[10] - Re-install and close the filler cap and relief valve cap.
Check the cooling system for leaks; seeReference 230-15-070, Check Cooling System for
Leaks.
On tractors from serial no. 425329

EXHAUST SYSTEMS
LEGEND:
A Drain plug
B Filler cap
IMPORTANT:


EXHAUST SYSTEMS
[1] - Tighten coolant drain plug (A) to the torque value quoted below, and remove filler cap
(b) from the expansion tank.
Coolant drain plug Torque 4—5 N˙m
3—3.7 lb-ft
→NOTE:
Connect/disconnect control (C) is used to connect or disconnect chambers
[2] - On tractors withAutoPowr/IVT , the upper hose must also be removed from the
intercooler.
[3] - Add coolant up to the "max." mark.
[4] - On tractors withAutoPowr/IVT : As soon as coolant emerges from the intercooler hose,
connect the hose to the intercooler and secure it with a clamp.
[5] - Start the engine and run it for 5 minutes.
[7] - Start the engine and bring it up to operating temperature.
[9] - Turn the connect/disconnect control (C) to the right to position ”a” (closed).
[10] - Re-install and close the fill cap.
Check the cooling system for leaks; seeReference 230-15-070, Check Cooling System for
Leaks.

EXHAUST SYSTEMS
Relieve the Tension on the Drive Belt
LEGEND:
A Bore (cam)
B Bore (base plate)
C Tensioner roll
CAUTION:
Disconnect negative (—) cable from battery.
Remove cover on tensioner roll (C). Turn tensioner roll cap screw using a 15 mm (19/32 in.)
wrench (see arrow). Once released, the drive belt tensioner automatically goes back to the
tensioning position.
The drive belt tensioner can be kept in relieved position as follows:
Turn tensioner roll cap screw (see arrow) until bores (A) and (B) are aligned. Insert a 5 mm
(0.2 in.) dia. pin into the two holes that are in alignment.

EXHAUST SYSTEMS
For tensioning, turn tensioner roll slightly to release metal pin and pull it from the bores. The
drive belt tensioner returns to its tensioning position automatically.

EXHAUST SYSTEMS
Replacing the Drive Belt
CAUTION:
Disconnect negative (—) cable from battery.
Before relieving the tension on the old drive belt, see reference ”Relieving Tension on the
Drive Belt” .
Tractors with front-wheel drive shaft:
Before detaching the drive shaft between the clutch and the torsion damper, see
reference”Installing and Removing the Drive Shaft”.
LEGEND:
A Corrugated-head screws
B Drive belt
C Fan
Take the six screws (A) out of the fan.
Take drive belt (B) off over fan (C) and put on a new drive belt (see below for routing of belt).
IMPORTANT:
When installing, always use new corrugated-head screws.
Tighten corrugated-head screws to the following specification.

EXHAUST SYSTEMS
Attachment to fan Torque 22 – 28 N˙m
16 – 21 lb-ft
LEGEND:
A Crankshaft
B Coolant pump
C Tensioner roll
D Fan pulley
E Alternator
F Deflector roll
G Compressor (air conditioning system)
H Compressor (air brakes)
Install the drive belt correctly and slacken drive belt tensioner again.
If equipped:
Before re-attaching the drive shaft (front-wheel drive), see reference”Installing and Removing
the Drive Shaft”.
Replacing the Drive Belt Tensioner

EXHAUST SYSTEMS
Slacken drive belt and remove the three cap screws (A).
When installing, tighten the three cap screws (A) to the following torque:
Torque 50 N˙m
37 lb-ft
Re-install drive belt.
The tensioner roll is kept in released position by means of a metal pin with a dia. of 5 mm
(0.2 in.). For tensioning, turn tensioner roll slightly to release metal pin and pull it from the
bores. The drive belt tensioner returns to its tensioning position automatically.

EXHAUST SYSTEMS
Repairing the Fan Console
LEGEND:
A Hub
B Snap ring
C Bearing
D Console
Relieve and remove drive belt.
Remove fan and viscous fan drive.
Remove fan console.
Using a puller, remove hub (A).
Remove snap ring (B).
Press out bearing (C) making sure not to break the console (D).

EXHAUST SYSTEMS
When pressing in the bearing, use disks that match exactly.
→NOTE:
The bearing can be pressed in easier when it has been cooled beforehand.
Slightly grease the bearing bore. Locate the bearing and press it in using a bushing until the
snap ring can be installed. When pressing in, apply force only to the bearing cup!
Place a pressure disk under bearing shaft (C). Apply force only to the shaft!
Install hub by means of a bushing making sure to keep to dimension ”a”.
Dimension ”a”: 110.76 to 110,96 mm (4.36063 to 4.3685 in.)
IMPORTANT:
Make absolutely sure that dimension ”a” is kept.
Remove and Install Fan Console (with Mechanical

Group 25: Cold-Weather Starting Aids
EXHAUST SYSTEMS
Coolant Pump)
LEGEND:
A Cap screws
B Fan console
C Coolant pump (integrated in fan console)
On tractors with AutoPowr/IVT transmission (from serial no. 446370)
Relieve tension on drive belt and remove belt.
Remove fan and viscous fan drive.
Remove fan console.
Cap screws at fan console with integrated coolant pump Torque 70 N˙m
52 lb-ft

EXHAUST SYSTEMS
Group 25 - Cold-Weather Starting Aids

Fuel Preheater
LEGEND:
A Cap
B Heating element
C Seal
D Fuel filter head

EXHAUST SYSTEMS
With Bosch VP44 injection pump and Denso/Stanadyne
LEGEND:
A Heater coil
B O-rings
Electrical Starting Aid

EXHAUST SYSTEMS
LEGEND:
A Air intake pipe
B Cap screw
C Seal
D Heating element
E Seal
F Hex. nut
Coolant Heater

Group 30: Exhaust System
EXHAUST SYSTEMS
LEGEND:
A Heating element
B Seal ring
C O-ring
D Adapter
E Collar nut
F Connecting cable
G Cable binder
H Clamp

EXHAUST SYSTEMS
Group 30 - Exhaust System

Exhaust System (Summary of References)
”Installing the muffler”
”Exhaust pipe or intermediate exhaust pipe”
”Exhaust pipe or intermediate exhaust pipe —upright”
General Information
→NOTE:
For instructions on how to repair the turbocharger, see relevant

Component Technical Manual for “Engines”.
When assembling parts of the exhaust system that need to be joined together, use paste
L102219.
Specifications
Clamp, muffler Torque 10 to 14 N˙m
8 to 10 lb-ft
Pipe clamp (25) Torque 48—60 N˙m
32—44 lb-ft
Pipe clamp (20; spherical) Distance ”a” when tightened 4 mm
0.15 inch
Exhaust pipe or intermediate exhaust pipe —upright
Pipe clamp (items 3 and 7) Torque 48—60 N˙m
32—44 lb-ft

EXHAUST SYSTEMS
Installing the Muffler
LEGEND:
1 Muffler
2 Retaining strap
3 M8x70 hex. socket screw
4 Bracket
5 Washer
6 Cap screw
7 Bracket
8 Hex. nut
9 Heat shield
10 Washer
11 Cap screw
12 Cap screw
13 Clamp
Stage I engines to 97/68/EC
Secure bracket (7) to the engine block.
Secure bracket (4) to bracket (7), but leave it slack enough to turn.
Install retaining strap (2) on the muffler and on bracket (4).
Install the muffler on the turbocharger.
Turn clamp (13) several times while tightening. Tighten hex. socket screw (14) to the torque
value given in the table.

EXHAUST SYSTEMS
8 to 10 lb-ft
Stage II engines to 97/68/EC
LEGEND:
1 Muffler
2 Retaining strap
4 Bracket
5 Washer
6 Cap screw
7 Bracket
8 Washer
9 Hex. nut
10 Cap screw
11 Heat shield
12 Cap screw
13 Clamp
Secure bracket (7) to the engine block.
Secure bracket (4) to bracket (7), but leave it slack enough to turn.
Install retaining strap (2) on the muffler and on bracket (4).
Install the muffler on the turbocharger.
Turn clamp (13) several times while tightening. Tighten hex. socket screw (14) to the torque
EXHAUST SYSTEMS
value given in the table.
8 to 10 lb-ft

EXHAUST SYSTEMS
Exhaust Pipe or Intermediate Exhaust Pipe
LEGEND:
1 Exhaust pipe
2 Clamp
3 Clamp
4 Hex. nut (2 used)
5 Washer (2 used)

EXHAUST SYSTEMS
6 Sheet-metal nut (8 used)

7 Cap screw (2 used)
8 Hex. nut (4 used)
9 Washer (2 used)
10 Washer (2 used)
11 Washer (4 used)
12 Rubber bearing (2 used)
13 Console
14 Bushing (2 used)
16 Console
17 Washer (3 used)
18 Hex. socket screw (3 used)
19 Pan-head screw (3 used)
20 Pipe clamp (2 used)
21 Flexible pipe
22 Heat shield (assembly)
23 Spring
24 Hex. nut
25 Pipe clamp (2 used)
26 Intermediate exhaust pipe
27 Heat shield
Tighten pipe clamps (20) and (25) as specified.
Pipe clamp (spherical)
Pipe clamp (25) Torque 48—60 N˙m
32—44 lb-ft
Pipe clamp (20; spherical) Distance ”a” when tightened 4 mm
0.15 inch

ELECTRICAL SYSTEM (g) by Belgreen
Exhaust Pipe or Intermediate Exhaust Pipe

—Upright
LEGEND:
1 Exhaust pipe
2 Clamp
3 Clamp
4 Intermediate exhaust pipe
5 Flanged screw
6 Console
7 Clamp
8 Pan-head screw
9 Protective panel
Items 3 and 7 (pipe clamps) must be tightened to the torque values given in the table below.
Pipe clamps (3) and (7) Torque 48—60 N˙m
32—44 lb-ft

Section 40 - ELECTRICAL SYSTEM

Table of contents
Group 05 - Electrical Connectors ............................................................................................ 1
Connectors - Summary of References .................................................................................... 1
Special or Essential Tools ....................................................................................................... 2
General .................................................................................................................................. 6
Using high-pressure washers ................................................................................................. 6
Disconnecting electrical circuits ............................................................................................. 7
Strip Wire Ends ...................................................................................................................... 7
Install a Terminal ................................................................................................................... 8
WEATHER PACK Connectors ................................................................................................. 10
METRI PACK Connectors with Terminal Lock at the Rear ..................................................... 13
METRI PACK Connectors with Terminal Lock at the Front .................................................... 17
METRI PACK Connectors ....................................................................................................... 20
Connector at CAN Bus Terminating Resistor ........................................................................ 25
Connectors for Electronic Control Units ............................................................................... 28
Connectors ........................................................................................................................... 34
CRIMP SNAP IN Connectors .................................................................................................. 41
KOSTAL Connectors ............................................................................................................. 44
DEUTSCH Connectors ........................................................................................................... 47
Individual Terminals ............................................................................................................. 52
Connector for Bosch VP44 Injection Pump ........................................................................... 54
Fuse and Relay Boxes on Tractors with Operator′s Cab ....................................................... 57
Group 10 - Wiring Harnesses ................................................................................................. 61
Wiring Harnesses for Tractors with PowrQuad Plus or AutoQuad Transmissions and Stage I
Engine to 97/68/EC — Recondition (Summary of References) ...................................... 61
Wiring Harnesses for Tractors with PowrQuad Plus or AutoQuad Transmissions and Stage II
Engine to 97/68/EC — Recondition (Summary of References) ...................................... 63
Wiring Harnesses for Tractors with PowrQuad Plus or AutoQuad Plus Transmission from Serial
No. 398656 — Recondition (Summary of References) .................................................. 65
Wiring Harnesses for Tractors with AutoPowr/IVT Transmission and Stage I Engine to
97/68/EC — Recondition (Summary of References) ...................................................... 67
Wiring Harnesses for Tractors with AutoPowr/IVT Transmission and Stage II Engine to
97/68/EC — Recondition (Summary of References) ...................................................... 69
Wiring Harnesses for Tractors with AutoPowr/IVT transmission from Serial No. 398656 —
Recondition (Summary of References) .......................................................................... 71
Disconnecting electrical circuits ........................................................................................... 72
Ground Point Locations ........................................................................................................ 74
Removing and Installing Harness W01 — Power Supply ...................................................... 75
Removing and Installing Harness W02 — Engine Wiring Harness for Stage I Engine to
97/68/EC (ECU Level 4) ................................................................................................. 77
Removing and Installing Harness W02 — Engine Wiring Harness for Stage II Engine to
97/68/EC (ECU Level 11) ............................................................................................... 79
Removing and Installing Harness W02 — Engine (Level 11 ECU) from Serial No. 398656
....................................................................................................................................... 81
Removing and Installing Harness W03 — Starting Aid for Stage I and II engines to 97/68/EC
(Level 4 or 11 ECUs) ...................................................................................................... 82
Removing and Installing Harness W03 — Starting Aid (Level 11 ECU) from Serial No. 398656

....................................................................................................................................... 84
Removing and Installing Harness W03 — Starting Aid for Stage I and II engines to 97/68/EC
(Level 4 or 11 ECUs) (AutoPowr/IVT transmission) ........................................................ 86
Removing and Installing Harness W03 — Starting Aid (Level 11 ECU) (AutoPowr/IVT
transmission) from Serial No. 398656 ........................................................................... 87
Removing and Installing Harness W04 — Headlights ........................................................... 88
Removing and Installing Harness W06 — Front-Wheel Drive Axle with TLS ......................... 90
Removing and Installing Harness W07 — Front PTO ............................................................ 90
Removing and Installing Harness W08 — Cab, with Stage I Engine to 97/68/EC .................. 92
Removing and Installing Harness W08 — Cab, with Stage II Engine to 97/68/EC ................. 95
Removing and Installing Harness W08 — Cab from Serial No. 398656 ................................ 98
Removing and Installing Harness W08 — Cab, with Stage I engine to 97/68/EC (AutoPowr/IVT
transmission) .............................................................................................................. 101
Removing and Installing Harness W08 — Cab, with Stage II engine to 97/68/EC (AutoPowr/IVT
transmission) .............................................................................................................. 104
Removing and Installing Harness W08 — Cab (AutoPowr/IVT Transmission) from Serial No.
398656 ........................................................................................................................ 107
Removing and Installing Harness W09 — Cowl, with Stage I Engine to 97/68/EC .............. 110
Removing and Installing Harness W09 — Cowl, with Stage II Engine to 97/68/EC ............. 112
Removing and Installing Harness W09 — Cowl from Serial No. 398656 ............................ 114
Removing and Installing Harness W09 — Cowl, with Stage I engine to 97/68/EC (AutoPowr/IVT
transmission) .............................................................................................................. 116
Removing and Installing Harness W09 — Cowl, with Stage II engine to 97/68/EC
(AutoPowr/IVT transmission) ....................................................................................... 118
Removing and Installing Harness W09 — Cowl (AutoPowr/IVT Transmission) from Serial No.
398656 ........................................................................................................................ 120
Removing and Installing Harness W10 — Shift Console ..................................................... 121
Removing and Installing Harness W11 — Transmission Shift and Hand Throttle ............... 121
Removing and Installing Harness W11 — Speed Control Lever and Hand Throttle
(AutoPowr/IVT transmission) ....................................................................................... 122
Removing and Installing Harness W12 — Command Arm (AutoPowr/IVT transmission) .... 124
Removing and Installing Harness W13 — Clutch Sending Unit .......................................... 125
Removing and Installing Harness W14 — 3-Terminal Power Outlet Socket ........................ 125
Removing and Installing Harness W15 — ECU for Stage I engines to 97/68/EC (Level 4 ECU)
..................................................................................................................................... 126
Removing and Installing Harness W15 — ECU for Stage II engines to 97/68/EC (Level 11 ECU)
..................................................................................................................................... 127
Removing and Installing Harness W15 — Engine Control Unit (Level 11 ECU) from Serial No.
398656 ........................................................................................................................ 128
Removing and Installing Harness W16 — SIC with Stage I engine to 97/68/EC .................. 129
Removing and Installing Harness W16 — SIC with Stage II engine to 97/68/EC ................. 131
Removing and Installing Harness W17 — Multi-function Unit ............................................ 132
Removing and Installing Harness W18 — Windshield Wiper Switch (Without Intermittent
Wipe) ........................................................................................................................... 133
Removing and Installing Harness W18 — Windshield Wiper Switch (with Intermittent Wipe)
..................................................................................................................................... 134
Removing and Installing Harness W19 — Cab Roof, with Stage I Engine to 97/68/EC ....... 136
Removing and Installing Harness W19 — Cab Roof, with Stage II Engine to 97/68/EC ...... 138
Removing and Installing Harness W20 — Turn Signal and Clearance Lights ..................... 140
Removing and Installing Harness W21 — Worklights on Front of Cab Roof ....................... 144

Removing and Installing Harness W22 — Worklights on Rear of Cab Roof ........................ 144
Removing and Installing Harness W22 — Xenon (HID) Worklights on Rear of Cab Roof .... 145
Removing and Installing Harness W23 — Windshield Wiper Switch (Without Switch for
Windshield) ................................................................................................................. 146
Removing and Installing Harness W23 — Windshield Wiper (With Switch for Windshield)
..................................................................................................................................... 148
Removing and Installing Harness W24 — Rear Window Wiper ........................................... 150
Removing and Installing Harness W25 — Rear Window Wiper Switch ............................... 150
Removing and Installing Harness W26 — Fan and Air-Conditioner .................................... 151
Removing and Installing Harness W26 — Fan and Air-conditioner from Serial No. 398656
..................................................................................................................................... 152
Removing and Installing Harness W26 — ClimaTrak (Cab) ................................................ 153
Removing and Installing Harness W28 — Front End of Transmission ................................. 156
Removing and Installing Harness W28 — Front End of Transmission (AutoPowr/IVT
transmission) .............................................................................................................. 158
Removing and Installing Harness W29 — Valve Block (AutoPowr/IVT transmission) .......... 159
Removing and Installing Harness W30 — Rear End of Transmission ................................. 161
Removing and Installing Harness W31 — 7-Terminal Power Outlet Socket ........................ 163
Removing and Installing Harness W32 — Stepper Motors, with Stage I engine to 97/68/EC
..................................................................................................................................... 164
Removing and Installing Harness W32 — Stepper Motors, with Stage II engine to 97/68/EC
..................................................................................................................................... 166
Removing and Installing Harness W33 — Service .............................................................. 168
Removing and Installing Harness W34 — Electric Rear-View Mirrors ................................. 169
Removing and Installing Harness W35 — Access Step Lighting and Battery Cut-off Switch
(Version 1) .................................................................................................................. 170
Removing and Installing Harness W35 — Access Step Lighting and Battery Cut-off Switch
(Version 2) .................................................................................................................. 171
Removing and Installing Harness W36 — 60-amp GreenStar Socket for Stage I Engine to
97/68/EC ..................................................................................................................... 173
Removing and Installing Harness W36 — 60-amp GreenStar Implement Socket ............... 174
Removing and Installing Harness W37 — GreenStar Port .................................................. 176
Removing and Installing Harness W39 — GreenStar (Cab), for Stage I Engine to 97/68/EC
..................................................................................................................................... 176
Removing and Installing Harness W39 — GreenStar (Cab) ................................................ 178
Removing and Installing Harness W39 — GreenStar with TEC (Cab), for Stage I Engine to
97/68/EC ..................................................................................................................... 179
Removing and Installing Harness W39 — GreenStar with Tractor Equipment interface
Controller (Cab) ........................................................................................................... 182
Removing and Installing Harness W40 — GreenStar (Cab Roof), for Stage I Engine to
97/68/EC ..................................................................................................................... 183
Removing and Installing Harness W40 — GreenStar (Cab Roof) ........................................ 184
Removing and Installing Harness W41 — JDLink ................................................................ 184
Removing and Installing Harness W42 — Battery Cut-Off Switch, Version 1 ...................... 185
Removing and Installing Harness W42 — Battery Cut-Off Switch, Version 2 ...................... 186
Removing and Installing Harness W47 — ClimaTrak (Cab Roof) ........................................ 188
Removing and Installing Harness W48 — ClimaTrak (Cowl) ............................................... 189
Removing and Installing Harness W49 — ClimaTrak (Evaporator Housing) ....................... 190
Removing and Installing Harness W50 — GreenStar (CAN BUS Terminator) ..................... 192
Removing and Installing Harness W51 — AutoTrac (Cab) .................................................. 192

Removing and Installing Harness W52 — AutoTrac (Steering Angle Sensor) ..................... 194
Removing and Installing Harness W53 — AutoTrac (Command Arm) ................................ 195
Removing and Installing Harness W55 — Display .............................................................. 195
Removing and Installing Harness W56 — Serial Interface, Adapter ................................... 196
Removing and Installing Harness W57 — Electro-hydraulic Pick-up Hitch (Cab) ................ 197
Removing and Installing Harness W58 — Electro-hydraulic Pick-up Hitch (Valves) ........... 198
Group 15 - Charging Circuit ................................................................................................. 200
Charging Circuit - Summary of References ........................................................................ 200
Special Tools ...................................................................................................................... 200
Specifications ..................................................................................................................... 200
Repairing the Alternator ..................................................................................................... 200
Disconnecting Electrical Circuits ........................................................................................ 201
Relieving Drive Belt Tension .............................................................................................. 201
Remove/Install the Alternator ............................................................................................ 203
Remove and Install the Pulley ............................................................................................ 205
Group 20 - Starter Motor Circuit ......................................................................................... 207
Starter Motor Circuit - Summary of References ................................................................. 207
Special tools ....................................................................................................................... 207
Specifications ..................................................................................................................... 207
Repairing the Starter Motor ............................................................................................... 207
Removing and installing the starter motor ......................................................................... 209
Group 25 - Fuses, Relays and Switches ............................................................................. 211
Fuses, Relays and Switches — Recondition (Summary of References) .............................. 211
General Information ........................................................................................................... 212
Special Tools ...................................................................................................................... 212
Specifications ..................................................................................................................... 214
Removing Trim Panels from Cowl ....................................................................................... 214
Fuse and Relay Boxes on Tractors with Operator′s Cab up to Serial No. 398655 ............... 217
Fuse and Relay Boxes on Tractors with Operator′s Cab from Serial No. 398656 ............... 233
Fuse and Relay Boxes on Tractors with Operator′s Cab and AutoPowr/IVT Transmission up to
Serial No. 398655 ........................................................................................................ 249
Fuse and Relay Boxes on Tractors with Operator′s Cab and AutoPowr/IVT Transmission from
Serial No. 398656 ........................................................................................................ 265
Replacing the Main Fuses .................................................................................................. 280
Replacing Fuses of Electrical Starting Aid for Stage I and II Engines to 97/68/EC (Level 4 or 11
ECUs) .......................................................................................................................... 283
Replacing Fuses of Electrical Starting Aid for Stage I and II Engines to 97/68/EC (Level 4 or 11
ECUs) (AutoPowr/IVT Transmission) ............................................................................ 285
Replacing Fuse for Fuel Injection Pump (with Stage I Engines to 97/68/EC (Level 4 ECU)
..................................................................................................................................... 287
Replacing Fuse for Fuel Injection Pump (with Stage I Engines to 97/68/EC (Level 4 ECU)
(AutoPowr/IVT Transmission) ...................................................................................... 289
Replacing the LTC Coolant Pump Fuse (AutoPowr/IVT Transmission) ................................ 291
Replace the Fuse for the Implement BUS (60-amp Implement Socket) ............................. 293
Replacing Starting Motor Relay for Stage I and II Engines to 97/68/EC (Level 4 or 11 ECUs)
..................................................................................................................................... 295
Replacing Starting Motor Relay for Stage I and II Engines to 97/68/EC (Level 4 or 11 ECUs)
(AutoPowr/IVT Transmission) ...................................................................................... 297

Replacing Relay of Electrical Starting Aid for Stage I and II Engines to 97/68/EC (Level 4 or 11
ECUs) .......................................................................................................................... 299
Replacing Relay of Electrical Starting Aid for Stage I and II Engines to 97/68/EC (Level 4 or 11
ECUs) (AutoPowr/IVT Transmission) ............................................................................ 301
Replacing Relay for Fuel Injection Pump (with Stage I Engines to 97/68/EC only (Level 4 ECU))
..................................................................................................................................... 302
Replace the Power Supply Relay for the Implement BUS ................................................... 303
Replacing Battery Cut-off Switch Relay .............................................................................. 304
Replacing Battery Cut-off Switch Relay .............................................................................. 307
Replacing the Main Switch ................................................................................................. 308
Replacing the Brake Switches ............................................................................................ 310
Replacing the Light Switch ................................................................................................. 310
Replacing the Worklight Switches ...................................................................................... 312
Replacing the Switch for Lights on Cab Frame ................................................................... 314
Replacing the Beacon Light Switch .................................................................................... 316
Replacing the Hazard Warning Light Switch ...................................................................... 317
Replacing Switches on Multi-Function Unit ......................................................................... 319
Replacing the Rear Window Wiper and Washer Switch ...................................................... 327
Replacing the Windshield/Rear Window Switch ................................................................. 329
Replacing the Dome Light Door Switch .............................................................................. 331
Replacing the Handbrake Switch ....................................................................................... 333
Replacing the Front Wheel Drive Switch ............................................................................ 335
Replacing the Headland Management (HMS) Switch ......................................................... 336
Replacing the Record/Save Switch ..................................................................................... 337
Replacing the Program Switch ........................................................................................... 338
Replacing the Rear PTO Preselector Switch ....................................................................... 341
Replacing the Switch for AutoQuad Transmission .............................................................. 342
Replace the Switch for Gear Selector and Auto-mode ....................................................... 343
Replacing the Park Lock Switch on Tractors with PowrQuad Plus, AutoQuad or AutoQuad Plus
Transmissions ............................................................................................................. 348
Replacing the Fan Switch ................................................................................................... 350
Replacing the Switch of the Air-Conditioning System Compressor .................................... 352
Replacing the Differential Lock Switch. .............................................................................. 353
Replacing the PTO Switches ............................................................................................... 354
Replacing the External Control Switch for the Rear PTO .................................................... 358
Replacing the Rockshaft′s Remote Control Switch ............................................................. 360
Replacing the Switches for the Electrical Rear-View Mirrors .............................................. 361
Replacing the Switch for the Heated Rear-View Mirrors ..................................................... 361
Replacing the Switch for the Heated Rear Window ............................................................ 362
Replacing Switch of Battery Cut-off Switch ........................................................................ 364
Replace the AutoTrac Switch ............................................................................................. 366
Replacing the Switch for the Electro-hydraulic Pick-up Hitch ............................................. 369
Replacing the Cruise Control Potentiometer on Tractors with AutoQuad Transmission ..... 371
Replacing the Cruise Control Potentiometer on Tractors with AutoPowr/IVT Transmission
..................................................................................................................................... 373
Replace the Auto-mode Potentiometer on Tractors with AutoQuad Plus Transmission ...... 375
Rockshaft Control ............................................................................................................... 377
Electrical Activators for Selective Control Valves (E-SCV) .................................................. 388
Electrical Activators for Independent Control Valves (E-ICV) ............................................. 392
Group 30 - Monitoring Systems .......................................................................................... 396

Monitoring Systems - Recondition (Summary of References) ............................................ 396

Information for Tractors with Stage I Engine to 97/68/EC (Level 4 ECU) ............................ 396
Information for Tractors with Stage II Engine to 97/68/EC (Level 11 ECU) ......................... 396
Information for Tractors with AutoTrac (SSU Control Unit) ................................................. 397
Disconnecting electrical circuits ......................................................................................... 397
Replacing the sender for the coolant temperature gauge (B08) ........................................ 398
Replacing Acoustic Warning Signal Sending Unit ............................................................... 399
Replace the Acoustic Alarm (Park Lock) on Tractors with AutoPowr/IVT Transmission ...... 401
Group 40 - Electrical Components ...................................................................................... 403
Electrical Components - Recondition (Summary of References) ........................................ 403
Special or Essential Tools ................................................................................................... 403
Specifications ..................................................................................................................... 404
Disconnecting electrical circuits ......................................................................................... 404
Replacing the 7-Terminal Power Outlet Socket .................................................................. 405
Replacing the 3-Terminal Power Outlet Socket .................................................................. 407
Replacing the Multiple Power-Outlet Socket Strip .............................................................. 409
Replacing the Service Socket ............................................................................................. 411
Removing the Wiper Motor ................................................................................................ 413
Adjusting the Headlights .................................................................................................... 416
Adjusting the Lights on the Cab Frame .............................................................................. 417
Safety Instructions for Replacing a Halogen Bulb .............................................................. 419
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units .............................. 421
Replacing Xenon (HID) Worklights and Ballast Units .......................................................... 424

Section 40 - ELECTRICAL SYSTEM Group 05: Electrical Connectors
Group 05 - Electrical Connectors

Connectors - Summary of References
”Special tools”
”Using high-pressure washers”
”Disconnecting electrical circuits”
”Stripping wire ends”
”Installing electrical connectors”
”WEATHER PACK connectors”
”METRI PACK connectors with terminal lock at the rear”
”METRI PACK connectors with terminal lock at the front”
”METRI PACK connectors”
”Connector at CAN Bus terminating resistor”
”Connectors for electronic control units”
”Connectors”
”CRIMP SNAP IN connector”
”KOSTAL connectors”
”DEUTSCH connectors”
”Individual terminals”
”Connector for Bosch VP44 injection pump”
”Fuse and relay boxes on tractors with operator′s cab”

Special or Essential Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™

Catalog or European Microfiche Tool Catalog (MTC).
Wiring harness repair kit
FKM10461
Repairing wiring harnesses
Connector set
AL70932
Extraction tool
JDG364

Removing electrical connectors
Extraction tool
JDG776
Extraction tool
JDG777
Crimping pliers
FKM10427
Installing a terminal
Crimping pliers

FKM10469
JDG359
Repairing DEUTSCH connectors
Terminal puller
JDG1369
JDG1369
For pulling terminals off the injection pump connector.
AMP crimping pliers
JDG708

JDG708

General
Electrical connectors must not be forcibly mated or unmated. All are designed to be mated
easily. If you have to use tools, you may be doing something wrong. Prying or forcing
connectors may cause permanent damage to the locking mechanism, contacts, or both.
When working on connectors, make sure you are working on the correct terminal. Remember
that male and female halves are mirror images of each other. Look for the terminal number
on the connector body. The connection of improper electrical circuits can cause unusual
electrical symptoms.
When an electrical connector is repaired, it is important that the proper terminals are used. In
some of these connectors, different terminals are used to carry different currents. If contacts
of different materials are mated, corrosion may develop that could affect performance.
When removing terminals from connectors, it is very important to use the correct extraction
tool and gently remove the terminal. The connector body can be damaged if terminals are
just "jerked" out of it. The damage caused will prevent the new terminal from staying in the
connector, making replacement of the connector body necessary.
When installing a new terminal on a wire, make sure the insulation crimp and wire crimp are
both made properly. Each part of the terminal crimps is designed for a specific purpose.
Failure to properly crimp the wire contact area can result in poor or no electrical contact.
Failure to crimp the insulation support properly can result in problems getting the terminal
into the connector body, thus causing premature failure.
Using high-pressure washers

IMPORTANT:
Directing pressurized water at electronic/electrical components or

connectors, bearings and hydraulic seals, fuel injection pumps or other
sensitive parts and components may cause product malfunctions. Reduce
pressure, and spray at a 45 to 90° angle.
Disconnecting electrical circuits
Before working on the electrical system, always disconnect battery ground strap (-).
Strip Wire Ends
Use special pliersKLM10019-1(A) to strip wire ends.

→NOTE:
Special pliersKLM10019-1are included in electrical repair tool kitFKM10461
Electrical repair tool kit
FKM10461
Place the wire in the matching recess of crimping pliers, with the portion to be stripped
sticking out.
Squeeze the pliers until they engage.
To open the pliers, pull the release lever.
Take the wire out of the recess and pull the insulation off the end of the wire.
Install a Terminal

Use special pliersKLM10019-1(A) to install male and female terminals of the following types:
WEATHER PACK connectors

METRI PACK connectors
CAN bus terminating resistor connectors
Connectors
KOSTAL connectors
Individual terminals
Fuse box
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
Strip insulation from wire to expose 6 mm (0.24 in.) length of wire.
Place male or female terminal in matching recess of the crimping pliers.
Place the stripped portion of the wire in the recess in the male or female terminal, and
squeeze the pliers until they engage.

WEATHER PACK Connectors
→NOTE:
WEATHER PACK ™ connector
→NOTE:
1- to 6-pin connectors are used on the tractor.
LEGEND:
A Male Terminal Body
B Female Terminal Body
[1] - Remove terminal
→NOTE:
The terminals and wire seals are held in place on the terminal body by a
lock. This must be lifted up before removing the terminal.
JDG364extraction tool (A) for WEATHER PACK connectors.

[2] - Install wire seal
→NOTE:
Wire seals are color-coded to indicate different wire sizes and connector
types.
Green - wire size 1 mm 2 (17 AWG)

Gray - wire size 2.5 mm 2 (13 AWG)
Blue - wire size 4 mm 2 (11 AWG)
Slip the correct size seal onto the wire.

IMPORTANT:
The seal must fit snugly against the lead insulation, without a gap between
the seal and the insulation. Furthermore, the outer lips of the seal must fit
snugly against the wall of the terminal body.
Strip insulation from wire to expose 6 mm (0.24 in.) length of wire. Move the seal all the way
to the edge of the insulation.

[3] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).

→NOTE:
Place the stripped portion of the wire and wire seal in the recess in the male or female
terminal, and squeeze the pliers until they engage.
→NOTE:
The wire seal is crimped to the terminal together with the wire in one
single process.
[4] - Install terminal
Before installing a male or female terminal, bend locking tang (A or B) back to its original
position.
From the back, insert the male terminal into the terminal body.
Close the locking cap.

METRI PACK Connectors

with Terminal Lock at the Rear
→NOTE:
METRI PACK
[ METRI PACK is a trademark of Packard Electric ]

connector
→NOTE:
LEGEND:
A Male Terminal Body
B Female Terminal Body

→NOTE:
locking cap. This must be removed before removing the terminal.
Extraction toolJDG776(A) for METRI PACK connectors, Series 280 and 630.
→NOTE:
locking cap. This must be removed before removing the terminal.
Extraction toolJDG777(A) for METRI PACK connectors, Series 150.

→NOTE:
Wire seals are color-coded to indicate different wire sizes and connector
types.
Red - wire size 1 mm 2 (17 AWG)

Gray - wire size 2.5 mm 2 (13 AWG)
Blue - wire size 4 mm 2 (11 AWG)

IMPORTANT:

Place male or female terminal in matching recess of crimping pliersKLM10019-1.

→NOTE:
→NOTE:
single process.
Before installing a male or female terminal, bend locking tang (A) back to its original position.
Put on the locking cap.


with Terminal Lock at the Front
→NOTE:
METRI PACK

connector
→NOTE:
[1] - Remove terminal lock
Use a small screwdriver to disengage terminal lock (A) at the points indicated, and pull it out.
JDG777extraction tool (A) for METRI PACK connectors.


IMPORTANT:

→NOTE:
→NOTE:
single process.

Put on the locking cap.

→NOTE:
METRI PACK

connector
2-pin or 3-pin connectors
[1] - Extract female terminal
Use a pointed tool (A) to press in the locking tang.

Press the female terminal forward and out of the terminal body.
[2] - Strip wire
From the back, feed the wire through the rubber seal and through the terminal body.

[3] - Replace female terminal
Place the female terminal in the matching recess in crimping pliersKLM10019-1.

→NOTE:
Place the stripped portion of the wire in the recess in the female terminal, and squeeze the
pliers until they engage.
Before installing a female terminal, bend the locking tang back to its original position.
Pull the female terminal back into the terminal body.
6-pin connector

[1] - Remove connector body
Use a small screwdriver (C) to disengage the lock at the points indicated, and pull connector
(A) out of terminal body (B).
Use a small screwdriver (E) to disengage terminal lock (D), then push it out and take it off.
Using a pointed tool (F), depress the locking tang and pull the female terminal out of the
body.


IMPORTANT:
Place male or female terminal in matching recess of crimping pliersJDG1727(JDG783).

→NOTE:
Special pliersJDG1727are included in harness repair tool kitJDG1744.
→NOTE:
single process.

From the back, insert the female or male terminal into the terminal body.
Put the terminal lock back on.

Connector at CAN Bus Terminating Resistor

[1] - Removing terminal lock
Press the catches (B) to release the terminal locks (A).

Pull the lock out of the terminal body.
[2] - Extracting a female terminal
Use extraction tool JD777 (C)

Extraction tool
JDG777

to press in the locking tang, and pull the female terminal out from the rear.

[3] - Installing a wire seal

IMPORTANT:
The seal must fit snugly against the wire insulation, without a gap between
Strip insulation from wire to expose 6 mm (0.24 in.) length of wire. Align seal with edge of
insulation.

[4] - Replacing a female terminal
Place female terminals in the matching recess in crimping pliers KLM10019-1.

→NOTE:
Special pliers KLM10019-1 are included in wiring harness repair kit
FKM10461.
FKM10461
Place the stripped portion of the wire and wire seal in the recess in the female terminal, and
squeeze the pliers until they engage.
→NOTE:
The wire seal is crimped to the female terminal together with the wire in
one single process.

From the back, insert the female terminal into the terminal body.
Insert the terminal lock.

Connectors for Electronic Control Units

[1] - Remove cover
Remove the cable binder.

Press up locking tang and slide cover (A) to the left.
Use extraction toolFKM10457(B) to press in the locking tang and extract the female terminal
from the rear.
→NOTE:
Extraction toolFKM10457is included in wiring harness repair kitFKM10461


IMPORTANT:

→NOTE:
→NOTE:
single process.

Slide on the cover and install the cable binder.
30-pin connector
[1] - Extract Female Terminal
Use a pointed tool (A) to press in the locking tang.

Press the female terminal forward and out of the terminal body.
[2] - Strip Wire
From the back, feed the wire through the rubber seal and through the terminal body.

[3] - Replace Female Terminal
Place female terminals in the matching recess in crimping pliersKLM10019-1.

→NOTE:
Place the stripped portion of the wire in the recess in the female terminal, and squeeze the
pliers until they engage.
Pull the female terminal back into the terminal body.
[1] - Remove cover
Press the two locking tangs (A) outward and slide cover (B) away to the front.

Pull terminal lock (A) out of terminal body.

[3] - Extract Female Terminal
LEGEND:
A Chamber
B Openings
Use extraction toolJDG1725to press in the locking tangs in openings (B) and extract the
female terminal from the rear of the chamber.
→NOTE:

Place male or female terminal in matching recess of the crimping pliersJDG1727.

→NOTE:
→NOTE:
single process.
From the back, insert the female or male terminal into the terminal body.
Slide on the cover and install the cable binder.

Connectors
10-, 16- and 24-pin connectors
Pull terminal locks (A) out of terminal body.

[2] - Extract terminal
Use extraction toolFKM10456(A) to press in the locking tang and extract the male or female
terminal from the rear.
→NOTE:
Extraction toolFKM10456is included in electrical repair tool kitFKM10461.

[3] - Install Wire Seal

IMPORTANT:

→NOTE:
→NOTE:
single process.

42-pin connector
Pull terminal locks (A) out of terminal body.

[2] - Extract Terminal
Use extraction toolFKM10456orFKM10457(A) to press in the locking tang and extract the
male or female terminal from the rear.
→NOTE:
Extraction toolFKM10456orFKM10457is included in electrical repair tool
kitFKM10461.

[3] - Install Wire Seal

IMPORTANT:

→NOTE:
→NOTE:
single process.

62-pin connector
[1] - Release terminal lock
Release terminal locks (A) as shown (see arrow).

[2] - Extract Terminal
Use extraction toolFKM10456orFKM10457(A) to press in the locking tang and extract the
male or female terminal from the rear.
→NOTE:
Extraction toolFKM10456orFKM10457is included in electrical repair tool
kitFKM10461.


IMPORTANT:

→NOTE:
→NOTE:
single process.


CRIMP SNAP IN Connectors
→NOTE:
CRIMP SNAP IN
[ CRIMP SNAP IN is a trademark of the AMP company ]

connectors
LEGEND:
A Connector assembly
Remove the cap
Remove the cable binder.
Pull body (A) out of cap (B).
Remove terminal lock

Pull terminal lock (C) out of the body.
Extract female terminal
Use a pointed tool to press in locking tang (D) and pull the female terminal out of the body.
Install a female terminal

Place female terminals in the matching recess in crimping pliers “FKM10427”
Crimping pliers
FKM10427
Insert the stripped portion of the wire into the female terminal.
Squeeze the pliers together.
From the back, insert the female terminal into the terminal body.
Put on the cap and install the cable binder.

KOSTAL Connectors
→NOTE:
KOSTAL connector
[ KOSTAL is a trademark of KOSTAL Kontakt-Systeme ]
[1] - Disengage terminal lock
Use a small screwdriver (B) to press terminal lock (A) out at the point indicated.
Use extraction toolKLM10019-4(A) to extract the female terminal.

→NOTE:
Extraction toolKLM10019-4is included in harness repair tool kitFKM10461.


IMPORTANT:
Place male or female terminal in matching recess of crimping pliersKLM10019-1.

→NOTE:
→NOTE:
single process.


DEUTSCH Connectors
→NOTE:
DEUTSCH ™ connectors
[1] - Extract male or female terminals
Position extraction toolJDG362against wire as shown in the illustration.

→NOTE:
Extraction toolJDG362is included in wiring harness repair tool kitJDG359
JDG359
.
Slide extraction tool to the rear along the wire until the tip of the tool engages in the wire.
IMPORTANT:
When inserting the tool into the terminal body, take care NOT to twist the
tool.
Slide the extraction tool along the wire into the terminal body until it is located over the
terminal.
Remove the wire from the terminal body using the extraction tool.

[2] - Install a terminal
Strip insulation from the end of the wire to a length of 6 mm (1/4 in.).
Adjust crimping pliersJDG360for correct wire size at selector (A).
→NOTE:
Crimping pliersJDG360are included in wiring harness repair tool kitJDG359
JDG359
.
Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
IMPORTANT:
Select proper size of male or female terminal.

Insert terminal (A) and turn adjusting screw (D) until the terminal is flush with cover (B).
Tighten locknut (C).
IMPORTANT:
The terminal must remain centered between the indenters on the pliers
while it is being crimped onto the wire.
Insert wire into terminal and squeeze the handles of the crimping pliers until they touch.
Release the handle and remove the terminal.
IMPORTANT:
If all wire strands are not crimped into the terminal, cut off wire at terminal
and repeat the installation procedures.
→NOTE:
Re-adjust crimping tool before each crimping procedure.

IMPORTANT:
Use a grommet of the appropriate size to insert the terminal at the correct
location.
Slide the terminal into the terminal body until resistance is encountered.
Check that the terminal is seated firmly in the terminal body by pulling gently on the wire.

Individual Terminals
[1] - Extract individual terminals
Use a small screwdriver to press in the locking tang (A).

Pull the terminal out of the terminal body.

[2] - Change a terminal

Place terminals in the matching recess in crimping pliersKLM10019-1.
→NOTE:
Special pliersKLM10019-1are included in electrical repair tool kitFKM10461
Electrical repair tool kit
FKM10461

.
Place the stripped portion of the wire in the recess in the terminal, and squeeze the pliers
until they engage.
Bend the locking tang back to its original position before re-installing the terminal in the
terminal body.
From the back, insert the terminal into the terminal body.

Connector for Bosch VP44 Injection Pump
How to use AMP crimping pliers
LEGEND:
A Locator assembly
B Locator
C Wire
D Crimping slot
E Crimping slot
F Terminal
G Insulation barrel
H Wire barrel
[1] - Press the JDG1369 terminal extraction tool into the face of the connector and remove
the wire and terminal from the back of the connector.
Terminal extraction tool
JDG1369
JDG1369
For pulling terminals off the injection pump connector.
[2] -
→NOTE:
Verify length of stripped wire and crimp height before using the AMP
crimping tool. See instructions provided with the tool.
Strip new wire to the length indicated in tool instructions. Do not nick or cut wire strands.

[3] - Hold the JDG708 AMP crimping tool so that the back (wire side) is facing you. Squeeze
tool handles together and allow them to open fully.
AMP crimping pliers
JDG708
JDG708
For crimping terminal wire ends onto the injection pump connector.
[4] -
→NOTE:
See instructions provided with tool to determine which crimping slot (D or
E) to use.
Holding the terminal (F) by the mating end, insert the insulation barrel (G) first, through the
front of the tool and into the appropriate crimp slot (D or E).
[5] -
IMPORTANT:
Make sure that both sides of the insulation barrel (G) are inserted evenly
into the crimping section. Do NOT attempt to crimp an improperly
positioned contact.
Position the terminals so that the open “U” of the wire and insulation barrels (H and G) faces
the top of the tool. Place the terminal up into the nest so that the movable locator (B) drops
into the slot in the terminal as shown. Butt the front end of the wire barrel (H) against the
movable locator.
[6] - Hold the terminal (F) in position and squeeze the tool handles together until the ratchet
engages sufficiently to hold the terminal in position. Do NOT deform the insulation barrel or
wire barrel.
[7] - Insert stripped wire (C) into terminal insulation and wire barrels until it is butted against
the wire stop.

[8] -
Crimping a terminal
LEGEND:
A Wire and terminal
Hold the wire and terminal (A) in place. Squeeze tool handles together until the ratchet
releases. Allow tool handles to open, and remove crimped terminal.
→NOTE:
The crimped terminal may stick in the crimping area. It can be easily
removed by pushing downward on the top of the locator.
[9] - Install wire in connector.

Fuse and Relay Boxes on Tractors with Operator′s

Cab
Opening the fuse and relay boxes
Open fuse and relay boxes towards the front.
Extracting a female terminal from relay boxes (K01 and K10)
[1] - Removing a terminal lock
Pull terminal lock (A) out at the rear.

Use a small screwdriver to press in the locking tang and extract the female terminal from the
rear.
Extracting a female terminal from relay boxes (K02, K08 and K09)

Pull terminal lock (A) out at the front.

rear.
Extracting female terminals from fuse boxes (F03, F04, F05, F06 and
F07)

Pull terminal lock (A) out from underneath.

rear.
Replacing a female terminal

Section 40 - ELECTRICAL SYSTEM Group 10: Wiring Harnesses
Place terminals in the matching recess in crimping pliers KLM10019-1.
→NOTE:
Special pliers KLM10019-1 are included in wiring harness repair kit

FKM10461
FKM10461
Place the stripped portion of the wire in the recess in the terminal, and squeeze the pliers
until they engage.
Bend the locking tang back to its original position before re-installing the terminal in the
terminal body.
From the back, insert the terminal into the fuse and relay boxes.
Close fuse and relay boxes towards the rear.

Group 10 - Wiring Harnesses

Wiring Harnesses for Tractors with PowrQuad Plus
or AutoQuad Transmissions and Stage I Engine to
97/68/EC — Recondition (Summary of References)
”Disconnecting electrical circuits” .
”Ground point locations” .
”Removing and installing harness W01 — Power supply” .
”Removing and installing harness W02 — Engine wiring harness for Stage I engine to
97/68/EC (Level 4 ECU)” .
”Removing and installing harness W03 — Starting aid for Stage I and II engines to
97/68/EC (Level 4 or 11 ECUs)” .
”Removing and installing harness W04 — Headlights”.
”Removing and installing harness W06 — Front-wheel drive axle with TLS” .
”Removing and installing harness W07 — Front PTO” .
”Removing and installing harness W08 — Cab, for Stage I engine to 97/68/EC” .
”Removing and installing harness W09 — Cowl, for Stage I engine to 97/68/EC” .
”Removing and installing harness W10 — Shift console” .
”Removing and installing harness W11 — Transmission shift and hand throttle” .
”Removing and installing harness W13 — Clutch sending unit” .
”Removing and installing harness W14 — 3-terminal power outlet socket” .
”Removing and installing harness W15 — ECU for Stage I engines to 97/68/EC (Level 4
ECU)” .
”Removing and installing harness W16 — SIC with Stage I engine to 97/68/EC” .
”Removing and installing harness W17 — Multi-function unit” .
”Removing and installing harness W18 — Windshield wiper switch (without intermittent
wipe)” .
”Removing and installing harness W18 — Windshield wiper switch (with intermittent
wipe)” .
”Removing and installing harness W19 — Cab roof, for Stage I engine to 97/68/EC” .
”Removing and installing harness W20 — Turn signal and clearance lights”.
”Removing and installing harness W21 — Worklights on front of cab roof” .
”Removing and installing harness W22 — Worklights on rear of cab roof” .
”Removing and installing harness W22 — Xenon (HID) worklights on rear of cab roof”.
”Removing and installing harness W23 — Windshield wiper (without switch for
windshield)” .
”Removing and installing harness W23 — Windshield wiper (with switch for windshield)”
.
”Removing and installing harness W24 — Rear window wiper” .
”Removing and installing harness W25 — Rear window wiper switch” .
”Removing and installing harness W26 — Fan and air-conditioner” .
”Removing and installing harness W28 — Front end of transmission” .
”Removing and installing harness W30 — Rear end of transmission”.

”Removing and installing harness W32 — Stepper motors for Stage I engine to
97/68/EC” .
”Removing and installing harness W33 — Service” .
”Removing and installing harness W34 — Electric rear-view mirrors”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(version 1)”.
(version 2)”.
”Removing and installing harness W36 — 60-amp GreenStar socket for Stage I engine
to 97/68/EC”.
”Removing and installing harness W37 — GreenStar port”.
”Removing and installing harness W39 — GreenStar (cab), for Stage I engine to
97/68/EC”.
”Removing and installing harness W39 — GreenStar with TEC (cab), for Stage I engine
to 97/68/EC”.
”Removing and installing harness W40 — GreenStar (cab roof), for Stage I engine to
97/68/EC”.
”Removing and installing harness W41 — JDLink”.
”Removing and installing harness W42 — Battery cut-off switch, version 1”.


or AutoQuad Transmissions and Stage II Engine to
97/68/EC — Recondition (Summary of References)
”Removing and installing harness W02 — Engine wiring harness for Stage II engine to
97/68/EC (Level 11 ECU)”.
97/68/EC (Level 4 or 11 ECUs)” .
”Removing and installing harness W08 — Cab, for Stage II engine to 97/68/EC”.
”Removing and installing harness W09 — Cowl, for Stage II engine to 97/68/EC”.
”Removing and installing harness W15 — ECU for Stage II engines to 97/68/EC (Level 11
ECU)”.
”Removing and installing harness W16 — SIC with Stage II engine to 97/68/EC”.
wipe)” .
wipe)” .
”Removing and installing harness W19 — Cab roof, for Stage II engine to 97/68/EC”.
windshield)” .
.
”Removing and installing harness W32 — Stepper motors for Stage II engine to
97/68/EC”.


(version 1)”.
(version 2)”.
to 97/68/EC”.
”Removing and installing harness W39 — GreenStar (cab)”.
”Removing and installing harness W39 — GreenStar with tractor equipment interface
controller (cab)”.
”Removing and installing harness W40 — GreenStar (cab roof)”.


or AutoQuad Plus Transmission from Serial No.
398656 — Recondition (Summary of References)
”Removing and installing harness W02 — Engine (Level 11 ECU) from serial no.
398656”.
”Removing and installing harness W03 — Starting aid (Level 11 ECU) from serial no.
398656”.
”Removing and installing harness W08 — Cab from serial no. 398656”.
”Removing and installing harness W09 — Cowl from serial no. 398656”.
”Removing and installing harness W15 — Engine control unit (Level 11 ECU) from serial
no. 398656”.
wipe)” .
wipe)” .
windshield)” .
.
”Removing and installing harness W26 — Fan and air-conditioner from serial no.
398656”.
”Removing and installing harness W26 — ClimaTrak (cab)”.

97/68/EC”.
(version 1)”.
(version 2)”.
to 97/68/EC”.
”Removing and installing harness W47 — ClimaTrak (cab roof)”.
”Removing and installing harness W48 — ClimaTrak (cowl)”.
”Removing and installing harness W49 — ClimaTrak (evaporator housing)”.
”Removing and installing harness W50 — GreenStar (CAN BUS terminator)”.
”Removing and installing harness W51 — AutoTrac (cab)”.
”Removing and installing harness W52 — AutoTrac (steering angle sensor)”.
”Removing and installing harness W53 — AutoTrac (Command Arm)”.

Wiring Harnesses for Tractors with AutoPowr/IVT

Transmission and Stage I Engine to 97/68/EC —
Recondition (Summary of References)
”Removing and installing harness W02 — Engine wiring harness for Stage I engine to
97/68/EC (Level 4 ECU)” .
97/68/EC (Level 4 or 11 ECUs) (AutoPowr/IVT transmission)”.
”Removing and installing harness W08 — Cab, with Stage I engine to 97/68/EC
(AutoPowr/IVT transmission)” .
”Removing and installing harness W09 — Cowl, with Stage I engine to 97/68/EC
”Removing and installing harness W11 — Speed control lever and hand throttle
”Removing and installing harness W12 — Command Arm (AutoPowr/IVT transmission)” .
”Removing and installing harness W15 — ECU for Stage I engines to 97/68/EC (Level 4
ECU)” .
”Removing and installing harness W16 — SIC with Stage I engine to 97/68/EC” .
wipe)” .
wipe)” .
”Removing and installing harness W19 — Cab roof, for Stage I engine to 97/68/EC” .
windshield)” .
.
”Removing and installing harness W28 — Front end of transmission (AutoPowr/IVT

transmission)” .
”Removing and installing harness W29 — Valve block (AutoPowr/IVT transmission)” .
”Removing and installing harness W32 — Stepper motors for Stage I engine to
97/68/EC” .
(version 1)”.
(version 2)”.
to 97/68/EC”.
”Removing and installing harness W39 — GreenStar (cab), for Stage I engine to
97/68/EC”.
”Removing and installing harness W39 — GreenStar with TEC (cab), for Stage I engine
to 97/68/EC”.
”Removing and installing harness W40 — GreenStar (cab roof), for Stage I engine to
97/68/EC”.


Transmission and Stage II Engine to 97/68/EC —
Recondition (Summary of References)
”Removing and installing harness W02 — Engine wiring harness for Stage II engine to
97/68/EC (Level 11 ECU)”.
97/68/EC (Level 4 or 11 ECUs) (AutoPowr/IVT transmission)”.
”Removing and installing harness W08 — Cab, with Stage II engine to 97/68/EC
(AutoPowr/IVT transmission)”.
”Removing and installing harness W09 — Cowl, with Stage II engine to 97/68/EC
”Removing and installing harness W15 — ECU for Stage II engines to 97/68/EC (Level 11
ECU)”.
wipe)” .
wipe)” .
windshield)” .
.

transmission)” .
97/68/EC”.
(version 1)”.
(version 2)”.
to 97/68/EC”.


transmission from Serial No. 398656 — Recondition
(Summary of References)
”Removing and installing harness W02 — Engine (Level 11 ECU) from serial no.
398656”.
”Removing and installing harness W03 — Starting aid (Level 11 ECU) (AutoPowr/IVT
transmission) from serial no. 398656”.
”Removing and installing harness W08 — Cab, with Stage I engine to 97/68/EC
”Removing and installing harness W09 — Cowl (AutoPowr/IVT transmission) from serial
no. 398656”.
”Removing and installing harness W15 — Engine control unit (Level 11 ECU) from serial
no. 398656”.
wipe)” .
wipe)” .
”Removing and installing harness W22 — Worklights on rear of cab roof”.
windshield)” .
.
”Removing and installing harness W26 — Fan and air-conditioner from serial no.
398656”.

”Removing and installing harness W26 — ClimaTrak (cab)”.

transmission)” .
97/68/EC”.
(version 1)”.
(version 2)”.
to 97/68/EC”.
”Removing and installing harness W47 — ClimaTrak (cab roof)”.
”Removing and installing harness W48 — ClimaTrak (cowl)”.
”Removing and installing harness W49 — ClimaTrak (evaporator housing)”.
”Removing and installing harness W50 — GreenStar (CAN BUS terminator)”.
”Removing and installing harness W51 — AutoTrac (cab)”.
”Removing and installing harness W52 — AutoTrac (steering angle sensor)”.
”Removing and installing harness W53 — AutoTrac (Command Arm)”.
”Removing and installing harness W55 — Display”.
”Removing and installing harness W56 — Serial interface, adapter”.
”Removing and installing harness W57 — Electro-hydraulic pick-up hitch (cab)”.
”Removing and installing harness W58 — Electro-hydraulic pick-up hitch (valves)”.


Ground Point Locations

There are 17 ground point locations (XGND1 - XGND57), see pictures on the following pages)
Battery
Battery-to-engine ground (A)
Engine-to-cab frame ground (B)
Cab frame ground (C)
Electronic component ground (D). This is located on the cab frame to the left of the fuse box.
Removing and Installing Harness W01 — Power

Supply

LEGEND:
G01 Terminal with ring, for positive terminal of battery
F13 Main fuse
F14 Main fuse
X473 Connecting point — power supply harness (W08)

Removing and Installing Harness W02 — Engine

Wiring Harness for Stage I Engine to 97/68/EC (ECU
Level 4)
LEGEND:
G02 Alternator
K40 Injection pump relay
M01 Starting motor

X02 Connecting point — front PTO harness (W07)

X66/1 Horn plug
X66/2 Horn plug
X70 Plug for sending unit (air cleaner restriction warning light)
X79 Plug for fuel preheater element
X130 Plug for compressor clutch (air conditioning)
X205 Connecting point — wiring harness W06 (FWD axle with TLS)
X261 Plug for sending unit (coolant temperature)
X262 Plug for sending unit (coolant temperature gauge)
X305 Plug for voltage-to-ground on radiator
X351 Plug for injection pump
X356 Plug for sending unit (crankshaft speed)
X357 Plug for fuel transfer pump
X358 Plug for sending unit (engine oil pressure)
X359 Plug for sending unit (camshaft speed)
X364 Plug for sending unit (fuel pressure)
X411 Connecting point — headlight harness (W04)
X450 Connecting point — engine harness (W08)
X547 Connecting point — starting aid harness (W03)
XGND9 Ground point


Wiring Harness for Stage II Engine to 97/68/EC (ECU
Level 11)
LEGEND:
G02 Alternator
M01 Starting motor

X66/1 Horn plug

X66/2 Horn plug
X70 Plug for sending unit (air cleaner restriction warning light)
X79 Plug for fuel preheater element
X130 Plug for compressor clutch (air conditioning)
X205 Connecting point — wiring harness W06 (FWD axle with TLS)
X261 Plug for sending unit (coolant temperature)
X262 Plug for sending unit (coolant temperature gauge)
X301 Plug for sending unit (intake air temperature)
X305 Plug for voltage-to-ground on radiator
X356 Plug for sending unit (crankshaft speed)
X358 Plug for sending unit (engine oil pressure)
X359 Plug for sending unit (camshaft speed)
X411 Connecting point — headlight harness (W04)
X550 Plug for sending unit (fuel temperature)
X566 Plug for fuel valve
X567 Plug for water separator sender in fuel filter
X568 Plug for injection valves
X569 Plug for fan valve
X575 Plug for fuel transfer pump
X610 Ground connection for screening of wires
X625 Plug for sending unit (injection pressure)
XGND9 Ground point


(Level 11 ECU) from Serial No. 398656
LEGEND:
G02 Alternator
M01 Starting motor
X02 4-pin plug — Connection point for front PTO wiring harness (W07)
X66/1 1-pin plug, horn
X66/2 1-pin plug, horn
X70 2-pin plug, sender for restricted air cleaner warning light
X79 2-pin plug, fuel preheater element
X130 1-pin plug for air-conditioner compressor clutch
8-pin plug — Connection point of harness for front-wheel drive axle
X205
with TLS (W06)
X261 2-pin plug, coolant temperature sender
X301 2-pin plug, manifold air temperature sender
X305 1-pin plug, voltage-to-ground on radiator
X356 2-pin plug, crankshaft speed sender
X358 3-pin plug for engine oil pressure sender
X359 2-pin plug for camshaft speed sender
X411 8-pin plug — Connection point for headlight wiring harness (W04)
X450 42-pin plug — Connection point for engine wiring harness (W08)
X547 10-pin plug — Connection point for starting aid wiring harness (W03)
X550 2-pin plug for fuel temperature sender
X566 2-pin plug for fuel valve
X567 2-pin plug for sender of water separator in fuel filter
X568 12-pin plug for injection valves
X575 2-pin plug for fuel transfer pump
X604 2-pin plug for front ambient air temperature sensor (ClimaTrak)
X625 3-pin plug for injection pressure sender
XGND9 Ground point
Removing and Installing Harness W03 — Starting

Aid for Stage I and II engines to 97/68/EC (Level 4 or
11 ECUs)

LEGEND:
D31 Diode for electrical starting aid
F09 Fuse for heater element (electrical starting aid)
Fuse for fuel injection pump (with Stage I engines to 97/68/EC only
F10
(Level 4 ECU))
F11 Fuse for electrical starting aid
G02 Terminal with ring, for alternator

K01 Starting motor relay

K36 Relay for electrical starting aid
R15 Terminal with ring, for heater element (electrical starting aid)

Aid (Level 11 ECU) from Serial No. 398656
LEGEND:
F09 Glow plug fuse

X630 1-pin plug — Connection point for glow plug wiring harness


Aid for Stage I and II engines to 97/68/EC (Level 4 or
11 ECUs) (AutoPowr/IVT transmission)
LEGEND:
D31 Diode for electrical starting aid

F09 Fuse for heater element (electrical starting aid)

Fuse for fuel injection pump (with Stage I engines to 97/68/EC only
F10
(Level 4 ECU))
F22 Fuse for LTC coolant pump
R15 Terminal with ring, for heater element (electrical starting aid)
X528 Plug for LTC coolant pump

Aid (Level 11 ECU) (AutoPowr/IVT transmission)
from Serial No. 398656

LEGEND:
F09 Glow plug fuse
F22 Fuse for LTC coolant pump
X528 3-pin plug for LTC coolant pump
X630 1-pin plug — Connection point for glow plug wiring harness
Removing and Installing Harness W04 — Headlights

W04 - Harness for headlights, with worklights on front corner

W04 - Headlight wiring harness
LEGEND:
X67 Plug for r.h. headlight
X68 Plug for l.h. headlight
X69/1 Plug for front corner worklight, r.h.
X69/2 Plug for front corner worklight, l.h.
X411 Connecting point — Headlight harness (W02)
Removing and Installing Harness W06 — Front-

Wheel Drive Axle with TLS
LEGEND:
Connecting point — Wiring harness W02 (front-wheel drive axle with
X205
TLS)
X206 Plug for solenoid valve on front-wheel drive axle with TLS
X207 Plug for solenoid valve on front-wheel drive axle with TLS
X209 Plug for position sensor on front-wheel drive axle with TLS
Removing and Installing Harness W07 — Front PTO

LEGEND:
X166 Plug for front PTO solenoid valve
X167 Plug for sending unit (front PTO speed)

Removing and Installing Harness W08 — Cab, with

Stage I Engine to 97/68/EC
LEGEND:
X34 Plug for the remote-control switch of the rockshaft control, left
X35 Plug for the remote-control switch of the rockshaft control, right
X37 Plug for front loader
X40 Connecting point — rear window wiper harness (W24)
X44 Plug for rear window washer pump
X50 Connecting point — harness for air-conditioning and fan (W26)
X106 Plug for tail, brake and turn signal lights (right)
X107 Plug for tail, brake and turn signal lights (left)
X113/1 Plug for license plate or worklight on left fender
X113/2 Plug for license plate or worklight on right fender

X122 Plug for differential lock switch

X128 Plug for cigarette lighter
X132 Signal socket
X171/1F Connecting point — worklights on fender
X171/1M Connecting point — license plate or worklight on right fender
X171/2F Connecting point — license plate light
X171/2M Connecting point — license plate or worklight on left fender
X174 Plug for remote-control switch of rear PTO, left
X230 Plug for seat switch
X235 Plug for handbrake switch
X236 Plug for cruise control potentiometer
Connecting point — harness for 3-terminal power outlet socket
X239
(W14)
X242 Plug for HMS switch
X243 Plug for rear PTO preselector switch
X245 Plug for front-wheel drive switch
X247 Plug for monitor unit
X248 Plug for lighting system monitor unit
X260 Plug for worklight switch
X285 Plug for windshield washer pump
X371 Plug for accelerator pedal potentiometer
X400 Connecting point — cab roof harness (W19)
X403 Connecting point — cowl harness (W09)
X409 Connecting point — ECU harness (W15)
X409/1 Connecting point — ECU harness (W15)
Connecting point — shift console harness (W10) or Command Arm
X422
harness (W12)
X423 Connecting point — E-SCV / E-ICV controller (SIC) harness (W16)
X430 Connecting point — harness at rear end of transmission (W30)
X440 Plug for record/save switch
Connecting point — transmission shift and hand throttle harness
X441
(W11) or Command Arm harness (W12)
Plug for switch that operates the worklights at the rear of the cab
X472/1
roof
Plug for switch that operates the worklights at the front of the cab
X472/2
roof
X483/1 Plug for basic control unit (BCU)
X485 Plug for SFA control unit
X488 Plug for operator′s seat
X489 Plug for electronic PowrQuad controller (EPC)
X489/1 Prewiring for electrical range shift
X500 Connecting point — harness at front end of transmission (W28)
X501 Connecting point — wiring harness of GreenStar port (W37)
X503 Plug for park lock switch
X522 Connecting point — service harness (W33)
X540 Connecting point — wiring harness, GreenStar (cab) (W39)

Connecting point — wiring harness, access-step light and battery

X544
cut-off switch (W35)
X545 Plug for implement switch
X551 Plug for creeper switch
XGND 1 Ground point
XGND 5 Ground point
XGND43 Ground point for electronics
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point


Stage II Engine to 97/68/EC
LEGEND:
X14/1 Plug for position feedback unit
X14/2 Plug for sensitivity potentiometer


X125 Plug for rear PTO switch
X127 Plug for front PTO switch
X132 Signal socket
X239
(W14)
X244 Plug for ECO/power mode switch
X249 Plug for gear selector switch
X423 Connecting point — E-SCV / E-ICV controller (SIC) harness
X460/1 Plug for hand throttle potentiometer
X471 Plug for program selector switch
X472/1
roof
X472/2
roof
X489 Plug for electronic PowrQuad controller (EPC)
X503 Plug for park lock switch

X522 Connecting point — GreenStar harness (W39)

X544
cut-off switch
X571 Service socket (CAN BUS)
XGND1 Ground point
XGND5 Ground point
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point

Removing and Installing Harness W08 — Cab from

Serial No. 398656
LEGEND:
F03 Fuses (fuse and relay boxes)
K01 Relays (fuse and relay boxes)
K09 Relays and diodes (fuse and relay boxes)

X14/1 8-pin plug for feedback unit

X14/2 3-pin plug for sensitivity potentiometer
X34 6-pin plug for remote-control switch of rockshaft control, right
X35 6-pin plug for remote-control switch of rockshaft control, left
X37 2-pin plug for front loader
X37/3 2-pin plug for accessories
X40 6-pin plug — Connection point for rear window wiper harness (W24)
X44 2-pin plug for rear window washer pump
X106 4-pin plug for right tail, brake and turn signal lights
X107 4-pin plug for left tail, brake and turn signal lights
X113/1 2-pin plug for license plate/fender worklight, left
X113/2 2-pin plug for license plate/fender worklight, right
X122 2-pin plug for differential lock switch
X125 3-pin plug for rear PTO switch
X127 3-pin plug for front PTO switch
X128 2-pin plug for cigarette lighter
X132 7-pin signal socket
X171/1F 1-pin plug — Connection point, fender-mounted worklights
1-pin plug — Connection point for license plate/fender worklight,
X171/1M
right
X171/2F 1-pin plug — Connection point for license plate light
X171/2M 1-pin plug — Connection point for license plate/fender worklight, left
3-pin plug for the remote-control switch of the rear PTO (switch on
X174
l.h. side)
X230 2-pin plug for seat switch
X235 2-pin plug for handbrake switch
X236 4-pin plug for cruise control potentiometer
3-pin plug — Connection point of harness for 3-terminal power
X239
outlet socket (W14)
X242 3-pin plug for HMS switch
X243 3-pin plug for rear PTO preselector switch
X245 3-pin plug for front wheel drive switch
X247 26-pin plug for monitor unit
X248 26-pin plug for lighting monitor unit
X260 10-pin plug for worklight switch
X285 2-pin plug for windshield washer pump
X371 6-pin plug for accelerator pedal potentiometer
X400 42-pin plug — Connection point for cab roof wiring harness (W19)
X403 42-pin plug — Connection point for cowl wiring harness (W09)
X409 24-pin plug — ECU wiring harness connection point (W15)
X409/1 1-pin plug — ECU wiring harness connection point (W15)
X409/2 6-pin plug — ECU wiring harness connection point (W15)
X423 16-pin plug — SIC harness connection point (W16)
42-pin plug — Connection point for harness at rear of transmission
X430
(W30)
X440 3-pin plug for record/save switch
X460/1 3-pin plug for hand throttle potentiometer
X471 4-pin plug for program selector switch
X472/1 4-pin plug, switch for worklights on rear of cab roof

X472/2 4-pin plug, switch for worklights on front of cab roof

2-pin plug — Connecting point for power supply wiring harness
X473
(W01)
X483/1 68-pin plug for BCU
X485 45-pin plug for the SFA controller
X488 2-pin plug for operator′s seat
42-pin plug, connection point for harness at front end of
X500
transmission (W28)
X503 2-pin plug for park lock switch
10-pin plug — Connection point for GreenStar wiring harness (cab);
X522
W39
2-pin plug — Connection point for harness of access-step light and
X544
battery cut-off switch (W35)
X545 2-pin plug for implement switch
X571 9-pin service socket (CAN BUS)
7-pin plug — Connection point for fan and air-conditioning harness
X577
(W26)
X577/1 2-pin plug — Connection point for ClimaTrak harness (cab), W26
X623
r.h. side)
X651 4-pin plug for switches on shift lever
X653 3-pin plug for Auto-mode potentiometer
X657 68-pin plug for Electronic PowrQuad Controller (EPC)
X660 3-pin plug for gear selector switch
XGND1 Ground point
XGND4 Collective ground point for XGND43
XGND5 Ground point
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point


Stage I engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
R18 Resistor for brake sensors

X132 Signal socket
X133 Plug for UIC controller
X239
(W14)
X332 Plug for transmission control unit (TCU)
X367 Plug for AutoPowr selector
X382 Plug for park lock controller (PLC)
X422
harness (W12)
X472/1
roof
X472/2
roof
X482 Connecting point — valve block harness (W29)
Connecting point — speed control lever and hand throttle harness
X484


X544
XGND1 Ground point
XGND5 Ground point
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point


Stage II engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:

X132 Signal socket
X133 Plug for UIC controller
X239
(W14)
X332 Plug for transmission control unit (TCU)
X367 Plug for AutoPowr selector
X382 Plug for park lock controller (PLC)
X422
harness (W12)
X423 Connecting point — E-SCV / E-ICV controller (SIC) harness
X472/1
roof
X472/2
roof
Connecting point — speed control lever and hand throttle harness
X484

X522 Connecting point — GreenStar harness (W39)

X544
cut-off switch
X571 Service socket (CAN BUS)
XGND1 Ground point
XGND5 Ground point
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point

Removing and Installing Harness W08 — Cab

(AutoPowr/IVT Transmission) from Serial No.
398656
LEGEND:
K09 Relays and diodes (fuse and relay boxes)

X34 6-pin plug for remote-control switch of rockshaft control, left
X35 6-pin plug for remote-control switch of rockshaft control, right
X37 2-pin plug for front loader
X37/3 2-pin plug for accessories
X40 6-pin plug — Connection point for rear window wiper harness (W24)
X44 2-pin plug for rear window washer pump
X106 4-pin plug for right tail, brake and turn signal lights
X107 4-pin plug for left tail, brake and turn signal lights
X113/1 2-pin plug for license plate/fender worklight, left
X113/2 2-pin plug for license plate/fender worklight, right
X122 2-pin plug for differential lock switch
X128 2-pin plug for cigarette lighter
X132 7-pin signal socket
X133 68-pin plug for user interface controller (UIC)
X171/1F 1-pin plug — Connection point, fender-mounted worklights
1-pin plug — Connection point for license plate/fender worklight,
X171/1M
right
X171/2F 1-pin plug — Connection point for license plate light
X171/2M 1-pin plug — Connection point for license plate/fender worklight, left
X174
l.h. side)
X230 2-pin plug for seat switch
X235 2-pin plug for handbrake switch
X236 4-pin plug for cruise control potentiometer
3-pin plug — Connection point of harness for 3-terminal power
X239
outlet socket (W14)
X242 3-pin plug for HMS switch
X243 3-pin plug for rear PTO preselector switch
X245 3-pin plug for front wheel drive switch
X247 26-pin plug for monitor unit
X248 26-pin plug for lighting monitor unit
X260 10-pin plug for worklight switch
X285 2-pin plug for windshield washer pump
X332 68-pin plug for TCU
X367 3-pin plug for AutoPowr selector
X382 45-pin plug for PLC
X400 42-pin plug — Connection point for cab roof wiring harness (W19)
X409 24-pin plug — ECU wiring harness connection point
24-pin plug — Connection point for shift console harness (W10) or
X422
Command Arm harness (W12)
X423 16-pin plug — SIC harness connection point (W16)
42-pin plug — Connection point for harness at rear of transmission
X430
(W30)
X440 3-pin plug for record/save switch
X472/1 4-pin plug, switch for worklights on rear of cab roof

X472/2 4-pin plug, switch for worklights on front of cab roof

2-pin plug — Connecting point for power supply wiring harness
X473
(W01)
42-pin plug, connection point for harness at front end of
X481
transmission (W28)
42-pin plug — Connection point for valve block wiring harness
X482
(W29)
24-pin plug — connecting point for speed control lever and hand
X484
throttle harness (W11) or for Command Arm harness (W12)
X485 45-pin plug for the SFA controller
X488 2-pin plug for operator′s seat
X522
W39
2-pin plug — Connection point for harness of access-step light and
X544
battery cut-off switch (W35)
X571 9-pin service socket (CAN BUS)
X577
(W26)
X577/1 2-pin plug — Connection point for ClimaTrak harness (W26)
X623
r.h. side)
XGND1 Ground point
XGND5 Ground point
XGND47 Ground point
XGND48 Ground point
XGND49 Ground point
XGND50 Ground point
XGND52 Ground point

Removing and Installing Harness W09 — Cowl, with

Stage I Engine to 97/68/EC
LEGEND:
S01 Plug for main (key) switch
S09 Plug for light switch
X20A Connecting point — windshield wiper harness (W23)
X20B Connecting point — windshield wiper harness (W18)
X25 Plug for basic informator (BIF)
X120/1 Plug for air-brake pressure gauge
X126 Plug for hazard warning light switch

X270 Plug for CAN BUS terminator (29-bit)

X322 Connecting point — clutch sender harness (W13)
X324 Plug for brake switch
X487 Connecting point — multi-function lever harness (W17)
X490/1 Plug for electrical reverser control
XGND40 Ground point


Stage II Engine to 97/68/EC
LEGEND:


X487 Connecting point — multi-function unit harness (W17)
X490/1 Plug for electrical reverser control
XGND40 Ground point

Removing and Installing Harness W09 — Cowl from

Serial No. 398656
LEGEND:
S01 8-pin plug for main (key) switch
S09 5-pin plug for light switch
X20A 1-pin plug — Connection point for windshield wiper harness (W23)
X20B 3-pin plug — Connection point for windshield wiper harness (W18)
X25 26-pin plug for basic informator (BIF)
X120/1 1-pin plug for air-brake pressure gauge
X126 3-pin plug for hazard warning light switch

X322 6-pin plug — Connection point for clutch sending unit harness (W13)
X324 8-pin plug for brake switches
10-pin plug — Connection point for multi-function unit harness
X487
(W17)
X615 6-pin plug for CAN BUS terminator (29-bit)
X654 8-pin plug for electrical reverser control
XGND40 Ground point


Stage I engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:

X323 Plug for reverse drive lever
X343 Plug for neutral start switch
XGND40 Ground point


Stage II engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:

X323 Plug for reverse drive lever
X343 Plug for neutral start switch
XGND40 Ground point

Removing and Installing Harness W09 — Cowl

(AutoPowr/IVT Transmission) from Serial No.
398656
LEGEND:
S01 8-pin plug for main (key) switch
S09 5-pin plug for light switch
X20A 1-pin plug — Connection point for windshield wiper harness (W23)
X20B 3-pin plug — Connection point for windshield wiper harness (W18)
X126 3-pin plug for hazard warning light switch
X322 6-pin plug — Connection point for clutch sending unit harness (W13)
X323 10-pin plug for reverse drive lever
X324 8-pin plug for brake switches
X343 2-pin plug for neutral start switch
10-pin plug — Connection point for multi-function unit harness
X487
(W17)
X615 6-pin plug for CAN BUS terminator (29-bit)
XGND40 Ground point
Removing and Installing Harness W10 — Shift

Console
LEGEND:
X14/1 Plug for position feedback unit
X14/2 Plug for sensitivity potentiometer
X422 Connecting point — switch console harness (W08)
X471 Plug for program selector switch

Removing and Installing Harness W11 —

Transmission Shift and Hand Throttle
LEGEND:
X244 Plug for ECO/power mode switch
X249 Plug for gear selector switch
Connecting point — harness for transmission shift and hand throttle
X441
(W08)
X460/1 Plug for hand throttle potentiometer
X477 Plug for range selector switch
Removing and Installing Harness W11 — Speed

Control Lever and Hand Throttle (AutoPowr/IVT
transmission)

LEGEND:
X334 Plug for speed control lever
X349 Plug for potentiometer of speed control lever
X370 Plug for hand throttle potentiometer
Connecting point — harness for speed control lever and hand throttle
X484
(W08)

Removing and Installing Harness W12 — Command

Arm (AutoPowr/IVT transmission)
LEGEND:
X334 Plug for speed control lever
X349 Plug for potentiometer of speed control lever
X370 Plug for hand throttle potentiometer
X422 Connecting point — Command Arm harness (W08)
X436 Plug for E-SCV 1 switch


X468 Plug for depth-setting regulator
X469 Plug for position feedback unit
X470 Plug for rapid withdrawal switch
X471 Plug for program switch
X484 Connecting point — Command Arm harness (W08)
Removing and Installing Harness W13 — Clutch

Sending Unit
LEGEND:
S72 Clutch switch
X322 Connecting point — clutch switch harness (W08)
X328 Plug for clutch pedal potentiometer
Removing and Installing Harness W14 — 3-Terminal

Power Outlet Socket
LEGEND:
X06-15 Plug for 3-terminal power outlet socket
X239 Connecting point — harness for 3-terminal power outlet socket (W08)
Removing and Installing Harness W15 — ECU for

Stage I engines to 97/68/EC (Level 4 ECU)

LEGEND:
X361 Plug, ECU for Stage I engine to 97/68/EC (Level 4 ECU)
XGND1 Ground point
Removing and Installing Harness W15 — ECU for

Stage II engines to 97/68/EC (Level 11 ECU)

LEGEND:
X570/1 Plug, ECU for Stage II engine to 97/68/EC (Level 11 ECU)
X570/2 Plug, ECU for Stage II engine to 97/68/EC (Level 11 ECU)

Control Unit (Level 11 ECU) from Serial No. 398656

LEGEND:
X409 24-pin plug — ECU wiring harness connection point (W08)
X570/1 30-pin plug for control unit (ECU)
X570/2 30-pin plug for control unit (ECU)
Removing and Installing Harness W16 — SIC with

Stage I engine to 97/68/EC

LEGEND:
X219 Plug for multi-function lever
X456 Plug for E-SCV / E-ICV controller (SIC)
X552 Plug for E-SCV encoder
X553 Plug for E-SCV transport lock
X554 Plug for E-SCV indicator light

Removing and Installing Harness W16 — SIC with

Stage II engine to 97/68/EC
W16 - Wiring harness, SIC with E-SCV / E-ICV

W16 - Wiring harness, SIC with E-ICV
LEGEND:
X456 Plug for E-SCV / E-ICV controller (SIC)
X552 Plug for E-SCV encoder
X553 Plug for E-SCV transport lock
X554 Plug for E-SCV indicator light

Removing and Installing Harness W17 — Multi-

function Unit
LEGEND:
S08/LH Left-turn signal switch
S08/RH Right-turn signal switch
S10 Full/dipped-beam switch
X59 Plug for horn switch
X60 Plug for horn switch
X61 Plug for flash-to-pass switch
X62 Plug for flash-to-pass switch
X487 Connecting point — multi-function lever harness (W09)
Removing and Installing Harness W18 — Windshield

Wiper Switch (Without Intermittent Wipe)

LEGEND:
S15 Plug for windshield wiper switch
S31 Digital instrument set switch
X20B Connecting point — washer switch harness (W09)
X39 Connecting point — windshield wiper harness (W23)
X63 Plug for windshield washer switch

Wiper Switch (with Intermittent Wipe)

LEGEND:
K26 Intermittent-wipe relay
S15 Plug for windshield wiper switch
S31 Digital instrument set switch
X20B Connecting point — washer switch harness (W09)

Removing and Installing Harness W19 — Cab Roof,

with Stage I Engine to 97/68/EC
LEGEND:
B28/LH Door switch for dome light, l.h.
B28/RH Door switch for dome light, r.h.
X43 Plug for rear window wiper motor
X105 Plug for radio
X121 Plug for dome and console lights
X142/1 Prewiring for beacon light
X142/2 Ground terminal with ring, for beacon light
X158 Plug for radio antenna ground

X401 Connecting point — harness for electric rear-view mirror (W34)

X433 Connecting point — harness for worklights at rear of cab roof (W22)
X434 Connecting point — harness for worklights at front of cab roof (W21)
Connecting point — harness for r.h. turn-signal and clearance lights
X442
(W20)
Connecting point — harness for l.h. turn-signal and clearance lights
X443
(W20)
X475 Connecting point — not used
X486 Plug for performance monitor (PRF)
X530 Connecting point — JDLink harness (W41)
X531/1 Plug for heated rear window switch
X532/1 Plug for heated rear window resistor
XGND10 Ground point
XGND14 Ground point
XGND41 Ground point

Removing and Installing Harness W19 — Cab Roof,

with Stage II Engine to 97/68/EC
LEGEND:
B28/LH Door switch for dome light, l.h.
B28/RH Door switch for dome light, r.h.
X43 Plug for rear window wiper motor
X121 Plug for dome and console lights
X142/1 Prewiring for beacon light
X142/2 Ground terminal with ring, for beacon light
X158/1 Plug for radio antenna ground
X158/2 Plug for radio antenna

X434 Connecting point — harness for worklights at front of cab roof (W21)
X442
(W20)
X443
(W20)
X475 Connecting point — not used
X486 Plug for performance monitor (PRF)
X613 Plug for radio
XGND10 Ground point
XGND14 Ground point
XGND41 Ground point

Removing and Installing Harness W20 — Turn Signal

and Clearance Lights
W20 - Harness for l.h. turn-signal and clearance lights

W20 - Harness for r.h. turn-signal and clearance lights

W20 - Harness for l.h. turn-signal and clearance lights

W20 - Harness for r.h. turn-signal and clearance lights
LEGEND:
X108 Plug for r.h. turn signal and clearance lights
X109 Plug for l.h. turn signal and clearance lights
X110 Plug for light on left of cab frame
X115 Plug for light on right of cab frame
X162/1 Plug for worklight on left side of cab frame
X162/2 Plug for worklight on right side of cab frame
X111 Plug for light on left of cab frame
X116 Plug for light on right of cab frame
X442
(W19)

X443
(W19)
Removing and Installing Harness W21 — Worklights

on Front of Cab Roof
LEGEND:
Connecting point — harness for worklights at front of cab roof
X434
(W19)
X452/1F1 Plug for outer right worklight on front of cab roof
X452/1F2 Plug for inner right worklight on front of cab roof
X452/2F1 Plug for outer left worklight on front of cab roof
X452/2F2 Plug for inner left worklight on front of cab roof
Removing and Installing Harness W22 — Worklights

on Rear of Cab Roof

LEGEND:
X114/1F1 Plug for outer right worklight on rear of cab roof
X114/1F2 Plug for inner right worklight on rear of cab roof
X114/2F1 Plug for outer left worklight on rear of cab roof
X114/2F2 Plug for inner left worklight on rear of cab roof
Removing and Installing Harness W22 — Xenon

(HID) Worklights on Rear of Cab Roof

LEGEND:
X542/1 Plug of ballast unit for Xenon (HID) worklights at rear of cab roof, left
X542/2 Plug of ballast unit for Xenon (HID) worklights at rear of cab roof, right

Wiper Switch (Without Switch for Windshield)


LEGEND:
X38 Plug for windshield wiper motor

Wiper (With Switch for Windshield)


LEGEND:
X38 Plug for windshield wiper motor
X583F Plug of harness for windshield switch
X583M Plug of harness for windshield switch
S17 Windshield switch
Removing and Installing Harness W24 — Rear

Window Wiper
LEGEND:
S20 Rear window switch
X42M Connecting point — harness for rear window wiper switch (W25)
Removing and Installing Harness W25 — Rear

Window Wiper Switch

LEGEND:
X42 Plug for rear window wiper switch
X42F Connecting point — rear window wiper harness (W24)
Removing and Installing Harness W26 — Fan and

Air-Conditioner

LEGEND:
X28 Plug for pressure switch (air-conditioning)
X46 Plug for fan motor
X47 Plug for fan motor
X48 Plug for resistors
X50 Connecting point — fan harness (W08)
X73/1 Plug for thermostat switch
X73/2 Plug for thermostat switch
X100 Plug for fan switch
X448 Plug for air-conditioning switch
X449/1 Plug for de-icer switch
X449/2 Plug for de-icer switch
XGND15 Ground point
Removing and Installing Harness W26 — Fan and

Air-conditioner from Serial No. 398656

LEGEND:
X28 2-pin plug for air-conditioner pressure switch
X46 2-pin plug for fan motor
X48 4-pin plug for resistors
X73/1 1-pin plug for thermostat switch
X73/2 1-pin plug for thermostat switch
X100 6-pin plug for fan switch
X448 3-pin plug for air conditioner switch
X449/1 1-pin plug for de-icer switch
X449/2 1-pin plug for de-icer switch
X577 7-pin plug — Connection point for fan wiring harness (W08)
X665 1-pin plug, voltage-to-ground on evaporator
XGND15 Ground point
Removing and Installing Harness W26 — ClimaTrak

(Cab)

LEGEND:
X577
(W08)
X577/1 2-pin plug — Connection point for ClimaTrak harness (cab) (W08)
42-pin plug — Connection point for ClimaTrak harness (cab roof)
X595
(W47)
X599 8-pin plug — Connection point for ClimaTrak harness (cowl) (W48)
X600 3-pin plug for refrigerant pressure sending unit
X602 2-pin plug for inside air temperature sender
X655 6-pin plug for water valve
7-pin plug — Connection point for ClimaTrak harness (evaporator

X664
housing) (W49)
XGND15 Ground point

Removing and Installing Harness W28 — Front End

of Transmission
LEGEND:
X30 Prewiring for radar connection
X80 Plug for switch that warns of a restriction at the transmission oil filter
X83 Plug for sending unit (engagement oil warning light)
X86 Plug for sending unit (fuel gauge and fuel transfer pump)
X91 Plug for solenoid valve (front-wheel drive)
X307 Plug for sending unit (transmission oil temperature)

X420 Plug for air brake system solenoid valve
X459 Plug for sending unit (transmission enable pressure)
X492 Plug for K3 solenoid (Y32)
X493 Plug for forward solenoid valve (Y33)
X494 Plug for reverse solenoid valve (Y36)
X495 Plug for proportional valve (Y38)
X496 Plug for K2 solenoid valve (Y39)
X497 Plug for K1 solenoid valve (Y40)
X499/1 Plug for transmission speed sender
X499/2 Plug for transmission speed sender
X546 Plug for switch that warns of a restriction at the hydraulic oil filter

Removing and Installing Harness W28 — Front End

of Transmission (AutoPowr/IVT transmission)
LEGEND:
X30 Prewiring for radar connection
X86 Plug for sending unit (fuel gauge and fuel transfer pump)
X91 Plug for solenoid valve (front-wheel drive)
X336 Plug for transmission speed sender
X337 Plug for switch at transmission oil filter
X338 Plug for transmission oil pressure switch

X339 Plug for sending unit (hydrostatic speed)
X340/1 Plug for park lock solenoid valve
X340/2 Plug for park lock solenoid valve
X341 Plug for sending unit (transmission input speed)
X375 Plug for sending unit (transmission output speed)
X397 Plug for cold-weather starting pressure switch
X410 Plug for sending unit (front-wheel drive speed)
X413 Plug for sending unit (park lock pressure)
X420 Plug for air brake system solenoid valve
X546 Plug for switch that warns of a restriction at the transmission oil filter
Removing and Installing Harness W29 — Valve

Block (AutoPowr/IVT transmission)
W29 - Valve block harness (AutoPowr/IVT transmission)

W29 - Valve block harness with GreenStar port, for Stage I engines to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
X482/1 Plug for valve block
X543 Connecting point — Harness for 60-amp GreenStar socket (W36)
X543/1 Connecting point — Harness for 60-amp GreenStar socket (W36)

Removing and Installing Harness W30 — Rear End

of Transmission
W30 - Wiring Harness - Rear End of Transmission

W30 - Wiring Harness - Rear End of Transmission (with E-SCV / E-ICV)
LEGEND:
X71 Plug for draft potentiometer
X87 Plug for differential lock solenoid
X88/1 Plug for sending unit (wheel speed)
X88/2 Plug for sending unit (wheel speed)
X92 Plug for stepper motor (hitch control)
X94 Plug for sending unit (rear PTO speed)
X95 Plug for rear PTO solenoid valve
X96 Plug for position sensor (hitch control)
X234 Connecting point — harness for -7-terminal power outlet socket (W31)
X462 Connecting point — stepper motor harness (W32)
X524 Plug for cab suspension solenoid
X525 Plug for cab suspension solenoid
X526 Plug for position sensor (cab suspension)
Removing and Installing Harness W31 — 7-Terminal

Power Outlet Socket
LEGEND:
X05 Plug for 7-terminal power outlet socket
X234 Connecting point — harness for 7-terminal power outlet socket (W30)

Removing and Installing Harness W32 — Stepper

Motors, with Stage I engine to 97/68/EC
W32 - Wiring harness, stepper motors with E-SCV / E-ICV

W32 - Wiring harness, stepper motors with E-ICV
LEGEND:
X251 Plug for E-ICV 2 stepper motor
X464 Plug for E-SCV 1 stepper motor

Removing and Installing Harness W32 — Stepper

Motors, with Stage II engine to 97/68/EC
W32 - Wiring harness, stepper motors with E-SCV / E-ICV

W32 - Wiring harness, stepper motors with E-ICV

W32 - Wiring harness, stepper motors with E-SCV
LEGEND:

Removing and Installing Harness W33 — Service
LEGEND:
X571 Service plug (CAN BUS)
Removing and Installing Harness W34 — Electric

Rear-View Mirrors

LEGEND:
X556/1 Plug for adjusting motor (left)
X556/2 Plug for adjusting motor (right)
X557 Plug for mirror adjusting switch
X558 Plug for mirror support adjusting switch
X559 Plug for mirror heater switch
Removing and Installing Harness W35 — Access

Step Lighting and Battery Cut-off Switch (Version 1)

LEGEND:
Connecting point — wiring harness, access-step light and battery cut-
X544
off switch (W08)
X593 Plug for switch that operates the battery cut-off switch
X606/1 Plug for r.h. access-step light
X606/2 Plug for l.h. access-step light
X607 Connecting point — harness for battery cut-off switch (W42)
Removing and Installing Harness W35 — Access

Step Lighting and Battery Cut-off Switch (Version 2)
LEGEND:
Connecting point — wiring harness, access-step light and battery cut-
X544
off switch (W08)
X606/1 Plug for r.h. access-step light
X606/2 Plug for l.h. access-step light
X696 Plug for the switch that operates the battery cut-off switch
X697 Connecting point — harness for battery cut-off switch (W42)

Removing and Installing Harness W36 — 60-amp

GreenStar Socket for Stage I Engine to 97/68/EC
LEGEND:
F16 Fuse for 60-amp socket
F17 Fuse for 60-amp socket
K46 Relay for 60-amp socket
K47 Relay for 60-amp socket

R20 Resistor
R21 Resistor
X533/1 Plug for 60-amp socket
X533/2 Plug for 60-amp socket
X533/3 60-amp socket
X541 Terminal with ring for battery power
X543 Connecting point — wiring harness of GreenStar port (W37 or W29)
X543/1 Connecting point — wiring harness of GreenStar port (W37 or W29)
XGND51 Ground point
Removing and Installing Harness W36 — 60-amp

GreenStar Implement Socket

LEGEND:
F16 Fuse for implement BUS (components)
F17 Fuse for implement BUS (CAN BUS)
K46 Relay for implement BUS (components)
K47 Relay for implement BUS (CAN BUS)
R20 Resistor
R21 Resistor
X533/1 2-pin plug for 60-amp implement socket
X533/2 4-pin plug for 60-amp implement socket
X533/3 60-amp implement socket
X541 Terminal with ring for battery power

10-pin plug — Connection point for GreenStar (60-amp implement
X543
socket) (W39)
XGND51 Ground point
Removing and Installing Harness W37 — GreenStar

Port
LEGEND:
X543 Connecting point — Harness for 60-amp GreenStar socket (W36)
X543/1 Connecting point — Harness for 60-amp GreenStar socket (W36)

(Cab), for Stage I Engine to 97/68/EC

LEGEND:
K51 Timer
X522/1 Connecting point — service harness (W33)
X535 Connecting point — wiring harness, GreenStar (cab roof) (W40)

X591F Connecting point — CAN BUS (GreenStar)

X591M Connecting point — CAN BUS (GreenStar)

(Cab)
LEGEND:
K51 5-pin plug for timer
X522 10-pin plug — Connection point for GreenStar (cab) (W08)

X535 10-pin plug — Connection point for GreenStar (cab roof) (W40)
10-pin plug — Connection point for GreenStar harness (60-amp
X543
implement socket) (W36)
X571F 9-pin plug for CAN BUS connection
X571M 9-pin service socket (CAN BUS)
X591F 4-pin plug — Connection point for CAN BUS (GreenStar)
X591M 4-pin plug — Connection point for CAN BUS (GreenStar)

with TEC (Cab), for Stage I Engine to 97/68/EC

LEGEND:
X522/1 Connecting point — service harness (W33)
X535 Connecting point — wiring harness, GreenStar (cab roof) (W40)
X572 Plug for TEC

X591F Connecting point — CAN BUS (GreenStar)

X591M Connecting point — CAN BUS (GreenStar)


with Tractor Equipment interface Controller (Cab)
LEGEND:
X522
W39
10-pin plug — Connection point for GreenStar harness (cab roof)
X535
(W40)
X543
X571F 9-pin plug for CAN BUS connection
X571M 9-pin service socket (CAN BUS)
X572 68-pin plug for tractor equipment interface controller (TEC)
X591F 4-pin plug — Connection point for CAN BUS (GreenStar)

X591M 4-pin plug — Connection point for CAN BUS (GreenStar)

X615F/2 6-pin plug for CAN BUS terminator (29-bit)
X615M/1 6-pin plug for CAN BUS connection (29-bit)
3-pin plug for AutoTrac switch or connection point, harness for
X636
AutoTrac Command Arm (W53)
4-pin plug — Connection point for AutoTrac wiring harness (cab)
X641
(W51)
X656 24-pin plug (GSD 2100)
X659 3-pin plug (GSD 2100)

(Cab Roof), for Stage I Engine to 97/68/EC
LEGEND:

X535 Connecting point - wiring harness, GreenStar (cab roof) (W39)

X536 Plug for CAN BUS terminator (GreenStar)
X538 Plug for mapping processor
X539 Plug for GreenStar display
X565 Plug for GPS position receiver

(Cab Roof)
LEGEND:
10-pin plug — Connection point for GreenStar wiring harness (cab roof)
X535
(W39)
X536 6-pin plug for CAN BUS terminator (GreenStar)
X538 10-pin plug for mapping processor
X539 10-pin plug for GreenStar display
X565 12-pin plug, connection point for position receiver (GPS)

Removing and Installing Harness W41 — JDLink
LEGEND:
X529 Plug for JDLink control unit (JDL)
Removing and Installing Harness W42 — Battery

Cut-Off Switch, Version 1

LEGEND:
K48 Relay for battery cut-off switch
X607
X86 Connecting point - harness at front end of transmission (W28)
X86/1 Plug for fuel gauge and fuel pump
XGND56 Ground point
XGND57 Ground terminal with ring, for battery cut-off relay

Removing and Installing Harness W42 — Battery

Cut-Off Switch, Version 2
LEGEND:
K56 Battery cut-off relay
K57 Relay for battery cut-off switch
X86/1 Plug for fuel gauge and fuel pump


X697
XGND56 Ground point

(Cab Roof)
LEGEND:
X594 2-pin plug for rear ambient air temperature sensor

42-pin plug — Connection point for ClimaTrak harness (cab roof)

X595
(W26)
X597 32-pin plug — Connection point for ClimaTrak control unit (ATC)
X652 2-pin plug of defog sensor for windshield

(Cowl)

LEGEND:
X599 8-pin plug — Connection point for ClimaTrak harness (cowl) (W26)
X601 2-pin plug for sending unit for actual outlet air temperature
X605 6-pin plug of adjusting motor for air distribution

(Evaporator Housing)
LEGEND:
X598 2-pin plug, sending unit for evaporator core temperature
X603 6-pin plug for the fan motor driver unit
7-pin plug — Connection point for ClimaTrak harness (evaporator
X664
housing) (W26)
X665 1-pin plug, voltage-to-ground on evaporator

(CAN BUS Terminator)
LEGEND:
X543
X658 6-pin plug for CAN BUS terminating resistor
Removing and Installing Harness W51 — AutoTrac

(Cab)

LEGEND:
X631/1 32-pin plug for AutoTrac control unit (SSU)
X632/1 4-pin plug for steering input device
X632/2 4-pin plug for steering input device
X635 4-pin plug for steering valve

6-pin plug — Connection point for AutoTrac wiring harness (steering

X637
angle sensor) (W52)
4-pin plug — Connection point for AutoTrac wiring harness (cab)
X641
(W39)
XGND60 Ground point

(Steering Angle Sensor)

LEGEND:
X633 6-pin plug for steering angle sensor
6-pin plug — Connection point for AutoTrac wiring harness (steering
X637
angle sensor) (W51)

(Command Arm)
LEGEND:
3-pin plug — Connection point for AutoTrac wiring harness (Command
X636
Arm) (W39/1)
X636/1 3-pin plug for AutoTrac switch

Removing and Installing Harness W55 — Display
LEGEND:
X656 Connecting point - GreenStar wiring harness with TEC (Cab); W39/1
X692 Plug for UIM controller
X693 Plug for RCD display
X698 Connecting point - serial interface harness, adapter (W56)
Removing and Installing Harness W56 — Serial

Interface, Adapter

LEGEND:
X698 Connecting point - serial interface harness, adapter (W55)
X699 Plug for serial interface 1
X712 Plug for serial interface 2
Removing and Installing Harness W57 — Electro-

hydraulic Pick-up Hitch (Cab)

LEGEND:
X37F Plug for front loader
X37M Connecting point — front loader (W08)
Connecting point — wiring harness for electro-hydraulic pick-up hitch
X644
(valves) (W58)
X645 Plug for switch that operates the pick-up hitch
Removing and Installing Harness W58 — Electro-

hydraulic Pick-up Hitch (Valves)

Section 40 - ELECTRICAL SYSTEM Group 15: Charging Circuit
LEGEND:
X642 Plug for solenoid valve of electro-hydraulic pick-up hitch (on/off switch)
Plug for solenoid valve of electro-hydraulic pick-up hitch
X643
(retract/extend)
Connecting point — wiring harness for electro-hydraulic pick-up hitch
X644
(cab) (W57)

Group 15 - Charging Circuit

Charging Circuit - Summary of References
”Special tools”
”Specifications”
”Repairing the alternator”
”Relieving tension on the drive belt”
”Removing/installing the alternator”
”Pulley removal and installation”
Special Tools
→NOTE:

KJD10227- Special tool
KJD10278- Special tool
Specifications
Hex. nut at terminal 30 Torque 18 N˙m
13 lb-ft
Hex. nut at terminal D+ Torque 5 N˙m
4 lb-ft
Cap screws Torque 50 N˙m
37 lb-ft
Pulley on alternator shaft Torque 80 N˙m
60 lb-ft
Repairing the Alternator

For complete repair information the component technical manual (CTM) “Alternators and
Starting Motors” is also required.
Use the component technical manual in conjunction with this machine manual.
Disconnecting Electrical Circuits
Before working on the electrical system, always disconnect battery ground cable (-).
Relieving Drive Belt Tension

Open the hood.
Take off the cover that conceals the cap screw.
Tighten tensioner roll (C) cap screw clockwise (arrow) using a 15 mm (19/32 in.) wrench until
holes (A) and (B) are in alignment.
Insert a 5 mm (0.2 in.) dia. pin into the two holes that are in alignment.
For tensioning, turn tensioner roll slightly to release metal pin and pull it from the bores. The
drive belt tensioner returns to its tensioning position automatically.

Remove/Install the Alternator
LEGEND:
A Wire (terminal 30)
B Wire (terminal D+)
C Attaching screws
Open the hood.
CAUTION:
Disconnect the battery ground cable (-).
IMPORTANT:
Always relieve tension on drive belt before removing the alternator.
Take the drive belt off the pulley.
Disconnect wires (A) and (B) from the alternator.

Take out the two attaching screws (C).
Replace the alternator.
Tightening torques for installation:
Hex. nut (A) at terminal 30 Torque 18 N˙m
13 lb-ft
Hex. nut (B) at terminal D+ Torque 5 N˙m
4 lb-ft
Attaching screws (C) Torque 50 N˙m
37 lb-ft

Remove and Install the Pulley
LEGEND:
A Pulley
Tools for pulley removal
LEGEND:
A [ Torque wrench Commercially-available tool ]
B KJD10227Special tool
C KJD10278Special tool
D [ Extension with 1/2 in. drive (50 mm, 2 in. in length) Commercially-available tool ]
E [ Ratchet with 1/2 in. drive Commercially-available tool ]
Open the hood.

Section 40 - ELECTRICAL SYSTEM Group 20: Starter Motor Circuit
CAUTION:
Disconnect negative (-) cable from battery.
IMPORTANT:
Always relieve tension on drive belt before removing the pulley.
Take the drive belt off the pulley.
Remove pulley using tools (A), (B), (C), (D) and (E).
Tightening torque for installation:
Pulley on alternator shaft Torque 80 N˙m
60 lb-ft

Group 20 - Starter Motor Circuit

Starter Motor Circuit - Summary of References
”Special tools”
”Repairing the starter motor”
”Removing and installing the starter motor”
Special tools
→NOTE:

KJD10213
Special wrench
Removing and installing the starter motor
Specifications
23 lb-ft
Cheese-head screw (C) at terminal 50 Torque 1 - 1.3 N˙m
9 - 11 lb-in.
Repairing the Starter Motor

For complete repair information, the component technical manual (CTM) ”Alternators and
Starter Motors” is also required.
Use the component technical manual in conjunction with this machine manual.

LEGEND:
A Hex. nut
B Cover
C Wire and fillister-head screw
D Special box wrench KJD10213
Open the hood and take off the l.h. side panel.
CAUTION:
Remove hex. nut (A).
Disconnect the wires at the connecting pins.
Remove cover (B).

Section 40 - ELECTRICAL SYSTEM Group 25: Fuses, Relays and Switches
Disconnect wires (C) at the solenoid switch.
Use special box wrench KJD10213 (D)
KJD10213
Special wrench
to remove the starter motor.
23 lb-ft
Fillister-head screw (C) at terminal 50 Torque 1 - 1,3 N˙m
9 - 11 lb-in.

Group 25 - Fuses, Relays and Switches

Fuses, Relays and Switches — Recondition
”Removing trim panels from cowl”.
”Fuse and relay boxes on tractors with operator′s cab up to serial no. 398655” .
”Fuse and relay boxes on tractors with operator′s cab from serial no. 398656”.
”Fuse and relay boxes on tractors with operator′s cab and AutoPowr/IVT transmission up
to serial no. 398790” .
”Fuse and relay boxes on tractors with operator′s cab and AutoPowr/IVT transmission
from serial no. 398791”.
”Replacing the main fuses” .
”Replacing fuses of electrical starting aid for Stage I and II engines to 97/68/EC (Level 4
or 11 ECUs)” .
”Replacing fuses of electric starting aid for Stage I and II engines to 97/68/EC (Level 4 or
11 ECUs) (AutoPowr/IVT transmission)”.
”Replacing fuse for fuel injection pump (with Stage I engines to 97/68/EC (Level 4 ECU)”
.
”Replacing fuse for fuel injection pump (with Stage I engines to 97/68/EC (Level 4 ECU)
”Replacing the LTC coolant pump fuse (AutoPowr/IVT transmission)”.
”Replacing the fuse for the implement BUS (60-amp implement socket)”.
”Replacing starting motor relay for Stage I and II engines to 97/68/EC (Level 4 or 11
ECUs)” .
”Replacing starting motor relay for Stage I and II engines to 97/68/EC (Level 4 or 11
ECUs) (AutoPowr/IVT transmission)”.
”Replacing relay of electrical starting aid for Stage I and II engines to 97/68/EC (Level 4
or 11 ECUs)” .
”Replacing relay of electric starting aid for Stage I and II engines to 97/68/EC (Level 4 or
11 ECUs) (AutoPowr/IVT transmission)”.
” Replacing relay for fuel injection pump with Stage I engines to 97/68/EC (Level 4
ECU)” .
”Replacing the power supply relay for the implement BUS”.
”Replacing the battery cut-off relay”.
”Replacing the battery cut-off switch relay”.
”Replacing the main switch” .
”Replacing the brake switches” .
”Replacing the light switch” .
”Replacing the worklight switches” .
”Replacing the switch for lights on cab frame”
”Replacing the beacon light switch” .
”Replacing the hazard warning light switch” .
”Replacing switches on multi-function unit” .

”Replacing the rear window wiper and washer switch” .

”Replacing the windshield/rear window switch” .
”Replacing the dome light door switch”
”Replacing the handbrake switch” .
”Replacing the front-wheel drive switch” .
”Replacing the Headland Management (HMS) switch” .
”Replacing the record/save switch” .
”Replacing the program switch” .
”Replacing the rear PTO preselector switch” .
”Replacing the switch for AutoQuad transmission”
”Replacing the switch for gear selector and Auto-mode” .
”Replacing the park lock switch on tractors with PowrQuad Plus and AutoQuad
transmissions” .
”Replacing the fan switch” .
Replacing the switch of the air-conditioning system compressor” .
”Replacing the differential lock switch” .
”Replacing the PTO switches” .
”Replacing the external control switch for the rear PTO” .
”Replacing the rockshaft remote control switch” .
”Replacing the switch for the electrical rear-view mirrors”
”Replacing the switch for the heated rear-view mirrors”
”Replacing the switch for the heated rear window”
”Replacing switch of battery cut-off switch”.
”Replacing the AutoTrac switch”.
”Replacing the switch for the electro-hydraulic pick-up hitch”
”Replacing the cruise control potentiometer on tractors with AutoQuad transmission” .
”Replacing the cruise control potentiometer on tractors with AutoPowr/IVT
transmission” .
”Replacing the Auto-mode potentiometer on tractors with AutoQuad Plus transmission”.
”Hitch control” .
”Electrical activators for Selective Control Valves (E-SCV)” .
”Electrical activators for Independent Control Valves (E-ICV)” .
General Information
Switches not mentioned in this Group are described in the Groups dealing with the
corresponding components.
Special Tools
→NOTE:


Extraction tool
JDG777

Specifications
Cable to starter motor relay, M8 hex. nut Torque 6 N˙m
4.4 lb-ft
Cable to starter motor relay, M5 hex. nut Torque 3.5 to 4 N˙m
2.6 to 3 lb-ft
Starter motor relay to bracket, M6 cap screws Torque 8 N˙m
5.9 lb-ft
Cable to relay for electrical starting aid, M8 hex. nut Torque 6 N˙m
4.4 lb-ft
Cable to relay for electrical starting aid, M5 hex. nut Torque 3.5 to 4 N˙m
2.6 to 3 lb-ft
Relay for electrical starting aid to bracket, M6 cap screws Torque 8 N˙m
5.9 lb-ft
Battery cable to battery cut-off relay (version 1), M10 hex. nut Torque 18 to 22 N˙m
13 to 16 lb-ft
Control line to battery cut-off relay (version 1), M5 hex. nut Torque 3 to 5 N˙m
2.2 to 3.7 lb-ft
11 to 15 lb-ft
Control line to battery cut-off relay (version 2), M4 cap screw Torque 2.2 N˙m
1.6 lb-ft
Steering wheel to steering column, hex. nut Torque 50 N˙m
35 lb-ft
Removing Trim Panels from Cowl
LEGEND:
A Cooling compartment
Open cooling compartment (A).

LEGEND:
B Screw
C Trim panel
Remove screws (B).
Remove panels (C).



Cab up to Serial No. 398655
Fuse and relay boxes up to serial no. 398655
→NOTE:
Depending on how the tractor is equipped, it may not have all the fuses
and relays shown below.
The fuse and relay boxes are located behind the operator′s seat just below the rear window.
Press down latches (A) and lift off the trim panel.
LEGEND:
A Relay box K01
B Relay box K02
C Fuse box F03
D Fuse box F04
E Fuse box F05
F Fuse box F06
G Fuse box F07

H Relay box K08
I Relay box K09
J Relay box K10
Relays (relay box K01) up to serial no. 398655
DEFINITIONS:
K01/1 Relay for accessories
K01/2 Relay for power supply to electronics
K01/4 Acoustic alarm

DEFINITIONS:
K02/1 Not used
K02/2 Alternator relay
K02/3 Not used
K02/4 Not used
K02/5 Relay for power supply to E-ICV
K02/6 Not used
K02/7 Not used

Fuses (fuse box F03) up to serial no. 398655
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F03/01 10-amp, Basic Control Unit (power supply)
10-amp, Basic Control Unit (BCU) (PTO, front-wheel drive, differential
F03/02
lock, HMS II, handbrake, wheel-speed sending unit, radar)
F03/03 20-amp, right turn signal, hazard warning lights

F03/04 20-amp, left turn signal
F03/05 Not used
F03/06 10-amp, brake light
F03/07 20-amp, brake switch
F03/08 10-amp, controller for suspended front axle (SFA) (battery voltage)
F03/09 Not used
F03/10 20-amp, power supply to E-ICV
F03/11 Not used
F03/12 Not used
F03/13 10-amp, SIC controller (battery voltage)
F03/14 10-amp, JDLink, GreenStar
F03/15 10-amp, SIC controller (power supply)
F03/16 20-amp, heated rear window

IMPORTANT:
DEFINITIONS:
F04/01 10-amp, ECU controller (power supply)
F04/02 20-amp, ECU controller (battery voltage)
F04/03 Not used
F04/04 15-amp, main switch (BAT)
F04/05 30-amp, accessories

F04/06 30-amp, power supply for electronics

F04/08 20-amp, fuel preheater
F04/09 10-amp, basic informator, SFA controller (power supply)
F04/10 10-amp, basic informator (battery voltage)
F04/11 10-amp, fuel pump, injection pump shut-off valve
F04/12 10-amp, performance monitor (PRF)
F04/13 10-amp, CAN BUS terminator, service socket
F04/14 10-amp, electrical reverser control
F04/15 10-amp, EPC controller (power supply)
F04/16 10-amp, EPC controller (battery voltage)

IMPORTANT:
DEFINITIONS:
F05/01 10-amp, air-conditioning system and relay for fan
F05/02 10-amp, 2-pin plug for front loader
F05/03 Not used
F05/04 Not used
F05/05 Not used

F05/06 Not used

F05/07 Not used
F05/08 10-amp, windshield wiper and washer
F05/09 10-amp, rear window wiper and washer
F05/10 10-amp, electrical rear-view mirror
F05/11 10-amp, GreenStar, TEC controller (power supply)
F05/12 10-amp, dome light, radio (battery voltage)
F05/13 20-amp, fan
F05/14 20-amp, fan
F05/15 10-amp, 3-terminal socket, socket strip (power supply)
F05/16 30-amp, 3-terminal socket, socket strip (battery voltage)

IMPORTANT:
DEFINITIONS:
F06/01 10-amp, horn
F06/02 10-amp, cigarette lighter
F06/03 10-amp, operator′s seat
F06/04 10-amp, radio (power supply)
F06/05 10-amp, console light, radio lighting

F06/06 10-amp, beacon light

F06/07 10-amp, front corner worklight
F06/08 10-amp, worklights on fenders (rear-facing)
F06/09 10-amp, outer worklight on rear of cab roof
F06/10 10-amp, inner worklight on rear of cab roof
F06/11 10-amp, outer worklight on front of cab roof
F06/12 10-amp, inner worklight on front of cab roof
F06/13 Fuse tester
F06/14 Not used
F06/15 Not used
F06/16 15-amp, light switch (pin B)

IMPORTANT:
DEFINITIONS:
F07/01 Not used
F07/02 Not used
F07/03 Not used
F07/04 10-amp, worklights on cab frame
F07/05 Not used

F07/06 10-amp, dipped-beam headlight, left

F07/07 10-amp, dipped-beam headlight, right
F07/08 15-amp, full-beam headlights
F07/09 30-amp, lights on cab frame
F07/10 10-amp, r.h. tail light, l.h. clearance light, license plate light
F07/11 10-amp, l.h. tail light, r.h. clearance light
F07/12 10-amp, lighting
F07/13 10-amp, dipped beam, left (lights on cab frame)
F07/14 10-amp, dipped beam, right (lights on cab frame)
F07/15 30-amp, headlights

DEFINITIONS:
K08/1 Relay for full-beam headlights
K08/2 Relay for dipped-beam headlights
K08/3 Relay for lights on cab frame
K08/4 Relay for headlights and worklights on cab frame
K08/5 Relay for worklights on front of cab roof
K08/6 Relay for worklights on rear of cab roof
K08/7 Relay for front corner/fender worklights (rear-facing)

DEFINITIONS:
K09/1 3-amp, lighting diode
K09/1 1-amp, diode for power supply to electronics
K09/2 3-amp, CAN BUS diode
K09/3 Relay for fuel preheater
K09/4 Relay for air-conditioning system
K09/5 Transmission enable relay
K09/6 Not used
K09/7 3-amp, diode (not connected)
K09/7 1-amp, diode for electronic engine control (ECU, Level 1)

DEFINITIONS:
K10/1 Fan relay
K10/2 Not used
K10/3 Relay for 3-terminal socket, power outlet strip
K10/4 Plug for ”come home” mode


Cab from Serial No. 398656
Fuse and relay boxes from serial no. 398656
→NOTE:
LEGEND:
A Relay box K01
B Relay box K02
C Fuse box F03
D Fuse box F04
E Fuse box F05
F Fuse box F06
G Fuse box F07

H Relay box K08
I Relay box K09
J Relay box K10
Relays (relay box K01) from serial no. 398656
DEFINITIONS:

DEFINITIONS:
K02/1 Not used
K02/3 Not used
K02/4 Not used
K02/6 Not used
K02/7 Not used

Fuses (fuse box F03) from serial no. 398656
IMPORTANT:
DEFINITIONS:
F03/02
lock, HMS II, handbrake, wheel-speed sending unit and radar)

F03/05 Not used
F03/09 Not used
F03/11 Not used
F03/12 Not used
F03/14 10-amp, service plug, JDLink, GreenStar (battery power)

IMPORTANT:
DEFINITIONS:
F04/03 10-amp, GreenStar (power supply)
F04/04 15-amp, main (key) switch (battery voltage)


F04/09 10-amp, basic informator BIF, SFA controller (power supply)
F04/10 10-amp, basic informator BIF (battery voltage)
F04/11 10-amp, fuel pump, injection pump shut-off valve
F04/12 10-amp, performance monitor PRF, JDLink (power supply)
F04/13 10-amp, CAN BUS terminator
F04/14 Not used
F04/15 Not used
F04/16 Not used

IMPORTANT:
DEFINITIONS:
10-amp, air-conditioning system, relay for fan, ClimaTrak (power
F05/01
supply)
F05/03 Not used
F05/04 10-amp, EPC controller (power supply)

F05/05 10-amp, EPC controller (battery voltage)

F05/06 10-amp, EPC controller (gear selection)
F05/10 10-amp, electric rear-view mirrors, signal socket
F05/13 20-amp, fan
F05/13 30-amp, ClimaTrak (fan)
F05/14 20-amp, fan
F05/14 10-amp, ClimaTrak (battery voltage)

IMPORTANT:
DEFINITIONS:
F06/01 10-amp, horn
F06/05 10-amp, shift console light, radio lighting


15-amp, outer worklight on rear of cab roof or Xenon (HID) worklight
F06/09
on right rear of cab roof
15-amp, inner worklight on rear of cab roof or Xenon (HID) worklight
F06/10
on left rear of cab roof
F06/13 Fuse tester
F06/14 10-amp, AutoTrac (power supply)
F06/15 10-amp, AutoTrac (battery voltage)

IMPORTANT:
DEFINITIONS:
F07/01 Not used
F07/02 Not used
F07/03 Not used
F07/05 Not used



DEFINITIONS:

DEFINITIONS:
K09/5 Transmission enable relay
K09/6 Not used
K09/7 Not used

DEFINITIONS:
K10/1 Fan relay
K10/1 ClimaTrak bridging plug


Cab and AutoPowr/IVT Transmission up to Serial No.
398655
Fuse and relay boxes on tractors with AutoPowr/IVT transmission up to
serial no. 398655
→NOTE:
LEGEND:
A Relay box K01
B Relay box K02
C Fuse box F03
D Fuse box F04

E Fuse box F05
F Fuse box F06
G Fuse box F07
H Relay box K08
I Relay box K09
J Relay box K10
Relays (relay box K01) on tractors with AutoPowr/IVT transmission up

to serial no. 398655
DEFINITIONS:


DEFINITIONS:
K02/1 Enable relay
K02/3 Relay for LTC coolant pump
K02/4 Not used
K02/6 Relay for power supply to E-SCV 3, E-SCV 4

Fuses (fuse box F03) on tractors with AutoPowr/IVT transmission up to

serial no. 398655
IMPORTANT:

DEFINITIONS:
F03/02
lock, HMS II, handbrake, wheel-speed sending unit, radar)
F03/05 Not used
F03/09 20-amp, LTC coolant pump
F03/11 10-amp, power supply to E-SCV 3, E-SCV 4
F03/14 10-amp, JDLink, GreenStar

serial no. 398655

IMPORTANT:
DEFINITIONS:
F04/03 Not used
F04/04 15-amp, main switch (BAT)


F04/09 10-amp, basic informator, SFA controller (power supply)
F04/10 10-amp, basic informator (battery voltage)
F04/11 10-amp, fuel pump
F04/12 10-amp, performance monitor (PRF)
F04/13 10-amp, CAN BUS terminator, service socket
F04/14 10-amp, UIC controller (power supply)
F04/15 10-amp, TCU controller (power supply)
F04/16 Not used

serial no. 398655

IMPORTANT:
DEFINITIONS:
F05/01 10-amp, air-conditioning system and relay for fan
F05/03 10-amp, PLC controller (power supply)
F05/04 10-amp, PLC controller (battery voltage)
F05/05 10-amp, TCU controller (battery voltage)

F05/06 Not used

F05/07 Not used
F05/10 10-amp, electrical rear-view mirror
F05/13 20-amp, fan
F05/14 20-amp, fan

serial no. 398655

IMPORTANT:
DEFINITIONS:
F06/01 10-amp, horn
F06/05 10-amp, shift console light, radio lighting


F06/09 10-amp, outer worklight on rear of cab roof
F06/10 10-amp, inner worklight on rear of cab roof
F06/13 Fuse tester
F06/14 Not used
F06/15 Not used

serial no. 398655

IMPORTANT:
DEFINITIONS:
F07/01 Not used
F07/02 Not used
F07/03 Not used
F07/05 Not used




DEFINITIONS:


DEFINITIONS:
K09/5 Not used
K09/6 Not used
K09/7 Not used


DEFINITIONS:
K10/1 Fan relay
K10/2 Acoustic alarm for park lock


Cab and AutoPowr/IVT Transmission from Serial No.
398656
Fuse and relay boxes on tractors with AutoPowr/IVT transmission from
serial no. 398656
→NOTE:
LEGEND:
A Relay box K01
B Relay box K02
C Fuse box F03
D Fuse box F04

E Fuse box F05
F Fuse box F06
G Fuse box F07
H Relay box K08
I Relay box K09
J Relay box K10
Relays (relay box K01) on tractors with AutoPowr/IVT transmission

from serial no. 398656
DEFINITIONS:


DEFINITIONS:
K02/1 Enable relay
K02/3 Not used
K02/4 Not used

Fuses (fuse box F03) on tractors with AutoPowr/IVT transmission from

serial no. 398656
IMPORTANT:

DEFINITIONS:
F03/02
lock, HMS II, handbrake, wheel-speed sending unit and radar)
F03/05 Not used
F03/09 Not used
F03/14 10-amp, service plug, JDLink, GreenStar

serial no. 398656

IMPORTANT:
DEFINITIONS:
F04/03 10-amp, GreenStar (power supply)
F04/04 15-amp, main (key) switch (battery voltage)


F04/09 10-amp, basic informator BIF, SFA controller (power supply)
F04/10 10-amp, basic informator BIF (battery voltage)
F04/11 10-amp, fuel pump
F04/12 10-amp, performance monitor PRF, JDLink (power supply)
F04/13 10-amp, CAN BUS terminator
F04/14 10-amp, UIC controller (power supply)
F04/15 10-amp, TCU controller (power supply)
F04/16 Not used

serial no. 398656

IMPORTANT:
DEFINITIONS:
10-amp, air-conditioning system, relay for fan, ClimaTrak (power
F05/01
supply)
F05/03 10-amp, PLC controller (power supply)
F05/04 10-amp, PLC controller (battery voltage)

F05/05 10-amp, TCU controller (battery voltage)

F05/06 Not used
F05/10 10-amp, electric rear-view mirrors, signal socket
F05/13 20-amp, fan
F05/13 30-amp, ClimaTrak (fan)
F05/14 20-amp, fan
F05/14 10-amp, ClimaTrak (battery voltage)

serial no. 398656

IMPORTANT:
DEFINITIONS:
F06/01 10-amp, horn
F06/05 10-amp, shift console light and radio lighting


15-amp, outer worklight on rear of cab roof or Xenon (HID) worklight
F06/09
on right rear of cab roof
15-amp, inner worklight on rear of cab roof or Xenon (HID) worklight
F06/10
on left rear of cab roof
F06/13 Fuse tester
F06/14 10-amp, AutoTrac (power supply)
F06/15 10-amp, AutoTrac (battery voltage)

serial no. 398656

IMPORTANT:
DEFINITIONS:
F07/01 Not used
F07/02 Not used
F07/03 Not used
F07/05 Not used




DEFINITIONS:


DEFINITIONS:
K09/5 Not used
K09/6 Not used
K09/7 Not used


DEFINITIONS:
K10/1 Fan relay
K10/1 ClimaTrak bridging plug
K10/2 Acoustic alarm for park lock
Replacing the Main Fuses

LEGEND:
A Fuse covers
B Main fuse (F13)
C Main fuse (F14)
The two main fuses are located under the engine hood, where they are secured on the r.h.
side of the hood frame just above the battery.
F13–80-amp battery circuit (main power supply)
F14–80-amp battery circuit (main power supply)
IMPORTANT:
Open the hood.
Take covers (A) off the two fuses.
Replace fuse (B) or (C).

Put the covers back on the fuses.

Replacing Fuses of Electrical Starting Aid for Stage I

and II Engines to 97/68/EC (Level 4 or 11 ECUs)
The fuses for the electrical starting aid are on the right side of the engine block.
Open the hood.
Replacing the fuse for the heater element (electrical starting aid)
LEGEND:
A Fuse F09 for heater element (electrical starting aid)
F09 - 70-amp, heating element in electrical starting aid
IMPORTANT:
Take the cover off the fuse.

Replace fuse (A).
Put the cover back on the fuse.
Replacing the indicator light fuse (electrical starting aid)
LEGEND:
B Fuse F11 for indicator light (electrical starting aid)
F11 - 10-amp, indicator light in electrical starting aid
IMPORTANT:
Replace fuse (B).

Replacing Fuses of Electrical Starting Aid for Stage I

(AutoPowr/IVT Transmission)
The fuses for the electrical starting aid are on the right side of the engine block.
Open the hood.
Replacing the fuse for the heater element (electrical starting aid)
LEGEND:
A Fuse (F09) for heater element (electrical starting aid)
F09 - 70-amp, heating element in electrical starting aid
IMPORTANT:

Replace fuse (A).
Replacing the indicator light fuse (electrical starting aid)
LEGEND:
B Fuse F11 for indicator light (electrical starting aid)
F11 - 10-amp, indicator light in electrical starting aid
IMPORTANT:
Replace fuse (B).

Replacing Fuse for Fuel Injection Pump (with Stage

I Engines to 97/68/EC (Level 4 ECU)
LEGEND:
A Fuse covers
B Fuse F10 for fuel injection pump (Level 4 ECU)
The injection pump fuse is located on the right side of the engine block.
F10—20-amp, fuel injection pump (Level 4 ECU)
IMPORTANT:
Open the hood.
Take cover (A) off the fuse.
Replace fuse (B).


Replacing Fuse for Fuel Injection Pump (with Stage

I Engines to 97/68/EC (Level 4 ECU) (AutoPowr/IVT
Transmission)
LEGEND:
A Fuse covers
B Injection pump fuse (F10)
The injection pump fuse is located on the right side of the engine block.
F10—20-amp, fuel injection pump (Level 4 ECU)
IMPORTANT:
Open the hood.

Replace fuse (B).

Replacing the LTC Coolant Pump Fuse

LEGEND:
A Fuse covers
B Fuse F22 for LTC coolant pump fuse (AutoPowr/IVT transmission)
The fuse for the LTC coolant pump is on the right side of the engine block.
F22 - 30-amp, LTC coolant pump
IMPORTANT:
Open the hood.
Replace fuse (B).


Replace the Fuse for the Implement BUS (60-amp

Implement Socket)
LEGEND:
A Fuse covers
B Fuse for power supply to implement BUS (components) (F16)
C Fuse for power supply to implement BUS (CAN BUS) (F17)
The two fuses for the power supply to the implement BUS are located under the engine hood,
where they are secured on the l.h. side of the hood frame just above the battery.
F16—60-amp, power supply to implement BUS (components)
F17—30-amp, power supply to implement BUS (CAN BUS)
IMPORTANT:
Lift hood.

Take covers (A) off the two fuses.
Replace fuse (B) or (C).
Put the covers back on the fuses.

Replacing Starting Motor Relay for Stage I and II

Engines to 97/68/EC (Level 4 or 11 ECUs)
LEGEND:
A Starting motor relay cover
B Cap screw
C Starting motor relay (K01)
The starting motor relay is on the left side of the engine block.
CAUTION:
Open the hood.
Remove cap screw (B) and cover (A).

→NOTE:
For identification purposes, mark the wires before disconnecting them.
Disconnect relay (C) and insert a new one.
4.4 lb-ft
2.6 to 3 lb-ft
5.9 lb-ft

Replacing Starting Motor Relay for Stage I and II

Engines to 97/68/EC (Level 4 or 11 ECUs)
LEGEND:
A Starting motor relay cover
B Cap screw
C Starting motor relay (K01)
The starting motor relay is on the left side of the engine block.
CAUTION:
Open the hood.
Remove cap screw (B) and cover (A).

→NOTE:
4.4 lb-ft
2.6 to 3 lb-ft
5.9 lb-ft

Replacing Relay of Electrical Starting Aid for Stage I

LEGEND:
A Cover of relay for electrical starting aid
B Nut with protective cap
C Relay K36, electrical starting aid
The electrical starting aid relay is located at the right-hand side of the engine block.
CAUTION:
Open the hood.
Take off the protective cap and nut (B).
Remove cover (A).

→NOTE:
4.4 lb-ft
2.6 to 3 lb-ft
5.9 lb-ft

Replacing Relay of Electrical Starting Aid for Stage I

LEGEND:
A Cover of relay for electrical starting aid
B Nut with protective cap
C Relay K36, electrical starting aid
The electrical starting aid relay is located at the right-hand side of the engine block.
CAUTION:
Open the hood.
Take off the protective cap and nut (B).

Remove cover (A).
→NOTE:
4.4 lb-ft
2.6 to 3 lb-ft
5.9 lb-ft
Replacing Relay for Fuel Injection Pump (with Stage

I Engines to 97/68/EC only (Level 4 ECU))
LEGEND:
A Attaching screw
B Plug
C Injection pump relay (K40)
The injection pump relay is located under the engine hood, where it is secured on the r.h.
side of the hood frame just above the battery.
Open the hood.

Take out attaching screw (A).
Replace relay (C) with a new one.
Replace the Power Supply Relay for the Implement

BUS
LEGEND:
A Attaching screw
B Plug
C Relay for power supply to implement BUS (components) (K46)
D Attaching screw
E Plug
F Relay for power supply to implement BUS (CAN BUS) (K47)
The two relays for the power supply to the implement BUS are located under the engine
hood, where they are secured on the l.h. side of the hood frame just above the battery.
Lift hood.
Remove attaching screw (A) or (D).
Disconnect plug (B) or (E).
Replace relay (C) or (F) with a new one.

Replacing Battery Cut-off Switch Relay

Version 1
LEGEND:
A Nut and washer
B Nut and washer
C Screw
D Battery cut-off relay (version 1) (K50)
Cab
The battery cut-off relay (version 1) is located under the engine hood, just above the battery
CAUTION:
Open the hood.
Disconnect the battery.
Remove nuts and washers (A) and battery cable.
Remove nut and washer (B) and control line.
Take out screws (C) and replace battery cut-off relay (version 1) (D) with a new one.

13 to 16 lb-ft
Control line to battery cut-off relay (version 1), M5 hex. nut Torque 3 to 5 N˙m
2.2 to 3.7 lb-ft
Version 2
LEGEND:
A Latches
B Covers
C Nuts and washers
D Screws and washers
E Screws and nuts
F Battery cut-off relay (version 2) (K56)
Cab
The battery cut-off relay (version 2) is located under the engine hood, just above the battery

CAUTION:
Open the hood.
Disconnect the battery.
Open latches (A) and remove covers (B).
Remove nuts and washers (C) and battery cable.
→NOTE:
Remove screws and washers (D) and control line.
Take off screws and nuts (E) and replace the battery cut-off relay (version 2) (F).
11 to 15 lb-ft
Control line to battery cut-off relay (version 2), M4 cap screw Torque 2.2 N˙m
1.6 lb-ft

Replacing Battery Cut-off Switch Relay

Version 1
LEGEND:
A Screw
B Relay K48 for battery cut-off switch (version 1)
C Plug
Cab
The relay for the battery cut-off switch (version 1) is located under the engine hood, just
above the battery
Open the hood.
Take out screw (A) and remove relay (B).
Disconnect plug (C) and replace relay.
Version 2

LEGEND:
A Screw
B Relay K57 for battery cut-off switch (version 2)
C Plug
Cab
The relay for the battery cut-off switch (version 2) is located under the engine hood, just
above the battery
Open the hood.
Take out screw (A) and remove relay (B).
Disconnect plug (C) and replace relay.
Replacing the Main Switch
LEGEND:
A Main switch
B Plug
C Special nut
If necessary: Carry out preliminary work, refer to“Removing Trim Panels from Cowl”.
CAUTION:
Take off the special nut (C) on the outside.

Pull out main switch (A).
Pull off plug (B) and install new switch.

Replacing the Brake Switches
LEGEND:
A Brake switch
B Plug
C Screws
For preliminary work, refer to“Removing Trim Panels from Cowl”.
Take out screws (C) and replace brake switch (A) with a new one.
For brake switch adjustment (brake valve with Power-Fill), refer to “Brake Valve with Power-
Fill”, Section 60, Group 15.
For brake switch adjustment (Power-Fill brake valve with MFWD and disk brake), refer to
“Power-Fill Brake Valve with MFWD and Disk Brake“, Section 60, Group 15.
IMPORTANT:
Only on tractors with AutoPowr/IVT transmission: If you replace the brake

switches, you should check the user interface controller (UIC) for diagnostic
trouble codes. Refer to “Reference 245-05-002 , Accessing the Addresses
and Diagnostic Trouble Codes”.
Replacing the Light Switch

LEGEND:
A Screws
B Screws
C Console
D Sheet-metal nut
E Light switch
Pull the knob off the light switch.
Take out screws (A) and lift off the dashboard trim.
Take out screws (B) and tilt console (C).
Take off sheet-metal nut (D) and pull out the light switch (E).
Disconnect the plug and replace the light switch with a new one.

Replacing the Worklight Switches
LEGEND:
A Worklight switches
B Plugs
C Worklight switch
D Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plugs (B).
Press the worklight switches (A) out to the front of the console and replace them with new
ones.
or
Disconnect plug (D).
Extract the wires of the relevant worklight switch (C) from the plug using a JDG777
Extraction tool
JDG777

extraction tool.
Extract terminals from plug (refer to“METRI PACK Connectors with Terminal Lock at the
Rear”in Section 40, Group 05).
→NOTE:
For identification purposes, mark the layout of the leads before you extract
them.
Press the worklight switches (C) out to the front of the console and replace them with new
ones.

Replacing the Switch for Lights on Cab Frame
LEGEND:
A Switch for lights on cab frame
B Plug
Extract the wires of the switch (A; for lights on cab frame) from the plug using a JDG777
Extraction tool
JDG777

extraction tool.
→NOTE:
them.
Press the switch for lights on cab frame (A) out to the front of the console and replace it with
a new one.

Replacing the Beacon Light Switch
LEGEND:
A Beacon light switch
B Plug
Extract the wires of the switch (A; for beacon light) from the plug using a JDG777
Extraction tool
JDG777

extraction tool.
→NOTE:
them.
Press the beacon light switch (A) out to the front of the console and replace it with a new one.
Replacing the Hazard Warning Light Switch
LEGEND:
A Screws
B Screws
C Console
D Hazard warning light switch
Take out screws (A) and lift off the dashboard trim.
Take out screws (B) and tilt console (C).
Disconnect the plug.
Press out hazard warning light switch (D) to the front of the console and replace it with a new
one.

IMPORTANT:
If you replace the hazard warning light switch, you should check the basic
control unit (BCU) for diagnostic trouble codes. See “Reference 245-05-002
, Accessing the Addresses and Diagnostic Trouble Codes”.

Replacing Switches on Multi-Function Unit

Tractor with electrical reverser control (PowrQuad Plus and AutoQuad
transmissions) up to serial no. 398655 (version 1)
→NOTE:
The lever for electrical reverser control (version 1) is no longer available.

The version 1 lever is now replaced by a special version 2 lever that is
available as a spare part.

LEGEND:
A Switch (turn signal/horn/full-beam)
B Switch (electrical reverser control)
C Screws
D Screws
E Screws
F Screws
G Screws
H Wiring harness (W18; windshield wiper switch)
J Microswitch (roll mode)

K Lever (roll mode)

L Windshield wiper and washer switch
M Mounting
N Grip for windshield wiper and washer
O Cover
P Guide sleeve
Remove the steering wheel.
Take out screws (F) and lift off cover (O).
Take out screws (C) and lift off switch (A). Take out screws (E) and (D) and lift off switch (B).
Take out screws (G) and lift off guide sleeve (P).
Replace switches (A) or (B) as complete assemblies.
Pull out the intermittent-wipe relay.
Pull mounting (M) with grip (N) out of its guide.
Disconnect plug from switch (L) and replace switch.
Pull lever (K) out of its guide and replace microswitch (J).
Tighten the steering wheel nut.
35 lb-ft
IMPORTANT:
If you replace switch (A) or microswitch (J), you must check the basic
control unit (BCU) for diagnostic trouble codes. See ”Reference 245-05-002
IMPORTANT:
If you replace switch (B), you must check the electronic PowrQuad
controller (EPC) for diagnostic trouble codes. See ”Reference 245-05-002 ,
Accessing the Addresses and Diagnostic Trouble Codes”.

Tractor with electrical reverser control (PowrQuad Plus and AutoQuad

Plus transmissions) from serial no. 398656 (version 2)
LEGEND:
B Switch (reverser control)
C Screws
D Cover
E Screws
F Screws
G Screws
H Guide sleeve
J Wiring harness (W18; windshield wiper switch)
K Intermittent-wipe relay
L Microswitch (roll mode)
M Lever (roll mode)
N Windshield wiper and washer switch
O Mounting
P Grip for windshield wiper and washer
Take out screws (C) and remove cover (D).
Take out screws (E) and lift off switch (A).
Take out screws (F) and lift off switch (B).
Take out screws (G) and lift off guide sleeve (H).
Pull out the intermittent-wipe relay (K).
Pull out mounting (O) and grip (P).
Disconnect plug from switch (N) and replace switch.
Pull lever (M) out of its guide and replace microswitch (L).
35 lb-ft

IMPORTANT:
If you replace switch (A) or microswitch (L), you must check the basic
IMPORTANT:
If you replace switch (B), you must check the electronic PowrQuad
controller (EPC) for diagnostic trouble codes. See ”Reference 245-05-002 ,
Tractors with reverser control (AutoPowr/IVT transmission)

LEGEND:
B Switch (reverser control)
C Screws
D Cover
E Screws
F Screws
G Screws
H Guide sleeve
J Wiring harness (W18; windshield wiper switch)
K Intermittent-wipe relay
L Microswitch (roll mode)

M Lever (roll mode)
N Windshield wiper and washer switch
O Mounting
P Grip for windshield wiper and washer
Take out screws (C) and remove cover (D).
Take out screws (E) and lift off switch (A).
Take out screws (F) and lift off switch (B).
Take out screws (G) and lift off guide sleeve (H).
Pull out the intermittent-wipe relay (K).
Pull out mounting (O) and grip (P).
Disconnect plug from switch (N) and replace switch.
Pull lever (M) out of its guide and replace microswitch (L).
35 lb-ft
IMPORTANT:
If you replace switch (A) or microswitch (L), you must check the basic
IMPORTANT:
If you replace switch (B), you must check the user interface controller (UIC)
for diagnostic trouble codes. See ”Reference 245-05-002 , Accessing the
Addresses and Diagnostic Trouble Codes”.

Replacing the Rear Window Wiper and Washer

Switch
LEGEND:
A Knob
B Sheet-metal nut
C Symbol disk
→NOTE:
For identification purposes, mark the plugs before you pull them out.
Disconnect plug and remove consoles.
Pull off knob (A).
Remove sheet-metal nut (B) and symbol disk (C).
Pull the rear window wiper and washer switch out to the rear.

Disconnect the plug and replace the rear window wiper and washer switch with a new one.

Replacing the Windshield/Rear Window Switch

Replacing the windshield switch
LEGEND:
A Wiring connector
B Screws
C Cover
D Windshield switch
For preliminary work, refer to“Removing Trim Panels from Cowl”.
Disconnect connector (A).
→NOTE:
them.
Using JDG777
Extraction tool
JDG777
tool, extract male terminal body.
→NOTE:
Attach a fish-tape (wire-snake) to the old wiring harness to aid installation

of the new harness.
Take out the attaching screws (B) and remove cover (C) of the windshield switch (D).
Pull out switch/harness assembly and replace with new parts.
CAUTION:
Make sure that wires are connected correctly.
Terminal no. Wire no. and cross section Wire color
A .......... 224KZ-1 .......... yellow
B .......... 236KZ-1 .......... light blue
C .......... 227KZ-1 .......... purple
Setting:
Set the windshield switch so that windshield wiper can operate properly when the windshield
is locked shut.

Replacing the rear window switch
LEGEND:
A Screws
B Rear window switch
Remove the trim panel around the fuse and relay boxes.
Remove the screws (A) that hold on the rear window switch.
Cut off wires directly at the rear window switch (B).
Connect wires to new rear window switch by soldering, and insulate them.
Setting:
Set the rear window switch so that rear window wiper can operate properly when the rear
window is locked shut.
Replacing the Dome Light Door Switch
LEGEND:

A Dome light door switch
Remove cab frame cover.
Remove the screws that hold on dome light door switch (A).
Cut off wires directly at the dome light door switch.
Connect wires to new dome light door switch by soldering, and insulate them.
Setting:
Set the dome light switch to position 2.
Set the dome light door switch so that the dome light goes out when the door is closed.

Replacing the Handbrake Switch
LEGEND:
A Screws
B Trims
C Screws
D Washers
E Bracket
F Plug
G Handbrake switch
Take out screws (A) and remove trims (B).
Remove trim panels from the rear wall of the cab.

Take out screws (C) and lift off washers (D).
Take off bracket (E).
Disconnect plug (F).
Replace handbrake switch (G) together with wiring harness.
Setting:
Adjust the handbrake switch so that the handbrake indicator light comes on when the 2nd
notch above the lowest point is reached. Pressure on the handbrake lever in this position
must not cause the indicator light to go out. In the lowest position, raising the handbrake
lever slightly should not cause the handbrake indicator light to come on.
IMPORTANT:
If you replace the handbrake switch, you should check the basic control
unit (BCU) for diagnostic trouble codes. See “Reference 245-05-002 ,

Replacing the Front Wheel Drive Switch
LEGEND:
A Front-wheel drive switch
B Plug
Press the front-wheel drive switch (A) out to the front of the console and replace it with a new
one.
IMPORTANT:
If you replace the front-wheel drive switch, you should check the basic

Replacing the Headland Management (HMS) Switch
LEGEND:
A Switch for Headland Management System (HMS)
B Plug
Press out the HMS switch (A) to the front of the console and replace it with a new one.
IMPORTANT:
If you replace the HMS switch, you should check the basic control unit
(BCU) for diagnostic trouble codes. See “Reference 245-05-002 , Accessing
the Addresses and Diagnostic Trouble Codes”.

Replacing the Record/Save Switch
LEGEND:
A Record/save switch
B Plug
Press the record/save switch (A) out to the front of the console and replace it with a new one.
IMPORTANT:
If you replace the record/save switch, you should check the basic control
unit (BCU) for diagnostic trouble codes. See “Reference 245-05-002 ,

Replacing the Program Switch

Tractors with shift console
LEGEND:
A Program switch
B Plug
C SCV control levers
Remove the grips from the SCV control levers (C).
Remove cover from switch console.
Press the program switch (A) out to the front of the console and replace it with a new one.

IMPORTANT:
If you replace the program switch, you should check the basic control unit
Tractors with Command Arm
LEGEND:
A Screws
B Screws

C Cover
D Program switch
E Plug
On the underside of the Command Arm, take out screws (A).
Take out screws (B) and lay the panel on one side.
Fold out cover (C).
Disconnect plug (E).
From the inside, press out program switch (D) and replace it with a new one.
IMPORTANT:
If you replace the program switch, you should check the basic control unit

Replacing the Rear PTO Preselector Switch
LEGEND:
A Rear PTO preselector switch
B Plug
Press the rear PTO preselector switch (A) out to the front of the console and replace it with a
new one.
IMPORTANT:
If you replace the rear PTO preselector switch, you should check the basic

Replacing the Switch for AutoQuad Transmission
LEGEND:
A Switch for AutoQuad transmission
B Plug
Press out switch (A; for AutoQuad transmission) to the front of the console and replace it with
a new one.
IMPORTANT:
If you replace the switch for AutoQuad transmission, you should check the
electronic PowrQuad controller (EPC) for diagnostic trouble codes. See
“Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
Codes”.

Replace the Switch for Gear Selector and Auto-

mode
Switches on range shift lever
LEGEND:
1 Shift lever for PowrQuad Plus and AutoQuad transmissions
2 Shift lever for AutoQuad Plus transmission
A Screws
B Grip
C Plug

D Microswitch
Cab
Take out screws (A) and disassemble grip (B) on the range shift lever.
Pull off plug (C) and replace micro-switch (D) with a new one.
CAUTION:
The symbols on all the gear selector switches must match (i.e. the symbols
must be the same at the switches on the range shift lever and on the
console).
IMPORTANT:
If you replace the micro-switches on the range shift lever, you must check
the electronic PowrQuad controller (EPC) for diagnostic trouble codes. See
”Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
Codes”.
Switch in shift console up to serial no. 398655
LEGEND:
A Gear selector switch
B Plug
Cab
Remove panel from control console.

Press gear selector switch (A) out to the top and replace it with a new one.
CAUTION:
must be the same at the switches on the console and on the range shift
lever).
IMPORTANT:
If you replace the gear selector switch on the shift console, you must check
Codes”.
Switch in shift console from serial no. 398656

LEGEND:
A Bowden cables
B Screws
C Screw
D Cable binder
E Plug
F Gear selector switch
Cab
Remove floor mat and control console trim panels.
Put identifying marks on the existing bowden cables (A), then remove them.
Take out screws (B).
Take out screw (C).
Carefully lift the shift unit up a little.
Take off cable binder (D).
Press out gear selector switch (F) to the front of the console and replace it with a new one.
CAUTION:
must be the same at the switches on the console and on the range shift
lever).
IMPORTANT:
If you replace the gear selector switch on the shift console, you must check
Codes”.

Replacing the Park Lock Switch on Tractors with

PowrQuad Plus, AutoQuad or AutoQuad Plus
Transmissions
Tractors with cab and PowrQuad Plus or AutoQuad transmissions up to
serial no. 398655
LEGEND:
A Park lock switch
B Stud with nut
C Plug
D Neutral position of range shift lever
E Switch point
Remove floor-mat and take trim elements off the control console.
Disconnect plug (C).
Take the nuts off studs (B).

Replace the park lock switch (A) as a complete unit.
Adjustment:
Adjust the park lock switch until switch point (E) is not located in the neutral position (D) of
range shift lever when it is moved to park lock position.
IMPORTANT:
If you replace the park lock switch, you should check the electronic
PowrQuad controller (EPC) for diagnostic trouble codes. See ”Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
Tractors with cab and PowrQuad Plus or AutoQuad Plus transmissions

LEGEND:
A Park lock switch
The park lock switch can be replaced only as an assembly together with the park lock
quadrant. See”Reconditioning the Range Shift Mechanism (PowrQuad Plus and AutoQuad Plus
transmissions from tractor serial no. 398656)”.
IMPORTANT:
If you replace the park lock switch, you should check the electronic

Replacing the Fan Switch

LEGEND:
A Console
B Knobs
C Phillips-head screws
D Panel
E Phillips-head screws
F Cover
G Phillips-head screws
H Cover
Carefully pry out consoles (A) using a screwdriver at the locations indicated (arrows).
→NOTE:
Disconnect plug and remove consoles.
Pull off knobs (B).
Remove Phillips-head screws (C).
Pull plugs off the air-conditioning system compressor switch, the speed ("cruise") control, the
cigarette lighter and the rear window wiper/washer switch, and remove trim panel (D).
Remove Phillips-head screws (E) and cover (F) and fold out heater control unit.
Remove Phillips-head screws (G) and cover (H).
Pull out the fan switch and disconnect the plug.
Replace the fan switch with a new one.

Replacing the Switch of the Air-Conditioning System

Compressor
LEGEND:
A Compressor switch (air conditioning)
B Plug
→NOTE:
Disconnect plug and remove console.
Press out the air-conditioning compressor switch (A) from the inside.
Pull off plug (B) and install a new switch.

Replacing the Differential Lock Switch.
LEGEND:
A Differential lock switch
B Floor plate
C Screws
Remove the floor-mat.
Take screws (C) out of floor-plate (B), and remove the floor-plate.
Pull out the plug.
Remove differential lock switch (A) from the floor-plate, and replace it with a new one.
IMPORTANT:
If you replace the differential lock switch, you should check the basic

Replacing the PTO Switches

Removing the rear PTO switch and/or front PTO switch from tractors
with shift console
Rear PTO switch
Front PTO switch
LEGEND:
A PTO switch
B Plug
Remove panel from control console.
Replacing the PTO switch on tractors with shift console

LEGEND:
A Knob
B Knob cap
C Snap ring
D Washer
E Spring
F Washer
G Collar
H Shift console
I Switch
Remove knob cap (B) and snap ring (C).
Remove knob (A) and parts (D - G).
Replace parts or switch (I) as necessary.

IMPORTANT:
If you replace the rear PTO switch or front PTO switch, you should check
the basic control unit (BCU) for diagnostic trouble codes. See “Reference
Removing the rear PTO switch and/or front PTO switch from tractors
with Command Arm

LEGEND:
A Screws
B Screws
C Cover
D Rear PTO switch
E Plug
F Front PTO switch
G Plug
Open out cover (C).
Disconnect plug (E) or (G).
From the inside, press out rear PTO switch (D) or front PTO switch (F) and replace it/them
with (a) new one(s).
IMPORTANT:
If you replace the rear PTO switch or the front PTO switch, you should
check the basic control unit (BCU) for diagnostic trouble codes. See
Codes”.

Replacing the External Control Switch for the Rear

PTO
LEGEND:
A Screws
B Cover
C Plug
D Threaded bushing
Take out screws (A) and remove cover (B).
On the inside of the fender, screw down threaded bushing (D).
Pull out the external control switch for the rear PTO and replace it with a new one.

IMPORTANT:
If you replace the external control switch for the rear PTO, you should
Codes”.

Replacing the Rockshaft′s Remote Control Switch
LEGEND:
A Screws
B Cover
C Plug
D Screws
Take out screws (A) and remove cover (B).
On the inside of the fender, take out Phillips-head screws (D). Pull out the rockshaft′s remote
control switch and replace it with a new one.
IMPORTANT:
If you replace the rockshaft′s remote control switch, you should check the
basic control unit (BCU) for diagnostic trouble codes. See ”Reference

Replacing the Switches for the Electrical Rear-View

Mirrors
LEGEND:
A Switch for the electrical rear-view mirrors
B Plugs
Carefully pry out the consoles using a screwdriver at the locations indicated (arrows).
→NOTE:
Press out switches (A; for electrical rear-view mirrors) to the front of the console and replace
them with new ones.

Replacing the Switch for the Heated Rear-View

Mirrors
LEGEND:
A Switch for the heated rear-view mirrors
B Plug
Press out switch (A; for heated rear-view mirror) to the front of the console and replace it with
a new one.
Replacing the Switch for the Heated Rear Window

LEGEND:
A Switch for the heated rear window
B Plug
→NOTE:
Press out switch (A; for heated rear window) to the front of the console and replace it with a
new one.

Replacing Switch of Battery Cut-off Switch

Version 1
LEGEND:
A Console
B Lock-nut
C Switch of battery cut-off switch (version 1) (S117)
D Plug
Tractors with cab, and SE tractors
Remove left-hand access step.
Remove locknut (B).
Pull the switch (C) inwards out of the console (A).
Disconnect plug (D) and replace the switch that operates the battery cut-off switch with a
new one.
Version 2

LEGEND:
A Console
B Switch of battery cut-off switch (version 2) (S125)
C Plug
Tractors with cab, and SE tractors
Remove left-hand access step.
Pull plug (C) out of the switch that operates the battery cut-off switch.
Press switch (B) forward out of console (A).

Replace the AutoTrac Switch

Tractors with shift console
Remove the grips from the selective control valve levers.
Disconnect plug.
Press out AutoTrac switch (A) to the front of the console and replace it with a new one.
IMPORTANT:
If you replace the AutoTrac switch with a new one, you must check the
AutoTrac control unit (SSU) for diagnostic trouble codes. See ”Reference
Tractors with Command Arm

LEGEND:
A Screws
B Screws
C Cover
D AutoTrac switch
E Plug
Open out cover (C).

From the inside, press out AutoTrac switch (D) and replace it with a new one.
IMPORTANT:
If you replace the AutoTrac switch with a new one, you must check the
AutoTrac control unit (SSU) for diagnostic trouble codes. See ”Reference

Replacing the Switch for the Electro-hydraulic Pick-

up Hitch
LEGEND:
A Screws
B Screws
C Cover
D Switch for the electro-hydraulic pick-up hitch
E Plug
Tractors with cab and CommandArm only

On the underside of the CommandArm, take out screws (A).
Fold out cover (C).
From the inside, press out the switch for the electro-hydraulic pick-up hitch (D), and replace it
with a new one.

Replacing the Cruise Control Potentiometer on

Tractors with AutoQuad Transmission
LEGEND:
A Knob
B Hex. nut
C Plug
→NOTE:
Pull off knob (A).
Take off hex. nut (B) and pull the cruise control potentiometer inwards out of the guide.
Disconnect plug (C) and replace the cruise control potentiometer with a new one.

IMPORTANT:
If you replace the cruise control potentiometer, you should check the
engine control unit (ECU) for diagnostic trouble codes. See “Reference

Replacing the Cruise Control Potentiometer on

Tractors with AutoPowr/IVT Transmission
LEGEND:
A Knob
B Hex. nut
C Plug
→NOTE:
Pull off knob (A).
Take off hex. nut (B) and pull the cruise control potentiometer inwards out of the guide.
Disconnect plug (C) and replace the cruise control potentiometer with a new one.

IMPORTANT:
If you replace the cruise control potentiometer, you should check the user
interface controller (UIC) for diagnostic trouble codes. See “Reference

Replace the Auto-mode Potentiometer on Tractors

with AutoQuad Plus Transmission
→NOTE:
Disconnect plugs and remove console.
Pull off knob (A).
Take off hex. nut (B) and pull the Auto-mode potentiometer inwards out of the guide.
Disconnect plug (C) and replace the Auto-mode potentiometer with a new one.

IMPORTANT:
If you replace the Auto-mode potentiometer, you must check the electronic

Rockshaft Control
Replacing the sensitivity potentiometer of rockshaft control on
tractors with shift console
LEGEND:
A Sensitivity potentiometer of rockshaft control
B Shield
C Plug
D Screw
E Hex. nut

Take out screw (D) and remove shield (B).
Pull off the knob.
Take off hex. nut (E).
Replace the sensitivity potentiometer (A) with a new one.
IMPORTANT:
If you replace the sensitivity potentiometer of rockshaft control, you should

Codes”.
IMPORTANT:
If you replace the sensitivity potentiometer of rockshaft control, you should

recalibrate the basic control unit (BCU). See Reference 245-BCU-002 ,
Calibration and Input Addresses (Rockshaft Control)”.
Replacing position feedback unit on tractors with shift console

LEGEND:
A Position feedback unit
B Plug
C Hex. socket screws
D SCV control levers
Remove the grips from the SCV control levers (D).
Take the covers off the control console.
Pull off connector (B) and remove the control console cover that has position feedback unit
(A) on it.
Take out hex. socket screws (C).
Remove the position feedback unit from the control console cover and install a new unit.

IMPORTANT:
If you replace the position feedback unit, you should check the basic
IMPORTANT:
If you replace the rockshaft′s position feedback unit, you should recalibrate
the basic control unit (BCU). See Reference 245-BCU-002 , Calibration and
Input Addresses (Hitch Control)”.
Replacing the position feedback unit′s potentiometer and switch on

tractors with shift console

LEGEND:
A Knobs
B Hex. nuts
C Depth-setting potentiometer of rockshaft control
D Hex. socket screw
E Screws
F Position feedback unit′s harness
Remove the control console cover that has the position feedback unit on it.
For removal of the position feedback unit, refer to “Replacing the Position Feedback Unit”,
Section 40, Group 25.
Pull off knobs (A).
Take off hex. nuts (B).
Using a screwdriver, carefully press out the depth-setting potentiometer (C).
Unscrew the hex. socket screw (D).
Disassemble the position feedback unit as shown in the illustration.
Remove the two screws (E).
Replace the position feedback unit′s harness (F) together with its potentiometer and switch.

IMPORTANT:
If you replace the position feedback unit′s harness, you should check the
basic control unit (BCU) for diagnostic trouble codes. See “Reference
IMPORTANT:
If you replace the rockshaft′s position feedback unit′s harness, you should
recalibrate the basic control unit (BCU). See Reference 245-BCU-002 ,
Calibration and Input Addresses (Rockshaft Control)”.
Replacing the rockshaft control potentiometer on tractors with

Command Arm

LEGEND:
A Screws
B Screws
C Cover
D Rockshaft control potentiometers
E Plug
Fold out cover (C).
Pull off the knobs.
Take off the lock nut.
Pull out potentiometer (D) and install a new one.
IMPORTANT:
If you replace the potentiometers, you should check the basic control unit
IMPORTANT:
If you replace the rockshaft control potentiometers, you should recalibrate

the basic control unit (BCU). See Reference 245-BCU-002 , Calibration and
Input Addresses (Hitch Control)”.

Replacing the depth-setting potentiometer on tractors with Command

Arm
LEGEND:
A Screws
B Screws
C Cover
D Depth-setting potentiometer of rockshaft control
E Plug

Fold out cover (C).
Carefully pry out the depth-setting potentiometer (D) using a screwdriver at the location
indicated (arrow).
Replace the depth-setting potentiometer with a new one.
IMPORTANT:
If you replace the depth-setting potentiometer of rockshaft control, you

should check the basic control unit (BCU) for diagnostic trouble codes. See
Codes”.
IMPORTANT:
If you replace the depth setting potentiometer of rockshaft control, you

should recalibrate the basic control unit (BCU). See Reference 245-BCU-002
, Calibration and Input Addresses (Rockshaft Control)”.
Replacing the rapid withdrawal switch on tractors with Command Arm

LEGEND:
A Screws
B Screws
C Cover
D Rockshaft control rapid withdrawal switch
E Plug
Fold out cover (C).
From the inside, press out rapid withdrawal switch (D) and replace it with a new one.

IMPORTANT:
If you replace the rapid withdrawal switch, you should check the basic
IMPORTANT:
If you replace the rapid withdrawal switch, you should recalibrate the basic
control unit (BCU). See Reference 245-BCU-002 , Calibration and Input
Addresses (Rockshaft Control).

Electrical Activators for Selective Control Valves (E-

SCV)
Replacing the control lever
LEGEND:
A Screws
B Screws
C Cover
D Electrical activators of the selective control valves
E Plugs

F Screws
Fold out cover (C).
Disconnect the relevant plug (E).
Take out the relevant screw (F).
Take out the relevant electrical SCV activator (D), and install a new one.
IMPORTANT:
If you replace any of the SCVs′ electrical activators, you should check the E-
SCV/E-ICV controller (SIC) for diagnostic trouble codes. See “Reference
IMPORTANT:
If you replace any of the SCVs′ electrical activators, you should recalibrate
the E-SCV/E-ICV controller (SIC). See Reference 245-SIC-001 , Calibration
and Input Addresses (E-SCV and E-ICV)”.
Replacing the function adjustment wheel

LEGEND:
A Function adjustment wheel
B Grub screws
C Control knob
D Nut
E Plug
Slacken off grub screws (B) and pull off control knob (C).
Take off nut (D) and pull out the function adjustment wheel.
Disconnect plug (E) and replace the function adjustment wheel with a new one.
Replacing the transport lock switch

LEGEND:
A Transport lock switch
B Plug
Press out transport lock switch (A) to the front of the console and replace it with a new one.

Electrical Activators for Independent Control Valves

(E-ICV)
Removing the multi-function lever console
LEGEND:
A Hex. socket screw
B Multi-function lever console
C Bracket
D Armrest of operator′s seat
Disconnect the plug behind the operator′s seat.

Take out hex. socket screw (A).
Lift the multi-function lever console (B) and bracket (C) out of the armrest (D) on the
operator′s seat.
Pull the wires out of the guides in the armrest.
IMPORTANT:
If you replace the multi-function lever console, you should check the E-
SCV/E-ICV controller (SIC) for diagnostic trouble codes. See “Reference
IMPORTANT:
If you replace the multi-function lever console, you should recalibrate the
E-SCV/E-ICV controller (SIC). See Reference 245-SIC-001 , Calibration and
Input Addresses (E-SCV and E-ICV)”.
Replacing the multi-function lever and/or transport lock switch

LEGEND:
A Phillips-head screw
B Cover
C Plug
D Transport lock switch
E Screw
F Clamp
G Screw
H Pin
J Actuator of interlock switch
K Hex. socket screw
L Multi-function lever
M Bracket
For removal of the multi-function lever console, see “Removing the Multi-Function Lever
Console”, Section 40, Group 25.
Take out the five Phillips-head screws (A) and lift off cover (B).

Section 40 - ELECTRICAL SYSTEM Group 30: Monitoring Systems
Disconnect plug (C), press out transport lock switch (D), and replace it with a new switch.
Take out screw (E) and remove the wiring harness from clamp (F).
Take out screws (G) and press pin (H) out of the guide. Take off the actuator of multi-function
lever interlock switch (J).
Take out hex. socket screws (K). Pull the multi-function lever (L) out through bracket (M) and
replace it together with the wiring harness.
IMPORTANT:
If you replace the multi-function lever, you should check the E-SCV/E-ICV
controller (SIC) for diagnostic trouble codes. See “Reference 245-05-002 ,
IMPORTANT:
If you replace the multi-function lever, you should recalibrate the E-SCV / E-
ICV controller (SIC). See 245-SIC-001 , Calibration and Input Addresses (E-
SCV and E-ICV)”.

Group 30 - Monitoring Systems

Monitoring Systems - Recondition (Summary of
References)
”Information for tractors with Stage I engine to 97/68/EC (Level 4 ECU)”
”Information for tractors with Stage II engine to 97/68/EC (Level 11 ECU)”
”Information for tractors with AutoTrac (SSU controller)”
”Replacing the sending unit for the coolant temperature gauge (B08)”
”Replacing acoustic warning signal sending unit”
”Replacing the acoustic alarm (park lock) on tractors with AutoPowr/IVT transmission”
General Information
Sending units not mentioned in this Group are described in the Groups dealing with the
corresponding components.
Information for Tractors with Stage I Engine to

97/68/EC (Level 4 ECU)
For tractors with Stage I engines to 97/68/EC (Level 4 ECU), the sending units are dealt with
in the Component Technical Manual ” POWERTECH ™ 4.5 l & 6.8 l Diesel Engines Level 4
Electronic Fuel Systems With Bosch VP44 Pump”.
IMPORTANT:
If you replace a sending unit on a tractor with a Stage I engine to 97/68/EC

(Level 4 ECU), you should check the engine control unit (ECU) for diagnostic
trouble codes. See ”Reference 245-05-002 , Accessing the Addresses and
Diagnostic Trouble Codes”.
Information for Tractors with Stage II Engine to

97/68/EC (Level 11 ECU)
For tractors with Stage II engines to 97/68/EC (Level 11 ECU), the sending units are dealt with
in the Component Technical Manual ” POWERTECH ™ 4.5 l & 6.8 l Diesel Engines Level 11
Electronic Fuel Systems with Denso HPCR”.

IMPORTANT:
If you replace a sending unit on a tractor with a Stage II engine to 97/68/EC

(Level 11 ECU), you should check the engine control unit (ECU) for
diagnostic trouble codes. See ”Reference 245-05-002 , Accessing the
Addresses and Diagnostic Trouble Codes”.
Information for Tractors with AutoTrac (SSU Control

Unit)
On tractors with AutoTrac (SSU control unit), the wheel angle sensor (WAS) is dealt with in
the Component Technical Manual for Front-Wheel Drive Axles 730, 733, 740, 745 and 750.
IMPORTANT:
If you replace a wheel angle sensor (WAS) on a tractor with AutoTrac (SSU
control unit), you must check the SSU control unit for diagnostic trouble
codes. SeeOperation and General Information on Diagnostics - Accessing
the Addresses and Diagnostic Trouble Codes.
IMPORTANT:
If you replace a wheel angle sensor (WAS) on a tractor with AutoTrac (SSU
control unit), you must recalibrate the SSU control unit. See SSU -
Calibration and Input Addresses.
Replacing the sender for the coolant temperature

gauge (B08)
LEGEND:
A Sender for coolant temperature gauge (B08)
B Connectors
C Coolant temperature sender (B56)
CAUTION:
Any coolant that emerges may be hot!
The sender for the coolant temperature gauge is located in the thermostat housing.
Open the hood.
Partially drain the coolant. See “Removing the radiator” , section 30, group 20.
→NOTE:
Pay attention to colors of the leads at the plug connection!
Terminal number Function Wire no. and cross–section Wire color
A .......... Signal lead .......... 329-1 .......... white
B .......... Ground .......... 050-1 .......... black
Replace the coolant temperature sender (A).

Add coolant until it reaches the required level.
IMPORTANT:
If you replace the sender for the coolant temperature gauge, you should
check the instrument panel (BIF) for diagnostic codes. See “245-05-002 ,
Calling up addresses and diagnostic codes”.
Replacing Acoustic Warning Signal Sending Unit
LEGEND:
A Latches
B Acoustic alarm
The acoustic alarm is located in the fuse and relay boxes behind the operator′s seat just
below the rear window.
Pull out acoustic alarm (B) and replace it with a new one.


Section 40 - ELECTRICAL SYSTEM Group 40: Electrical Components
Replace the Acoustic Alarm (Park Lock) on Tractors

with AutoPowr/IVT Transmission
LEGEND:
A Latches
B Acoustic Alarm for Park Lock
The acoustic alarm for the park lock is located in the fuse and relay boxes behind the
operator′s seat just below the rear window.
Pull out the park lock′s acoustic alarm (B) and replace it with a new one.
Re-assemble all parts in reverse order.
IMPORTANT:
If you replace the park lock sending unit on tractors with AutoPowr/IVT
transmission, you must check the park lock controller (PLC) for diagnostic
trouble codes. SeeOperation and General Information on Diagnostics -
Accessing the Addresses and Diagnostic Trouble Codes.


Group 40 - Electrical Components

Electrical Components - Recondition (Summary of
References)
”Special tools”
”Replacing the 7-terminal power outlet socket”
”Replacing the 3-terminal power outlet socket”
”Replacing the multiple power-outlet socket strip”
”Replacing the service socket”
”Removing the wiper motor”
”Adjusting the headlights”
”Adjusting the lights on the cab frame”
”Safety instructions for replacing a halogen bulb”
”Safety instructions for replacing xenon (HID) bulbs and ballast units”
”Replacing xenon (HID) worklights and ballast units”
General Information
Parts not mentioned in this Group are described in the Groups dealing with the corresponding
components.
→NOTE:

JDG359

Specifications
Wires to multiple power-outlet socket strip, hex. nut Torque 3 N˙m
2.2 lb-ft
Multiple power-outlet socket strip to bracket, M6 cap screw Torque 5 N˙m
3.7 lb-ft
Bracket of multiple power-outlet socket strip, M6 cap screw Torque 11 N˙m
8.5 lb-ft

Replacing the 7-Terminal Power Outlet Socket
Take out the screws.
Pull the cover off the rear of the power outlet socket.
Pull the connector out of the rear of the power outlet socket.
Replace the power outlet socket.
Check the power supply to the seven terminals in the socket.

Terminal 3 (A) is the ground connection.

Terminal Function Wire no. and cross section Wire color
1 (L) .......... L.h. turn signal .......... 125E-1 .......... dark green
2 (54G) .......... not used
3 (31) .......... Ground .......... 310DH-2.5 .......... black
4 (R) .......... R.h. turn signal .......... 107D-1 .......... pale purple
5 (58R) .......... R.h. tail light .......... 128D-1 .......... gray
6 (54) .......... Brake lights .......... 106E-1 .......... light blue
7 (58L) .......... L.h. tail light .......... 118D-1 .......... gray
→NOTE:
Power is supplied to terminals 1 (L) and 4 (R) via the turn signal control
circuit.
Terminals 5 (58R) and 7 (58L) are supplied with power via the light switch.
Terminal 6 (54) is supplied with power via the brake switches.
Terminal 2 (54G) does not receive any power.

Replacing the 3-Terminal Power Outlet Socket
CAUTION:
The 3-terminal power outlet socket is located in the rear wall of the operator′s cab, just below
the fuse box on the r.h. side.
Open the cover on the fuse box.
Remove the trim panel.
→NOTE:

Disconnect plug.
Take out the screws that hold the socket on.
Replace the power outlet socket.
Connect wires to new socket.
CAUTION:
Make sure the wires are connected properly.
Check the power supply to the three terminals in the socket.

Terminal 31 is the ground connection.
Terminal no. Function Wire no. and cross section Wire color
15/30 .......... Battery voltage .......... 307HB-2.5 .......... purple
31 .......... Ground .......... 310HB-4 .......... black
82 .......... Electronics .......... 312HB-1.5 .......... red
→NOTE:
Terminal 82 is supplied via relay K10/3 when the main switch is in position
IGN. During the starting procedure this terminal is dead.
Terminal 15/30 is supplied with battery voltage from fuse F05/16.

Replacing the Multiple Power-Outlet Socket Strip
CAUTION:
Remove floor mat and control console trim.
Remove bracket cap screws from the outside of fender.
Remove socket strip from bracket by removing the cap screws and nuts.
→NOTE:
Disconnect wires and replace socket strip.

CAUTION:
Make sure wires are connected correctly.
Connect wires to new socket strip.
Wires to multiple power-outlet socket strip, hex. nut Torque 3 N˙m
2.2 lb-ft
Check the power supply to the three terminals in the multiple socket strip.
Terminal 3 is the ground connection.
Terminal Function Wire no. and cross section Wire color
1 .......... Electronics .......... 312D-2.5 .......... red
2 .......... Battery voltage .......... 214B-2.5 .......... yellow
3 .......... Ground .......... 310DH-4 .......... black
→NOTE:
Terminal 1 is supplied via relay K10/3 when the main switch is in position
IGN. During the starting procedure this terminal is dead.
Terminal 2 is supplied with battery voltage from fuse F05/16.
Install socket strip to bracket using cap screws and nuts.
Multiple power-outlet socket strip to bracket, M6 cap screw Torque 5 N˙m
3.7 lb-ft
Use cap screws to secure the socket strip to the fender.
Bracket of multiple power-outlet socket strip, M6 cap screw Torque 11 N˙m
8.5 lb-ft
Replace trim and floor mat.

Replacing the Service Socket

Operator′s cab (tractors with Stage I engine to 97/68/EC)
The service socket is located in the rear wall of the operator′s cab, just below the fuse box on
the l.h. side.
Disconnect the socket from the wiring harness.
Replace socket and harness.
Operator′s cab (tractors with Stage II engine to 97/68/EC)

CAUTION:
The service socket is located in the rear wall of the operator′s cab, just below the fuse box on
the l.h. side.
Pull out socket to the rear.
→NOTE:
For identification purposes, mark the wires before extracting them.
Extract service socket terminals using the appropriate extraction tool from JDG359 electrical
repair tool kit.
JDG359
For extracting service socket terminals refer to “"DEUTSCH Connectors"” in Section 40, Group
05.

CAUTION:
Make sure that wires are connected correctly.
Terminal no. Function Wire no. and cross section Wire color
A .......... Ground 050-1 .......... black
B .......... Battery voltage 952-1 .......... red
C .......... CAN-BUS 934-1 .......... yellow
D .......... CAN-BUS 935-1 .......... dark green
E .......... — vacant
F .......... — vacant
G .......... — vacant
H .......... — vacant
J .......... — vacant
Connect wires to new socket.
Removing the Wiper Motor

LEGEND:
A Nut
B Wiper arm
C Motor cover
D Plug
E Screw
F Attaching screws
Before removing the outer roof, see “ Removing the Outer Roof ”, Section 90, Group 25.
Slide the roof back to gain access to the wiper motor.
→NOTE:
Mark the position of the wiper on the windshield.
Take off nut (A) and pull off wiper arm (B).
Remove motor cover (C).
Disconnect plug (D).

Take out screw (E) and lift off the ground cable.
Take out attaching screws (F) and lift off the wiper assembly.
→NOTE:
The wiper motor is not repairable.
Replace the wiper motor assembly with a new one.

Adjusting the Headlights

With testing device
To adjust headlights, use a commercial headlight testing device with optical lens system.
Test each light individually. Make the required corrections by turning adjusting screws (A).
Without testing device

Park tractor on a level surface 5 m (16 ft 6 in) from a vertical wall.
Using the adjusting screws, adjust each headlight so that the bright/dark border forms a
horizontal line 5 cm (2 in.) lower than headlight height (H).
Switch to full beam. Align the lights sideways so that the distance between the center of the
light beams on the wall is the same as the distance (A) between the lights.
Adjusting the Lights on the Cab Frame
Adjust the setting of the lights by slackening screw (A) and nut (B).

Park tractor on a level surface 5 m (16.5 ft) from a vertical wall.
Adjust each light so that the bright/dark border forms a horizontal line 29 cm (11 in.) lower
than the height (H) of the lights.
Switch to full beam. Align the lights sideways so that the distance between the center of the
light beams on the wall is the same as the distance (A) between the lights.

Safety Instructions for Replacing a Halogen Bulb

When replacing a halogen bulb, always comply with the following safety instructions:
CAUTION:
Always switch the lights off before you change a bulb.
CAUTION:
First allow the bulb to cool down (may cause burns).
CAUTION:
Wear safety goggles and gloves when changing the bulb.
CAUTION:
The bulb is made of glass and contains halogen gas; the bulb is under high
pressure, so there is a risk of it shattering.
CAUTION:
Do NOT use any bulbs that have fallen on the ground or have scratches on
their surface, as there is a risk of them shattering.
CAUTION:
Make sure that the bulb is seated correctly in its holder in the light.
CAUTION:
Check the light for signs of damage and make sure the seals are seated
correctly.

IMPORTANT:
Use only bulbs that are of the same type, same voltage and same wattage
as the bulb that is being replaced.
IMPORTANT:
Never touch the glass surface of the halogen bulb, hold it only by its base.
IMPORTANT:
Use a clean cloth and alcohol to remove any fingerprints from the glass
bulb.
IMPORTANT:
Old halogen bulbs that have been replaced must be disposed of properly
(i.e. as hazardous waste).

Safety Instructions for Replacing Xenon (HID) Bulbs

and Ballast Units
When replacing a xenon (HID) bulb or ballast unit, it is essential to comply with the following
safety instructions:
CAUTION:
Switch the light off and disconnect it from the power supply before
changing a bulb.
CAUTION:
Never insert foreign objects or fingers into the bulb holder (high-tension
voltage - potential for FATAL ACCIDENTS).
CAUTION:
The ballast unit must never be operated when the bulb is missing, as this
may cause a dangerous flash-over at the bulb sockets, resulting in serious
damage (high-tension voltage - potential for FATAL ACCIDENTS).
CAUTION:
First allow the bulb to cool down (may cause burns).
CAUTION:
Wear safety goggles and gloves when changing the bulb.
CAUTION:
The bulb is made of glass and contains xenon gas and metallic salts; the
bulb is under high pressure, so there is a risk of it shattering.

CAUTION:
Do NOT use any bulbs that have fallen on the ground or have scratches on
their surface, as there is a risk of them shattering.
CAUTION:
Make sure that the bulb is seated correctly in its holder in the light.
CAUTION:
If a xenon (HID) bulb ever bursts inside a closed space (e.g. workshop),
leave the area, making sure it is well ventilated, and wait for 20 minutes
before returning. This will eliminate the risk to health caused by gases.
CAUTION:
Check the light for signs of damage and make sure the seals are seated
correctly.
CAUTION:
High-tension voltage is conducted by the electrical connection between the

worklights and the ballast unit; this connection must never be broken
(high-tension voltage - potential for FATAL ACCIDENTS).
CAUTION:
Make sure that the power supply line between the worklights and ballast
unit is never twisted through more than 90° and/or bent for more than a
length of 20 mm (0.79 in.).
IMPORTANT:
Use only bulbs that are of the same type and wattage as the bulb that is
being replaced.

IMPORTANT:
Never touch the glass surface of the xenon bulb, hold it only by its base.
IMPORTANT:
Use a clean cloth and alcohol to remove any fingerprints from the glass
bulb.
IMPORTANT:
Old xenon (HID) bulbs that have been replaced must be disposed of
properly (i.e. as hazardous waste).

Replacing Xenon (HID) Worklights and Ballast Units

General information
CAUTION:
For safety reasons, never attempt to repair a xenon (HID) worklight!
CAUTION:
Before replacing a xenon (HID) worklight or its ballast unit, always make
sure that the battery is disconnected!
CAUTION:
Comply with safety instructions!
The tractor may be equipped with high-intensity discharge (HID) xenon worklights. The
identifying characteristic of these worklights is that they are elongated in comparison with
other worklights.
→NOTE:
Unlike the bulbs on H3 worklights, which fail suddenly when the filament
burns through or breaks, xenon (HID) bulbs show that they are approaching
the end of their useful life by slowly losing their brightness. The end comes
when the ballast unit ceases to ignite the xenon bulb.

Xenon (HID) worklights come in two versions:
Version 1: In this case, the ballast unit is fixed to the worklight. Replacement always involves
the ballast unit.
Version 2: In this case, the ballast unit is connected to the worklight by a plug. The worklight
and ballast unit can be replaced separately.
→NOTE:
Only complete xenon (HID) worklights including the ballast unit are
supplied as spare parts.
Removing xenon (HID) worklights

LEGEND:
A Plug
B Lead
C Grommet
D Nut and washer
E Strap
1 Green lead
2 White lead
3 Brown lead
CAUTION:
CAUTION:
CAUTION:
Before removing the outer roof, see reference ” Removing the Outer Roof ” in Section 90,
Group 25.
Pull out plug (A).
Pull out the terminal lock and extract the terminals.

Pull lead (B) through grommet (C).
Take off nuts and washers (D) and remove strap (E).
Lift off the xenon (HID) worklight as an assembly complete with its mounting.
Disassemble the mounting and replace the xenon (HID) worklight with a new one.
Plug arrangement:
Pull out the terminal lock.
Insert the green lead in chamber 1, the white lead in chamber 2 and the brown lead in
chamber 3; press them in until they engage.
Press in the terminal lock.
Removing the ballast unit
LEGEND:
A Plug
B Plug
C Rivets

AUTOPOWR/IVT TRANSMISSION (g) by Belgreen
CAUTION:
CAUTION:
CAUTION:
Before removing the outer roof, see reference ” Removing the Outer Roof ” in Section 90,
Group 25.
Disconnect plugs (A) and (B).
On the outside of the roof, drill out rivets (C).
Replace the ballast unit with a new one.


Table of contents
Group 00 - Removal and Installation of AutoPowr/IVT Transmission ............................... 1
Special Tools .......................................................................................................................... 1
Dealer-Fabricated Special Tools ............................................................................................. 2
Repair Specifications .............................................................................................................. 3
Remove the AutoPowr/IVT Transmission ................................................................................ 5
Install the AutoPowr/IVT Transmission ................................................................................. 14
Group 05 - Transmission Shift Controls ............................................................................... 22
AutoPowr/IVT Transmission Shift Units - Reconditioning (Summary of References) ............. 22
Reconditioning the Speed Control Lever .............................................................................. 23
Reverser control, reconditioning .......................................................................................... 34
Reconditioning the Clutch Actuation Mechanism ................................................................. 37
Reconditioning the Manual Park Lock Release Mechanism .................................................. 43
Releasing the Park Lock Manually ........................................................................................ 45
Group 10 - Input Housing ....................................................................................................... 49
AutoPowr/IVT Transmission Input Housing - Reconditioning (Summary of References) ....... 49
Special Tools ........................................................................................................................ 50
Specifications ....................................................................................................................... 51
Installing and Removing the Vibration Damper (Repair Level 1 and 2) ................................ 53
Removing Clutch Control Block (Repair Level 1 and 2) ........................................................ 57
Repairing Clutch Control Block (Repair Level 1 and 2) ......................................................... 59
Installing Clutch Control Block (Repair Level 1 and 2) ......................................................... 66
Installing and Removing the Transmission Oil Filter (Repair Level 1 and 2) ........................ 71
Removing the System Pressure Control Block (Repair Level 1 and 2) ................................. 73
Installing System Pressure Control Block (Repair Level 1 and 2) ......................................... 76
Replacing Thermostat Valve (Repair Level 1 and 2) ............................................................ 81
Replacing Filter By-Pass Valve (Cold-Weather Starting) (Repair Level 1 and 2) ................... 82
Removing the Transmission Oil Pump (Repair Level 1 and 2) .............................................. 83
Repairing the Transmission Oil Pump (Repair Level 1 and 2) ............................................... 85
Installing the Transmission Oil Pump (Repair Level 1 and 2) ............................................... 89
Removing and Installing Front Plate (Repair Level 1 and 2) ................................................. 93
Separating Transmission Halves, Input/Output Housing (Repair Level 2) ............................ 99
Removing BG Disk Brake (Repair Level 2) ......................................................................... 101
Installing BG Disk Brake (Repair Level 2) ........................................................................... 104
Removing Shift Turret (Repair Level 2) .............................................................................. 107
Installing Shift Turret (Repair Level 2) ............................................................................... 111
Repairing Through-Drive Shaft (Repair Level 2) ................................................................. 113
Repairing P4 Planet Pinion Carrier and C3/C4 Clutch (Repair Level 2) ............................... 118
Repairing P4/BG Ring Gear (Repair Level 2) ...................................................................... 124
Removing Hydrostatic Unit (Repair Level 2) ...................................................................... 129
Installing Hydrostatic Unit (Repair Level 2) ........................................................................ 133
Repairing Hydrostatic Unit Output Shaft (Repair Level 2) .................................................. 139
Preparations for Installation of Individual Components in Input Housing (Repair Level 2)
..................................................................................................................................... 146
Measuring Gaps Between Transmission Shafts in Input/Output Housing (Repair Level 2)
..................................................................................................................................... 149
Joining Transmission Halves, Input/Output Housing (Repair Level 2) ................................. 155

Layout and Location of the Individual Transmission Sending Units .................................... 157
Replacing Pressure Sending Units B87, S73, S74 of System Pressure Control Block (Repair
Level 1 and 2) ............................................................................................................. 159
Replace Hydrostatic Unit Speed Sending Unit (B62) (Repair Level 1 and 2) ...................... 161
Group 15 - Output Housing .................................................................................................. 162
AutoPowr/IVT Transmission Output Housing - Reconditioning (Summary of References)
..................................................................................................................................... 162
Special Tools ...................................................................................................................... 163
Specifications ..................................................................................................................... 165
Removing Park Lock Control Block (Repair Level 1 and 2) ................................................. 167
Repairing Park Lock Control Block (Repair Level 1 and 2) .................................................. 169
Installing Park Lock Control Block (Repair Level 1 and 2) .................................................. 188
Repairing Locking Pawl of Park Lock (Repair Level 1 and 2) .............................................. 190
Removing Direction Turret and Reverse Intermediate Shaft (Repair Level 2) .................... 195
Removing Hydrostatic Unit Drive Shaft (Repair Level 2) .................................................... 200
Removing Through-Drive Shaft (Repair Level 2) ................................................................ 203
Removing Pneumatic Pump and Idler Gear (Repair Level 2) .............................................. 206
Installing Pneumatic Pump and Idler Gear (Repair Level 2) ............................................... 213
Installing Hydrostatic Unit Drive Shaft (Repair Level 2) ..................................................... 226
Installing Through-Drive Shaft (Repair Level 2) ................................................................. 230
Installing Direction Turret and Reverse Intermediate Shaft (Repair Level 2) ..................... 235
Layout and Location of the Individual Transmission Sending Units .................................... 241
Replacing Transmission Speed Sending Unit (B63) (Repair Level 1 and 2) ........................ 243
Replacing Transmission Input Speed Sending Unit (B61) (Repair Level 1 and 2) ............... 244
Replace the Transmission Output Speed Sending Unit (B84) (Repair Level 1 and 2) ......... 244
Replace Pressure Sending Unit (B90) for Park Lock Control Block (Repair Level 1 and 2)
..................................................................................................................................... 245
Group 20 - Differential Drive Shaft Assembly ................................................................... 247
AutoPowr/IVT Transmission - Differential Drive Shaft, Summary of References ................. 247
Specifications ..................................................................................................................... 247
Sectional View of Differential Drive Shaft .......................................................................... 247
Removing the Differential Drive Shaft ................................................................................ 249
Disassemble Differential Drive Shaft .................................................................................. 250
Cone Point Adjustment ....................................................................................................... 253
Assembling the Differential Drive Shaft ............................................................................. 256

Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Group 00 - Removal and Installation of

AutoPowr/IVT Transmission
Special Tools
→NOTE:

Catalog or in the European Microfiche Tool Catalog (MTC).
Lifting eye
JDG19
Installing and removing tractor components
Load-positioning sling
D01042AA
[ This tool permits the adjustment of the angle of the load being handled. ]

Transmission
Dealer-Fabricated Special Tools

Unlocking Device
dealer fabricated
LEGEND:
A Threaded rod M6, 170 mm (6.7 in.)
B Nut M6 (14M7272)
C Washer 20 mm x 2.5 mm (3/4” x 0.1 in.)
D Nut M6 (14M7272)
E Yoke (L80051)
F Pin (AL79051)
For unlocking the park lock.
Suspension Device
dealer fabricated

Transmission
LEGEND:
A 145 mm (5.7 in.)
B 15 mm (0.6 in.)
C 15 mm (0.6 in.)
D Bore, 13 mm (1/2”)
E Bore, 11 mm (7/16”)
F 90 mm (3.54 in.)
G 15 mm (0.6 in.)
H 15 mm (0.6 in.)
I Bore, 11 mm (7/16”)
For suspending the AutoPowr/IVT transmission horizontally.As feedstock, use equal angle
steel 35 x 35 x 5 mm (1.4 x 1.4 x 0.2 in.) in accordance with DIN EN 10 025 (or
similar norms).
Repair Specifications
Cap Screws, AutoPowr/IVT Transmission to Differential Housing Torque 135 N˙m
(100 lb.-ft.)
Attaching Screws, Suction Line to Input Housing Torque 18 N˙m
(13.5 lb.-ft.)

Transmission
Cap Screws, Front Cab Mountings to Main Frame Torque 240 N˙m
175 lb.-ft.

Transmission
Remove the AutoPowr/IVT Transmission

[1] - Tilt the cab up. See Tilting the Operator′s Cab Upward in Section 90, Group 00.
[2] - Remove the front-wheel drive clutch. See Remove the Front-Wheel Drive Clutch in
[3] -
LEGEND:
A Drain Plug, AutoPowr/IVT Transmission
B Drain Plug, Differential Housing
Remove plugs (A) and (B) and drain transmission/hydraulic oil.
[4] - Remove the transmission oil filter(s) and hydraulic oil filter(s).
[5] -
Disconnect oil cooler hoses (B) where they join the transmission. Trap the oil as it emerges.
Remove u.j. shaft and ring-shaped cooler (A). See Removing and Installing the Ring-Shaped
Cooler in Section 56, Group 05.

Transmission
[6] -
Loosen the plastic ties at the fuel tank, push the tank outward and remove the mounting
screws (A) of the front left cab mounting. Remove cab mounting.
CAUTION:
Depending on the amount of fuel in the tank, it can weigh up to approx.
200 kg (440 lb). Therefore proceed with due care and if in doubt, support
the fuel tank to prevent it from falling.
[7] -
Remove suction line (A) and detach fittings (B) from the input housing.
→NOTE:
Trap the oil as it emerges.

Transmission
[8] -
Disconnect fittings (A), (B) and (C).

[9] -
Mark all the connectors so that they can be reinstalled in the same position, and completely
detach the transmission harness from the input housing. Disconnect connectors (A), (B; 3
used), (C), (D) and (E).
→NOTE:
Some of the connectors are not visible in this illustration. Always mark all
of the connectors to facilitate their re-installation, then disconnect them
from the output housing.

Transmission
Pull hose (F) off the hose fitting. Seal the end of the hose and the hose fitting, so that no dust
can penetrate.
[10] -
Disengage the bowden cable for park lock disengagement both at yoke (A) and at counter-
bracket (B).
In place of the bowden cable, install unlocking device (C; dealer-fabricated) as shown
anddisengage the park lock. Do this by tightening the hex. nut on the device until the lever
reaches the position (2) shown in the illustration.
Disengage the park lock

LEGEND:
A Yoke
B Counter-Bracket
C Special Tool (Dealer-Fabricated)
1 Park Lock Engaged
2 Park Lock Disengaged
Unlocking Device
dealer fabricated

Transmission
LEGEND:
B Nut M6 (14M7272)
D Nut M6 (14M7272)
E Yoke (L80051)
F Pin (AL79051)
CAUTION:
The disengaging lever is subject to great tension. Improper handling may
result in personal injury.
[11] -

Transmission
LEGEND:
A Special Tool (Dealer-Fabricated)
B JDG19 Lifting Eye
C JDG19 Lifting Eye
D D01042AA Load-Positioning Sling
Screw the dealer-fabricated special tool (A) onto the output housing as shown and attach a
lifting eye (B) to it. Attach another lifting eye (C) at the input housing.
Lifting eye
JDG19

Suspension Device
dealer fabricated

Transmission
LEGEND:
A 145 mm (5.7 in.)
B 15 mm (0.6 in.)
C 15 mm (0.6 in.)
D Bore, 13 mm (1/2”)
E Bore, 11 mm (7/16”)
F 90 mm (3.54 in.)
G 15 mm (0.6 in.)
H 15 mm (0.6 in.)
I Bore, 11 mm (7/16”)
similar norms).
D01042AA

Transmission

Using load-positioning slings as a means of suspension (D), attach lifting tackle.

IMPORTANT:
When securing lifting eyes and lifting tackle, be sure to use high-grade
hardware. Select screws that are long enough to be screwed in to the
maximum depth available.
→NOTE:
The AutoPowr/IVT transmission must to be tilted as it is lifted out. It is
therefore essential to use the D01042AA load-positioning slings.
[12] -
Take out all the screws on the flange. Then use a crowbar at the locations provided to lever
the AutoPowr/IVT transmission off.
→NOTE:
Due to the use of flexible sealant, the housing flanges adhere to each other
strongly.

Transmission
Move the AutoPowr/IVT transmission as far forward as possible (viewed in direction of travel).
[13] -
Using the D01042AA load-positioning sling (A), move the AutoPowr/IVT transmission to the
position shown and at the same time lift it up and out.
→NOTE:
As you raise the AutoPowr/IVT transmission, tilt it gradually.
[14] - Put the AutoPowr/IVT transmission down and seal all the openings so that no dust can
get in.

Transmission
Install the AutoPowr/IVT Transmission

[1] - Clean the housing flanges thoroughly and coat one side with a thin layer of LOCTITE ™
574 (64500) flexible sealant.
[2] - Install special tool (C; dealer-fabricated) anddisengage the park lock. Do this by
tightening the hex. nut on the device until the lever reaches the position shown in the
illustration (2).
Disengage the park lock

LEGEND:
C Special Tool (Dealer-Fabricated)
1 Park Lock Engaged
2 Park Lock Disengaged
Unlocking Device
dealer fabricated
LEGEND:
B Nut M6 (14M7272)

Transmission
D Nut M6 (14M7272)
E Yoke (L80051)
F Pin (AL79051)
CAUTION:
[3] -
Install shaft (A).

[4] -

Transmission
LEGEND:
A Special Tool (Dealer-Fabricated)
B JDG19 Lifting Eye
C JDG19 Lifting Eye
D D01042AA Load-Positioning Sling
Screw the dealer-fabricated special tool (A) onto the output housing as shown and attach a
lifting eye (C) to it. Attach another lifting eye (B) at the input housing. Use load-positioning
sling (D) to suspend the AutoPowr/IVT transmission at an angle (i.e. tilted), as shown.
Lifting eye
JDG19

Suspension Device
dealer fabricated

Transmission
For suspending the AutoPowr/IVT transmission horizontally.

[ This bracket is bolted to the output housing. A JDG19 suspension eye is secured to the hole marked (D). ]
D01042AA


Transmission
IMPORTANT:
→NOTE:
As you lower the transmission, gradually align the input housing until it is
horizontal in relation to the differential housing.
[5] -
When the AutoPowr/IVT transmission is in the position shown, the input flange of the
transmission must be turned until you feel the teeth engage. Then place the AutoPowr/IVT
transmission against the differential housing so that proper contact is achieved, and install
the attaching screws.
[6] -
Tighten all attaching screws to the specified torque.

Cap Screws, Output Housing to Differential Housing Torque 135 N˙m
(100 lb.-ft.)

Transmission
→NOTE:
Some of the attaching screws are hard to reach. In this case, use a
suitable, commercially-available tool.
[7] -
Engage the park lock, remove unlocking device (A) and install the bowden cable.
CAUTION:
[8] - For further installation, follow removal procedure in reverse order.

Transmission
[9] -
For information on installing the ring-shaped cooler and u.j. shaft (A), see Removing and
Installing the Ring-Shaped Cooler in Section 56, Group 05.
Connect the oil hoses (B).
IMPORTANT:
Every time you disconnect an oil hose with a quick-coupler, replace the
retaining clip with a new one. Once clips are installed, check that they are
seated correctly. The bent ends of the clip must touch each other.
Otherwise, the coupler can become loose.
[10] - Connect transmission harness (B) at all its connecting points, and lay out the harness.
IMPORTANT:
Pay attention to the following points when laying out harnesses and hoses:
Before installing, inspect for damage and replace if necessary

Do not subject them to tension, crushing or bending forces
Do not install them in the vicinity of moving parts
Keep them away from sharp edges

Section 53 - AUTOPOWR/IVT TRANSMISSION Group 05: Transmission Shift Controls
[11] -
Check the seals, install suction line (A) and tighten the attaching screws to the specified
torque.
Attaching Screws, Suction Line to Input Housing Torque 18 N˙m
(13.5 lb.-ft.)
Connect lines (B).

[12] - Install front-wheel drive clutch. See Install the Front-Wheel Drive Clutch in Section 56,
Group 00.
[13] - Top up with transmission/hydraulic oil.
[14] -
Install cab mounting and tighten cap screws (A) to the specified torque.
Cap Screws, Front Cab Mountings to Main Frame Torque 240 N˙m
175 lb.-ft.
[15] - Install fuel tank.

[16] - Tilt operator′s cab back down. See Tilting the Operator′s Cab Downward in Section 90,
Group 00.


AutoPowr/IVT Transmission Shift Units -
Reconditioning (Summary of References)
”Reconditioning the speed control lever”
”Reconditioning the reverser control”
”Reconditioning the clutch actuation mechanism”
”Reconditioning the manual park lock release mechanism”
”Releasing the park lock manually”

Reconditioning the Speed Control Lever
CAUTION:
When performing the work described below, comply with the safety
instructions in the relevant Technical Manuals.
CAUTION:
Components that are coated with locking paint must NOT be opened,
adjusted or repaired. These components may only be replaced as complete
assemblies.
IMPORTANT:
DISCONNECT ELECTRICAL CIRCUIT

Before working on the electrical system, always disconnect battery ground
cable (-).
Removing and installing the grip on the speed control lever

[1] -
Take out the attaching screw (A) and lift off half (B) of the grip.
[2] -
Using a screwdriver, carefully pry out cover (A) together with its bearing (see exploded view).
[3] -
Take out support (A).

→NOTE:
Hold the potentiometer still while you unscrew the support.
[4] - Remove speed wheel (B).

[5] -
Disconnect plug (A), which connects potentiometer (B).

[6] -
Remove attaching screws (A).

[7] - Remove half (B) of the grip from the speed control lever.
[8] -
Remove the lower halves (A) of the grip.

[9] - Recondition the speed control lever as required.
Assembly: Re-assemble the parts in reverse order, referring to the exploded view (drawing).
IMPORTANT:
When installing the potentiometer on the rear threads (see arrow), apply a
little LOCTITE ™ 241 in order to secure support (C) (see exploded view).
Hold the potentiometer still while you tighten support (C).

Support Torque 1.2 N˙m
0.89 lb-ft
Exploded view showing the grip on the speed control lever

LEGEND:
A Cover
B Bearing
C Support
D Speed wheel
E Left half of grip
F Potentiometer
G Right half of grip
H Bottom left half of grip
K Bottom right half of grip
Removing and installing the operation unit

[1] -
Take out attaching screws (A).

[2] - Remove operation unit (B) together with its cover.
[3] - Disconnect the operation unit from its electrical connectors.
→NOTE:
Before pulling out the connectors, mark them so as to avoid installing them
in the wrong positions.
[4] -
Remove strap (A).

[5] - Remove attaching screws (B).

[6] - Pull out connector (C).
[7] - Take the operation unit out of its cover.
Removing and installing the operation unit (tractors with Command

Arm)
[1] -

[2] -
On the underside, take out attaching screws (A).

[3] -
Disconnect the operation unit (A) from its electrical connectors.

→NOTE:
[4] -

[5] - Take the operation unit out of its cover.
Replacing the potentiometer and switchboard
[1] -
Take off cable binders (A).

[2] - Take out attaching screws (B) and disconnect plug (C).
[3] - Take off the wiring harness together with the switchboard.
[4] -
Remove retaining nuts (A).

[5] - Carefully pull potentiometer (B) out of toothed segment (C).

→NOTE:
While doing so, make sure that spring (D) does not fall out.
[6] -
Assembly: Re-assemble the parts in reverse order, referring to the exploded view (drawing).
IMPORTANT:
When installing the potentiometer, make sure that the toothed segment is
inserted as shown, with the broad tooth (A) in the corresponding gap.
Also, remember to check that spring (B) is installed in the correct position.
The toothed segment must be free to move within the backlash range; it
must be returned by the force of the spring.
Exploded view of operation unit

LEGEND:
A Right half of grip
B Grip assembly
C Gate (with Command Arm)
D Gate
E Strap
F Potentiometer
G Wiring harness assembly and switchboard
H Operation unit
I Spring
J Toothed segment

Reverser control, reconditioning
CAUTION:
CAUTION:
assemblies.
IMPORTANT:

cable (-).

[1] -
Remove steering wheel (A).

[2] - Remove multi-function unit (B).
[3] -

[4] - Fold back trim panel (A).

[5] -

[6] -
Remove the reverse drive lever (A) from the multi-function unit.
→NOTE:
Do not remove any more parts from reverse drive lever. The reverse drive
lever can only be replaced as an assembly (order through normal parts
channels).
Install new reverse drive lever, reversing removal procedure.

Reconditioning the Clutch Actuation Mechanism
CAUTION:
CAUTION:
assemblies.
IMPORTANT:

cable (-).
Replacing the potentiometer

[1] -
Fold back the cup holder (A).

[2] - Use a Phillips-head screwdriver to take out retaining screws (B), and lift off trim (C).
[3] -
Disengage ball joint (A) at the potentiometer.

[4] -

[5] - Pull off connector (B) and take off the potentiometer.
Assembly: Re-install the parts in reverse order, referring to the exploded view (drawing).

Reconditioning the clutch pedal
[1] -

[2] - Take off hex. nut (B).
→NOTE:
Proceed with care, as the components are subject to preload.
[3] - Take out retaining screw (C) and lift out the clutch pedal.
[4] -
Take belleville spring (A), back-up ring (B) and friction washer (C) off the bearing journal (D).

[5] - Recondition the clutch actuation as required.
[6] - Locate the clutch pedal on adapter (A) and tighten hex. nut (B) by hand.
[7] - Now install the clutch pedal on the bearing journal of the console.
[8] - Tighten retaining screw (C) just enough for the pedal to touch console but remain free
of play. Now tighten the attaching screw to its final torque value.
Self-locking retaining screw, clutch pedal to console Torque 10 N˙m
7 lb-ft
IMPORTANT:
The clutch pedal′s retaining screw has a self-locking capability; for this
reason, every time it is removed, it must be replaced with a new one.
[9] -
Adjust the preload at spring (A).

Screw in hex. nut (B) until dimension (C) is 7.5 mm (0.3 in.).
Exploded view of clutch actuation mechanism

LEGEND:
A Console
B Belleville spring
C Back-up ring
D Friction washer
E Hex. nut
F Bearing
G Ball socket
H Clutch pedal
I Bushing
J Washer
K Self-locking fillister screw
L Stop
M Potentiometer (B65)
N Cover
O Ball end
P Ball joint assembly

Q Leaf spring
R Adapter
S Spring
T Adapter
U Retaining screw
V Wiring harness, with clutch pedal switch (S72)

Reconditioning the Manual Park Lock Release

Mechanism
[1] -

[3] -
Referring to the drawing that shows the exploded view, remove and install the park lock
release bowden cable (A).
IMPORTANT:
When removing and installing the bowden cable, take care not to bend it.
When routing the bowden cable, take care that it does not chafe and is not
subjected to tension.
Exploded view of manual park lock release mechanism

LEGEND:
A Threaded pin
B Knurled nut
C Bowden cable
D Clamp
E Plug
F Clamp
G Spring clip
H Pin

Releasing the Park Lock Manually
CAUTION:
Perform the manual park lock release procedure only when the tractor
needs to be towed and the park lock cannot be released normally.
CAUTION:
The reverse drive lever must be in the "Park" position in order to manually
release the park lock.
CAUTION:
The tractor must never be operated (even for short test drives) when the
park lock is manually released.
CAUTION:
The tractor can roll away when the park lock is disengaged. Secure the
tractor so that it cannot roll either forwards or backwards.
CAUTION:
After towing, the manual park lock release cable must be reconnected.

[1] -

[3] -
Take plug (A) out of the threaded bore.

[4] -
Disconnect bowden cable (A) from the clamp.

[5] -
Unscrew threaded stud (A) and knurled nut (B).

[6] -
Slightly depress the clutch pedal.

[7] - Thread the bowden cable (A) through the eye (B) on the clutch pedal or adapter.

Section 53 - AUTOPOWR/IVT TRANSMISSION Group 10: Input Housing
[8] -
Adjust the cable with knurled nut (A) until all slack is removed. Knurled section must be
uppermost.
IMPORTANT:
The cable must be tight in order to assure complete release of the park
lock.
[9] -
Fully depress clutch pedal.

IMPORTANT:
If the clutch pedal cannot be depressed to the stop and the threaded stud
cannot be adjusted further, unscrew the knurled nut until the clutch pedal
can be depressed against its stop.
[10] - Screw threaded stud (A) into opening (B) in order to secure the clutch in this position
and maintain the park lock in the released position.

Group 10 - Input Housing

AutoPowr/IVT Transmission Input Housing -
”Special tools”
”Installing and removing the vibration damper”
”Removing the clutch control block”
”Reconditioning the clutch control block”
”Installing the clutch control block”
”Removing and installing the transmission oil filter”
”Removing the system pressure control block”
”Installing the system pressure control block”
”Replacing the thermostat valve”
”Replacing the filter by-pass valve (cold-weather starting)”
”Removing the transmission oil pump”
”Reconditioning the transmission oil pump”
”Installing the transmission oil pump”
”Removing and installing the front plate”
”Removing the BG disk brake”
”Installing the BG disk brake”
”Removing the shift turret”
”Installing the shift turret”
”Reconditioning the through-drive shaft”
”Reconditioning the P4 planetary carrier and C3/C4 clutch”
”Reconditioning the ring gear (P4/BG)”

”Removing the hydrostatic unit”
”Installing the hydrostatic unit”
”Reconditioning the hydrostatic unit output shaft”
”Preparations for installation of individual components in input housing”
”Measuring gaps between transmission shafts in input/output housing”
”Separating transmission halves, input/output housing”
”Joining transmission halves, input/output housing”
”Layout/location of individual transmission sending units”
”Replacing pressure sending units (B87, S73, S74) of system pressure control block”
”Replacing the hydrostatic speed sending unit (B62)”
Special Tools
→NOTE:

Seal installer
KJD10235
Installation of transmission oil pump seal (repair level 1 and 2)

Specifications
Fitting, vibration damper Torque 80 N˙m
59 lb-ft
Solenoid valves to control block, attaching screws Torque 6 N˙m
4 lb-ft
Proportional valves to control block, attaching screws Torque 6 N˙m
4 lb-ft
Passage plate to control block, attaching screws Torque 10 N˙m
7 lb-ft
Clutch control block to input housing, attaching screws Torque 10 N˙m
7 lb-ft
Screw plug on cover, clutch control block Torque 25 N˙m
18 lb-ft
Clutch control block cover to housing, attaching screws Torque 10 N˙m
7 lb-ft
Thermostat valve, M36 x 1.5 screw plug Torque 130 N˙m
95 lb-ft
Filter by-pass valve (cold-weather starting), M22 x 1.5 screw plug Torque 30 N˙m
22 lb-ft
Filter housing to system pressure control block Torque 50-60 N˙m
37-44 lb-ft
System pressure control block, screws for filter plate on valve plate Torque 6 N˙m
4 lb-ft
System pressure control block to transmission housing, attaching screws Torque 10 N˙m
7 lb-ft
Pressure sending unit on filter housing Torque 12 N˙m
9 lb-ft
Cable holder to filter housing, attaching screw Torque 9 N˙m
7 lb-ft
Transmission oil pump attaching screws Torque 23 N˙m
17 lb-ft
Front plate, M14x1.5 screw plug Torque 35 N˙m
26 lb-ft
37 lb-ft
40 lb-ft
Front plate attaching screws Torque 23 N˙m

17 lb-ft
Front plate, fitting Torque 80 N˙m
59 lb-ft
BG disk brake, attaching screws Torque 115 N˙m
85 lb-ft
Cable holder, attaching screws Torque 10 N˙m
7 lb-ft
Hydrostatic unit, end play End play 0.2 — 0.5 mm
0.008 — 0.020 in.
Pressure hose to fitting Torque 40 N˙m
30 lb-ft
Pressure hose to hydrostatic unit, hollow screw Torque 50 N˙m
37 lb-ft
Hydrostatic unit, attaching cap screws Torque 115 N˙m
85 lb-ft
Pressure hose to elbow Torque 80 N˙m
59 lb-ft
Transmission housing, M14x1.5 screw plugs Torque 35 N˙m
26 lb-ft
Transmission housing, M38x2 screw plugs Torque 140 N˙m
103 lb-ft
Elbow, hex. nut Torque 80 N˙m
59 lb-ft
Hydrostatic unit pressure hose, fitting Torque 50 N˙m
37 lb-ft
End play between shift turret and direction turret End play 0,20 — 0,40 mm
0.008 — 0.016 in.
Direction turret taper roller bearing End play 0 — 0,08 mm
0 — 0.003 in.
Output to input housing, attaching screws Torque 46 N˙m
34 lb-ft
Hydrostatic speed sending unit Torque 10 N˙m
7 lb-ft

Installing and Removing the Vibration Damper

(Repair Level 1 and 2)
Vibration damper removal
[1] -
Loosen fittings (A) and remove vibration damper (B).

[2] -
Remove the line.

[3] -
Remove the fitting.

[4] -
Remove the line.

[5] -
Remove fitting with filter.
Vibration damper installation

[1] - Install O-rings (A) and (B) at the fittings.
Fitting with filter
Fitting
[2] -
Install fitting with filter (A) onshorter end of vibration damper.

[3] - Install fitting (B).

Tighten the fittings (A) and (B).
59 lb-ft
[4] - Install lines at vibration damper but do not tighten connections yet.
[5] -
Install vibration damper (B) with lines on transmission and align

[6] - Tighten the fittings (A).
59 lb-ft

Removing Clutch Control Block (Repair Level 1 and

2)
Preliminary work:
For information on removing the left half of the main frame, refer to “Removing and installing
the main frame (summary of references)” .
[1] - Remove screw plug (A) from the underside of the cover and drain oil.
[2] - Take attaching screws (B) out of the cover. Remove cover and gasket.
[3] -
Disconnect harness from solenoid and proportional valves.

[4] - Pull temperature sending unit (A) out of the bore.

[5] -
Take the attaching screws out of the control block. While doing this, make sure not to drop
the control block.
[6] -
Remove control block and gasket

Repairing Clutch Control Block (Repair Level 1 and

2)
Preliminary work:
Refer to “Removing the clutch control block” .
Clutch control block - Sectional view
LEGEND:
A Solenoid valve, BG disk brake
B Solenoid valve, C1 clutch
C Solenoid valve, C2 clutch

D Solenoid valve, C4 clutch

E Solenoid valve, C3 clutch
F CF proportional valve
G Damper piston CF
H Damper piston CR
I CR proportional valve
J Pressure reduction valve
Disassembly of clutch control block
[1] -
Take attaching screws (A) out of the passage plate. Remove passage plate and gasket.
[2] -
If required, remove both screens (see arrows) from the passage plate.

[3] -
Remove attaching screws (A) and retaining plates (B) of proportional valves.
[4] - Pull both proportional valves out of bore.
[5] -
Remove attaching screws and retaining plates. Remove the solenoid valves.
→NOTE:
The solenoid valves are subject to great tension.
→NOTE:
Do not remove any more parts from clutch control block.
The clutch control block can be ordered as an assembly through normal
parts channels.
Clutch control block assembly

[1] -
Before re-installing proportional and solenoid valves check O-rings (A), and replace them as
necessary.
[2] -
Install solenoid valves using retaining plates and screws.

→NOTE:
Insert retaining plates with the claw facing the housing.
→NOTE:
Align solenoid valves before tightening, using the drawing as a guide.
Solenoid valves to control block, attaching screws Torque 6 N˙m
4 lb-ft

[3] -
Install proportional valves using retaining plates and screws.

→NOTE:
Insert retaining plates with the claw facing the housing.
→NOTE:
Align proportional valves before tightening, using the drawing as a guide.
Proportional valves to control block, attaching screws Torque 6 N˙m
4 lb-ft
[4] -
Align solenoid and proportional valves as shown on drawing and tighten them.

[5] -
Place gasket on control block.

→NOTE:
For easier installation use two attaching screws (see arrows).
[6] -
Insert both screens (A) in passage plate.

IMPORTANT:
The convex side of the screens must face downward.

[7] -
Place passage plate on control block.

[8] -
Insert attaching screws (A) and tighten them.

Passage plate to control block, attaching screws Torque 10 N˙m
7 lb-ft
Final assembly:
Refer to “Installing the clutch control block” .

Installing Clutch Control Block (Repair Level 1 and

2)
[1] -
Install control block with gasket (A).

[2] -
Slightly tighten attaching screws.

→NOTE:
During installation, note the different screw lengths.

[3] -
For the time being, tighten attaching screws to 7 N˙m (5 lb-ft) in ascending order of the
position numbers indicated in the drawing.
[4] - Tighten attaching screws now to their final torque in ascending order of the position
numbers indicated in the drawing.
Clutch control block to input housing, attaching screws Torque 10 N˙m
7 lb-ft

[5] -
Put harness in place and connect to solenoid and proportional valves.

[6] -
The mounting depth of temperature sending unit is limited by a cable binder.

Mounting depth is 20 mm (0.78 in.); it must be checked before installation.
[7] -
Insert temperature sending unit (A) into the bore.

[8] -
Install screw plug with O-ring on cover and tighten.

Screw plug on cover, clutch control block Torque 25 N˙m
18 lb-ft
[9] -
Install the gasket.

[10] -
Install cover.
IMPORTANT:
During installation take care that the gasket remains in place and the
harness is not trapped.
[11] -
Install attaching screws and tighten them evenly.

Clutch control block cover to housing, attaching screws Torque 10 N˙m
7 lb-ft
Final assembly:
For information on installing the left half of the main frame, refer to “Removing and installing
the main frame (summary of references)” .

Installing and Removing the Transmission Oil Filter

Removing the transmission oil filter
[1] -
Remove filter housing (A).

[2] -
Take the filter element out of the filter housing.

[3] - Remove O-ring (A).
Installing the transmission oil filter

[1] -
Check O-ring (A) and filter element. Replace, if necessary.

[2] - Install O-ring (B) in the groove in the filter housing.
[3] -
Attach filter housing (A) with element and tighten.

Filter housing to system pressure control block Torque 50—60 N˙m
37—44 lb-ft

Removing the System Pressure Control Block

Preliminary work:
Refer to "Remove engine u.j. shaft" .
Refer to “Removing and installing the transmission oil filter” .
[1] -
Remove the cable holder.

[2] -
LEGEND:
A Sending unit, cold-weather starting valve (B87):
B Sending unit, oil filter restriction indicator light (S73)
C Sending unit, system pressure indicator light (S74)
Remove sending units (A), (B) and (C).

[3] -
Take the attaching screws out of the control block.

[4] -
Lift off filter plate and gasket.

[5] -
Remove valve plate and gasket.

→NOTE:
Only the cold-weather starting valve may be replaced on the system
pressure control block. Refer to"Replacing filter by-pass valve (cold-
weather starting)". Do not remove any more parts.
→NOTE:
The valve plate can be ordered as an assembly through normal parts
channels.
Final assembly:
Refer to “Installing the system pressure control block” .

Installing System Pressure Control Block (Repair

Level 1 and 2)
[1] -
LEGEND:
A Gasket
B Valve plate
C Gasket
D Filter plate
Assemble system pressure control block using two attaching screws (see illustration).
→NOTE:
If transmission is removed, use two opposite attaching screws. If
transmission is not removed, use the two long upper attaching screws.

[2] -
Install the system pressure control block.

[3] -
Insert attaching screws.

[4] - For the time being, tighten attaching screws to 7 N˙m (5 lb-ft) in ascending order of
position numbers indicated in the drawing.
[5] -

Tighten attaching screws now to their final torque in ascending order of the position numbers
indicated in the drawing.
System pressure control block to transmission housing, attaching screws Torque 10 N˙m
7 lb-ft

[6] -
Check the O-ring (A) at the pressure sending unit and replace if necessary.
[7] -
LEGEND:
A Sending unit for filter by-pass valve (B87; cold-weather starting)
Secure pressure sending units (A), (B) and (C).
Pressure sending unit on filter housing Torque 12 N˙m
9 lb-ft

[8] -
Secure cable from sending unit for system pressure indicator light using the cable holder.
7 lb-ft
[9] -
Tie the sending unit cables together as illustrated by using cable straps.
Final assembly:
Reference ”Removing and installing the transmission oil filter” .
Reference "Install engine u.j. shaft" .

Replacing Thermostat Valve (Repair Level 1 and 2)

[1] -
Take out screw plug (A).

[2] -
Thermostat valve - exploded view

LEGEND:
A Spring
B Thermal element
C Disk
D O-ring
E Screw plug
Disassemble thermostat valve.
[3] - After installation of new valve tighten screw plug to the specified torque.
Thermostat valve, M36 x 1.5 screw plug Torque 130 N˙m
95 lb-ft

Replacing Filter By-Pass Valve (Cold-Weather

Starting) (Repair Level 1 and 2)
[1] -

[2] -
Filter by-pass valve (cold-weather starting) - exploded view

LEGEND:
A Thermal element
B Piston
C Spring
D O-ring
E Screw plug
Disassemble filter by-pass valve (cold-weather starting).
[3] - After installation of new valve tighten screw plug to the specified torque.
Filter by-pass valve (cold-weather starting), M22 x 1.5 screw plug Torque 30 N˙m
22 lb-ft

Removing the Transmission Oil Pump (Repair Level

1 and 2)
Preliminary work:
Refer to "Remove engine u.j. shaft" .
[1] -
Remove shaft seal ring from housing.

→NOTE:
Removal always damages the seal ring.
[2] -
Remove the snap ring.

[3] -
Take out the attaching screws.

[4] -
Use two M6 screws (A) to press off the transmission oil pump′s housing and then remove it.

Repairing the Transmission Oil Pump (Repair Level

1 and 2)
Preliminary work:
Refer to “Removing the transmission oil pump” .
Disassembling the transmission oil pump
[1] -
Remove O-ring (A).

[2] -
Remove pump gear (C) and toothed ring (B) from housing (A).

[3] -

[4] -
Remove the ball bearing.
Assembling the transmission oil pump
[1] -
Install the ball bearing.

[2] -
Install the snap ring.

[3] -
Install the toothed ring with chamfer (see arrow) facing downward.
[4] -
Install the pump gear with chamfer (see arrow) facing downward.

[5] -
Install O-ring (A).
Final assembly:
Refer to “Installing the transmission oil pump” .

Installing the Transmission Oil Pump (Repair Level 1

and 2)
[1] -
Heat up bearing cone of ball bearing.

[2] -
Move the transmission oil pump to correct position at the front plate until it stops.

[3] -
Tighten the attaching screws on the transmission oil pump.

Transmission oil pump attaching screws Torque 23 N˙m
17 lb-ft

[4] -
→NOTE:
If the snap ring does not engage, the through-drive shaft has to be pulled
out until it can go no further.
→NOTE:
Before attaching extracting tool remove O-ring from through-drive shaft to
avoid damage.

[5] -
Install seal ring with LOCTITE ™ 242 (TY9370).

Seal installer
KJD10235
Installation of transmission oil pump seal.

[6] - Use KJD10235 seal installer (A) to install the seal ring.
→NOTE:
Insert seal ring flush with base of the chamfer. Do not insert seal ring up to
stop.
Final assembly:
Refer to "Install engine u.j. shaft" .

Removing and Installing Front Plate (Repair Level 1

and 2)
Preliminary work:
Refer to “Removing the system pressure control block” .
Refer to “Removing the transmission oil pump” .
Removing the front plate
[1] -
Remove threaded connector, if necessary.

[2] -
Take the retaining screws out of the front plate.
CAUTION:
Secure the front plate so that it does not fall off (see next step).

[3] -
Detach the front plate from the housing.
CAUTION:
During disassembly, secure the front plate with two M8 threaded rods (A)
so that it does not fall off.
[4] -
Remove front plate.

[5] -
Remove gasket.
Installing the front plate
[1] -
Insert dowel pins (A) into housing as far as they will go.
[2] -
Install gasket on housing.

[3] -
Install screw plugs in front plate and tighten them.

26 lb-ft
37 lb-ft
40 lb-ft
[4] -
Move front plate to correct position.

[5] -
Make sure front plate contacts housing and tighten attaching screws slightly.
→NOTE:
Do not tighten the attaching screws to their final torque until after the
transmission oil pump has been installed.
Front plate attaching screws Torque 23 N˙m
17 lb-ft

[6] -
Install screw union to front plate and tighten.

Front plate, fitting Torque 80 N˙m
59 lb-ft
Final assembly:
Refer to “Installing the transmission oil pump” .
Refer to “Installing the system pressure control block” .

Separating Transmission Halves, Input/Output

Housing (Repair Level 2)
Preliminary work:
Refer to “Removing the AutoPowr/IVT transmission” .
[1] -
LEGEND:
A Input housing
B Output housing
Secure transmission by attaching it to a suitable hoist and turn it by 90°.
[2] -
Secure input housing by attaching it to a suitable hoist and remove attaching screws.

[3] -
Separate transmission halves by using a pry bar.

→NOTE:
The transmission halves are held in position by two dowel pins which
cannot be removed.
[4] -
Be careful when separating the transmission halves.

→NOTE:
Push harness connector evenly in the direction indicated by the arrow to
avoid damage to it.

Removing BG Disk Brake (Repair Level 2)

Preliminary work:
See reference”Separating Transmission Halves, Input/Output Housing”.
[1] -
If necessary, remove bearing cup of double gear bearing with rollers.

→NOTE:
Make sure not to drop the rollers during disassembly.
[2] -
If necessary, remove direction turret bearing cup.

[3] -
Remove cable holder.

[4] -
Disconnect both connections to hydrostatic unit.

→NOTE:
[5] -
Remove BG disk brake attaching screws.

[6] -
Pry BG-housing from dowel pins.

[7] -
Remove BG disk brake.

→NOTE:
Do not remove any more parts from BG disk brake.
The BG disk brake can be ordered as an assembly through normal parts
channels.
Final assembly:
See reference”Installing the BG Disk Brake”.

Installing BG Disk Brake (Repair Level 2)

[1] -
Apply some petroleum jelly to O-rings (A) before inserting them into new BG disk brake.
[2] -
Place BG disk brake on shift turret.

IMPORTANT:
Make sure that all disks are properly positioned and the BG disk brake
contacts housing.

[3] -
Drive in both dowel pins until they are flush with the surface.
[4] -
Install BG disk brake attaching screws and tighten them.

BG disk brake, attaching screws Torque 115 N˙m
85 lb-ft

[5] -
Place wiring harness in cover notch and fix it by means of cable holders.

Cable holder, attaching screws Torque 10 N˙m
7 lb-ft
[6] -
Join both plug connections to hydrostatic unit.

→NOTE:
Note the marks to avoid installation in the wrong position.
→NOTE:
Make sure that the cables are not under tension.
Final assembly:
See reference”Measuring Gaps between Transmission Shafts in Input/Output Housing”.

Removing Shift Turret (Repair Level 2)

Preliminary work:
See reference”Removing BG Disk Brake”.
[1] -
Carefully lift shift turret out of the transmission housing.

[2] -
Remove shim.

[3] -
Remove ring gear (P4/BG) from P4 planetary drive.

[4] -
Remove spacer.

[5] -
Lift P4 planetary drive-C3/C4 clutch assembly out of shift turret.

[6] -
If necessary, pull through-drive shaft (A) out of shift turret.

[7] - Remove gear (B).

[8] -
If necessary, remove shift turret ball bearing.

→NOTE:
Do not remove any more parts from shift turret.
The shift turret with through-drive shaft can be ordered as an assembly
through normal parts channels.
Final assembly:
See reference”Repairing Through-Drive Shaft”.
See reference”Installing Shift Turret”.

Installing Shift Turret (Repair Level 2)

[1] -
Heat up ball bearing (A) and insert it into housing as far as it will go.
[2] -
Make sure that the five seal rings (A) are installed in the middle of the shaft.
[3] -
Carefully install shift turret making sure not to damage seal rings on shaft.

Final assembly:
See reference”Installing the BG Disk Brake”.

Repairing Through-Drive Shaft (Repair Level 2)

Preliminary work:
See reference”Removing Shift Turret”.
[1] -
Insert ball bearing into P1 planetary drive as far as it will go.

[2] -
Install gear.

[3] -
Apply some petroleum jelly to O-ring and install it in through-drive shaft ring groove (arrow).
[4] -
Install three seal rings (A) and close them.

→NOTE:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
[5] -
Support shift turret and carefully insert pre-assembled through-drive shaft.

[6] -
Turn shift turret by 180°; while doing this hold through-drive shaft and gear in position.
[7] - Check test dimension (experience has shown that this value is 38.5 mm; 1.5 in.)
between shift turret face and C1/C2 clutch cylinder face.
→NOTE:
If all components are installed correctly, test dimension is 38.5 mm (1.5
in.).
[8] -
Install three seal rings (A) and close them.

→NOTE:

[9] -
Install P4 planetary drive with C3/C4 clutch.

→NOTE:
Frequently turn P4 planetary drive with C3/C4 clutch slightly and raise it at
the same time in order to engage the disks in the splines.
[10] -
Check test dimension (experience has shown that this value is 76 mm; 3 in.) between shift
turret face and C3/C4 clutch carrier face.
→NOTE:
If installation was carried out correctly, test dimension is 76 mm (3 in.).

[11] -
Install P4/BG ring gear.

[12] -
Install five seal rings (A) and close them.

→NOTE:
Final assembly:

Repairing P4 Planet Pinion Carrier and C3/C4 Clutch

(Repair Level 2)
Preliminary work:
Removing P4 planet pinion carrier and C3/C4 clutch
[1] -
Remove shim (shift turret end play).

[2] -

[3] -
Remove spacer.
[4] -
Lift P4 planetary drive-C3/C4 clutch assembly out of shift turret.

→NOTE:
Do not remove any more parts from P4 planetary drive with C3/C4 clutch.
The P4 planetary drive with C3/C4 clutch can be ordered as an assembly
through normal parts channels.
Installing P4 planet pinion carrier and C3/C4 clutch

[1] -
Before installing the planet pinion carrier, check the three seal rings (A). Install the seal rings
and close them.
→NOTE:
[2] -
Check test dimension (experience has shown that this value is 38.5 mm; 1.5 in.) between
shift turret face and C1/C2 clutch cylinder face.
→NOTE:
If all components are installed correctly, test dimension is 38.5 mm (1.5
in.).

[3] -
Install P4 planetary drive with C3/C4 clutch.

→NOTE:
Frequently turn P4 planetary drive with C3/C4 clutch slightly and raise it at
the same time in order to engage the disks in the splines.
[4] -
Install the spacer.

[5] -
Check test dimension (experience has shown that this value is 76 mm; 3 in.) between shift
turret face and C3/C4 clutch carrier face.
→NOTE:
If installation was carried out correctly, test dimension is 76 mm (3 in.).
[6] -
Install P4/BG ring gear.

[7] -
Install shim.
Final assembly:

Repairing P4/BG Ring Gear (Repair Level 2)

Preliminary work:
Removal and disassembly of ring gear (P4/BG)
[1] -
Remove shim (shift turret end play).

[2] -

[3] -
Remove snap ring (A).

[4] -
Remove ring gear carrier (A) from ring gear.

[5] -
Remove snap ring (A) and ball bearing.
Assembly of ring gear (P4/BG)

[1] -
Install ring gear carrier in BG ring gear as shown.

[2] -

[3] -
Insert ball bearing.

[4] -

[5] -
Install the ring gear (P4/BG).

[6] -
Install shim (shift turret end play).

Final assembly:

Removing Hydrostatic Unit (Repair Level 2)

Preliminary work:
[1] -
Remove pressure hoses (A) and (B) to hydrostatic unit.

[2] -
Remove the hydrostatic unit attaching screws.

[3] -
Carefully lift hydrostatic unit out of the transmission housing.

[4] -
Remove pressure hose.

[5] -
Remove the fitting, if necessary.

[6] -
Remove hollow screw and pressure hose.

→NOTE:
Do not remove any more parts from hydrostatic unit.
The hydrostatic unit can be ordered as an assembly through normal parts
channels.
[7] -
Remove the fitting, if necessary.

[8] -
Remove elbow, if necessary.

→NOTE:
Mark radial position of elbow for re-installation.
[9] -
Remove wiring harness from housing, if necessary.
Final assembly:
See reference”Installing Hydrostatic Unit”.

Installing Hydrostatic Unit (Repair Level 2)

[1] -
Determine dimension from hydrostatic unit contact surface to flat surface of snap
ring in output shaft.
As an example, the dimension is 191.80 mm (7.551 in.).
[2] -
Determine dimension (A) from output shaft face to metal bushing of rubber
mounting.
As an example, dimension (A) is 189.20 mm (7.448 in.)
[3] - Subtract specified end play (e.g. 0.20 mm; 0.008 in.) from the difference of the two
dimensions.
The result is the thickness of the shim to be used.
Hydrostatic unit, end play End play 0.2 - 0.5 mm
0.008 - 0.020 in.

[4] - Example:
Dimension (A): 191.80 mm (7.551 in.)
Dimension (B): 189.20 mm (7.448 in.)
191.80 mm - 189.20 mm = 2.60 mm
7.551 in. - 7.448 in. = 0.102 in.
2.60 mm - 0.20 mm end play = 2.40 mm
0.102 in. - 0.008 in. = 0.094 in.
Shim thickness in the example is 2.40 mm (0.094 in.).
[5] -
Install the required shim with a thickness of 2.40 mm (0.094 in.) in the hollow output shaft.
[6] -
Install fitting for the pressure hose with O-ring to hydrostatic unit and tighten it.
37 lb-ft
[7] - Coat O-ring (A) with oil and install it in the ring-shaped groove.

[8] -
Install pressure hose in the position shown and tighten it.

30 lb-ft
[9] -
Install O-ring (A) in the ring-shaped groove.

[10] -
Install O-ring on hollow screw, and install pressure hose in the position shown to damper.
[11] - Tighten the hollow screw.
Pressure hose to hydrostatic unit, hollow screw Torque 50 N˙m
37 lb-ft
[12] -
Insert hydrostatic unit into input housing and install it on output shaft.

[13] -
Insert hydrostatic unit attaching screws and tighten them.

Hydrostatic unit, attaching cap screws Torque 115 N˙m
85 lb-ft
[14] -
Connect pressure hose (A) to housing and tighten.

30 lb-ft
[15] - Connect pressure hose (B) to housing and tighten.

Pressure hose to elbow Torque 80 N˙m
59 lb-ft
Final assembly:

If necessary, see reference”Preparations for installation of individual components in

transmission housing”.

Repairing Hydrostatic Unit Output Shaft (Repair

Level 2)
Preliminary work:
See reference”Removing Hydrostatic Unit”.
Removing hydrostatic unit output shaft
[1] -
Pull out hollow output shaft.

[2] -
Remove shim (hydrostatic unit end play) and snap ring from shaft.

[3] -
Remove snap ring.

[4] -
Remove snap ring and closure disk from the shaft.

[5] -
Remove snap ring.

[6] -
Pull the shaft out of the gear, using a suitable internal puller.
[7] -
Remove ball bearing from hollow output shaft.

[8] -
Remove gear from housing.

[9] -
Extract ball bearing by using a slide hammer.
Installing hydrostatic unit output shaft
[1] -
Insert ball bearing as far as it will go into bore.

[2] -
Press ball bearing on output shaft until it is in contact with the short collar.
[3] -
Heat up ball bearing.

[4] -
Insert gear and output shaft as far as it will go.

IMPORTANT:
Re-seat output shaft after ball bearing has cooled down.

[5] -
Install output shaft snap ring.

[6] -
Insert closure disk into hollow shaft with the curved side down and install snap ring to secure
it.

[7] -
Install snap ring (mounting for shim determining hydrostatic unit end play).
IMPORTANT:
The thickness of the shim (for hydrostatic unit end play) must be
determined. See Installing the Hydrostatic Unit.
[8] -
Install hollow output shaft.
Final assembly:
If necessary, see reference”Preparations for installation of individual components in

transmission housing”.
See reference”Installing Hydrostatic Unit”.

Preparations for Installation of Individual

Components in Input Housing (Repair Level 2)
[1] -
Install wiring harness in input housing.

Check the two O-rings (A) and make sure they are installed correctly.
[2] - Attach wiring harness using a cable strap (B).
[3] -
Remember to include the O-rings, screw in all plugs and tighten.

Transmission housing, M14x1.5 screw plugs Torque 35 N˙m
26 lb-ft
Transmission housing, M38x2 screw plugs Torque 140 N˙m
103 lb-ft

[4] -
Install O-ring (A) on elbow and insert O-rings (B) into ring grooves.
[5] -
Insert elbow and align.

→NOTE:
When aligning, note radial position or mark applied to elbow before
removal.

[6] -
Tighten the elbow fitting.

Elbow, hex. nut Torque 80 N˙m
59 lb-ft
[7] -
Install the fitting for the pressure hose with O-ring to hydrostatic unit and tighten it.
37 lb-ft

Measuring Gaps Between Transmission Shafts in

Input/Output Housing (Repair Level 2)
Adjusting end play between shift turret and direction turret
IMPORTANT:
In order to obtain a correct result of the various play adjustments, carry

out measuring procedure on transmission housing in vertical position.
Make sure that shift turret, direction turret or the transmission shafts,
bearings and components concerned are installed in centered position.
[1] -
Rotate shift turret several times in both directions to seat the parts (axial needle bearings).
Determine dimension (A) measured from (input) transmission housing flange
surface to ball bearing cone of P4 planetary drive.
As an example, dimension (A) is 13,60 mm (0.535 in.)

[2] -
Place gasket (A) on the flange surface of transmission housing (output transmission).
IMPORTANT:
Make sure that direction turret is centered and correctly positioned on the
taper roller bearing.
[3] - Measure dimension (B) from the gasket on flange surface to face of direction
turret hollow shaft.
As an example, dimension (B) is 11.40 mm (0.448 in.)
[4] - Subtract specified end play from the difference of the two dimensions. The higher range
of the end play tolerance is preferable (e.g. 0.30 mm; 0.012 in.).
End play between shift turret and direction turret End play 0.20 - 0.40 mm
0.008 - 0.016 in.
Example:
13.60 mm - 11.40 mm = 2.20 mm
0.535 in. - 0.448 in. = 0.087 in.
Difference 2.20 mm - specified end play 0.30 mm = 1.90 mm
Difference 0.087 in. - specified end play 0.012 in. = 0.075 in.

[5] -
Install a shim of the calculated thickness.

→NOTE:
Use some petroleum jelly to keep shim in position on bearing.
Adjustment of direction turret taper roller bearing
[1] -
Measure distance (A) between transmission housing (input transmission) flange

and shoulder of taper roller bearing cup seat.

[2] -
The taper roller bearing cup must be placed in exactly centered position.
Place gasket (A) on the flange surface of transmission housing (output transmission).
Measure dimension (B) from the gasket on flange surface of output transmission
to taper roller bearing cup.
Measure at various points and determine the average value.
As an example, average value of dimension (B) is 2.45 mm (0.096 in.).
IMPORTANT:
Make sure that direction turret is centered and correctly positioned on the
taper roller bearing.
[3] - Subtract specified end play from the difference of the two dimensions. The middle range
of the end play tolerance is preferable (e.g. 0.04 mm; 0.0016 in.).
Direction turret taper roller bearing End play 0 - 0.08 mm
0 - 0.003 in.
Example:
4.24 mm - 2.45 mm = 1.79 mm
0.167 in. - 0.096 in. = 0.070 in.
Difference 1.79 mm - specified end play 0.04 mm = 1.75 mm
Difference 0.070 in. - specified end play 0.0016 in. = 0.069 in.

[4] -
Install a shim of the calculated thickness.

[5] -
Install taper roller bearing cup as far as it will go.

[6] -
→NOTE:
Heat the bearing cone before installation.

Heat bearing cone of double gear bearing with rollers and install as far as it will go.
→NOTE:
Reseat bearing cone after it has cooled down.
[7] -
→NOTE:
Use some petroleum jelly to keep rollers in position and to prevent them
from falling out.
Install roller bearing of double gear as far as it will go.
Final assembly:
See reference”Joining Transmission Halves, Input/Output Housing”.

Joining Transmission Halves, Input/Output Housing

(Repair Level 2)
Preliminary work:
Refer to"Measuring gaps between transmission shafts in input/output housing".
[1] -
Using a suitable hoist, move input housing (A) to a position above output housing (B).
[2] - Make sure that gasket (C) is properly positioned.
[3] - Lower input housing until it contacts output housing.
→NOTE:
For easier installation turn the various shafts when joining the
transmission halves
→NOTE:
Be sure not to damage the wiring harness connector (D) when joining the
transmission halves.
[4] -
Evenly drive in both dowel pins.

[5] -
Install and tighten attaching screws.

Output to input housing, attaching screws Torque 46 N˙m
34 lb-ft
Final assembly:
Refer to "Installing the AutoPowr/IVT transmission" .

Layout and Location of the Individual Transmission

Sending Units
LEGEND:
1 Transmission speed sending unit (B63)
2 Transmission input speed sending unit (B61)
3 Transmission ouput speed sending unit (B84)
4 Sending unit, system pressure indicator light (S74)
5 Sending unit, oil filter restriction indicator light (S73)
6 Sending unit for filter by-pass valve (B87; cold-weather starting)
7 Hydrostatic speed sending unit (B62)
8 Pressure sending unit (B90), park lock control block
9 Wiring harness
10 Locking paint
→NOTE:
When replacing speed sending units (1) and (7), the retaining screws must
be coated with locking paint.
Pressure sending unit for park lock control block (8) is located on the side
of the transmission, inside the park lock control block.
For replacing transmission sending units refer to:
“Replacing Pressure Sending Units (B87, S73, S74 of System Pressure Control Block”
“Replace Pressure Sending Unit (B90) for Park Lock Control Block”
“Replacing the Hydrostatic Speed Sending Unit (B62)”
“Replacing Transmission Speed Sending Unit (B63)”
“Replacing Transmission Input Speed Sending Unit (B61)”
“Replacing Transmission Output Speed Sending Unit (B84)”

Replacing Pressure Sending Units B87, S73, S74 of

System Pressure Control Block (Repair Level 1 and
2)
[1] -
LEGEND:
A Sending unit for filter by-pass valve (B87; cold-weather starting)

Disconnect pressure sending unit plugs from transmission wiring harness.

→NOTE:
[2] - Remove attaching screw and cable holder.

[3] - Remove the pressure sending units.
[4] - Put an O-ring (see arrow) on each of the pressure sending units.
[5] - Install the pressure sending units.
Pressure sending unit to system pressure control block Torque 12 N˙m
9 lb-ft
[6] - Secure cable from sending unit for system pressure indicator light using the cable
holder.
7 lb-ft
[7] - Tie pressure sending unit cables together by means of cable straps.
[8] - Connect pressure sending unit plugs to transmission wiring harness.

Section 53 - AUTOPOWR/IVT TRANSMISSION Group 15: Output Housing
Replace Hydrostatic Unit Speed Sending Unit (B62)

[1] -
Apply oil to the O-ring (see arrow) and install it on the sending unit.
[2] -
Align and tighten speed sending unit at transmission housing as shown.

Hydrostatic speed sending unit Torque 10 N˙m
7 lb-ft
IMPORTANT:
After tightening the fillister-head screw, secure it with thread lock paint
(L116666). This simultaneously serves as confirmation that the speed
sending unit has been correctly installed.

Group 15 - Output Housing

AutoPowr/IVT Transmission Output Housing -
”Special tools”
”Removing the park lock control block”
”Reconditioning the park lock control block”
”Installing the park lock control block”
”Reconditioning the locking pawl of park lock”
”Removing direction turret and reverse intermediate shaft”
”Installing direction turret and reverse intermediate shaft”
”Removing the hydrostatic unit drive shaft”
”Installing the hydrostatic unit drive shaft”
”Removing the through-drive shaft”
”Installing the through-drive shaft”
”Removing the pneumatic pump and idler gear”
”Installing the pneumatic pump and idler gear”
”Layout/location of individual transmission sending units”
”Replacing transmission speed sending unit (B63)”
”Replacing transmission input speed sending unit (B61)”
”Replacing transmission output speed sending unit (B84)”
”Replacing the pressure sending unit (B90) for park lock control block”

Special Tools
→NOTE:

Installation tool
dealer-fabricated
Removing and installing the park lock control block and the check valve (repair level 1 and 2)
Tube

dealer-fabricated
Removing and installing the park lock control block cylinder and piston (repair level 1 and 2)
Lifting bail
KJD10242
Removal and installation of direction turret (repair level 2)
Adapter
[ Adapter KJD 10241 must be used on tractors up to serial no. 327230. ]
KJD10241
Removal and installation of direction turret, pulling off taper roller bearing (repair level 2)
Adapter
[ Adapter KJD 10477 must be used on tractors from serial no. 327231. ]
KJD10477
Removal and installation of direction turret, pulling off taper roller bearing (repair level 2)

Specifications
Check valve (A), park lock control block Torque 18 N˙m
13 lb-ft
Check valve (B), park lock control block Torque 15 N˙m
11 lb-ft
M40 x 2 screw plug, park lock control block Torque 70 N˙m
52 lb-ft
Check valve, park lock control block Torque 10 N˙m
7 lb-ft
M14 x 1.5 screw plug, park lock control block Torque 15 N˙m
11 lb-ft
Pressure sending unit, park lock control block Torque 10 N˙m
7 lb-ft
Attaching screws, solenoid valve Torque 10 N˙m
7 lb-ft
Test port, park lock control block Torque 15 N˙m
11 lb-ft
Attaching screws, park lock control block Torque 11 N˙m
8 lb-ft
M18 x 1.5 screw plug Torque 50 N˙m
37 lb-ft
Pneumatic pump, screw plug Torque 140 N˙m
104 lb-ft
Idler gear Rolling drag torque 0.1—0.8 N˙m
0.074—0.60 lb-ft
Transmission housing, M14x1.5 screw plug Torque 35 N˙m
26 lb-ft
Transmission housing, M10x1 screw plug Torque 25 N˙m
18 lb-ft
37 lb-ft
41 lb-ft
104 lb-ft
Threaded pins, through-drive shaft Torque 15 N˙m
11 lb-ft
Transmission speed sending unit Torque 10 N˙m

7 lb-ft
Transmission input speed sending unit Torque 30 N˙m
22 lb-ft
Transmission output speed sending unit Torque 30 N˙m
22 lb-ft

Removing Park Lock Control Block (Repair Level 1

and 2)
Preliminary work:
• Depending on how the tractor is equipped or on the amount of work, remove right main
frame half.
Refer to "Removing and Installing the Main Frame (Summary of References)" .
• Alternatively, the transmission assembly can be completely removed.
Refer to “Removing the AutoPowr/IVT transmission” .
[1] -
Remove attaching screws (A) and lift off cover (B).

[2] -
Pull out pin (A).

[3] -

[4] - Remove control block (B).

Repairing Park Lock Control Block (Repair Level 1

and 2)
Preliminary work:
Refer to “Removing the Park Lock Control Block” .
Park lock control block — Sectional view
LEGEND:
A Lever
B Lever arm
C Pressure sending unit
D Screw plug
E Check valve
F Solenoid valve
G Housing
H Screw plug
I Tappet
J Cylinder
K Piston
L Washer
M Spring
N Spring
O Rod

Disassembling the park lock control block
[1] -
Remove nuts (A).

[2] - Remove the coils from the solenoid valves.
[3] -
IMPORTANT:
If the cylinder and piston are to be removed, you MUST first take out the
check valve that lies under screw plug (A).

[4] -
Remove plate (C) and solenoid valves (B). Remove pressure sending unit (A) and connecting
fitting (D).
[5] -

[6] -
Use an installation tool (A; dealer-fabricated)
Installation tool
dealer-fabricated
Removing and installing the park lock control block and the check valve.
to remove the check valve.
→NOTE:
As soon as the check valve has been removed, the cylinder and piston can
be taken out.
[7] - If required, remove all the other check valves.

[8] -

[9] -

[10] -
Use a compression device and tube (A; dealer-fabricated) to press the cylinder downward.
Tube
dealer-fabricated
Removing and installing the park lock control block, cylinder and piston.
[11] -
While it is compressed, remove lever (B) and lever arm (C).

[12] -
Remove cylinder (B) and tappet (A).

[13] - Take the seal rings off the cylinder.
[14] -
Remove piston (A).

[15] - Take the seal rings off the piston.
[16] -
Remove rod (B) and washer (A).

[17] -
Remove springs (A) and (B) and washer (C).
Assembling the park lock control block
[1] -
Press bushing (A) into the housing until it is flush.

[2] -
Press bushing (A) in until it is flush, and install seal ring (B).

[3] -
Install check valves (A), (B) and (C).

13 lb-ft
Check valve (B), park lock control block Torque 15 N˙m
11 lb-ft
[4] -
Install check valve (A).

13 lb-ft

[5] -

13 lb-ft
[6] -
Install O-ring (A) in the cylinder.

[7] -
Carefully compress back-up ring (A), and install.

[8] -
Make sure that the seal ring is making proper contact.

[9] -
Install O-ring (A).

[10] -
Install O-ring (A) on the piston.

[11] -
Install back-up ring (A).

[12] -
Place washer (A) in the housing bore.

[13] -
Install the outer and inner springs.

[14] -
Install rod (B) and washer (A).

[15] -
Apply oil to the seal rings on piston (A).

[16] - Insert the piston.
[17] -
Apply oil to the seal rings on cylinder (B).

[18] - Install the cylinder and tappet (A).

[19] -
Turn the cylinder so that the opening in the cylinder is properly aligned with the housing.
[20] -
Use a compression device and tube (A; dealer-fabricated) to press the cylinder downward.
Tube
dealer-fabricated

[21] -
While it is compressed, install lever (B) and lever arm (C).

[22] -
Install snap ring (A) on the lever arm.

[23] -
Install screw plug (A).

M40 x 2 screw plug, park lock control block Torque 70 N˙m
52 lb-ft

[24] -

[25] -
Use an installation tool (A; dealer-fabricated) to tighten the check valve.

7 lb-ft

[26] -
Install screw plug (A).

M14 x 1.5 screw plug, park lock control block Torque 15 N˙m
11 lb-ft
[27] -
Install pressure sending unit (A) and connecting fitting (B).

7 lb-ft

[28] -
Install solenoid valves (A).

[29] - Install plate (C) by means of retaining screws (B), and tighten.
Attaching screws, solenoid valve Torque 10 N˙m
7 lb-ft
[30] -
Install coils (A) on the solenoid valves.

[31] -
Screw in test port (A) and tighten it.

Test port, park lock control block Torque 15 N˙m
11 lb-ft
Final assembly:
Refer to “Installing the park lock control block” .

Installing Park Lock Control Block (Repair Level 1

and 2)
[1] -
Align control block (B) and gasket at housing.

[2] - Tighten attaching screws (A).
8 lb-ft
[3] -
Install pin (A).

[4] -
Install cover (B) and gasket. Tighten attaching screws (A).

8 lb-ft
Final assembly:
Refer to "Removing and Installing the main frame (summary of references)" .
Refer to "Installing the AutoPowr/IVT transmission" .

Repairing Locking Pawl of Park Lock (Repair Level 1

and 2)
Preliminary work:
Refer to “Removing the Park Lock Control Block” .
Park lock - exploded view
LEGEND:
A Locking pawl
B Cotter pin
C Pin
D Washer
E Roller
F Lock cam
G Thrust bearing
H Axial needle bearing
I Bushing
J Shaft
K Compression spring
L O-ring
M Screw plug
N Lever
O Spring pin
Removing locking pawl of park lock
[1] -
Take out screw plug (A) and compression spring (B).

[2] -
Drive out pin and remove lever (A).

[3] -
Pull out shaft (A).

[4] - Remove locking pawl (B).

[5] -
Remove lock cam (A), thrust bearing and bushing (B).

[6] -
Check the roller (A), it must be undamaged and turn freely.

[7] - If required, remove cotter pin, shim and pin (B).
[8] - Replace roller (A) and reassemble the locking pawl.
Installing locking pawl of park lock

[1] -
Install lock cam (A) and axial bearing (B).

[2] -
Install bushing (A).

[3] -
Install locking pawl (B) and shaft (A).

[4] -
Align lever (A) as shown and drive in spring pin.

[5] -
Install compression spring (B). Tighten screw plug (A).

37 lb-ft
Final assembly:
Refer to “Installing the park lock control block” .

Removing Direction Turret and Reverse

Intermediate Shaft (Repair Level 2)
Preliminary work:
See reference ”Removing the AutoPowr/IVT Transmission” .
See reference”Separating Transmission Halves, Input/Output Housing”.
[1] -
Remove gasket and O-rings (A).

[2] -
Remove connecting tube (A).

[3] -
Before removing direction turret and reverse intermediate shaft, remove speed sending units
(A) and (B).
IMPORTANT:
To avoid damage, the speed sending units must be removed before the
direction turret.
[4] -
Take out the screw plug.

→NOTE:
The screw plug secures the direction turret.
[5] -

Attach KJD10242 lifting bail and KJD10241 adapter

[ Adapter KJD 10241 must be used on tractors up to serial no. 327230. Adapter KJD 10477 must be used on tractors from serial no. 327231. ]
to direction turret taper roller bearing.
Lifting bail
KJD10242
Removal and installation of direction turret

Adapter
KJD10241
Removal and installation of direction turret, pulling off taper roller bearing

[6] - Slightly lift reverse intermediate shaft and direction turret at the same time.
[7] - Remove reverse intermediate shaft and direction turret from transmission housing.

[8] -
Remove seal rings.

[9] -
Pry roller bearing from reverse intermediate shaft. Make sure that the bearing rollers do not
fall out.
→NOTE:
The bearing cone remains in the output housing.

[10] -
Remove direction turret taper roller bearing cup.

[11] -
If necessary, remove all screw plugs.
Final assembly:
See reference”Installing the Direction Turret and Reverse Intermediate Shaft”.

Removing Hydrostatic Unit Drive Shaft (Repair

Level 2)
Preliminary work:
See reference”Removing the Direction Turret and Reverse Intermediate Shaft”.
[1] -
Pull hollow shaft off drive shaft.

[2] -
Remove snap ring from hollow shaft.

[3] -

[4] -
Pull drive shaft with ball bearing out of the housing.

[5] -
Press ball bearing from drive shaft.

[6] -
Remove both snap rings (A).

[7] -
Press second ball bearing from drive shaft.
Final assembly:
See reference”Installing hydrostatic unit drive shaft”.

Removing Through-Drive Shaft (Repair Level 2)

Preliminary work:
[1] -
Remove the seven seal rings.

[2] -

[3] -
Turn housing through 180° and remove the second snap ring.
[4] -
Remove through-drive shaft using a suitable puller.

[5] -

[6] - Pull off ball bearing (A).
[7] - Remove seal rings (B) from through-drive shaft.
Final assembly:
See reference”Installing through-drive shaft”.

Removing Pneumatic Pump and Idler Gear (Repair

Level 2)
Preliminary work:
Removing idler gear
[1] -
Remove snap ring (shaft, pneumatic pump).

[2] -
Remove shaft using a slide hammer.

[3] -
Remove snap ring (shaft, idler gear) and shim behind it.
[4] -
Remove shaft using a slide hammer.

[5] -
Take idler gear (A) out of housing.

→NOTE:
While doing so, make sure that bearing cones do not fall out.

[6] -
If necessary, remove both bearing cups (A) from idler gear.

[7] -
Move gear (A) (gear with cam-pneumatic pump) to the rear position (see arrow).
[8] - Remove gear (B) (hydrostatic unit drive gear, through-drive shaft) from transmission
housing.

[9] -
Remove gear (A) (gear with cam-pneumatic pump) from transmission housing.
→NOTE:
Make sure that the two needle bearings and the thrust washer between
them do not fall out.
[10] - Remove needle bearings and the thrust washer between them from gear.
[11] -
Remove thrust washer from transmission housing.
Removing pneumatic pump

[1] -
Remove the pneumatic pump′s tappet (A).

[2] -

[3] -

[4] -
Remove the valve with its O-ring, washer and spring.

[5] -
Pull out the piston.

[6] -
Remove ball and retaining ring from piston.

[7] -

[8] -
Remove piston and spring from the housing.
Final assembly:
See reference”Installing pneumatic pump and idler gear”.

Installing Pneumatic Pump and Idler Gear (Repair

Level 2)
Installing pneumatic pump
[1] -
Install the pneumatic pump′s tappet in bore.

[2] -
Insert thrust washer.

IMPORTANT:
Be sure to insert washer correctly. Lug on washer must be positioned in
recess in housing to prevent washer from turning.

[3] -
Insert pump gear into transmission housing.

IMPORTANT:
Be sure to insert gear correctly. Cam on gear must point downward to
tappet.
[4] -
Install both needle bearings with thrust washer (A) in pump gear.

[5] -
Loosely install hydrostatic unit drive gear in transmission housing before securing pump gear
with shaft.
[6] -
Install cylindrical pin in shaft as far as it will go.

[7] -
Align pump gear and install shaft.

→NOTE:
Align shaft so that the cylindrical pin is located in the housing recess.
[8] -

[9] -
LEGEND:
A Snap ring
B Valve
C O-ring
D Washer
E Spring
F Retaining ring
G Ball
H Piston
I Pneumatic pump tappet
Check pneumatic pump parts before installation. Replace, if necessary.
[10] -
Install the ball and retaining ring on the piston.

→NOTE:
Be sure to insert ball and retaining ring correctly (install retaining ring with
ball socket pointing to the ball).

[11] -
Install piston with ball and retaining ring.

[12] -
Install the spring.

[13] -
Install the O-ring and washer on the valve.

[14] -
Install the valve.

[15] -

[16] -
Install screw plug with O-ring.

[17] - Tighten screw plug.
Pneumatic pump, screw plug Torque 140 N˙m
104 lb-ft

[18] -
Install the spring and piston in the housing.

[19] -
Install screw plug with O-ring.

[20] - Tighten screw plug.
37 lb-ft
Installing idler gear

[1] -
Install snap ring.

→NOTE:
Install snap ring in contact with upper groove face.
[2] -
Measure dimension (A) from housing flange to lower side of snap ring.
→NOTE:
The snap ring must be in contact with upper groove face.
[3] - Remove snap ring again afterwards.

[4] -
Install both bearing cups (A) as far as they will go.

[5] -
Install both bearing cones.

[6] -
Align idler gear for shaft installation.

[7] -
Heat up housing and bearing cones.

[8] -
Chill idler gear shaft before installation.

[9] - Insert shaft into idler gear. Make sure that shaft contacts bearing cone and a slight
bearing preload is noticeable.
IMPORTANT:
When turning idler gear, a slightly increased bearing preload must be felt.

[10] -
Measure dimension (B) from housing flange to shaft face.

Thedifference of the two dimensions is the thickness of the shim to be used.
Example
180.30 mm - 178.30 mm = 2.00 mm
7.10 in. - 7.02 in. = 0.08 in.
Difference 2.00 mm (0.08 in.)
[11] -
Insert a shim of the calculated thickness.

[12] -
Install snap ring.

[13] -
Remove slight bearing preload which was previously applied by using a slide hammer.
[14] - Afterwards check rolling drag torque by turning idler gear.
Idler gear Rolling drag torque 0.1—0.8 N˙m
0.074—0.60 lb-ft
If the required rolling drag torque is not obtained, adjust to correct value by using an
appropriate shim.
Final assembly:

Installing Hydrostatic Unit Drive Shaft (Repair Level

2)
[1] -
Press ball bearing on drive shaft until it stops.

[2] -
Secure ball bearing with snap ring.

[3] -
Install snap ring for second ball bearing.

[4] -
Press ball bearing on shaft until it contacts the snap ring.

[5] -
Install drive shaft.

[6] -
Secure drive shaft with snap ring.

[7] -
Install snap ring in hollow shaft.

[8] -
Install hollow shaft until it contacts the drive shaft.

Final assembly:

Installing Through-Drive Shaft (Repair Level 2)

[1] -
Install direction turret taper roller bearing cup as far as it will go.
[2] -
Apply sealing compound LOCTITE ™ 270 (high strength) to the four threaded pins.
[3] - Install threaded pins and tighten to specification.
Threaded pins, through-drive shaft Torque 15 N˙m
11 lb-ft

[4] -
Heat up ball bearing.

[5] - Install hot ball bearing on through-drive shaft as far as it will go.
[6] -

[7] -
Install four seal rings (A) and close them.

IMPORTANT:
[8] -
Insert through-drive shaft in housing or in gear (hydrostatic unit drive gear) which had been
inserted beforehand.

[9] -
Secure through-drive shaft with snap ring.

[10] -
Turn housing through 180° and install second snap ring.

[11] -
Install the seven seal rings and close them.

IMPORTANT:
Final assembly:

Installing Direction Turret and Reverse

Intermediate Shaft (Repair Level 2)
[1] -
Install connecting tube as far as it will go.

[2] -
Install the seal ring and close it.

→NOTE:
Use some petroleum jelly to keep the seal ring centered.

[3] -
Attach KJD10242 lifting bail (A) and KJD10241 adapter

[ Adapter KJD 10241 must be used on tractors up to serial no. 327230. Adapter KJD 10477 must be used on tractors from serial no. 327231. ]
(B) to direction turret taper roller bearing.
Lifting bail
KJD10242
Removal and installation of direction turret

Adapter
KJD10241
Removal and installation of direction turret, pulling off taper roller bearing

[4] - Assemble direction turret and shaft (C).

[5] -
Carefully insert direction turret/reverse intermediate shaft as far as it will go.

IMPORTANT:
Install direction turret and reverse intermediate shaft as an assembly.
IMPORTANT:
Take care not to damage the seal rings during installation.
[6] -
Remembering to include the O-ring, screw in plug and tighten.

26 lb-ft
→NOTE:
The screw plug secures the direction turret.

[7] -
Remembering to include O-rings, screw in all plugs and tighten.

18 lb-ft
26 lb-ft
37 lb-ft
41 lb-ft
104 lb-ft
[8] -
Coat O-rings (A) with oil and install them on connecting tube.

[9] -
Install connecting tube (A).

[10] - Install O-rings (B).
[11] -
Drive in both dowel pins (A).

→NOTE:
Drive in dowel pins until their tops are 3 mm (0.47 in.) above flange
surface.
→NOTE:
Finally, when transmission halves are joined the dowel pins are pressed in
even further.
[12] - Afterwards place gasket on housing.
Final assembly:
See reference”Measuring Gaps between Transmission Shafts in Input/Output Housing”.
See reference”Joining Transmission Halves, Input/Output Housing”.

See reference ”Installing the AutoPowr/IVT Transmission” .

Layout and Location of the Individual Transmission

Sending Units
LEGEND:
1 Transmission speed sending unit (B63)
2 Transmission input speed sending unit (B61)
3 Transmission ouput speed sending unit (B84)
4 Sending unit, system pressure indicator light (S74)
5 Sending unit, oil filter restriction indicator light (S73)
6 Sending unit for filter by-pass valve (B87; cold-weather starting)
7 Hydrostatic speed sending unit (B62)
8 Pressure sending unit (B90), park lock control block
9 Wiring harness
10 Locking paint
→NOTE:
When replacing speed sending units (1) and (7), the retaining screws must
be coated with locking paint.
Pressure sending unit for park lock control block (8) is located on the side
of the transmission, inside the park lock control block.
For replacing transmission sending units refer to:
“Replacing Pressure Sending Units (B87, S73, S74 of System Pressure Control Block”
“Replace Pressure Sending Unit (B90) for Park Lock Control Block”
“Replacing the Hydrostatic Speed Sending Unit (B62)”
“Replacing Transmission Speed Sending Unit (B63)”
“Replacing Transmission Input Speed Sending Unit (B61)”
“Replacing Transmission Output Speed Sending Unit (B84)”

Replacing Transmission Speed Sending Unit (B63)

[1] -
[2] -

Transmission speed sending unit Torque 10 N˙m
7 lb-ft
IMPORTANT:

Replacing Transmission Input Speed Sending Unit

(B61) (Repair Level 1 and 2)
[1] -
[2] -

Transmission input speed sending unit Torque 30 N˙m
22 lb-ft
IMPORTANT:
Replace the Transmission Output Speed Sending

Unit (B84) (Repair Level 1 and 2)

[1] -
Apply oil to O-ring (A) and install it on the sending unit.

[2] -
Position speed sending unit (A) on the transmission housing as shown and tighten to the
specified torque.
Transmission output speed sending unit Torque 12 N˙m
9 lb-ft
Replace Pressure Sending Unit (B90) for Park Lock

Control Block (Repair Level 1 and 2)

Section 53 - AUTOPOWR/IVT TRANSMISSION Group 20: Differential Drive Shaft Assembly
[1] -
Apply oil to the O-ring (A) and install it on the sender.

[2] -
Place sending unit (A) on park lock control block and tighten it.
7 lb-ft

Group 20 - Differential Drive Shaft Assembly

AutoPowr/IVT Transmission - Differential Drive
Shaft, Summary of References
AutoPowr/IVT Transmission - Differential Drive Shaft, Summary of References
Differential Drive Shaft, Sectional View
Remove the Differential Drive Shaft
Disassemble the Differential Drive Shaft
Cone Point Adjustment
Assemble the Differential Drive Shaft
Specifications
Special nut at differential drive shaft Torque 550 N˙m
400 lb-ft
Differential drive shaft Axial play 0.01 — 0.08 mm
0.0004 — 0.003 in.
Differential drive shaft assembly to differential housing, cap screws Torque 90 N˙m
65 lb-ft
Sectional View of Differential Drive Shaft

LEGEND:
A O-ring
B Seal ring
C Ring
D Housing
E Shim (quantity and thickness as required)
F Cap screw (6 used)
G Cover
H Differential drive shaft
I Special nut
J Shim (quantity and thickness as required)
K Front-wheel drive gear
L Snap-ring
Removing the Differential Drive Shaft
Preliminary work: See reference ”Removing the AutoPowr/IVT Transmission” in Section 53,
Group 00.
[1] - Remove cap screws.

[2] -
Unlock and slightly loosen special nut.

[3] -
Use two M8 screws (A) to press housing off.

Disassemble Differential Drive Shaft

[1] -
Remove O-ring (B).

[2] - Remove special nut (A).
[3] -
Press differential drive shaft from bearing seat of taper roller bearing.
[4] -
Remove taper roller bearing cone (C), spacer (B) and washers (A).

[5] -
Remove snap ring from groove.

[6] -
Pull out the differential drive shaft. Remove snap ring (A).
[7] -
Press the taper roller bearing cone from the differential drive shaft.

[8] -
Separate the cover and housing.

[9] -
Remove the front-wheel drive gear (A).

[10] -
Remove the tapered roller bearing cup.

Cone Point Adjustment

[1] -

Note the letter (A) stamped on the upper left side of the front face of the differential housing
and refer to the chart below for the corresponding dimension.
→NOTE:
If letter is absent, assume a measurement of 205.00 mm (8.071 in.).
Letter on housing Measurement
A 204.89 mm (8.067 in.)
B 204.95 mm (8.069 in.)
C 205.00 mm (8.071 in.)
D 205.05 mm (8.073 in.)
E 205.10 mm (8.075 in.)
[2] - Measure bore depth (B) at cover.

[3] - Note the measurement (C) stamped on the pinion face.
[4] - Determine bearing width (D).

[5] - Calculate thickness of spacer washer pack (X).

Add the bore depth (B) to value (A), to be read from the table. Subtract the dimension (C)
and bearing width (D).
Formula: X = A + B - C - D
Cone point adjustment - Example
Character read from differential housing and dimension from table... A = 204.89 mm (8.067 in.)
Bore depth measured at cover... B = 22.23 mm (0.875 in.)
Dimension stamped on bevel gear face, read... C =180.02 mm (7.088 in.)
Width of taper roller bearing is... D = 46.26 mm (1.821 in.)
X = 204.89 mm + 22.23 mm - 180.02 mm - 46.26 mm

X = 0.84 mm
X = 8.067 in. + 0.875 in - 7.088 in - 1.821 in.
X = 0.033 in.
Shims are available in the following thicknesses:

0.254 mm (0.010 in.)
0.127 mm (0.005 in.)
0.076 mm (0.003 in.)
In the example three 0.254 mm (0.010 in.) shims and one 0.076 mm (0.003 in.) shim are to be used.

Assembling the Differential Drive Shaft

[1] -
Install shims of calculated thickness (to adjust cone point).

[2] -
Press tapered roller bearing cup into the cover.

[3] -
Press tapered roller bearing cup (A) into housing.

[4] -
Install front-wheel drive gear (A) in housing.

[5] -
Install dowel pins (A). Press cover and housing together.

[6] -
Heat up tapered roller bearing cone (A) and install on differential drive shaft.

[7] -
Align snap ring (A) and install differential drive shaft

[8] -
Install snap ring in groove.

[9] -
Insert piston ring (A) on spacer and engage.

[10] -
Install spacer.
[11] -
Install shims (to adjust end play of differential drive shaft).

[12] -
Heat up tapered roller bearing cone and install.

[13] -
Reseat bearing.
[14] -
Install special nut (A) and tighten.

Special nut at differential drive shaft Torque 550 N˙m
400 lb-ft
[15] -
Move the differential drive shaft to and fro to seat the bearings.

POWRQUAD PLUS, AUTOQUAD AND AUTOQUAD PLUS (g) by Belgreen
TRANSMISSIONS
[16] - Measure axial play of differential drive shaft.

Differential drive shaft Axial play 0.01 — 0.08 mm
0.0004 — 0.003 in.
[17] - Adjust the axial play through removal or installation as required. Tighten special nut to
specification.
[18] - Check axial play again.
[19] - When the axial play has been set correctly, the special nut must be locked.
[20] -
Install differential drive shaft assembly in differential housing. Tighten the cap screws.
Differential drive shaft assembly to differential housing, cap screws Torque 90 N˙m
65 lb-ft
[21] -
Cover O-ring (A) with a thin layer of Vaseline and install on housing.
Next step: See reference ”Installing the AutoPowr/IVT Transmission” in Section 53, Group 00.

Section 55 - POWRQUAD PLUS, AUTOQUAD AND

AUTOQUAD PLUS TRANSMISSIONS
Table of contents
Special Tools .......................................................................................................................... 1
PowrQuad Plus Transmission, Removal and Installation ........................................................ 2
Remove and Install the AutoQuad Transmission .................................................................... 3
Remove PowrQuad Transmission ........................................................................................... 4
Install PowrQuad Transmission .............................................................................................. 8
Remove the Creeper Transmission ...................................................................................... 11
Install the Creeper Transmission .......................................................................................... 13
Remove Range Transmission ............................................................................................... 15
Install Range Transmission .................................................................................................. 17
Group 05 - Transmission Shift Controls ............................................................................... 19
PowrQuad Transmission Shift Units - Reconditioning (Summary of References) .................. 19
Specifications ....................................................................................................................... 19
Repairing the Range Shift Linkage (PowrQuad Plus and AutoQuad Transmissions) ............. 20
Reconditioning the Range Shift Linkage (PowrQuad Plus and AutoQuad Plus Transmissions
from Tractor Ser. No. 398656) ...................................................................................... 25
Checking and Adjusting the Shift Controls/Linkages (PowrQuad Plus and AutoQuad
transmissions) ............................................................................................................... 37
Checking and Adjusting the Shift Controls/Linkages (PowrQuad Plus and AutoQuad Plus
Transmissions from Tractor Ser. No. 398656) ............................................................... 44
Repairing the Clutch Actuation (PowrQuad Plus, AutoQuad and AutoQuad Plus Transmissions)
....................................................................................................................................... 48
Group 10 - PowrQuad Module ................................................................................................ 55
PowrQuad, PowrQuad Plus and AutoQuad Transmissions - Summary of References ........... 55
Special tools ......................................................................................................................... 56
Specifications ....................................................................................................................... 58
Transmission Components ................................................................................................... 59
Replacing the temperature sensor and pressure switches .................................................. 61
Removing and Installing the Oil Filter Housing .................................................................... 62
Replacing the Oil Filter ......................................................................................................... 63
Removing and Installing the Front Valve Housing ................................................................ 64
Removing and Installing the Valves in the Front Valve Housing .......................................... 66
Removing and Installing the Front Transmission Cover ....................................................... 71
Removing and Installing the Valves in the Front Transmission Cover .................................. 73
Removing and Installing the Shift Valve Housing ................................................................. 77
Remove and Install the Valves in the Shift Valve Housing ................................................... 78
Removing the Transmission Oil Pump .................................................................................. 82
Repairing the Transmission Oil Pump ................................................................................... 84
Installing the Transmission Oil Pump ................................................................................... 93
Removing the Gear-Shift Planetary Drive ............................................................................ 94
Repairing the Gear-Shift Planetary Drive ............................................................................. 96
Install Gear-Shift Planetary Drive ....................................................................................... 104
Removing the B1 Brake Housing ........................................................................................ 111

Reconditioning the B1 Brake .............................................................................................. 113

Installing the B1 Brake Housing ......................................................................................... 115
Removing the B2-B3 Brake Housing .................................................................................. 115
Installing the B2-B3 Brake Housing .................................................................................... 121
Removing the C4 Clutch .................................................................................................... 122
Reconditioning the C4 Clutch ............................................................................................. 123
Installing the C4 Clutch ...................................................................................................... 135
Removing the reverse brake .............................................................................................. 136
Repairing the reverse brake ............................................................................................... 138
Installing the reverse brake ............................................................................................... 140
Removing the Forward Clutch with Planetary Drive (Forward/Reverse) ............................. 142
Reconditioning the Forward Clutch with Planetary Drive (Forward/Reverse) ..................... 143
Installing the Forward Clutch with Planetary Drive (Forward/Reverse) .............................. 161
Replacing the output shaft ................................................................................................. 163
Group 15 - Creeper Transmission ....................................................................................... 166
Creeper Transmission - Reconditioning (Summary of References) .................................... 166
Special tools ....................................................................................................................... 166
Repair specifications .......................................................................................................... 166
Removing the creeper transmission .................................................................................. 166
Repairing the creeper transmission ................................................................................... 168
Installing the creeper transmission .................................................................................... 185
Group 20 - Range Transmission .......................................................................................... 187
Range Transmission - Reconditioning (Summary of References) ....................................... 187
Special tools ....................................................................................................................... 187
Removing the range transmission ..................................................................................... 189
Range Transmission - Sectional View ................................................................................. 190
Repairing the Range Transmission ..................................................................................... 192
Installing the range transmission ....................................................................................... 220
Repairing the shift cover .................................................................................................... 221
Replacing the speed sender ............................................................................................... 224

Group 00: Removal and Installation of Components

Special Tools
→NOTE:

Lifting eye
JD-244-1
Removing and installing tractor components
Lifting eye
JDG19

See also Section 99, Group 05.

Device for suspending the PowrQuad module during removal and installation
Specificatio
Item Measurement
n
Cap Screw, PowrQuad Module to Creeper Transmission Torque 70 N˙m
50 lb.-ft.
Cap Screw, Range Transmission Housing to Differential Housing Torque 90 N˙m
66 lb.-ft.
Cap Screw, PowrQuad Module to Range Transmission Torque 70 N˙m
50 lb.-ft.
Cap Screw, Creeper Transmission to Range Transmission Torque 70 N˙m
50 lb.-ft.
Cap Screw, Suction Line to PowrQuad Module Torque 18 N˙m
13.3 lb.-ft.
Cap Screw, U.J. Shaft to Torsion Damper and Drive Flange Torque 135 N˙m
100 lb.-ft.
PowrQuad Plus Transmission, Removal and

Installation
See Remove PowrQuad Transmission .
See Install PowrQuad Transmission .

Remove and Install the AutoQuad Transmission

See Remove PowrQuad Transmission .
See Install PowrQuad Transmission .

Remove PowrQuad Transmission
→NOTE:
The following applies regardless of what transmission type is used on the

tractor, provided it is based on the PowrQuad module.
[1] - Open the hood.
Disconnect the negative terminal (—) on the battery. The version shown here has a negative
terminal at the location marked (A).
CAUTION:
Always pay close attention to battery terminals.
Comply with safety instructions on how to handle batteries (see Section
05).
[2] - Tilt up the operator′s cab; see Tilting the Operator′s Cab Upward in Section 90, Group
00.
[3] -
Remove drain screw (A) and allow the transmission oil to drain out.
[4] -
Remove u.j. shaft (B). See Removing the U.J. Shaft (Engine) in Section 56, Group 05.
On tractors with creeper transmission, remove cooler (A); see Removing and Installing the
Ring-Shaped Cooler in Section 56, Group 05.
→NOTE:
Trap any oil as it emerges. Seal the open ends so that no dust can
penetrate.
[5] -
Mark all the connectors on the transmission wiring harness to facilitate their re-installation,
then disconnect them.
Disconnect both oil cooler hoses (A) at the junction with the PowrQuad module. If equipped,
pull hose (C) from the hose fitting. Remove line (B).
→NOTE:
penetrate.
On tractors with creeper transmission, remove transmission oil filter.

[6] - If the PowrQuad module has mechanical shifting and mechanically actuated reverser
control, disengage the bowden cables.

[7] -
Take out screws (A) and pull suction line (B) out of the differential housing.
→NOTE:
penetrate.
[8] -
Remove cable clamp (A) and move the wiring harness to the rear after disconnecting all
connectors.
[9] -

Install dealer-fabricated suspension device (A) on the PowrQuad module and attach lifting
tackle.
Suspension Device
dealer fabricated
Take all screws (B) out of the flange, move the PowrQuad module to the front, and lift it out.

Install PowrQuad Transmission
→NOTE:
The following applies regardless of what transmission type is used on the

tractor, provided it is based on the PowrQuad module.
[1] -
Install dealer-fabricated suspension device (A) on the PowrQuad module and attach lifting
tackle.
Suspension Device
dealer fabricated

Clean the sealing surfaces thoroughly, install gasket (C) and, if necessary, keep it in place
with grease.
→NOTE:
Check that the bushing (B) is seated correctly. Move the drive shaft to help
the gears to mesh.
Locate the PowrQuad module against the range transmission or creeper, and tighten all the
screws (D) in the flange to the prescribed torque.
Cap Screws, PowrQuad Module to Range Transmission or Creeper Torque 70 N˙m
50 lb.-ft.
IMPORTANT:
Tighten screws in flange in cross-wise fashion (alternately by small
amounts).

[2] -
Check all seals, install suction line (B) and tighten screws (A) to the specified torque.
Attaching Screws, Suction Line to PowrQuad Module Torque 18 N˙m
13 lb.-ft.
→NOTE:
Check all gaskets/seals before installing.
[3] - For further assembly, follow disassembly procedure in reverse order.

[4] - Fill with transmission oil. Check oil level and top up, if necessary.
[5] - When assembly is completed, perform the following:
Adjusting the reverse drive linkage (if equipped), Section 55, Group 05.
Installing the U.j. Shaft (Engine) , Section 56, Group 05.
[6] -
IMPORTANT:
For further assembly, follow disassembly procedure in reverse order.

Remove the Creeper Transmission
Remove the PowrQuad module. See Remove PowrQuad Module in this Group.
Disengage linkage (A) and bowden cable (B).
Attach lifting eyes JD-244-1 (A) and secure the housing to a suitable hoist.
Lifting eye
JD-244-1

Remove bracket (D).
Remove cap screws (B).
→NOTE:
A further cap screw is located in line connector bore (C); this screw must
also be removed.
Remove creeper transmission.
→NOTE:
The housing flanges are sealed with flexible sealant. Therefore, the
housings adhere firmly to each other even after the cap screws have been
removed.

Install the Creeper Transmission

Use TY6305 cleaning agent to clean residual sealant off the housing sealing surfaces.
→NOTE:
Carefully scrape off any residual sealant with a scraper.
Then apply a thin, even layer of LOCTITE ™ 574 (L64500) sealant to the housing flange.
Attach lifting eyes JD-244-1 (A) and secure the housing to a suitable hoist.
Lifting eye
JD-244-1
Applying even pressure, locate the creeper transmission on the range transmission.

Install cap screws (A) and tighten them to the specified torque.
Cap Screws, Creeper Transmission to Range Transmission Torque 70 N˙m
50 lb.-ft.
→NOTE:
A further cap screw (B) is located in the line connector bore; this screw
must be tightened also.

Remove Range Transmission

[1] - Remove PowrQuad module or creeper transmission. See Remove PowrQuad Module or
Remove the Creeper Transmission in this Group.
[2] -
Mark the bowden cables (A) of the shift cover, as well as the respective levers, so as to
facilitate reassembly. Then disengage all the bowden cables.
→NOTE:
Depending on transmission version, cable arrangement may be different.
[3] -
Disconnect connector (A) of the solenoid valve for the front-wheel drive clutch.
Remove pressure line (B) from the front-wheel drive valve.
Remove the front-wheel drive clutch. See Remove the Front-Wheel Drive Clutch in Section
80, Group 00.
→NOTE:
It is not absolutely necessary to remove the front-wheel drive clutch.
However, it makes it easier to perform the subsequent tasks on the range
transmission.

[4] -
Screw the JDG19 lifting eyes (A) onto the housing and attach the hoist.
Lifting eye
JDG19
IMPORTANT:
Remove all screws (B) and move the range transmission towards the front. Then lift out the
housing.
→NOTE:
The housing flanges are sealed with flexible sealant. Therefore, the
housings adhere firmly to each other even after the cap screws have been
removed.

Install Range Transmission

[1] - Thoroughly clean sealing surfaces of the housing.
→NOTE:
Carefully scrape off any residual sealant with a scraper.
Then apply a thin, even layer of LOCTITE ™ 574 (L64500) sealant to the housing flange.
[2] -
Screw the JDG19 lifting eyes (A) onto the housing and attach the hoist.
Lifting eye
JDG19
IMPORTANT:
Position the range transmission on the differential housing.

→NOTE:
Make sure that the housing is suspended exactly horizontally.
Screw in all cap screws (B) and tighten in cross-wise fashion to the torque prescribed.
Cap Screws, Range Transmission to Differential Housing Torque 90 N˙m
65 lb.-ft.

Group 05: Transmission Shift Controls
[3] - For further assembly, follow disassembly procedure in reverse order. Then see Install
PowrQuad Transmission or Install Creeper or Option Transmission .


PowrQuad Transmission Shift Units - Reconditioning
”Reconditioning the range shift linkage (PowrQuad Plus and AutoQuad transmissions)”
”Checking and adjusting the shift controls/linkages (PowrQuad Plus and AutoQuad
transmissions)”
”Reconditioning the range shift linkage (PowrQuad Plus and AutoQuad Plus transmissions
from tractor ser. no. 398656)”
”Checking and adjusting the shift controls/linkages (PowrQuad Plus and AutoQuad Plus
transmissions from tractor ser. no. 398656)”
”Reconditioning the clutch actuation (PowrQuad Plus, AutoQuad and AutoQuad Plus
transmissions)”
Specifications
Shift lever to support, self-locking hex. nut Torque 35 N˙m
25 lb-ft
Shift elements to bearing pins Preload 0.9 to 1.5 mm
0.035 to 0.059 in.
7 lb-ft
Bearing pin attaching screw Torque 25 N˙m
19 lb-ft
Attaching screw, shift quadrant stop Torque 25 N˙m
19 lb-ft

Repairing the Range Shift Linkage (PowrQuad Plus

and AutoQuad Transmissions)
LEGEND:
1 Gear selector
2 Handle
3 Shifting gate
4 Park lock switch
5 Cap screw
6 Washer
7 Bearing bushing
8 Shift quadrant, park lock
9 Support pin
10 Support pin

11 Belleville spring
12 Shift quadrant, ranges A and B
13 Support
14 Self-locking hex. nut
15 Shift lever with harness
16 Shift quadrant, ranges C and D
17 Shift quadrant, range E
18 Rubber bearing
19 Washer
20 Shim (thickness as required)
21 Bracket
22 Bowden cable, park lock
23 Bowden cable, ranges A and B
24 Bowden cable, ranges C and D
25 Bowden cable, range E
26 Rubber sleeve
27 Cap screw
[1] - Repair or assemble the parts of the shift mechanism as required, using the illustration
as a guide.
[2] - Apply John Deere EP multi-purpose grease to all the moving parts on support pin (10).
[3] - Tighten self-locking hex. nut (14).
Shift lever to support, self-locking hex. nut Torque 35 N˙m
25 lb-ft
[4] -
→NOTE:
Threads of attaching screws and the threaded bores must be clean and dry
(i.e. free of oil and grease).
Coat screws (5) and (27) with (LOCTITE ™ 242) and tighten screws to specified torque.
Support pin attaching screw Torque 25 N˙m
19 lb-ft
Adjusting preload at quadrants

[1] -
Install parts 5 to 18.

→NOTE:
Note specified tightening torques.
[2] - Without pretensioning the belleville springs (11), measure distance (a), which is how far
support pin (10) sticks out.
[3] - Adjust the preload at the shift linkage parts.
Calculate thickness of shims (d). Add the preload value to the distance the support pin sticks
out.
Shift elements to support pin Preload 0.9 to 1.5 mm
0.035 to 0.059 in.
The sum represents the thickness of shims to be used (19).
d (min.) = a + 0.9 mm (0.035 in.)

d (max.) = a + 1.5 mm (0.059 in.)
[4] - If necessary, round off the result. When (d) is at its minimum, round the sum up; when
(d) is at its maximum, round the sum down.
→NOTE:
A selection of shims with different thicknesses is available through normal
parts channels.
Example

Measured distance (a) (distance the support pin sticks out):
a = 0.3 mm (0.012 in.)
d (min.) = 0.3 mm + 0.9 mm = 1.2 mm

d (min.) = 0.012 in + 0.035 in = 0.047 in
d (max.) = 0.3 mm + 1.5 mm = 1.8 mm

d (max.) = 0.012 in. + 0.059 in. = 0.071 in.
In this example, shim (19) must be 1.5 mm (0.059 in.) thick.
Removing and installing the bowden cables
IMPORTANT:
When removing and installing bowden cables, take care not to bend them.
When routing the bowden cables, take care that they do not chafe and are
not subjected to tension.
[1] -
Removing the bowden cable together with the damper

Disconnect the bowden cable′s yoke.
[2] - When removing the bowden cable, hold down locking lug (A) and at the same time twist
the cable through 90°.
[3] - The bowden cable can now be pulled out of the console.

[4] -
Installing the bowden cable together with the damper

When installing a bowden cable, insert it into the console as shown.
[5] - Twist the bowden cable through 90° until locking lug (A) clicks into place.
[6] - Attach the bowden cables to the transmission as illustrated.
LEGEND:
A Bowden cable, park lock
B Bowden cable, range E
C Bowden cable, ranges A and B
D Bowden cable, ranges C and D

Reconditioning the Range Shift Linkage (PowrQuad

Plus and AutoQuad Plus Transmissions from Tractor
Ser. No. 398656)
Reconditioning the selector grip with gear-shift switches
[1] -
Shift lever, AutoQuad Plus
Shift lever, PowrQuad Plus

The PowrQuad Plus shift lever and the AutoQuad Plus shift lever are both disassembled in the
same way.

[2] -
LEGEND:
A Attaching screws
Take screws (A) out of the back of the grip, and lift off the front half of the grip.
[3] -
LEGEND:
A Circuit board with gear-shift switches
B Attaching screws
C Grip
Carefully pull the circuit board with gear-shift switches (A) off the plug.
Take out attaching screws (B) and pull off grip (C).
Recondition or assemble the selector grip with gear-shift switches as required, using the
exploded view as a guide.
Removing the shifter unit

[1] - Take off the trim panels.
LEGEND:
A Electrical plug connection
B Electrical plug connection
C Electrical plug connection
[2] - Disconnect the shifter unit from electrical plug connections (A), (B) and (C).

[3] -
LEGEND:
A Bowden cables
Put identifying marks on the existing bowden cables (A), then remove them.
[4] -
LEGEND:
A Attaching screws
Take out screws (A).

[5] -
LEGEND:
A Attaching screw
B Shifter unit
Take out attaching screw (A).
[6] - Lift shifter unit (B) out of the console.
Reconditioning the shifter unit
→NOTE:
Recondition or assemble the parts of the shift mechanism as required,

using the illustration as a guide.
To facilitate subsequent re-assembly, put identifying marks or numbers on

the components before taking them off.

→NOTE:
Attaching screws for which no tightening torque is quoted must be

tightened to the maximum torque value for screws in their grade. See
Reference ”Metric Bolt and Cap Screw Torque Values” .
LEGEND:
A Spring
B Wire loop
To make it easier to engage and disengage springs (A), make a loop of wire (B).
The springs must be installed as shown. The springs must touch the sides of the cam (see
arrow).

LEGEND:
A Wiring harness
B Cable binder
Secure harness (A) to the cam by means of cable binder (B), making sure that there is no
tension in the harness regardless of whichever position the shift lever is in. To make sure,
move the shift lever to each range in turn.
Do not tighten the cable binder until you are sure that the harness is free of tension no
matter what position the shift lever is in.

LEGEND:
1 Handle assembly, AutoQuad Plus transmission
2 Handle assembly, PowrQuad Plus transmission
3 O-ring
4 Screw
5 Locking washer
6 Console

LEGEND:
1 Shift lever assembly with harness
2 Bushing
3 Pin assembly
4 Spring pin
5 Carriage bolt
6 Console
7 Screw
8 Clamp
9 Support
10 Hex. nut

11 Support
12 Screw
13 Washer
14 Washer
15 Screw
16 Spring
17 Console
18 Flanged nut
19 Clamp
20 Carriage bolt
21 Bracket
22 Screw

Exploded view, range shift A-E
LEGEND:
1 Cams
2 Side frame
3 Bushing
4 Retaining clip
5 Screw
6 Washer
7 Lever
8 Pin
9 End panel
11 Quadrant, E
12 Lever
13 Quadrant, C-D
14 Quadrant, A-B
15 Quadrant, park lock
16 Retaining washer
17 Spacer
18 Shaft
19 Pin
20 Park lock switch
21 Spring

Checking and Adjusting the Shift Controls/Linkages

(PowrQuad Plus and AutoQuad transmissions)
CAUTION:
Do not perform any adjustments with the engine running, as the tractor
could move unexpectedly. Switch off the ignition and remove the key.
IMPORTANT:
Make this adjustment when the tractor is on firm, level ground.
Checking and adjusting the range shift linkage
[1] -

LEGEND:
A Shift lever
B Bowden cable, range E
C Bowden cable, ranges C and D
D Bowden cable, ranges A and B
E Park lock cable
Move range shift lever (A) back and forth in the neutral zone.
• The shift lever must not bump, jam or catch against the shift gate.
Use range-shift lever (A) to select each range and the park lock.
[2] - If necessary, disconnect bowden cables (B), (C) and (D), and adjust the range shift
linkage.
→NOTE:
Slacken off the yoke′s locknut before disengaging the bowden cable.
[3] - Turn the yoke until the holes in the yoke and in the shift quadrant are aligned precisely.
[4] - Engage the bowden cable and lock it with the locknut.
[5] - Re-check the adjustment once again.
Adjusting the park lock

[1] -
Disengage the park lock cable (A).

[2] -
Check the torque value to which attaching screws (A) and (B) are tightened. Tighten
attaching screws (A) and (B) to the specified torque. Press the shift quadrant as far as it will
go in the direction shown by the arrow. The shift quadrant must physically touch the stop and
must not move in the opposite direction to the arrow.
Attaching screws Torque 25 N˙m
19 lb-ft
[3] -

Check the adjustment of the shift quadrants and park lock switch. Adjust, if necessary.
Park lock shift quadrant (D) is adjusted correctly when range shift quadrants (A), (B) and (C)
are precisely aligned with park lock shift quadrant (D) (see the broken lines in the
illustration).
Press the shift quadrant (D) as far as it will go in the direction shown by the arrow. The shift
quadrant must physically touch the stop and must not move in the opposite direction to the
arrow.
Park lock switch (A) is adjusted correctly when its actuating spring is pressed by the park lock
shift quadrant, causing the switch to trip (see top arrow). At the same time as the switch
trips, the shift quadrant should come into contact with the stop (see bottom arrow). The
switch must not push the shift quadrant away from the stop.
If necessary, adjust the shift quadrant or the park lock switch.

[4] -
Take off the park lock switch. Slacken off attaching screws (A) and (B).
[5] - Adjust stop (C) so that the park lock quadrant aligns with the range shift quadrants (see
the broken lines in the illustration).
[6] - Tighten attaching screws (A) and (B) to the specified torque value, changing repeatedly
from one to the other and back again so that pressure is applied evenly. Make sure that stop
(C) does not become displaced.
Attaching screws Torque 25 N˙m
19 lb-ft
[7] -
Install park lock switch (A) and tighten retaining nuts (B) by a small amount. Slide the switch
(A) in the slots until its actuating spring is pressed by the park lock shift quadrant, causing
the switch to trip (see top arrow). At the same time as the switch trips, the shift quadrant
should come into contact with the stop (see bottom arrow). The switch must not push the
shift quadrant away from the stop.

[8] - Tighten retaining nuts (B) to their full torque value.

[9] - Engage the park lock bowden cable or - if the shift quadrant has been adjusted - adjust
the bowden cable.
[10] - Adjust the park lock cable Move range shift lever (A) to its neutral position.
[11] - Disconnect the park lock cable (J).

→NOTE:
[12] -
IMPORTANT:
Make sure that the park lock is disengaged properly.
Do this by pressing the bowden cable (J) down (use force).

[13] - To make the adjustment, pull gently on the cable yoke so that the free play before
actuation (approx. 2 mm; 0.08 in.) is removed from the cable.
[14] - Hold the cable in this position (free of play) and turn the yoke until the yoke holes and
shift quadrants are precisely aligned.
[16] - Re-check the adjustment.
Checking the park lock
[1] - Drive tractor on a slope (ramp) and bring it to a standstill.

[2] - Shift lever to the "park" position.
[3] - Slowly release the brake pedal.
[4] - Park lock must engage and the tractor must not roll away.
CAUTION:
If the tractor does roll away, the park lock must be checked on the
transmission end and the cause must be identified.

Checking and Adjusting the Shift Controls/Linkages

(PowrQuad Plus and AutoQuad Plus Transmissions
from Tractor Ser. No. 398656)
CAUTION:
Do not adjust the shift linkage with engine running because the tractor
might move unexpectedly. Switch off the ignition and remove the key.
Checking and adjusting the range shift linkage
[1] -
Move the range-shift lever (A) to neutral position. From there, the shift lever moves
automatically to the shift position C-D.
[2] - Use range-shift lever (A) to select each range and the park lock.
→NOTE:
Slight resistance can be felt when shifting from ranges A-B to the park
position and from ranges C-D to range E.
→NOTE:
If the park lock should happen to have the teeth on the gear and on the
pawl clashing against each other, slightly more force is required to engage
the park lock.

• It must be possible to move the shift lever to its park position without any difficulty
whatsoever.
[3] -
LEGEND:
A Bowden cable, range E
B Bowden cable, ranges C and D
C Bowden cable, ranges A and B
D Park lock cable
If necessary, disconnect cables (A), (B), or (C), and adjust the range shift linkage.
→NOTE:
Slacken off the locknut on the relevant yoke before disengaging the
bowden cable.
[4] - Turn the yoke of the bowden cable until the holes in the yoke and in the shift quadrant
are aligned precisely.
→NOTE:
Make sure the hole in the shift quadrant is the correct one (the retaining
pin can only be installed at this hole).
[5] - Engage the bowden cables and lock them with the locknuts.

Adjusting the park lock
[1] -
Move the range-shift lever (A) to neutral position. From there, the shift lever moves
automatically to the shift position C-D.
[2] - Disengage the park lock bowden cable (B).
→NOTE:

[3] -
IMPORTANT:
Make sure that the park lock is disengaged properly.
Do this by pressing the bowden cable (B) down (use force).

[4] - Turn the yoke of the bowden cable until the holes in the yoke and in the shift quadrant
are aligned precisely.
→NOTE:
Make sure the hole in the shift quadrant is the correct one (the retaining
pin can only be installed at this hole).
Checking the park lock
[1] - Drive tractor on a slope (ramp) and bring it to a standstill.

[2] - Shift lever to the "park" position.
[3] - Release the brake pedal.
[4] - Park lock must engage and the tractor must not roll away.
CAUTION:
If the tractor does roll away, the park lock must be checked on the
transmission end and the cause must be identified.

Repairing the Clutch Actuation (PowrQuad Plus,

AutoQuad and AutoQuad Plus Transmissions)
CAUTION:
CAUTION:
assemblies.
IMPORTANT:

cable (-).
Replacing the potentiometer

[1] -

[3] -

[4] -

[5] - Pull off connector (B) and take off the potentiometer.
Repairing the clutch pedal
[1] -
Disengage ball joint (A).

[2] - Remove hex. nut (B).
→NOTE:
Proceed with care, as the components are subject to preload.

[3] - Take out retaining screw (C) and lift out the clutch pedal.
[4] -
Take belleville spring (A), back-up ring (B) and friction washer (C) off the bearing journal (D).
[5] - Recondition the clutch actuation as required.
[6] - Locate the clutch pedal on adapter (A).
Apply some John Deere EP multipurpose grease to bearing (B) before installation. Install hex.
nut (C).
[7] - Now install the clutch pedal on the bearing journal of the console.

[8] -
Tighten retaining screw (A) just enough for the pedal to touch console but remain free of
play. Now tighten the attaching screw to its final torque value.
7 lb-ft
IMPORTANT:
The clutch pedal′s retaining screw has a self-locking capability; for this
reason, every time it is removed, it must be replaced with a new one.
[9] -
Adjust the preload at spring (A).

Screw in hex. nut (B) until dimension (C) between adapter and clutch pedal is 7.5 mm (0.3
in.).

Exploded view of clutch actuation mechanism
LEGEND:
A Console
B Belleville spring
C Back-up ring
D Friction washer
E Hex. nut
F Bearing
G Ball socket
H Clutch pedal
I Bushing
J Washer
K Self-locking fillister head screw
L Limit stop
M Potentiometer (B65)
Group 10: PowrQuad Module
N Cover
O Ball end
P Ball joint assembly
Q Leaf spring
R Adapter
S Spring
T Adapter
U Attaching screw
V Wiring harness, with clutch pedal switch (S72)

Group 10 - PowrQuad Module

PowrQuad, PowrQuad Plus and AutoQuad
Transmissions - Summary of References
Before reconditioning the PowrQuad module, refer to the following:
”Special tools”
”Replace the temperature sensor and pressure switches”
”Remove and install the oil filter housing”
”Remove and install the front valve housing”
”Remove and install the valves in the front valve housing”
”Remove and install the front transmission cover”
”Remove and install the valves in the front transmission cover”
”Remove and install the shift valve housing”
”Remove and install the valves in shift valve housing”
”Remove transmission oil pump”
”Recondition transmission oil pump”
”Install transmission oil pump”
”Remove the gear-shift planetary drive”
”Recondition the gear-shift planetary drive”
”Install the gear-shift planetary drive”
”Remove the B1 brake housing”
”Recondition the B1 brake”
”Install the B1 brake housing”
”Remove the B2-B3 brake housing”
”Install the B2-B3 brake housing”
”Remove the C4 clutch”
”Recondition the C4 clutch”
”Install the C4 clutch”
”Remove the reverse brake”
”Recondition the reverse brake”
”Install the reverse brake”
”Remove the forward clutch with planetary drive (forward/reverse)”
”Recondition the forward clutch with planetary drive (forward/reverse)”
”Install the forward clutch with planetary drive (forward/reverse)”
”Replace the output shaft”

Special tools
→NOTE:

Seal installer
JDG775
Installing the seal ring in front valve housing
Bushing installer
JDG765
Installing bushings
Installation tool for the input planetary
JDG772
Assembling the planetary housing
Bushing, bearing, and seal driver sets

D01045AA
Driving in bushings, bearings and seals
Hydraulic puller set
D01048AA
Removal of bearings
Mechanical puller set
D01173AA
Removal of bearings

Specifications
Specificatio
Item Measurement
n
System pressure, pressure switch Torque 4 to 7 N˙m
3 to 5 lb-ft
Clutch pressure, pressure switch Torque 9 N˙m
6 lb-ft
Pressure switch, restriction indicator of the transmission oil filter Torque 4 to 7 N˙m
3 to 5 lb-ft
Temperature sensor Torque 4 to 7 N˙m
3 to 5 lb-ft
Oil filter housing, screw Torque 11 N˙m
8 lb-ft
Transmission oil filter to filter housing Torque 30 N˙m
22 lb-ft
Front valve housing, screw Torque 11 N˙m
8 lb-ft
Transmission oil filter by-pass valve, plug Torque 20 N˙m
15 lb-ft
Cooler relief valve, plug Torque 30 N˙m
22 lb-ft
Lube oil relief valve, plug Torque 20 N˙m
15 lb-ft
Reverse solenoid (Y36) Torque 45 N˙m
33 lb-ft
Forward solenoid (Y33) Torque 45 N˙m
33 lb-ft
Enable proportional solenoid (Y38), screw Torque 25 N˙m
18 lb-ft
Front transmission cover, screw Torque 60 N˙m
44 lb-ft
Cover for return valve and gear-to-gear modulation valve, screw Torque 12 N˙m
9 lb-ft
Pressure-regulating valve, plug Torque 30 N˙m
22 lb-ft
Cooling oil control valves and cooling valve, plug Torque 20 N˙m
15 lb-ft
Shift valve housing, screw Torque 11 N˙m
8 lb-ft
K1 solenoid valve (Y40) Torque 45 N˙m

Specificatio
Item Measurement
n
33 lb-ft
33 lb-ft
33 lb-ft
Transmission oil pump to front transmission cover, screw Torque 25 N˙m
18 lb-ft
Ring gear cover, screw Torque 10 N˙m
7 lb-ft
B1 brake housing, screw Torque 60 N˙m
44 lb-ft
B3 piston plate, screw Torque 6 N˙m
4.4 lb-ft
C4 clutch cover, screws Torque 25 N˙m
18 lb-ft
Reverse brake housing, screw Torque 50 N˙m
37 lb-ft
Forward clutch drum, screw Torque 50 N˙m
37 lb-ft
Transmission Components

Electrically actuated PowrQuad module
LEGEND:
A Disk brake housing (reverse brake)
B Planet gear housing with forward clutch and C4 clutch
C B2-B3 brake housing
D B1 brake housing
E Front transmission cover
F Front valve housing
G Transmission oil filter housing
H Shift valve housing

Replacing the temperature sensor and pressure

switches
→NOTE:
Before installing the pressure switches, check that the bores are clean and
allow a through-passage.
LEGEND:
A System pressure, pressure switch
B Pressure switch for clutch pressure
C Pressure switch for the transmission oil filter restriction indicator
Replace system pressure switch (A), and tighten it to its proper torque value.
System pressure, pressure switch Torque 4 to 7 N˙m
3 to 5 lb-ft
Replace clutch pressure switch (B), and tighten it to its proper torque value.
Clutch pressure, pressure switch Torque 9 N˙m
6 lb-ft
Replace pressure switch (C; for indicating a restriction at the transmission oil filter), and
tighten it to its proper torque value.
Pressure switch, restriction indicator of the transmission oil filter Torque 4 to 7 N˙m
3 to 5 lb-ft

→NOTE:
Before installing the temperature sensor, check that its bore is clean and
allows a through-passage.
Replace temperature sensor (A), and tighten it to its proper torque value.
Temperature sensor Torque 4 to 7 N˙m
3 to 5 lb-ft
Removing and Installing the Oil Filter Housing
[1] - Take screws (A) out of the oil filter housing.

[2] -
→NOTE:
Before installing the oil filter housing, clean all the sealing faces. Use a new
gasket, if necessary.
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
Install the oil filter housing, tightening all the screws evenly. Before tightening, allow the

screws at least 3 minutes to settle.

Oil filter housing, screw Torque 11 N˙m
8 lb-ft
Replacing the Oil Filter

[1] -
Coat the sealing ring (A) on the new oil filter with a little grease or oil. By hand, screw the oil
filter onto the filter housing.
[2] -
Tighten the transmission oil filter to the specified torque value.

Transmission oil filter to filter housing Torque 30 N˙m
22 lb-ft

Removing and Installing the Front Valve Housing

Preliminary work:
Refer to “Removing the PowrQuad Transmission” in this Section, Group 00.
Refer to “Removing and Installing the Oil Filter Housing” .
Removing and installing the front valve housing
[1] -
Take screws (A) out of the front valve housing.

[2] - Remove two gaskets and separator plate.

[3] -
If necessary, replace seal ring (A). Use oil seal installer JDG775 to do this.
Seal installer
JDG775
Installing the seal ring in front valve housing

[4] -
→NOTE:
Before installing the front valve housing, clean all the sealing faces. Use a
new gasket, if necessary.
→NOTE:
Tighten screws in clockwise direction, starting with the innermost screws.
Install the front valve housing and tighten the screws evenly to a temporary torque of 10
N˙m (7 lb-ft).
[5] - Before tightening to a final torque, allow the screws at least 5 minutes to settle.
Front valve housing, screw Torque 11 N˙m
8 lb-ft
Final assembly:
Refer to “Removing and Installing the Oil Filter Housing” .
Refer to “Installing the PowrQuad Transmission” in this Section, Group 00.

Removing and Installing the Valves in the Front

Valve Housing
Exploded view of valves and front valve housing
LEGEND:
A Transmission oil filter by-pass valve
B Cooler relief valve
C Lube oil relief valve
D Reverse solenoid (Y36) and shift valve (reverse)
E Forward solenoid (Y33) and shift valve (forward)
F Enable proportional solenoid (Y38)
Reconditioning the by-pass valve of the transmission oil filter

[1] -
Remove plug (A), spring (B) and valve (C).

[2] - Check components for wear. Replace, if necessary.
[3] -
→NOTE:
Before installing the valve, check that its bore is clean.
Install valve (C), spring (B) and plug (A). Tighten the plug.
Transmission oil filter by-pass valve, plug Torque 20 N˙m
15 lb-ft
Reconditioning the pressure-relief valve of the cooler
[1] -

[3] -
→NOTE:

22 lb-ft
Reconditioning the lube oil relief valve
[1] -

[3] -
→NOTE:
Lube oil relief valve, plug Torque 20 N˙m
15 lb-ft
Reconditioning the reverse solenoid (Y36) and the shift valve

[1] -
Remove solenoid valve (A), spring (B) and shift valve (C).
[3] -
→NOTE:
Install shift valve (C), spring (B) and solenoid valve (A). Tighten solenoid valve (A).
Reverse solenoid (Y36) Torque 45 N˙m
33 lb-ft
Reconditioning the forward solenoid (Y33) and shift valve
[1] -
Remove solenoid valve (A), spring (B) and shift valve (C).
[3] -
→NOTE:

Install shift valve (C), spring (B) and solenoid valve (A). Tighten solenoid valve (A).
Forward solenoid (Y33) Torque 45 N˙m
33 lb-ft
Reconditioning the enable proportional solenoid (Y38)
[1] -
Remove the enable proportional solenoid valve (A).

[2] - Replace, if necessary.
[3] -
→NOTE:
Install the enable proportional solenoid valve (A) and tighten it to its proper torque.
Enable proportional solenoid (Y38), screw Torque 25 N˙m
18 lb-ft

Removing and Installing the Front Transmission

Cover
Preliminary work:
Refer to “Removing and Installing the Front Valve Housing” .
[1] -
Take screws (A) out of the front transmission cover.

→NOTE:
On the side with the shift valve housing, two screws (A) are inserted into
the front transmission cover from the rear.

[2] -
Before installing the front transmission cover, clean the sealing faces. Use a new gasket, if
necessary.
[3] - Install the front transmission cover, tightening all the screws evenly.
Front transmission cover, screw Torque 60 N˙m
44 lb-ft
Final assembly:
Refer to “Removing and Installing the Front Valve Housing” .

Removing and Installing the Valves in the Front

Transmission Cover
Exploded view, front transmission cover
LEGEND:
A Return valve, gear-to-gear modulation
B Gear-to-gear modulator valve and accumulator (gear-to-gear modulation)
C Pressure-regulating valve
D Cooling oil control valves and clutch cooling valve
Reconditioning the return valve of the gear-to-gear modulator valve

[1] -
Remove cover (A).

[2] -
Remove return valve (A) and spring (B).

[4] -
→NOTE:
Before installing the valve, check that its bores are clean and allow a
through-passage.
Reinstall the return valve and put the cover back on. Tighten cap screws.
9 lb-ft
Reconditioning the gear-to-gear modulator valve and pressure

accumulator

[1] -
Remove cover (A).

[2] -
Remove accumulator (A), pin (B), the two springs (C) and modulator valve (D).
[4] -
→NOTE:
Before installing the valve, check that its bores are clean and allow a
through-passage.
Reinstall the valves and put the cover back on. Tighten cap screws.
9 lb-ft
Reconditioning the pressure-regulating valve

[1] -
Remove plug (A) together with washers (B), spring (C) and pressure-regulating valve (D).
[2] - Check parts for wear and replace if necessary.
[3] -
→NOTE:
Install the pressure-regulating valve and tighten the plug.

Pressure-regulating valve, plug Torque 30 N˙m
22 lb-ft
Reconditioning the cooling oil control valves and cooling valve
[1] -
Take out plug (A) and remove the cooling oil control valves (B), clutch cooling valve (C) and
springs (D).

[3] -
→NOTE:
Before installing the valves, check that the bore is clean and allows a
through-passage.
Install the valves and tighten the plug.

Cooling oil control valves and clutch cooling valve, plug Torque 20 N˙m
15 lb-ft
Removing and Installing the Shift Valve Housing

[1] -
Take screws (A) out of the shift valve housing.

[2] -
→NOTE:
Before installing the shift valve housing, clean all the sealing faces. Use a
new gasket, if necessary.
Install the shift valve housing, tightening all the screws evenly.
Shift valve housing, screw Torque 11 N˙m
8 lb-ft

Remove and Install the Valves in the Shift Valve

Housing
Exploded view of shift valve housing
LEGEND:
A K1 solenoid valve (Y40) and B1-B2 shift valve
B K2 solenoid valve (Y39) and B2-B3 shift valve
C K3 solenoid valve (Y32) and B3-C4 shift valve

IMPORTANT:
The K3 solenoid valve (Y32) is omitted from tractor serial no. 398656.
Solenoid valve K1 is now designated as solenoid valve 2 (Y63); it shifts B3-

C4.
Solenoid valve K2 is now designated as solenoid valve 1 (Y62); it shifts B1-

B2.
Solenoid valve and B1-B2 shift valve
[1] -
Remove the K1 solenoid valve (A; Y40), shift valve (B) and spring (C).
[3] -
→NOTE:
Install the valve, tightening it to its proper torque.

33 lb-ft
Solenoid valve and B2-B3 shift valve

[1] -
[3] -
→NOTE:

33 lb-ft
Solenoid valve and B3-C4 shift valve
[1] -
[3] -
→NOTE:


33 lb-ft
IMPORTANT:
The K3 solenoid valve (Y32) is omitted from tractor serial no. 398656.
Instead of the solenoid valve, a screw plug is installed.

Removing the Transmission Oil Pump

Preliminary work:
See reference “Removing and Installing the Front Valve Housing” in this Group.
See reference “Removing and Installing the Front Transmission Cover” in this Group.
[1] -

[2] -
Take screws (A) out of the transmission oil pump.

[3] -
Check flange face (A) of the transmission oil pump. Surface (A) must be free of scoring and
other signs of damage. If necessary, replace the housing.

Repairing the Transmission Oil Pump

Preliminary work:
Refer to “Removing the Transmission Oil Pump” in this Group.
Exploded view of the transmission oil pump
LEGEND:
A Bushing
B Input shaft
C Bearing
D Screw (6 used
E Pump housing
F Dowel pin (2 used)
G Drive gear
H Idler gear
I Air pump operating pin
J Pump piston
K Rubber ball
L Lower spring retainer
M Spring
N Upper spring retainer with O-ring
O Snap ring

P Front transmission cover

Q Bearing
R Snap ring
S Seal ring
T O-ring
U Input flange
V Plastic binder
W Bellows
X Input flange
Y Input shaft
Disassembling the transmission oil pump
[1] -
LEGEND:
A Pump housing
B Pump gears
C Input shaft
Remove input shaft (C).
[2] - Take the pump gears (B) out of the pump housing.

[3] - Check the input shaft for wear.
LEGEND:
A Input shaft on tractor 6820
B Input shaft on tractor 6920
[4] -
Check bearing bushing (A). Replace, if necessary.

[5] - Install new bearing bushing using JDG765 bushing installer.
Bushing installer
JDG765
Installing bushings

[6] -
Check the needle bearing (A). Replace, if necessary.

[7] - Insert the needle bearing (A) so that it lies flush with the surface. Do this using a
mandrel and the 82.6 mm (3-1/4") and 93.7 mm (3-11/16") dia. washers.
Bushing, bearing and seal driver sets
D01045AA
[8] -
Check the ball bearing (A) in the front transmission cover. Replace, if necessary.
[9] -
→NOTE:
When installing or removing the ball bearing, support the rear surface of
the bearing bore to prevent damage to the housing.
Insert the ball bearing and press it right down. Do this using a mandrel and the 44.5 mm
(1-3/4") and 73 mm (2-7/8") dia. washers.
D01045AA
Hydraulic puller set
D01048AA
Removal of bearings
D01173AA
Removal of bearings
Repairing the pneumatic pump

[1] -
LEGEND:
A Pneumatic pump operating pin
B Piston
C Rubber ball
D Lower spring retainer
E Spring
F Upper spring retainer with O-ring
G Snap ring
Remove the air pump operating pin (A) from the pump housing.

[2] - Remove snap ring (G).

→NOTE:
When disassembling, proceed with care as the snap ring is under pressure.
[3] - Remove upper spring retainer (F), spring (E), lower spring retainer (D), rubber ball (C)
and piston (B).
[4] - Check components (A) to (G) for signs of wear. Replace, if necessary.
[5] -
→NOTE:
Apply clean oil to all moving parts before installing.
Insert air pump operating pin (A) and install parts (B) to (F).
[6] -
Install snap ring (G).
Assembling the transmission oil pump
[1] -
Drive in the dowel pins until dimension “a” is 6 ± 1 mm (0.24 ± 0.04 in.).

[2] -
→NOTE:
Apply clean oil to all moving parts before installing.
Install the pneumatic pump operating pin (A) in pump housing.

[3] -
Install pump gears (A) and (B) in the pump housing so that the side of the gears marked “UP”
(C) is visible.
IMPORTANT:
Install the pump gears so that the side of the gears marked “UP” (C) faces
away from the housing (chamfered side of gears must face towards the
base of the pump housing).

[4] -
Insert input shaft (A). Note the position of the pneumatic pump operating pin.
Final assembly:
Refer to “Installing the Transmission Oil Pump” in this Group.

Installing the Transmission Oil Pump

[1] -
Install the transmission oil pump on the front transmission cover.

[2] -
IMPORTANT:
The attaching screws have self-locking characteristics, and must therefore
be replaced with new screws every time they are taken out.
Tighten attaching screws (A) evenly.

Transmission oil pump to front transmission cover, screw Torque 25 N˙m
18 lb-ft
[3] -
Install snap ring (A).
Final assembly:
See reference “Removing and Installing the Front Transmission Cover” in this Group.
See reference “Removing and Installing the Front Valve Housing” in this Group.

Removing the Gear-Shift Planetary Drive

Preliminary work:
See reference ”Removing and Installing the Front Transmission Cover” in this Group.
[1] -
LEGEND:
A Cover
B Ring gear
Remove cover (A) and ring gear (B).
→NOTE:
From tractor serial no. 424468, partial uncovering no longer suffices; it
must be uncovered fully.

[2] -
LEGEND:
A Planetary carrier
B 3rd gear sun gear
C 2nd gear sun gear
D 1st gear sun gear
Remove the planetary carrier assembly (A).
[3] - Remove sun gears (B to D).
→NOTE:
When removing the sun gears, take care not to pull the C4 clutch hub out
of the disk pack.

Repairing the Gear-Shift Planetary Drive

Preliminary work:
See reference ”Removing the Gear-Shift Planetary Drive” in this Group.
Exploded view of the planetary drive
LEGEND:
A B1 brake housing
B Screw
C Bushing
D 1st gear sun gear
E Thrust washer
F 2nd gear sun gear
[ A bearing bushing is integrated into the sun gear only from tractor serial no. 392759. ]
G Thrust washer
H 3rd gear sun gear with thrust washer
I Planetary carrier
J Thrust washer
K Spiral ring
[ The spiral rings are omitted from tractor serial number 343455. ]
L Spiral ring
M Ring gear with thrust washer
N Planet gear shaft
O Retaining pin
P Thrust washer
Q Bearing
R Spacer
S Planet gear
T Thrust washer
U Cover
[ From tractor serial no. 424468, partial uncovering no longer suffices; it must be uncovered fully. ]
V Screw
[1] -
LEGEND:
A Thrust washer
B Ring gear
Inspect thrust washer (A) and ring gear (B). Replace, if necessary.

[2] -
LEGEND:
A Spiral ring
B Spiral ring
Inspect spiral rings (A) and (B). Replace, if necessary.
CAUTION:
Take care when disassembling. The spiral rings are under pressure.

[3] -
LEGEND:
A 3rd gear sun gear with thrust washer
B Thrust washer
C 2nd gear sun gear
[ A bearing bushing is integrated into the sun gear only from tractor serial no. 392759. ]
D Thrust washer
E 1st gear sun gear
F Thrust washer
Check parts (A) to (F). Replace, if necessary.
[4] -
LEGEND:
A Thrust washer
Check the 3rd gear sun gear with its thrust washer (A). Replace, if necessary.

[5] -
LEGEND:
A Bearing bushing
Check the 2nd gear sun gear with its bearing bushing (A). Replace, if necessary.
→NOTE:
A bearing bushing is integrated into the sun gear only from tractor serial
no. 392759.
[6] -
LEGEND:
A Bearing bushing
Check the 1st gear sun gear with its bearing bushing (A). Replace, if necessary.
[7] - Install bushing flush with surface of gear. Do this using a mandrel and the 93.7 mm
(3-13/16") and 109.5 mm (4-5/16") dia. washers.
D01045AA

Disassembling the planetary carrier
[1] -
In order to remove the planet gear shafts, the retaining pins must be driven into the planet
gears shafts.
IMPORTANT:
Take care when driving in a retaining pin. Force it in only far enough for it
to be concealed by the planet gear shaft.
[2] -
Pull out the planet gear shaft and remove the retaining pin.

[3] -
LEGEND:
A Planetary carrier
B Planet gear
C Planet gear shaft
D Retaining pin
E Thrust washers
F Needle bearing
G Spacer
Remove needle bearings (F) and spacers (G) from planet gear (B).
[4] - Clean and check the various parts. Replace, if necessary.
Assembling the planetary carrier
[1] -
LEGEND:
A Needle bearing
B Spacer
Insert needle bearings (A) and spacer (B) into the planet gear.

[2] -
IMPORTANT:
Before assembling, make sure that the oil passages in the planet gear
shafts and planetary carrier are not blocked.
LEGEND:
A Thrust washer
B Planet gear shaft
Insert the planet gear in the planetary carrier, remembering to include thrust washers (B).
[3] - Install planet gear shaft (B).
[4] -
Drive in the retaining pin until it is flush.
Final assembly:
See reference ”Installing the Gear-Shift Planetary Drive” in this Group.

Install Gear-Shift Planetary Drive

[1] -
LEGEND:
A Thrust washer
B Spiral ring
Check thrust washer (A). The thrust washer must not be worn or damaged.
[2] - Install the bottom spiral ring (B)
.

[3] -
LEGEND:
A Mark
Apply paint to indicate the three marks (A) stamped on the edge of the ring gear (as help in
installing the planetary carrier), as the marks are concealed when the top spiral ring
is put on.

[4] -
LEGEND:
A Spiral ring
Install the top spiral ring (A)
in such a way that the ends (A) of the top and bottom spiral rings are at opposite sides.

[5] -
LEGEND:
A Timing mark on ring gear
B Timing mark on planet gear
Install the planet gear carrier in the ring gear in such a way that the timing marks on the
planet gears are opposite the timing marks on the ring gear.
[6] -
Turn the planet gear carrier and ring gear. Make sure the marks remain synchronized with
each other.

[7] - Install the JDG772 planetary installation tool.

Planetary holding tool
JDG772
Assembling the planetary housing

[8] -
LEGEND:
A Teeth
Place the transmission housing in the vertical position.
[9] - Align the teeth on disks (A).

[10] -
LEGEND:
A 1st gear sun gear
B 2nd gear sun gear
C 3rd gear sun gear
D Thrust washer
E Thrust washer
F Thrust washer
G Thrust washer on 3rd gear sun gear
Refer to the cross-sectional view before installing the sun gears and thrust washers.
[11] -
LEGEND:
A 1st gear sun gear
B 2nd gear sun gear
C 3rd gear sun gear with thrust washer
Install sun gears (A), (B) and (C), remembering to include thrust washers.

[12] -
Install the planetary drive on the sun gears using a JDG772 planetary holding tool.
→NOTE:
Turn the planetary drive to and fro; this will help facilitate its installation.

[13] -
LEGEND:
A Cover
Put on cover (A). Coat the screws with Thread Lock and Sealer LOCTITE ™ 243 (L41475), and
tighten.
Ring gear cover, screw Torque 10 N˙m
7 lb-ft
→NOTE:
From tractor serial no. 424468, partial uncovering no longer suffices; it
must be uncovered fully.
Final assembly:
See reference ”Removing and Installing the Front Transmission Cover” in this Group.
Removing the B1 Brake Housing

Preliminary work:

See reference “Removing the Gear-Shift Planetary Drive” in this Group.

Reconditioning the B1 Brake

Preliminary work:
See reference ”Removing the B1 Brake Housing” in this Group.
[1] -
LEGEND:
A Spring (4 used)
B Piston plate, B1-B2 disks
Take off the parts of the B1-B2 brake and check them. Replace, if necessary.
[2] -
Remove B1 brake piston (A) and check it. Replace, if necessary.

[3] -

LEGEND:
A B2-B3 brake housing
B Sealing ring
C B2 piston
D B2 piston plate
E B2 disk
F B1-B2 separator plate
[ From tractor ser. no. 411806, the separator plate is replaced by two thinner plates ]
G Spring
H B1 disk
I B1 plate
J B1 piston plate
K B1 piston
L B1 brake housing
M Attaching screw
Refer to the exploded view before assembling the B1-B2 brake.
Final assembly:
See reference ”Installing the B1 Brake Housing” in this Group.

Installing the B1 Brake Housing

[1] -
Insert seal ring (A) and the O-rings.

[2] -
Install the B1 brake housing. Make sure that the seal ring and O-rings are seated correctly.
[3] - Tighten the attaching screws evenly.
B1 brake housing, attaching screws Torque 60 N˙m
44 lb-ft
Final assembly:
See reference “Installing the Gear-Shift Planetary Drive” in this Group.
Removing the B2-B3 Brake Housing

Preliminary work:
See reference “Removing the B1 Brake Housing” in this Group.

Remove the B2-B3 brake housing (A).


Preliminary work:
See reference ”Removing the B2-B3 Brake Housing” in this Group.
[1] -
LEGEND:
A Springs (4 used)
B Piston plate, B1-B2 disks
Take off the various parts of the B1-B2 brake and check them. Replace, if necessary.
[2] -
Remove B2 brake piston (A). Replace, if necessary.

[3] -
LEGEND:
A B2-B3 brake housing
B Seal ring
C B2 brake piston
D B2 piston plate
E B2 disk
F B1-B2 separator plate
[ From tractor ser. no. 411806, the separator plate is replaced by two thinner plates ]
G Spring
H B1 disk
I B1 plate
J B1 piston plate
K B1 brake piston
L B1 brake housing
Refer to the exploded view before assembling the B2 brake.
Final assembly:
See reference ”Installing the B2-B3 Brake Housing” in this Group.


Preliminary work:
See reference “Removing the B2-B3 Brake Housing” in this Group.
[1] -
Remove B3 brake piston (A) and check it. Replace, if necessary.

[2] -

[3] - Take out the various components of the B3 brake and check them. Replace, if
necessary.
[4] -

LEGEND:
A Planet gear housing
B Seal
C B3 plate
D B3 disk
E B3 piston plate
F Spring
G B3 brake piston
H B2-B3 brake housing
I Dowel pin
J Screw
Refer to the exploded view before assembling the B3 brake.
[5] -
→NOTE:

Tighten attaching screws (A) evenly.

B3 piston plate, screw Torque 6 N˙m
4.4 lb-ft
Final assembly:
See reference “Installing the B2-B3 Brake Housing” in this Group.
Installing the B2-B3 Brake Housing

[1] -
Insert seal (A) and the O-rings.

[2] -
Install the B2-B3 brake housing (A). Make sure that the seal and O-rings are seated correctly.
Final assembly:
See reference “Installing the B1 Brake Housing” in this Group.
Removing the C4 Clutch

Preliminary work:
See reference “Removing the B2-B3 Brake Housing” in this Group.
Take out the C4 clutch (A).

Reconditioning the C4 Clutch

Preliminary work:
See reference ”Removing the C4 Clutch” in this Group.
Exploded view of C4 clutch
LEGEND:
A Planet gear housing
B Thrust washer
C Sealing ring
D Bushing
E C4 clutch drum
F Dowel pin
G Sealing ring
H Sealing ring
I C4 clutch piston
J Clutch hub
K Piston plate
L Disk
M Disk
N Pin
O Spring
P Clutch cover
Q Screw
R Suction valves
S Dowel pin
T Thrust washer
Bushing
U [ From tractor serial no. 392759, the bearing bushing is omitted from the C4 clutch drum. Thereafter, the bearing
bushing is integrated into the 2nd gear sun gear. Remember this when ordering spare parts. ]
V Retainer
W Anti-cavitation check valve
X Thrust washer
Recondition or assemble the C4 clutch as required, using the illustration as a guide.
[1] - Take out screws (Q) and remove clutch cover (P).
[2] - Remove clutch hub (J), disks (L) and (M) and piston plate (K).
[3] - Remove springs (O) and pins (N).
[4] - Remove the C4 clutch piston (I) and C4 clutch drum (E), and the piston seal rings (G)
and (H).
Assembling C4 clutch

[1] -
LEGEND:
A Anti-cavitation check valves
Inspect clutch piston and anti-cavitation check valves (A).
→NOTE:
LEGEND:
A Retainer
B Ball
The anti-cavitation check valve consists of retainer (A) and ball (B). The
valve ball must not be jammed; it must move freely.

[2] -
LEGEND:
A Seal ring
Coat seal ring (A) with grease and install it in the piston groove.
→NOTE:
Position the seal ring in the ring groove so that it is not damaged when the
piston is installed.
[3] -
LEGEND:
A Bushing
Inspect bushing (A). Replace, if necessary.

[4] -
LEGEND:
A Bushing
Install new bushing using JDG765 Bushing Installer.
Bushing installer
JDG765
Installing bushings
→NOTE:
Press in bushing (A) until it is 1.5 mm (0.06 in.) below the surface.

[5] -
LEGEND:
A Sun gear, bearing bushing
From tractor serial no. 392759, the bearing bushing is omitted from the C4 clutch drum.
Thereafter, bearing bushing (A) is integrated into the 2nd gear sun gear.
[6] -
LEGEND:
A Bushing
Inspect bushing (A). Replace, if necessary.

[7] -
LEGEND:
A Bushing
B Surface
Install new bushing using D01045AA Driver Set. Do this using a mandrel and the 57.2 mm
(2-1/4") and 66.7 mm (2-5/8") dia. washers.
D01045AA
→NOTE:
Press in bushing (A) until it is 0.5 mm (0.02 in.) below the surface (B).
[8] -
At the clutch drum, apply a light coat of grease to the mounting surfaces of the clutch piston.

[9] -
LEGEND:
A Seal ring
Coat seal ring (A) with grease and install it in the groove at the clutch drum.
→NOTE:
[10] -
LEGEND:
A Piston
B Guides
Place piston (A) in clutch drum with guides (B) for piston plate installation in the position
shown.
[11] - Press piston (A) down in the clutch drum.
IMPORTANT:
Be careful to avoid damaging the seal rings.

[12] -
LEGEND:
A Piston plate
Insert piston plate (A).
[13] -
LEGEND:
A Thrust washer
Install the thrust washer (A).
→NOTE:
Slightly coat the thrust washer with grease to prevent it from falling out.

[14] -
LEGEND:
A Clutch hub
Insert the clutch hub (A).
[15] -
LEGEND:
A Disk with liner
B Disk without liner
Assemble the disk pack as required. Start with a lined disk (A).
[16] - Then install disks without liner (B) and disks with liner (A) alternately.

[17] -
LEGEND:
A Guide pin
Install the spring guide pins (A).
[18] -
LEGEND:
A Spring
Insert the springs (A).

[19] -
Apply sealing compound LOCTITE ™ 243 (medium strength) to the threaded bores.
[20] -
LEGEND:
A Hole
B Dowel pin
Install the clutch cover. Position the clutch cover so that the bores (A) for the dowel pins (B)
are aligned.

[21] -
LEGEND:
A Attaching screw
Insert clutch cover attaching screws (A) and slightly tighten them in cross-wise fashion until
clutch cover contacts clutch drum.
[22] -
Tighten clutch cover attaching screws (A) to the specified torque.

C4 clutch cover, screws Torque 25 N˙m
19 lb-ft
Final assembly:
See reference ”Installing the C4 Clutch” in this Group.
Installing the C4 Clutch

[1] -
Make sure that seal rings (A) and thrust washer (B) are positioned correctly.
[2] - Check the suction valves (C) for the forward clutch and C4 clutch. The valve ball must
not be jammed; it must move freely.
[3] -
Install the C4 clutch (A).
Final assembly:
See reference “Installing the B2-B3 Brake Housing” in this Group.
Removing the reverse brake

Preliminary work: See “Removing the PowrQuad transmission” .

[1] -
Take out screws (A) and remove the reverse brake housing.
[2] - Repair the reverse brake. See “Repairing the reverse brake” in this group.

Repairing the reverse brake

Preliminary work: See “Removing the reverse brake” .
[1] -
Remove the pack of brake disks (A).

[2] -
Remove pressure plate (A) and springs (B).

[3] -
Removing the reverse brake piston (A).

[4] -
LEGEND:
A Dowel pin
B Bearing bushing
C Seal ring
D Mounting screw
E Reverse brake housing
F Gasket
G Reverse brake piston
H Piston plate
Reverse brake disk (4
[ Tractors 6820 ]
I or 5
[ Tractors 6920 ]
used)
J Spring (8 used)

Reverse brake plate (3

[ Tractors 6820 ]
K or 4
[ Tractors 6920 ]
used)
L Ring gear
M Pressure plate
Repair or assemble the reverse brake as required, using the exploded view as a guide.
[5] -
Check the bearing bushing (A) in the reverse brake housing. Replace, if necessary.
[6] - When installing, turn bushing (A) so that its hole is aligned with the hole in the housing
(see arrow).
[7] - Press bushing (A) into the housing in such a way that it lies flush with the surface on the
side of the piston. Do this using a mandrel and the 93.7 mm (3-11/16") and 100 mm
(3-15/16") dia. washers.
D01045AA
Final assembly: Refer to “Installing the reverse brake” .
Installing the reverse brake

[1] - Clean the sealing surfaces and install the gasket.

[2] -
Install the reverse brake housing and tighten screws (A).

Reverse brake housing, screw Torque 50 N˙m
37 lb-ft
Final assembly: See “Installing PowrQuad transmission” .

Removing the Forward Clutch with Planetary Drive

(Forward/Reverse)
Preliminary work:
See reference “Removing the Reverse Brake” in this Group.
[1] -
Remove pressure plate (A) and ring gear (B).

[2] -
→NOTE:
The forward clutch and planetary drive are very heavy. Proceed with care
and use suitable lifting tackle.
Remove the forward clutch with planetary drive.

Reconditioning the Forward Clutch with Planetary

Drive (Forward/Reverse)
Preliminary work:
See reference ”Removing the Forward Clutch with Planetary Drive (Forward/Reverse)” in this
Group.
Cross-sectional and exploded views of the forward clutch and

planetary drive
LEGEND:
A Piston plate
B Disk
C Clutch plate

D Planetary carrier
E Retaining pin
F Thrust washer
G Planet gear
H Planet gear shaft
I Clutch hub
J Thrust washer
K Needle bearing
L Bushing
M Spring
N Guide pin
O Seal ring
P Clutch piston
Q Seal ring
R Bushing
S Drive shaft
T Snap-ring
U Thrust washer
V Clutch drum
W Overspeed relief valve

LEGEND:
1 Planet gear housing
2 Thrust washer
3 Seal ring
4 Drive shaft
5 Snap-ring
6 Clutch hub
7 Snap-ring
8 Bushing
9 Clutch piston
10 Seal ring
11 Seal ring
12 Thrust washer
13 Clutch drum
14 Attaching screw
15 Bushing
16 Ball
17 Spring
18 Retainer
19 Spring
20 Guide pin
21 Piston plate
22 Disk with liner
23 Disk without liner
24 Retaining pin
25 Thrust washer
26 Planet gear
27 Needle bearing
28 Planet gear shaft
29 Planetary carrier
30 Thrust washer
Recondition or assemble the forward clutch and planetary drive as required, using the cross-
section and exploded views as guidelines.
[1] -
→NOTE:
It is not necessary to remove drive shaft (A) unless it is damaged.

LEGEND:
A Drive shaft
B Snap-ring
Drive shaft (A) is locked to the clutch drum by snap ring (B).
Snap ring (B) will be damaged if the shaft is removed. Press the drive shaft (A) out in the
direction shown by the arrow.
[2] -
LEGEND:
A Clutch drum
Take out the attaching screws and lift off clutch drum (A).

[3] -
LEGEND:
A Disk pack
Take disk pack (A) and the clutch hub, springs, guide pins and clutch piston out of the clutch
drum.
Check components for wear. Replace, if necessary.
[4] - Install the forward clutch
LEGEND:
A Bushing
Install bushing (A) in the clutch drum; make sure it is flush. Do this using a mandrel and the
57.2 mm (2-1/4") and 66.7 mm (2-5/8") dia. washers.
D01045AA

[5] -
LEGEND:
A Bushing
B Snap-ring
Install bushing (A) in the hub; make sure it is flush. Do this using a mandrel and the 74.6 mm
(2-15/16′′) dia. washer.
D01045AA
[6] - Insert snap ring (B) into the ring groove in the hub.
[7] -
LEGEND:
A Overspeed relief valves
Check the clutch piston and the overspeed relief valves (A).
→NOTE:
The overspeed relief valve consists of a ball, spring and retainer. The valve
ball must not be jammed; it must move freely against the spring.

[8] -
LEGEND:
A Seal ring
Coat seal ring (A) with grease and install it in the piston groove.
→NOTE:
[9] -
At the clutch drum, apply a light coat of grease to the mounting surfaces of the clutch piston.

[10] -
LEGEND:
A Seal ring
Coat seal ring (A) with grease and install it in the groove at the clutch drum.
→NOTE:
[11] -
LEGEND:
A Piston
B Guide
Place piston (A) in clutch drum with guides (B) for piston plate installation in the position
shown.
[12] - Press piston (A) down in the clutch drum.
IMPORTANT:
Be careful to avoid damaging the seal rings.

[13] -
LEGEND:
A Piston plate
B Guide pin
C Guides
Insert the piston plate (A) together with the guide pins (B), paying attention to guides (C).
[14] -
LEGEND:
A Thrust washer
Install the thrust washer (A).
→NOTE:
Slightly coat the thrust washer with grease to prevent it from falling out.

[15] -
LEGEND:
A Clutch hub
Insert the clutch hub (A).
[16] -
LEGEND:
A Disk with liner
B Disk without liner
Assemble the disk pack as required. Start with a lined disk (A).
Then install disks without liner (B) and disks with liner (A) alternately.

[17] -
LEGEND:
A Spring
Insert the springs (A).
[18] -
LEGEND:
A Clutch cover
Position the clutch cover and planetary carrier so that the blind holes (A) for springs (B) are
aligned.

[19] -
LEGEND:
A Attaching screws
Before turning the forward clutch with the planetary carrier through 180°, install two
attaching screws (A) and tighten them a little, so that the various components stay in
position.
[20] -
Take out the two attaching screws that were already installed.
Apply sealing compound LOCTITE ™ 243 (medium strength) to all the attaching screws.

[21] -
Install the attaching screws and slightly tighten them in cross-wise fashion until the clutch
cover touches the clutch drum.
[22] - Now tighten the clutch cover attaching screws to the specified torque.
Forward clutch drum, screw Torque 50 N˙m
37 lb-ft

[23] -
LEGEND:
A Drive shaft
B Snap-ring
Put snap ring (B) on the drive shaft (A).
→NOTE:
There is a chamfer on the front end of the splines in the clutch drum to
allow the drive shaft with snap ring in place to be installed more easily.
[24] - Press drive shaft (A) into the clutch drum as shown by the arrow.
Reconditioning the planetary carrier

[1] -
In order to remove the planet gear shafts, the retaining pins must be driven into the planet
gears shafts.
IMPORTANT:
Take care when driving in a retaining pin. Force it in only far enough for it
to fall into the planet gear shaft.
[2] -
LEGEND:
A Planet gear shaft
B Planet gear
C Retaining pin
Pull out planet gear shaft (A) and take off planet gear (B) with its thrust washers and needle
bearing.
[3] - Remove retaining pin (C) from planet gear shaft (A).

[4] -
LEGEND:
A Thrust washers
B Needle bearing
C Planet gear
D Planet gear shaft
E Retaining pin
Check the components. Replace, if necessary.
[5] -
LEGEND:
A Thrust washers
B Needle bearing
C Planet gear
Assembling the planetary carrier
Insert needle bearing (B) and install thrust washers (A) on planet gear (C).
[6] -
IMPORTANT:
Before installing, make sure that the oil passages in the planet gear shafts
and planetary carrier are not blocked.

Insert the planet gear in the planetary carrier, remembering to include TWO thrust washers
(A).
[7] - Install planet gear shaft (B).
[8] -
Drive in the retaining pin until it is flush.
Final assembly:
See reference ”Installing the Forward Clutch with Planetary Drive (Forward/Reverse)” in this
Group.

Installing the Forward Clutch with Planetary Drive

(Forward/Reverse)
[1] -
Make sure that seal rings (A) and thrust washer (B) are positioned correctly.
[2] -
→NOTE:
The forward clutch and planetary drive are very heavy. Proceed with care
and use suitable lifting tackle.
→NOTE:
Avoid damaging the sealing rings.
Install the forward clutch with planetary drive.

[3] -
Install pressure plate (A) and ring gear (B).
Final assembly:
See reference “Installing the Reverse Brake” in this Group.

Replacing the output shaft

Preliminary work: See “Removing the PowrQuad transmission” .
Exploded view of output shaft
LEGEND:
A Seal ring
B Transmission output shaft
C Bearing bushing
D O-ring
E Snap ring
F Sleeve
G Rear PTO drive shaft
Repair or assemble the components of the drive shaft as required, using the exploded view
illustration as a guide.

[1] - Check the transmission output shaft, the rear PTO drive shaft, the sleeve and all
components for wear. Replace, if necessary.
LEGEND:
A Sleeve
B Rear PTO drive shaft
C Transmission output shaft
[2] -
LEGEND:
A Seal ring
B O-rings
C Bushing
D Oil passage
Press in the bushing (C) to a depth of 2 mm (0.079 in.) beneath the base of the chamfer in
the transmission output shaft. Do this using a mandrel and the 93.7 mm (3-11/16") and 100
mm (3-15/16") dia. washers.
D01045AA
[3] - Make sure the oil passages (D) of the transmission output shaft are open.

Group 15: Creeper Transmission
Final assembly: See “Installing PowrQuad transmission” .

Group 15 - Creeper Transmission

Creeper Transmission - Reconditioning (Summary of
References)
”Removing the creeper transmission”
”Reconditioning the creeper transmission”
”Installing the creeper transmission”
Special tools
→NOTE:

Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
Repair specifications
Shifter fork detent pin, spring Free length approx. 20 mm
approx. 0.8 in.
Test length 12 mm at 58 to 72 N
0.5 in. at 12 to 16 lb
Friction brake, spare part Disk thickness 2,33 to 2,43 mm
0.092 to 0.096 in.
Plate thickness 1,52 mm to 1,62 mm
0.060 to 0.064 in.
Backing plate to input shaft, hex. socket screw Torque 4 N˙m
3 lb-ft
Intermediate plate to range transmission, cap screw Torque 70 N˙m
50 lb-ft

Removing the creeper transmission

Preliminary work:
For information on removing the PowrQuad, PowrQuad Plus and AutoQuad transmissions, see
“Removing the PowrQuad transmission” .
Before removing the creeper transmission, see “Removing the creeper or intermediate
transmission” .
[1] -
Remove creeper transmission.

[2] -
If necessary, remove intermediate plate (A).

[3] - Remove cap screws (B) and intermediate plate.

Repairing the creeper transmission

Preliminary work:
See “Removing the creeper transmission” .
Creeper transmission — Sectional view


LEGEND:
1 Roller bearing
2 Snap ring
3 Snap ring
4 Wear sleeve
5 Ball bearing
6 Snap ring
7 Snap ring
8 Lube passage seal
9 Input shaft with gear
10 Drive sleeve
11 Housing
12 Shift collar
13 Output gear
14 Thrust washer
15 Snap ring
16 Output drive gear/friction brake
17 Snap ring
18 Bushing
19 Spring (friction brake)
20 Brake disks (3 used)
21 Externally splined disk (3 used)
22 Backing plate
24 Thrust washer
25 Needle bearing
26 Snap ring
27 Transmission lube oil seal
28 Countershaft
29 Needle bearing
30 Countershaft drive gear
31 Intermediate plate
Exploded view of the input/output drive shaft and shifter assembly

LEGEND:
1 Output sleeve
2 Input shaft
3 Shift collar
4 Dowel pin
5 Spring pin
6 Shift fork
7 Ball bearing
8 Snap ring
9 Snap ring
10 O-ring
11 Shifter shaft
12 Lever
13 Detent pin
14 Spring

15 Washer
16 Plug
17 Shifter fork detent
18 Sealing sleeve
19 Snap ring
20 Thrust washer
21 Needle bearing
22 Snap ring
23 Snap ring
24 Thrust washer
25 Drive gear
26 Input shaft
27 Bushing
28 Spring washer
29 Externally splined disk (3 used)
30 Brake disks (3 used)
31 Backing plate
Repair or assemble the input/output shaft and shifter assembly as required, using the
exploded view illustration as a guide.
Shifter assembly components — Sectional view
LEGEND:
A Shifter shaft
B O-ring
C Spring pin

D Shift fork
E Dowel pin
F Distance 6.75 to 7.25 mm (0.266 to 0.285 in.)
G Spring
H Detent pin
I Washer
J Plug
Repairing the input/output shaft and shifter assembly
[1] -
Remove snap ring (A), thrust washer (B) and gear (C).
[2] -
Remove plug (A) and shifter fork detent parts.

Shifter fork detent pin, spring Free length approx. 20 mm
approx. 0.8 in.
Test length 12 mm at 58 N to 72 N
0.5 in. at 12 lb to 16 lb

[3] -
LEGEND:
A Shifter fork
B Spring pins
C Lever, shifter shaft
D Shift collar
E Dowel pins
Turn shifter fork (A) to the front and remove shift collar (D). Now the output shaft can be
removed.
[4] - If necessary, remove spring pins (B) and pull out lever (C) with shifter shaft.
[5] - Check the dowel pins (E) for wear. Replace, if necessary.
The dowel pins must protrude 6.75 to 7.25 mm (0.266 to 0.285 in.) from finished face of the
shifter fork.
[6] -
LEGEND:
A Snap ring
B Shaft
C Bearing
D Snap ring
[7] - Remove input/output shaft (B) rearward through bearing (C).

[8] - Check bearing (C) for wear. Replace, if necessary.

→NOTE:
To disassemble the bearing the countershaft drive gear must be removed.
See "Repairing the countershaft".
[9] - Remove bearing snap ring (D).

[10] - Remove the countershaft drive gear.
[11] - Remove bearing (C) using the driver (102 mm; 4 in. dia.).
D01045AA
[12] - Install a new bearing (C) using a 110 mm (4-5/16 in.) driver disk and a 70 mm (2-3/4
in.) pilot disk.
D01045AA
[13] - Install bearing snap ring (D).
[14] -
Remove snap ring (A), the roller bearing (B) of the range transmission shaft and thrust
washers.
[15] - Remove internal snap ring (C).
[16] -
Remove output shaft/friction brake (A) from input shaft (B).

[17] - Remove drive sleeve (C) from shaft.

[18] -
Take out cap screws (A).

[19] -
LEGEND:
A Backing plate
B Brake disks (3 used)
C Externally splined disk (3 used)
D Spring washer
Remove parts (A—D).
Friction brake, spare part Disk thickness 2,33 to 2,43 mm
0.092 to 0.096 in.
Plate thickness 1,52 mm to 1,62 mm
0.060 to 0.064 in.
[20] -
Inspect the bearing bushing (A) for wear. Replace, if necessary.

[21] - Install new bearing bushing using a 50 mm (1-15/16 in.) driver disk and a 46 mm
(1-13/16 in.) pilot disk.
D01045AA
→NOTE:
Insert the bearing at a depth of up to 1 mm (0.039 in.) beneath the surface
of the hub.
[22] -
LEGEND:
A Backing plate
B Brake disks
C Externally splined disks
D Spring washer
Install spring washer (D) with ID against the hub face.
[23] - Alternately install three disks (B) and three externally splined disks (C), starting with
an externally splined disk against the spring washer.
[24] - Install backing plate (A).
[25] -
Apply L41475 ( LOCTITE ™ 243) to threads of cap screws (A).

[26] - Install hex. socket screws. Do not tighten the at this stage.
[27] - Align the tangs (B) on the brake disks.

[28] -
Align the splines on the input drive shaft with the brake disk tangs and install the input drive
shaft (A) into the output drive shaft/friction brake assembly (B).
[29] - Tighten the hex. socket screws (C).
Backing plate to input shaft, hex. socket screw Torque 4 N˙m
3 lb-ft
[30] - Remove the input drive shaft (A) from the assembly.
[31] -
Install the transmission drive sleeve (C) onto the input drive shaft (B).
[32] - Install the output shaft/friction brake (A) onto the input drive shaft (B).
[33] -
Install internal snap ring (C).

[34] - Install the roller bearing (B) of the range box shaft, together with a thrust washer on
each end.
[35] - Install snap ring (A).

[36] -
LEGEND:
A Snap ring
B Shaft
C Bearing
D Snap ring
Push the input/output shaft (B) through bearing (C).
[38] -
Position the shift collar (A) at the dowel pins (C) of the shifter fork (B) and push onto the
output drive shaft.

[39] -
Install output drive gear (C) onto the shaft.

[40] - Install thrust washer (B) and snap ring (A).
Exploded view of the countershaft and housing
LEGEND:
A Cap screw (8 used)
B Dowel pin (2 used)
C Intermediate plate
D Countershaft drive gear
E Dowel pin (2 used)

G Housing
H Roller bearing
I Snap ring
J Snap ring
K Wear sleeve
L Cover
M Cap screw (5 used)
N Oil seal
O Countershaft
P Needle bearing
Q Cap screw (3 used)
R Plug
S O-ring
Repair or assemble the countershaft as required, using the illustration as a guide.
Repairing the countershaft
[1] -
LEGEND:
A Shaft snap ring
B Shaft
C Countershaft drive gear
D Bearing snap ring
E Shaft bearing
Pull the snap ring (A) and the countershaft (B) rearwards out of the bearing and the
countershaft drive gear (C).
[2] - Take the drive gear (C) out of the housing.
[3] - Remove the snap ring (D) and remove bearing (E) from housing, if necessary.

[4] - Remove bearing from the rear using a 60 mm (2-3/8 in.) driver.
D01045AA
[5] -
Remove needle bearing (A) from housing, if necessary, using a 50 mm (2 in.) driver.
D01045AA
[6] - Install a new bearing in the housing. Use a 64 mm (2-1/2 in.) driver disk with a 43 mm
D01045AA
[7] - Install the new bearing from rear of housing until rear bearing surface is flush with
housing surface.
[8] -
Remove transmission lube oil seal (A) from rear of countershaft, if necessary.
[9] - Install new seal ring using a 30 mm (1-3/16 in.) socket wrench.

[10] -
Remove wear sleeve (A) from front of countershaft, if necessary.

[11] - Install new sleeve using a 32 mm (1-1/4 in.) driver.
D01045AA
[12] -
LEGEND:
A Shaft snap ring
B Shaft
C Countershaft drive gear
D Bearing snap ring
E Shaft bearing
If required, install a new bearing (E) using a 60 mm (2-3/8-in.) driver disk and a 28.5 mm
D01045AA
[13] - Install snap ring (D).
[14] - Install countershaft drive gear (C) into the housing with widest flange toward front of
housing.
[15] - Install countershaft (B) into the housing through rear needle bearing, drive gear, and
front roller bearing (E).
Final assembly:
See “Installing the creeper transmission” .

Installing the creeper transmission

[1] -
Check cover (A) and sealing sleeve (B). Replace, if necessary.

[2] - Install cover (A) in range transmission using L41477 ( LOCTITE ™ 603).
[3] - Install sealing sleeve (B).
[4] -
Install intermediate plate (A).

[5] - Apply a thin and even layer of L64500 ( LOCTITE ™ 574) to the sealing faces.
[6] - Tighten cap screws (B).
Intermediate plate to range transmission, cap screw Torque 70 N˙m
50 lb-ft

Group 20: Range Transmission
[7] -
Install the creeper transmission. See “Installing the creeper or option transmission” .
Final assembly:
See “Installing PowrQuad transmission” .

Group 20 - Range Transmission

Range Transmission - Reconditioning (Summary of
References)
”Special tools”
”Removing the range transmission”
”Range transmission - Sectional view”
”Reconditioning the range transmission”
”Installing the range transmission”
”Reconditioning the shift cover”
”Replace speed sending unit”
Special tools
→NOTE:

2-1/2 in. heavy duty socket
JDT44
Removing and tightening intermediate shaft nut
D01045AA
Removal and installation of bearings and bushings
Puller set
D01047AA
Removal of bearings and bushings

Bracket
Dealer-fabricated
A-Flat steel bar 25x10x145 mm; (1x0.4x5.7 in.)
Holding the shift rod detent when adjusting the shifting mechanism

Drive shaft Axial play 0.013 to 0.080 mm
0.0005 to 0.0030 in.
Adjustment ring retaining plate, cap screw Torque 25 N˙m
18 lb-ft
Park lock pawl, spring Free length approx. 62 mm
approx. 2.44 in.
Test length 57 mm at 38±9 N
2.2 in. at 8.5±2 lb
Intermediate shaft nut Torque 550 N˙m
405 lb-ft
Adjusting intermediate shaft Axial play 0.013 to 0.080 mm
0.0005 to 0.0030 in.
Shift fork detent, spring Free length approx. 43 mm
approx. 1.69 in.
Test length 35.9 mm at 100±10 N
1.41 in. at 22.05 ± 2.2 lb
Threaded pins of shift forks Torque 40 N˙m
30 lb-ft
Shift cover to range transmission, cap screws Torque 70 N˙m
50 lb-ft
Mounting screws, speed sender Torque 20 N˙m
15 lb-ft
Removing the range transmission

Preliminary work:
Before removing the range transmission, see “Removing the range transmission” .

CAUTION:
The range transmission is heavy. Support it securely before carrying out

any service work to avoid personal injury.
Range Transmission - Sectional View
Range transmission (40 km/h; 25 mph version)
LEGEND:

A Drive shaft
B Gear, range C
C Synchronizer unit
D Gear, range D
E Synchronizer unit
F Gear, range E
G Differential drive shaft
H Gear
I Gear
J Front-wheel drive gear
K Gear
L Gear, range B
M Synchronizer unit
N Gear, range A

Repairing the Range Transmission

Preliminary work: “Removing the range transmission” .
→NOTE:
Repairing the 40 km/h (25 mph) range transmission is explained here.
Shifter assembly components — Sectional view
LEGEND:
A Shifter fork, ranges C and D
B Shift rod, range E
C Shift rod, ranges C and D
D Shift rod, ranges A and B
E Balls
F Locking pin
Repair (remove and install) the shifter assembly parts using the sectional view illustration as
a guide.

→NOTE:
Shift rods and forks are marked. The shift forks are marked with the range
designations (e.g., “A - B”). The shift rods have the designations stamped
on the front.
Removing the differential drive shaft
[1] -
Parking lock lever (A) in park position

Move parking lock lever to park position to prevent differential drive shaft from rotating.
[2] -
Remove intermediate shaft nut using special tool JDT44 or a commercial socket.
2-1/2 in. Heavy Duty Socket
JDT44
Remove and install differential drive shaft nut

[3] -
Remove shift cover (A).

[4] -
Remove detent springs (A). Using a magnet, remove detent balls.

[5] -
Remove plug (A) and spring (B).

[6] - Remove snap ring (C) and parking lock pawl.

[7] -
Remove shift rod (A) and shift fork of range A and B.

→NOTE:
During removal, pay attention to the locking pin and detent balls of the
shift rods. See sectional view illustration of shifter assembly parts.
[8] -
Lightly strike the end of differential drive shaft with a plastic hammer until bearing cone can
be removed.

[9] -
Carefully pull out differential drive shaft and remove parts from shaft.
Removing the drive shaft
[1] -
LEGEND:
A Shift rod, range E
B Shift fork, range E
D Shift fork, ranges C and D
Remove shift rods and forks.

[2] -
Remove cap screw (A) and locking plate (B).

[3] - Turn adjusting ring (C) counterclockwise and remove.
[4] -
Take out drive shaft.
Exploded view of drive shaft

40 km/h (25 mph) drive shaft - Exploded view
LEGEND:
1 Snap ring
2 Taper roller bearing cup
3 Cap screw
4 Housing
5 Plug
6 Retaining plate
7 Cap screw
9 Adjusting ring
10 Sealing sleeve
11 Taper roller bearing cone
12 Drive shaft
13 Gear, range E
14 Synchronizer unit
15 Thrust washer
16 Sleeve
17 Gear (range D)

19 Sleeve
20 Gear, range C
21 Thrust washer
23 Snap ring (thickness as required)
50 km/h (31 mph) drive shaft - Exploded view
LEGEND:
1 Snap ring
3 Cap screw
4 Housing
5 Plug
6 Retaining plate
7 Cap screw
9 Adjusting ring
10 Sealing sleeve
12 Thrust washer
13 Needle bearing
14 Gear, range A
15 Sleeve
16 Drive shaft
17 Thrust washer
18 Gear, range E
20 Thrust washer
21 Sleeve
22 Gear, range D
24 Gear, range C
25 Thrust washer
27 Snap ring (thickness as required)
Check the drive shaft and repair or assemble it as required, using the exploded view
Exploded view of differential drive shaft

LEGEND:
A Differential drive shaft
B Taper roller bearing assy.
C Spacer washer (quantity and thickness as required)
D Spacer
E Spacer washer (quantity and thickness as required)
F Taper roller bearing assy.
G Adjusting ring
H Wear sleeve
I Gear, range A
J Synchronizer unit
K Sleeve
L Gear, range B
M Gear, range E
N Front-wheel drive gear
O Gear, range D
P Gear, range C
Check the differential drive shaft and repair or assemble it as required, using the exploded
view illustration as a guide.

Shifting mechanism - Exploded view
LEGEND:
1 Ball
2 Locking pin
3 Spring
4 Shift rod, range E
5 Shift rod, ranges C and D
6 Shift rod, ranges A and B
7 Shift fork, ranges C and D
8 Shift fork, range E
9 Shifter fork, ranges A and B
10 Wear lining
11 Threaded pin
Check the shifting mechanism and repair or assemble it as required, using the exploded view

→NOTE:
When installing, refer to the sectional view illustration of the shifter

assembly parts as well.
Apply grease to balls and locking pins so that the shift rods remain in place
during installation.
Shift rods and forks are marked. The shift forks are marked with the range
designations (e.g., “A - B”). The shift rods have the designations stamped
on the front.
Park lock - exploded view
LEGEND:
1 Pin
2 Bushing
3 Washer
4 Locking pawl

5 Bushing
6 Shaft
7 Snap ring
8 Spring
9 O-ring
10 Plug
11 Cotter pin
12 Locking cam
13 Thrust washer
14 Needle bearing
15 Washer
16 Lever arm
17 Spring pin
18 O-ring
19 Dowel pin
20 Spring
21 Square plate
22 Washer
23 Bushing
24 Cotter pin
25 Retaining clip
26 Lever arm
27 Support bushing
28 Washer
29 Screw
30 Rod
31 Hex. nut
32 Slotted nut
Check the park lock components and repair or assemble it as required, using the exploded
view illustration as a guide.
Repairing the drive shaft
[1] -

[2] -
Place puller as shown in the illustration. Pull off taper roller bearing cone (B) and remove the
components.
Puller Set
D01047AA
Remove bearings and bushings
[3] -
CAUTION:
Heat bearing in a bearing heater. Do not exceed 150°C (300°F). Proceed

with care to avoid burns.
Install bearing cone (A).

[4] -
Install range E gear (C), synchronizer (B) and thrust washer (A).
[5] -
Install range D gear (B) with sleeve and synchronizer (A).

[6] -
Install range C gear (B) with sleeve and thrust washer (A).

[7] -
CAUTION:


[8] -
→NOTE:
Snap rings (A) are available in various thicknesses. Use the thickest snap
ring that fits in the groove.
Install snap ring (A).
Installing the drive shaft

[1] -
Insert taper roller bearing cup (B) in housing and install snap ring (A).
[2] -
Press taper roller bearing cup (A) into adjusting ring (B).
[3] -
Install drive shaft in housing.

[4] -
Screw in adjustment ring (A).
Adjusting end play of drive shaft
[1] -
Tighten adjusting ring until specified end play is obtained.

Drive shaft adjustment End play 0.013 to 0.080 mm
0.0005 to 0.0030 in.

[2] -
Install locking plate (B) and cap screw (A).

[3] -
→NOTE:
If necessary, turn adjusting ring until locking plate fits in the next recess.
Tighten cap screw.

Adjusting ring - locking plate, cap screw Torque 25 N˙m
18 lb-ft
[4] -
LEGEND:
A Shift rod, range E
B Shift fork, range E
D Shift fork, ranges C and D
Install drive shaft shift rods and forks.
→NOTE:
When installing, refer to the sectional and exploded view illustrations of
the shifter assembly parts.

Install drive shaft and adjust cone point
[1] -
Note the letter (A) stamped on the upper left side of the front face of the differential housing
and refer to the chart below for the corresponding dimension.
→NOTE:
If letter is absent, always assume a measurement of 205.00 mm (8.071 in.).
Letter on housing Measurement
A 204.89 mm (8.067 in.)
B 204.95 mm (8.069 in.)
C 205.00 mm (8.071 in.)
D 205.05 mm (8.073 in.)
E 205.10 mm (8.075 in.)
[2] - The fixed measurement is always 24.06 mm (0.947 in.)

[3] -
Note the measurement (C) stamped on the pinion face.

[4] - Calculate thickness of spacer washer pack (D).

D=A-B-C
Example:
Letter from housing
and corresponding measurement
from chart .......... A=204.89 mm (8.067 in.)
Specified fixed measurement .......... B=24.06 mm (0.947 in.)
Measurement stamped on
pinion face .......... C=180.05 mm (7.088 in.)
D = 204.89 mm - 24.06 mm - 180.05 mm

D = 0.78 mm
D = 8.067 in. - 0.947 in. - 7.088 in.

D = 0.030 in.
[5] -
Install shims (A) of the calculated thickness.

[6] -
Install taper roller bearing cup (A).

[7] -
CAUTION:

Install taper roller bearing cone (A) on differential drive shaft.

→NOTE:
Press taper roller bearing cone as far as it will go.
[8] -
Push differential drive shaft into housing and install parts.

→NOTE:
Also install shift fork for ranges A and B on synchronizer. When installing
shifter fork later, all the shift rods have to be removed again.

[9] -
Install spacer (A) and shims (B).

→NOTE:
If differential drive shaft end play has to be re-adjusted, shims of 2 mm
(0.078 in.) thickness must be installed.
[10] - Install taper roller bearing cone (C).

[11] -
Install shift rod (A), ranges A and B.

→NOTE:
When installing, refer to the sectional and exploded view illustrations of
the shifter assembly parts.

[12] -
Install parking lock pawl and snap ring (C).

[13] - Install spring (B) and plug (A).
Parking lock pawl spring Free length approx. 62 mm
approx. 2.44 in.
Test length 57 mm at 38±9 N
2.2 in. at 8.5±2 lb
Adjusting end play of differential drive shaft

[1] -
Install shims of 2 mm (0.078 in.) thickness behind taper roller bearing cone.
[2] - Temporarily attach shift cover with two screws and move parking lock lever to parking
position to prevent differential drive shaft from rotating.
[3] - Tighten differential drive shaft nut using special tool JDT44 or a commercial socket.
JDT44
Differential drive shaft nut Torque 550 N˙m
405 lb-ft
[4] - Determine end play.

[5] - Remove shims until specified end play is obtained.
Differential drive shaft adjustment End play 0.013 to 0.080 mm
0.0005 to 0.0030 in.

[6] - Tighten differential drive shaft nut again using special tool JDT44 or a commercial
socket and secure it in two places.
JDT44
Differential drive shaft nut Torque 550 N˙m
405 lb-ft
[7] -
Install balls and springs (A) of shift rod detent.

Shift fork lock, spring Free length approx. 43 mm
approx. 1.69 in.
Test length 35.9 mm at 100±10 N
1.41 in. at 22.05 ± 2.2 lb force
Adjusting the range shift linkage

[1] -
Attach the dealer-manufactured retainer (A) that acts as a detent for the shift rods.
Retainer
dealer-fabricated
A-Flat steel bar 25x10x145 mm; (1x0.4x5.7 in.)

Holding the shift rod detent when adjusting the shifting mechanism
[2] - Thoroughly clean threaded pins and apply L41475 ( LOCTITE ™ 243) to them.
[3] - Move the shift rods to their neutral positions.
[4] - Adjust shift forks by means of threaded pins until they are centered in relation to shift
collars.
[5] - Move the shift forks to all positions.
→NOTE:
Shift forks must not rub laterally at the shift collars in ANY of the shift
positions.

[6] - Tighten threaded pins of shift forks.

Threaded pins of shift forks Torque 40 N˙m
30 lb-ft
[7] - Check the shift mechanism again.
Final assembly: “Installing the range transmission” .

Installing the range transmission

[1] -
Move range transmission (shift rods) in neutral position.

[2] - Install the two cap screws (A) for attaching the range transmission.
[3] - Align shift levers on shift cover with the shift rods in the housing. Install shift cover on
housing.
50 lb-ft
[5] -
Install the range transmission.
Final assembly: Before installing the range transmission, see “Installing the range
transmission” .

Repairing the shift cover

[1] -
Remove shift cover (A).

[2] -
LEGEND:
A Lever
B Spring pin
C Gasket
D Dowel pin
E Shift cover
F Locking cam
G Thrust washer
H Needle bearing
I Cap screw
J O-ring
K Washer
L Lever arm
M O-ring
N Lever, ranges A and B
O Lever, range E
P Spring pin
Q Lever, ranges C and D
Repair or assemble the shift cover as required, using the exploded view illustration as a
guide.

[3] -
Install the two cap screws (A) for attaching the range transmission.
[4] - Align shift levers on shift cover with the shift rods in the housing. Install shift cover on
housing.
50 lb-ft

Replacing the speed sender

[1] -
LEGEND:
Sender for ground speed (B35)
A Sender for ground speed (B09)
[ For tractors with creeper ]
B Sender for transmission speed (B104/1)
Disconnect speed sender from plugs.
→NOTE:
Before disconnecting the plugs, mark them so as to avoid installing them in
the wrong positions.
[2] - Remove mounting screw (C).

[3] - Pull sender out of housing.
[4] -

DRIVE SYSTEMS (g) by Belgreen
LEGEND:
A Ground speed sender (B35)
B Ground speed sender (B09)
[ For tractors with creeper ]
C Transmission speed sender (B104/1)
D O-ring
E Protective cap
F Terminal
G Mounting screw
Install new sender in housing with O-ring.
[5] - Tighten mounting screws (C).
Mounting screw, speed sender Torque 20 N˙m
15 lb-ft

Section 56 - DRIVE SYSTEMS

Table of contents
Special Tools .......................................................................................................................... 1
Remove the Front-Wheel Drive Clutch ................................................................................... 9
Install the Front-Wheel Drive Clutch .................................................................................... 11
Remove the Differential Housing ......................................................................................... 13
Install the Differential Housing ............................................................................................. 27
Remove Final Drives ............................................................................................................ 33
Install Final Drives ................................................................................................................ 41
Remove Rear PTO ................................................................................................................ 47
Install Rear PTO .................................................................................................................... 50
Remove Front PTO ............................................................................................................... 51
Install Front PTO ................................................................................................................... 54
Group 05 - U-Jointed Shafts and Torsion Damper .............................................................. 55
Summary of References (U-Jointed Shafts and Torsion Damper) ......................................... 55
Special Tools ........................................................................................................................ 55
Use of Special Tool KJD10426 .............................................................................................. 57
Repair specifications ............................................................................................................ 58
Remove Front-Wheel Drive U.j. Shaft ................................................................................... 59
Reconditioning the U.j. Shaft (Front-Wheel Drive) ............................................................... 61
Install Front-Wheel Drive U.j. Shaft ...................................................................................... 65
Removing the U.J. Shaft (Engine) ......................................................................................... 68
Removing and Installing the Ring-Shaped Cooler ................................................................ 69
Removing the Torsion Damper ............................................................................................ 70
Changing the Torsion Damper Bearings ............................................................................... 71
Installing the Torsion Damper .............................................................................................. 71
Installing the U.j. Shaft (Engine) ........................................................................................... 73
Group 10 - Front-Wheel Drive Clutch ................................................................................... 74
Drive Systems - Front-Wheel Drive Clutch, Summary of References ................................... 74
Special tools ......................................................................................................................... 75
Other material ...................................................................................................................... 76
Repair Specifications ............................................................................................................ 77
Front-Wheel Drive Clutch - Sectional View ........................................................................... 77
Front-Wheel Drive Clutch — Exploded View ......................................................................... 79
Front-Wheel Drive Clutch - Replace Front-Wheel Drive Axle Speed Sensor (B89) ................ 82
FWD Clutch — Replacing Solenoid Valve ............................................................................. 83
Replacing the FWD Clutch .................................................................................................... 85
Group 15 - Differential .......................................................................................................... 105
Drive Systems - Differential, Summary of References ....................................................... 105
Special tools ....................................................................................................................... 105
Differential - Specifications ................................................................................................ 106
Differential - Sectional View ............................................................................................... 106
Differential - Exploded View ............................................................................................... 108
Remove the Differential ..................................................................................................... 110
Recondition the Differential ............................................................................................... 113

Install the Differential ......................................................................................................... 120

Differential - Adjust Preload ............................................................................................... 122
Differential - Adjust Backlash ............................................................................................. 124
Group 20 - Hydraulic Pump Drive ....................................................................................... 126
Hydraulic Pump Drive — Summary of References ............................................................. 126
Special tools ....................................................................................................................... 127
Repair Specifications .......................................................................................................... 127
Remove and Disassemble Pump Drive Pinion Gear ........................................................... 129
Remove and Disassemble the Pump Drive Gear ................................................................ 132
Assemble and Install Pump Drive Pinion Gear .................................................................... 134
Assembling and installing the pump drive pinion ............................................................... 137
Checking and adjusting the backlash of the pump drive pinion ......................................... 141
Group 25 - Final Drives ......................................................................................................... 142
Drive Systems - Final Drives, Summary of References ...................................................... 142
Final Drives - Special Tools ................................................................................................ 142
Final Drives - Repair Specifications .................................................................................... 143
Final Drives - Sectional View .............................................................................................. 143
Remove Planetary Carrier .................................................................................................. 145
Disassemble Planetary Carrier ........................................................................................... 147
Assemble Planetary Carrier ................................................................................................ 149
Remove Axle Housing ........................................................................................................ 152
Disassemble and Asssemble Axle Housing ........................................................................ 153
Disassemble and Assemble Axle Shaft ............................................................................... 155
Final Drives - Install Axle Housing ...................................................................................... 157
Final Drives - Install Planetary Carrier and Check Rolling Drag Torque .............................. 158
Group 30 - Rear PTO ............................................................................................................. 167
Drive Systems - Rear PTO, Summary of References .......................................................... 167
Special tools ....................................................................................................................... 168
Specifications ..................................................................................................................... 170
Repair Instructions ............................................................................................................. 170
Repair Rear PTO ................................................................................................................. 172
Remove and Disassemble Countershaft ............................................................................ 185
Assemble and Install Countershaft ..................................................................................... 189
Remove and Disassemble Output Shaft ............................................................................. 192
Assemble and Install PTO Output Shaft .............................................................................. 198
Remove PTO Shifter ........................................................................................................... 202
Install PTO Shifter ............................................................................................................... 205
Replacing Oil Seal on PTO Output Shaft ............................................................................. 207
Remove Modulating Valve .................................................................................................. 207
Disassemble and Assemble Modulating Valve ................................................................... 209
Install Modulating Valve ..................................................................................................... 211
Changing and adjusting the bowden cable ........................................................................ 212
Group 35 - Front PTO ............................................................................................................ 216
Front PTO - Reconditioning (Summary of References) ....................................................... 216
Other Material .................................................................................................................... 216
Specifications ..................................................................................................................... 217
General Repair Procedures ................................................................................................ 218
Replace Y01 - Solenoid Valve for Front PTO ....................................................................... 218
Reconditioning the Modulator Valve .................................................................................. 220
Replace B58 - Front PTO Speed Sensor .............................................................................. 222

Cleaning and Replacing the Filter ...................................................................................... 222

Reconditioning the Pressure-Regulating Valve .................................................................. 224
Checking the Cooler Relief and Filter By-Pass Valves ........................................................ 225
Removing and Installing the Valve Plate ............................................................................ 225
Front PTO — Sectional View ............................................................................................... 227
Disassembling the Front PTO ............................................................................................. 231
Reconditioning the Oil Pump .............................................................................................. 234
Reconditioning the PTO Clutch ........................................................................................... 239
Reconditioning the PTO Brake ............................................................................................ 245
Reconditioning the Intermediate Gear Shaft (PTO Rotating Counterclockwise) ................. 249
Reconditioning the Drive Shaft .......................................................................................... 251
Assembling the Front PTO .................................................................................................. 257
Group 40 - Front Implement Drive ...................................................................................... 266
Front Implement Drive (Summary of References) .............................................................. 266
Special Tools ...................................................................................................................... 266
Summary of Torques .......................................................................................................... 267
Preliminary Work ................................................................................................................ 268
Installing and Removing Drive Shaft .................................................................................. 270

Section 56 - DRIVE SYSTEMS Group 00: Removal and Installation of Components

Special Tools
→NOTE:

Pulling device
KJD10169
Pulling dowel pins out of main frame
Support stand
JT05723
Removing and installing the transmission assembly and differential housing. Also required: 2
commercial 8-metric ton vehicle jacks
Support stand

JT05724
Raising and supporting front end of tractor. Also required: 2 commercial 5-metric ton vehicle
jacks
Support stand
JT05725
Supporting tractor during rear wheel removal. Also required: 1 commercial 12-ton vehicle
jack
Lifting sling
JDG23

Removal and installation of the operator′s cab
Support stand
D05007ST
Removing and installing final drives, front axle or front-wheel drive axle
Flywheel turning tool
JDG820
Turning flywheel on 6-cylinder engines


Adapter Strut
dealer fabricated
LEGEND:
A 80 mm (3.2 in.)
B 45 mm (1.8 in.)
C 400 mm (16 in.)
D 360 mm (14.17 in.)
E 140 mm (5.51 in.)
F 13 mm (1/2 in.) dia. bore
G 19 mm (3/4 in.) dia. bore
H 8 mm (5/16”)
Allows installation of the JT05723 stand on the rear PTO housing. Made from U-shaped steel
to U-80 DIN1026-St37-2 (UNP-80 EN10279) standard. When selecting hardware, be sure to
choose high-tensile attaching screws. When securing the adapter strut, only use DIN6918
washers, which have a tilt of 8%, on the inside of the strut. Hardware required: Two M12 x 60
mm cap screws and two M16 x 40 mm cap screws.
Holding fixture
dealer fabricated

LEGEND:
a 250 mm (10 in.)
b 50 mm (2 in.)
c 15 mm (0.6 in.)
d 205 mm (8.1 in.)
e 16 mm (0.6 in.)
f 18 mm (45/64 in.) dia. hole
A M12x30mm Screw
Used in conjunction with support stand D05007ST during the removal of tractor components.
Also required: two M16x350 mm threaded rods. When used to remove the final drives, screw
(A) is used to support the edge of the flat piece of metal.
Lifting eyes (2 used)
dealer fabricated

LEGEND:
A Commercial M16, DIN 582 Lifting Eye Nut
B M16 Nut
C Threaded Rod M16 x 100 mm (4 in.), Grade 8.8
Coat threaded rod (C) with LOCTITE ™ 270 (L41476), and screw it into eye nut (A) until it
bottoms. Lock with nut (B).
Holding fixture
dealer fabricated

Removal and installation of final drive housings and other tractor components. Used in
conjunction with support stand D05007ST.

Specificatio
Item Measurement
n
Cap Screws, Range Transmission to Differential Housing Torque 90 N˙m
66 lb.-ft.
Cap Screws, Differential Housing to Main Frame Torque 525 N˙m
385 lb.-ft.
Cap Screws, Final Drive Housing to Differential Housing Torque 230 N˙m
170 lb.-ft.
Cap Screws, Rear Cab Mounting Torque 200 N˙m
145 lb.-ft.
Hex. Socket Screw, Bracket of Stabilizer Bar to Final Drive Housing Torque 710 N˙m
525 lb.-ft.
Cap Screws, Front-Wheel Drive Clutch Housing to Range Transmission Torque 50 N˙m
37 lb.-ft.
Cap Screws, Rear PTO Housing to Differential Housing Torque 240 N˙m
175 lb.-ft.
Attaching Screws, Center Link Bracket to PTO Housing / Differential Housing Torque 340 N˙m
250 lb.-ft.
Cap Screws, Front PTO to Support Torque 600 N˙m
445 lb.-ft.

Remove the Front-Wheel Drive Clutch
Disconnect handbrake bowden cable (A) and remove lever (B).
Remove U-jointed front-wheel drive shaft. See Remove the U.J. Shaft (Front-Wheel Drive Axle)
Remove transmission oil drain screw (B) at front-wheel drive clutch housing and drain oil into
a suitable container.
Then disconnect pressure line (A) at the solenoid valve. Also disconnect connector (C).
→NOTE:
Seal the open ends with plastic plugs.

Place hoist underneath front-wheel drive clutch housing, then remove attaching screws.
→NOTE:
To gain access to all the screws, first remove the front-wheel drive clutch
solenoid valve.
Remove housing from below.
→NOTE:
Housing flanges are coated with flexible sealant. For this reason, the
housings may stick to each other even if the cap screws have been
removed.
If a pick-up hitch is equipped, carefully guide the front-wheel drive clutch housing past shield
(A).

Install the Front-Wheel Drive Clutch
Thoroughly clean sealing surfaces of range transmission housing and front-wheel drive clutch
housing, then coat them with LOCTITE ™ 574 (L64500) flexible sealant.
Using a hoist, move front-wheel drive clutch housing under range transmission housing.
Move front-wheel drive clutch housing until it contacts range transmission, making sure that
the two dowel pins are correctly located in the bores provided.
Tighten the cap screws to the specified torque.
Cap Screws, Front-Wheel Drive Clutch Housing to Range Transmission Torque 50 N˙m
37 lb.-ft.
Fill with transmission oil. Check oil level and top up, if necessary (see operator′s manual).
Adjust the handbrake. See Adjusting the Handbrake in Section 60, Group 20.

IMPORTANT:
On tractors equipped with air brakes, it is vitally important to check that

the trailer brake valve is set correctly.

Remove the Differential Housing

CAUTION:
05).
[2] - Take off the two rear wheels. See Removing the Front and Rear Wheels in Section 80,
Group 10.
[3] - Remove the fuel tank. See Removing the Fuel Tank in Section 30, Group 10.
[4] - Remove the u.j. shaft of the front-wheel drive axle. See Remove the U.J. Shaft (Front-
Wheel Drive Axle) in Section 56, Group 05.
[5] - If equipped, disengage the clutch cable.

[6] -
→NOTE:
Trap the oil in a container with a capacity of at least 60 liters (15 U.S.gal.).
[7] -
LEGEND:
A JT05724 Universal Support Stand
B JT05723 Universal Support Stand
C Front Support of JT05723
D L78499 Bracket

E Wooden Block
F Adapter Strut (Dealer-Fabricated)
Attach JT05724 support stand (A) to both main frame sides. Two L78499 brackets (D) may be
used. Also put two suitable wooden blocks (E) between the main frame and the universal
support stand.
Support stand
JT05724
Raising and supporting front end of tractor. Also required: 2 commercial 5-metric ton vehicle
jacks
Place support stand JT05723 (B) underneath the transmission unit. Adjust the supports so
that the front one (C) makes contact under the front-wheel drive clutch and the rear one
makes contact under the PTO housing.
Support stand
JT05723
Removing and installing the transmission assembly and differential housing. Also required: 2

commercial 8-metric ton vehicle jacks

To secure the support stand to the PTO housing, a dealer-fabricated adapter strut (F) must be
used. This strut must be bolted securely both to the PTO housing and to the universal support
stand.
Adapter Strut
dealer fabricated
LEGEND:
A 80 mm (3.2 in.)
B 45 mm (1.8 in.)
C 400 mm (16 in.)
D 360 mm (14.17 in.)
E 140 mm (5.51 in.)
H 8 mm (5/16”)
Allows installation of the JT05723 stand on the rear PTO housing. Made from U-shaped steel
to U-80 DIN1026-St37-2 (UNP-80 EN10279) standard. When selecting hardware, be sure to
choose high-tensile attaching screws. When securing the adapter strut, only use DIN6918
washers, which have a tilt of 8%, on the inside of the strut. Hardware required: Two M12 x 60
mm cap screws and two M16 x 40 mm cap screws.
→NOTE:
The adapter strut is not necessary for some tractor versions.
IMPORTANT:
When selecting hardware, be sure to choose high-tensile attaching screws.
When securing the adapter strut, only use DIN6918 washers, which have a
tilt of 8%, on the inside of the strut.

[8] -
Install dealer-manufactured lifting eyes (B), lifting sling (A; JDG23) and lifting tackle on the
roof of the operator′s cab.
Lifting sling
JDG23

dealer fabricated

LEGEND:
B M16 Nut
Coat threaded rod (C) with LOCTITE ™ 271 (TY43513), and screw it into eye nut (A) until it
[9] -
Loosen the front cab mounting screws (A), but do NOT take them out.

[10] -
On tractors with a cab, take out cap screws (A) (on both sides).
[11] - To make the following jobs easier, the cab or open platform can now be raised at the
rear by several centimeters.
IMPORTANT:
When doing this, make sure that none of the tractor′s components become
strained.
[12] -
Take off the cover and disconnect the two connectors (A).

[13] -
If the tractor has an independent control valve (ICV or E-ICV), unscrew fittings (C), trap any oil
that emerges and seal the open ends so that no dust can get in. Then remove bracket (A)
from bracket (B).
Disconnect connector (D).
[14] -

LEGEND:
A Steering Pressure Line
B Steering LS Line
C SCV Bowden Cables
D Connector
E Height-Adjustable Trailer Hitch Rails
F Connector
G Bowden Cable
H Center Link
I Connector
J Connector
K Hose
Disconnect or remove all components shown here.
[15] -
Disconnect all transmission shift bowden cables (A).

→NOTE:
There may be differences here depending on how the tractor is equipped.
Disengage park lock bowden cable (B) at the lever and counter-bearing.
Take out the screws that hold bracket (C) onto the final drive housing.

[16] -
Unscrew brake line fittings (B) and take out the screws that hold on bracket (A). Release the
brake lines from the clamps on the main frame.
→NOTE:
penetrate.
If the transmission assembly is subsequently to be disassembled, the brake
lines can remain secured to the differential housing.
[17] -
Tractors with TLS front-wheel drive axle:

Disconnect the two lines (A) and hose (B).

[18] -
Take out screw (A).

[19] -
Disconnect return hose (A) and hose (B). Take out the screw that holds on the hose bracket.

[20] -
Disconnect the oil cooler hoses (A).

IMPORTANT:
[21] -
Remove cap screws (A) using the special tools (B) and (C).
Support stand
D05007ST

Removal and installation of differential housing.

Extension
JDG749
IMPORTANT:
Before doing so, make sure that the support stands are installed securely.
CAUTION:
Once the cap screws have been removed, do not perform any jobs between
the main frame and transmission assembly or underneath the tractor, as
these areas are potentially hazardous.

[22] -
Roll the transmission assembly out to the rear.

→NOTE:
This job requires several assistants.
Watch out for any additional equipment that may be installed.
Take care to prevent hoses, wiring or bowden cables from getting caught.
[23] - Remove all transmission housings, the final drive housings and the PTO housing.
CAUTION:
In this procedure, it is important to keep changing the position of the
stand supports. When removing the first final drive housing, remember to
support the other final drive housing (the one on the opposite side).
For the necessary steps, see the following:
Remove PowrQuad Transmission in Section 55, Group 00.

Remove Range Transmission in Section 55, Group 00.
Remove Final Drives in Section 56, Group 00.
Remove Rear PTO in Section 56, Group 00.
Removing and Installing the Charge Pump in Section 70, Group 10.
Hitch - Remove Lift Cylinders in Section 70, Group 20.
Removing the Selective Control Valves in Section 70, Group 25.

Install the Differential Housing

[1] - Bolt the differential housing to a JT05723 support stand.
CAUTION:
Universal support stand JT05723 (A) must be installed with support (B)
underneath the range transmission.
Support stand
JT05723
Removing and installing the transmission assembly and differential

housing. Also required: 2 commercial 8-metric ton vehicle jacks
[2] - Pre-assemble the transmission assembly.

For the necessary steps, see the following:
Install Range Transmission in Section 55, Group 00.

Install Final Drives in Section 56, Group 00.
Install Rear PTO in Section 56, Group 00.
[3] -
Install the transmission assembly on the main frame, and align.

→NOTE:
This job requires several assistants.
[4] -
IMPORTANT:
During installation, put the flange (A) of the u.j. shaft into the transmission
input shaft, and use the JDG820 flywheel turning tool to allow the splines
on the shafts to mesh.
JDG820

[5] -
Remove cap screws (A) using the special tools (B) and (C).
Support stand
D05007ST

Extension
JDG749

[6] - Reverse removal procedure to install the bowden cables, brake lines and hydraulic
hoses back in place.

[7] - Lower and mount the operator′s cab.
Tighten the front cab mounting screws (A) to the torques prescribed.
Front Cab Mounting, Cap Screw Torque 220 N˙m
160 lb.-ft.
Tighten the rear cab mounting screws (A) to the specified torque.
Cab to Final Drive Housing, Cap Screw Torque 220 N˙m
160 lb.-ft.

[8] -
Install oil cooler hoses (A).

IMPORTANT:
[9] - Run the clutch cable along the left side of the flywheel housing to the clutch pedal.
IMPORTANT:
Run the clutch cable so that following criteria are met:
The cable must be free of tension.

The cable must not come into contact with moving parts.
The cable must not be bent or crushed.
The cable must not chafe against other components when the clutch is
operated.

[11] - When assembly is completed, perform the following:
Check the adjustment of all shift mechanisms/linkages.With PowrQuad transmission,

see Checking and Adjusting the Shift Mechanism/Linkages (Reverser Control on Steering
Column) and Adjusting the Reverse Drive Lever (Reverser Control on Steering Column)
Check the adjustment of the speed control lever (mechanical speed control only).
Accelerator Pedal with Mechanical Speed Control in Section 30, Group 05.
Check the setting of the clutch pedal. Adjusting the Clutch Pedal (PowrQuad
Transmission) or Adjusting the Clutch Pedal in Sections 50 or 55, Group 05.
Bleed and check the brakes. Bleeding the Brakes (Power-Fill Brakes and MFWD and Disk
Brake) in Section 60, Group 15 or 20.
Bleed and check the hydraulic trailer brake (if equipped).See Bleeding the Trailer Brake
Valve and Checking the Hydraulic Trailer Brake Valve in Section 60, Group 30.
Check all functions and rectify any faults (refer to corresponding Technical Manual).

Remove Final Drives

CAUTION:
05).
[2] -
→NOTE:

[3] -
Place chock blocks under the front wheels to prevent the tractor from rolling away.
Raise tractor and support it SECURELY with support stand JT05725 (A).
Support stand
JT05725
Raising and supporting tractor

[4] -
Take off one of the rear wheels. See Removing the Front and Rear Wheels in Section 80,
Group 10.
[5] -
If equipped, remove bracket (A) of the stabilizer bar.

[6] -
When removing the right final drive housing: If equipped, disconnect lines (B), take out the
screws that hold bracket (A) to bracket (C), and then take off bracket (C).

[7] -
When removing the right final drive, also take off bracket (A).
[8] -
Install dealer-manufactured lifting eyes (B), lifting sling (A; JDG23) and lifting tackle on the
roof of the operator′s cab.
Lifting sling
JDG23

dealer fabricated

LEGEND:
B M16 Nut
Coat threaded rod (C) with LOCTITE ™ 271 (TY43513), and screw it into eye nut (A) until it
[9] -
Loosen the front cab mounting screws (A), but do NOT take them out.

[10] -
When removing the left final drive from tractors equipped with air brakes, take off brackets
(A), (B) and (C).
[11] -
Attach support stand D05007ST (A) to the final drive housing, using adapter (B) and holding
device (C) (both dealer-fabricated).
Support stand
D05007ST

Removal and installation of final drive housings. Also required: dealer-fabricated holding
devices, see Special Tools (Dealer-Fabricated).
Holding fixture
dealer fabricated
LEGEND:
a 250 mm (10 in.)
b 50 mm (2 in.)
c 15 mm (0.6 in.)
d 205 mm (8.1 in.)
e 16 mm (0.6 in.)
A M12x30 mm screw
Holding fixture
dealer fabricated

→NOTE:
Use the screw in the center of holding device (C) to align the device
horizontally.
Take out all cap screws (D) and roll the final drive housing clear.
IMPORTANT:
As the housing is sealed with flexible sealant, in most cases it adheres
firmly to the flange even after the cap screws have been taken out. For this
reason, it is necessary to use a heavy plastic hammer to separate the
housing from the flange.
Take action to prevent the final drive shaft and brake disk from falling out.

Install Final Drives
Before installing the final drives, make sure that the brake piston is properly in contact with
the differential housing. Install the brake disk and brake plate.
See Installing the Rear Brakes in Section 60, Group 15.
IMPORTANT:
Make sure that the ring gear is positioned as shown in the illustration, with
the groove facing the differential housing (see arrow).

Thoroughly clean the housing flange, then coat flange (A) with LOCTITE ™ 574 (L64500)
flexible sealant.
Attach support stand D05007ST (B) to the final drive housing, using adapter (C) and holding
device (D) (both dealer-fabricated).
Support stand
D05007ST

Removal and installation of final drive housings. Also required: dealer-fabricated holding
devices, see Special Tools (Dealer-Fabricated).
Holding fixture
dealer fabricated
LEGEND:
a 250 mm (10 in.)
b 50 mm (2 in.)
c 15 mm (0.6 in.)
d 205 mm (8.1 in.)
e 16 mm (0.6 in.)
A M12x30 mm screw
Holding fixture
dealer fabricated

Removal and installation of front axle or front-wheel drive axle. Used in conjunction with
support stand D05007ST.
Install the final drive and tighten the cap screws crosswise to the specified torque.
Cap Screws, Final Drive Housing to Differential Housing Torque 230 N˙m
170 lb.-ft.

Lower the cab and tighten cap screws (A) to the specified torque.
Cap Screws, Rear Cab Mounting Torque 200 N˙m
145 lb.-ft.
Install the bracket of the stabilizer bar and tighten the hex. socket screws to the specified
torque.
Hex. Socket Screw, Bracket of Stabilizer Bar to Final Drive Housing Torque 710 N˙m
525 lb.-ft.

Install the rear wheel and tighten the wheel bolts to the value specified. See Installing the
Front and Rear Wheels in Section 80, Group 10.
Fill with transmission oil. Check oil level and top up, if necessary (see operator′s manual).
Lubricate both rear axle bearings with 6 to 8 strokes of grease gun. Use John Deere EP
Multipurpose Grease or SAE EP Multipurpose Grease.
CAUTION:
Bleed the brakes. See Bleeding the Brakes in Section 60, Group 15.

Remove Rear PTO

CAUTION:
05).
[2] -
→NOTE:

[3] -
Disconnect connector (A). Remove the height-adjustable trailer hitch (B), if equipped. See
Installing the Guide Rails in Section 80, Group 15.
Disconnect connector (C) and bowden cable (D) and remove center link (E).
Disconnect pressure line (F) to PTO housing.

[4] -
Use a suitable hoist to remove PTO housing.

Remove cap screws (A) and lift off PTO housing.
→NOTE:
Slide a suitable pipe section over the PTO stub shaft. This will allow the
PTO housing to be removed from the differential housing at right angles.

Install Rear PTO

[1] -
Thoroughly clean the sealing surfaces and coat them with LOCTITE ™ 574 (L64500) flexible
sealant.
Suspend the housing from suitable lifting tackle and install it on the differential housing.
→NOTE:
To align the housing, use a tube as shown.
Turning the PTO output shaft makes it easier for the gears to mesh.
[2] -
Tighten cap screws (A) in cross-wise fashion to the specified torque.

Cap Screws, Rear PTO Housing to Differential Housing Torque 240 N˙m
175 lb.-ft.
Attaching Screws, Center Link Bracket to PTO Housing / Differential Housing Torque 340 N˙m
250 lb.-ft.

When finished, add transmission oil and check the oil level.

Remove Front PTO

CAUTION:
05).
[2] -
Remove grille screen.

Disconnect hoses (A) from front PTO oil cooler and seal open ends.

[3] -
Disconnect connector (A) from solenoid valve.

[4] -
Attach front PTO to hoist as shown.

Remove cap screws (A) and lift away front PTO to the front.
→NOTE:
Using a tube (B) pushed onto PTO shaft, align housing.

CAUTION:
Once the front PTO has been removed, it is essential to seal all the lines
and remove the drive shaft BEFORE starting the tractor.

Section 56 - DRIVE SYSTEMS Group 05: U-Jointed Shafts and Torsion Damper
Install Front PTO

[1] -
Attach front PTO to suitable hoist and move in position.

IMPORTANT:
As you move the front PTO into position, pay special attention to the drive
shaft. Slide in drive shaft.
Use flywheel turning tool JDE83 to change position of shaft.
→NOTE:
Using a tube (B) pushed onto PTO shaft, align housing.
[2] -
Tighten cap screws (A) to the specified torque.

Cap Screws, Front PTO to Main Frame or Front Axle Support Torque 600 N˙m
445 lb.-ft.
[3] - For further installation, follow removal procedure in reverse order.

Group 05 - U-Jointed Shafts and Torsion Damper

Summary of References (U-Jointed Shafts and
Torsion Damper)
”Special tools”
”Use of special tool KJD10426”
”Removing the u.j. shaft (front-wheel drive)”
”Reconditioning the u.j. shaft (front-wheel drive)”
”Installing the u.j. shaft (front-wheel drive)”
”Removing the u.j. shaft (engine)”
”Removing and installing the ring-shaped cooler”
”Removing the torsion damper”
”Change torsion damper bearings”
”Installing the torsion damper”
”Installing the u.j. shaft (engine)”
Special Tools
→NOTE:

JDG820
Adapter
KJD10426

Tighten the screws of the engine u.j. shaft. Also refer to“Use of Special Tool KJD10426”.

Use of Special Tool KJD10426
LEGEND:
A Torque wrench
B Socket wrench insert
C Adapter KJD10426
D Torque wrench
BeforeKJD10426adapter is used, the torque wrench must be adjusted. This determines a
setting that compensates forKJD10426(C) being used on the longer lever arm.
1. Adjust torque wrench (A) to 135 N˙m (100 lb-ft).

2. InstallKJD10426adapter (C) on a second torque wrench.
3. Connect both torque wrenches by using a standard 17 mm hex. socket insert (B).
4. Turn the torque wrenches in opposite directions and correct the adjustment of wrench
(D) until both wrenches trip at the same time.
5. Record value of (D) for next use.
→NOTE:
Now the torque wrench is actually set to 135 N˙m (100 lb-ft) though the
torque value indicated is lower.

Specificatio
Item Measurement
n
U.j. shaft to FWD axle, cap screw Torque 125 N˙m
92 lb-ft
Anti-wrap guard, cap screw Torque 35 N˙m
26 lb-ft
Torsion damper bearings, cap screw Torque 65 N˙m
48 lb-ft
Torsion damper to flywheel, cap screw Torque 35 N˙m
26 lb-ft
Engine u.j. shaft to flywheel and transmission flange, corrugated-head screws Torque 135 N˙m
100 lb-ft
U.j. shaft (engine) and torsion damper
LEGEND:
A M12 corrugated-head screw
B M12 corrugated-head screw
C M10 cap screw
D M8 cap screw

Remove Front-Wheel Drive U.j. Shaft

[1] -
LEGEND:
A Anti-wrap guard
B Anti-wrap guard
Remove anti-wrap guards (A) and (B).

[2] -
Tractor without TLS axle
Tractors with TLS axle (not available for all models)

LEGEND:
A U.j. shaft
B Screw
Remove screws (B) from the flange.
[3] - Disconnect u.j. shaft (A) from the flange and pull it off the clutch shaft.

Reconditioning the U.j. Shaft (Front-Wheel Drive)

Disassembling the u.j. shaft (FWD)
[1] -
LEGEND:
A Snap ring
Remove snap ring (A) from each side of universal joint.
[2] -
→NOTE:
Use specially shaped blocks on the vise to protect shaft and fork.
LEGEND:
A Bearing cup
B Connecting fork
Place connecting fork (B) on top of an open vise. Do NOT clamp it in the vise!
[3] - Drive bearing cup (A) out of jointed shaft.
[4] - Turn jointed shaft round and remove bearing cup on opposite side.

[5] -
Drive bearing cups out of connecting fork.

[6] -
Remove the universal joint.
Assembling the u.j. shaft (FWD)
[1] -
Carefully pull the bearing cups out of the universal joint.

[2] - Insert universal joint.

[3] -
LEGEND:
A Universal joint
B Bearing cup
Install first bearing cup in connecting fork.
[4] - Slide universal joint (A) as far as possible into the bore to provide a guide for the
needles of bearing cup (B).
[5] - Drive bearing cup with universal joint far enough into bore of fork so that snap ring can
be installed.
[6] -
LEGEND:
A Bearing cup
B Universal joint
Insert second bearing cup (A) into bore of connecting fork. Slide universal joint (B) to the right
and use it as a guide for the second bearing cup.
[7] - Drive in and secure bearing cup.

[8] -
→NOTE:
Install bearing cups in the same way as installing bearing cups in
connecting fork.
Install bearing cups in jointed shaft.

[9] -
LEGEND:
A Snap ring
Install the snap rings.
[10] - Universal joints should have an axial play that is as close to zero as possible.

Install Front-Wheel Drive U.j. Shaft

[1] -
LEGEND:
A Back-up ring
B Plastic bushing
Slide back-up ring (A) and plastic bushing (B) onto clutch shaft.

[2] -
Tractor without TLS axle
Tractors with TLS axle (not available for all models)

LEGEND:
A U.j. shaft
B Screw
Install u.j. shaft (A) on the clutch shaft and on the flange of the front-wheel drive axle.
[3] -
IMPORTANT:
When installing, always use new corrugated-head screws (L171873).
Tighten screws (B) to the specified torque.

U.j. shaft to u.j. shaft flange, screws Torque 180 N˙m
133 lb-ft

[4] -
LEGEND:
A Anti-wrap guard
B Anti-wrap guard
Install anti-wrap guards (A) and (B) and tighten screws to the specified torque.
Anti-wrap guard to bracket, cap screw Torque 35 N˙m
26 lb-ft
Anti-wrap guard to front-wheel drive housing, cap screw Torque 25 N˙m
18 lb-ft

Removing the U.J. Shaft (Engine)

[1] -
Remove the four corrugated-head screws (A) at the torsion damper and the three cap screws
(B) at the ring-shaped cooler. If necessary, remove the floor-plate from the cab or the open
operator′s station.
→NOTE:
If a FWD axle with TLS is installed, or the transmission has an option
housing, tip up the operator′s cab. Refer to “Tilting the Operator′s Cab
Upward” in Section 90, Group 00.
[2] -
Push ring-shaped cooler (A) to the side and take out the four corrugated-head screws (B) at
the clutch input shaft.
→NOTE:
Replace one of the four corrugated-head screws with an M12x40 threaded
pin. This threaded pin makes installation easier.

Removing and Installing the Ring-Shaped Cooler

[1] - Disconnect the coolant and transmission oil hoses from the ring-shaped cooler and seal
the ends with dummy plugs. Trap any escaping fluids in a suitable container.
[2] -
Remove the four corrugated-head screws (A) at the torsion damper and the three cap screws
(B) at the ring-shaped cooler. If necessary, remove the floor-plate from the cab or the open
operator′s station.
→NOTE:
If a FWD axle with TLS is installed, or the transmission has an option
housing, tip up the operator′s cab. Refer to “Tilting the Operator′s Cab
Upward” in Section 90, Group 00.
[3] -
Push ring-shaped cooler (A) to the side and take out the four corrugated-head screws (B) at
the clutch input shaft. Remove the universal-jointed shaft and ring-shaped cooler.
→NOTE:
Replace one of the four corrugated-head screws with an M12x40 threaded
pin. This threaded pin makes installation easier.


Corrugated-head screws Torque 135 N˙m
100 lb-ft
Check fluid levels. Refer to “Capacities” , Section 10, Group 05, and top up the fluids if
necessary.
→NOTE:
Remember to replace the M12x40 threaded pin with a corrugated-head

screw.
IMPORTANT:
Every time you connect an oil hose with a quick-coupler, make sure that the
retaining clip on the hose coupler is seated correctly. The bent ends of the
clip must be almost touching. If they are not, the coupler may come adrift.
Removing the Torsion Damper
CAUTION:
The torsion damper is heavy. Danger of crushing!
[1] - Tilt the operator′s cab up. Refer to “Tilting the Operator′s Cab Upward” , Section 90,
Group 00.

[2] - Before removing engine u.j. shaft, refer to “Removing the U.J. Shaft (Engine)” in this
Group.
[3] - Remove cap screw (C) and cap screws (A).
[4] - To press off the torsion damper, use two M10x80 screws (B).
Changing the Torsion Damper Bearings

[1] -
LEGEND:
A Bearing bushings
Remove the torsion damper. Remove bearing housing.
[2] - Press bearing bushings (A; 2 used) into the bearing housing.
[3] -
LEGEND:
A Torsion damper
B Bearing housing
Install torsion damper (A) on bearing housing (B).
[4] - Install torsion damper.

Installing the Torsion Damper

[1] -
Change the torsion damper bearing (B).

[2] - Install washer (D) and tighten the cap screw or corrugated-head screw (C).
Torsion damper bearings, cap screw Torque 65 N˙m
48 lb-ft
[3] -
IMPORTANT:
If the bearing is held in place by a corrugated-head screw, the latter must
be used only once, and then replaced.
Tighten the six M8 cap screws.

Torsion damper to flywheel, cap screw Torque 35 N˙m
26 lb-ft
[4] - Ensure seal (A) is seated correctly.

Section 56 - DRIVE SYSTEMS Group 10: Front-Wheel Drive Clutch
Installing the U.j. Shaft (Engine)
IMPORTANT:
The corrugated-head screws must be used once only and then be replaced.
IMPORTANT:
Under any circumstances follow the directions given in “Use of Special Tool
KJD10426” if special tool KJD10426
Adapter
KJD10426
Tightening u.j. shaft screws
is used.
Install the ring-shaped cooler on the universal-jointed shaft.
Secure the ring-shaped cooler with the three flange screws (C).
Tighten the four corrugated-head screws (A) and the four corrugated-head screws (B).
Engine u.j. shaft to flywheel and transmission flange, corrugated-head screws Torque 135 N˙m
100 lb-ft
Tilt the operator′s cab down. Refer to “Tilting the Operator′s Cab Downward” , Section 90,
Group 00.

Group 10 - Front-Wheel Drive Clutch

Drive Systems - Front-Wheel Drive Clutch, Summary
of References
Special Tools
Front-Wheel Drive Clutch - Sectional View
Front-Wheel Drive Clutch - Exploded View
Front-Wheel Drive Clutch - Replace Front-Wheel Drive Axle Speed Sensor (B89)
Front-Wheel Drive Clutch - Replace Solenoid Valve
Recondition the Front-Wheel Drive Clutch

Special tools
→NOTE:

Puller
JDG811
Removing the taper roller bearing cup from housing
Bushing
Dealer-fabricated
Removing and installing Belleville spring
D01045AA
Removing and installing bearings and bushings.

Other material
Number Name Use
• L41475 (us) Cementing the oil transfer plate in the clutch
Adhesive
• 243 LOCTITE ™ (loctite) drum
• L64500 (us)
Liquid sealant Clutch housing to transmission housing
• 574 LOCTITE ™ (loctite)

Clutch shaft Axial play 0.025 to 0.100 mm
0.001 to 0.004 in.
Bearing quill to housing, cap screw Torque 25 N˙m
18 lb-ft
Handbrake band adjusting screw, lock nut Torque 37 ± 7 N˙m
27 ± 5 lb-ft
FWD clutch, oil drain screw Torque 50 N˙m
35 lb-ft
Solenoid valve, cap screw Torque 8 to 12 N˙m
6 to 9 lb-ft
Solenoid valve coil, nut Torque 3 to 4 N˙m

[ on earlier solenoid valves only ]
2.5 to 3.0 lb-ft
Housing, dowel pins Amount of protrusion 12 mm
0.47 in.
Front-Wheel Drive Clutch - Sectional View

LEGEND:
A Clutch Shaft
B Belleville Spring
C Piston Housing
D Handbrake Band
E Piston
F Front-Wheel Drive Gear
G Disk Pack
H Check Valve
I Housing
J Solenoid Valve
K Hub
L Speed Sensor
[ AutoPowr/IVT transmission only ]
M Impulse Disk

Front-Wheel Drive Clutch — Exploded View


LEGEND:
1 Gear
[ 50 km/h version only ]
2 Clutch drum
[ 50 km/h version only ]
3 Spring
4 Check valve (3 used)
5 Lock washer (3 used)
6 Taper roller bearing
7 Thrust washer
8 Thrust plate
9 Oil transfer plate
10 Bearing bushing (2 used)
11 Clutch drum and gear
12 Thrust washer
13 Hub
Externally splined disk (7 used
[ at 6820 ]
14 ; 9 used
[ 6920 and 6920S ]
)
Internally splined disk (6 used
[ 6820 ]
15 ; 8 used
[ 6920 and 6920S ]
)
16 Bearing bushing
17 Piston (thickness varies with no. of disks)
18 O-ring
20 Ring
21 Snap ring
22 Plug (8 mm; 0.32 in. dia.)
23 Seal ring (2 used)
24 Clutch shaft
25 Seal ring
26 Taper roller bearing
27 Shim (quantity as required)
28 Speed sending unit
29 O-ring
30 Bearing quill
31 Seal ring
32 Protective panel
33 Housing
34 Speed sensor
35 Solenoid valve
36 Dowel pin (2 used)
37 LOCTITE ™ 574 (L64500) liquid sealant

Front-Wheel Drive Clutch - Replace Front-Wheel

Drive Axle Speed Sensor (B89)
LEGEND:
A Protective panel
B Sensor B89
[1] - Remove protective panel

(A).
[2] - Pull out plug on wiring harness and remove sensor B89
(B).
[3] - Check sensor, and replace if necessary.
[4] - Apply oil to new O-ring and install on sensor.
[5] - Install sensor B89 (B) and put the wiring harness plug back in.
Front-wheel drive axle speed sensor (B89) to front-wheel drive clutch Torque 10 - 12 N˙m
7 - 9 lb-ft
[6] - Attach protective panel (A).

FWD Clutch — Replacing Solenoid Valve
Previous solenoid valve
New solenoid valve
[1] - Pull out wiring harness plug (A).

[2] - Remove cap screws (B) on support plate.
[3] - Remove solenoid valve.

[4] - Clean components, inspect them for wear or damage and replace as necessary.
[5] - Install solenoid valve.
[6] - Attach cap screws (B) on support plate.
Solenoid valve, cap screws Torque 8 to 12 N˙m
6 to 9 lb-ft
[7] - Tighten the hex. nut

[ on earlier solenoid valves only ]
(C) on the coil.
Solenoid valve coil, nut Torque 3 to 4 N˙m
2.5 to 3.0 lb-ft
[8] - Connect wiring harness plug (A).

Replacing the FWD Clutch
→NOTE:
Before removing the FWD clutch, refer to “Removing the FWD Clutch” in
this Section, Group 00.
Disassembling FWD clutch
[1] -
Remove the solenoid valve. Refer to “FWD Clutch - Replacing Solenoid Valve” in this Group.
[2] - Remove the speed sending unit. Refer to “FWD Clutch - Replacing Speed Sensor” in this
Group.
[3] - Remove cap screws (A) and bearing quill (B).
[4] -
Remove plug (C).

[5] - Remove spring pin (A) and pull out lever shaft (B).

[6] -
Remove plug (A).

[7] -
Use an M6 screw to pull out shaft (A).

[8] -
Pull out the clutch shaft (A).

[9] - Remove shims and taper roller bearing cup.

[10] -
Remove the clutch and handbrake band from the housing.

[11] -
Remove handbrake band from clutch.

[12] -
Remove the taper roller bearing cup using JDG811 puller.

Bearing cup removal tool
JDG811
Remove taper roller bearing cup from housing

[13] -
Use dealer-fabricated bushing (A) to compress the belleville springs in a spring compressor.
Bushing
dealer-fabricated
Removing and installing belleville spring
[14] - Remove the snap ring.

[15] -
Take off ring (A) and belleville spring (B).

[16] -
Remove piston (A).

[17] -
Remove hub (A).

[18] -
Remove the pressure ring (A) and the thrust washer underneath it.
[19] - Remove disk pack (B).
[20] -
Remove retaining washer (A), check valve and spring.

[21] - Remove retaining washers (B) and check valves.
Assembling the FWD clutch

[1] -
Assembly instructions:
a. Clean the various parts, inspect them for wear or damage and replace as necessary.
b. When assembling, coat all components with hydraulic oil.
c. When assembling, coat pressure washers and seal rings with a thin film of grease.
d. Never clean the disks with a cleaning agent.
e. Before assembly, soak disks in hydraulic oil for 15 minutes.
[2] - Press bushing (A) into the clutch drum.

[3] -
Apply a thin coating of LOCTITE ™ 243 (L41475) to the outside edge of oil transfer plate (A).
Number Name Use
• L41475 (us) Cementing the oil transfer plate in the clutch
Threadlocker
• 243 LOCTITE ™ (loctite) drum
[4] - Attach oil transfer plate.
[5] -
→NOTE:
Install the check valves using the hole leading to the housing.

Install spring, check valve and retaining washer in hole (A).

[6] - Install check valves and retaining washers in holes (B).
[7] -
Install thrust washer (A).

[8] -

[9] -
Install hub (A).

[10] -
→NOTE:
Before installing the disks, dip them in oil.
Install disk pack (A). Start installing disks with an externally splined one.
[11] -
Press bushing (A) into the piston.

[12] -
Apply oil to O-ring (A), and install.

[13] -
Installing the piston (A).

[14] -
Install the belleville spring (B) with the convex side facing the piston.
[15] - Install O-ring (A).

[16] -
Install snap ring.

[17] -
Use dealer-fabricated bushing (A) to compress the belleville springs in a spring compressor.
Bushing
dealer-fabricated
Removing and installing belleville spring

[18] - Install the snap ring.

[19] -
Install taper roller bearing cup (A).

[20] -
Check handbrake components and replace, if necessary. Refer to “Exploded View of

Handbrake - 6820 Tractor” or “Exploded View of Handbrake - 6920 and 6920S Tractors” in
[21] -
→NOTE:
Pin (B) is held in place by straps (A) only. When installing, hold the brake
band linkage in the position shown, otherwise the pin will fall out.
Install handbrake band onto clutch as shown in illustration.

[22] -
→NOTE:
Make sure the brake band linkage pin does not fall out.

Install clutch and handbrake band.

[23] -
Make sure that plug (A) has been inserted into the end of the clutch shaft.
[24] - Replace seal rings (B), if necessary.
[25] - Replace oil seal (C).
[26] - Replace taper roller bearing (D), if necessary.

[27] -
Install speed sender

(A).
[28] -
Install clutch shaft (A).

[29] - Install taper roller bearing cup.
[30] -

[31] -

[32] -

[33] -
Install shaft (A).

[34] -
Screw in plug (A).

[35] -
Screw in plug (C).

[36] - Install lever shaft (B) and drive in spring pin (A).
[37] -
If necessary, install new sealing ring (A) flush with bearing quill surface.
[38] - Apply grease to the seal ring (A) between the sealing lips.
[39] - Install new O-ring (B).

[40] -
Install bearing quill (B) temporarily without shims.

[41] - Tighten cap screws (A).
18 lb-ft
Adjusting end play of FWD clutch shaft
[1] -
Rotate the clutch assembly several times in both directions to seat the bearings.
[2] - Measure end play.
[3] - Install shims under the bearing quill in order to provide correct end play.
Clutch shaft End play 0.025 to 0.100 mm
0.001 to 0.004 in.
[4] - Tighten bearing quill cap screws.

18 lb-ft

[5] - Check end play again.
FWD clutch — Final assembly
[1] -
Adjust the brake band at adjusting screw (A). The clutch drum must turn freely without any
undue resistance.
[2] - Tighten adjusting screw lock nut.
Lock nut Torque 37 ± 7 N˙m
27 ± 5 lb-ft
[3] -
Install oil drain plug (A).

[4] - Install the speed sending unit. Refer to “FWD Clutch - Replacing Speed Sensor” in this
Group.
[5] - Install the solenoid valve. Refer to “FWD Clutch - Replacing Solenoid Valve” in this
Group.

Section 56 - DRIVE SYSTEMS Group 15: Differential
[6] -
Ensure the dowel pins (A) are inserted at the correct depth.
Dowel pins Protrusion 12 mm
0.47 in.
[7] - Install front wheel drive clutch. Refer to “Installing the FWD Clutch” in Group 00 of this
Section.

Group 15 - Differential
Drive Systems - Differential, Summary of
References
Special Tools
Differential - Repair Specifications
Differential - Sectional View
Differential - Exploded View
Remove Differential
Recondition the Differential
Install Differential
Differential - Adjust Preload
Differential - Adjust Backlash
Special tools
→NOTE:

Seal installation tool
JDG236
Installing seal rings and bearing cups
17-1/2 ton puller set
D01173AA
Removing and installing bearings
D01045AA

Removing and installing bushings, bearings, bearing cups, and oil seal rings
Differential removal tool
JT07131
Removing and installing the differential
Differential - Specifications
Differential lock solenoid valve Y05, screws Torque 8 - 12 N˙m
6 - 9 lb-ft
Clutch disks Thickness (when new) 3.3 mm
0.129 in.
Bevel pinion shaft, retaining screw Torque 150 N˙m
110 lb-ft
Cover to housing, screw Torque 150 N˙m
110 lb-ft
Bearing quill to differential housing, screw Torque 90 N˙m
65 lb-ft
Differential Bearing preload 0.05 - 0.13 mm
0.002 - 0.005 in.
Value etched on outer circumference of gear, ±

Differential Backlash
0.11 mm (0.004 in.)
Differential - Sectional View

LEGEND:
A Left bearing quill
B Bearing cone
C Bearing cup
D Thrust washer
E Drive bevel gear
F Support
G Thrust washer
H Drive bevel gear

I Disks
J Disk
K Ring gear
L Piston
M Differential cover
N Bearing cup
O Bearing cone
P Right bearing quill
Q Seal rings
R Thrust washer
S Shaft
T Needle bearing thrust washers
U Needle bearing
V Thrust washers (with tang)
W Snap rings
Differential - Exploded View
LEGEND:

A Bearing quill, l.h. side

B Shims (quantity as required)
C Tapered roller bearing cone
D Oil line
E Seal rings
F Tapered roller bearing cone
G Bearing quill, r.h. side
H Differential ring gear
I Shaft
J Cap screw
K Tapered roller bearing cup
L Housing
M Thrust washer
N Bevel gear
O Thrust washer
P Bevel gear
Q Bevel gear
R Internally splined disk
S Externally splined disk
T Piston
U Housing cover
V Tapered roller bearing cup

Remove the Differential

Preliminary work:
See Remove the Rear PTO in Section 56.
See Remove the Final Drives in Section 56.
[1] -
LEGEND:
A Oil line
Remove oil line (A) of the differential lock.
[2] -
→NOTE:
Keep the shims with the corresponding bearing quill.
Remove both bearing quills with shims.

[3] -

LEGEND:
A Nut
B Bracket
C Threaded rod
D Bracket
E Handle
F Nut
G Extension
InstallJT07131removal tool.
[4] - Install nut (A) and bracket (B) on threaded rod (C). Tighten nut.
[5] - Loosely install bracket (D), handle (E), and nut (F).
[6] - Insert the tool assembly through the differential housing as illustrated.

[7] - Rotate bracket (B) by a 1/4 turn and tighten nut (F). Make sure the bracket is retained
crossways in the opening of the housing.
[8] - Install extension (G) and remove the differential. Use a suitable hoist.
Next step:
See Recondition the Differential in Section 56.

Recondition the Differential

Preliminary work:
See Remove the Differential in Section 56.
Disassemble the differential
[1] -
LEGEND:
A Screws
Remove screws (A).
[2] - Lift cover off housing.
Replace the ring gear:
IMPORTANT:
Ring gear and differential shaft must be replaced as a matched set. Be sure
numbers stamped on ring gear and on the end of the differential shaft are
the same. Adjust cone point when replacing ring gear and differential shaft.
See Install Differential Drive Shaft and Adjust Cone Point in Section 55.
Inspect ring gear and differential shaft for excessive wear or damage. Remove ring gear from
housing if necessary.
[3] -
CAUTION:
Heat ring gear in a bearing heater. Do not exceed 150 °C (300 °F). Proceed
Install ring gear.

[4] -
LEGEND:
A Piston inlet
Remove the differential lock piston from the cover by applying air to piston inlet (A).
[5] -
LEGEND:
A Bevel gear
B Internally splined disks
Remove bevel gear (A) from housing.
[6] - Remove disk pack (B) and (C).
Clutch disks Thickness (when new) 3.3 mm
0.129 in.
[7] -
Remove bearing cup from cover or housing.

[8] - Remove screw (A).

[9] -
Remove the shaft.

[10] - Take off the bevel gears and thrust washers.
[11] -
LEGEND:
A Differential pinion
B Thrust washer
Remove the differential pinion (A) and thrust washer (B).
Assemble the differential
[1] -
LEGEND:
A Tapered roller bearing cup
B Tapered roller bearing cup
Install tapered roller bearing cup (A) in the housing.
[2] - Install tapered roller bearing cup (B) on the housing cover using installation toolJDG236.
[3] -
LEGEND:
A Bevel gear
B Thrust washer
Install thrust washer (B) and bevel gear (A) in the housing.
[4] -
LEGEND:
A Tangs
Apply light, clean grease to the curved thrust washers and install in housing. Make sure the
tangs (A) are positioned in the recesses.
[5] -
Install bevel gears and shaft.

[6] -
LEGEND:
A Screw
Install screw (A) on the bevel gear shaft and tighten to specified torque.
Bevel gear shaft, retaining screw Torque 150 N˙m
110 lb-ft
[7] -
LEGEND:
A Bevel gear
B Thrust washer
Install thrust washer (B) on bevel gear (A).

[8] -
LEGEND:
A Bevel gear
B Internally splined disks
Install the internally splined disks (B) and externally splined disks (C) alternately on bevel
gear (A). Start with an internally splined disk.
[9] - Install the bevel gear and disk pack in the housing.
[10] -
LEGEND:
A Piston
Coat the seal lips with oil, install piston (A) in the differential cover and apply grease to retain
the piston.

[11] -
LEGEND:
A Screw
Put the cover on the housing and tighten the screws to specified torque.
Cover to housing, screw Torque 150 N˙m
110 lb-ft
[12] -
CAUTION:
LEGEND:
A Bearing quill
B Bearing quill
C Seal rings
Heat tapered roller bearing cones in a bearing heater. Do not exceed 150
°C (300 °F). Proceed with care to avoid burns.
Install tapered roller bearing cones in bearing quills (A) and (B).
[13] - Check seal rings (C) on differential lock.
Next step:
SeeInstall the Differentialin Section 56.

Install the Differential

[1] -
LEGEND:
G Extension
Use removal toolJT07131and extension (G) to lift the differential into the housing.
[2] -
→NOTE:
Install the shims that were used previously with the corresponding bearing
quill.
When using new bearings, install shims as necessary to obtain a
measurable axial play and backlash.
The differential lock oil line fitting is positioned on the right quill.
Install both differential bearing quills with shims.

[3] - Install screws on right-hand and left-hand differential bearing quills and tighten to
specified torque.
Differential bearing quill, screw Torque 90 N˙m
66 lb-ft

[4] -
LEGEND:
A Nut
B Bracket
C Threaded rod
D Bracket
E Handle
F Nut
G Extension
RemoveJT07131removal tool.
Next step:
SeeDifferential - Adjust Preloadin Section 56.

Differential - Adjust Preload

Preliminary work:
See Remove the Rear PTO in Section 56.
[1] -
IMPORTANT:
Rotate the differential several times in each direction to seat the roller
bearings. Repeat before each axial play measurement.
Measure the axial play.

[2] -
→NOTE:
Shims are available in various sizes. (See parts catalog). Measure shims
individually for accurate measurement.
If necessary, add or remove shims on both differential bearing quills (maintaining backlash)
to obtain bearing preload.
Differential bearing Bearing preload 0.05 - 0.13 mm
0.002 - 0.005 in.

[3] - Install screws on right-hand and left-hand differential bearing quills and tighten to
specified torque.
Differential bearing quill, screws Torque 90 N˙m
66 lb-ft
Next step:
SeeDifferential - Adjust Backlashin Section 56.

Differential - Adjust Backlash

Preliminary work:
SeeDifferential - Adjust Preloadin Section 56.
[1] -
IMPORTANT:
Adjust backlash after preload adjustment.
→NOTE:
Some ring gears may not have numbers on them.
If the ring gear has a number on the outer circumference, it is metric.
Make sure that the differential preload is adjusted correctly.

[2] - Read the value etched onto the outer circumference of the ring gear.
[3] - Measure backlash at three locations 120° apart.
[4] - Backlash should be equivalent to the value read on the ring gear.
Differential Backlash Value etched on outer circumference of gear ± 0.11 mm (0.004 in.)

Section 56 - DRIVE SYSTEMS Group 20: Hydraulic Pump Drive
[5] -
IMPORTANT:
Shims must not be removed or added.
Shims are moved from one side to the other to adjust backlash.
If backlash is excessive, transfer shims from the right to the left quill.
If there is not enough backlash, transfer shims from the left to the right
quill.
If there is too much backlash, remove shims from the right quill and place them under the left
quill.
[6] - If there is not enough backlash, remove shims from the left quill and place them under
the right quill.
[7] -
Install the differential lock oil line (A).
Next step:
SeeInstall the Rear PTOin Section 56.
SeeInstall the Final Drivesin Section 56.

Group 20 - Hydraulic Pump Drive

Hydraulic Pump Drive — Summary of References
Before reconditioning the pump drive, refer to the following:
”Special tools”
”Remove and disassemble pump drive pinion gear”
”Remove and disassemble pump drive gear”
”Assemble and install pump drive gear”
”Assemble and install pump drive pinion”
”Checking and adjusting the backlash of the pump drive pinion”

Special tools
→NOTE:

Bearing installer tool set
JDG781
Installing the pump drive gear and pump drive pinion roller bearings
Backlash adjusting tool
JDG869
Adjusting pump drive pinion backlash
Spigot wrench
KJD10168
Removing, installing and adjusting the adjustment ring

Pump drive gear (snap ring and bearing cone) Axial play 0.11 mm
0.004 in.
Pump drive pinion (snap ring and bearing cone) Axial play 0.11 mm
0.004 in.
Pump drive pinion backlash Backlash 0.229—0.305 mm
(0.009—0.012 in.)

Remove and Disassemble Pump Drive Pinion Gear
LEGEND:
A Pump Drive Pinion Gear
B Snap Ring
C Pinion Gear Bearing Cone (2 used)
D Pinion Gear Bearing Cup (2 used)
E Sleeve
F Bearing Spacer Ring (Inner)
G Bearing Snap Ring (Outer)
H Sleeve Locking Dowel Pin
I Bearing Snap Ring (Outer)
J Drive Gear Bearing Cup (2 used)
K Drive Gear Bearing Cone (2 used)
L Snap Ring
M Bearing Spacer Ring (Inner)

N Pump Drive Gear

O Shim Pack
[1] -
Remove the charge pump. See Removing the Charge Pump in Section 70, Group 10.
[2] - Put marks (A), using a center punch, adjacent to each other on the sleeve and the
differential housing. These marks are necessary for re-installation.
[3] - Remove dowel pin (B).
[4] -
Remove the sleeve/drive pinion assembly usingKJD10168Ring Nut Socket.

[5] -
Install a knife-edge puller under the sleeve.

[6] - Remove the snap ring (A) from the pinion shaft. Remove the shaft from the sleeve and
the upper bearing using a press with a 44.5 mm (1-3/4 in.) disk.
Bushing, Bearing, and Seal Driver Set
D01045AA
Remove and install bushings, bearings, bearing cups, and oil seals

[7] -
Remove the bearing spacer ring. Install a knife-edge puller under the lower bearing and
remove the shaft from the bearing using a 44.5 mm (1-3/4 in.) disk.
[8] -
→NOTE:
The bearing cups are a loose fit.
Remove the bearing cups from the sleeve.

[9] - Remove the bearing cup snap ring (A).

Remove and Disassemble the Pump Drive Gear
[1] - Remove the differential. See Remove Differential in Section 56, Group 20.
[2] - With AutoPowr/IVT transmission: See Remove the AutoPowr/IVT Transmission in Section
53, Group 00.
All other transmissions: See Remove Range Transmission in Section 55, Group 00.
[3] - Remove the pump drive pinion gear. See Remove and Disassemble Pump Drive Pinion
Gear in this Group.
[4] - Remove snap ring (A) from the drive gear shaft.
[5] - Remove the drive gear from the differential housing and front bearing using a 44.5 mm
(1-3/4 in.) driver disk, a 25.4 mm (1 in.) pilot disk, and a handle.
[6] -
Remove the bearing spacer. Install a knife-edge puller under the rear bearing and remove the
shaft from the bearing using a 44.5 mm (1-3/4 in.) disk.
[7] -
Remove shims (A) from the shaft.

[8] -
→NOTE:
The bearing cups are a loose fit.
Remove the bearing cups and the outer bearing snap ring (A) from the differential housing.

Assemble and Install Pump Drive Pinion Gear

[1] -
IMPORTANT:
Each cup and cone of the bearing assembly is a matched set and must be
assembled together.
Install the bearing cup spacer snap ring (A) and bearing cups in the differential housing.
[2] -
Note the stamped number (A) on the upper left side of the front face of the differential
housing.
→NOTE:
The stamped number is a reference for establishing the shim pack for the
differential pinion shaft.
If there is no number, use the 0.71 mm (0.028 in.) shim pack.

[3] - The stamped number, when referred to the pump drive gear shim chart below, provides
the thickness of the shim pack to be used to adjust the cone point of the pump drive shaft.
Pump drive gear shim chart
Number on housing Shim pack thickness
1 0.46 mm (0.018 in.)
2 0.56 mm (0.022 in.)
3 0.64 mm (0.025 in.)
4 0.71 mm (0.028 in.)
5 0.79 mm (0.031 in.)
6 0.86 mm (0.034 in.)
7 0.94 mm (0.037 in.)
8 1.02 mm (0.040 in.)
→NOTE:
Shims are available in various sizes (see Parts Catalog). Measure shims
[4] -
Determine the correct shim pack using the Pump Drive Gear Shim Chart.
[5] - Place the shim pack and the rear bearing on the pinion shaft. Make sure the side of the
bearing with the larger diameter is against the shims.
[6] - Install the bearing using a press and the bearing installer from JDG781 bearing installer
tool set.
Bearing Installer Tool Set
JDG781
Install pump drive gear and pump drive pinion roller bearings

[7] -
Install the bearing spacer ring on the shaft and install the shaft assembly in the differential
housing.
[8] - Install the front bearing onto the shaft, larger OD toward the driver, using the JDG781
Bearing Installer Tool Set.
[9] -
→NOTE:
Snap rings are available in various sizes (see Parts Catalog).
[10] - Install the bearing cones tight against the pump drive gear shim pack and install the
thickest snap ring (A) possible. Install two snap rings, if necessary.
Pump Drive Gear (Snap Ring and Bearing Cone) Axial Play 0.11 mm
0.004 in.
[11] - Install the pump drive pinion gear. See Assemble and Install Pump Drive Pinion Gear in
this Group.
[12] - Install the differential. See Install Differential in Group 15 of this Section.

Assembling and installing the pump drive pinion

[1] -

IMPORTANT:
LEGEND:
A Pump drive pinion
B Clamping ring
C Top bearing cone
D Bearing cup
E Bearing spacer ring
F Cup clamping ring
G Sleeve
H Bearing cup
I Bottom bearing cone
Each cup and cone of the bearing assembly is a matched set and must be
assembled together.
Install the bearing cup clamping ring (F) and bearing cups (D) and (H) into the sleeve bore.
[2] - Install the bottom bearing cone (I) with the larger OD against the gear. To do so, use the
bearing installer from the JDG781 bearing installer tool set.
Bearing installer tool set
JDG781
Installing the pump drive gear and pump drive pinion roller bearings
[3] - Install the bearing cone shim (E) on the shaft.
[4] - Install the sleeve assembly onto the drive shaft.
[5] - Install the top bearing (C) on the shaft, with the larger bearing OD against the driver. To
do so, use the bearing installer from the JDG781 bearing installer tool set.
[6] -
→NOTE:
Clamping rings are available in various sizes (see Parts Catalog).
Install the bearing cones against the gear shoulder and install the thickest clamping ring (B)
possible. Install two clamping rings, if necessary.
Pump drive pinion (clamping ring and bearing cone) Axial play 0.11 mm
0.004 in.
[7] -
IMPORTANT:
Take care to avoid cross-threading the sleeve during installation into the
housing.
Install the pinion shaft assembly into the differential housing.

[8] - Tighten the sleeve carefully using KJD10168 ring nut socket, until the pump drive pinion
and the pump drive gear mesh and contact.
Spigot wrench
KJD10168
Removing, installing and adjusting the adjustment ring

[9] -
Loosen the sleeve to align the punch marks (A).

[10] - Install the dowel pin (B).
[11] - Check the pump drive pinion backlash.

Section 56 - DRIVE SYSTEMS Group 25: Final Drives
Checking and adjusting the backlash of the pump

drive pinion
[1] -
Attach the JDG869 adjusting tool (A) and the dial indicator with the dial′s probe touching the
line (B).
[2] - Check the backlash at three different positions , each 120° apart.
Pump drive pinion Backlash 0.229—0.305 mm
0.009—0.012 in.
[3] - Adjust the backlash by rotating the sleeve one notch at a time. Check backlash and
repeat adjustment if necessary.
[4] - Remove adjusting tool and insert dowel pin (C).
[5] - Install the charge pump. See “Installing the charge pump” in section 70, group 10.

Group 25 - Final Drives

Drive Systems - Final Drives, Summary of
References
Drive Systems - Final Drives, Summary of References
Final Drives - Special Tools

Final Drives - Specifications
Final Drives - Sectional View
Final Drives - Exploded View
Remove Planetary Carrier
Disassemble Planetary Carrier
Assemble Planetary Carrier
Remove Axle Housing
Disassemble and Assemble Axle Housing
Disassemble and Assemble Axle Shaft
Final Drives - Install Axle Housing
Final Drives - Install Planetary Carrier and Check Rolling Drag Torque
Final Drives - Special Tools
→NOTE:

JDG778A- Adjusting Tool
DFLX42- Turning Device
DFRW30- Lifting Tool
JT01673- Installation Tool
D01045AA- Bushing, Bearing, and Seal Driver Set

Final Drives - Repair Specifications

Planetary Pinion, New Bearings Rolling Drag Torque 0.6 - 3.0 N˙m
6 - 24 lb.-in.
Planetary Pinion, Used Bearings Rolling Drag Torque 0.3 - 1.5 N˙m
3 - 12 lb.-in.
Axle Diameter at Outer Bearing New Diameter 81.050 - 81.083 mm
3.191 - 3.192 in.
Planetary Carrier to Axle Shaft, Special Twelve-Point Screw Torque 400 N˙m
295 lb.-ft.
Final Drive Housing, New Bearings Rolling Drag Torque 16 - 20 N˙m
12 - 15 lb.-ft.
Final Drive Housing, Used Bearings Rolling Drag Torque 8 - 16 N˙m
6 - 12 lb.-ft.
Planetary Carrier to Axle Shaft, Special Twelve-Point Screw Torque 908 N·m
670 lb.-ft.
Final Drives - Sectional View

LEGEND:
A Retaining washer
B Screw
C Tapered roller bearing
D Planetary gear
E Outer tapered roller bearing
F Seal cup
G Outer seal
H Special twelve-point screw
I O-ring
J Retaining washer
K Locking plate
L Planetary carrier
M Ring gear
N Bronze thrust washer
O Inner tapered roller bearing
P Inner oil seal
Q Housing
R Axle shaft
S Additional lubrication
T Brake piston
U Brake disk
V Retraction pin
W Brake plate

Remove Planetary Carrier

Preliminary work:
[1] -
LEGEND:
A Ring gear
B Planet gear screw
C Special twelve-point screw
D Locking plate
Remove ring gear (A).
[2] -
→NOTE:
Because of the high torque applied to planet gear screws (B), loosen these
screws while the planetary carrier is installed in the axle housing. This will
prevent the planetary carrier from turning when loosening the screws.
Loosen screws (B), if it is necessary to remove the planet gears.

[3] - Remove O-ring and locking plate (D). Loosen or tighten special twelve-point screw (C), if
necessary, for removal of plate.
[4] - Remove the special twelve-point screw and lift out the planetary carrier.

[5] -
Check the condition of the locking plate.

[6] - Replace plate, if distorted.

Disassemble Planetary Carrier

[1] -
→NOTE:
Refer to final drive cross-sectional view during disassembly and assembly.
Remove the planet pinion retaining cap screw and special washer.
[2] - Remove the planet pinion and the top bearing cone from the carrier using a puller with
a 50 mm (1-15/16 in.) driver disk fromD01045AAdriver set.
[3] -
Remove the bottom bearing cone from the carrier using a puller with a 50 mm (1-15/16 in.)
driver disk fromD01045AAdriver set.

[4] -
Remove one bearing cup from the planet pinion using a brass drift (A).
[5] -
Remove the remaining bearing cup using a 75 mm (2-15/16 in.) driver disk
fromD01045AAdriver set and a handle.

Assemble Planetary Carrier
LEGEND:
A Planetary carrier
B Inner pinion bearing cone
C Inner pinion bearing cup
D Planet pinion
E Outer pinion bearing cup
F Outer pinion bearing cone
G Pinion retaining washer
H Pinion retaining cap screw
I Carrier-to-axle shaft retaining washer
[1] - Install new bearing cups, small ID toward the inside shoulder, into the planet pinion.
Install tight against the shoulder using a 76 mm (3-3/16 in.) driver disk and handle.
[2] - Heat the bottom bearing cone and install with the large OD against the carrier shoulder.
Allow the bearing cone to cool and seat the bearing cone using a brass drift.
→NOTE:
Install the carrier-to-axle shaft retaining washer in the center of the carrier
with the stepped side facing the end of the axle shaft before installing the
last planet pinion.
[3] - Install the planet pinion assembly.

[4] - Heat the top bearing cone and install leaving end play between the cup and the cone.
[5] -
IMPORTANT:
Thoroughly clean the oil from the internal and external threads. Use only
the specified retaining compound.
Clean the threads and apply a 12 mm (0.5 in.) bead of TY15941 Retaining Compound to the
cap screw, starting at the thread end.
[6] - Clean the threads and apply TY15941 Retaining Compound to the carrier threads. Make
sure no retaining compound gets into the bearings.
[7] - Apply oil to the bearing cones.
[8] - Put the washers over the bearing cones and start the cap screws into the carrier.
[9] - Tighten the cap screws while rotating the planet pinions until a slight drag occurs.
[10] -
InstallJDG778AAdjusting Tool (A) and note the drag torque while rotating the pinion with the
tool.
[11] - Tighten the cap screw until drag torque on the pinion is:
Planet pinion, new bearings Rolling drag torque 0.6 to 3.0 N˙m
6 to 24 lb-in.
Planet pinion, used bearings Rolling drag torque 0.3 to 1.5 N˙m
3 to 12 lb-in.
IMPORTANT:
Rotate the pinion a minimum of three revolutions after each cap screw
adjustment before checking the drag torque.

[12] - Install the planetary carrier assembly and check the rolling drag torque. See “Install
Planetary Carrier and Check Rolling Drag Torque” in this group.

Remove Axle Housing

[1] - Remove the ring gear.
[2] - Remove planetary carrier. See “Remove Planetary Carrier” in this group.
[3] - Remove the carrier-to-bearing thrust washer.
[4] -
Press axle shaft through inner bearing using a hydraulic jack andDFRW30tool (A).
[5] - Remove the hydraulic jack and the tool. Remove bearing.
[6] - Remove the axle housing from the axle shaft using a hoist. Be sure the housing is
balanced on the chain or strap.
[7] -
Inspect the ring gear for damage.

Disassemble and Asssemble Axle Housing

[1] -
Inspect outer seal retainer (A) for wear or damage. Pry retainer from housing to replace it, if
necessary.
[2] - Install seal retainer against outer face of housing.
[3] -
Install outer bearing cup against bottom shoulder usingJT01673Installer.

→NOTE:
Use a 0.05 mm (0.002 in.) feeler gauge to check that the bearing cup is in
contact with the bottom shoulder of the housing.
[4] -
Remove the inner oil seal from the housing.

[5] - Install the oil seal with the spring-loaded side facing the driver. Use 100 mm (4 in.) and
76 mm (3-1/16 in.) driver disks fromD01045AAdriver set and a handle (A).
[6] -
Install the inner bearing cup usingJT01673Installer. Install cup against bottom shoulder.
→NOTE:
Use a 0.05 mm (0.002 in.) feeler gauge to check that the bearing cup is in
contact with the bottom shoulder of the housing.

Disassemble and Assemble Axle Shaft

[1] -
IMPORTANT:
LEGEND:
A Strap
B Puller
C Puller legs
D Puller cross bar
E 76 mm (3 in.) disk
F Hydraulic jack
DO NOT use a torch to remove axle bearings. Heating of the axle shaft will
cause early failure.
Inspect, remove, and replace parts as required.

[2] - Remove parts from the axle shaft using puller tools and a hydraulic jack. Make sure the
puller is hooked over the outer bearing spacer.
[3] - Measure the axle diameter at the outer bearing.
Axle diameter at outer bearing New diameter 81.050 to 81.083 mm
3.191 to 3.192 in.

[4] -
IMPORTANT:
Install the oil seal with the metal side toward the outer end of the axle. If
the seal has metal on both sides, follow the directions stamped on the seal.
Install the outer seal over the spacer after the spacer has cooled. “This Side Out” must face
the outer end of the axle.
Make sure the oil seal lips are filled with grease before installing the axle shaft in the axle
housing.
[5] -
CAUTION:
Heat bearing cone in a bearing heater. Use a thermometer and do not
exceed 150°C (300°F). Proceed with care to avoid burns.
Heat the outer bearing cone to 150°C (300°F) maximum and install on the shaft against the
oil seal. Allow the bearing cone to cool and then reseat the bearing and spacer against the
shaft shoulder using a brass drift. Lightly oil the bearing. Do not use grease at this time.
[6] - Install the nylon spacer ring on the axle shaft with the chamfered inside facing the
bearing.

Final Drives - Install Axle Housing

[1] -
Before installing the axle shaft, coat the inner seal lip with grease and make sure the outer
seal lips are filled with grease.
[2] - Coat the splines of the axle shaft with heavy grease to prevent damage to the inner
seal.
[3] - Install the axle housing on the axle shaft using a hoist. Be sure housing is balanced and
take care to avoid damaging the inner seal.
[4] -
CAUTION:
Heat bearing cone in a bearing heater. Use a thermometer and do not
exceed 150°C (300°F). Proceed with care to avoid burns.
Heat the inner bearing cone to 150°C (300°F) maximum and install on the shaft. DO NOT
install the bearing cone tight into the bearing cup. This assures end play.
[5] - Install the planetary carrier assembly and check the rolling drag torque. SeeFinal Drives
- Install Planetary Carrier and Check Rolling Drag Torquein Section 56.
[6] - Install the bronze thrust washer on the shaft against the inner bearing.

Final Drives - Install Planetary Carrier and Check

Rolling Drag Torque
Install planetary carrier
[1] -
LEGEND:
A Special Twelve-Point Screw
B Washer
Install planetary carrier on shaft.
[2] -
→NOTE:
Lubricate inner and outer bearings with oil before tightening the special
twelve-point screw at the carrier retainer.
Install the special twelve-point screw (A) through retainer (B) of the planetary carrier.
[3] -
IMPORTANT:
Do not re-use the special twelve-point screw; it may be used once only.

LEGEND:
Manually screw the special twelve-point screw (A) into the axle shaft. While doing so, make
sure the washer is in the specified position in the planetary carrier.
[4] -
LEGEND:
To press the bearings into the correct position, tighten special twelve-point screw (A) to the
specified torque.
Planetary carrier to axle shaft, special twelve-point screw Torque 400 N˙m
295 lb-ft
[5] - Rotate the axle housing at least six full revolutions in each direction to ensure proper
seating of the bearing rollers.

[6] - Tighten special twelve-point screw (A) once again to specified torque.
Planetary carrier to axle shaft, special twelve-point screw Torque 400 N˙m
295 lb-ft
[7] -
Remove the planetary carrier from the axle shaft and tap the end of the axle shaft as shown.
This will relieve the bearing preload and thus provide some axial play between bearing and
bearing cone.
Check rolling drag torque
[1] -
IMPORTANT:
Do NOT check the rolling drag torque with the ring gear installed.
LEGEND:
A DFLX42 - Turning Device
B Torque Wrench without Ratchet
To measure the rolling drag torque of the final drives, use turning deviceDFLX42(A) and a
torque wrench (B) without ratchet.

[2] - Rotate the axle housing and record the rolling drag torque. Repeat the procedure three
times and take the average of the results. This figure represents the initial rolling drag
torque.
[3] -
IMPORTANT:
Be sure thrust washer (A) is still positioned correctly.
→NOTE:
Lead balls (R72232) can be ordered through normal parts channels.
LEGEND:
A Lead Ball
B Thrust Washer
180° apart, place two lead balls with a diameter of 8 - 10 mm (0.3 - 0.4 in.) on end of the axle
shaft. Apply grease to hold the balls in place.
[4] -
Install the planetary carrier and tighten the special twelve-point screw to 200 Nm (148 lb-ft).

[5] -
LEGEND:
Rotate the axle housing at least three full revolutions in each direction, then use turning
deviceDFLX42(A) and torque wrench (B) to measure the rolling drag torque.
Repeat the procedure at least three times, measure the rolling drag torque and take the
average of the results.
The following value must be added to the initial rolling drag torque:
Final drive housing, new bearings Rolling drag torque 16 - 20 N˙m
12 - 15 lb-ft
Final drive housing, used bearings Rolling drag torque 8 - 16 N˙m
6 - 12 lb-ft
Sample calculation:
Calculated initial rolling drag torque
(average of three measurements) .......... 10 N˙m (7.5 lb-ft)
+ rolling drag torque for new bearings .......... + 16-20 N˙m (12-15 lb-ft)
= total rolling drag torque .......... = 26-30 N˙m (20-22 lb-ft)
In the sample calculation, total rolling drag torque must be 26-30 N˙m (20-22 lb-ft).
[6] - Tighten the special twelve-point screw in steps of 25-50 N˙m (18.5-37 lb-ft) each until
the calculated total rolling drag torque is achieved.

[7] -
LEGEND:
A Lead Ball
B Shim Pack
C Thrust Washer
Remove and measure individual thickness of flattened lead balls (A). Average thickness of
two lead balls equals thickness of shim pack required.
[8] -
→NOTE:
Shims must always be measured individually due to slight variations in
thickness. Never measure an entire shim pack at once.
Relieve the bearing preload by lifting the final drive and hitting the inner end of the axle with
a heavy lead hammer.
[9] - Install shim pack (B) of required thickness as determined previously. Be sure thrust
washer (A) is positioned correctly.
[10] -
IMPORTANT:
Relieve any bearing preload before ADDING shims.

Install the planetary carrier and tighten the special twelve-point screw to 200 Nm (148 lb-ft).
[11] -
LEGEND:
Rotate the axle housing at least three full revolutions in each direction, then use turning
deviceDFLX42(A) and torque wrench (B) to measure the rolling drag torque.
Repeat the procedure at least three times, measure the rolling drag torque and take the
average of the results.
[12] -
→NOTE:
Adding or removing a shim with a thickness of 0.13 mm (0.005 in.) will
change the rolling drag torque by approx. 8 N˙m (71 lb-in).
→NOTE:
Add shims if the rolling drag torque is too high or remove shims if the
rolling drag torque is too low.
Adjust the thickness of the shim pack as needed until the calculated rolling drag torque is
achieved.

[13] -
LEGEND:
A Torque Multiplier
Tighten the special twelve-point screw using a torque multiplier (A) to the final torque as
specified.
Planetary carrier to axle shaft, special twelve-point screw Torque 908 N·m
670 lb-ft
[14] -
LEGEND:
A Locking Plate
B Lock Lugs
C O-Ring
Replace the locking plate (A) if required.
[15] - Install the locking plate with the lugs between the lock lugs (B) on the carrier. If the
notches in the plate will not fit over the lock lugs, tighten the special twelve-point screw
slightly (8° maximum).

Section 56 - DRIVE SYSTEMS Group 30: Rear PTO
[16] - Install the O-ring (C) around the head of the special twelve-point screw with the
locking plate installed.
[17] - Fill the outer bearing compartment and the bearing with grease.
[18] -
LEGEND:
A Ring Gear
Install ring gear (A) with groove (see arrow) facing upward.
Next step:
See Install the Final Drives in Section 56.

Group 30 - Rear PTO

Drive Systems - Rear PTO, Summary of References
Special Tools
Specifications
Repair Instructions
Repair Rear PTO
Remove and Disassemble Countershaft
Assemble and Install Countershaft
Remove and Disassemble Output Shaft
Assemble and Install Output Shaft
Remove PTO Shifter
Install PTO Shifter
Replacing Oil Seal on PTO Output Shaft
Remove Modulating Valve
Disassemble and Assemble Modulating Valve
Install Modulating Valve
Change and Adjust Bowden Cable

Special tools
→NOTE:

Driver
JDG753 or KJD10171
Installing the seal ring on PTO output shaft
Spring compressor
JDG754
Compressing PTO clutch return springs
PTO clutch bushing installer
JDG755
Installing PTO clutch bushing
17-1/2 ton puller set

D01173AA
Removing and installing bearings
D01045AA
Removing and installing bearing cups, bearing cones, and bushings

Specifications
Clutch backing plate, cap screw Torque 35 N˙m
26 lb-ft
Bearing support to PTO housing, cap screw Torque 90 N˙m
66 lb-ft
Clutch assembly End play 0.015 to 0.15 mm
0.001 to 0.006 in.
Countershaft bearing quill, cap screw Torque 50 N˙m
37 lb-ft
Countershaft End play 0.025 to 0.13 mm
0.001 to 0.005 in.
Output shaft End play 0.015 to 0.15 mm
0.001 to 0.006 in.
Shifter support, cap screw Torque 70 N˙m
52 lb-ft
Shift detent spring Free length approx. 20 mm
approx. 0.8 in.
Test length 12 mm at 65 N
0.5 in. at 15 lb force
PTO modulating valve, outer spring Free length approx. 70 mm
approx. 2.75 in.
PTO modulating valve, inner spring Free length approx. 111 mm
approx. 4.4 in.
PTO modulating valve, test plug Torque 12 N˙m
9 lb-ft
PTO modulating valve - valve housing and retaining plate, cap screw Torque 16 N˙m
11 lb-ft
PTO modulating valve to PTO housing, cap screw Torque 16 N˙m
11 lb-ft
Repair Instructions
When assembling, coat all components with hydraulic oil.
When assembling, coat needle bearings, thrust washers and sealing rings with a thin
film of grease.
Never clean the clutch plates in cleaning agent. Before assembling new clutch plates,

soak them for 15 minutes in hydraulic oil.

Never heat bearing cones to temperatures higher than 150°C (300°F).

Repair Rear PTO

[1] -
Remove the rear PTO. See “Removing the Rear PTO” in Group 00 of this Section.
[2] - Remove the PTO master-shield (A).
[3] - Take the snap ring off the PTO output shaft and pull out the shaft.
[4] - Remove oil deflector plate
.
[5] -
Remove the bearing support (A).

[6] -
Remove the bearing cup snap rings (A) of the clutch front bearing and output shaft.
17-1/2 Ton Puller Set
D01173AA
Remove and install bearings.
[7] - Remove bearing cups (B).
Remove and disassemble PTO clutch

PTO clutch—sectional view
LEGEND:
A Bearing cone
B Bearing cup
C Snap ring
D Backing plate with gear
E Clutch hub with thrust washers
F Disk (4 used)
G Externally splined disk (3 used)
H Clutch return plate
I Clutch piston
J Clutch drum
K Brake plate
L Brake piston
M Seal ring (2 used)
N Bearing cup
O Bearing cone
P Snap ring
Q Lube cut-off valve
R PTO housing
S Piston seal (2 used)
T Bushing
U Piston return spring (7 used)
V Snap ring
W Bearing support

LEGEND:
A Bearing cup
B Bearing cone
C Snap ring
D Lube cut-off valve
E Brake piston
F Brake plate
G Clutch drum
H Inner piston seal ring
I Outer piston seal ring
J Clutch piston
K Piston return spring (7 used)
L Snap ring
M Seal ring (2 used)
N Bushing
O Thrust washer (2 used)
P PTO clutch hub with thrust washer (2 used)
Q Return plate
R Disk (4 used)

S Externally splined disk (3 used)

T Backing plate with gear
U Bearing cone
V Cap screw (6 used)
[1] -
Remove the output drive gear.

[2] - Remove the PTO clutch assembly from the PTO housing.
[3] -
Remove the bearing cup from the PTO housing.

17-1/2 Ton Puller Set
D01173AA
Remove and install bearings.
[4] - Remove the PTO brake plate and brake piston (A).
[5] -
Remove the clutch backing plate with gear.

[6] - Remove the front bearing cone using a press, a knife-edge puller and a 55.5 mm
(2-3/16 in.) disk.
D01045AA
Remove and install bearing cups, bearing cones, and bushings.
[7] -
LEGEND:
A PTO clutch hub
B Washers
D Return plate
Remove parts (A to D).
[8] -
Remove the lube cut-off valve retaining ring (A) and valve (B).
[9] -
Inspect the sealing rings (A).

[10] - Remove the rear bearing cone using a press, a knife-edge puller and a 44.5 mm (1-3/4
in.) disk.
[11] -
Put the clutch drum assembly in a press and install JDG754 Spring Compressor Tool.
Spring compressor
JDG754
Compress PTO clutch return springs

[12] - Compress the return springs and remove the snap ring (A).
[13] - Remove the return springs and the clutch piston.
[14] -
Replace the piston seals (A).
Assemble and install PTO clutch

[1] -
Install the rear bearing (A) on the clutch drum against the shoulder using a press and a 50
mm (2 in.) disk.
[2] - Install the lube cut-off valve (B) and valve retainer (C).
[3] -
Install the sealing rings (A) making sure the ends are not in the line and are solidly hooked.
[4] -
Install the clutch piston.

[5] - Install the seven return springs alternately, starting with the outer circumference
against the piston.

[6] -
Put the clutch drum assembly in a press and install JDG754 Spring Compressor Tool.
Spring compressor
JDG754
Compress PTO clutch return springs

[7] - Compress the return springs and install the snap ring.
[8] - Install the bushing using JDG755 Bushing Installer.
PTO Clutch Bushing Installer
JDG755
Install PTO clutch bushing

[9] -
LEGEND:
A PTO clutch hub
B Disks (4 used)
C Externally splined disk (3 used)
D Return plate
Install PTO clutch hub (A).
[10] - Install the clutch return plate (D).
[11] - Install the externally splined disks (C) and disks (B) alternately starting with a disk
against the return plate.
[12] -
Heat the bearing cone and install on the backing plate. Allow the bearing cone to cool and
seat the bearing against the shoulder using a brass drift. See Repair Instructions in this
group.
[13] - Install the clutch backing plate with gear. Tighten cap screws.
Clutch backing plate, cap screw Torque 35 N˙m
26 lb-ft

[14] -
Install the brake piston and plate (A) in the housing.

[15] -
Install the output drive gear.

[16] - Install the PTO clutch assembly into the PTO housing.
[17] -
Install the bearing support (A).

[18] - Tighten cap screws.

66 lb-ft
[19] -
Install the front bearing cup and a thin snap ring.

[20] - Rotate the clutch assembly several times in each direction to seat the bearings.
[21] - Install a dial indicator with the pointer resting on the end of the clutch assembly.
[22] - Force the clutch assembly up and down using a pry bar. Measure the end play.
[23] - Measure the thickness of the snap ring installed during the end play check.
→NOTE:
[24] - Select a snap ring that will provide specified end play.
Clutch assembly End play 0.015 to 0.15 mm
0.001 to 0.006 in.
[25] - Install
oil deflector plate.
[26] - Install the rear PTO. See “Installing the Rear PTO” in Group 00 of this Section.

Remove and Disassemble Countershaft

[1] -
Remove oil deflector plate

.
[2] - Remove the bearing support (A).
[3] -
→NOTE:
The front output drive gear bearing is a loose fit.
Remove the output drive gear, front bearing and bearing-to-gear thrust washer.

PTO countershaft — sectional view

LEGEND:
A Snap ring
B Countershaft drive gear
C Bearing cone
D Bearing cup
E Bearing quill
F Shim pack
G PTO housing
H Bearing cup
I Bearing cone
J Countershaft

PTO countershaft — exploded view

LEGEND:
A Bearing cup
B Bearing cone
C Snap ring
D Output gear (540E rpm)
E Countershaft
F Bearing cone
G Bearing cup
H Shim pack
I Bearing quill
J Cap screw (4 used)
K Countershaft drive gear
L Snap ring

[4] -
Remove the snap ring (A) and countershaft drive gear (B).
[5] - Remove the bearing quill and shims (C).
[6] - Remove the countershaft from the PTO housing.
[7] -
Remove the bearing cup from the quill using a press and a 72.6 mm (2-7/8 in.) driver disk.
D01045AA
[8] - Install a new bearing cup using a 66.7 mm (2-5/8 in.) driver disk and a press.

Assemble and Install Countershaft

[1] -
Install a new rear bearing cup in the housing using a 74.6 mm (2-15/16 in.) driver disk.
D01045AA
[2] -
Install a new rear bearing cone (A) on the shaft using a 44.5 mm (1-3/4 in.) driver disk.
[3] - Heat the front bearing cone (B) and install on the shaft. Allow the bearing cone to cool
and seat the bearing against the shoulder using a brass drift. See “Repair Instructions” in this
group.

[4] -
Install the countershaft into the housing.

[5] - Install the same shim pack that was removed.
[6] - Install the bearing quill. Tighten cap screws.
37 lb-ft
[7] - Rotate the countershaft several times in each direction to seat the bearings.
[8] - Install a dial indicator with the pointer resting on the end of the countershaft.
[9] - Force the countershaft up and down using a pry bar. Measure the end play.
→NOTE:
Shims are available in various sizes (see Parts Catalog). Measure shims
[10] - Remove the quill and add or subtract shims to provide correct end play.
Countershaft End play 0.025 to 0.13 mm
0.001 to 0.005 in.
[11] -
Install the countershaft drive gear (B) and retaining snap ring (A).
[12] -
→NOTE:
Install the output shaft drive gear, thrust washer between gear and front bearing and front
bearing.
[13] - Install the bearing support.
[14] - Install
66 lb-ft

Remove and Disassemble Output Shaft
LEGEND:
A Bearing support
B Snap ring
C Bearing cup
D Bearing cone
E Thrust washer
F Output gear (1000 rpm)
G Snap ring
H Sleeve
I Collar
J Output gear (540 rpm)
K Output shaft
L Magnetic speed pickup disk

M Bearing cone
N Bearing cup
O PTO housing
P Oil seal
Q Snap ring
R Thrust washer
S Needle bearing (2 used)
T Needle bearing spacer
LEGEND:
A Shift collar (2 used)
B Output gear (540E rpm)
C Snap ring (4 used)

D Thrust washer
E Output gear (540E rpm)
F Shift collar support
G Thrust washer
H Needle bearing (2 used)
I Needle bearing spacer
E Output gear (1000 rpm)
K Thrust washer
L Bearing cone
M Output shaft
N Speed pick-up disk
O Bearing cone
P Bearing cup
Q Seal ring
R Output shaft
S Snap ring
[1] -
Remove oil deflector plate

.
[2] - Remove bearing support (A).

[3] -
→NOTE:
Remove the front bearing, bearing-to-gear thrust washer and output shaft drive gear from
the shaft.
[4] -
LEGEND:
A Spring pin
B Shifting gate
C Shift yoke and collar
D Countershaft snap ring
E Countershaft drive gear
F Bearing quill and shims
Remove spring pin (A) between shifting gate and cam shaft.
[5] - Push the shifting gate (B) against the housing.
[6] - Remove the shift yoke and shift collar (C) from the shifter rails and the output shaft.
[7] - Remove the snap ring (D) and gear (E).
[8] - Remove the countershaft bearing quill and shims (F).
[9] - Remove the countershaft from the PTO housing.
[10] - Remove the output shaft from the PTO housing.

[11] -
Remove rear oil seal (A). Do not install the new seal until after the output shaft is installed in
the housing. See “Replacing Oil Seal on PTO Output Shaft” in this group.
[12] - Remove rear bearing cup (B).
[13] -
Remove thrust washer (A) between shaft and output gear.

[14] - Remove the snap ring (B) and sleeve (C).
[15] -
Remove the snap ring (A) and the 540 rpm output gear (B).

[16] -
Remove the magnetic speed pickup disk and rear bearing using a press and a knife-edge
puller.

Assemble and Install PTO Output Shaft

[1] -
Install the magnetic speed pick up disk against the shoulder using a brass drift.
[2] - Heat the rear bearing cone and install on the shaft. Allow the bearing to cool and seat it
against the magnetic speed pickup disk using a brass drift. See “Repair Instructions” in this
group.
[3] -
Install the 540 rpm output gear (B) and snap ring (A).
[4] -
Install sleeve (C).

[5] - Install the sleeve retaining snap ring (B).
[6] - Install thrust washer (A) between shaft and output gear.

[7] -
LEGEND:
A Spring pin
B Shifting gate
C Shift yoke and collar
D Countershaft snap ring
E Countershaft drive gear
F Bearing quill and shims
Install the output shaft into the housing.
[8] - Install the shift yoke and shift collar (C) on the shifter rails and the output shaft.
[9] - Push the cam of shifting gate (B) inward aligning the yoke roller in the shifting gate
track.
[10] - Rotate the shifter shaft so the arm is pointing to the front. Install the spring pin (A).
[11] - Install the output shaft into the housing.
[12] - Install the countershaft into the PTO housing.
[13] - Install the countershaft bearing quill with shims (F). Tighten cap screws.
37 lb-ft
[14] - Install the countershaft drive gear (E) and snap ring (D).
→NOTE:
Make sure the thrust washer between output shaft and gear is installed.

[15] -
Install the output gear, two bearings with a spacer between them and the thrust washer
between output gear and front bearing.
→NOTE:
[16] - Install the front bearing cone on the shaft.

[17] -
Install the bearing support.

66 lb-ft
[19] - Install the front bearing cup and a thin snap ring.
[20] - Rotate the output shaft several times in each direction to seat the bearings.
[21] - Install a dial indicator with the pointer resting on the end of the shaft.
[22] - Force the shaft up and down using a pry bar. Measure the end play.
[23] - Remove the front bearing retaining snap ring and measure the thickness.
→NOTE:
[24] - Select a snap ring that will provide specified end play.
Output shaft End play 0.015 to 0.15 mm
0.001 to 0.006 in.
[25] - Install oil deflector plate

.

Remove PTO Shifter
PTO shifter components
LEGEND:
A O-ring
B Selector shaft
C Cap screw
D Bracket
E Shifting gate
F Bearing bushing (4 used)
G Spring pin (2 used)
H Bushing (2 used)
I Selector shaft bearing
J Cap screw (2 used)
K Shifter yoke
L Shifter yoke
M Cap screw
N Locking tab
O Detent spring
[1] - Remove oil deflector plate

.

[2] -
Remove the bearing support (A).

[3] -
→NOTE:
Remove output drive gear front bearing, thrust washer and gear with two bearings and
bearing spacer.

[4] -
Remove spring pin (A) between shifting gate and cam shaft.
[5] -
Push the cam (A) against the housing wall.

[6] - Remove the shifter yoke and shift collar (B) from the shifter rails and the output shaft.
[7] -
Remove the spring pin between support (A) and cam shaft and remove the cam shaft from
the housing, cam, and support.
[8] - Remove the support (B) with the cam detent and detent spring.
Detent spring Free length approx. 20 mm
approx. 0.8 in.
0.5 in. at 15 lb
[9] - Remove the shifter rails (C) with E-Clips from the housing.

Install PTO Shifter

[1] -
Install the shifter rails with E-Clips (C), short end first into the housing.
[2] - Install the hollow dowels into the support (B) so one-half of the dowel protrudes from
the support surface.
[3] - Install the support (B) with the shifter detent hole on the bottom facing outward.
Tighten cap screws.
Shifter support, cap screw Torque 70 N˙m
52 lb-ft
[4] - Hold the shifting gate with detent reliefs on the bottom and the hub facing outward in
line with the support.
[5] - Install the cam shaft with O-ring through the housing, shifting gate and support. Install
the spring pin (A).
[6] - Install the detent spring and the detent in the support.
[7] -
Install the shift yoke and collar (B) onto the shifter rails and the output shaft with the large
bushing on top.
[8] -
IMPORTANT:
The lever on the camshaft must point forward.
Push the cam shaft into the shifting gate (A) until the spring pin holes align.

[9] - Install the spring pin.

[10] -
→NOTE:
Install the output drive gear, two bearings and bearing spacer, thrust washer between gear
and bearing, and front bearing cone.
[11] -
Install the bearing support (A).

[12] - Install
66 lb-ft

[14] - Install the PTO.
Replacing Oil Seal on PTO Output Shaft

[1] -
Remove the PTO output shaft snap ring, the shaft and the old oil seal.
[2] - Install the new oil seal using seal installer JDG753 or KJD10171 (A).
Driver
JDG753 or KJD10171
Installing the oil seal on PTO output shaft

[3] - Install the PTO output shaft and snap ring.
Remove Modulating Valve

[1] -
Remove six valve housing cap screws (A) and remove the valve housing and gasket.

[2] -
Remove housing-to-mounting plate cap screws (A) and remove the plate and gasket.

Disassemble and Assemble Modulating Valve

[1] -
LEGEND:
A Snap Ring
B Plug with O-Ring
C Accumulator Piston
D Outer Spring
E Inner Spring
F Pin
G Modulating Valve
H Test Port Plug with O-Ring (2 used)
I Valve Housing
J Valve Housing-to-Mounting Plate Plate Gasket
K Mounting Plate
L Mounting Plate-to-PTO Housing Gasket
Inspect parts and replace as necessary.
PTO modulating valve, outer spring Free length approx. 70 mm
approx. 2.75 in.
PTO modulating valve, inner spring Free length approx. 111 mm
approx. 4.4 in.

[2] - Tighten test port plugs with O-rings (H).

PTO modulating valve, test plug Torque 12 N˙m
9 lb-ft

Install Modulating Valve

[1] -
Install valve housing-to-mounting plate gasket and cap screws (A). Tighten screws.
PTO modulating valve - valve housing and retaining plate, cap screw Torque 16 N˙m
11 lb-ft
[2] -
Install six cap screws (A) and tighten.

PTO modulating valve to PTO housing, cap screw Torque 16 N˙m
11 lb-ft

Changing and adjusting the bowden cable
Actuating components of PTO shift with Command Arm
LEGEND:
A Shifter shaft
B Yoke
C Lock nut
D Bowden cable
E Rubber sleeve
F Retainer
G Retainer
H PTO speed selector lever
I Handle
J Washer
K Hex. nut
L Washer
M Washer
N Spring washer
O Self-locking hex. nut
[1] -

Actuating components of PTO shift without Command Arm

LEGEND:
A Shifter shaft
B Retainer
C Retainer
D Bowden cable
E Rubber sleeve
F Retainer
G Retainer
Section 56 - DRIVE SYSTEMS Group 35: Front PTO
H PTO speed selector lever

I Handle
J Washer
K Hex. nut
L Cover
M Washer
N Spring washer
O Bushing
P Creeper selector lever
[ If equipped ]
Q Bushing
R Washer
S Self-locking hex. nut
Disengage bowden cable (D) at shifter shaft (A).
[2] - Remove the trim panels from the shift console and disengage bowden cable (D) at
selector lever (H).
[3] - Run the new bowden cable past the hydraulic pump and through the lift shaft support.
[4] - Engage bowden cable in selector lever, and secure.
Adjusting the PTO shift
[1] - Move shifter shaft (A) at the transmission to the “1000 rpm” position.
[2] - Also move selector lever (H) on the console to the “1000 rpm” position.
[3] - Adjust the bowden cable on the yoke so that it is aligned with the holes in the shifter
shaft. Secure with the retaining pin.
[4] - Tighten the lock nut on the yoke, making sure that the yoke does not twist in relation to
the shifter shaft.
[5] - Check that PTO engages and disengages properly at all speeds.
[6] - Attach the panels.

Group 35 - Front PTO

Front PTO - Reconditioning (Summary of
References)
Before reconditioning the front PTO, refer to the following:
”Other material”
”General repair procedures”
”Replacing the solenoid valve”
”Reconditioning the modulator valve”
”Replacing the front PTO speed sending unit (B58)”
”Cleaning and replacing the filter”
”Reconditioning the pressure-regulating valve”
”Checking the cooler relief and filter by-pass valves”
”Removing and installing the valve plate”
”Front PTO — Sectional view”
”Disassembling the front PTO”
”Reconditioning the oil pump”
”Reconditioning the PTO clutch”
”Reconditioning the PTO brake”
”Reconditioning the intermediate gear shaft (PTO rotating counterclockwise)”
”Reconditioning the drive shaft”
”Assembling the front PTO”
Other Material
Number Name Use
• L64500 (loctite) Flexible sealant Sealing the surfaces on the front PTO
• L41475 (loctite) Thread lock Cementing screws at the front PTO
• L156817 (loctite) Molykote “Long Term” Applying grease to the spline on the drive shaft

Specifications
Y01 - Solenoid valve for front PTO to housing, screws Torque 8 - 10 N˙m
6 - 7.5 lb-ft
Modulating valve to front PTO, screws Torque 16 N˙m
12 lb-ft
B58 - Front PTO speed sensor to housing Torque 10-12 N˙m
7.5-9 lb-ft
Pressure-regulating valve Pressure 1200 kPa
12 bar
174 psi
15 lb-ft
Valve plate to front PTO, screws Torque 10 N˙m
7.5 lb-ft
Oil manifold, screw Torque 10 N˙m
7.5 lb-ft
Oil pump installation, screws Torque 10 N˙m
7.5 lb-ft
PTO clutch gear, screw Torque 23 N˙m
17 lb-ft
PTO stub shaft, hex. nut Torque 50 N˙m
36.5 lb-ft
Lid on clutch cage, screw Torque 10 N˙m
7.5 lb-ft
Ring gear at PTO brake Torque 10 N˙m
7.5 lb-ft
Drive shaft and housing cover, tapered roller bearings Capacity 20 ml
0.68 fl oz
Housing cover, screw Torque 23 N˙m
17 lb-ft
Bearing quill and housing cover, tapered roller bearings Capacity 40 ml
1.4 fl oz
Bearing quill to housing cover, screw Torque 10 N˙m
7.5 lb-ft
Output shaft, tapered roller bearings Preload 0.01 to 0.04 mm
0.0004 to 0.0016 in.
7.5 lb-ft

Bearing quill to housing cover, screws Torque 10 N˙m
7.5 lb-ft
Drive shaft, axial play Axial play 0.05 to 0.1 mm
0.002 to 0.004 in.
Bearing quill to housing cover, screws Torque 10 N˙m
7.5 lb-ft
Intermediate gear shaft, tapered roller bearings Preload 0 to 0.03 mm
0 to 0.0012 in.
7.5 lb-ft
General Repair Procedures

Thoroughly clean the PTO housing before taking it apart.
Use LOCTITE ™ 574 (L64500) on sealing surfaces.
Number Name Use

Apply LOCTITE ™ 243 (L41475) thread lock and sealer to screws.
Number Name Use

IMPORTANT:
Heat bearing cones in a bearing heater. Use a thermometer and do not

exceed 150°C (300°F).
IMPORTANT:
Do NOT use solvent to clean clutch plates or brake disks. Use a lint-free
cloth. New disks should be soaked in hydraulic oil for 15 minutes before
assembly.
Replace Y01 - Solenoid Valve for Front PTO

[1] -
LEGEND:
A Solenoid valve
Disconnect the connector.
[2] - Take out the screws and remove solenoid valve (A).
[3] - Install the new solenoid valve and tighten the screws to the specified torque.
Y01 - Solenoid valve for front PTO to housing, screws Torque 8 - 10 N˙m
6 - 7.5 lb-ft
[4] - Connect the connectors.

Reconditioning the Modulator Valve

[1] -
Take out cap screws.

[2] - Lift off modulator valve (A) together with its gasket.
[3] -
LEGEND:
A Spool
B Spring
C Spring
D Spring pin
E Sleeve
F O-ring
G Plug
H Snap ring
Check the valve for damage, clean, oil and re-assemble.

[4] -
LEGEND:
A Outer spring
B Inner spring
Check spring forces.
Modulating valve, outer spring Free length approx. 70 mm
approx. 2.75 in.
Test length 43.5 mm at 105 to 130 N
1.7 in. at 23.6 to 29.3 lb
Modulating valve, inner spring Free length approx. 100 mm
approx. 3.95 in.
Test length 60 mm at 68.5 to 84.5 N
2.35 in. at 15.4 to 19 lb
[5] -
Install modulator valve (A) together with its gasket.

[6] - Tighten the cap screws evenly.

Modulating valve to front PTO, cap screws Torque 16 N˙m
12 lb-ft
Replace B58 - Front PTO Speed Sensor

[1] -
Disconnect the connector.

[2] - Remove sensor (A).
[3] - Install a new sensor using a new O-ring.
[4] - Tighten the sensor to the specified torque.
B58 - Front PTO speed sensor to housing Torque 10-12 N˙m
7.5-9 lb-ft
[5] - Connect the connectors.
Cleaning and Replacing the Filter

LEGEND:
A Plug
B O-ring
C Filter element
D O-ring
[1] - Remove plug (A). Remove the filter element.

[2] - Wash the filter element in fuel.
[3] - Install the filter element. Tighten the plug.

Reconditioning the Pressure-Regulating Valve
LEGEND:
A Plug
B O-ring
C Shim (quantity as required)
D Spring
E Valve spool
[1] - Remove plug (A). Remove the valve.

[2] - Check the valve for damage, clean, oil and re-assemble.
[3] - Pressure can be adjusted by adding or removing shims (C).
Pressure-regulating valve Pressure 1200 kPa
12 bar
174 psi
[4] - Install valve. Tighten the plug.

Checking the Cooler Relief and Filter By-Pass Valves
LEGEND:
A Cooler relief valve
B Filter by-pass valve
Apply Thread Lock and Sealer L41475 ( LOCTITE ™ 243) to the threads and contact surfaces
of both plugs.
Number Name Use

Tighten the cooler relief valve plug.
15 lb-ft
Removing and Installing the Valve Plate

[1] -
Remove modulator valve (B).

[2] - Remove hex. socket screws of valve plate (A).
[3] - When assembling parts, apply LOCTITE ™ 574 flexible sealant to the sealing surfaces.
Number Name Use
[4] - Tighten the hex. socket screws evenly.
Valve plate to front PTO, cap screws Torque 10 N˙m
7.5 lb-ft

Front PTO — Sectional View
Clockwise-rotating front PTO (viewed in direction of travel)
LEGEND:
A Cover
B Special sealing ring
C Shift collar
D Drive gear
E Special sealing ring
F Drive shaft
G Ring gear
H Disk clutch
I Cover
J PTO stub shaft
K PTO brake
L Oil distribution baffle
M Spring
N Housing cover
O Pressure-regulating valve
P Housing

Counterclockwise-rotating front PTO (viewed in direction of travel)
LEGEND:
A Cover
B Special sealing ring
C Shift collar
D Drive gear
E Special sealing ring
F Drive shaft
G Idler gear shaft
H Ring gear
I Disk clutch
J Cover
K PTO stub shaft
L PTO brake
M Spacer bushing
N Oil distribution baffle
O Spring
P Housing cover
Q Housing

Disassembling the Front PTO

[1] - Drain the oil.
[2] - Remove PTO guard.
[3] - Before removing the front PTO, see reference “Removing the Front PTO” , Section 56,
Group 00.
[4] - Before disassembling the front PTO, see reference“General Repair Procedures”.
Disassembly
[1] -
Take hex. socket screws (A) out of the housing cover.

[2] - Put the back of the front PTO on a flat surface and support it.
[3] -
Remove bearing quills (A) and (B). When removing the quills, note position and number of
shims.

[4] -
Remove housing cover. When removing cover, shift pawl (D) may stick to the shift collar;
therefore hold cover at an angle when lifting it off.
[5] -
Remove the outer taper roller bearing cup (A) from the housing cover.

[6] -
Clockwise-rotating front PTO
Counter-clockwise-rotating front PTO

Take off metal cover (B).
[7] - Remove output shaft (A).
[8] - Remove drive shaft (C).
[9] - PTO rotating counterclockwise: Remove intermediate gear shaft (D).

Reconditioning the Oil Pump

Removing the oil pump
Preliminary work: Before removing the output shaft, see reference“Disassembling the Front
PTO”.
[1] -
Take off metal cover (A).

[2] -
Remove snap ring (B) and pull off gear (A).

[3] -
Take out key (A).

[4] - Take out cap screws (B).
LEGEND:
A Snap ring
B Gear
C Key
D Pin (4 used)
E Cover
F Bushing (4 used)
G Gear
H Gear
I Housing
J Cap screws (4 used)
K Cover

L Oil manifold
M Hex. socket screw (4 used)
Removing/installing the oil manifold
[1] -
Remove oil manifold (B), if necessary.

[2] - When assembling parts, apply LOCTITE ™ 574 flexible sealant to the sealing surface
which faces the PTO housing.
Number Name Use
[3] - Tighten hex. socket screws (A) evenly.
Oil manifold, hex. socket screw Torque 10 N˙m
7.5 lb-ft
Installing the oil pump

[1] -
When assembling the oil pump, coat cover-to-housing sealing surfaces with LOCTITE ™ 574
flexible sealant.
Number Name Use
Oil all parts.
[2] -
When installing the oil pump, coat oil pump-to-oil manifold sealing surfaces with LOCTITE ™
574 flexible sealant.
Number Name Use
[3] - Tighten cap screws (B) evenly.
Oil pump installation, cap screws Torque 10 N˙m
7.5 lb-ft
[4] - Install key (A).

[5] -
Install gear (A) and secure it with snap ring (B).

IMPORTANT:
Rotate pump to make sure that all parts move easily.
[6] -
Install metal cover (A).
Next step: Before installing the output shaft, see reference“Assembling the Front PTO”.

Reconditioning the PTO Clutch

PTO”.
Disassembling the PTO clutch
[1] -
Position assembly in a vise as shown (PTO stub shaft clamped in the vise). Use specially
shaped blocks on the vise to protect the shaft against damage.
[2] - Slacken hex. nut (use a spanner with a width of 65 mm), then take the assembly out of
the vise and take off the hex. nut.
[3] - Pull out PTO stub shaft.
[4] -
Remove 18 hex. socket screws of gear.

[5] -
IMPORTANT:
Make sure that puller jaws are not positioned on the bearing cage.
Pull out the bearing, using disks that match exactly.


D01173AA
Pulling off the taper roller bearings
[6] -
Press the gear and roller bearing off the clutch cage. Use disks that match exactly!
[7] - Remove snap ring (A).
[8] - Remove hub (B) and disk pack.
[9] -
CAUTION:
The spring is tensioned!

[10] -
→NOTE:
Puller is in a slightly inclined position.
Remove bearing; to do so, position a puller below the first spring coil.

D01173AA
Exploded view of PTO clutch
LEGEND:
A Clutch cage
B Seal ring
C Seal ring
D Back-up ring
E Piston
F Disk with teeth on outside
G Disk with teeth on inside
H Pressure plate
I Snap ring
J Spring
K Spring support
L Pressure ring

M Roller bearing
N Snap ring
O Hub
P Gear
Q Snap ring
R Thrust washer
S Roller bearing
T Hex. socket screw (18 used)
U Pressure ring
V Taper roller bearing
W PTO stub shaft
X Hex. nut
Assembling the PTO clutch
[1] -
Press piston out of clutch cage, using compressed air.

[2] - Check that the brake thrust pin (C; located in clutch cage) can move freely.
[3] - Replace seal rings on shaft (A) and on piston (B).
[4] - Re-install the piston.
[5] - When installing piston, make sure that piston rings do not get damaged and that the
piston is properly positioned.

[6] -
Place spring, spring support and thrust washer into clutch cage.
[7] - Press in bearing, using disks that match exactly! Do not press the bearing in deeper
than necessary (it must be possible to install the snap ring).
[8] -
Install hub (B).

[9] -
→NOTE:
Install disk pack; first place a disk with teeth on the outside against the piston, then install
disks with teeth on inside and outside alternately.
[10] - Install pressure plate last.
[12] - Coat gear contact surface on hub with LOCTITE ™ 574 flexible sealant.
Number Name Use

[13] -
Install snap ring in gear.

[14] - Place gear on hub. Press in roller bearing and install spacer. Press in taper roller
bearing.
[15] - Tighten the hex. socket screws.
PTO clutch gear, hex. socket screw Torque 23 N˙m
17 lb-ft
[16] -
Insert PTO stub shaft.

[17] - Coat the large hex. nut with LOCTITE ™ 243 thread lock and sealant, and tighten.
Number Name Use
PTO stub shaft, hex. nut (65 mm across flats) Torque 50 N˙m
36.5 lb-ft

Reconditioning the PTO Brake
LEGEND:
A Clutch cage
B Thrust pin (6 used)
C Pressure plate
D Disk with teeth on inside
E Disk with teeth on outside
F Spring (6 used)
G Cover
H Taper roller bearing
I Cap screw (4 used)
J Stop (4 used)
K Gear with stop

PTO”.
[1] -
CAUTION:
The six springs (A) are tensioned!
Remove hex. socket screws.

[2] - Remove cover (B).
[3] - Remove and check disk pack and pressure plate (C). Check thrust pins in clutch cage for
free movement. Check taper roller bearing and replace, if necessary.
D01173AA
[4] -
Install pressure plate (A) with the blind holes facing upward (see arrow).

[5] -
→NOTE:
Install a disk with teeth on the outside first, then install disks with teeth on the inside and
outside alternately. Position disks (B; with teeth on the outside) so that semicircular recesses
are aligned with blind holes of the pressure plate (see arrow).
[6] -
Place springs (A) into blind holes of pressure plate.

[7] -
Install cover, making sure that springs are properly positioned in blind holes of cover.
[8] - Coat hex. socket screws with LOCTITE ™ 243 thread lock and sealant, and tighten them
evenly.
Lid on clutch cage, cap screw Torque 10 N˙m
7.5 lb-ft

[9] -
Replace piston rings (A).

[10] - Apply some grease to the piston rings and position them in the middle of the shaft.
[11] - Make sure that oil bores (B) are not obstructed.
[12] -
→NOTE:
The piston rings may also be replaced with the housing closed by removing
valve plate (C) from the back of the housing.

[13] -
Replace ring gear (A).

[14] - Install stops (B).
[15] - Tighten cap screws (C).
Ring gear at PTO brake Torque 10 N˙m
7.5 lb-ft
[16] - Make sure that springs are properly positioned.
Reconditioning the Intermediate Gear Shaft (PTO

Rotating Counterclockwise)
LEGEND:
A Taper roller bearing assembly
B Intermediate gear shaft

C Taper roller bearing assembly

D Shim (quantity as required)
E Spacer bushing
F Cover
F Cap screws (4 used)
Before removing or installing the intermediate gear shaft, see references“Disassembling the
Front PTO”and“Assembling the Front PTO”.
Inspect all components, and replace if necessary.

Reconditioning the Drive Shaft
LEGEND:
A Seal ring
B Taper roller bearing assy.
C Special sealing ring
D Snap ring
E Washer
F Ball bearing
G Spacer
H Snap ring
I Gear
J Drive shaft
K Spring (5 used)
L Ball (5 used)

M Shift collar
N Special sealing ring
O Taper roller bearing assy.
P Key
Q Snap ring
R Shift pawl
S Plastic tip (2 used)
T Shifter shaft
U O-ring
V Shift lever
W Shim (thickness as required)
X Cover
[1] -
LEGEND:
A Taper roller bearing cone
B Special seal
C Gear
D Shift collar
E Special seal
F Taper roller bearing cone
Pull off tapered roller bearing cone (A) and remove special seal (B).
[2] - Pull off tapered roller bearing cone (F) and remove special seal (E).

[3] -
Remove shift collar (D).

→NOTE:
Be careful when removing the shift collar; locking balls and springs will be
ejected!
[4] - Remove snap ring (A).

[5] - Remove washer (B).
[6] - Press gear (C) down and off the shaft.
[7] -
Remove ball bearing (A).

[8] -
Remove the shim(s).

[9] -
Remove snap ring (A) and ball bearing (B).

[10] - Assemble the gear in reverse order.
[11] -
Install shift collar (D) on the new drive shaft. Make sure the springs and balls are pressed
down.
[12] - Install gear (C) and ring (B).


[14] -
Install special sealing ring (B) as shown in the drawing.

IMPORTANT:
Make absolutely certain that the sealing ring is installed in the correct
position.
→NOTE:
The drawing shows the direction in which the ring′s sealing lip must face.
[15] - Install tapered roller bearing (A).

IMPORTANT:
Heat the bearing cone in a bearing heater. Use a thermometer and do not
exceed 150°C (300°F).

[16] -
Do not assemble the drive shaft beyond the stage shown. Do not install the special seal and
taper roller bearing (on the shift collar side) until the housing cover has been installed.

Assembling the Front PTO

[1] -
Before installing the drive shaft, fill the space (see arrow) between the sealing ring and
tapered roller bearing with special grease (L154115).
Input shaft and housing cover, taper roller bearings Capacity 20 ml
0.68 fl oz
Number Name Use

• L154115 (us) Special grease Lubricating the taper roller bearings
[2] -
Install drive shaft.

→NOTE:
The special sealing ring becomes displaced when the drive shaft is
installed.
[3] - Install special sealing ring (A) so that it is properly in contact with the base of the hole.

[4] -
IMPORTANT:
Make absolutely certain that the sealing ring is seated in the correct
position.
Check again that the special sealing ring is properly positioned.

[5] -
IMPORTANT:
When installing the output shaft, be careful not to damage the piston rings
in the housing.
Insert output shaft (A) into housing.

[6] - Install metal cover (B).
[7] - PTO rotating counterclockwise: Install the intermediate gear shaft (not illustrated).

[8] -
As shown in the drawing, install special sealing ring (A) in the housing cover.
IMPORTANT:
Make absolutely certain that the sealing ring is installed in the correct
position.
→NOTE:
The drawing shows the direction in which the ring′s sealing lip must face.

[9] -
Coat housing sealing surfaces with sealant.

Number Name Use
[10] - Put on the housing cover (without bearing quill). Make sure that pads (A) of shifter fork
are properly positioned in relation to the shift collar.
[11] - Tighten the hex. socket screws on the housing cover.
Housing cover, hex. socket screw Torque 23 N˙m
17 lb-ft
[12] -
Install tapered roller bearing cone (C) on the drive shaft. Fill the space between special seal
ring and taper roller bearing with special grease (L154115).
Bearing quill and housing cover, taper roller bearings Capacity 40 ml
1.4 fl oz
Number Name Use

[13] - Make sure that the special seal does not get damaged!
[14] - Install taper roller bearing cups (A) and (B).

[15] -
Install seal ring (A).
Adjusting the taper roller bearing at the output shaft

[1] -
Install bearing quill (A) without shims to obtain a measurable axial play. Tighten the hex.
socket screws evenly.
Bearing quill to housing cover, hex. socket screw Torque 10 N˙m
7.5 lb-ft

[3] - Remove bearing quill.
[4] - Place shims under bearing quill until a bearing preload is obtained.
Output shaft, taper roller bearings Preload 0.01 to 0.04 mm
0.0004 to 0.0016 in.
[5] - Apply sealant to bearing quill and re-install it. Tighten the hex. socket screws.
Number Name Use
7.5 lb-ft

Adjusting end play of drive shaft
[1] -
Install bearing quill (A). Tighten the hex. socket screws evenly.
Bearing quill to housing cover, hex. socket screws Torque 10 N˙m
7.5 lb-ft

[3] - Remove bearing quill.

[4] - Keep adding shims until the prescribed end play is reached.
Drive shaft, end play End play 0.05 to 0.1 mm
0.002 to 0.004 in.
[5] - Fill the space between bearing and bearing quill with special grease (L154115).
Number Name Use
[6] - Apply LOCTITE ™ 574 (L64500) flexible sealant to the sealing surface of the bearing
quill. Install the bearing quill.
Number Name Use
Bearing quill to housing cover, hex. socket screws Torque 10 N˙m
7.5 lb-ft
Adjusting the taper roller bearing of the intermediate gear shaft (not
illustrated)
[1] - At four locations separated from one another by 90°, use a suitable depth gauge to
measure the distance from the bearing quill contact surface to the installed bearing.
[2] - Place shimsunder the spacer until a bearing preload is obtained.
Intermediate gear shaft, taper roller bearings Preload 0 to 0.03 mm
0 to 0.0012 in.
[3] - Apply sealant to bearing quill and re-install it. Tighten cap screws.
Number Name Use
7.5 lb-ft
Final assembly

Section 56 - DRIVE SYSTEMS Group 40: Front Implement Drive
[1] -
Apply Molykote Long Term (L156817) to the splines on the drive shaft (see arrow).
[2] - Before installing the front PTO, see reference“Installing the Front PTO”, Section 56,
Group 00.
[3] - Fill with fresh oil.
[4] - Install PTO guard.

Group 40 - Front Implement Drive

Front Implement Drive (Summary of References)
”Special tools”
”Summary of torques”
”Preliminary work”
”Removing and installing the drive shaft”
General Information
CAUTION:
If a drive shaft is installed, the tractor may be operated only if a front

implement is actually attached. Under no circumstances operate the
tractor with a drive shaft in place but no front implement attached!
IMPORTANT:
If no front implement is to be fitted to the tractor, remove the drive shaft.
Special Tools
→NOTE:

JDG820

Damper to drive shaft, hex. socket screws Torque 34±3 N˙m
25±2 lb-ft
Coupler to drive shaft, cap screws Torque 34±3 N˙m
25±2 lb-ft
Coupler and shaft to torsion damper, cap screws Torque 46±3 N˙m
34±2 lb-ft
Summary of Torques
Drive shaft (6-cylinder tractors with Stage II engine to 97/68 EC)
LEGEND:
1 M8 screw; 8 used/34±3 N˙m (25±2 lb-ft)

Preliminary Work
Open the hood
Pull the catch (see arrow) and lift the hood up.
Removing the battery
Disconnect battery terminals and remove the battery.
CAUTION:
Disconnect the negative terminal first. Always reconnect the positive

terminal first. Always pay attention to the positive/negative markings on
the battery.
Take off the front plate or basic weight (if equipped)

Take off front plate (A) or basic weight.

Installing and Removing Drive Shaft

What follows is a description telling you how to install the drive shaft. It is removed in reverse
order.
6-cylinder tractors
Secure damper (A) to the drive shaft. Tighten the hex. socket screws.
Damper to drive shaft, hex. socket screws Torque 34±3 N˙m
25±2 lb-ft

Install the shaft from the front.
On tractors with suspended front-wheel drive axles, the radiator must be raised slightly to
allow the drive shaft to be installed. Do this by slackening off the screws (A) that hold on the
battery plate (to which the radiator is secured).
6-cylinder tractors (with Stage II engine to 97/68 EC)
LEGEND:

STEERING AND BRAKES (g) by Belgreen
A Coupler
B Drive shaft
C M8 cap screw
D M10 cap screw
E Torsion damper
F Washer
Secure coupler (A) to the drive shaft (B). Tighten the eight cap screws (C) in cross-wise
fashion.
Coupler to drive shaft, cap screws Torque 34±3 N˙m
25±2 lb-ft
Secure the coupler and shaft to torsion damper (E). Tighten cap screws (D).
Coupler and shaft to torsion damper, cap screws Torque 46±3 N˙m
34±2 lb-ft
→NOTE:
On 6-cylinder tractors with engines up to serial no. 352949, replace the old
torsion damper RE59827 with new torsion damper RE509264.

Section 60 - STEERING AND BRAKES

Table of contents
Group 05 - Hydrostatic Steering ............................................................................................. 1
Hydrostatic Steering (Summary of References) ..................................................................... 1
Special Tools .......................................................................................................................... 2
Preliminary Work .................................................................................................................... 4
Disconnect/Connect Steering or Brake Hoses ........................................................................ 5
Remove Steering Column and Steering Valve ........................................................................ 7
Disassembling the Steering Valve ........................................................................................ 14
Exploded View of Steering Valve .......................................................................................... 18
Assembling the Steering Valve ............................................................................................ 20
Adjusting the Shock Valves .................................................................................................. 31
Steering Wheel and Steering Column (With Cab) ................................................................. 32
Recondition the Steering Column ......................................................................................... 33
Install Steering Column and Steering Valve ......................................................................... 35
Group 10 - Brake Valve ........................................................................................................... 42
Steering and Brakes - Brake Valve, Summary of References ............................................... 42
Brake Valve - Special Tools .................................................................................................. 42
Brake Valve - Repair Specifications ...................................................................................... 43
Accumulators - Remove and Install from Tractor Serial Number 440694 ............................ 45
Recondition Guide Piece and Piston ..................................................................................... 47
Brake Valve - Exploded View ................................................................................................ 51
Remove Brake Valve (Power Fill Brakes) .............................................................................. 57
Recondition Brake Valve (Power Fill Brakes) ........................................................................ 59
Install Brake Valve (Power Fill Brakes) ................................................................................. 75
Power-Fill Brake Valve with MFWD and Disk Brake (up to Tractor Serial Number 444807)
....................................................................................................................................... 77
Remove Power-Fill Brake Valve with MFWD and Disk Brake .............................................. 102
Recondition Power-Fill Brake Valve with MFWD and Disk Brake ........................................ 106
Install Power-Fill Brake Valve with MFWD and Disk Brake .................................................. 125
Tests and Adjustments - Adjust the Brake Pedals and Switches ........................................ 128
Group 15 - Rear Wheel Brakes ............................................................................................ 132
Summary of References (Rear Brakes) .............................................................................. 132
Rear Brakes, Specifications ................................................................................................ 132
Preliminary Work ................................................................................................................ 132
Remove the Rear Brakes .................................................................................................... 132
Rear Brakes—Exploded View ............................................................................................. 133
Recondition the Rear Wheel Brakes ................................................................................... 135
Install the Rear Brakes ....................................................................................................... 137
Final Assembly ................................................................................................................... 138
Bleeding the Brakes (Brake Valve, Power-Fill Brakes and MFWD and Disk Brake) ............. 139
Group 20 - Handbrake ........................................................................................................... 143
Summary of References (Handbrake) ................................................................................ 143
Handbrake - Specifications ................................................................................................ 143
Preliminary work ................................................................................................................ 143
Remove Handbrake ............................................................................................................ 144
Exploded view of handbrake - Tractor 6820 ....................................................................... 147

Exploded view of handbrake - Tractors 6920 and 6920S ................................................... 147

Installing the handbrake .................................................................................................... 150
Handbrake - Adjust the Brake Band ................................................................................... 153
Final assembly ................................................................................................................... 154
Handbrake components ..................................................................................................... 154
Handbrake - Replace Handbrake Cable .............................................................................. 156
Adjusting the Handbrake .................................................................................................... 158
Group 25 - Hydraulic Trailer Brake ..................................................................................... 159
Hydraulic Trailer Brake (Summary of References) ............................................................. 159
Special Tools ...................................................................................................................... 159
Specifications ..................................................................................................................... 159
Repair Instructions ............................................................................................................. 159
Hydraulic Trailer Brake Valve up to Serial No. 466428 ...................................................... 161
Hydraulic Trailer Brake Valve from Serial No. 466429 ....................................................... 167
Bleed Air from the Trailer Brake Valve ............................................................................... 169
Check Hydraulic Trailer Brake Valve .................................................................................. 170
Group 30 - Air Brakes up to Serial No. 398655 ................................................................. 172
Air Brakes up to Serial No. 398655 (Summary of References) ........................................... 172
Special tools ....................................................................................................................... 172
Safety instructions ............................................................................................................. 174
Screw Union Installation ..................................................................................................... 176
Change the Compressor ..................................................................................................... 177
Gaskets for the Compressor ............................................................................................... 178
Changing the compressed air tank .................................................................................... 181
Changing the preload valve ............................................................................................... 182
Changing the Pressure-Relief Valve ................................................................................... 183
Changing the pressure-regulating valve ............................................................................ 183
Changing the trailer control valve (dual-line + single-line brake) ...................................... 184
Changing the trailer control valve (single-line brake) ........................................................ 186
Changing the Coupling Ends .............................................................................................. 188
Changing the Pressure Gauge ............................................................................................ 189
Test Sequence ................................................................................................................... 191
Checking the system for leaks ........................................................................................... 192
Check the Supply Coupling End ......................................................................................... 192
Check the Dual-Line Brakes ............................................................................................... 194
Checking the Single-Line Brakes ........................................................................................ 196
Adjusting the air brake system handbrake ........................................................................ 196
Group 31 - Air Brakes from Serial No. 398656 .................................................................. 198
Air Brakes from Serial No. 398656 (Summary of References) ............................................ 198
Special Tools ...................................................................................................................... 198
Safety Instructions ............................................................................................................. 199
Screw Union Installation ..................................................................................................... 201
Change the Compressor ..................................................................................................... 202
Gaskets for the Compressor ............................................................................................... 203
Change Compressed Air Tank ............................................................................................ 206
Changing the Pressure-Regulating Valve ........................................................................... 207
Changing the Precharge Valve ........................................................................................... 208
Changing the Trailer Control Valve (Dual-Line Brake) ........................................................ 209

Changing the Trailer Control Valve (Single-Line Brake) ..................................................... 210

Change the Coupling Ends ................................................................................................. 212
Change the Pressure Gauge ............................................................................................... 213
Test Sequence ................................................................................................................... 214
Check the System for Leaks ............................................................................................... 215
Check the Supply Coupling End ......................................................................................... 215
Check Dual-Line Brake ....................................................................................................... 217
Checking the Single-Line Brakes ........................................................................................ 219
Adjusting the Handbrake (with Air Brake System) ............................................................. 219
Group 40 - AutoTrac .............................................................................................................. 221
Steering and Brakes - AutoTrac, Summary of References .................................................. 221
Specifications ..................................................................................................................... 221
Remove and Install Steering Control Valve (Y49) ............................................................... 222
Remove and Install Steering Wheel Position Sensor (B138) ............................................... 224

Section 60 - STEERING AND BRAKES Group 05: Hydrostatic Steering
Group 05 - Hydrostatic Steering

Hydrostatic Steering (Summary of References)
“Special tools”
“Repair specifications”
“Preliminary work”
“Disconnecting/connecting steering or brake hoses”
“Removing steering column and steering valve”
“Disassembling the steering valve”
“Assembling the steering valve”
“Adjusting the shock valves ”
“Steering wheel and steering column (with cab)”
“Repairing the steering column”
“Installing steering column and steering valve”

Special Tools
→NOTE:

Disconnecting tool
KJD10293
Disconnecting/connecting steering or brake hoses
Assembly tool set
KML10018A
LEGEND:
A Base (KML10018-1)
B Spring installer (KML10018-3)
C Shaft holder (KML10018-4)
D Seal installer (KML10018-2)
E Piston (KML10018-5)
F Seal installer (KML10018-6)
G Piston (KML10018-7)

Repair of steering units
Special tools required for repair
Steering valve type A B C D E F G

[ see type plate on steering valve ]
OSPF 160 LS (Danfoss) X X X X
OSPQ 125/200 LS (Danfoss) X X X X
Hydraulic hand-operated pump
D01019AA
Adjusting the shock valves
Adapter
JT03248
Adjusting the shock valves

Steering wheel and column

Steering wheel to spindle, cap screw (up to tractor serial no.
Torque 50 N˙m (35 lb-ft)
359011)
Steering wheel to spindle, cap screw (from tractor serial no.

359012)
Adjusting ring on spindle, self-locking hex. nut Torque 20 N˙m (15 lb-ft)
Steering valve
23500 to 25500 kPa (235 to 255 bar;
Shock valves Adjustment pressure
3400 to 3700 psi)
Cover to housing, cap screws Torque 30 N˙m (23 lb-ft)
Threaded plugs of shock valves Torque 30 N˙m (23 lb-ft)
Threaded plug on control valve (OSPQ 125/200 LS) Torque 50 N˙m (35 lb-ft)
Connectors (straight) to steering valve (connections for

pressure lines)
Connector (elbow) to steering valve (connection for LS-line) Torque 35 N˙m (25 lb-ft)
Preliminary Work
Disconnect battery ground strap (—).

Disconnect/Connect Steering or Brake Hoses
→NOTE:
Some of the following illustrations show the hydraulic hoses when

removed.
→NOTE:
Trap oil as it emerges in a suitable container. Seal the openings so that no

dust can penetrate.
Place KJD10293 disconnecting tool
Disconnecting tool
KJD10293
Disconnecting/connecting steering or brake hoses
(A) on hydraulic hose.

Press tool down (in the direction indicated by the arrow) until the red ring (B) is visible and
then disconnect coupler.
Connect steering or brake hoses
Without using a tool, push hydraulic hose into coupler until it engages. Move hydraulic hose
several times in the directions indicated by the arrows to ensure it is connected properly.

Remove Steering Column and Steering Valve

Steering valve (without steering column)
Remove cap screws (A) and (B).
Remove trim panel (C). Also remove second trim panel on the opposite side.
Remove screws (A) on both sides of trim. Take out screw (C).
→NOTE:
By removing the screws it is possible to lift trim (B) slightly. This makes the
removal of steering valve attaching screws easier.

Remove trim (A).
Disconnect hydraulic lines at steering valve (B).
Remove screws (A) and steering valve.
Steering column and steering valve
Remove screws (A) and (B).
Remove trim panel (C). Also remove second trim panel on the opposite side.

Remove screws (A) on both sides of trim. Take out screw (C).
→NOTE:
By removing the screws it is possible to lift trim (B) slightly. This makes it
easier to unplug the multi-function unit connectors.
Remove cover (A).
Remove self-locking hex. nut (A).

Remove adjusting ring (B) and washer.
Remove hex. nut (A) and pull off the steering wheel.
Remove washer (B).
Pull off knob (A).
Take out screws (B) and remove cover (C).

Take out screws (A) and lift up instrument unit (B).
Disconnect connectors and remove instrument unit.
Remove screws (A) and lift panel (B).
Disconnect all connectors at bracket.
Remove screws (A).

Disconnect all multi-function unit (A) connectors from below. Remove multi-function unit.
Remove housing (A) and pull off handle (B).
Remove cover (A).

Remove screws (A).
Remove steering column (B).
Remove trim (A).
Disconnect hydraulic lines at steering valve (B).
Remove screws (A) and steering valve.

Disassembling the Steering Valve
→NOTE:
The type plate shows the steering valve type (e.g. OSPQ 125/200 LS).
Place steering valve on assembly plate KML10018-1 (B).
Remove cover (A).
LEGEND:
A Stator
B Rotor
C Rotor shaft
D Distributor plate
Take off rotor (B) and stator (A).
Take off rotor shaft (C) and distributor plate (D).

Remove check valve (A) and suction valves (B).
→NOTE:
Shock valves are set to a specific pressure. Readjustment is necessary after

removal.
Remove plug (A).
Remove the shock valves.

On steering valve OSPQ 125/200 LS only:
Remove the control valve
Take out threaded plug (A).
Remove spring (B) and piston (A) from the control valve.
Place cross pin parallel to flattened face of steering valve by turning both spool and sleeve.
Remove spool and sleeve by applying slight pressure to valve spool and simultaneously
turning valve sleeve.

LEGEND:
A Thrust bearing assy.
B Retaining ring
C Leaf springs
D Valve sleeve
E Valve spool
F Cross-pin
Remove thrust bearing (A) and retaining ring (B).
Remove cross-pin (F).
Push valve spool (E) out of valve sleeve (D).
Remove leaf springs (C).
Remove seal ring (A) from housing.
Remove back-up ring and O-ring.

Exploded View of Steering Valve
LEGEND:
1 Shock valve (2 used)
2 Threaded plug (2 used)
3 Seal ring (2 used)
4 Adjusting screw (2 used)
5 Spring (2 used)
6 Spring guide (2 used)
7 Ball (2 used)
8 Suction valve assembly (2 used)
9 Seal ring assembly
10 Thrust washer
11 Thrust bearing
12 Thrust washer
13 Retaining ring
14 Valve spool

15 Cross-pin
16 Valve sleeve
17 Control valve assembly
[ Steering valve OSPQ 125/200 LS only ]
18 Threaded plug with O-ring

19 Spring
20 Control piston assembly

21 Control piston
22 Pin
23 Spring
24 Ball
25 Plug
26 Seal ring
27 Housing
28 Ball
29 Threaded bushing
30 Leaf springs
31 Rotor shaft
32 O-ring
33 Distributor plate
34 Rotor
35 O-ring
36 Stator
37 Cover
38 Seal washers (7 used)
40 Cap screw with spring pin
41 Type plate
42 Impact screws

Assembling the Steering Valve
Using a hammer and suitable round steel bar, lightly drive new seal ring (A) into housing
groove.
Coat the seal ring assembly, which consists of O-ring (A) and back-up ring (B), with grease
and install it on small piston KML10018-5
[ OSPF 200 steering valves ]

(C) or KML10018-7
[ OSPQ 125/200 LS ]
.
On steering valve OSPQ 125/200 LS, the broad end of the back-up ring must face away from
the tool.

Install the seal ring:
[1] - Press sleeve (B) of special tool KML10018-2

[ OSPF 200 steering valves ]
(A) or KML10018-6
[ OSPQ 125/200 LS ]
up to stop into steering valve housing.
[2] - Then slide large piston into sleeve until it bottoms.
[3] - Pull sleeve out of steering valve together with large piston.
→NOTE:
Small piston remains in steering unit until it is pushed out when spool and
sleeve are installed.

Here the seal rings of the different types of steering valve are shown in their installed
positions.
Steering valve type Seal ring
OSPF steering valves .......... A
OSPQ 125/200 LS .......... B

Place the two straight leaf springs in the slot in the spool.
Slide the curved leaf springs between the straight leaf springs.
Assemble valve spool and sleeve.
IMPORTANT:
The slots in the spool must face the holes in the sleeve (see arrows).

Align and center the leaf springs.
Install retaining ring (A).
IMPORTANT:
The retaining ring must be able to turn freely without interference from the
leaf springs.
Insert cross-pin (A) in valve assembly.

Install thrust washer (C), thrust bearing (B) and thrust washer (A).
IMPORTANT:
Chamfered side of thrust washer (C) must face towards top surface of valve
spool.
Coat valve spool assembly with oil and then install.
IMPORTANT:
Make sure that cross-pin of valve spool and sleeve is horizontal.
→NOTE:
Insert valve spool and sleeve into housing bore, applying slight turning
movements.

Installing check valve:
[1] - Place ball of check valve into the bore provided.

[2] - Screw in threaded bushing (A) until it is just below the surface of the housing.
Install both suction valves (spring pin assemblies with balls) in bores as shown.
Install distributor plate and rotor shaft:
[1] - Place O-ring in groove of housing.

[2] - Install distributor plate (A) so that the bores are aligned with the corresponding bores in
the housing.
[3] - Insert drive shaft (B) and hold with tool KML10018-4 (C).
LEGEND:
A Stator
B Rotor
C Cross-pin
D Rotor shaft
Coat O-rings of stator (A) with grease.
Position rotor (B) and stator as shown.
CAUTION:
Avoid accidents! Cross-pin must be in position shown.
IMPORTANT:
Rotor (B) and cross-pin (C) must be positioned as shown to ensure reliable
functioning of steering system.

Install cover.
Tighten the cap screws crosswise to 30 N˙m (23 lb-ft).
→NOTE:
Screw cap screw with spring pin into bore with threaded bushing.
Steering valve OSPQ 125/200 LS only
Install piston (A) and spring (B) in the control valve.

Tighten threaded plug (A) to 50 N˙m (35 lb-ft).
Install shock valves:
[1] - Place shock valve balls in their bores.

[2] - Coat spring guides (B) with grease and install them on springs (A).
[3] - Insert springs (A) together with spring guides (B) into the relevant bores.
[4] - Coat adjusting screws (C) with LOCTITE 243 (L41475) and screw them in until pressure
is applied to the springs. Adjust the shock valves.

Tighten threaded plug (A) to 30 N˙m (23 lb-ft).

Adjusting the Shock Valves
LEGEND:
A D01019AA hand-pump with gauge and hydraulic hose
B Hydraulic hose
C Adapter L38860
D Coupler JT03248
E Fitting
F Valve spool
G Shock valve (right-hand lock)
H Shock valve (left-hand lock)
→NOTE:
Shock valves must be readjusted if they have been removed.
Connecting the manually-operated hand-pump
Attach coupler JT03248 (D) and adapter L38860 (C) to hydraulic hose of hand pump
D01019AA.
Install a L41383 O-ring on the L41898 fitting (E) and on the “R” or “L” connection of the
steering valve. Secure hydraulic hose AL41621 (B) to the fitting and to the L38860 adapter
(C).
Checking and adjusting the shock valves
Operate the hand pump to obtain a pressure of 23500 to 25500 kPa (235 to 255 bar; 3400 to
3700 psi). Valve is set correctly if pressure then drops sharply.
If necessary, adjust the shock valves as follows:
[1] - Remove threaded plugs from shock valves (G) and (H) and coat the adjusting screws
underneath with LOCTITE 243 (L41475).

[2] - Screw adjusting screws in or out until a pressure of 23500 to 25500 kPa (235 to 255
bar; 3400 to 3700 psi) is obtained.
→NOTE:
Turning adjusting screws clockwise increases pressure. Turning adjusting
screws counterclockwise reduces pressure.
[3] - Tighten threaded plugs to 30 N˙m (23 lb-ft).
Steering Wheel and Steering Column (With Cab)
LEGEND:
A Cover
B O-ring
C Self-locking hex. nut

D Washer
E Adjusting ring
F Hex. nut
G Retaining plate
H Steering wheel
I Snap ring
J Washer
K Steering column assembly
L Top collar
M Collar insulator
N Bottom collar
Recondition the Steering Column
LEGEND:
A Cap
B Pin
C Lever
D Spring
E Pin
F Gas compression cylinder

G Bushing
H Hex. socket screws
I Snap-ring
J Washer
K Steering column
L Pin
M Shaft (replace as complete assembly)

Install Steering Column and Steering Valve

Installing steering valve (w/o steering column)
Secure steering valve (B) with screws (A).
Secure hydraulic lines to the steering valve.
Attach trim panel (A).
Install screws (A) on both sides of trim panel.

Install screw (B).
Install cover (C) using screws (A) and (B).
Install second cover and connect battery ground strap (—).
Steering column and steering valve
Secure steering valve (B) with screws (A).
Secure the hydraulic lines to the steering valve.

Secure steering column (B) by means of screws (A).
Attach trim panel (A).
Install cover (A) and handle (B).
→NOTE:
Install panel attaching screws only after installation of multi-function unit.

Install multi-function unit (A) and connect plugs.
Install screws (A).
Connect all the plugs to the console (B).
Put the console and the screws in place at the same time.
Attach console by means of screws (A).
Connect plugs to instrument unit (B).
Secure instrument unit using screws (A).

Install cover (C) and attach by means of screws (B).
Install knob (A).
Install screws (A) on both sides of trim panel.
Install screw (B).
Install washer (B) and snap ring (A).

Put on the steering wheel. Install the retaining plate and hex. nut (A).
Tighten hex. nut (A) to specified torque.
Steering wheel to spindle, hex. nut (up to tractor serial no. 359011) Torque 50 N˙m (35 lb-ft)
Steering wheel to spindle, hex. nut (from tractor serial no. 359012) Torque 30 N˙m (22 lb-ft)
Fold retaining plate.
Install washer and adjusting ring (B).
Install self-locking hex. nut (A) and tighten to 20 N˙m (15 lb-ft).

Section 60 - STEERING AND BRAKES Group 10: Brake Valve
Install cover (A).
Install cover (C) using screws (A) and (B).
Install second cover and connect battery ground strap (—).

Group 10 - Brake Valve

Steering and Brakes - Brake Valve, Summary of
References
Brake Valve - Special Tools
Brake Valve - Repair Specifications
Accumulators - Remove and Install from Tractor Serial Number 440694
Recondition Guide Piece and Piston
Brake Valve - Exploded View
Remove Brake Valve (Power Fill Brakes)
Recondition Brake Valve (Power Fill Brakes)
Install Brake Valve (Power Fill Brakes)
Power-Fill Brake Valve with MFWD and Disk Brake (up to Tractor Serial Number 444807)
Remove Power-Fill Brake Valve with MFWD and Disk Brake
Recondition Power-Fill Brake Valve with MFWD and Disk Brake
Install Power-Fill Brake Valve with MFWD and Disk Brake
Tests and Adjustments - Adjust the Brake Pedals and Switches
Brake Valve - Special Tools
→NOTE:

DFLX41- Socket Wrench Insert

Brake Valve - Repair Specifications

Brake Valve Attachment, Hex. Socket Screws Torque 100 N˙m
75 lb.-ft.
Adjusting the Brake Pedals Pedal Play 0.15 - 0.20 mm
0.006 - 0.008 in.
Point at which Brake Switch Trips Pedal Travel 6 mm
0.24 in.
Point at which Brake Switch Trips (with AutoPowr/IVT) Voltage 0.9 - 1.1 volts
Brake Switch to Bracket Torque 5 - 7 N˙m
4 - 5 lb.-ft.
Valve (Tractors with MFWD and Disk Brake) Torque 10 N˙m
7.4 lb.-ft.
Brake Valve, Attaching Screws Torque 100 N·m
75 lb.-ft.
Brake Switch to Bracket Torque 12 N·m
9 lb.-ft.
Restrictor (Filter Element) Torque 5 N·m
4 lb.-ft.
Valve (Tractors with MFWD and Disk Brake) Torque 10 N·m
7.4 lb.-ft.
Without Suspended Cab: M20x45 Screw on Final Drive Housing Torque 200 N·m
148 lb.-ft.
Guide Piece to Brake Valve Torque 100 N·m
75 lb.-ft.
Plug to Brake Valve Torque 100 N·m
75 lb.-ft.
Valve to Brake Valve, Plug Torque 15 N·m
11 lb.-ft.
Inlet Check Valve to Brake Valve Torque 10 N·m
7.5 lb.-ft.
Fitting to Brake Valve Torque 45 N·m
33 lb.-ft.
Plug to Brake Valve Torque 45 N·m
33 lb.-ft.
Cover to Brake Valve, Screws Torque 12 N·m
9 lb.-ft.
Outlet Valve to Brake Valve Torque 45 N·m
33 lb.-ft.

Filter in Brake Valve Torque 5 N·m
4 lb.-ft.

Accumulators - Remove and Install from Tractor

Serial Number 440694
IMPORTANT:
From tractor serial number 440694, tractors are equipped with an

accumulator; pressure has to be relieved at this accumulator before the
system can be serviced or repaired.
Removal:
Pressure is relieved as follows:
1. Shut off the tractor/ignition switched off.

2. At the rear of the tractor, put a transparent hose over each of the bleed valves; see
reference ”Bleeding the Brake Valve (Power-Fill Brake Valve with MFWD and Disk
Brake)” .
3. Unlock the brake pedals.
4. Pump the left and right brake pedals up and down until pedal travel becomes very long
and no pressure can be felt on the pedal.
5. Slowly unscrew the fitting on the accumulator.

→NOTE:
Before unscrewing the fittings, put down a suitable container to trap the
oil.
Installation:
After installation, check the level of the transmission oil, and add more oil if necessary (see
relevant Operator′s Manual).
Air must then be bled from the brake system; see reference ”Bleeding the Brake Valve
(Power-Fill Brake Valve with MFWD and Disk Brake)” .
If the bracket was removed from the final drive housing, the following specification applies
when it is re-installed.
Without suspended cab: M20x45 cap screw on final drive housing Torque 185 - 215 N˙m
135 - 160 4 lb-ft
→NOTE:
On tractors with suspended cab, the usual torque value applies; see the
torque table in ”Torques for Metric Screws” .

Recondition Guide Piece and Piston

Preliminary work: Remove the guide piece and piston
SeeRemove Brake Valve (Power Fill Brakes)in Section 60.
or
SeeRemove Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.
Assembly
[1] -
LEGEND:
A O-ring
B Snap ring
Install O-ring (A) and snap ring (B) on the piston.

[2] -
LEGEND:
A Seal ring
B Seal ring
Install seal rings (A) and (B).
[3] -
LEGEND:
A O-ring
Install O-ring (A) on annular piston.

[4] -
LEGEND:
A Seal ring
[5] -
LEGEND:
A Snap ring
Install the annular piston on the piston.

[7] -
LEGEND:
A Wiper seal
B O-ring
Install O-ring (B) and wiper seal (A) on the guide piece.
[8] -
LEGEND:
A Spring
B Guide
Install guide piece (B) on the piston.
[9] - Install spring (A).
Next step: Install the guide piece and piston
SeeInstall Brake Valve (Power Fill Brakes)in Section 60.
or
SeeInstall Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.

Brake Valve - Exploded View

Exploded view of power fill brake valve
Exploded view of power fill brake valve
LEGEND:
1 Cover
2 Intermediate Cover
3 Gasket
4 Stop Screw
5 Restrictor
6 O-Ring

7 Valve
8 O-Ring
9 O-Ring
10 Valve
11 O-Ring
12 Plug
13 LS Check Valve Assembly
14 Piston
15 Snap Ring
16 Seal Ring and O-Ring
17 Annular Piston
19 Seal Ring
20 Spring
21 Cover
22 O-Ring
23 O-Ring
24 Valve Assembly
25 Spring
26 Spool
27 Spring
28 O-Ring
29 Plug
30 Wiper Seal
31 O-Ring
32 Guide Piece
33 O-Ring
34 Inlet Check Valve Assembly
35 O-Ring
36 Valve Assembly
37 O-Ring
38 Fitting
39 O-Ring
40 Fitting
41 Orifice
42 Spring
43 O-Ring
44 Fitting
45 Outlet Valve Assembly
Exploded view - Power-fill brake valve with MFWD and disk brake (up
to tractor serial number 444807)

LEGEND:
1 Cap Screw (8 used)
4 Cover
6 Gasket
7 Plug
8 O-Ring
9 Valve
10 O-Ring
11 O-Ring
13 Plugs (2 used)

14 O-Ring (2 used)
15 Spring (2 used)
16 Spool (2 used)
17 Expansion Plug
18 Spring (2 used)
19 Valve Assembly (2 used)
20 O-Ring (2 used)
21 O-Ring (2 used)
22 Cover (2 used)
23 Plug
24 O-Ring
25 Spool
26 O-Ring
27 O-Ring
28 Expansion Plug (4 used)
30 Orifice (2 used)
31 Spring (2 used)
32 O-Ring (2 used)
33 Fitting (2 used)
34 Outlet Valve Assembly (2 used)
35 O-Ring
36 Fitting
37 O-Ring
38 Valve Assembly
39 O-Ring
40 Fitting
42 Wiper Seal (2 used)
43 O-Ring (2 used)
44 Guide Piece (2 used)
45 O-Ring (2 used)
46 Piston (2 used)
47 Snap Ring (4 used)
48 Seal Ring and O-Ring (2 used)
49 Annular Piston (2 used)
51 Seal Ring (2 used)
52 Spring
54 Hex. Nut (2 used)
55 Threaded Pin with Filter Insert
56 Valve (2 used)
57 O-Ring
58 Fitting
59 O-Ring
60 Spring
61 [ Valve Spool Parts must not be interchanged ]
62 [ Seal Ring Parts must not be interchanged ]

Exploded view - Power-fill brake valve with MFWD and disk brake
(from tractor serial number 444808)
Exploded view of power-fill brake valve with MFWD and disk brake
LEGEND:
1 Brake Valve Assembly
2 Cover Assembly
4 Gasket
5 O-Ring
6 O-Ring
7 Spring
8 Valve
9 Back-Up Ring

11 O-Ring
12 O-Ring
13 Plug
14 Expansion Plug
15 Spool
16 Spring
17 O-Ring
18 Plug
19 Spring
20 Valve Assembly
21 O-Ring
22 O-Ring
23 Cover
24 Expansion Plug
25 Spool Assembly
[ Parts must not be interchanged ]
26 Back-Up Ring
27 Back-Up Ring
28 O-Ring
29 Plug
30 Fitting
31 O-Ring
32 Spring
33 Orifice
34 Expansion Plug
35 Fitting
36 Fitting assembly
37 O-Ring
38 Fitting
39 Valve Assembly
40 O-Ring
41 Piston
42 O-Ring
43 Guide Piece
44 O-Ring
45 Wiper Seal
46 Snap Ring
48 Annular Piston
50 O-Ring
51 Spring
52 Brake Housing
53 Cap Screw
54 Hex. Nut
56 Valve
57 O-Ring
58 Cap Screws

Remove Brake Valve (Power Fill Brakes)

Preliminary work:
Disconnect battery ground cable (—).
Relieve accumulator pressure, seeAccumulators - Remove and Installin Section 60.
Remove the brake valve
[1] -
LEGEND:
A Screws
B Grip
C Trim Panel
Take out screws (A) and remove grip (B).
[2] - Fold trim panel (C) up.

[3] -
LEGEND:
A Pin
Take out pin (A) and lift off the brake pedals.
[4] -
LEGEND:
A Hydraulic Hose
B Hydraulic Hose
C Screw
D Screw
E Hydraulic Lines
Pull out the brake switch connectors and remove the brake switches.
[5] - Take off hydraulic hoses (A) and (B).
[6] - Disconnect hydraulic lines (E) from the brake valve.
[7] - Take out screw (C).
[8] - Take out the lower screw (D) and lift off the brake valve.
Next step:
SeeRecondition Brake Valve (Power Fill Brakes)in Section 60.

Recondition Brake Valve (Power Fill Brakes)

Preliminary work:
SeeRemove Brake Valve (Power Fill Brakes)in Section 60.
Disassemble the brake valve
[1] -
LEGEND:
A Cover
Remove cover (A).
[2] -
LEGEND:
A Valves
Remove valves (A).

[3] -
LEGEND:
A Filter
Remove filter (A).
[4] -
→NOTE:
When removing the plug and the spool, remember the spring force.
LEGEND:
A Plug
Remove plug (A).
[5] -
IMPORTANT:
Note correct side, correct direction and relation of the parts for re-
installation.

LEGEND:
A Spool
B Spring
Remove spring (B) and spool (A).
[6] -
LEGEND:
A Cover
B O-Ring
C O-Ring
D Valve Assembly
E Spring
F Spool
Disassemble the spool, check individual parts for wear and replace if necessary. Clean and
assemble the parts.

[7] -
LEGEND:
A Socket Wrench
Unscrew the guide piece using socket wrenchDFLX41(A).
[8] -
Remove the guide piece and piston.

[9] -
Disassemble the guide piece and piston, check for wear and replace parts as necessary.
SeeRecondition Guide Piece and Pistonin Section 60.
[10] -
LEGEND:
A Fitting
Remove fitting (A).
[11] -
Remove the inlet check valve.

[12] -
LEGEND:
A Plug
Remove plug (A).
[13] -
Drive out the LS check valve.

[14] -
LEGEND:
A Outlet Valve
Remove outlet valves (A).
Assemble the brake valve
IMPORTANT:
Before assembly, clean all components using clean hydraulic oil and blow
compressed air through them, then coat all components with oil and
assembly them.
→NOTE:
Examine all the components for signs of wear or damage. Damaged parts
must be replaced.

[1] -
LEGEND:
A Orifice
B Spring
C Fitting
Install orifices (A), springs (B) and fittings (C).
[2] - Tighten the outlet valves to the specified torque.
[3] -
LEGEND:
A O-Ring
Install O-ring (A) on the inlet check valve.

[4] -
Install the inlet check valve and tighten to the specified torque.
Inlet check valve to brake valve Torque 10 N˙m
7.5 lb-ft
[5] -
LEGEND:
A Fitting
Install fitting (A) and tighten to the specified torque.
Fitting to brake valve Torque 45 N˙m
33 lb-ft

[6] -
LEGEND:
A O-Ring
B O-Ring
Install O-rings (A) and (B) on the LS check valve and coat them with oil.
[7] -
Install the LS check valve.

[8] -
LEGEND:
A Plug
Install plug (A) and tighten to the specified torque.
Plug to brake valve Torque 45 N˙m
33 lb-ft
[9] -
LEGEND:
A Spring
B Guide Piece
Disassemble the piston with spring (A) and guide piece (B), check for wear and replace parts
as necessary.

[10] -
Position the piston and guide piece.

[11] -
Using socket wrenchDFLX41(A), tighten the guide piece to the specified torque.
Guide piece to brake valve Torque 100 N˙m
75 lb-ft
[12] -
IMPORTANT:
installation.

LEGEND:
A Spool
B Spring
Install spool (A) and spring (B).
[13] -
→NOTE:
When installing the plug, remember the spring force.
LEGEND:
A Plug
75 lb-ft

[14] -
LEGEND:
A Filter
Install filter (A) and tighten to the specified torque.
Filter in brake valve Torque 5 N˙m
4 lb-ft
[15] -
LEGEND:
A Valves
Install valves (A) and tighten to the specified torque.
Valve to brake valve, plug Torque 15 N˙m
11 lb-ft

[16] -
LEGEND:
A Intermediate Cover
Remove intermediate cover (A), clean it and install it on the cover.
[17] -
IMPORTANT:
Soak the gasket in clean hydraulic oil for 4 hours and allow it to expand.
LEGEND:
A Gasket
Install the expanded gasket (A) on the housing with the writing underneath.
[18] -
IMPORTANT:
Tighten screws (B) in the sequence shown.

Brake Valve - Tightening Sequence for Screws
LEGEND:
A Cover
B Screws
Install cover (A) and tighten screws (B) to the specified torque in the sequence shown.
Cover to brake valve, screws Torque 12 N˙m
9 lb-ft
Next step:
SeeInstall Brake Valve (Power Fill Brakes)in Section 60.

Install Brake Valve (Power Fill Brakes)

Install the brake valve
[1] -
→NOTE:
Do not tighten the screw at this stage; allow the brake valve some freedom
of movement.
Install hydraulic hoses (A) and (B).

[2] - Secure hydraulic lines (E) to the brake valve.
[3] - Install screws (C) and (D) and tighten to the specified torque.
Attaching Screws, Brake Valve Torque 100 N˙m
75 lb-ft
[4] - Install brake switch (F), tighten to the specified torque and connect the connector.
Brake Switch to Bracket Torque 12 N˙m
9 lb-ft

[5] -
LEGEND:
A Pin
Secure the brake pedals with pin (A).
Next step:
SeeTests and Adjustments - Adjust Brake Pedals and Brake Switchin Section 260 of the
relevant Diagnostic Manual.

Power-Fill Brake Valve with MFWD and Disk Brake

(up to Tractor Serial Number 444807)
Preliminary work
Remove the Brake Valve
Take out screws (A) and (B). Remove trim panel (C).

Pull out the brake switch connector (B). Disconnect hydraulic lines (E) and (F) from the brake
valve. Take out hex. socket screw (C). Slacken off the lower hex. socket screw (D) slightly.
Take off hydraulic hose (A).

Take out the lower hex. socket screw (A) and lift off the brake valve.
LEGEND:
A Cover
→NOTE:
Depending on tractor version, the brake switch may have to be taken off

first.
Remove cover (A).

Remove valves (A).
Remove filter (A).
Use socket wrench
Socket Wrench Insert
dealer fabricated

Socket wrench insert for removing the guide piece on brake valves with power-fill.
(A; dealer-fabricated) to unscrew the guide piece.
Take out the guide piece and piston.
Disassemble the guide piece and piston.

Remove plug (A).
Take out spring (B) and spool (A).
Disassemble the spool.
Remove plug (A).

Remove valve (A).
Unscrew the inlet check valve.

Remove plug (A).
Exploded view

LEGEND:
4 Cover
6 Gasket
7 Plug
8 O-Ring
9 Valve
10 O-Ring
11 O-Ring
13 Plugs (2 used)

14 O-Ring (2 used)
15 Spring (2 used)
16 Spool (2 used)
17 Expansion Plug
18 Spring (2 used)
19 Valve Assembly (2 used)
20 O-Ring (2 used)
21 O-Ring (2 used)
22 Cover (2 used)
23 Plug
24 O-Ring
25 Spool
26 O-Ring
27 O-Ring
30 Orifice (2 used)
31 Spring (2 used)
32 O-Ring (2 used)
33 Fitting (2 used)
34 Outlet Valve Assembly (2 used)
35 O-Ring
36 Fitting
37 O-Ring
38 Valve Assembly
39 O-Ring
40 Fitting
42 Wiper Seal (2 used)
43 O-Ring (2 used)
44 Guide Piece (2 used)
45 O-Ring (2 used)
46 Piston (2 used)
47 Snap Ring (4 used)
49 Annular Piston (2 used)
51 Seal Ring (2 used)
52 Spring
54 Hex. Nut (2 used)
56 Valve (2 used)
57 O-Ring
58 Fitting
59 O-Ring
60 Spring
61 [ Valve Spool Parts must not be interchanged ]
62 [ Seal Ring Parts must not be interchanged ]

LEGEND:
A Orifice
B Spring
C Fitting
Install the outlet valves.
Put O-ring (A) onto the inlet check valve.

Screw in the inlet check valve.
Screw in fitting (A).
Screw in the valve and tighten to specified torque.
Valve Torque 10 N˙m
7.4 lb.-ft.
Tighten plug (A).

Put O-rings (A) and (B) onto the LS check valve.
Install the LS check valve (A).

Screw in plug (A).
Install snap ring (B) on piston. Install O-ring (A).
Install seal ring (B). Install seal ring (A).

Install O-ring (A) on annular piston.
Install the annular piston on the piston. Install snap ring (A).

Install O-ring (B) and wiper seal (A) on the guide piece.
Install guide piece (B) on the piston. Install spring (A).
LEGEND:
A Cover
B O-Ring
C O-Ring
D Valve Assembly
E Spring
F Spool
Assemble the spool.
Screw in plug (A).

Install piston and guide piece.
Use socket wrench
Socket Wrench Insert
dealer fabricated
Socket wrench insert for removing the guide piece on brake valves with power-fill.
(A; dealer-fabricated) to screw in the guide piece.
Screw in filter (A) and tighten.
Torque 5 N˙m
4 lb.-ft.

Install valves (A).
Install gasket (A).
Install intermediate cover (A) on the cover.

Install cover (A).
Install the brake valve
→NOTE:
Do not tighten the hex. socket screw at this stage; allow the brake valve
some freedom of movement.
Secure the brake valve at the lower hex. socket screw (A).

LEGEND:
A Hydraulic Hose
B Brake switch, AutoPowr/IVT
Install hydraulic hose (A) and brake switch (B).
Install hydraulic hose (A).
Connect the brake switch connectors (B).
Secure hydraulic lines (E) and (F) to the brake valve.

Tighten hex. socket screws (C) and (D).
Brake Valve Attaching Screws Torque 100 N˙m
75 lb.-ft.
Adjusting the brake pedals
[1] - Lock the brake pedals together.

[2] - Measure pedal play at both pistons.

Pedal play must be within the following range.
Brake Pedals Pedal Play 0.15 to 0.20 mm
0.006 to 0.008 in.
[3] -
IMPORTANT:
Never adjust the pedals singly. The only way to adjust the pedals and
ensure that the brakes operate properly is to lock them together.
Adjust pedal play at screws (A).

→NOTE:
If the specified degree of play cannot be obtained at both pedals, one pedal
may have a greater play.
Adjust the brake switches (without AutoPowr/IVT)
[1] - Make sure that the brake pedals are adjusted correctly.
[2] - Adjust the brake switches at adjusting screws (A) so that the switches trip when the
pedal has travelled a specified distance.
Brake Switch Clearance 6 mm
0.24 in.
Adjusting the brake switches (with AutoPowr/IVT)

[2] - Unlock the brake pedals.
[3] - Ignition on.
[4] - Before entering the diagnostic mode, see Reference 245-05-001, General Operation and
Entering the Program Mode (on tractors with performance monitor, press the service button
for 2 seconds and select the controller).
[5] - Access the UIC control unit, and confirm.
[6] - Access address 27 (voltage display for left brake pedal).
[7] - Screw in adjusting screw (A) until voltage is between 0.9 and 1.1 volts.
[8] - Counterlock adjusting screw (A).
[9] - Access address 28 (voltage display for right brake pedal).
[10] - Screw in adjusting screw (B) until voltage is between 0.9 and 1.1 volts.
[11] - Counterlock adjusting screw (B).
[12] - Check the brake switch:
At the moment when the switch can be heard to trip, the voltage on the display must be
between 1.45 and 1.65 volts.
→NOTE:
The voltages at the pedals must not deviate from each other by more than
0.15 volts.
Final assembly

Attach trim panel (C) by means of screws (A) and (B). Connect ground (—) cable to battery.
Bleed air from the brakes
SeeTests and Adjustments - Adjust the Brake Pedals and Switchesin Section 60.

Remove Power-Fill Brake Valve with MFWD and Disk

Brake
Preliminary work:
Relieve pressure at accumulator.
SeeAccumulators - Removal and Installationin Section 60.
Remove the brake valve

[1] -
LEGEND:
A Screws
B Grip
C Trim Panel
Take out screws (A) and remove grip (B).
[2] - Fold trim panel (C) up.
[3] -
LEGEND:
A Pin

[4] -
LEGEND:
A Hydraulic Hose
B Connector
C Screw
D Screw
E Hydraulic Line
F Hydraulic Line
Pull out the brake switch connector (B).
[5] - Disconnect hydraulic lines (E) and (F) from the brake valve.
[6] - Take out screw (C).
[7] - Loosen lower screw (D), do not remove it.
[8] - Take off hydraulic hose (A).
[9] -
LEGEND:
A Hydraulic Hose

[10] -
LEGEND:
A Screw
Remove screw (A) and brake valve.
Next step:
SeeRecondition Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.

Recondition Power-Fill Brake Valve with MFWD and

Disk Brake
Preliminary work:
SeeRemove Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.
[1] -
→NOTE:
Depending on tractor version, the brake switch may have to be taken off
first.
LEGEND:
A Cover
Remove cover (A).

[2] -
LEGEND:
A Valves
Remove valves (A).
[3] -
LEGEND:
A Filter
Remove filter (A).
[4] -
→NOTE:
When removing the plug and the spool, remember the spring force.

LEGEND:
A Plug
Remove plug (A).
[5] -
IMPORTANT:
installation.
LEGEND:
A Spool
B Spring
Remove spring (B) and spool (A).

[6] -
LEGEND:
A Cover
B O-Ring
C O-Ring
D Valve Assembly
E Spring
F Spool
Check components of spool for wear, and replace if necessary. Clean and assemble the parts.
[7] -
LEGEND:
A Socket Wrench
Unscrew the guide piece using socket wrenchDFLX41(A).

[8] -
Remove the guide piece and piston.

[9] -
Disassemble the guide piece and piston, check for wear and replace parts as necessary.

[10] -
LEGEND:
A Plug
Remove plug (A).
[11] -
LEGEND:
A Valve
B Spring
Remove valve (A) and spring (B).

[12] -
LEGEND:
A Fitting
[13] -
Remove the inlet check valve.

[14] -
LEGEND:
A Plug
Remove plug (A).
[15] -

[16] -
LEGEND:
A Orifice
B Spring
C Fitting
Remove orifices (A), springs (B) and fittings (C).
IMPORTANT:
Before assembly, clean all components using clean hydraulic oil and blow
compressed air through them, then coat all components with oil and
assembly them.
→NOTE:
Examine all the components for signs of wear or damage. Damaged parts
must be replaced.

[1] -
LEGEND:
A Orifice
B Spring
C Fitting
Install orifices (A), springs (B) and fittings (C).
[2] - Tighten the outlet valves to the specified torque.
Outlet valve to brake valve Torque 45 N˙m
33 lb-ft
[3] -
LEGEND:
A O-Ring
Install O-ring (A) on the inlet check valve.

[4] -
Install the inlet check valve and tighten to the specified torque.
Inlet check valve to brake valve Torque 10 N˙m
7.5 lb-ft
[5] -
LEGEND:
A Fitting
Install fitting (A) and tighten to the specified torque.
Fitting to brake valve Torque 45 N˙m
33 lb-ft

[6] -
LEGEND:
A O-Ring
B O-Ring
Install O-rings (A) and (B) on the LS check valve and coat them with oil.
[7] -
LEGEND:
A LS Check Valve
Install the LS check valve (A).

[8] -
LEGEND:
A Plug
33 lb-ft
[9] -
LEGEND:
A Valve
B Compression Spring
Install valve and compression spring.

[10] -
LEGEND:
A Plug
33 lb-ft
[11] -
LEGEND:
A Spring
B Guide Piece
Disassemble the piston with spring (A) and guide piece (B), check for wear and replace parts
as necessary.

[12] -
Install the piston and guide piece.

[13] -
LEGEND:
A DFLX41 - Socket Wrench Insert
Using socket wrenchDFLX41(A), tighten the guide piece to the specified torque.
Guide piece to brake valve Torque 100 N˙m
75 lb-ft
[14] -
IMPORTANT:
installation.

LEGEND:
A Spool
B Spring
[15] -
→NOTE:
When installing the plug, remember the spring force.
LEGEND:
A Plug
75 lb-ft

[16] -
LEGEND:
A Filter
Install filter (A) and tighten to the specified torque.
Filter in brake valve Torque 5 N˙m
4 lb-ft
[17] -
LEGEND:
A Valves
Install valves (A) and tighten to the specified torque.
Valve to brake valve, plug Torque 15 N˙m
11 lb-ft

[18] -
LEGEND:
A Intermediate Cover
Remove intermediate cover (A), clean it and install it on the cover.
[19] -
IMPORTANT:
Soak the gasket in clean hydraulic oil for 4 hours and allow it to expand.
LEGEND:
A Gasket
Install the expanded gasket (A) on the housing with the writing underneath.
[20] -
IMPORTANT:
Tighten screws (B) in the sequence shown.

Brake Valve - Tightening Sequence for Screws
LEGEND:
A Cover
B Screws
Install cover (A) and tighten screws (B) to the specified torque in the sequence shown.
Cover to brake valve, screws Torque 12 N˙m
9 lb-ft
Next step:
SeeInstall Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.

Install Power-Fill Brake Valve with MFWD and Disk

Brake
[1] -
→NOTE:
Do not tighten the screw at this stage; allow the brake valve some freedom
of movement.
LEGEND:
A Screw
Secure the brake valve using the lower screw (A).

[2] -
LEGEND:
A Hydraulic Hose
B Brake Switch (with AutoPowr/IVT)
Install hydraulic hose (A) and brake switch (B).
[3] -
Install hydraulic hose (A).

[4] - Connect the brake switch connectors (B).
[5] - Secure hydraulic lines (E) and (F) to the brake valve.

[6] - Install screws (C) and (D) and tighten to the specified torque.
Brake Valve Attaching Screws Torque 100 N·m
75 lb.-ft.
[7] -
LEGEND:
A Pin
Next step:
SeeTests and Adjustments - Adjust Brake Pedals and Brake Switchin Section 260 of the
relevant Diagnostic Manual.

Tests and Adjustments - Adjust the Brake Pedals

and Switches
Adjusting the brake pedals
[1] -
IMPORTANT:
Brake pedals are adjusted with the pedals uncoupled; the setting is
checked with the pedals coupled together.
LEGEND:
A Adjusting Screw
B Roller
C Piston
Unlock the brake pedals.
[2] - Using adjusting screws (A), adjust the pedals so that rollers (B) can be turned by hand.
However, there must be no play noticeable between the roller and piston (C).
[3] -
IMPORTANT:
The locking pin must slide in easily; it may be necessary to re-adjust the
pedal stops.
Lock the brake pedals together and check the setting at the two pistons once again.
→NOTE:
It must be possible to turn the rollers by hand; however, the rollers must
not rise from the pistons.
Next step:
See Adjust the brake switches (without AutoPowr/IVT) or Adjust the brake switches (with

AutoPowr/IVT).
Adjust the brake switches (without AutoPowr/IVT)
LEGEND:
A Adjusting Screws
[2] - Adjust the brake switches at adjusting screws (A) so that the switches trip when the
pedal has travelled a specified distance.
Brake Switch Clearance 6 mm
0.24 in.
[3] -
LEGEND:
A Screws
B Grip
C Trim Panel
Attach trim panel (C) using screws (A) and re-install handle (B).

[4] - Connect ground (—) cable to battery.
Next step:
SeeSteering and Brakes - Bleed Air from the Brakesin Section 260.
Adjust the brake switches (with AutoPowr/IVT)
LEGEND:
A Adjusting Screw
B Adjusting Screw
[2] - Unlock the brake pedals.
[3] - Ignition on.
[4] - For entering the diagnostic mode, seeOperation and General Information on Diagnostics
- Summary of Referencesin Section 245.
[5] - Access the UIC control unit, and confirm.
[6] - Access address 27 (voltage display for left brake pedal).
[7] - Screw in adjusting screw (A) until voltage is between 0.9 and 1.1 volts.
[8] - Counterlock adjusting screw (A).
[9] - Access address 28 (voltage display for right brake pedal).
[10] - Screw in adjusting screw (B) until voltage is between 0.9 and 1.1 volts.
[11] - Counterlock adjusting screw (B).

Section 60 - STEERING AND BRAKES Group 15: Rear Wheel Brakes
[12] - Brake switch test:

At the moment when the switch can be heard to trip, the voltage on the display must be
between 1.45 and 1.65 volts.
→NOTE:
The voltages at the pedals must not deviate from each other by more than
0.15 volts.
[13] -
LEGEND:
A Screws
B Grip
C Trim Panel
Attach trim panel (C) using screws (A) and re-install handle (B).
[14] - Connect ground (—) cable to battery.
Next step:
SeeSteering and Brakes - Bleed Air from the Brakesin Section 260.

Group 15 - Rear Wheel Brakes

Summary of References (Rear Brakes)
”Remove Rear Brakes”
”Rear Brakes — Exploded View”
”Repairing the Rear Brakes”
”Installing the Rear Brakes”
”Final Assembly”
”Bleeding the Brakes (Brake Valve with Power-Fill Brakes, MFWD and Disk Brake)”
Rear Brakes, Specifications

Brake disk Thickness 5.5 mm
0.216 in.
Installation of retraction pins in brake plate Height 23.5 mm
0.925 in.
Preliminary Work
See “Removing the Final Drives” , Section 56, Group 00.
Remove the Rear Brakes

Preliminary work:
SeeRemove the Final Drivesin Section 56.

[1] -
LEGEND:
A Brake plate
B Final drive shaft
C Brake disk
Remove brake plate (A), brake disk (C) and final drive shaft (B).
[2] -
Remove the brake piston using a crowbar.
Rear Brakes—Exploded View

LEGEND:
A Ball
B O-ring
C Bleed screw
D Seal ring
E Seal ring
F Brake piston
G Brake disk
H Backing plate

Recondition the Rear Wheel Brakes

Preliminary work:
SeeRemove the Rear Wheel Brakesin Section 60.
[1] -
LEGEND:
A Brake piston
B Brake plate
Inspect brake piston (A) and backing plate (B) for flatness and for wear on the braking
surfaces.
[2] -
LEGEND:
A Brake disk
Check the lining of brake disk (A).
[3] - Check the splines (see arrow) of the brake disk for wear and damage.
Brake disk Thickness (Minimum) 5.5 mm (0.216 in.)

[4] -
LEGEND:
A Seal ring
Grease new seal ring (A) and install it on the brake piston.
[5] -
LEGEND:
A Seal ring
Grease new seal ring (A) and install it on the housing.
Next step:
SeeInstall the Rear Wheel Brakesin Section 60.

Install the Rear Brakes

[1] -
LEGEND:
A Brake piston
B Sealing surface
Thoroughly clean sealing surface (B).
[2] -
IMPORTANT:
Drive the brake piston as far as it will go into the differential housing.
Drive brake piston (A) in evenly.

[3] -
LEGEND:
A Brake plate
B Final drive shaft
C Brake disk
Install brake plate (A), brake disk (C) and final drive shaft (B) as shown.

Next step:
SeeInstall the Final Drivesin Section 56.
Final Assembly
See “Installing the Final Drives” , Section 56, Group 00.

Bleeding the Brakes (Brake Valve, Power-Fill Brakes

and MFWD and Disk Brake)
CAUTION:
Always follow the steps described here precisely. This is the only way of
assuring the tractor brakes have been correctly bled.
→NOTE:
To avoid oil foaming while bleeding, the procedure should not be started
after fast driving, working with hydraulic implements or carrying out
hydraulic tests. After such operation the tractor should be allowed to stand
for one hour to allow the oil to lose any accumulated foam.
Bleeding sequence:
Without trailer brake:
1. Left rear brake

2. Right rear brake
With hydraulic trailer brake
1. Left rear brake

2. Trailer brake valve
With air brake system:
1. Trailer control valve, rear bleed screw

2. Trailer control valve, front bleed screw
With air brake system and MFWD with disk brake:
1. Left front brake

2. Right front brake
3. Trailer control valve, bleed screw
4. Left rear brake
With hydraulic trailer brake and MFWD with disk brake:

1. Left front brake

2. Right front brake
3. Left rear brake
4. Trailer brake valve
Bleeding procedure
[1] -
Without trailer brake

LEGEND:
A Hex. nut
B Bleed screw
With the engine running, turn the steering wheel slowly and evenly two or three times from
left full lock to right full lock and back again. This fills the brake valve housing via the
steering valve return line. Shut off the engine.
[2] -
With hydraulic trailer brake

With air brake system
With MFWD and disk brake
Tractors without trailer brake: On both rear brakes, slacken off lock nut (A) and open
bleed screw (B) by one-and-a-half turns.
Tractors with hydraulic trailer brake: On the left-hand rear brake, slacken off lock nut (A)
and open bleed screw (B) by one-and-a-half turns. Slide a transparent bleed tube over the
bleed screw on the trailer brake valve. Put the other end of the tube in the filler neck. Open
the bleed screw by half a turn.
Tractors with air brake system: Slide two transparent bleed tubes over the bleed screws.
Place the other ends of the two bleed tubes in the oil filler neck. Open the bleed screws by

Section 60 - STEERING AND BRAKES Group 20: Handbrake
half a turn.
Tractors with MFWD and disk brake: Slide a transparent bleed tube over each bleed
screw (refer to Bleeding Sequence). Put the tube ends into a suitable container. Open the
bleed screws by half a turn.
[3] - Start the engine.
[4] - Couple the brake pedals together. Depress the pedals and hold them depressed for at
least 15 seconds.
[5] - Then depress the pedals briefly and release. Repeat this a few times. This should flush
out any air bubbles left in the fluid.
[6] - If necessary, repeat step 4.
[7] -
Air brake system (MFWD and disk brake)

LEGEND:
A Hex. nut
B Bleed screw
C Breather
Hold the pedals in the depressed position and close the bleed screws. Retighten the lock nuts
(if equipped).
[8] - Shut off the engine and actuate the brake pedals several times each (separately!) with
the engine shut off. This bleeds the last of the air out of the brake valve. There must be
perceptible (increasing) resistance before each pedal reaches its limit of travel.
IMPORTANT:
If pedal does sink noticeably after resistance has been reached, leaks in
the brake system may be the cause.

Group 20 - Handbrake
Summary of References (Handbrake)
”Preliminary work”
”Remove handbrake”
”Exploded view of handbrake - Tractor 6820”
”Exploded view of handbrake - Tractors 6920 and 6920S”
”Install handbrake”
”Adjusting the brake band”
”Final assembly”
”Handbrake components”
”Replacing the handbrake cable”
”Adjusting the handbrake”
Handbrake - Specifications
Quill of front-wheel drive clutch, screws Torque 25 N·m
18 lb.-ft.
Locknut Torque 37 ± 7 N·m
27 ± 5 lb.-ft.
Preliminary work
Remove FWD clutch. See “Removing the FWD clutch” , section 56, group 00.

Remove Handbrake
Preliminary work:
SeeRemove the Front-Wheel Drive Clutchin Section 56.
[1] -
LEGEND:
A Screws
B Bearing quill
Take out screws (A) and remove bearing quill (B).
[2] -
LEGEND:
A Spring pin
B Lever shaft
C Plug
Remove plug (C).
[3] - Remove spring pin (A) and pull out lever shaft (B).

[4] -
LEGEND:
A Plug
Remove plug (A).
[5] -
LEGEND:
A Shaft
Use a screw to remove shaft (A).

[6] -
LEGEND:
A Output shaft
Remove output shaft (A).
[7] - Take off the shims and tapered roller bearing.
[8] -
Remove the clutch and brake band from the housing.

[9] -
Take the brake band off the clutch.

Exploded view of handbrake - Tractor 6820
LEGEND:
A Lever
B Strap
C Lever
D Brake band
E Strap
F Lever shaft
G Strap
H Lever
I Arm
J Strap
K Seal ring
L Shaft

Exploded view of handbrake - Tractors 6920 and

6920S
LEGEND:
A Lever
B Strap
C Lever
D Brake band
E Brake band
F Strap
G Strap
H Lever shaft
I Strap
J Lever

K Arm
L Strap
M Seal ring
N Shaft

Installing the handbrake
Install taper roller bearing cone (A) in housing.
To prevent the thrust washer (A) from falling out during clutch installation, coat it with
grease.
Install the thrust washer on the clutch.
Check the handbrake components, and replace if necessary.
Preassemble the handbrake band using the exploded view illustration as a guide. Install the
band on the clutch as shown.
→NOTE:
Pin (B) is held in position only by the straps (A). When installing, hold the
brake band linkage in the position shown, otherwise the pin will fall out.
Install clutch and brake band.
→NOTE:
Make sure that the thrust washer and pin do not fall out.
Install shaft (A).
Install taper roller bearing.

Install shaft (A).
Screw in plug (A).
Screw in plug (C).
Install lever shaft (B) and drive in spring pin (A).

→NOTE:
If you have not replaced any of the components that affect the axial play of
the FWD clutch (for example, if you have replaced only the brake band),
the old shims can be reused. In this housing, there is no need to adjust the
axial play. Otherwise, see “Repairing the FWD clutch” , section 56, group
10.
Install shims. Attach bearing quill (B).
Tighten cap screws (A).
Cap screws (A) Torque 25 N˙m
18 lb-ft
Handbrake - Adjust the Brake Band

[1] -
→NOTE:
The clutch drum must turn freely without any undue resistance.

LEGEND:
A Adjusting screw
Adjust the brake band at adjusting screw (A).
[2] - Tighten locknut on adjusting screw to specified torque.
Locknut Torque 37 ± 7 N·m
27 ± 5 lb.-ft.
Next step:
SeeInstall the Front-Wheel Drive Clutchin Section 56.
Final assembly
Install the FWD clutch. See “Installing the FWD clutch” , section 56, group 00.
Handbrake components

LEGEND:
A Spring
B Unlocking rod
C Handle
D Handbrake lever
E Locking pawl
F Toothed segment
G Bracket
H Sender for handbrake indicator light
I Console
J Trim panel
K Rubber sleeve
L Handbrake cable (top part)
M Handbrake cable (bottom part)
N Terminal
O Bracket
P Bracket (AutoPowr/IVT transmission only)

Handbrake - Replace Handbrake Cable
1.
LEGEND:
A Yoke
Release the handbrake fully.
2. Disengage yoke (A) at the front-wheel drive clutch.
3.
LEGEND:
A Screws
B Trim panel
Take out screws (A) and remove trim panel (B).

4.
LEGEND:
A Pin
B Locking plate
Remove pin (A) and locking plate (B) from the handbrake lever.
5. Disconnect handbrake cable.
Removal
[1] -
→NOTE:
The handbrake cable can be disconnected underneath the cab. If required,
the two parts may be replaced independently of one another.
LEGEND:
A Snap ring
B Sleeve
C Locknut
D Handbrake cable (top part)
[2] - Unfasten locknut (C) and unscrew the sleeve (B).

Section 60 - STEERING AND BRAKES Group 25: Hydraulic Trailer Brake
[3] - Disconnect the top and bottom parts of the handbrake cable.
Installation
[1] - Connect the top and bottom parts of the handbrake cable by pushing their ends
together.
[2] - Screw the sleeve (B) onto the thread of the top part (D) of the handbrake cable. The end
of the sleeve must come between the grooves.
[3] - Coat the thread with Loctite ™ 243 (medium strength) and tighten locknut (C).
Next step:
SeeTests and Adjustments - Check and Adjust Handbrakein Section 260 of the relevant
Diagnostic Manual.
Adjusting the Handbrake

[1] -
Pull the handbrake lever up (apply brake).

It must be possible to pull the lever into the 4th notch using a force of 100 to 150 N (22 to 34
lb).
[2] - If necessary, adjust the handbrake by turning yoke (A).
[3] -
→NOTE:
Slackening the yoke makes the handbrake slacker. Tightening the yoke
makes the handbrake tighter.
Check the handbrake again.

Group 25 - Hydraulic Trailer Brake

Hydraulic Trailer Brake (Summary of References)
Special tools
Specifications
Repair information
Hydraulic trailer brake valve up to serial no. 466428
Hydraulic trailer brake valve from serial no. 466429
Bleeding the trailer brake valve
Check hydraulic trailer brake valve
Special Tools
→NOTE:

Catalog or from the European Microfiche Tool Catalog (MTC).
FKM10002 / JT05470- Universal pressure test kit

AR52361- Coupler socket
Specifications
Brake valve to console, cap screws Torque 10 to 12 N˙m (7 to 9 lb-ft)
Cover to valve housing, hex. socket screws Torque 13 N˙m (9.5 lb-ft)
Brake pressure, max. Pressure 12000—14000 kPa (120—140 bar; 1740—2031 psi)
Repair Instructions
CAUTION:
High pressure may be present at any of the hydraulic connections. Avoid

injury by relieving system pressure before disconnecting any hydraulic
lines, fittings or connections.
IMPORTANT:
Absolute cleanliness is essential when working on the hydraulic system.

Clean the area around the trailer brake valve thoroughly before removing
or servicing parts.
Replace all seals and O-rings.
Check for signs of wear, damage or deformation.
Clean all components in a clean detergent, and dry them with compressed air. Do NOT use
rags to wipe the components dry!
Before assembly, coat all internal components with clean hydraulic oil.
The valve spool must not jam in the housing bore.
When work on the trailer brake valve is completed, see “ Bleed the Brakes ” in Section 60,
Group 20.

Hydraulic Trailer Brake Valve up to Serial No.

466428
Changing the trailer brake valve
LEGEND:
A Cap screws
B Washers
Disconnect lines at the brake valve and remove cap screws (A).
Install washers (B) between the brake valve and the bracket.
Tighten cap screws (A) to 10 to 12 N˙m (7 to 9 lb-ft) and connect lines.
Cleaning the trailer brake valve
→NOTE:
From tractor serial no. 466429, the trailer brake valve cannot be cleaned.

IMPORTANT:
Absolute cleanliness is essential when working on the trailer brake valve.
There is no need to remove the brake valve for cleaning. Take out the three hex. socket
screws (B) and carefully remove cover (A). Take care, as components may fall out.
LEGEND:
A Valve spool
B Disk
C Spring
Use a magnet to extract the spring, disk and valve spool from the hole. Clean the
components and the hole, and re-install. Make sure they are located correctly. The collar on
disk (B) must face the spring.
LEGEND:
A Valve body
B Spring
C Guide
Use a magnet to extract the guide, spring and pressure-limiting valve body from the hole.
Clean the components and the hole, and re-install. Make sure they are located correctly.

LEGEND:
A Restriction valve
B Cover
C O-ring L53976
D O-ring R76617
Clean restriction valve (A) and blow compressed air through it. Do NOT remove or adjust the
valve! Insert new O-rings (C) and (D). Install cover (B) and tighten the three hex. socket
screws to 13 N˙m (9.5 lb-ft). Repeat the tests. If the specifications are still not met, replace
the trailer brake valve with a new one.
Cleaning the screen
Hydraulic line and fitting

LEGEND:
A Hydraulic line
B Fitting
C Screen
Disconnect hydraulic line (A) from fitting (B). Slacken the fitting and turn it to one side.
Remove the screen (C) from the hydraulic line. Clean the screen.
Insert the screen, and secure the hydraulic line and fitting.
Replacing the check valve
LEGEND:
A Check valve
B Trailer brake valve

When installing, make sure that ring (A) and O-ring (B) are seated correctly in check valve
(C). The O-ring faces towards the check valve.
Adjusting hydraulic trailer brake valve
[1] - Run the engine at 1500 rpm.
→NOTE:
Oil temperature must be at approx. 50°C (120°F).
[2] - Depress r.h. brake pedal until pilot pressure (see chart) has been reached.

[3] - Use an allen key to slacken off the valve pin by about 1 to 2 turns, and flush for approx.
10 seconds.
[4] - Release the brakes.
CAUTION:
Do NOT screw the valve pin as far as it can go, as this may damage the
valve seat.
[5] - Depress r.h. brake pedal until pilot pressure (see chart) has been reached.
[6] - Screw in the valve pin (by about 1 to 2 turns) until the corresponding brake pressure
(see chart) has been obtained.
[7] - Release the brakes.
[8] - Check that the correct pilot pressure is achieved at the correct brake pressure (see
table below).
Ratio
[ See reference ”Ascertaining the Pressure Ratio” in Section 260, Group 20 ]
1:6 1:9
(pilot and brake pressure)
1700 kPa 1100 kPa

Pilot pressure 17 bar 11 bar
247 psi 160 psi
9400—11000 kPa 9500—10800 kPa

Brake pressure
94—110 bar 95—108 bar
(at coupler)
1365—1600 psi 1378—1566 psi
If the brake pressure does not correspond to the specification quoted, screw the valve pin in
or out (see the test at point 6).
[9] - Lock the hex. nut and install protective cap.

Hydraulic Trailer Brake Valve from Serial No.

466429
Changing the trailer brake valve
LEGEND:
A Cap screws
B Washers
Disconnect lines at the brake valve and remove cap screws (A).
Install washers (B) between the brake valve and the bracket.
Tighten cap screws (A) to 10 to 12 N˙m (7 to 9 lb-ft) and connect lines.
Cleaning the trailer brake valve
→NOTE:
The trailer brake valve cannot be cleaned anymore.
Cleaning the screen

LEGEND:
A Hydraulic line
B Fitting
C Screen
Disconnect hydraulic line (A) from fitting (B). Slacken the fitting and turn it to one side.
Remove the screen (C) from the hydraulic line. Clean the screen.
Insert the screen, and secure the hydraulic line and fitting.
Replacing the check valve

LEGEND:
A Check valve
B Trailer brake valve
LEGEND:
A O-ring
B Check valve
When installing, make sure that O-ring (A) is seated correctly in check valve (B).
Bleed Air from the Trailer Brake Valve

See “ Bleed the Brakes ” in Section 60, Group 20.

Check Hydraulic Trailer Brake Valve
LEGEND:
A Pressure Gauge FKM10207
[ Included in pressure gauge set FKM10002 ]
B Connector FKM10302
C Pressure Hose FKM10209

D Connector FKM10303
E Connector FKM10305
F Quick Coupler Socket

[ Available as spare part ]
G Coupler Plug
H Pressure Gauge FKM10205
I Connector FKM10303
J Fitting KJD10128

Section 60 - STEERING AND BRAKES Group 30: Air Brakes up to Serial No. 398655
IMPORTANT:
To ensure proper function of the trailer brake valve, the tractor brakes
must be in full working order. Make sure that hydraulic brakes and trailer
brake valve have been bled properly, and that there are no leaks in the
brake system.
[1] - For brake pressure check: Connect pressure gauge (A) to coupler plug.
[2] - For pilot pressure check: Remove bleed screw from trailer brake valve. Install ring
L76408 on fitting KJD10128 (J). Screw in fitting and connect pressure gauge (H).
[3] - Heat hydraulic oil to 50°C (120°F).
[4] - Run the engine at 1500 rpm.
[5] - Read pressure with brake pedal not depressed.
With brake pedal not depressed, no pressure must be shown!
[6] - If pressure ratio of trailer brake valve is 1:6
Depress the right brake pedal until a pilot pressure of 930 - 1070 kPa (9.3 - 10.7 bar; 134.9 -
155.2 psi) is obtained. The brake pressure at the coupler must now be 6000 kPa (60 bar; 870
psi).
Repeat the test at the following values:
Pilot pressure at brake valve: 1700 kPa (17 bar; 246 psi).
Brake pressure at coupler: 9400 - 10800 kPa (94 - 108 bar; 1364 - 1568 psi)
Maximum pressure test:
Pilot pressure at brake valve: 2000 - 2300 kPa (20 - 23 bar; 290 - 330 psi)
[7] - If pressure ratio of trailer brake valve is 1:9
Depress the right brake pedal until a pilot pressure of 1100 kPa (11 bar; 160 psi) is obtained
at the trailer brake valve.
Perform the maximum pressure test at the following pressure.
Pilot pressure at brake valve: 1400 kPa (14 bar; 203 psi)
Up to serial no. 466428: If the brake pressure at the coupler does not correspond to the
specification quoted, the trailer brake valve must be dismantled and cleaned.
From serial no. 466429: If the brake pressure at the coupler does not correspond to the
specification quoted, the screen has to be cleaned, seeHydraulic Trailer Brake Valve from
Serial No. 466429.

Group 30 - Air Brakes up to Serial No. 398655

Air Brakes up to Serial No. 398655 (Summary of
References)
”Special tools”
”Safety instructions”
”Screw union installation”
”Changing the compressor”
”Gaskets for the compressor”
”Change compressed air tank”
”Change the preload valve”
”Changing the pressure-relief valve”
”Changing the pressure-regulating valve”
”Changing the trailer control valve (dual-line + single-line brake)”
”Changing the trailer control valve (single-line brake)”
”Change the coupling ends”
”Change the pressure gauge”
”Test sequence”
”Check the system for leaks”
”Checking the ”Supply” coupling end”
”Checking the dual-line brake”
”Checking the single-line brake”
”Adjusting the handbrake (with air brake system)”
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD

SERVICEGARD ™ Catalog or in the European Microfiche Tool Catalog (MTC).
Pressure test kit
KJD10194

Checking the air brake system

Operating pressure (downstream of pressure- 790 to 830 kPa (7.9 to 8.3 bar; 115 to
Pressure
regulating valve) 120 psi)
Pressure drop within a period

Leak test max. 16 kPa (0.16 bar; 2.3 psi)
of 10 min
Pressure with foot brake or 700 to 740 kPa (7.0 to 7.4 bar; 102 to
Dual-line brake check
hand brake engaged 107 psi)
Pressure with foot brake and 500 to 540 kPa (5.0 to 5.4 bar; 73 to 78
Single-line brake check
hand brake disengaged psi)
Time required to fill compressed air tank
—15 L (3.96 US.gal.) Time approx. 2.25 minutes at rated speed
Compressed air line for pressure gauge Torque 14 N˙m (10 lb-ft)
Air compressor
20 N˙m (15 lb-ft), then turn an

Cylinder head screws Torque
additional 90°
Hex. nut, belt pulley to crankshaft Torque 100 N˙m (75 lb-ft)
Screws, belt pulley to crankshaft Torque 25 N˙m (20 lb-ft)
6 N˙m (4.5 lb-ft), then turn an additional

Screws on connecting rod bearing Torque
70°
Screws, bearing flange to crankcase Torque 12 N˙m (9 lb-ft)
Safety instructions
IMPORTANT:
Safety instructions
IMPORTANT:
When performing the work described here, comply with the safety
instructions in section 05.
IMPORTANT:
Work on the brake system must be performed by qualified personnel only.

IMPORTANT:
Absolute cleanliness is essential when working on the air brake system.
IMPORTANT:
When replacing components of the air brake system, check for deposits
caused by burnt oil. If necessary, remove such deposits.
IMPORTANT:
Before working on the air brake system, all pressure must be released from
the system by activating the drain valve (A). Never do any welding on the
air brake system.

Screw Union Installation
Use a tool for cutting plastic pipe or a sharp knife to cut straight across the plastic hose. After
cutting the hose,carefully de-burr the ends; do NOT make the ends sharp.
Install collar nut (A), cutting ring (B) and sleeve (C). Install the cutting ring (B) with the thick
section first (narrower section facing the hose end). Push sleeve (C) on until its collar is in
contact.

When hose (A) is ready, slide it on as far as it will go and tighten the collar nut by hand as far
as it will go in relation to the cutting ring. Then use a wrench to tighten the collar nut by a
further 1 1/2 to 1 3/4 turns.
Change the Compressor
LEGEND:
A Pressure Oil Line
B Return Oil Line
C Air Intake Line
D Compressed Air Line
E Cap Screws
Relieve tension on drive belt (see Relieving Tension on the Drive Belt in Section 30, Group
20). Remove drive belt. Disconnect lines (A), (B), (C) and (D). Remove the four cap screws
(E). Re-install in reverse order.

Gaskets for the Compressor


LEGEND:
A Aluminium ring
B Plug
C Cylinder head screw (4 used)
D Cylinder head
E Gasket
F Valve plate
G Gasket
H Crankcase (compressor)
I O-ring
J Bearing quill
K Seal ring
L Nut
N Aluminium ring
O Plug
When replacing the gaskets, refer to the drawing opposite.
After assembly, take out plug (O). Add approx. 0.25 L (0.065 US.gal.) of engine oil to the
crankcase.
Tightening torques for installing the screws: Tighten cylinder-head screws (C) cross-wise to
20 N˙m (15 lb-ft). Then turn them cross-wise through a further 90°.
Tighten hex. nut (L; belt pulley to crankshaft) to 100 N˙m (75 lb-ft). Tighten the screws used
in assembling the belt pulley (not illustrated) to 25 N˙m (20 lb-ft).
Tighten the screws on the con-rod bearing (not illustrated) to 6 N˙m (4.5 lb-ft). Then turn
them through a further 70°. Tighten screws (M; bearing quill to crankcase) to 12 N˙m (9 lb-
ft).

Changing the compressed air tank
Support the tractor properly and remove the right rear wheel.
Disconnect lines (A), (B), (C) and (D).
Disconnect cable (E) on preload valve
Remove the two cap screws (F). Replace the compressed air tank with a new one.
For installation, reverse the removal procedure. Tighten line (D) to the following torque:
Compressed air hose Torque 14 N˙m
(10 lb-ft)

LEGEND:
1 Test and filler connection
2 Fitting
3 Lock nut
4 Thrust ring
5 O-ring
6 Compressed air tank
7 Bracket
8 Drain valve
9 Elbow fitting
10 Fitting
Changing the preload valve
Disconnect cable (A) on preload valve (D).
Remove cap screws (B).
Loosen collar nuts (C and E) and pull out hoses.

Remove preload valve (D).
For installation, reverse the removal procedure.
Preload valve cap screw (M8x50) Torque 28 N˙m
(20 lb-ft)
Changing the Pressure-Relief Valve
Disconnect the hoses (A and B) at the collar nuts.
Take out cap screws (C) and remove pressure-relief valve (D).
Preload valve, cap screw (M8x75) Torque 28 N˙m
(20 lb-ft)
Changing the pressure-regulating valve

IMPORTANT:
Before carrying out any work, be sure to observe all safety instructions.
Loosen collar nut (A) and remove cap screws (B, C).
Move pressure-regulating valve and preload valve (D) to the back.
Remove the hose clamp (A) and take out the damping element (B).
Loosen the lock nut (C) and remove the pressure-regulating valve by turning it.
Changing the trailer control valve (dual-line +

single-line brake)

Tilt cab (see "Tilting cab" , section 90, group 00).
Support the tractor properly and remove the left rear wheel.
Disconnect linkage (A) at handbrake.
Disconnect lines (B), (C), (D), and (G) and remove the dual-line brake valve (F) from the
bracket (E).
Adjust linkage (A) so that the threaded pin lies easily (tension-free) in the detents when the
handbrake is released.
→NOTE:
Bleed the hydraulic brakes (see "Bleeding the foot brakes" , section 60,
group 20).

Changing the trailer control valve (single-line

brake)
LEGEND:
A Hose to coupling end “black, single-line brake”
B Hose to trailer control valve (dual-line brake)
C Hose from trailer control valve (dual-line brake)
D Hose to trailer control valve (dual-line brake)
E M20x60 cap screw
Support the tractor properly and remove the left rear wheel.
Disconnect hoses (A), (B), (C) and (D).
Remove screw (E).
→NOTE:
Bleed the hydraulic brakes, see “Bleeding the brakes (Power-Fill brakes
and MFWD and disk brake)” , section 60, group 15.
Exploded view of trailer control valve

LEGEND:
1 Bracket
2 O-ring
3 Thrust ring
4 Lock nut
5 Elbow fitting
6 Cutting ring
7 Backup sleeve
8 Collar nut
9 Hose (from trailer control valve; dual-line brake)
10 Hose (to trailer control valve; dual-line brake)
11 Hose (to trailer control valve; dual-line brake)
12 Lock nut
13 Thrust ring
14 O-ring
15 Trailer control valve (single-line brake)
Single-line brake

Changing the Coupling Ends

LEGEND:
1 Plug (M22x1)
2 Quick-release valve
3 O-ring
4 Pressure ring
5 Hex. nut
6 Elbow fitting
7 Elbow fitting
8 Hex. nut
9 Fitting
10 Pressure ring
11 O-ring
12 Coupling end (red, supply)
13 Bracket
14 Coupling end (black, single-line brake)
15 Fitting
16 Coupling end (yellow, dual-line brake)
17 Hex. nut
18 Hose
19 Hose clamp
20 Elbow fitting
21 Cap screw
Disconnect the appropriate line (A).
Disconnect the appropriate coupling end (B) and take out the screw-in element.
Changing the Pressure Gauge
Take pressure gauge (A) out of its housing.
Take out plug (C) and remove line (B).
Re-install in reverse order.

Tighten line (B) to 14 N˙m (10 lb-ft).
Install toothed disks (D) between bracket (E) and the pressure gauge housing.

Test Sequence
IMPORTANT:
Before checking the air brakes, make sure that the tractor′s brakes are
operating correctly.
Visual check Operational check Test run
Check that components function Test drive the tractor, operate

Check for any damage:
correctly: the components:
•Do the lines and hoses rub? •Compressor drive •Leaks in the system
•Loose or defective attachments? •Air cleaner •Reaction time
•Variability of trailer control

•Coupling ends, function and condition •Lube supply
valve
•Is there corrosion or dirt in the system? •Pressure control valve •Handbrake
•Linkage, cables and joints must move freely.

•Trailer control valves
Any sign of damage?
•Any build-up of burnt-oil deposits? •Pressure gauge
•Drain valve
•Pressure limiting valve (if equipped)
•Time taken for filling

Checking the system for leaks

[1] -
LEGEND:
A KJD10194-1 pressure gauge
B KJD10194-2 test hose
Connect pressure test kit KJD10194 to test/filler connection
Pressure test kit
KJD10194
Checking the air brake system for leaks
[2] - Run engine at a speed of 1200 rpm until the pressure-regulating valve switches off.
[3] - Shut off engine.
[4] - Wait until the pressure-regulating valve stabilizes. It takes at least one minute for the
valve to stabilize. Now check the pressure reading.Pressure must be between 790 and 830
kPa (7.9 - 8.3 bar; 115 - 120 psi).
[5] - Check the pressure reading again after 10 minutes.Pressure drop within a period of 10
minutes must not exceed 16 kPa (0.16 bar; 2.3 psi).
[6] - If pressure drops too fast, check all connections for leaks by applying soap.
Check the Supply Coupling End

LEGEND:
A KJD10194-1 Pressure Gauge
B KJD10194-2 Hose
C KJD10194-5 Coupling End (Red)
D KJD10194-7 Test Fitting
[1] - Connect the KJD10194 pressure test kit to the red Supply coupling end.
[2] - Run the engine until the air brake system reaches operating pressure.
CAUTION:
Pressure at the coupling end must be between 790 and 830 kPa (7.9 and
8.3 bar; 115 and 120 psi).

Check the Dual-Line Brakes
LEGEND:
B KJD10194-2 hose
C KJD10194-4 coupler (yellow)
D KJD10194-7 test fitting
→NOTE:
Before bleeding the brakes, see reference ”Bleeding the Brakes (Power-Fill
Brake Valve with MFWD and Disk Brake)” or”Bleeding the Brakes (Brake
Valve without Power-Fill)”in Section 60, Group 20.
[1] - Make sure that the hydraulic brakes and the trailer control valve are bled correctly.
Make sure there are no leaks anywhere in the brake system.
[2] -
Pressure test kit
KJD10194
Pressure testing (dual-line brakes)
Connect the KJD10194 pressure gauge set to the coupler (yellow).
[3] - Run engine until the air brake system reaches its operating pressure.
[4] - Read pressure with handbrake and foot brakes not applied.
With neither footbrake not handbrake applied, the pressure reading at the yellow coupling
end should be zero.
Tractors with MFWD and disk brake
With neither footbrake nor handbrake applied(but ignition on) , the pressure reading at the
yellow coupling end should be zero.
With neither footbrake nor handbrake applied(but ignition off) , pressure should be
between 100 and 160 kPa (1.0 and 1.6 bar; 14.5 and 23.22 psi).

[5] - Apply foot brakes and read pressure.

With brake pedal fully depressed, pressure at the yellow coupling end should be between 650
and 810 kPa (6.5 and 8.1 bar; 94 and 118 psi).
[6] - Release foot brakes. No pressure should be registered any more.
[7] - Apply handbrake and read pressure.
With handbrake applied, pressure at yellow coupling end should be between 650 and 810 kPa
(6.5 and 8.1 bar; 94 and 118 psi).

Checking the Single-Line Brakes
LEGEND:
B KJD10194-2 hose
C KJD10194-3 coupler (black)
→NOTE:
[2] - Connect pressure test kit KJD10194 to single-line air brake coupler (black).
With handbrake and foot brakes not applied, pressure at coupler (black) should be between
500 and 540 kPa (5.0 and 5.4 bar; 73 and 78 psi).
[5] - Apply foot brakes and read pressure.With the brake pedal depressed fully, the pressure
reading at the black coupling end should be zero.
[6] - Release foot brakes. Now pressure should once again be between 500 and 540 kPa (5.0
and 5.4 bar; 73 and 78 psi).
[7] - Apply handbrake and read pressure.With the handbrake applied, the pressure reading
at the black coupling end should also be zero.
Adjusting the air brake system handbrake

Section 60 - STEERING AND BRAKES Group 31: Air Brakes from Serial No. 398656
If necessary, adjust linkage (A) until the prescribed pressure is reached.
Pressure test
700 to 740 kPa (7.0 to 7.4 bar; 102 to 107
Dual-line brake check Pressure with foot brake or hand brake engaged
psi)
Pressure with foot brake and hand brake

Single-line brake check 500 to 540 kPa (5.0 to 5.4 bar; 73 to 78 psi)
disengaged
IMPORTANT:
Other checks, such as measuring the braking force and the variability of
the trailer control valve, must be carried out at properly equipped
workshops.
Some of these checks are included in the regular vehicle inspections

prescribed by law.
Exceptions may apply in certain countries.

Group 31 - Air Brakes from Serial No. 398656

Air Brakes from Serial No. 398656 (Summary of
References)
”Special tools”
”Safety instructions”
”Screw union installation”
”Changing the compressor”
”Gaskets for the compressor”
”Change compressed air tank”
”Changing the pressure-regulating valve”
”Changing the precharge valve”
”Changing the trailer control valve (dual-line brake)”
”Changing the trailer control valve (single-line brake)”
”Changing the coupling ends”
”Change the pressure gauge”
”Test sequence”
”Check the system for leaks”
”Checking the ”Supply” coupling end”
”Checking the dual-line brake”
”Checking the single-line brake”
”Adjusting the handbrake (with air brake system)”
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD

SERVICEGARD ™ Catalog or in the European Microfiche Tool Catalog (MTC).
KJD10194- Pressure gauge set for air brakes

Operating Pressure (Downstream of 790 to 830 kPa (7.9 to 8.3 bar; 115 to 120
Pressure
Pressure Control Valve) psi)
Leak Test Pressure drop within 10 minutes max. 16 kPa (0.16 bar; 2.3 psi)
Pressure with Brake Pedal

700 to 740 kPa (7.0 to 7.4 bar; 102 to 107
Dual-Line Brake Depressed or Handbrake
psi)
Applied
Pressure with Brake Pedal and

Single-Line Brake 500 to 540 kPa (5.0 to 5.4 bar; 73 to 78 psi)
Handbrake Released
Compressed Air Tank Fill Time
approx. 2.25 minutes at rated engine

—15 L (3.96 US.gal.) Time
speed
Compressed-Air Line for Pressure Gauge Torque 14 N˙m (10 lb.-ft.)
Air Compressor
20 N˙m (15 lb.-ft.), then turn through a

Cheese-Head Screws Torque
further 90°
Hex. Nut, Belt Pulley to Crankshaft Torque 100 N˙m (75 lb.-ft.)
Screws, Pulley to Crankshaft Torque 25 N˙m (20 lb.-ft.)
6 N˙m (4.5 lb.-ft.), then turn through a

Screws, Connecting Rod Bearing Torque
further 70°
Screws, Bearing Flange to Crankcase Torque 12 N˙m (9 lb.-ft.)
Safety Instructions
IMPORTANT:
Safety instructions
IMPORTANT:
When performing the work described here, also comply with the safety
instructions in Section 05.
IMPORTANT:
Work on the brake system should be performed by qualified personnel

only.

IMPORTANT:
When working on the air brakes, cleanliness is of the utmost importance.
IMPORTANT:
When replacing air brake components, check for deposits caused by burnt
oil. If necessary, remove such deposits.
IMPORTANT:
Before working on the air brakes, always make the system pressure-free.
Operate drain valve (A) to make the system pressure-free. Do not carry out
any welding jobs on the air brake system.

Screw Union Installation
Use a tool for cutting plastic pipe or a sharp knife to cut straight across the plastic hose. After
cutting the hose,carefully de-burr the ends; do NOT make the ends sharp.
Install collar nut (A), cutting ring (B) and sleeve (C). Install the cutting ring (B) with the thick
section first (narrower section facing the hose end). Push sleeve (C) on until its collar is in
contact.

When hose (A) is ready, slide it on as far as it will go and tighten the collar nut by hand as far
as it will go in relation to the cutting ring. Then use a wrench to tighten the collar nut by a
further 1 1/2 to 1 3/4 turns.
Change the Compressor
LEGEND:
A Pressure Oil Line
B Return Oil Line
C Air Intake Line
D Compressed Air Line
E Cap Screws
Relieve tension on drive belt (see Relieving Tension on the Drive Belt in Section 30, Group
20). Remove drive belt. Disconnect lines (A), (B), (C) and (D). Remove the four cap screws
(E). Re-install in reverse order.

Gaskets for the Compressor


LEGEND:
A Aluminium ring
B Plug
C Cylinder head screw (4 used)
D Cylinder head
E Gasket
F Valve plate
G Gasket
H Crankcase (compressor)
I O-ring
J Bearing quill
K Seal ring
L Nut
N Aluminium ring
O Plug
When replacing the gaskets, refer to the drawing opposite.
After assembly, take out plug (O). Add approx. 0.25 L (0.065 US.gal.) of engine oil to the
crankcase.
Tightening torques for installing the screws: Tighten cylinder-head screws (C) cross-wise to
20 N˙m (15 lb-ft). Then turn them cross-wise through a further 90°.
Tighten hex. nut (L; belt pulley to crankshaft) to 100 N˙m (75 lb-ft). Tighten the screws used
in assembling the belt pulley (not illustrated) to 25 N˙m (20 lb-ft).
Tighten the screws on the con-rod bearing (not illustrated) to 6 N˙m (4.5 lb-ft). Then turn
them through a further 70°. Tighten screws (M; bearing quill to crankcase) to 12 N˙m (9 lb-
ft).

Change Compressed Air Tank
Support the tractor safely and remove the right rear wheel.
Disconnect lines (B), (C), (D) and (E).
Take out the two cap screws (A). Replace the compressed air tank with a new one.
For installation, follow removal procedure in reverse order. Tighten line (B) to the following
torque.
Compressed-air hose Torque 14 N˙m
(10 lb-ft)

LEGEND:
1 Test and filler connection
2 Sealing washer
3 Fitting
4 Lock nut
5 Thrust ring
6 O-ring
8 Bracket
9 Water drain valve
10 Elbow fitting
11 Fitting
Changing the Pressure-Regulating Valve
Remove compressed air tank. Remove pressure-regulating valve (A).

LEGEND:
2 Lock nut
3 Thrust ring
4 O-ring
5 Pressure-regulating valve
6 Fitting
Changing the Precharge Valve

Disconnect lines (B), (C), (D) and (E).
Take out cap screws (A) and remove the precharge valve (F).
For installation, follow removal procedure in reverse order. Tighten lines (B) to the following
torque.
Compressed-air hose Torque 14 N˙m
(10 lb-ft)
Changing the Trailer Control Valve (Dual-Line

Brake)

Support the tractor safely and remove the left rear wheel.
Disconnect handbrake linkage at ball head (E).
Disconnect lines (A), (B) and (C).
Disconnect the brake lines (D).
Remove the two screws (F).
→NOTE:
Bleed the hydraulic brakes, see "Bleeding the Brakes" , Section 60, Group
15).
Changing the Trailer Control Valve (Single-Line

Brake)
Disconnect lines (A), (B) and (C).
Remove the two screws (D).
→NOTE:
Bleed the hydraulic brakes, see"Bleeding the Brakes", Section 60, Group
15).

Change the Coupling Ends
Disconnect the appropriate line.
Disconnect the appropriate coupling end (A) and take out the screw-in element.
LEGEND:
1 Coupling End (Yellow, Dual-Line Brake)

2 O-Ring
3 Thrust Ring
4 Hex. Nut
5 Elbow Fitting
6 Coupling End (Black, Single-Line Brake)
7 O-Ring
8 Thrust Ring
9 Fitting
10 Hex. Nut
11 Coupling End (Red, Supply)
12 Cap Screw
13 [ Coupling End (Supply) For Great Britain only ]
14 [ Coupling End (Dual-Line Brake) For Great Britain only ]
Change the Pressure Gauge
Remove pressure gauge and housing from bracket.
Take pressure gauge (A) out of its housing (C).
Take out connector (D) and remove line (B).
Tighten line (B) to 14 N˙m (10 lb.-ft.).
Install the toothed disks between bracket and the pressure gauge (C) housing.

Test Sequence
IMPORTANT:
Before checking the air brakes, make sure that the tractor′s brakes are
operating correctly.
Visual check Operational check Test run
Check that components function Test drive the tractor, operate

Check for any damage:
correctly: the components:
•Do the lines and hoses rub? •Compressor drive •Leaks in the system
•Loose or defective attachments? •Air cleaner •Reaction time
•Variability of trailer control

•Coupling ends, function and condition •Lube supply
valve
•Is there corrosion or dirt in the system? •Pressure control valve •Handbrake
•Linkage, cables and joints must move freely.

•Trailer control valves
Any sign of damage?
•Any build-up of burnt-oil deposits? •Pressure gauge
•Drain valve
•Pressure limiting valve (if equipped)
•Time taken for filling

Check the System for Leaks

[1] -
LEGEND:
B KJD10194-2 Hose
Connect the KJD10194 pressure test kit to the check/fill port
Pressure Test Kit
KJD10194
Checking the air brake system for leaks
.
[2] - Run engine at a speed of 1200 rpm until the pressure regulating valve switches off.
[3] - Shut off the engine.
[4] - Wait until enough time has elapsed for the pressure control valve to stabilize. It takes at
least one minute for the valve to stabilize. Then take the pressure reading.Pressure must be
between 790 and 830 kPa (7.9 and 8.3 bar; 115 and 120 psi).
[5] - Check the pressure reading again after 10 minutes.Pressure drop within a period of 10
minutes must not exceed 16 kPa (0.16 bar; 2.3 psi).
[6] - If pressure drops too fast, check all connections for leaks by applying soap.
Check the Supply Coupling End

LEGEND:
B KJD10194-2 Hose
C KJD10194-5 Coupling End (Red)
[1] - Connect the KJD10194 pressure test kit to the red Supply coupling end.
[2] - Run the engine until the air brake system reaches operating pressure.
CAUTION:
Pressure at the coupling end must be between 790 and 830 kPa (7.9 and
8.3 bar; 115 and 120 psi).

Check Dual-Line Brake
LEGEND:
B KJD10194-2 Hose
C KJD10194-4 Coupling End (Yellow)
→NOTE:
Before bleeding the brakes, see Bleeding the Brakes (Power-Fill Brakes and
MFWD and Disk Brake) orBleeding the Brakes (Brake Valve without Power-
Fill)in Section 60, Group 20.
[1] - Make sure that the hydraulic brakes and the trailer control valve are bled correctly and
that there are no leaks anywhere in the brake system.
[2] -
Pressure test kit
KJD10194
Pressure testing (dual-line brakes)
Connect the pressure test kit to the coupling end (yellow).
[4] - With neither footbrake nor handbrake applied, the pressure reading at the yellow
coupling end must be zero.
[5] - Apply foot brakes and read pressure.
With brake pedal fully depressed, pressure at the yellow coupling end must be between 650
and 810 kPa (6.5 and 8.1 bar; 94 and 118 psi).
[6] - Release foot brakes. No pressure should be registered any more.

[7] - Apply handbrake and read pressure.

With handbrake applied, pressure at yellow coupling end must be between 650 and 810 kPa
(6.5 and 8.1 bar; 94 and 118 psi).

Checking the Single-Line Brakes
LEGEND:
B KJD10194-2 hose
C KJD10194-3 coupler (black)
→NOTE:
[2] - Connect pressure test kit KJD10194 to single-line air brake coupler (black).
With handbrake and foot brakes not applied, pressure at coupler (black) should be between
500 and 540 kPa (5.0 and 5.4 bar; 73 and 78 psi).
[5] - Apply foot brakes and read pressure.With the brake pedal depressed fully, the pressure
reading at the black coupling end should be zero.
[6] - Release foot brakes. Now pressure should once again be between 500 and 540 kPa (5.0
and 5.4 bar; 73 and 78 psi).
[7] - Apply handbrake and read pressure.With the handbrake applied, the pressure reading
at the black coupling end should also be zero.
Adjusting the Handbrake (with Air Brake System)

Section 60 - STEERING AND BRAKES Group 40: AutoTrac
Apply the handbrake.
Adjust linkage (A) until the prescribed pressure is reached.
IMPORTANT:
Other checks, such as measuring the braking force and the variability of
the trailer control valve, must be carried out at properly equipped
workshops.
Some of these checks are included in the regular vehicle inspections

prescribed by law.
Exceptions may apply in certain countries.

Group 40 - AutoTrac
Steering and Brakes - AutoTrac, Summary of
References
Steering and Brakes - AutoTrac, Summary of References
Remove and Install Steering Control Valve (Y49)
Remove and Install Steering Wheel Position Sensor (B138)
Specifications
Screw (E) at steering control valve (Y49) Torque 40 N˙m
29.5 lb-ft

Remove and Install Steering Control Valve (Y49)

[1] -
LEGEND:
A Connector
B Steering control valve (Y49)
Pull off connector (A).
[2] - Disconnect all hydraulic lines from steering control valve (B).

[3] -
LEGEND:
A Shims
B Washer
C Screw
D Steering control valve (Y49)
E Screw
F Bracket
Remove screws (E) and steering control valve (Y49).
[4] - Re-install in reverse order. For standard torques:
See Metric Bolt and Screw Torque Values in Section 10.
IMPORTANT:
Exception:
Screw (E) at steering control valve (Y49) Torque 40 N˙m
29.5 lb-ft
Next step:
A new steering control valve (Y49) must be calibrated.
SeeSSU - Calibration and Input Addressesin Section 245 of the relevant Diagnostic Manual.

Remove and Install Steering Wheel Position Sensor

(B138)
Preliminary work:
Remove covers, seeSteering Unit Removalin Section 60.
[1] -
LEGEND:
A Connectors
B Screws
C Steering column
Disconnect connectors (A), take out screws (B) and remove steering column (C).
[2] -
LEGEND:
A Cable strap
B Screws
C Metal panel
Cut through cable binder (A), take out screws (B) and remove metal panel (C).

[3] -
→NOTE:
When installing, make sure the cables are routed as shown for "removal",
otherwise the steering will not operate properly.
Re-install in reverse order. Calibration is not necessary. See below for details of how to
assemble the steering column.
LEGEND:
1 Snap ring
2 Turn-signal return guide

HYDRAULIC SYSTEM (g) by Belgreen
3 Steering column
4 Lever
5 Nut
6 Clips
7 Washer
8 Screw
9 Screw
10 Washer
11 Collar
12 Linkage
13 Pin
14 Gas-filled strut
15 Handle
16 B138 - Steering Wheel Position Sensor
17 Collar
18 Clutch
Next step:
SeeSteering Unit Installationin Section 60.

Section 70 - HYDRAULIC SYSTEM

Table of contents
Group 05 - Controls ................................................................................................................... 1
Hydraulic System — Controls (Summary of References) ....................................................... 1
Specifications ......................................................................................................................... 1
Selective Control Valves — Removing and Installing the Actuating Elements ....................... 3
Selective Control Valves - Adjust the Bowden Cable .............................................................. 7
Remove and Install Multifunction Lever (Shift Console) ......................................................... 8
Remove and Install the Multifunction Lever (Floor Plate) ..................................................... 10
Adjust the Multifunction Lever (Shift Console) ..................................................................... 12
Adjust the Multifunction Lever (Floor Plate) ......................................................................... 14
Group 10 - Hydraulic Pump and Charge Oil Pump ............................................................. 16
Other Material ...................................................................................................................... 16
Specifications ....................................................................................................................... 16
Removing and Installing the Charge Pump .......................................................................... 17
Reconditioning the Charge Pump ......................................................................................... 19
Charge Pump - Checking the Lube Oil Valve ........................................................................ 22
Hydraulic Oil Reservoir — Restrictor .................................................................................... 22
Hydraulic Pump — Removing and Installing the Pressure-and-Flow Controller .................... 24
Hydraulic Pump — Reconditioning the Pressure-and-Flow Controller .................................. 26
Remove and Install Hydraulic Pump ..................................................................................... 28
Reconditioning the Hydraulic Pump ..................................................................................... 32
Group 15 - Valves .................................................................................................................... 42
Repairing the Hydraulic System Valves — Summary of References .................................... 42
Special Tools ........................................................................................................................ 42
Special Tools (Dealer Fabricated) ......................................................................................... 43
Hydraulic System — General Instructions on Safety and Repair .......................................... 46
Direct Control of Rockshaft .................................................................................................. 47
Hitch Valve (Narrow Version) - Remove and Install the Spacer Housing .............................. 49
Removing the Rockshaft Valve ............................................................................................ 52
Recondition the Rockshaft Valve .......................................................................................... 53
Rockshaft Valve — Depth to Which Raising and Lowering Valves are Screwed In ............... 63
Rockshaft Valve — Removing and Installing the Stepper Motor ........................................... 64
Rockshaft Valve — Centering the Stepper Motor ................................................................. 65
Installing the Rockshaft Valve .............................................................................................. 67
Removing the Main Block ..................................................................................................... 69
Repairing the Main Block ..................................................................................................... 71
Installing the Main Block ...................................................................................................... 75
Repairing the Hydraulic Oil Filter ......................................................................................... 76
Power Beyond Valve—Exploded View .................................................................................. 80
Connecting the Power Beyond Valve ................................................................................... 82
Converting the Power Beyond Valve .................................................................................... 86
Group 20 - Hitch ....................................................................................................................... 88
Other Material ...................................................................................................................... 88
Hitch - Remove and Install the Electronic Control Unit ........................................................ 88
Hitch — Removing and installing the position sensor and toothed segment ....................... 89

Hitch — Removing and installing the lift shaft ..................................................................... 93

Hitch — Removing the lift shaft cylinders ............................................................................ 97
Hitch — Repairing the lift cylinder ....................................................................................... 98
Hitch — Installing the lift cylinders ..................................................................................... 101
Hitch — Removing and installing the draft load potentiometer and draft link support ...... 103
Group 25 - Selective Control Valves and Couplers .......................................................... 108
Repairing the Selective Control Valves and Couplers — Summary of References ............. 108
Special Tools ...................................................................................................................... 109
Special Tools (Dealer Fabricated) ....................................................................................... 109
Other Material .................................................................................................................... 110
Reconditioning the Selective Control Valves and Couplers — General Instructions on Safety
and Reconditioning ..................................................................................................... 114
SCV Identification ............................................................................................................... 116
Install Shuttle Valves .......................................................................................................... 118
Series 300 Selective Control Valves (Electrically Actuated) — Removing and Installing the
Stepper Motors ............................................................................................................ 122
Removing the Selective Control Valves ............................................................................. 125
Series 100 selective control valves — Repairing ................................................................ 128
Series 200/300 selective control valves (mechanically actuated) — Replacing the control
knobs .......................................................................................................................... 133
Series 200/300 selective control valves (mechanically actuated) — Inspecting the check
valves .......................................................................................................................... 135
Series 200/300 selective control valves (mechanically actuated) — Inspecting the inlet check
valve and metering valve ............................................................................................ 136
Series 200 selective control valves — Repairing ................................................................ 137
Series 300 selective control valves (mechan actuated) — Inspecting the pressure
compensator valve ...................................................................................................... 144
Series 300 selective control valves (mechan actuated) — Repairing ................................. 146
Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Check Valves
..................................................................................................................................... 155
Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Inlet Check Valve
..................................................................................................................................... 155
Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Pressure
Compensator Valve ..................................................................................................... 156
Series 300 Selective Control Valves (Electrically Actuated) — Reconditioning .................. 158
Installing the Selective Control Valves ............................................................................... 164
Selective Control Valves — Installing the Endplate ............................................................ 168
Selective Control Valves — Reconditioning the Couplers ................................................... 175
Group 30 - Independent Selective Control Valve ............................................................. 180
Reconditioning Independent Control Valves — Summary of References ........................... 180
Other Material .................................................................................................................... 180
Specifications ..................................................................................................................... 181
Removing the Independent Control Valve (M-ICV) ............................................................. 183
Reconditioning the Independent Control Valve (M-ICV) ..................................................... 185
Independent Control Valves — Reconditioning the Inlet Plate ........................................... 201
Assembling the Independent Control Valve (M-ICV) ........................................................... 202
Installing the Independent Control Valve (M-ICV) ............................................................... 205
Independent Control Valve (E-ICV) — Removing and Installing the Stepper Motors .......... 207
Removing the Independent Control Valve (E-ICV) .............................................................. 212

Reconditioning the Independent Control Valve (E-ICV) ...................................................... 214

Assembling the Independent Control Valve (E-ICV) ........................................................... 223
Installing the Independent Control Valve (E-ICV) ............................................................... 226

Section 70 - HYDRAULIC SYSTEM Group 05: Controls
Group 05 - Controls
Hydraulic System — Controls (Summary of
References)
Removal, installation and repair of selective control valve and rockshaft controls are dealt
with at the following references.
Selective control valves (levers and bowden cables):
”Selective Control Valves — Removing and Installing the Actuating Elements”in this
Group
”Selective Control Valves — Adjusting the Bowden Cable” in this Group
”Remove and Install the Multifunction Lever (Shift Console)”in this Group
”Remove and Install the Multifunction Lever (Floor Plate)”in this Group
”Adjust the Multifunction Lever (Shift Console)” in this Group
”Adjust the Multifunction Lever (Floor Plate)”in this Group
Selective control valves (controls and switches)
”Electrical Activators for Selective Control Valves (E-SCV)” in Section 40, Group 25
”Electrical Activators for Independent Control Valves (E-ICV)” in Section 40, Group 25
Rockshaft (controls and switches):
”Rockshaft Control” in Section 40, Group 25

”Replacing the Rockshaft′s Remote Control Switch” in Section 40, Group 25
Specifications
Control lever to bearing lever:

Cap screw Torque 5 N˙m
3.7 lb-ft
Bowden cable on SCV:

Sleeve to flange Torque 50 N˙m
37 lb-ft
Lock nut to sleeve Torque 50 N˙m
37 lb-ft
Bowden cable on independent SCV:

37 lb-ft

37 lb-ft
Lock nut to bowden cable Torque 20 N˙m
15 lb-ft

Selective Control Valves — Removing and Installing

the Actuating Elements
LEGEND:
A Sleeve
B Lock nut
C Cable binder
D SCV unit
E Bowden cable
F Grommet
G Clip
H Retainer
K Washer
L Bushing
[ If necessary ]
M Console
N Plastic bushing (3 used)
O Lever, 1st SCV
P Lever, 1nd SCV
Q Lever, 3rd SCV
R Handle
S Cap
T O-ring
U O-ring
V Cap screw
Removing the actuating elements
[1] - Remove the side-panel from the console.

[2] - Check the actuating elements for signs of damage, and remove and replace damaged
parts as necessary.
Installing the actuating elements
[1] - Install actuating elements using illustration as a guide.

[2] - Tighten cap screws (V).
Cap screw Torque 5 N˙m
3.7 lb-ft
[3] - Insert the bowden cable for the 1st SCV in the front hole of lever (O) and the cable for
the 3rd SCV in the rear hole in lever (Q) (viewed in direction of travel).
[4] - Lay out the bowden cable so that it is not bent and none of the moving parts come into
contact with each other. If necessary, secure the cable with a binder.
[5] -

LEGEND:
A Valve spool
B O-ring
C Flange
D O-ring
E Sleeve
F O-ring

G Lock nut
H Bowden cable
Put O-ring (D) on flange (C) of the SCV unit.
[6] - Engage bowden cable (H) in spool (A).
[7] - Tighten sleeve (E).
37 lb-ft
[8] - Tighten lock nut (G).

37 lb-ft
[9] - Adjust the bowden cable. See “Selective Control Valves — Adjusting the Bowden Cable”
in this Group.

Selective Control Valves - Adjust the Bowden Cable
[1] - The spool of the SCV must be in its neutral position.

[2] - Remove the side panel from the console and take out retaining pin (B).
[3] - Move control lever to neutral and lock it there with sliding lock (A).
[4] - Turn yoke (C) until the bore is aligned with the bore in the control lever, and make sure
that it is screwed in sufficiently far, i.e. by at least 6 mm (0.236 in.).
[5] - Install retaining pin, taking care to insert it in the correct bore in the 1st and 3rd levers.
On the 1st lever, insert the retaining pin in the front hole (seen in direction of travel), and on
the 3rd lever, insert the pin in the rearmost hole.
[6] - Tighten the locknut on the yoke.
[7] - Perform an operational check.
[8] - Put the side-panel back on the console.

Remove and Install Multifunction Lever (Shift

Console)
Installing the cable on an independent control valve (ICV)
Installing the cable on 3rd and 4th SCVs

Removing the multifunction lever
[1] - Remove the side panel from the console.

[2] - Check the multifunction lever and actuating elements for signs of damage, and remove
and replace damaged parts as necessary.
Installing the multi-function lever
[1] - From above, install the multifunction lever element in the console.
[2] - Engage and secure the bowden cables. Make sure that they are not crossed over, do
not chafe and are not bent.
[3] - Install fillister-head screws (A).
[4] - Install cap screws (B).
[5] - Make sure that the components of the multifunction element do not touch the moving
parts of the linkage.
[6] - Before connecting the bowden cables (H) to the selective control valves, move the
locking collar (C) on the multifunction lever to the unlocked position (four arrows).
[7] - Engage bowden cables in the spools of the selective control valves.
[8] - Tighten sleeve (E).
37 lb-ft
[9] - Tighten lock nut (G).

37 lb-ft
[10] - Adjust the multifunction lever. See ”Adjusting the Multifunction Lever (Shift Console)”
in this Group.

Remove and Install the Multifunction Lever (Floor

Plate)
Removing the multifunction lever
[1] - Move multifunction lever (A) to neutral position and lock it using lever (B).
[2] - Remove panel (C) and multifunction lever.
[3] - Remove screws (D), loosen screw (E) and remove the console.
[4] - Remove side panels from console.

[5] - Mark electrical connectors (if equipped) and disconnect them.

[6] -
→NOTE:
Mark bowden cables at selective control valve.
Slacken off lock nut (F), remove sleeve (G) from flange (H) and disconnect bowden cables.
[7] - Remove the multifunction lever.
Installing the multifunction lever
[1] - Make sure to follow the instructions below when installing the multifunction lever.
[3] - Make sure that the bowden cables are not crossed over, do not chafe and are not bent.
[4] - Note the marks before connecting the bowden cables and make sure that the spools of
the selective control valve are in neutral position.
[5] - Check O-ring at flange (H) for damage. Replace, if necessary.
[6] - Install sleeve (G) to flange (H) and tighten.
37 lb-ft
[7] - Tighten lock nut (F).

37 lb-ft
[8] - Perform an operational check.

[9] - Adjust the multifunction lever. See”Adjust the Multifunction Lever (Floor Plate)”in this
Group.

Adjust the Multifunction Lever (Shift Console)
R.h. bowden cable shown
[1] - Remove the side panel from the console.

[2] - First slacken off the locknuts, then adjust the left (inner) bowden cable (viewed in
direction of travel) at long adjusting nut (A) so that locking collar (B) can be turned clockwise
from the unlocked operating position (E) to the next operating position (F). Make sure that
locking cam (C) is now in the detent groove of the l.h. bowden cable.
The multifunction lever is free to move fore-and-aft (F), but left/right motion (G) is locked out.
[3] - First slacken off the locknuts, then adjust the right (outer) bowden cable (viewed in
direction of travel) at long adjusting nut (A) so that locking collar (B) can be turned clockwise
from the operating position (F) to the next operating position (G). Make sure that locking cam
(C) is now in detent groove (D) of the r.h. bowden cable.
The multifunction lever is free to move left and right (G), but fore-and-aft motion (F) is locked
out.
[4] - Tighten the locknuts at the bowden cable adjusting nuts (A).
The adjustment is correct provided the multifunction lever does not move when the locking
collar is turned, and the locking collar can be turned smoothly.
IMPORTANT:
The bowden cables and lever must move freely, and must not chafe.
[5] - Carry out a functional check.
CAUTION:
If front loader is equipped, make sure the multifunction lever operates in
accordance with the front loader functions.
[6] - Put the side-panel back on the console.

Adjust the Multifunction Lever (Floor Plate)
[2] - Loosen lock nuts (C) and (E).
[3] - Use threaded sleeve (D) to adjust bowden cable so that there is neither free play nor
preload at multifunction lever (A).
[4] - Tighten lock nut (E).
37 lb-ft
[5] - Tighten lock nut (C).

Lock nut to bowden cable Torque 20 N˙m
15 lb-ft
[6] - Unlock multifunction lever and check adjustment.
The adjustment is correct when the SCV can be operated without any play and the
multifunction lever (A) can be locked and unlocked by means of lever (B).

Section 70 - HYDRAULIC SYSTEM Group 10: Hydraulic Pump and Charge Oil Pump
[7] - Carry out a functional check.
CAUTION:
If front loader is equipped, make sure the multifunction lever operates in
accordance with the front loader functions.

Group 10 - Hydraulic Pump and Charge Oil Pump

Other Material
Number Name Use
• L41475 (us) Attaching the screw plug to the variable piston on
Thread lock
• 243 LOCTITE ™ (loctite) the hydraulic pump
Specifications
Charge pump:
Pump to differential housing, hex. socket screws Torque 100 N˙m
75 lb-ft
Pump cover to housing, hex. socket screw Torque 20 N˙m
15 lb-ft
Lube oil valve spring Length 160 mm
6.3 in.
Hydraulic pump:
Pressure-and-flow controller to pump housing, hex. socket screws Torque 12 N˙m
106 lb-in.
Hydraulic pump to charge pump, cap screws Torque 100 N˙m
75 lb-ft
Variable piston, screw plug Torque 190 N˙m
140 lb-ft
Connecting plate to pump housing, hex. socket screws Torque 58 N˙m
43 lb-ft

Removing and Installing the Charge Pump
Retaining clip (arrow)
Removing the charge pump
→NOTE:
Remove the hydraulic pump. See “Removing and Installing the Hydraulic
Pump” in this Group.
[1] - Disconnect the oil lines leading to the charge pump and seal the openings with plugs.
[2] - Take out the four hex. socket screws (A).
[3] - Take off the charge pump.
Installing the charge pump

[1] - Put new flange seal in position and apply oil to the four hex. socket screws (A), then
tighten them evenly.
Hex. socket screws Torque 100 N˙m
(75 lb-ft)
[2] -
IMPORTANT:
seated correctly. The bent ends of the clip must be almost touching. If they
are not, the coupler may come adrift.
Connect the oil lines and hoses.

→NOTE:
Once the charge pump has been repaired, change the hydraulic oil filter
and clean the filter screen.
→NOTE:
Install the hydraulic pump. See “Removing and Installing the Hydraulic
Pump” in this Group.

Reconditioning the Charge Pump
LEGEND:
A Metal seal
B Cover
C Gear set
D O-ring
E Housing
F Hex. socket screw
G Seal ring
H Back-up ring
I Valve spool
J Spring
K Seal ring
L Plug
M O-ring

Disassembling the charge pump
→NOTE:
Remove the charge pump. See “Removing and Installing the Charge Pump”
in this Group.
[1] - Disassemble the charge pump using the illustration as a guide.

[2] - Clean all parts, inspect them for wear or damage, and replace as necessary.
Assembling the charge pump
[1] - Install toothed ring. The chamfered edge (see arrow) of toothed ring (A) must face
towards pump housing (B).
[2] -
Replace back-up ring (A).

[3] -
Use a new set of seals. Insert O-ring (A) into groove in pump housing. Make sure pump cover
(B) is correctly positioned on pump housing.
[4] -
Put a new seal ring (D) on each of the two hex. socket screws (C), and tighten the screws.
Hex. socket screw Torque 20 N˙m
(15 lb-ft)
[5] - Check the lube oil valve. See “Charge Pump - Checking the Lube Oil Valve” in this
Group.

Charge Pump - Checking the Lube Oil Valve
LEGEND:
A Plug
B Seal ring
C Spring
D Valve spool
→NOTE:
The valve can be removed without taking off the charge pump.
[1] - Remove the lube oil valve.

[2] - Clean all parts, inspect them for wear or damage, and replace as necessary.
[3] - Check that the 0.8 mm (0.03 in.) dia. bore in valve spool (D) is clear.
[4] - Check that the valve spool can move freely in the housing bore.
[5] - Check the length of spring (C).
Spring Length 160 mm
(6.3 in.)
[6] - Re-install the lube oil valve.
→NOTE:
Install the charge pump. See “Removing and Installing the Charge Pump”
in this Group.

Hydraulic Oil Reservoir — Restrictor
Clean the restrictor (A) in the bleed connection.

Hydraulic Pump — Removing and Installing the

Pressure-and-Flow Controller
Removing the controller

CAUTION:

injury from high-pressure leaks by relieving system pressure before
disconnecting the hydraulic lines, fittings or connections.
IMPORTANT:
Absolute cleanliness is essential.
[1] - Carefully clean the area around the hydraulic pump and its controller (A).
[2] - Disconnect the LS pressure line (B) that leads to the controller.
[3] - Take out hex. socket screws (C), and lift off the controller.
Installing the controller
[1] - Inspect the controller for signs of damage before you install it.
[2] -
→NOTE:
Orifice (D) is not screwed in. It is retained in the bore by an O-ring.
Check that orifice (D) is installed in the correct position. The slit in the orifice must be in the
position shown in the illustration.
[3] - Install controller on pump housing using a new seal. Install the hex. socket screws, and
tighten them evenly.
106 lb-in.
[4] - Install the LS pressure line (B).

[5] - Check the system pressure. See reference "270-15-050 , Hydraulic Pump — Testing and
Adjusting the System Pressure (PFC Hydraulic System)".

Hydraulic Pump — Reconditioning the Pressure-and-

Flow Controller
LEGEND:
1 Adjusting screw
2 O-ring
3 Plate
4 Spring
5 Valve seat
6 Gasket
7 Orifice
8 O-ring
9 Pressure-regulating valve
10 Sealing ring (2 used)
11 Flow control valve
13 Valve seat
14 Spring
15 Plate
16 O-ring
17 Sealing ring (2 used)

18 Lock nut
19 Sealing ring
20 O-ring (3 used)
21 Pressure controller (earlier version)
Disassembling the controller
IMPORTANT:
→NOTE:
Remove the controller. See “Hydraulic Pump — Removing and Installing the
Pressure-and-Flow Controller” in this Group.
[1] - Measure and note dimension (X) at the adjusting screws (1).
[2] - Disassemble the controller.
[3] - Clean the various components and inspect them for signs of wear or damage.
[4] - Pressure-regulating valve (9) and flow control valve (11) must not stick in the bores.
[5] - If there is excessive wear, if the valves are stiff or if anything is damaged, replace the
entire controller with a new one.
Assembling the controller
[1] - Coat the various components with clean hydraulic oil to provide initial lubrication and
prevent seizure.
[2] - Assemble parts with the controller housing in a vertical position to prevent
misalignment of the valve seats.
[3] - Align the slit in orifice (7) vertically.
[4] - Screw in adjusting screws (1) until dimension (X; the dimension noted during
disassembly) is achieved.
[5] - Install the controller. See reference “Hydraulic Pump — Removing and Installing the

Remove and Install Hydraulic Pump

Remove hydraulic pump
LEGEND:
A Cap screws
B Suction port (oil reservoir)
C Leak-off oil line
D Pressure line, to main block
E LS pressure line
F Pressure line, via damper to power brake valve
[ if equipped ]
G Pressure line, to front-wheel drive axle with TLS

[ if equipped ]

CAUTION:

IMPORTANT:
→NOTE:
Tilt up the cab (see reference ”Tipping Up the Operator′s Cab” , Section 90,
Group 00.
[1] - Take off all the oil lines that lead to the hydraulic pump and oil reservoir. Seal all the
openings with plugs.
[2] - Take out the two cap screws (A).
[3] - Remove the hydraulic pump.
Install Hydraulic Pump

LEGEND:
C Leak-off oil line
H O-ring
I Leak-off oil line fitting
[1] - Install a new O-ring (H) on the hydraulic pump′s flange.

[2] - Install the hydraulic pump on the tractor.
[3] - Install the two cap screws (A).
75 lb-ft
[4] -
IMPORTANT:
Remember to fill the hydraulic pump with clean hydraulic oil!
Carefully add hydraulic oil at fitting (I) of leak-off oil line (C).
Hydraulic oil with new hydraulic pump, approx. Capacity 0.45 L
27.4 cu in.
[5] -
→NOTE:
Clean the restrictor in the bleed connection of the hydraulic oil reservoir.
Connect up the oil lines and install the oil reservoir.

[6] -
→NOTE:
Tilt the cab down (see ”Tipping Down the Operator′s Cab” , Section 90,
Group 00.
After starting the engine, run it for at least 10 seconds at slow idle to avoid damage to the
hydraulic pump
→NOTE:
Check the system pressure (see ”Reference 270-15-050 , Hydraulic Pump —

Testing and Adjusting the System Pressure (PFC Hydraulic System)”.

Reconditioning the Hydraulic Pump
Exploded view of 25 and 41 cm 3 (1.5 and 2.5 cu in.) hydraulic pumps
LEGEND:
2 Connecting plate
3 O-ring
4 Cylindrical pin
5 Bearing cup
6 Bearing cone
7 Distributor plate
8 Shim
9 Snap ring
10 Cylinder block spring
11 Back-up washer
12 Cylinder block
13 Pressure pin (3 used)
14 Spherical washer
15 Shoe plate
16 Piston and shoe assembly (9 used)
17 Swashplate
18 Bearing halves, swashplate (2 used)
19 Pump shaft
20 Bearing cone
21 Bearing cup
22 Pump housing
24 Seal ring
25 Snap ring
26 O-Ring, hydraulic pump flange
27 O-ring
28 Swashplate control spring
29 Piston rod
30 Swashplate piston
31 O-ring
32 Plug WITH circular groove, 25 cm 3 (1.5 cu in.) pump
33 Plug WITHOUT circular groove, 41 cm 3 (2.5 cu in.) pump
34 Gasket
35 Pressure-and-flow controller
Disassembling the hydraulic pump
IMPORTANT:
Absolute cleanliness is essential when working on hydraulic components.
→NOTE:
Remove the hydraulic pump. See reference “Removing and Installing the
Hydraulic Pump” in this Group.
→NOTE:
Recondition the controller. See “Hydraulic Pump — Reconditioning the


[1] - Disassemble the hydraulic pump. Refer to the drawing, and comply with the following
points.
[2] - Before removing the connecting plate (2) and pump housing (22), mark where they
stand relative to one another.
[3] - When taking off the connecting plate (2), distributor plate (7) may stick; if it does, hold
it securely so that it does fall off.
[4] - Before removing the cylinder block assembly, turn the pump so that it is lying
horizontally. Take care when removing the cylinder block assembly from the pump housing.
Make sure that it does not fall apart.
[5] -
CAUTION:
Do NOT disassemble parts 9 to 13. Spring (10) is under high tension and
can cause possible injury if the snap ring in the cylinder block is removed.
→NOTE:
No specific piston and bore orientation is required since pistons and bores
are not selectively fitted. Pumps with high hourly usage may have
developed wear patterns and replacing pistons in the original bores, if
possible, is recommended.
Inspect parts (14) to (16). If the pistons are discolored or show other signs of damage, the
entire hydraulic pump should be replaced.
Assembling the hydraulic pump
[1] - Clean all the various parts and inspect them carefully for signs of excessive wear,
discoloration, scoring and other types of damage.
If the distributor plate, pump shaft, taper roller bearing, cylinder block assembly or
swashplate are damaged, the entire hydraulic pump must be replaced with a new one.
The pistons and shoes must not have axial play in relation to each other.
If the pressure pins leave impressions on the spherical washer, the spherical washer
can still be re-used if it is turned radially.
Replace all the seal rings with new ones.
Before assembling the various parts, coat them with clean hydraulic oil.

[2] -
Insert the pump shaft and its bearings.

[3] -
→NOTE:
To make the swashplate′s bearing halves stick, apply clean grease to them.
Install bearing halves (A).

[4] -
→NOTE:
To make the swashplate control spring stick, apply clean grease to it.

Install spring (A). Make sure the spring is seated correctly.

[5] -
Install swashplate (A). Make sure the swashplate control spring is seated correctly.
[6] -
IMPORTANT:
Make sure the piston rod is seated correctly in the swashplate (see
enlargement in illustration).
Install piston rod (A). When inserting the piston rod, tilt is slightly in its seat so that it “clicks”
into place properly.

[7] -
Install the variable piston. Make sure the piston rod is seated correctly.
[8] -
Place a new O-ring on the screw plug. Coat the thread with L41475 (LOCTITE ™ 243) thread
lock and screw in the plug.
Plug Torque 190 N˙m
140 lb-ft
Number Name Use

• L41475 (us) Attaching the screw plug to the variable piston on
Thread lock
• 243 LOCTITE ™ (loctite) the hydraulic pump

[9] -
Put spherical washer (C) on the three pressure pins in cylinder block (D), and align the teeth.
Insert pistons (A) and shoe plate (B) into the cylinder block.
[10] -
Turn the hydraulic pump until it is lying horizontally, and insert the cylinder block assembly,
taking care that it does not fall apart.
[11] -
Install a shim.

[12] -
Install the taper roller bearing cone.

[13] -
Install a new O-ring (A).

[14] -
→NOTE:
To make the distributor plate and O-ring stick, apply clean grease to them.
Install the distributor plate on the connecting plate. Align groove (A) to dowel pin (B) on the
connecting plate.

[15] - Install a new O-ring (C).

[16] -
IMPORTANT:
Align the connecting plate and pump housing with the marks made before
they were removed. The pressure-oil bores in the connecting plate and
pump housing (see arrows) must be in alignment.
Install the connecting plate and distributor plate on the pump housing. Hold distributor plate
(A) in place so that it does not fall off.
[17] -
Install hex. socket screws (A).

43 lb-ft
[18] -
IMPORTANT:
Put adhesive tape on the pump shaft spline to protect the shaft sealing
ring from damage during installation.

Section 70 - HYDRAULIC SYSTEM Group 15: Valves
Apply clean grease to the sealing lip on a new shaft sealing ring (A). Carefully install the
sealing ring until the groove for the snap ring is revealed.
[19] -
Install the snap ring. Make sure that the snap ring is seated correctly in its groove.
[20] - Install the controller. See “Hydraulic Pump — Removing and Installing the Pressure-
and-Flow Controller” in this Group.
[21] - Install the hydraulic pump. See “Removing and Installing the Hydraulic Pump” in this
Group.
[22] -
→NOTE:
Excessive wear, deep scoring and discoloration of the various components
are usually caused by contaminated hydraulic oil (clogged oil filters, solids
in the oil), or by incorrect viscosity resulting in poor lubricity.
Check the hydraulic oil and oil filters for plugging and contamination. If necessary, change
the hydraulic oil and oil filters, and clean the primary filter screen.

Group 15 - Valves
Repairing the Hydraulic System Valves — Summary
of References
Repair of individual valves in the hydraulic system is dealt with at the following references.
Rockshaft valve, wide and narrow versions:
”Direct Control of Rockshaft”

”Rockshaft Valve (Narrow Version) — Removing and Installing the Spacer Housing”
”Removing the Rockshaft Valve”
”Repairing the Rockshaft Valve”
”Rockshaft Valve — Depth to which Raising and Lowering Valves are Screwed In”
”Rockshaft Valve — Removing and Installing the Stepper Motor”
”Rockshaft Valve — Centering the Stepper Motor”
”Installing the Rockshaft Valve”
Power beyond valve:
”Power Beyond Valve — Exploded View”

”Connecting the Power Beyond Valve”
”Converting the Power Beyond Valve”
Main block with priority valve:
”Removing the Main Block”

”Repairing the Main Block”
”Installing the Main Block”
Hydraulic oil filter:
”Repairing the Hydraulic Oil Filter”
Lube oil valve:
”Charge Pump - Checking the Lube Oil Valve” in Section 70, Group 10.
Special Tools

→NOTE:

Catalog or from the European Microfiche Tool Catalog (MTC).
Relief valve extractor
KJD10166
Removing pressure relief valve at rockshaft valve (wide version).
Special Tools (Dealer Fabricated)

Also refer to Section 99.
Socket wrench insert for removing the endplates from the SCV block or rockshaft valve
Take a standard, 17 mm (11/16 in.) across flats, hex. insert with a 1/2 in. square drive socket.
Turn the outside diameter of the hex. end until it is 22.5 mm (0.9 in.) across, to a distance of
13 mm (0.5 in.).

Rockshaft valve (wide version):

Valve spring Free length approx. 40 mm
approx. 1.57 in.
1.39 in. at 1.0 to 1.2 lb
Valve plug Torque 75 N˙m
55 lb-ft
Pressure relief valve Torque 60 to 68 N˙m
44 to 50 lb-ft
Valve sleeve of raising and lowering valves Torque 90 N˙m
66 lb-ft
Ball bearing to valve spool of raising and lowering valves Clearance 0.1 to 0.2 mm
0.004 to 0.008 in.
Stepper motor to rockshaft valve, hex. socket screws Torque 10 N˙m
8.5 lb-ft
Endplate to rockshaft valve, hex. nuts Torque 35 N˙m
26 lb-ft
Plug for extra connections Torque 75 N˙m
55 lb-ft
Rockshaft valve (narrow version):

Valve spring Free length approx. 15 mm
approx. 0.59 in.
0.43 in. at 0.45 to 0.90 lb
Valve plug Torque 75 N˙m
55 lb-ft
44 to 50 lb-ft
Raising or lowering valve Torque 90 N˙m
66 lb-ft
Ball bearing to valve spool of raising and lowering valves Clearance 0.1 to 0.2 mm
0.004 to 0.008 in.
Stepper motor to rockshaft valve, hex. socket screws Torque 10 N˙m
8.5 lb-ft
26 lb-ft
Plug for extra connections Torque 75 N˙m

55 lb-ft
Main block:
Valve spring Free length approx. 12.7 mm
approx. 0.5 in.
Test length 8.5 mm at 13.7 to 16.4 N
0.34 in. at 3.1 to 3.7 lb
Priority valve, spring on valve spool Free length approx. 59.15 mm
approx. 2.33 in.
Test length 42 mm at 254.9 N
1.65 in. at 57.3 lb
Main block to bracket, hex. socket screws Torque 100 N˙m
75 lb-ft
Main block bracket to rockshaft bearing support, hex. nuts and hex. socket
Torque 100 N˙m
screw
75 lb-ft
Hydraulic oil filter:

Filter housing to filter head (AutoPowr/IVT transmission) Torque 30 N˙m
22 lb-ft

Hydraulic System — General Instructions on Safety

and Repair
CAUTION:
Besides the safety measures mentioned below, also comply with the safety
measures given at the beginning of this manual. See Safety Measures in
Section 05 of the Repair Manual.
CAUTION:
During tests that involve running the engine, always engage the park lock.
CAUTION:

CAUTION:
If tests are to be carried out on moving parts (e.g. hitch, front hitch, front
loader, front-wheel drive axle with TLS, hydraulically suspended cab,
hydraulic cylinders etc.), be aware of the potential for accidents. Never
work within the operating range of moving parts.
Absolute cleanliness is essential when working on the hydraulic system. Clean the area
around the valves thoroughly before removing or servicing components.
Replace all seals, O-rings and back-up rings.
Check springs for signs of wear, damage or deformation.
If necessary, use a 280 grit honing stone to rub impurities off surfaces.
Clean all components in a clean detergent, and dry them with compressed air. Also clean the
oil passages with compressed air. Do not use shop towels to dry parts.
Apply clean hydraulic oil to all internal parts before assembling them.
The valves must NOT jam in the housing bores.
The following, together with other information, can be found under Specifications in
Section 10 of the Repair Manual.
For all capacities, see Capacities .

For different types of oil, see Transmission and Hydraulic Oil .
For grease, seeLubricants.
For general information on tightening torques, see Unified Inch Bolt and Cap Screw
Torque Values .
For general information on tightening torques, see Metric Bolt and Cap Screw Torque
Values .
For general information on tightening torques, see Torques for Inch Fittings used in the
Hydraulic System .
For general information on tightening torques, see Torques for Metric Fittings used in
the Hydraulic System .
Direct Control of Rockshaft
CAUTION:
Comply with safety instructions. See “Hydraulic System — General

Instructions on Safety and Repair” in this Group.
In the event of electrical failure, the rockshaft can be controlled as follows:
[1] - Disconnect cable connection (A) at the stepper motor.

[2] - Remove cap (B), which protects the pin on the stepper motor.
[3] - Run the engine.

[4] - From the operator′s seat, use a screwdriver to press down the pin until it engages, then
turn slowly to the right for RAISING, or left for LOWERING.

Hitch Valve (Narrow Version) - Remove and Install

the Spacer Housing
CAUTION:
Comply with repair instructions. See Hydraulic System - General

Instructions on Safety and Repair in this Group.
Removal
[1] - Remove 3rd or 4th SCV (if equipped). See Removing the Selective Control Valves in
[2] - Remove hydraulic lines from spacer housing.
[3] - Remove hex. nuts (A) and endplate (B).
[4] -
IMPORTANT:
There is a valve plate between the hitch valve and the spacer housing. Be
careful not to lose it.
Take off spacer housing (C).

[5] - Clean all parts, inspect them for wear or damage and replace as necessary.

Installation
[1] - Coat O-ring (A) and valve plate (B) with grease, and install on hitch valve.
[2] -
Install spacer housing (A).

[3] - Install O-ring (B) on spacer housing.
[4] - Where applicable:
a. For installation of 3rd or 4th SCV, see Installing the Selective Control Valves in Section
70, Group 25.
b. For installation of special endplate, see Selective Control Valves - Installing the Endplate
[5] - Install O-rings (C) on endplate.

[6] -
LEGEND:
A Standard Endplate
B LS Line
C Return Line
D Pressure Line
E Adjusting Screw, LS Pressure Relief
Install endplate (A).
Endplate to Spacer Housing, Hex. Nuts Torque 35 N˙m
26 lb.-ft.
[7] - Insert O-rings into spacer housing fittings (face) and install hydraulic lines (B), (C) and
(D).
[8] - On spacer housings with adjustable LS pressure relief (see detail E), check or adjust LS
pressure relief.
SeeReference 270-15-095, Selective Control Valves - Adjusting the Spacer Housing (with
Extra Ports and Adjustable LS Pressure Relief) in the Operation and Tests manual.

Removing the Rockshaft Valve

[1] -
CAUTION:
Comply with repair instructions. See ”Hydraulic System — General
→NOTE:
The stepper motor and raising/lowering valves can be repaired without
removing the rockshaft valve.
Where applicable:
a. Remove 3rd or 4th SCV. See ”Removing the Selective Control Valves” in Section 70,
Group 25.
b. Remove the spacer housing. Refer to”Rockshaft Valve (Narrow Version) — Removing
and Installing the Spacer Housing”in this Group.
[2] - Remove protective cap and disconnect connector (A) of stepper motor.
[3] - Take off hydraulic lines (C).
[4] -
→NOTE:
The valve plates between the rockshaft valve and main block, or between
the rockshaft valve and spacer housing may drop out.
Take off hex. nuts (B) and remove endplate (D).

[5] - Remove the studs.
[6] - Repair the rockshaft valve. Refer to ”Reconditioning the Rockshaft Valve” in this Group.

Recondition the Rockshaft Valve
Rockshaft valve (wide version)
LEGEND:
1 O-ring
2 Stopper
3 Raising valve
4 Valve housing
5 Stepper motor
7 Washer (4 used)
8 Woodruff key
9 Ball bearing
10 Cam
11 Ball bearing
12 O-ring
13 Lowering valve
14 Special stopper
15 O-ring
16 Spring
17 Ball
18 Ball seat
19 Cover
20 Pressure relief valve
21 O-ring
22 Back-up ring
23 O-ring
24 O-ring
25 Shims
26 Protective cap
LEGEND:
A Ball
B Spring
C O-ring
D Stopper
E Ball seat
Wide version
[1] -
CAUTION:
Comply with repair instructions; see reference ”Hydraulic System —
General Instructions on Safety and Repair” in this Group.
→NOTE:
For removal of the rockshaft valve refer to ”Removing the Rockshaft Valve”
in this Group.
Remove and inspect the check valve.

a. Check spring (B).

Spring Free length approx. 40 mm
(approx. 1.57 in.)
(1.39 in. at 1.0 to 1.2 lb force)
b. Check ball seat (E).

c. Install ball (A) and spring (B).
d. Install a new O-ring (C) on stopper (D).
Stopper Torque 75 N˙m
(55 lb-ft)
[2] -
Remove and inspect pressure-relief valve (C).
a. Check the valve (C) (see Reference 270-15-131 , ”Rockshaft Valve (Wide Version) —
Checking the Pressure Relief Valve” in the ”Operation and Tests” manual).
b. Replace O-ring (A) and back-up ring (B) in rockshaft valve housing.

c.
If the valve housing remains in the bore, remove it using special tool KJD10166 (A).
Relief valve extractor
KJD10166
Removing pressure relief valve at rockshaft valve
d. Put a new O-ring (D) on pressure relief valve (C), and install the valve.
(44 to 50 lb-ft)
[3] -
LEGEND:

A Back-up ring
B O-ring
C Back-up ring (2 used)
D O-ring
E O-ring
F Back-up ring
G Valve sleeve
H Shims
I O-ring
Remove the raising and lowering valves, and inspect them.
IMPORTANT:
If any of shims (H) are replaced, they must be replaced with a shim of
the same thickness.
Replace O-rings and back-up rings at valve sleeve.
b.
LEGEND:
A Valve sleeve
B Valve seat
C Valve spool
D Washer (2 used)
E Spring
F O-ring
G Seal
H O-ring
I Back-up ring
J Stopper
K O-ring
Install valve sleeve (A).
Valve sleeve of raising and lowering valves Torque 90 N˙m
(66 lb-ft)

c. Check the various components for signs of damage.

d. Replace O-rings and back-up rings.
e. Assemble and install raising and lowering valves. Check depth to which they are
screwed in. See ”Rockshaft Valve — Depth to Which Raising and Lowering Valves are
Screwed In” in this Group.
Rockshaft valve (narrow version)
LEGEND:
1 Stopper
2 O-ring
3 Raising valve
4 Valve housing
5 Stepper motor
7 Washer (4 used)

8 Woodruff key
9 Ball bearing
10 Cam
11 Ball bearing
12 O-ring
13 Lowering valve
14 Special stopper
15 O-ring
16 Spring
17 Valve
18 Valve seat
19 Protective cap
20 Pressure relief valve
21 O-ring
22 Back-up ring
23 O-ring
24 O-ring
25 Shims
26 O-ring
27 O-ring
28 Back-up ring
29 Back-up ring
30 O-ring
31 Washer
32 Spring
33 Valve spool
34 O-ring
35 Valve sleeve
36 O-ring
37 Back-up ring
38 Protective cap
LEGEND:
A Valve
B Spring
C O-ring
D Stopper
E Valve seat
Narrow version
[1] -
CAUTION:
Comply with repair instructions; see reference ”Hydraulic System —
General Instructions on Safety and Repair” in this Group.
→NOTE:
For removal of the rockshaft valve refer to ”Removing the Rockshaft Valve”
in this Group.
Remove and inspect the check valve.
a. Check spring (B).

Spring Free length approx. 15 mm
approx. 0.59 in.
0.43 in. at 0.45 to 0.90 lb
b. Check valve seat (E).

c. Install new O-ring (C), spring (B) and valve (A) on stopper (B).
d. Put on stopper (D).
Stopper Torque 75 N˙m
55 lb-ft

[2] -
Remove the pressure relief valve (C).
a. Replace O-ring (A) and back-up ring (B).

b. Put a new O-ring (D) on pressure relief valve (C), and install the valve.
Pressure relief valve Torque 60 – 68 N˙m
44 – 50 lb-ft
[3] -
→NOTE:
Mark raising and lowering valves before removing them.
Remove the raising (A) and lowering valve (B), and inspect them.
IMPORTANT:
If any of shims (B) are replaced, they must be replaced with a shim of
the same thickness.

LEGEND:
A Sleeve
B Shims
C O-ring
D O-ring
E Back-up ring
F Back-up ring
G O-ring
H Washer
I Spring
J Valve spool
K O-ring
L Valve sleeve
M O-ring
N Back-up ring
Check the various components for signs of damage.
b. Replace O-rings and back-up rings.

→NOTE:
Raising and lowering valves are of the same design. If the valve is
installed as lowering valve, remove (or do not install) the O-ring (M)
and the back-up ring (N).
Assemble and install raising and lowering valves. Check depth to which they are
screwed in. See ”Rockshaft Valve — Depth to Which Raising and Lowering Valves are
Screwed In” in this Group.
Raising or lowering valve Torque 90 N˙m
66 lb-ft

Rockshaft Valve — Depth to Which Raising and

Lowering Valves are Screwed In
[1] - Remove stepper motor. See “Rockshaft Valve — Removing and Installing the Stepper
Motor” .
[2] - Check clearance between ball bearing (A) and valve spool (B) using a feeler gauge.
Ball bearing to valve spool Clearance 0.1 to 0.2 mm
(0.004 to 0.008 in.)
[3] - Add or remove shims under valve sleeves (C), if necessary. Thickness of shim packs on
l.h. and r.h. sides must be the same.
[4] - Make sure that valve sleeves (C) are tightened to the correct torque.
Valve sleeves Torque 90 N˙m
(66 lb-ft)
[5] - Install the stepper motor. See “Rockshaft Valve — Removing and Installing the Stepper
Motor” in this Group.

Rockshaft Valve — Removing and Installing the

Stepper Motor
CAUTION:
Comply with repair instructions. See “Hydraulic System — General

Removing the stepper motor
[1] -
Turn the ignition off.

[2] - Take electrical connection (A) off the stepper motor.
[3] - Take the four hex. socket screws (B) out of the flange, and lift off the stepper motor.
Installing the stepper motor

[1] -
Locate ball bearing (A) in valve housing.

[2] - Fit key (B) to shaft of stepper motor.
[3] - Locate ball bearing (C), cam (D) and O-ring (E). The step on cam (D) must face toward
the valve housing.
[4] - Locate stepper motor on valve housing and install the hex. socket screws.
(8.5 lb-ft)
[5] - Install the rockshaft valve. See “Installing the Rockshaft Valve” in this Group.
[6] - Center the rockshaft valve. See “Centering the Rockshaft Valve” in this Group.
[7] - Join the electrical connection for the stepper motor and put on the protective cap.
[8] - Recalibrate the rockshaft. See reference "245-BCU-002 , Calibration and Input
Addresses (Rockshaft Control)" in the “Operation and Tests” manual.
Rockshaft Valve — Centering the Stepper Motor

[1] -
CAUTION:
Comply with repair instructions. See “Hydraulic System — General
Turn the ignition off.

[2] - Remove cable connection (A) and take off cap (B).
[3] - Use a screwdriver to press down the pin on the stepper motor and turn it slightly until it
engages. While pressing down on the pin, feel for the left and right stop positions of the
stepper motor and adjust so that the distance from stop to stop is the same. Then release the
pin.

Installing the Rockshaft Valve

[1] -
IMPORTANT:
Make sure that the valve plates are positioned correctly, otherwise they
may cause malfunctions in the hydraulic system.
Refer to ”Installing the Shuttle Valves” in Section 70, Group 25.
Apply grease to O-ring (A) and valve plate (B) and locate them on main block (C).
[2] - Attach studs (D) to the rockshaft valve. Screw in the studs as far as they will go, then
slacken them off by 1/4 of a turn.
[3] - Locate O-ring (E) on rockshaft valve.
[4] - Only on rockshaft valves (narrow version) with spacer housing:
a. Apply grease to the valve plate and locate it on the rockshaft valve.
b. Install the spacer housing. Refer to”Rockshaft Valve (Narrow Version) — Removing and
Installing the Spacer Housing”in this Group.

[5] - Only if a 3rd or 4th SCV is equipped, or a special endplate for independent control valve,
or the endplate has provision for extra power connections:
a. Apply grease to the valve plate and locate it on the rockshaft valve.
b. For installation of 3rd or 4th SCV and endplate, refer to ”Installing the Selective Control
Valves” in Section 70, Group 25.
[6] -
Locate endplate (D) (remembering to include O-rings), and tighten hex. nuts (B).
26 lb-ft
[7] - Join the plug connection for stepper motor (A) and put on the protective cap.
[8] - Connect hydraulic lines (C).
[9] - If the rockshaft or stepper motor has been repaired, the rockshaft must be recalibrated.
See ”Reference 245-BCU-002 , Calibration and Input Addresses (Rockshaft Control)” in the
”Operation and Tests” manual.

Removing the Main Block

[1] -
CAUTION:
Comply with safety instructions. See “Hydraulic System — General
→NOTE:
The priority valve and spring can be removed while the main block is still in
place. To do this, just remove line (B) and the fitting. Make sure that the
washer between spool and spring does not fall out. Refer to “Repairing the
Main Block” in this Group.
Remove the SCV units. See “Removing the Selective Control Valves” , Section 70, Group 25.
[2] - Remove rockshaft valve. See “Removing the Rockshaft Valve” in this Group.
[3] - Disconnect oil lines (A), (B), (C), (D) and (E) at main block and plug the openings with
stoppers.
[4] - Remove cap screws (F) and bracket (G).

[5] -
Remove hex. nuts (A) and hex. socket screw (B).

[6] - Repair the main block. See “Repairing the Main Block” in this Group.
[7] - Install the main block. See “Installing the Main Block” in this Group.

Repairing the Main Block
LEGEND:
A Priority valve spool
B Spring
C Spring
[ If equipped ]
D Check valve with throttle bore

[ If equipped ]

E Fine screen
F Pressure relief valve (steering)
G Shuttle valve
H O-ring
I Connection for LS pressure line, steering valve
J Plug
[ with 3rd or 4th 300 Series SCV, independent SCV or endplate with extra connectors ]
K Connection for LS pressure line, hydraulic pump

[ not with 3rd or 4th 300 Series SCV, independent SCV or endplate with extra connectors ]
L Adapter
[ Power-Fill brake valve and/or trailer brake ]
M Shuttle valve
[ Power-Fill brake valve and/or trailer brake ]
N Test port, system pressure
O Test port, LS pressure
[ not with 3rd or 4th 300 Series SCV, independent SCV or endplate with extra connectors ]
P Test port, steering pressure
Q Fine screen
R O-ring
S Seat, fine screen
T Retaining clip
U Washer
V Connection for LS pressure line, steering valve
W Connection for pressure line, hydraulic pump
X Connection, return line to sump
[1] -
→NOTE:
Remove the main block. See “Removing the Main Block” in this Group.
LEGEND:
A Connector with O-ring
B Spring
C Valve body
D Throttle bore
Remove bracket from main block.

[2] - Remove and inspect the check valve (B) and (C) (if equipped).
a. Make sure that throttle bore (D) is clear.

b. Check spring (B).
Spring Free length approx. 12.7 mm
approx. 0.5 in.
Test length 8.5 mm at 13.7 to 16.4 N
0.34 in. at 3.1 to 3.7 lb
[3] -
→NOTE:
The priority valve can be taken out without removing the main block.
LEGEND:
A Connector with O-ring
B Valve spool
C Washer
D Spring
Remove the priority valve.
[4] - Check valve spool (B) and make sure that the two throttle bores are clear.
[5] - Check spring (D).
Spring Free length approx. 59.15 mm
approx. 2.33 in.
1.65 in. at 57.3 lb
[6] - Apply clean hydraulic oil to priority valve and install it.
[7] - Make sure that valve spool (B) is moving freely.

[8] -
→NOTE:
The pressure relief valve and fine screen can only be removed after the
main block has been removed from the tractor.
LEGEND:
A Pressure-relief valve
B Fine screen
C Seal ring
Remove steering pressure relief valve.
[9] - Clean the various parts, inspect them for wear or damage and replace as necessary.
[10] - Assemble pressure relief valve, using illustration as a guide.
a. Slightly coat valve pin and spring with oil and insert them.
b. Screw in threaded pin until it contacts the spring.
c. Install the sealing ring and the lock nut.
[11] - Clean screen (B).

[12] - Re-install screen (B) and pressure relief valve (A).
[13] - Install the main block and check oil pressures. Refer to “Installing the Main Block” in
this Group.

Installing the Main Block

[1] -
Secure the main block to bracket (B).

Main block to bracket, hex. socket screws Torque 100 N˙m
75 lb-ft
[2] - Tighten hex. nuts (A) and hex. socket screw (C) of bracket.
Main block bracket to rockshaft bearing support, hex. nuts and hex. socket screw Torque 100 N˙m
75 lb-ft
[3] -
Connect the oil lines.

[4] - Install SCV units. Refer to ”Installing the Selective Control Valves” , Section 70, Group
25.
[5] - Install rockshaft valve, see ”Installing the Rockshaft Valve” in this group.
[6] - Attach bracket (A) for center link and trailer socket.
[7] - Check and/or adjust system, steering and LS oil pressures. Refer toReference
270-15-012, ”Check Hydraulic System” in the Operation and Tests Technical Manual.

Repairing the Hydraulic Oil Filter
CAUTION:
Comply with repair instructions. See ”Hydraulic System — General

IMPORTANT:
seated correctly. The bent ends of the clip must be almost touching. If they
are not, the coupler may come adrift.
Retaining clip (arrow)

LEGEND:
A Oil filter head
B Check valve
C Filter element
D Plug with O-ring
E Plug with O-ring
F Filter by-pass valve
G Threaded pin
[ if equipped ]
Restriction switch
[ if equipped ]
H [ two-stage pressure-differential switch ]
(B111)
[1] - Remove all parts, inspect them for dirt or damage and replace as necessary.
[2] - Apply a thin layer of oil to the sealing ring on filter element (C) prior to installation.
[3] - Check switch (H). See reference 240-15-002, Component Testing, Basic
Informator”Sending Unit for Hydraulic Oil Filter Warning Light (B111)”in the Operation and
Tests Technical Manual.
[4] - Check oil pressure. SeeReference 270-15-012”Check Hydraulic System”, steps 1 to 5 in
the Operation and Tests Technical Manual.

Version ”A”
Version ”B”

Version ”C”
LEGEND:
A Oil filter head
B Spool with O-ring
C Spring
Restriction switch
D [ one-stage pressure-differential switch ]
(B111)
E Filter element
F Filter housing
G Connection for oil pressure test
Restriction switch
H [ two-stage pressure-differential switch ]
(B111)
I Threaded pin
J O-ring
[1] - Remove all parts, inspect them for dirt or damage and replace as necessary.
[2] - Cover O-ring (J) with a thin layer of oil and install on filter housing (F) or filter head (A).
[3] - Insert the filter element in the housing and install it on the filter head.
Filter housing Torque 30 N˙m
22 lb-ft
[4] - Check switch (H). See reference 240-15-002, Component Testing, Basic
Informator”Sending Unit for Hydraulic Oil Filter Warning Light (B111)”in the Operation and
Tests Technical Manual.
[5] - Check oil pressure. SeeReference 270-15-012”Check Hydraulic System”, steps 1 to 5 in
the Operation and Tests Technical Manual.

Power Beyond Valve—Exploded View
LEGEND:
1 Plug
2 O-ring
3 Spring
4 Valve spool
Threaded pin
5 [ only with external “open-center” ]
system
6 O-ring
Plug
7 [ only with external “closed-center” ]
system
8 Fitting
Fitting
8a [ only with external “open-center” ]
system
9 Plug
10 Seal ring
11 Spring

12 Ball
13 Plug
14 O-ring
15 Set screw
16 Fitting
17 Plug
18 O-ring
Valve plate
19 [ only with external “closed-center” ]
system
20 Special plug
21 Valve body
22 Spring
23 Ring
24 Fitting
25 Ring (3 used)
27 Housing

Connecting the Power Beyond Valve
IMPORTANT:
Observe the utmost cleanliness when working on the power beyond valve.
→NOTE:
As delivered, the valve is intended for operation in a "closed-center"

system, but it can be converted for operation in an "open-center" system.
See”Converting the Power Beyond Valve”in this Group.
→NOTE:
For components of power beyond valve, see”Power Beyond Valve -

Exploded View”in this Group.
With closed-center external system
LEGEND:
Pressure connection ”A” to external control valve (1-14 UNF
A [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Pressure connection ”P” from endplate (1-14 UNF
B [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Load-sense connection ”LS” to endplate (9/16-18 UNF
C [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)

Example for installation
LEGEND:
A Pilot oil (LS pressure) to endplate
B Power beyond valve
C Pressure oil to external control valve
D External control valve (on implement)
E To consumer
F Return line from external control valve to endplate
G Pressure oil from endplate
H Rockshaft valve
I Right endplate
[ With extra ports and adjustable LS pressure relief ]
The oil line (C) between the power beyond valve and the external control valve should be 3 m
(120 in.) long.
The external control valve must NOT contain an inlet check valve, otherwise the power
beyond valve will not operate when raising a load.
Check power beyond valve for proper function and adjust it, if necessary. SeeReference
270-15-170, Adjusting the Power Beyond Valve in the Technical Manual ”Operation and
Tests”.
→NOTE:
With rockshaft valve (narrow version), the power beyond valve (B) can also
be connected to the tractor hydraulic system via the spacer housing

.

With open-center external system
LEGEND:
Pressure connection ”A” to external control valve (1-14 UNF
A [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Pressure connection ”P” from endplate (1-14 UNF
B [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Load-sense connection ”LS” to endplate (9/16-18 UNF
C [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Leak-off connection ”T” (9/16-18 UNF
D [ Pipe screw fitting with O-ring on end as per ISO/DIS 12151 ]
)
Example for installation
LEGEND:
A Pilot oil (LS pressure) to endplate
B Power beyond valve

C Pressure oil to external control valve
D External control valve (on implement)
E To consumer
F Return line from external control valve to endplate
G Pressure oil from endplate
H Rockshaft valve
I Right endplate
J Leak-off oil
Install the power beyond valve on the implement as close as possible to the external control
valve.
Connect the valve′s leak-off port ”T” directly to the external control valve′s return port by
means of a T-fitting.
Check power beyond valve for proper function and adjust it, if necessary. See
reference270-15-170, Adjusting the Power Beyond Valve in the Technical Manual ”Operation
and Tests”.
→NOTE:
With rockshaft valve (narrow version), the power beyond valve (B) can also
be connected to the tractor hydraulic system via the spacer housing

.

Converting the Power Beyond Valve
IMPORTANT:
Observe the utmost cleanliness when working on the power beyond valve.
→NOTE:
For connecting power beyond valve refer to“Connecting the Power Beyond
Valve”in this Group.
Converting the Power Beyond valve from external “closed- center system”
[ Constant pressure system ]

to “open-center system”
[ Constant flow system ]
[1] - Remove plug (A), take out shuttle valve (B) and re-install the plug.
[2] - Remove plug (C). Remove the loose threaded pin (D) from inside the plug.
[3] - Tighten adjusting screw (E) inside the bore as far as it will go.

Section 70 - HYDRAULIC SYSTEM Group 20: Hitch
[4] - Keep shuttle valve (B) underneath plug (C) (in case the system is to be changed back to
“closed-center”
[ Constant pressure system ]
at a later date). Re-install the plug (C).
[5] - Remove plug (F), and take spring (G) and valve spool (H) out of the bore.
[6] - Tighten threaded pin (D) as far as it will go inside the threaded bore on the end of the
valve spool (H).
[7] - Re-install valve spool (H), spring (G) and plug (F).
[8] - Remove the existing plug and install fitting 38H5002
(K).

Group 20 - Hitch
Other Material
Number Name Use
• L64500 (us)
Sealant Draft sensor cover to differential housing
Position Sensor and Toothed Segment:

Toothed Segment to Rockshaft, Hex. Socket Screws Torque 7 ± 1 N˙m
5 ± 0.7 lb.-ft.
Position Sensor to Rockshaft Bearing Block, Cap Screws Torque 5 N˙m
3.7 lb.-ft.
Hitch:
Rockshaft Bearing Block to Differential Housing, M16 Cap Screws Torque 300 N˙m
(221 lb.-ft.)
Lift Arms to Rockshaft, Cap Screws Torque 115 N˙m
85 lb.-ft.
Hitch - Remove and Install the Electronic Control

Unit
For installation or removal of the basic control unit (BCU) for hitch control, see Replace
Control Unit (BCU/HCU) in Section 90, Group 05.

Hitch — Removing and installing the position sensor

and toothed segment
LEGEND:
A Lift shaft
B Ratchet
C Hex. socket screw (2 used)
D O-ring
E Position sensor
F Washer (6 used)
G Cap screw (4 used)
H Protective cap
Removing the position sensor and toothed segment
[1] -
CAUTION:
Comply with safety instructions. See “Hydraulic system — General
instructions on safety and repair” in section 70, group 15.

Carefully clean the area around the position sensor (A).

[2] - Remove protective cap (B), and break the cable connection.
[3] -
Take out the four cap screws from housing (A) and lift off position sensor (A).
[4] - Take out hex. socket screws (B) and lift off toothed segment (C).
Installing the position sensor and toothed segment
[1] -
The lift arms must be in the lowest possible position.

[2] - As shown, attach toothed segment of position sensor to the lift shaft The collar of the
toothed segment must be on the r.h. side (as seen in direction of travel)!
[3] - Install hex. socket screws (A).
Toothed segment to lift shaft, hex. socket screws Torque 10 N˙m
(7.5 lb-ft)
[4] -
IMPORTANT:
Lift arms (A) must be in their lowest position possible!
Install an O-ring on the position sensor housing.

[5] - Put the position sensor on the lift shaft bearing block, making sure it is straight!
[6] - Install cap screws (B).
Position sensor to bearing block, cap screws Torque 5 N˙m
3.7 lb-ft
[7] - Reconnect the cable.

[8] -
Put the protective cap (B) on position sensor (A). Press the cap on until it clicks into place.

[9] -
Feed cables through cable guide (A). Make sure that the cables are not bent or jammed.
[10] - Check the position sensor. See "270-15-150 , Hitch — Checking the position sensor" in
the “Operation and Tests” manual.
[11] - Recalibrate hitch control. See "245-BCU-002 , Calibration and input addresses, hitch
control" in the “Operation and Tests” manual.

Hitch — Removing and installing the lift shaft
LEGEND:
A Support
B Bushing
C Lift shaft
D Wiper seal
E Backup ring
F Lift arm
G Washer
H Cap screw
I M20x60 cap screw (2 used)
J M16x60 cap screw (2 used)
K M16x90 cap screw (4 used)

L Grease fitting
M Position sensor
Removing the lift shaft
[1] -
CAUTION:
Remove the position sensor (B) and toothed segment! See “Hitch — Removing and installing
the position sensor and toothed segment”" in this group.
[2] - Remove the upper pins (A) from the lift links and lift shaft cylinders.
[3] - Take cover off intake filter (C).
[4] - Remove cap screw (D).
[5] - Mark position of lift arms relative to lift shaft, and remove lift arms.

[6] -
Remove the lift shaft.

→NOTE:
If only the bearing bushings are to be removed, push the lift shaft to the
opposite side until the bushing is free.
[7] - Remove backup ring (B) and seal ring (A), and take off the bearing bushing.
Installing the lift shaft
[1] -
Install new bearing bushings (A) with the slot facing downward.
[2] - Coat inside of bearing bushings with grease.

[3] -
LEGEND:
A Seal ring
B Backup ring
Install a new seal ring (A) 5 mm (0.2 in) from the outer edge of the bearing block with the
seal lip facing outward. Coat the seal lip with grease.
[4] - Install a new backup ring (B).
[5] - Insert the lift shaft or push it back, and apply grease to the teeth.
[6] -
Place lift arms on lift shaft.

→NOTE:
Make sure that lift arms are positioned correctly in relation to the lift shaft
(pay attention to the marks)!
[7] - Install the two lift arm cap screws (A) with washers. Tighten the screws.
Lift arms to lift shaft, cap screws Torque 115 N˙m
85 lb-ft
[8] - Reattach lift shaft cylinders and lift links.

[9] - Install the position sensor and toothed segment! See “Hitch — Removing and installing
the position sensor and toothed segment” in this group.
[10] - Lubricate lift shaft bearings.
Hitch — Removing the lift shaft cylinders

[1] -
CAUTION:
Before removing the two lift shaft cylinders, remove the position sensor or hold the lift arms
in the middle position!
[2] - Remove pressure line (B).
[3] - Take out pins (A). The pins have M10 threads and can be extracted using a screw.
[4] - Remove screw (C) and support plate (D).

Hitch — Repairing the lift cylinder

[1] -
CAUTION:
→NOTE:
Remove the lift cylinder. See “Hitch — Removing the lift cylinder” in this
group.
Remove and install the bearing.
a. Remove snap ring (B).

b. Press out bearing (A).
c. Bearing must be installed with its groove at right angles to center line of cylinder.

[2] -
Remove the piston rod.
a. Disengage one end of snap ring (A) by means of a screwdriver and press over collar.
b. Turn piston rod to remove snap ring.
c. Pull the piston rod out of the cylinder.

[3] -
LEGEND:
A Wiper seal
B Bushing
C Seal ring
D Bushing
E Snap ring
Remove and install the seals on the lift shaft cylinder.
a. Remove parts (A) to (E).

b. When the chamfers on bushings (B) and (D) are installed, they must face the snap rings
(E).
c. The sealing lip on seal ring (C) must face inward.

[4] -
Install piston rod.
a. Slide snap ring and piston rod into cylinder.

b. Use piston rod to press snap ring to cylinder base.
c. Press one end of snap ring over collar. Turn piston rod until snap ring is locked in piston
rod groove.
[5] - Install the lift cylinders. See “Hitch — Installing the lift cylinders” in this group.
Hitch — Installing the lift cylinders

[1] -
Install the lift shaft cylinders.

[2] - Install pins (A) with the threads facing outward.
[3] - Secure pin (A) with cotter pin.
[4] - Install and tighten screw (C) and support plate (D).

[5] - Attach pressure line (B). Make sure that the line does not touch or chafe against
anything.
[6] - Lubricate the cylinder bearings.

Hitch — Removing and installing the draft load

potentiometer and draft link support
LEGEND:
1 Backup ring
2 Seal ring
3 Snap ring
4 Bushing
5 Draft link bearing support
6 Holder
7 Pin
8 Retaining plate
9 Leaf spring
10 Clamp
11 Draft potentiometer

12 Cable strap
13 Bushing
14 Guide rail
15 Pin
16 Cover
18 Cover
Removing draft load potentiometer and draft link support
[1] -
Remove the draft links.

[2] - Remove the two covers (A) and (B) from underneath the differential housing.
[3] -
Pull retaining pin (A) out of the housing. To facilitate removal, the pin has an M8 thread.
[4] - Remove the cable strap and disconnect the plug connection. Remove clamp (B) and
draft potentiometer (C).

[5] -
CAUTION:
The leaf spring is under tension.
Use pliers to lever leaf spring (A) out of the two brackets.
[6] -
Bend the two retaining plates (C) downwards and pull pins (B) out of the shaft. The two
brackets (D) now come free.

[7] -
Remove draft link support (A).

[8] - Remove backup ring (C) and seals (B) on the draft link support.
Installing draft load potentiometer and draft link support
[1] -
To install, follow the removal procedure in reverse order, but note the following points:
[2] - Retaining plates (A) are located between the bracket and the shaft. Bend the plates
over so that the pins are secured.
[3] - When installing, make sure that leaf spring (B) is inserted in the correct position relative
to the bracket (see arrow).

Section 70 - HYDRAULIC SYSTEM Group 25: Selective Control Valves and Couplers
[4] -
Install draft potentiometer (C) and clamp (B). Pay heed to correct fitting of the clamp.
[5] - Insert retaining pin (A). The threaded bore must face downward.
[6] - For information on checking and setting the draft potentiometer, see "270-15-152 ,
Hitch — Checking and adjusting the draft potentiometer (6820 to 6920)" in the “Operation
and Tests” manual.
[7] - Before installing the covers, remove all the old sealant and apply new sealant L64500
(LOCTITE ™ 574).
Number Name Use
• L64500 (us)
Sealant Draft sensor housing cover to differential housing

Group 25 - Selective Control Valves and Couplers

Repairing the Selective Control Valves and Couplers
— Summary of References
Repairing the selective control valves and couplers is dealt with at the following references.
General:
“Repairing the Selective Control Valves and Couplers — General Instructions on Safety
and Repair”
“SCV Identification”
“Installing the Shuttle Valves”
“Removing the Selective Control Valves”
“Installing the Selective Control Valves”
“Selective Control Valves — Installing the Endplate”
“Selective Control Valves — Repairing the Couplers”
100 series SCVs:
“Series 100 Selective Control Valves — Repairing”
200 series SCVs:
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Replacing the

Control Knobs”
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Inspecting the
Check Valves”
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Inspecting the Inlet
Check Valve and Metering Valve”
“Series 200 Selective Control Valves — Repairing”
Series 300 SCVs (mechanically actuated):
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Replacing the

Control Knobs”
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Inspecting the
Check Valves”
“Series 200/300 Selective Control Valves (Mechanically Actuated) — Inspecting the Inlet
Check Valve and Metering Valve”
“Series 300 Selective Control Valves (Mechanically Actuated) — Inspecting the Pressure
Compensator Valve”
“Series 300 Selective Control Valves (Mechanically Actuated) — Repairing”

Series 300 SCVs (electrically actuated):
“Series 300 Selective Control Valves (Electrically Actuated) — Removing and Installing
the Stepper Motors”
“Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Check
Valves”
“Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Inlet Check
Valve”
“Series 300 Selective Control Valves (Electrically Actuated) — Inspecting the Inlet
Pressure Compensator Valve”
“Series 300 Selective Control Valves (Electrically Actuated) — Repairing”
Special Tools
→NOTE:

Installation tool
KJD10277
Selective control valves, reconditioning the couplers
Special Tools (Dealer Fabricated)

Also refer to Section 99.

Socket wrench insert for removing the endplates from the SCV block or rockshaft valve
Take a standard, 17 mm (11/16 in.) across flats, hex. insert with a 1/2 in. square drive socket.
Turn the outside diameter of the hex. end until it is 22.5 mm (0.9 in.) across, to a distance of
13 mm (0.5 in.).
Other Material
Number Name Use
• R117738 (us) Special grease SCVs, assembling the detent parts
• L41476 (us)
Securing the special screw for the detent or
• 270 LOCTITE ™ Sealant
centering spring to the valve spool (on the SCVs).
(loctite)

100 series SCVs:

Inlet check valve, new spring Free length (approx.) 27.7 mm
1.1 in.
0.71 in. at 24.3 to 28.8 lb
Valve spool, new centering spring Free length (approx.) 56 mm
2.2 in.
1.1 in. at 30 to 35 lb
Special screw - detent to valve spool Torque 11 N˙m
8 lb-ft
200 series SCVs:

Check valve, new spring Free length (approx.) 21.5 mm
0.9 in.
Test length 17.8 mm at 4 to 5.8 N
0.7 in. at 0.9 to 1.3 lb
Check valve plug Torque 45 N˙m
34 lb-ft
Detent assembly, hex. socket screws Torque 11 N˙m
8 lb-ft
Metering valve, new spring Free length (approx.) 29 mm
1.1 in.
0.8 in. at 13.5 to 16.2 lb
Metering valve plug Torque 65 N˙m
48 lb-ft
Detent piston, new spring Free length (approx.) 13 mm
0.5 in.
Test length 9 mm at 3.2 to 4 N
0.35 in. at 0.7 to 0.9 lb
2.2 in.
1.1 in. at 30 to 35 lb
300 series SCVs (mechanically actuated):

Check valves, new spring Free length (approx.) 21.5 mm
0.9 in.

0.7 in. at 0.9 to 1.3 lb
Check valves, plug Torque 45 N˙m
34 lb-ft
Pressure compensator valve, plug Torque 82 N˙m
60 lb-ft
Detent kick-out relief valve, new spring Free length (approx.) 21 mm
0.8 in.
0.7 in. at 7 to 10 lb
Metering valve, new spring Free length (approx.) 29 mm
1.1 in.
0.8 in. at 13.5 to 16.2 lb
Metering valve plug Torque 65 N˙m
48 lb-ft
0.5 in.
0.35 in. at 0.7 to 0.9 lb
2.2 in.
1.1 in. at 30 to 35 lb
Centering spring to valve spool, special screw Torque 11 N˙m
8 lb-ft
Detent assembly, hex. socket screws Torque 11 N˙m
8 lb-ft
300 series SCVs (electrically actuated):

Inlet check valve, plug Torque 65 N˙m
48 lb-ft
Check valves, new spring Free length (approx.) 21.5 mm
0.9 in.
0.7 in. at 0.9 to 1.3 lb
Check valves, plug Torque 45 N˙m
34 lb-ft
Pressure compensator valve, plug Torque 82 N˙m
60 lb-ft

Special screw on valve spool Torque 10 N˙m
7.4 lb-ft
End-cap, hex. socket screws Torque 10 N˙m
7.4 lb-ft
Stepper motor, hex. socket screws Torque 10 N˙m
7.4 lb-ft
Bowden cable on SCV:

37 lb-ft
37 lb-ft
Endplate to SCV unit, hex. nut Torque 35 N˙m
26 lb-ft
Hydraulic couplers:
Inner to rear assembly Torque 50 N˙m
37 lb-ft
Fitting to housing Torque 100 N˙m
74 lb-ft
Coupler to SCV Torque 65 N˙m
48 lb-ft

Reconditioning the Selective Control Valves and

Couplers — General Instructions on Safety and
Reconditioning
CAUTION:
You should comply with the safety measures at the beginning of this
manual as well as the ones mentioned below. See Safety Measures, Repair
Manual, Section 05, Group 05.
CAUTION:
During tests that involve running the engine, always engage the parking
lock.
CAUTION:

disconnecting the hydraulic lines, fitting or connections.
CAUTION:
If tests are to be carried out on moving parts (e.g. rockshaft, front hitch,
front loader, front-wheel drive axle with TLS, hydraulically suspended cab,
hydraulic cylinders etc.), be aware of the potential for accidents. Never
work within the operating range of moving parts.
Absolute cleanliness is essential when working on hydraulic components. Clean the area
around the valves thoroughly before removing or servicing components.
The selective control valve must be marked and installed in the original position from which it
was removed.
SCV and valve components must be held with a holding fixture using BRASS jaws. Valve
components are critically machined and can be easily damaged.
Replace all seals, O-rings and back-up rings.

Check springs for signs of wear, damage or deformation.
If necessary, use a 280 grain whetstone to rub impurities off surfaces.
Clean all components with clean solvent and dry with compressed air. Also clean the oil
passages with compressed air. Do not use shop towels to dry parts.
Apply clean hydraulic oil to all internal parts before assembling them.
Coat the detent parts with R117738 special grease.
The valves must NOT jam in the housing bores.
The following, together with other information, can be found in the Part 1 of the Repair
Manual, Section 10, Group 05 under ”Specifications”.
For all capacities, see ”Capacities” .

For different types of oil, see ”Transmission and Hydraulic Oil” .
For grease, see ”Grease” .
For general information on tightening torques, see ”Unified Inch Bolt and Cap Screw
Torque Values” .
For general information on tightening torques, see ”Metric Bolt and Cap Screw Torque
Values” .
For general information on tightening torques, see ”Torques for Inch Fittings used in the
Hydraulic System” .
For general information on tightening torques, see ”Torques for Metric Fittings used in
the Hydraulic System” .

SCV Identification
1.
100 series (standard):
mechanically actuated
with fixed cap
2.
200 series (DeLuxe SCV):
detent knob with two operating positions

3.
300 series (Super DeLuxe SCV):
detent knob with three operating positions
4.
300 series (E-SCV, Super DeLuxe SCV):
electrically actuated
with stepper motor

Install Shuttle Valves
Valve block with rockshaft valve (wide version)
Valve block with rockshaft valve (narrow version)
LEGEND:
A Left endplate
B SCV (pos. 1)
C SCV (pos. 2)
D Main block with priority valve
E Rockshaft valve
F SCV (pos. 3)
G SCV (pos. 4)
H Right endplate
K Valve plates
Spacer housing
L [ With extra ports and adjustable LS pressure relief (for connection of external control valves) ]
[ With extra ports and LS pressure increase (with an independent control valve (ICV)) ]

On the right-hand side of valve block components (A), (B), (C), (D), (E), (F) and (L) (viewed in
the direction of travel), there is a recess which, depending on tractor equipment, may contain
a valve plate (dime valve).
IMPORTANT:
Make sure that valve plates (K) are positioned correctly, otherwise they
may cause malfunctions in the hydraulic system.
If there is an SCV (C) at position 2, a valve plate is installed in the recess on its r.h. side.
If there is an SCV (B) at position 1, a valve plate is installed in the recess on its r.h. side.
A valve plate is used between the left endplate (A) and the adjoining component (B) or
(C)only if the endplate has a connection for an external control line (Load-Sensing line).
A valve plate is installed on the r.h. side of the main block (D), in the recess between it and
rockshaft valve (E).
Rockshaft valve (E) (wide version) has a valve plate in the recess on its r.h. sideonly if a SCV
(F) on pos. 3 or a special endplate
[ With extra ports and adjustable LS pressure relief (for connection of external control valves) ]
is equipped.
Rockshaft valve (E) (narrow version) has a valve plate in the recess on its r.h. sideonly if a
spacer housing (L) is equipped.
Spacer housing (L) has a valve plate in the recess on its r.h. sideonly if a SCV (F) on pos. 3 or
a special endplate
is equipped.
The SCV unit (F) on pos. 3 has a valve plate in the recess on its r.h. sideonly if a SCV unit (G)
on pos. 4 or a special endplate
is equipped.
No valve plate is ever installed in the recess at the SCV unit (G) on pos. 4.
Additional shuttle valves

In a power-fill tractor brake system, a valve plate is installed in the main block at the load-
sensing line connection (A).
LEGEND:
A Housing for shuttle valves
B LS port, trailer brake valve
C LS port, TLS Front Wheel Drive axle
D LS port to main block
E LS port, power-fill brake valve
If there is an extra hydraulic trailer brake and/or front-wheel drive axle with TLS, a housing
with additional shuttle valves is installed between the load sensing lines. The housing is
attached to the right of the rockshaft bearing block.
SeeReference 270-20-030, PFC Hydraulic System — Symbolic Representation in the

”Operation and Tests” manual.
If an independent control valve is equipped, a valve plate is installed between each of the
control valves.
SeeReference 270-20-510, Independent Control Valve — Operation, in the Technical Manual

”Operation and Tests”.

Series 300 Selective Control Valves (Electrically

Actuated) — Removing and Installing the Stepper
Motors
CAUTION:
Comply with the general instructions on safety and reconditioning. See

“Reconditioning the Selective Control Valves and Couplers — General
Instructions on Safety and Reconditioning” in this Group.
Remove the stepper motors.
[1] -
→NOTE:
Mark the stepper motors according to their position before removing them
(SCV on pos. 1, 2, 3 or 4).
Near the SCV (pos. 1) connector the wiring harness has a red mark and a
yellow one near the SCV (pos. 4) connector. Before you disconnect them,
check that the colored marks are still visible; if they are not, mark the
plugs accordingly.
Disconnect plug (A) at the stepper motor.

[2] - Remove the three hex. socket screws (B) and lift off the stepper motor.

[1] -
Install a new O-ring (A) in the housing under the back-up washer.
[2] - Install a new O-ring (B) on the flange.
[3] - Align rack (C).
Seen in the direction of travel:

SCV on pos. 1 and 3: Teeth facing to front.
SCV on pos. 2 and 4: Teeth facing to rear.
[4] -
→NOTE:
Note the marks applied before removal and re-install the stepper motors on
their original positions.
Align stepper motor and put it in place.
Seen in the direction of travel:

SCV on pos. 1 and 3: Stepper motor′s plug aligned to front.
SCV on pos. 2 and 4: Stepper motor′s plug aligned to rear.

[5] - Install the three hex. socket screws (B), tightening them evenly.
7.4 lb-ft
[6] - Connect plug (A).

[7] - If a new stepper motor has been installed, its identifying name and afterwards the SCV
must be calibrated.
See reference 245-SIC-001, Calibration and Input AddressesAddress SIC 040 — Calibration of
Stepper Motor - IdentificationandAddress 020 — Calibration of Selective Control Valves (E-
SCV and E-ICV)in the Operation and Tests Technical Manual.

Removing the Selective Control Valves
CAUTION:

Instructions on Safety and Reconditioning” in this Group.
IMPORTANT:
There are valve plates between the various valves. Take care not to lose
any of the plates.
→NOTE:
Before removing the electrically actuated SCVs, mark the stepper motors
according to their position (SCV on pos. 1, 2, 3 or 4).

[1] -
Mechanically actuated SCVs
Electrically actuated SCVs

— With mechanically actuated SCVs: Mark the bowden cable. Remove lock nut (A), then
special nut (B). Disconnect the bowden cable.
— With electronically actuated SCVs:
→NOTE:
yellow mark near the SCV (pos. 4) connector. Before you disconnect them,
check that the colored marks are still visible; if they are not, mark the
plugs accordingly.
Disconnect electrical plugs (C) at the stepper motor.

[2] - If oil lines (D) and (E) are equipped, take them off.
[3] - Disconnect the oil leak-off lines at the couplers.

[4] -
— If a pos. 1 SCV is equipped, remove the lift arm. See “Rockshaft — Removing and Installing
the Rockshaft” in Section 70, Group 20.
— If a SCV or special endplate
[ With independent control valve or endplate with extra connections ]
is equipped at position 4, remove the lift arm. See “Rockshaft — Removing and Installing the
Rockshaft” in Section 70, Group 20.
[5] - Place a small container beneath the SCV to trap any oil that escapes.
[6] - Remove the three hex. nuts (A) or cap screws
[ With one SCV ]
using the socket wrench insert (see “Special Tools (Dealer Fabricated)” in this Group).
[7] - Take off endplate (B) and SCV unit.
[8] - Recondition the SCVs. See “Reconditioning the Selective Control Valves and Couplers —
Summary of References” in this Group.

Series 100 selective control valves — Repairing

Disassembling the selective control valve
LEGEND:

1 Plug
2 Cover
4 Plate
5 Sleeve
6 Ball
7 Spring
8 Detent sleeve
9 Seal plate
10 Spacer
11 Balls
12 Special screw detent
13 Spring seat
14 Spring
15 Control spool
16 Wiper seal
17 O-ring
18 Housing
19 Control valve
20 Spring
21 O-ring
22 O-ring
23 Valve plate (if equipped)
24 Flange
CAUTION:
Comply with the general instructions on safety and repairing. See

“Repairing the selective control valves and couplers — General instructions
on safety and repairing” in this group.
Removing the SCVs. See “Removing the selective control valves” in this group.
[1] - Using the illustration as a guide, disassemble the SCVs as necessary.

[2] - The thread on special screw (12) is coated with L41476 (LOCTITE ™ 270) sealant.
[3] - Clean the various components carefully and inspect them for signs of damage.
Assembling the selective control valve

IMPORTANT:
To prevent SCV malfunction, clean all thread-locking material from threads

on special screw (H) and from inside of valve spool (A).
IMPORTANT:
Control valve must be securely held using a vice with BRASS jaws. Failure
to use brass jaws will result in damage to the control valve requiring
complete valve replacement.
→NOTE:
Apply a light coating of R117738 special grease when assembling the

following metal detent parts.
LEGEND:
A Control spool
B O-ring
C Wiper seal
D Seal plate
E Spring seat
F Centering spring
G Spring seat
H Special screw detent
I Balls (4 used)
J Spacer
K Seal plate
L Spring

M Ball
N Detent sleeve
O Sleeve
P Plate
Q Cover
[1] -
Place valve spool in vice and insert O-ring (A) and wiper seal (B).

[2] - Check the centering spring (E).

New centering spring Free length (approx.) 56 mm
(2.2 in.)
(1.1 in. at 30 to 35 lb force)
[3] - Locate seal plate (C), spring seat (D) and spring (E).
[4] - Coat the thread on special screw (F) with L41476 (LOCTITE ™ 270) sealant, and install
the screw.
Number Name Use
• L41476 (us)
Sealant Securing the special detent screw to the valve spool.
Special screw on valve spool Torque 11 N˙m
(8 lb-ft)
[5] -
IMPORTANT:
Allow a minimum of 30 minutes cure time before installing valve spool.
Once valve spool (G) is assembled, submerge it in clean hydraulic oil and install it in housing
(H). Insert spring and ball (see arrow).
[6] - Install spacer (I), seal plates (J) and detent sleeve (K) (with the lipped end uppermost).
Locate balls (L).
[7] - Check inlet check valve and spring (M).
New spring Free length (approx.) 27.7 mm
(1.1 in.)
(0.71 in. at 24.3 to 28.8 lb)
[8] - Install the inlet check valve (M), spring and O-ring.
[9] - Put on sleeve (N) and plate (O).
[10] - Install and tighten cover (P).
[11] - Locate O-ring (Q) and install flange (R), using hex. socket screws (S).
[12] - Removing the SCVs. See “Removing the selective control valves” in this group.

Series 200/300 selective control valves

(mechanically actuated) — Replacing the control
knobs
[1] -
IMPORTANT:
To prevent damaging the internal parts, remove the knob assemblies from
the SCV housing. Do NOT remove the control knobs on the SCV.
Remove the detent or metering valve knob assembly from valve housing. Press the pin (A)
out and remove the knob.
[2] -
LEGEND:
A Plug
B plate
C V-seal
D Detent selector knob
E Pin
F Seal proctector
Install plate (B) on plug (A).

[3] - Install V-seal (C) approximately halfway along the plug, making sure that the seal is
positioned as illustrated.
[4] - Align the holes in knob (D) with the hole in plug (A). Use the knob to complete the
installation of the V-seal. Make sure that the bottom lips of the seal are not bent double.
[5] - Install pin (E).
[6] - — Install the metering valve′s control knob. See “Series 200/300 selective control
valves— Inspecting the inlet check valve and metering valve”, step 4 in this group.
— Install the detect selector knob. See “Series 200 selective control valves— Repairing”,
Assembling the SCVs, step 19 and “Series 300 selective control valves— Repairing”,
Assembling the SCVs, step 30 in this group.


(mechanically actuated) — Inspecting the check
valves
[1] -
→NOTE:
The 300 SCV series uses two load-check valves.
LEGEND:
A Plug
B Spacer
C Spring
D Control valve
Inspect parts (A) to (D).
0.9 in.
0.7 in. at 0.9 to 1.3 lb
[2] - Install the valve components. Make sure that recessed side of spacer ring (B) is
positioned toward spring (C).
[3] - Install and tighten plug (A).
Plug Torque 45 N˙m
34 lb-ft


(mechanically actuated) — Inspecting the inlet
check valve and metering valve
[1] -
IMPORTANT:
Do not attempt to remove the metering valve knob with the valve
remaining in the housing.
→NOTE:
A repair kit is available for the metering valve.
Inspect valve parts (A) to (C).

[2] - Check spring (B).
New spring Free length (approx.) 29 mm
(1.1 in.)
(0.8 in. at 13.5 to 16.2 lb)
[3] - Valve (C) should slide smoothly in the housing bore.

[4] - Turn the control knob in the “rabbit” direction at least one turn and install the metering
valve assembly.
[5] - Tighten plug (A).
Plug Torque 65 N˙m
(48 lb-ft)

Series 200 selective control valves — Repairing

LEGEND:
A Knob
B Hex. socket screw (2 used)
C Spring washer (2 used) (if equipped)
D Detent housing
E Spool assembly
F Seal plate
G Backup ring
H O-ring
J Check valve

K O-ring
L Flange
N Valve plate (if equipped)
O O-ring
P Housing
Q Control spool
R Inlet check valve and metering valve
S Special screw
CAUTION:

Remove the control knobs. See “Series 200/300 selective control valves — Replacing
the control knobs” in this group.
Inspect the check valve. See “Series 200/300 Selective control valves — Inspecting the
check valves” in this group.
Inspect the inlet check valve and metering valve. See “Series 200/300 selective control
calves (mechanically actuated) — Inspecting the inlet check valve and metering valve”
in this group.

[2] - The thread on special screw (S) is coated with L41476 (LOCTITE ™ 270) sealant.
IMPORTANT:

on special screw (J) and from inside of valve spool (A).

LEGEND:
A Control spool
B Spring seat
C Spring
D Piston
E O-ring
F Wiper seal
G Seal plate
H Spring seat (2 used)
I Spring
J Special screw detent
K Spacer
L Washer
M Wave springs (2 used)
N Alignment plate
O Detent sleeve
P Balls (4 used)
Q Detent sleeve
R Detent assembly
S Gasket

[1] -
LEGEND:
A Piston
B Spring
C Spring seat
D Orifice
E Threads
Put the end of the valve spool at an angle on a table. Carefully remove parts (A) to (C). Do
this by directing compressed air into orifice (D).
[2] -
IMPORTANT:
The thread (E) inside the valve spool must be clear of all thread-locking
material.
Inspect spring (B) and seat (C).

0.5 in.
0.35 in. at 0.7 to 0.9 lb

[3] -
LEGEND:
A Backup ring
B O-ring
C Spring
D Spring seat
E Control spool
Replace parts (A) and (B).
[4] - Insert spring (C) and spring seat (D) in the piston. Use petroleum jelly to hold the parts
in position.
[5] - Carefully install the piston assembly in the spool (E). Keep the spool in vertical position.
Use a small rod to push the piston into position (approximately 14 mm (9/16 in.) from top of
piston to spool end).
[6] -
IMPORTANT:
→NOTE:

Install the control valve in a vertical position using a vice with brass jaws.
[7] - Install ring (A) and wiper seal (B) with inner lip positioned up.
[8] - Install seal plate (C) with tab (D) and pointer (E) positioned as illustrated.
[9] - Inspect the centering spring (G).
2.2 in.
1.1 in. at 30 to 35 lb
[10] - Install spring seats (F) and spring (G).

[11] - Clean the thread on the special screw detent (H), removing old sealer material. Apply
L41476 (LOCTITE ™ 270) sealant to the threads, and install the special screws.
Number Name Use
• L41476 (us) Securing the special detent screw to the valve spool
Sealant
• 270 LOCTITE ™ (loctite) (on the SCVs).
IMPORTANT:
[12] - Install spacer (I) and washer (J).

[13] - Install the two wave springs (K). Make sure the cut ends are not together.
[14] - Install the alignment plate (M) with index mark (L) toward spacer (I). Note alignment
points (N).

[15] -
Install sleeve (B) with the lip side up.

[16] - Install the four steel balls (C). Use a small amount of R117738 special grease to hold
balls in position.
[17] - Install detent assembly (D) in the detent sleeve (E). Install the detent and sleeve over
the balls. Note alignment points (F).
[18] - Install gasket (G).
[19] -
LEGEND:
A Pointer
B Sleeve notches
C Internal knob notches
D Detent selector knob
Install detent selector knob (D) on the valve spool assembly, with notches (B) aligning with
pointer (A) and notches (C) aligning correctly inside the knob.
IMPORTANT:
The notches must align properly, otherwise the knob assembly will be
damaged.
→NOTE:
Install spring washers with bowed ID toward screw heads.

[20] - Install and hand tighten the hex. socket screws of the detent housing (remember to
use lock washers
[ Not used in all designs ]
), then tighten.
8 lb-ft
[21] -
Using hex. socket screws (C), install O-ring (A) and flange (B).
Series 300 selective control valves (mechan

actuated) — Inspecting the pressure compensator
valve
→NOTE:
The pressure compensator valve is serviced as a kit.
Visually inspect the compensator valve. Valve should slide into the housing without binding.
Install valve (B) with new O-ring on plug. Tighten plug (A).
Plug Torque 82 N˙m
60 lb-ft

Series 300 selective control valves (mechan

actuated) — Repairing
LEGEND:
A Knob
B Relief valve
C Hex. socket screw (3 used)
D Spring washer (3 used) (if equipped)
E O-ring
F Detent housing
G Spool assembly
H Check valve
J Check valve
K O-ring
L Flange
N Pressure compensating valve
O Valve plate (if equipped)
P O-ring
Q Inlet check valve and metering valve
R Housing
S Backup ring
T O-ring
U Control spool
V Special screw
CAUTION:

Remove the control knobs. See “Series 200/300 selective control valves — Replacing
the control knobs” in this group.
Inspect the check valve. See “Series 200/300 selective control valves (mechanically
actuated) — Inspecting the check valves” in this group.
Inspect the inlet check valve and metering valve. See “Series 200/300 selective control
calves (mechanically actuated) — Inspecting the inlet check valve and metering valve”
in this group.
Inspect the pressure compensator valve. See “Series 300 selective control valves
(mechanically actuated) — Inspecting the pressure compensator valve” in this group.

[2] - The thread on special screw (V) is coated with L41476 (LOCTITE ™ 270) sealant.
IMPORTANT:

on special screw (S) and from inside of valve spool (A).
LEGEND:
A Control spool
B Spring seat
C Spring
D Detent piston
E Pin
F Wiper seal
G O-ring
H Retaining clip
I Wave springs (2 used)
J Float detent sleeve
K Balls (4 used)
L Detent sleeve
M Washer
N O-ring
O Seal ring
P Spring seat
Q Spring
R Spring seat
S Special screw
T O-ring
U Backup ring

[1] -
LEGEND:
A Elongated hole
B Hole
C Spring seat
D Spring
E O-ring
F Backup ring
Remove the detent piston assembly from the valve spool. Access the detent assembly using
an O-ring tool through the elongated hole (A) and hole (B).
[2] - Inspect the spring seat (C) and spring (D).
0.5 in.
0.35 in. at 0.7 to 0.9 lb
[3] - Replace parts (E) and (F) with new ones.

[4] -
LEGEND:
A Spring seat
B Hole
C Control spool
D Pin
Install the spring and spring seat (A) on the detent piston. Use a small amount of petroleum
jelly to hold parts in position.

[5] - Align the hole (B) in the detent piston with the elongated hole in valve spool (C).
[6] - Carefully install the detent piston with the valve spool positioned vertically. Use a small
rod to push the detent piston into position.
[7] - Install the pin (D) into hole (B) after installing the piston assembly.
IMPORTANT:
The detent piston assembly must be able to move up and down if correctly
installed.
[8] - Remove the assembly from the valve if detent piston does not move. Align the spring
seat again and install vertically into the valve.
[9] -
IMPORTANT:
→NOTE:
Install the control valve in a vertical position using a vice with brass jaws.
[10] - Install scraper ring (A) and O-ring (B).

[11] - Install retainer (C) with smaller inner ring positioned up.
[12] - Install the two wave springs (D). Make sure the cut ends are not together.
[13] - Install the float detent sleeve (E) with the notches positioned up.
[14] - Install the four steel balls (F). Use a small amount of R117738 special grease to hold
balls in position.
[15] - Install the detent sleeve (G) with the notches positioned up.
[16] - Install washer (H) and O-ring (I).
[17] - Install seal ring (J) (with notches positioned up), remembering to include backup ring
(N), O-ring (O) and spring seat (K).
[18] - Inspect and install spring (L) and spring seat (M).
2.2 in.
1.1 in. at 30 to 35 lb
[19] -
Install a new O-ring on special screw (A) and apply L41476 sealant (LOCTITE 270) to the
thread.
[20] -
IMPORTANT:
Install special screw (A) on the valve spool, and tighten.

Special screw Torque 11 N˙m
8 lb-ft
[21] -
→NOTE:
The detent kick-out relief valve is serviced as a kit.

LEGEND:
A Detent housing
B Access hole
C O-ring
D Relief valve plug
E Poppet valve
F Seal ring
G Spring
H Adjustment screw
I O-ring
J Backup ring
K O-ring
Remove detent kick-out relief valve from housing (A) using a small rod through hole (B).
[22] - Disassemble and inspect parts (C) to (J), making sure orifices are clear of
contamination.
[23] - Inspect spring (G).
0.8 in.
Test length 18 mm at 32 at 44 N
0.7 in. at 7 to 10 lb
[24] - Lubricate the new O-rings and backup ring. Install ring (C) from OPPOSITE end of valve
(D) to prevent cutting the O-ring.
[25] - Lubricate the valve assembly and install it in the housing using a brass drift.
[26] - Apply grease to O-ring (K) and install it on the housing.

[27] -
LEGEND:
A O-ring
B O-ring
C O-ring
D Backup ring
Inspect O-ring (B) for correct position. Use petroleum jelly to hold the ring in position.
[28] - Install new components (A), (C) and (D) in the detent housing.
[29] -
LEGEND:
A Valve spool assembly
B Gasket
C Detent housing
D Notches
Install valve spool assembly (A) through the detent housing (C).
[30] - Install knob assembly, making sure notches (D) align correctly.
[31] -
→NOTE:
For designs using lock washers, install washers with bowed ID toward
screw heads.
Install and hand tighten the hex. socket screws of the detent assembly with lock washers
[ Not used in all designs ]
, then tighten.

8 lb-ft
[32] - Knob should turn without binding.

[33] -
Using hex. socket screws (C), install ring (A) and flange (B).


Actuated) — Inspecting the Check Valves
[1] -
→NOTE:
The check valves at the extend port and retract port are both of the same
design. The illustration shows the valve at the extend port.
Inspect parts (A) to (D) for signs of damage.

0.9 in.
0.7 in. at 0.9 to 1.3 lb
[2] - Install valve components making sure recessed side of spacer ring (B) is positioned
toward spring (C).
[3] - Install a new O-ring on plug (A).
Plug Torque 45 N˙m
34 lb-ft

Actuated) — Inspecting the Inlet Check Valve
→NOTE:
New E-SCVs are not equipped with an inlet check valve because it is no
longer needed.

[1] -
If equipped, inspect spring (B) and valve (C) for signs of damage.
[2] - Valve (C) should slide smoothly in the housing bore.
[3] - Install plug (A) using a new O-ring.
Plug Torque 65 N˙m
48 lb-ft

Actuated) — Inspecting the Pressure Compensator
Valve
→NOTE:
The pressure compensator valve is serviced as a kit.
Visually inspect the compensator valve. Valve should slide into the housing without binding.
Install valve (B) with new O-ring on plug. Tighten plug (A).

Plug Torque 82 N˙m
60 lb-ft


Actuated) — Reconditioning
LEGEND:
A Stepper motor
B Rack

C O-ring
D O-ring
E Back-up washer
[ Housing version 1 only (see sectional views) ]
F Inlet check valve

[ If equipped ]
G Shuttle valve
[ If equipped ]
H O-ring
I Pressure compensator valve
J Spool
K O-ring
L Wiper seal
M Seal plate
N Spring seat
O Centering spring
P Spacer ring
[ If equipped ]
Q Special screw
R Shim
[ If equipped ]
S Endplate
T Filter element
U Check valve (extend port)
V Check valve (retract port)
1 Housing version 1
2 Housing version 2
CAUTION:

reference ”Reconditioning the Selective Control Valves and Couplers —
General Instructions on Safety and Reconditioning” in this Group.
Remove the SCVs. See reference ”Remove Selective Control Valves” in this Group.
Inspect the check valves. See ”Series 300 Selective Control Valves (Electrically
Actuated) — Inspecting the Check Valves” in this Group.
→NOTE: New E-SCVs are not equipped with an inlet check valve
because it is no longer needed.
Inspect the inlet check valves. See ”Series 300 Selective Control Valves (Electrically
Actuated) — Inspecting the Inlet Check Valves” in this Group.
Inspect the pressure compensator valve. See ”Series 300 Selective Control Valves
(Electrically Actuated) — Inspecting the Pressure Compensator Valve” in this Group.

[1] -
→NOTE:
Before disassembly, check whether the stepper motors have been marked
for re-installation in the same position on the tractor (SCV on pos. 1, 2, 3
and 4).
Using the illustration as a guide, disassemble the SCVs as necessary.

[2] - The thread on special screw (Q) is coated with L41476 (LOCTITE ™ 270) sealant.
IMPORTANT:
on special screw (Q) and from inside of valve spool (J).
[1] -
IMPORTANT:
The spool must be securely held using a vise with BRASS jaws. Failure to
use brass jaws will result in damage to the spool requiring complete valve
replacement.
Install O-ring (A) and wiper seal (B). Install wiper seal (B) with its lip facing towards sealing
plate (C).
[2] - Locate seal plate (C), spring seats (D) and centering spring (E).

[3] -
Put spacer ring (if equipped) on special screw (F). Coat the thread on the special screw with
L41476 (LOCTITE 270) sealant, and install the screw on the valve spool.
7.4 lb-ft
[4] - Housing version 2

[ See exploded view ]
only: Install O-ring (L) in groove.
[5] -
IMPORTANT:
Once valve spool (G) is assembled, apply a light coating of clean hydraulic oil to it and install
it in housing (H). If equipped, position shim (I).

[6] - Install end-cap (J) and hex. socket screws (K).

7.4 lb-ft
[7] -
Housing version 1
[ See exploded view ]
only: Position O-ring (L) and back-up washer (M) and press them evenly into the housing as
far as they will go.
[8] - Install O-ring (N). Install rack (O) and align the teeth with regard to the direction of
forward travel.
SCV on pos. 1 and 3: Teeth facing to front.

SCV on pos. 2 and 4: Teeth facing to rear.
[9] -
→NOTE:
Note the marks applied before removal of SCVs and re-install the stepper
motors on their original positions.
Align the plug housing on stepper motor (Q) towards the teeth on the rack, and install the
stepper motor on the housing. Install hex. socket screws (P), and tighten them evenly.

7.4 lb-ft
[10] - Install the SCVs. See reference ”Install Selective Control Valves” in this Group.

Installing the Selective Control Valves

[1] -
Preliminary work with mechanically actuated SCVs: If a SCV unit is replaced as a unit, remove
wiper seal (B; if equipped) from the new unit and replace seal plate (A) with flange (C). Make
sure that flange (C) has a groove for O-ring (D).
[2] -
IMPORTANT:
Make sure that the valve plates are installed correctly. See “Installing the
Shuttle Valves” in this Group.
→NOTE:
Note the marks applied before removal and re-install the SCVs with stepper
motors to their original positions.
→NOTE:
If there is only one SCV, assembly is facilitated by screwing two studs into
the main block and placing the SCV on the studs. Then install the 1st cap
screw and replace the studs with the remaining cap screws.
Insert the end with the shorter thread and screw in studs (A) (if equipped) as far as they will
go, then slacken them off by 1/4 of a turn.

[3] - Install O-ring (B).

[4] - Coat valve plate (C; if equipped) lightly with grease, and install it in the recess.
[5] - — With electronically actuated SCVs: Align the SCV in relation to the direction of forward
travel:
SCV on pos. 1 and 3: Stepper motor′s plug aligned to front.

SCV on pos. 2 and 4: Stepper motor′s plug aligned to rear.
[6] - Place the SCV on the studs and slide it into position. Make sure that the valve plate does
not become skewed or falls out.
[7] - Install the endplate. See “Selective Control Valves — Installing the Endplate” in this
Group.
[8] -

LEGEND:
A Valve spool
B O-ring
C Flange
D O-ring
E Sleeve
F O-ring
G Lock nut
H Bowden cable
— With mechanically actuated SCVs: Reconnect the bowden cable.
a. Put O-ring (D) on flange (C) of the SCV unit.

b. Engage bowden cable (H) in spool (A).
c. Tighten sleeve (E).
37 lb-ft
d. Tighten lock nut (G).

37 lb-ft

[9] -
— With electronically actuated SCVs: Connect plugs (C).

→NOTE:
yellow mark near the SCV (pos. 4) connector.
→NOTE:
— If new stepper motors have been installed, the correct identifying names
and afterwards the SCV must be calibrated.
— If the selective control valves have been repaired, the SCV must be
calibrated.
See reference 245-SIC-001, Calibration and Input AddressesAddress SIC
040 — Calibration of Stepper Motor - IdentificationandAddress 020 —
Calibration of Selective Control Valves (E-SCV and E-ICV)in the Operation
and Tests Technical Manual.
[10] - Install oil lines (D) and (E) are, if equipped.

[11] - Reconnect the oil leak-off lines at the couplers.

Selective Control Valves — Installing the Endplate

Left endplate (standard version)
[1] -
Apply some grease and put O-rings (A), (B), (C) and (D) in position.
[2] - There must be NO valve plate between the endplate and the adjoining component!
[3] - Put on the endplate and tighten the hex. nuts evenly.
Hex. nut Torque 35 N˙m
26 lb-ft
Left endplate
[ Used to connect external control valves ]
(with LS pressure port and adjustable LS pressure relief)

[1] -
LEGEND:
A Endplate
B O-ring
C O-ring
D O-ring
E O-ring
F Valve plate
G LS pressure port
H Restrictor screw
Make sure that the throttle bore in the endplate is clear to a diameter of 0.8 mm (0.03 in.).
[2] - Install seal rings.
[3] - Coat valve plate (F) lightly with grease, and install it in the recess.
26 lb-ft
→NOTE:
Adjust throttle screw (H) for LS pressure relief, seeReference 270-15-093,

Selective Control Valves — Adjusting Left Endplate (with LS Pressure Port
and Adjustable LS Pressure Relief) in the Technical Manual ”Operation and
Tests”.
Left endplate
[ With hydraulically suspended cab ]
[ With electro-hydraulic pick-up hitch ]

(with LS port and pressure port)
[1] -
LEGEND:
A Endplate
B O-ring
C O-ring
D O-ring
E O-ring
F Valve plate
G LS pressure port
H Pressure connection
Install seal rings.
[2] - Coat valve plate (F) lightly with grease, and install it in the recess.
26 lb-ft
Right endplate
[ Not if a 300 Series SCV is installed at position 3 or 4 ]
(standard version)

[1] -
Install seal rings.

26 lb-ft
Right endplate
[ With a 300 Series SCV at position 3 or 4 ]
(with LS pressure port)

[1] -
LEGEND:
A Endplate
B Valve body
[ If equipped ]
C Spring
[ If equipped ]
D O-ring
E LS pressure port
F O-ring
G Load-sense line to hydraulic pump
H O-ring
J O-ring
K O-ring
L O-ring
Inspect the check valve
[ If equipped ]
. Make sure that the throttle bore in the valve body is clear to a diameter of 0.8 mm (0.03
in.).
[2] - Install seal rings.
26 lb-ft
Right endplate
[ With independent selective control valve (ICV) ]
(with extra ports and LS pressure increase)

[1] -
LEGEND:
A Seal ring
B Valve plate
C Endplate
[2] - Coat valve plate (B) lightly with grease, and install it in the recess.
26 lb-ft
Right endplate
[ Used to connect external control valves ]
(with extra ports and adjustable LS pressure relief)

[1] -
LEGEND:
A Seal ring
B Valve plate
C Endplate
[2] - Coat valve plate (B) lightly with grease, and install it in the recess.
26 lb-ft
→NOTE:
Adjust throttle screw (D) for LS pressure relief, seeReference 270-15-094,

Selective Control Valves — Adjusting Right Endplate (with Extra Ports and
Adjustable LS Pressure Relief) in the Technical Manual ”Operation and
Tests”.

Selective Control Valves — Reconditioning the

Couplers
DeLuxe coupler (version ”A”)
LEGEND:
A O-ring
B Fitting, width across flats 42 mm
C O-ring
D Back-up ring
[ If equipped ]
E Leakage ring
F O-ring
G Housing, front, width across flats of 42 mm
H Inner assembly
I Housing, center, width across flats of 42 mm
J Housing, rear, width across flats of 46 mm
K Backup ring
L O-ring
M Seal ring with profile
N O-ring
O Backup ring

P O-ring
Q Ball (6 used)
R O-ring
S Backup ring
T Backup ring
U O-ring
DeLuxe coupler (version ”A”)
→NOTE:
If housing or other coupler parts are damaged (with the exception of back-
up and seal rings) the coupler must be replaced as a complete assembly.
→NOTE:
Observe the utmost cleanliness and install accurately.
[1] - Remove fitting (B).

[2] - Remove leakage ring (E).
[3] - Remove housing (G).
[4] -
→NOTE:
Make sure that balls (Q) do not fall out.
Hold rear assembly using KJD10277 special tool and screw out the inner assembly (H) by
means of a 12 mm hex. wrench.
Installation tool
KJD10277
Selective control valves, reconditioning the couplers

[5] - Remove the sealing cone, the sealing ring with profile (M), the spring seat and the
spring from the inner assembly (H).
[6] - Clean the various components and inspect them for signs of wear or damage.
[7] - Replace all back-up and seal rings.

[8] -
→NOTE:
There are two versions of couplers; the earlier version does not have the
back-up ring (D) in the fitting (B).
Before installation apply a light coating of grease to back-up and seal rings.
[9] - Re-assemble the coupler, reversing disassembly procedure and comply with the
following points.
[10] -
→NOTE:
Make sure that all balls (Q) are installed.
Screw the inner assembly (H) onto the rear coupler assembly using KJD10277 special tool.
Inner to rear assembly Torque 50 N˙m
37 lb-ft
[11] - Install fitting (B).

Fitting to housing Torque 100 N˙m
74 lb-ft
[12] - Attach coupler to SCV and check that it operates correctly and does not leak.
48 lb-ft

DeLuxe coupler (version ”B”)
LEGEND:
A Backup ring
B O-ring
C O-ring
D Leakage ring
E Snap ring
F O-ring
DeLuxe coupler (version ”B”)
→NOTE:
If housing or other coupler parts are damaged (with the exception of the
outer back-up and seal rings) the coupler must be replaced as a complete
assembly.
→NOTE:
Observe the utmost cleanliness and install accurately.
[1] - Remove parts (A) to (F).

Section 70 - HYDRAULIC SYSTEM Group 30: Independent Selective Control Valve
[3] - Thoroughly clean the grooves for the seal rings.
[4] -
→NOTE:
Make sure backup ring (A) with asymmetrical shape is correctly installed,
see detail drawing.
Before installation apply a light coating of grease to back-up and seal rings.
[5] - Attach coupler to SCV and check that it operates correctly and does not leak.
48 lb-ft

Group 30 - Independent Selective Control Valve

Reconditioning Independent Control Valves —
Summary of References
Reconditioning the mechanically (M-ICV
[ M-ICV = Mechanically-controlled - Independent Control Valve ]

) and electrically (E-ICV
[ E-ICV = Electronically-controlled - Independent Control Valve ]
) actuated independent control valves is dealt with at the following references.
For M-ICV (with pressure compensator or inlet check valve):
Removing the Independent Control Valve (M-ICV)

Reconditioning the Independent Control Valve (M-ICV)
Independent Control Valves — Reconditioning the Inlet Plate
Assembling the Independent Control Valve (M-ICV)
Installing the Independent Control Valve (M-ICV)
For E-ICV:
Independent Control Valve (E-ICV) — Removing and Installing the Stepper Motors
Removing the Independent Control Valve (E-ICV)
Reconditioning the Independent Control Valve (E-ICV)
Independent Control Valves — Reconditioning the Inlet Plate
Assembling the Independent Control Valve (E-ICV)
Installing the Independent Control Valve (E-ICV)
Other Material
Number Name Use
• R117738 (us) Special grease Assembling the detent parts

Specifications
M-ICV (with pressure compensator): Control valve for loader boom

Centering spring Free length (approx.) 56.64 mm
2.23 in
Test length 27.7 mm at 132 N
1.09 in. at 29.7 lb
Detent spring Free length (approx.) 26.5 mm
1.04 in.
Test length 17.46 mm at 76 ± 7.6 N
0.69 in. at 17 ± 1.7 lb
M-ICV (with pressure compensator): Control valve for loader bucket

1.84 in
0.814 in. at 29.3 lb
M-ICV (with inlet check valve): Control valve for loader boom
1.84 in
0.814 in. at 29.3 lb
1.04 in
0.69 in. at 17 ± 1.7 lb
M-ICV (with inlet check valve): Control valve for loader bucket
1.70 in
E-ICV: Control valve for loader boom

Centering spring Free length (approx.) 61 mm
2.4 in
1.170 in. at 15 lb
E-ICV: Control valve for loader bucket

2.4 in
1.170 in. at 15 lb
E-ICV: Control valve for additional function

2.4 in
1.170 in. at 15 lb
Spring on piston of pressure compensator Free length (approx.) 21.5 mm
0.85 in
0.42 in. at 3.21 lb
Special screw, centering spring Torque 10 N˙m
7.4 lb-ft
Hex. socket screws, detent housing to control valve housing Torque 11 N˙m
8 lb-ft
Hex. socket screws, end-cap to control valve Torque 11 N˙m
8 lb-ft
Hex. socket screws, flange to control valve Torque 10 N˙m
7.4 lb-ft
Inlet plate and endplate to control valves:

5/16" hex. nuts Torque 19 N˙m
14 lb-ft
33 lb-ft
Pressure limiting valve to inlet plate Torque 45 N˙m
33 lb-ft
Threaded pin with restrictor to inlet plate Torque 9 N˙m
6.6 lb-ft
SCVs to console, cap screws Torque 55 N˙m
40 lb-ft
Console to main frame, cap screws Torque 200 N˙m
150 lb-ft
M-ICV: Bowden cables on SCV

37 lb-ft
37 lb-ft
E-ICV: Stepper motor to control valve

7.4 lb-ft

Removing the Independent Control Valve (M-ICV)
CAUTION:

Instructions on Safety and Reconditioning” in Section 70, Group 25.
[1] -
→NOTE:
Mark the bowden cables before removing them.
Remove lock nut (B) and sleeve (A). Disengage bowden cable.
[2] -
Disconnect the oil lines at the ICV and seal the openings with plugs.
[3] - Take out the two cap screws (A) and lift off the ICVs with console.
[4] - Take out the four cap screws (B) on the console.

[5] - — For reconditioning the ICV refer to “Reconditioning the Independent Control Valve (M-
ICV)” in this Group.
For installation of the ICV refer to “Installing the Independent Control Valve (M-ICV)” in this
Group.

Reconditioning the Independent Control Valve (M-

ICV)
Reconditioning control valves (with pressure compensator)
M-ICV with pressure compensator
LEGEND:
1 Inlet plate
2 O-ring
3 Pressure limiting valve with seal
4 O-ring
5 Control valve housing for loader boom
6 Spool
7 O-ring

8 Spacer ring
9 O-ring
10 Spring seat
11 Centering spring
12 O-ring
13 Special screw
14 Ball (4 used)
15 Detent spring
16 Ball
17 Housing
18 Sleeve
19 Plate
20 Snap ring
21 Cap
23 Spacer sleeve (2 used)
24 Pressure compensator piston
25 Spring
26 Control valve housing for loader bucket
27 Spool
28 Wiper seal
29 Seal plate
30 Centering spring
31 Special screw
32 Endplate
34 Endplate
35 5/16" stud (2 used)
36 5/16" hex. nut (4 used)
37 3/8" hex. nut (2 used)
38 3/8" studs
39 Flange
40 O-ring
41 Hex. socket screws
42 Shuttle valve
43 Threaded pin with throttle bore
General information
For removal of the ICV, refer to ”Removing the Independent Control Valve (M-ICV)” in this
Group.
For reconditioning the inlet plate (1), refer to ”Independent Control Valves — Reconditioning
the Inlet Plate” in this Group.

CAUTION:

General Instructions on Safety and Reconditioning” in Section 70, Group
25.
IMPORTANT:
The SCV unit and valve spool must be held firmly in a vice with brass jaws,
otherwise the SCV unit may become damaged and have to be replaced.
Disassembling the control valves
[1] - Mark the control valves.

[2] - Using the illustration as a guide, disassemble the control valves as necessary.
[3] - Take care when removing sleeve (18), as balls (14) and (16) may spring out.
Assembling the control valves
Control valve (no. 1) for loader boom
[1] - Install spacer (A) using a new O-ring.

[2] - Inspect the centering spring (C).

2.23 in
1.09 in. at 29.7 lb
[3] - Install spring seats (B) and centering spring (C).

[4] -
Install special screw (D) using a new O-ring.

7.4 lb-ft
[5] - Once valve spool (E) is assembled, apply a light coating of clean hydraulic oil to it and
install it in housing (F).
[6] - Inspect the detent spring.
1.04 in
0.69 in. at 17 ± 1.7 lb
[7] - Coat the detent spring and balls with special grease (R117738), and insert (see arrows).
Number Name Use

[8] -
Install detent housing (G) and spacer sleeves (H). Tighten hex. socket screws (I) by hand.
[9] - Insert the detent sleeve (J) so that the four outer balls just make contact and no more.
Use a suitable tool to press the center ball down a little against the spring, and at the same
time press back on sleeve (J) until the balls engage. Check that sleeve (J) and the five balls
are installed in their correct positions (see sectional view).
[10] -
Install plate (K) and put on snap ring (L).

[11] - Tighten hex. socket screws (I). Put on the protective cap (M).
8 lb-ft

[12] -
Install O-ring (N). Install flange (O) and hex. socket screws (Q).
7.4 lb-ft
[13] - Inspect spring (S) of the pressure compensator.

Spring Free length (approx.) 21.5 mm
0.85 in
0.42 in. at 3.21 lb
[14] - Install the piston (R) of the pressure compensator nose-down on the valve. Include
spring (S).
Control valve (no. 2) for loader bucket
[1] - Install O-ring (A) and wiper seal (B). Install wiper seal (B) with its lip facing towards
sealing plate (C).

[2] - Inspect the centering spring (E).

1.84 in
0.814 in. at 29.3 lb
[4] -
Install special screw (F), remembering to include a new O-ring.

7.4 lb-ft
[5] - Once valve spool (G) is assembled, apply a light coating of clean hydraulic oil to it and
install it in housing (H).
[6] -
Install end-cap (I) and hex. socket screws (J).

8 lb-ft

[7] - Install O-ring (K). Install flange (L) and hex. socket screws (M).
7.4 lb-ft
[8] - Inspect spring (O) of the pressure compensator.

0.85 in
0.42 in. at 3.21 lb
[9] - Install the piston (N) of the pressure compensator nose-down on the valve. Include
spring (O).
[10] - Go to: ”Independent Control Valves — Reconditioning the Inlet Plate” in this Group.
Reconditioning control valves (with inlet check valve)

M-ICV with inlet check valve
LEGEND:
1 Inlet plate
2 O-ring
3 Plug
4 O-ring
6 Spool
7 O-ring
8 Spacer ring
9 O-ring
10 Spring seat
11 Centering spring
12 O-ring
13 Special screw

14 Ball (4 used)
15 Detent spring
16 Ball
17 Housing
18 Sleeve
19 Plate
20 Snap ring
21 Cap
24 Valve
25 Spring
27 Spool
28 Wiper seal
29 Seal plate
30 Centering spring
31 Special screw
32 Endplate
34 Endplate
35 5/16" stud (2 used)
36 5/16" hex. nut (4 used)
38 3/8" studs
39 Flange
40 O-ring
42 Shuttle valve
General information
For removal of the ICV, refer to ”Removing the Independent Control Valve (M-ICV)” in this
Group.
CAUTION:

25.
IMPORTANT:


[3] - Take care when removing sleeve (18), as balls (14) and (16) may spring out.

1.84 in
0.814 in. at 29.3 lb

[4] -

7.4 lb-ft
[6] - Inspect the detent spring.
1.04 in
0.69 in. at 17 ± 1.7 lb
[7] - Coat the detent spring and balls with special grease (R117738), and insert (see arrows).
Number Name Use

[8] -
Install detent housing (G) and spacer sleeves (H). Tighten hex. socket screws (I) by hand.
[9] - Insert the detent sleeve (J) so that the four outer balls just make contact and no more.
Use a suitable tool to press the center ball down a little against the spring, and at the same
time press back on sleeve (J) until the balls engage. Check that sleeve (J) and the five balls
are installed in their correct positions (see sectional view).
[10] -
Install plate (K) and put on snap ring (L).

[11] - Tighten hex. socket screws (I). Put on the protective cap (M).
8 lb-ft

[12] -
Install O-ring (N). Install flange (O) and hex. socket screws (Q).
7.4 lb-ft
[13] - Inspect spring (S) of the inlet check valve.

0.85 in
0.42 in. at 3.21 lb
[14] - Install inlet check valve (R) and spring (S).
[1] - Install O-ring (A) and wiper seal (B). Install wiper seal (B) with its lip facing towards
sealing plate (C).

[2] - Inspect the centering spring (E).

1.70 in
[4] -
Install special screw (F) using a new O-ring.

7.4 lb-ft
[5] - Once valve spool (G) is assembled, apply a light coating of clean hydraulic oil to it and
install it in housing (H).
[6] -
Install end-cap (I) and hex. socket screws (J).

8 lb-ft

[7] - Install O-ring (K). Install flange (L) and hex. socket screws (M).
7.4 lb-ft
[8] - Inspect spring (O) of the inlet check valve.

0.85 in
0.42 in. at 3.21 lb
[9] - Install inlet check valve (N) and spring (O).

[10] - Go to: ”Assembling the Independent Control Valve (M-ICV)” in this Group.

Independent Control Valves — Reconditioning the

Inlet Plate
→NOTE:
Pressure limiting valve (A) and threaded pin with throttle bore (B) is
present on independent control valves (ICV) with pressure compensator,
only.
[1] - Remove the various components, clean them and inspect them for signs of damage.
[2] - Replace pressure limiting valve (A) as a single unit, if necessary.
Pressure limiting valve Torque 45 N˙m
33 lb-ft
[3] - Check that the throttle bore (B) on the threaded pin is not blocked.
Threaded pin with throttle bore Torque 9 N˙m
6.6 lb-ft
[4] - Go to:
— ”Assembling the Independent Control Valve (M-ICV)” in this Group.
—”Assembling the Independent Control Valve (E-ICV)”in this Group.

Assembling the Independent Control Valve (M-ICV)

[1] -
→NOTE:
Pay attention to the marks made prior to disassembly.
LEGEND:
A Inlet plate
B O-ring
C 5/16" studs
D 3/8" studs
Screw hex. nuts onto the ends of the studs with the shorter thread. Tighten nuts so that one
turn of the thread protrudes from the nut.
[2] - Insert studs (C) and (D) into the inlet plate (A) as shown.
[4] -
With the O-ring groove uppermost, install the control valve (A) for loader boom operation on
the inlet plate.
→NOTE:
The control valve for loader boom operation has the longer end-cap.

[5] - Install O-ring (D).

[6] - On control valve with pressure compensator: Check that the pressure compensator′s
piston (nose-down on the valve) and spring (B) are installed in their correct positions.
On control valve with inlet check valve: Check that the inlet check valve′s piston (without
nose) and spring (B) are installed in their correct positions.
[7] - Install shuttle valve (C).
[8] -
Install the control valve (A) for loader bucket with the O-ring groove uppermost.
[9] - Install O-ring (C).
[10] - On control valve with pressure compensator: Check that the pressure compensator′s
piston (nose-down on the valve) and spring (B) are installed in their correct positions.
On control valve with inlet check valve: Check that the inlet check valve′s piston (without
nose) and spring (B) are installed in their correct positions.
[11] - This time, do NOT install a shuttle valve!
[12] -
Install the endplate (A) as shown. Tighten hex. nuts (B) and (C) by hand. Then tighten them
evenly to a preliminary torque of approx. 13 N˙m (10 lb-ft).

[13] - Tighten the two 5/16" hex. nuts (C).

14 lb-ft
[14] - Tighten the 3/8" hex. nuts (B).

33 lb-ft
[15] - Make sure the two valve spools (D) are free to move!
[16] - For installation of the ICV, refer to ”Installing the Independent Control Valve (M-ICV)” in
this Group.

Installing the Independent Control Valve (M-ICV)

[1] -
Attach the ICV unit to the console as shown using the four cap screws (B).
40 lb-ft
[2] -
Install the ICV unit and console on the frame and tighten the two cap screws (A).
Console to frame, cap screws Torque 200 N˙m
150 lb-ft
[3] - Take out the plugs and re-attach the oil lines.
[4] - Put O-ring (B) on the flange for the bowden cable.

[5] -
When reconnecting bowden cables, pay attention to the marks. Before connecting the
bowden cables to the selective control valves, move the locking collar on the multi-function
lever to the unlocked position (four arrows).
[6] - Engage bowden cables in the spools of the selective control valves.
[7] - Tighten sleeve (A).
37 lb-ft
[8] - Tighten lock nut (B).

37 lb-ft
[9] - Carry out a functional check, and re-adjust the control lever if necessary. See “Adjusting
the Multifunction Lever” , Section 70, Group 05.

Independent Control Valve (E-ICV) — Removing and

Installing the Stepper Motors
CAUTION:

Remove the stepper motors
[1] -
→NOTE:
(SCV on pos. 1, 2 or 3).
Near the pos. 1 SCV (loader boom) connector the wiring harness has a red
mark and a yellow mark near the pos. 2 SCV (loader bucket) connector.
Before you disconnect them, check that the colored marks are still visible;
if they are not, mark the plugs accordingly.
Control valve positions

LEGEND:
A SCV no. 1
B SCV no. 2
C SCV no. 3
[ If equipped ]
D Plugs
E Hex. socket screws
Disconnect plugs (D) at stepper motors.
[2] - Take out hex. socket screws (E) and lift off the stepper motors.
[3] - For removal of the ICV refer to“Removing the Independent Control Valve (E-ICV)”in this
Group.

[1] -
LEGEND:
A Flange, stepper motor
B Control valve housing
C Valve spool
D Rack
Identify the racks for the individual control valves.
a. Measure overall length (a) of rack (D).

b. Determine distance (b) between valve spool end (C) and flange (A). When doing this,
the valve spool must be in neutral position.
c. If the distance (b) is:
10.3 mm (0.405 in.), use a rack with an overall length of (a) 54 mm (2.126 in.).
23.0 mm (0.905 in.), use a rack with an overall length of (a) 44 mm (1.732 in.).
[2] -
Install a new O-ring (D) in the flange.

[3] - Check that the racks are installed in their correct positions.
SCV no. 1: Teeth (A) aligned to the top.

SCV no. 2: Teeth (B) aligned to the bottom.
SCV no. 3
[ If equipped ]
: Teeth (C) aligned to the top.
[4] -
→NOTE:
Note the marks applied before removal and re-install the stepper motors on
their original positions.
Align stepper motor and put it in place.
SCV no. 1: Stepper motor connector facing up

SCV no. 2: Stepper motor connector facing down
SCV no. 3
[ If equipped ]
: Stepper motor connector facing up
[5] - Install the three hex. socket screws (A), tightening them evenly.
7.4 lb-ft

[6] -
Re-establish connections (A) paying attention to the marks.

[7] - — If new stepper motors have been installed, the correct identifying names and
afterwards the SCV must be calibrated.
— If the control valves have been reconditioned, the SCV must be calibrated.
See reference 245-SIC-001, Calibration and Input AddressesAddress SIC 040 — Calibration of
Stepper Motor - IdentificationandAddress 020 — Calibration of Selective Control Valves (E-
SCV and E-ICV)in the Operation and Tests Technical Manual.

Removing the Independent Control Valve (E-ICV)

[1] -
CAUTION:
→NOTE:
(SCV on pos. 1, 2 or 3).
Remove stepper motors (A, B, C

[ If equipped ]
), refer to“Independent Control Valve (E-ICV) — Removing and Installing the Stepper
Motors”in this Group.
[2] -
Take out racks (A).

[3] - Disconnect the oil lines (B), (C) and (D) at the ICV and seal the openings with plugs.
[4] - Remove the four console cap screws (E) and the SCV.

[5] - — For reconditioning the ICV refer to“Reconditioning the Independent Control Valve (E-
ICV)”in this Group.
— For installation of the ICV refer to“Installing the Independent Control Valve (E-ICV)”in this
Group.

Reconditioning the Independent Control Valve (E-

ICV)
LEGEND:
1 Inlet plate
2 O-ring
3 Pressure limiting valve
4 O-ring
6 Spool
7 O-ring
8 Spacer ring
9 O-ring
10 Spring seat
11 Centering spring
12 O-ring
13 Special screw
14 Spacer ring
15 Endplate
16 Plug
19 Pressure compensator piston
20 Spring
22 Spool
23 Special screw
24 Endplate
25 Endplate
26 5/16" stud (2 used)
27 5/16" hex. nut (4 used)
29 3/8" studs
30 O-ring
31 Flange
33 O-ring
34 Shuttle valve
35 Threaded pin with throttle bore
36 Control valve for loader boom
37 Control valve for loader bucket
38 Control valve housing for additional function
39 5/16" stud (2 used)
40 3/8" studs
General information
For removal of the ICV, refer to”Removing the Independent Control Valve (E-ICV)”in this
Group.
For reconditioning the inlet plate (1), see ”Independent Control Valves — Reconditioning the
Inlet Plate” in this Group.

CAUTION:

25.
IMPORTANT:
If components on electronically actuated control valve are ever replaced,

the E-SCV / E-ICV controller (SIC) must be recalibrated. See Reference 245-
SIC-001 , Calibration and Input Addresses of Control Valves (E-SCV and E-
ICV) in the Technical Manual ”Operation and Tests”.
IMPORTANT:
Reconditioning control valves



2.4 in
1.170 in. at 15 lb

[4] -

7.4 lb-ft
install it in housing (F). Install spacer (G).

[6] -
Install end-cap (H), spacer sleeves (I) and hex. socket screws (J).
8 lb-ft
[7] - Install O-ring (K) in the housing and O-rings (L) and (M) on flange (N). Install flange (N)
using hex. socket screws (O).
7.4 lb-ft
[8] - Inspect spring (Q) of the pressure compensator.

0.85 in
0.42 in. at 3.21 lb
[9] - Install the piston (R) of the pressure compensator nose-down on the valve. Include
spring (Q).


2.4 in
1.170 in. at 15 lb

[4] -

7.4 lb-ft

[6] -
Install end-cap (G), spacer sleeves (H) and hex. socket screws (I).
8 lb-ft
[7] - Install O-ring (J) in the housing and O-rings (K) and (L) on flange (M). Install flange (M)
using hex. socket screws (N).
7.4 lb-ft

0.85 in
0.42 in. at 3.21 lb
[9] - Install the piston (O) of the pressure compensator nose-down on the valve. Include
spring (Q).
[10] - — If the unit has two control valves, go to ”Independent Control Valves —
Reconditioning the Inlet Plate” in this Group.
— If the unit has three control valves, go to ”Control Valve (No. 3) for Additional Function”.

Control valve (no. 3) for additional function:

2.4 in
1.170 in. at 15 lb

[4] -

7.4 lb-ft

[6] -
Install end-cap (G), spacer sleeves (H) and hex. socket screws (I).
8 lb-ft
[7] - Install O-ring (J) in the housing and O-rings (K) and (L) on flange (M). Install flange (M)
using hex. socket screws (N).
7.4 lb-ft

0.85 in
0.42 in. at 3.21 lb
[9] - Install the piston (O) of the pressure compensator nose-down on the valve. Include
spring (Q).
[10] - Go to: ”Independent Control Valves — Reconditioning the Inlet Plate” in this Group.

Assembling the Independent Control Valve (E-ICV)
→NOTE:
Pay attention to the marks made prior to disassembly.
[1] -
LEGEND:
A Inlet plate
B O-ring
C 5/16" studs
D 3/8" stud
Screw hex. nuts onto the studs. Use the ends of the studs with the shorter thread. Tighten
nuts so that one circuit of thread protrudes out of the nut.
[2] - Pass studs (C) and (D) through the inlet plate (A) as shown in the illustration.

[4] -
With the O-ring groove uppermost, install the control valve (A) for loader boom operation on
the inlet plate.
→NOTE:
The control valve for loader boom operation has the longer end-cap.
[5] - Install O-ring (D).

[6] - Install the pressure compensator′s piston nose-down on the valve, and check that spring
(B) is installed in its correct position.
[7] - Install shuttle valve (C).

[8] -
With two control valves
With three control valves

Install the control valve (A) for loader bucket with the O-ring groove uppermost.
[10] - Install the pressure compensator′s piston nose-down on the valve, and check that
spring (B) is installed in its correct position.
[11] - — Unit with two control valves, for loader boom and bucket: Do NOT include ANY
shuttle valve! Go to step 16 , Installing the Endplate.
— Unit with three control valves, for loader boom and bucket plus additional function: Install
shuttle valve (D). Go to 12.

[12] -
Install the control valve (A) for an additional function with the O-ring groove uppermost.
[14] - Install the pressure compensator′s piston nose-down on the valve, and check that
spring (B) is installed in its correct position.
[15] - This time, do NOT include ANY shuttle valve!
[16] -
Install the endplate (A) as shown. Tighten hex. nuts (B) and (C) by hand. Then tighten them
evenly to a preliminary torque of approx. 13 N˙m (10 lb-ft).
[17] - Tighten the 5/16" and 3/8" hex. nuts (C and B respectively).
14 lb-ft
33 lb-ft
[18] - Make sure that the valve spools (D) are free to move!
[19] - For installation of the ICV refer to“Installing the Independent Control Valve (E-ICV)”in
this Group.

MISCELLANEOUS (g) by Belgreen
Installing the Independent Control Valve (E-ICV)

[1] -
Attach the ICV unit to the console using the cap screws.
40 lb-ft
[2] - Remove plugs and connect oil lines (B), (C) and D.
[3] - For installation of the stepper motors refer to“Independent Control Valve (E-ICV) —
Removing and Installing the Stepper Motors”in this Group.

Table of contents
Special Tools .......................................................................................................................... 1
Remove and Install the Main Frame (Summary of References) ............................................. 6
Remove the Main Frame ........................................................................................................ 7
Install the Main Frame .......................................................................................................... 19
Remove and Install the Front Axle or Front-Wheel Drive Axle (Summary of References)
....................................................................................................................................... 22
Remove the Front-Wheel Drive Axle .................................................................................... 23
Install the Front-Wheel Drive Axle ........................................................................................ 27
Remove the Front-Wheel Drive Axle with TLS ...................................................................... 30
Install the Front-Wheel Drive Axle with TLS ......................................................................... 39
Remove and Install the Front Axle Support (Summary of References) ................................ 42
Remove Front Axle Support ................................................................................................. 43
Install Front Axle Support ..................................................................................................... 53
Group 05 - Main Frame ........................................................................................................... 56
Repair specifications ............................................................................................................ 56
Repairing the main frame .................................................................................................... 57
Group 10 - Front Wheels, Rear Wheels and Fenders ......................................................... 60
Front Wheels, Rear Wheels and Fenders - Reconditioning (Summary of References) .......... 60
Special tools ......................................................................................................................... 60
Pivoting Front Fender ........................................................................................................... 62
Removing the Front and Rear Wheels .................................................................................. 65
Reconditioning the Front and Rear Wheels .......................................................................... 68
Installing the Front and Rear Wheels ................................................................................... 70
Group 15 - Trailer Mounting and Swinging Drawbar ......................................................... 76
Trailer Mounting and Swinging Drawbar — Reconditioning (Summary of References) ........ 76
Specifications ....................................................................................................................... 77
Check the Manually-Operated Trailer Hitch for Wear ........................................................... 78
Check Remote Controlled Trailer Hitch for Wear .................................................................. 82
Checking the Tow-Hook for Wear ......................................................................................... 86
Checking the Hitch Ball for Wear ......................................................................................... 86
Checking the Swinging Drawbar for Wear ............................................................................ 88
Installing trailer mounting for center link ............................................................................. 89
Installing the Guide Rails ..................................................................................................... 90
Reconditioning the Automatic Trailer Hitch (One-Lever Operation) ..................................... 95
Reconditioning the Automatic Trailer Hitch (Two-Lever Operation) ................................... 100
Reconditioning the Automatic Trailer Hitch (One-Lever Operation) ................................... 103
Remote Control for Automatic Trailer Hitch ....................................................................... 111
Reconditioning the height-adjustable trailer hitch (Italy and Spain only) ........................... 118
Swinging Drawbar - Exploded View .................................................................................... 120
Swinging drawbar (with pick-up hitch) ............................................................................... 121
Group 20 - Triple Link Suspension (TLS) of Front-Wheel Drive Axle ............................ 122
Triple Link Suspension (TLS) of Front-Wheel Drive Axle - Summary of References ............ 122

Special or Essential Tools ................................................................................................... 123

Other material .................................................................................................................... 126
Relieving Pressure in the Hydraulic System ....................................................................... 130
Removing/Installing the oscillation limiter ......................................................................... 132
Removing the Panhard link ................................................................................................ 134
Installing the Panhard Link ................................................................................................. 137
Removing and Installing the Sensor Rod ............................................................................ 138
Removing the Position Sensor ............................................................................................ 139
Reconditioning the Position Sensor .................................................................................... 141
Installing the Position Sensor ............................................................................................. 143
Removing Hydraulic Cylinder ............................................................................................. 145
Repairing the Hydraulic Cylinder ........................................................................................ 157
Installing Hydraulic Cylinder .............................................................................................. 175
Removing the Control Valve Block ..................................................................................... 183
Repairing the Valves in the Control Valve Block ................................................................ 186
Installing the Control Valve Block ....................................................................................... 195
Removing the Accumulator ................................................................................................ 197
Reconditioning the Accumulator ........................................................................................ 198
Installing the Accumulator ................................................................................................. 198
Removing and repairing the bearing support ..................................................................... 200
Installing the bearing support ............................................................................................ 212
Group 25 - Pick-Up Hitch ...................................................................................................... 220
Pick-Up Hitch - Summary of References ............................................................................. 220
Specifications ..................................................................................................................... 221
Other material .................................................................................................................... 221
Pick-Up Hitch — General Safety and Repair Information .................................................... 222
Check Tow Hook on Pick-Up Hitch for Wear ....................................................................... 223
Removing and Installing Pick-Up Hitch ............................................................................... 226
Pick-Up Hitch — Exploded View ......................................................................................... 228
Pick-Up Hitch — Control Lever and Lift Links ..................................................................... 230
Pick-Up Hitch — Hydraulic Parts ......................................................................................... 233
Electro-Hydraulically-Controlled Pick-Up Hitch — Electro-Hydraulic Parts .......................... 235
Repairing the Retainer Spring ............................................................................................ 237
Repairing the Latch Housing .............................................................................................. 240
Recondition the Hydraulic Cylinder .................................................................................... 243
Adjusting the Lift Links ....................................................................................................... 246
Adjusting the Guide Stop ................................................................................................... 248
Adjusting the Locking Pin ................................................................................................... 250
Pick-Up Hitch — Operational Check ................................................................................... 251

Section 80 - MISCELLANEOUS Group 00: Removal and Installation of Components

Special Tools
→NOTE:

Support stand
JT05725
Supporting tractor during rear wheel removal
Support stand
JT05724

Installing and removing tractor components. Also required: 2 commercial 5-metric ton vehicle
jacks
Support stand
JT02044
Support stand for universal use
Support stand
D05007ST

Removing and installing front axle or front-wheel drive axle
Extension
JDG749
Pivot
JDG750
Removal and installation of front axle or front-wheel drive axle.


Holding fixture
dealer fabricated
Used in conjunction with support stand D05007ST
Holding fixture
dealer fabricated

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)
Used to support drive shaft housing on TLS front-wheel drive axles
→NOTE:
This tool is attached to the support of a commercial jack. The correct hole
pattern of part (E) depends on the type of jack being used. Determine the
correct hole pattern and attach tool to the support of the jack, using at
least two M8 screws.

Cap Screws, Main Frame to Engine Mountings Torque 95 N˙m
70 lb.-ft.
Cap Screws, Main Frame to Support Torque 550 N˙m
405 lb.-ft.
Cap Screws, Main Frame to Cab Support Torque 240 N˙m
175 lb.-ft.
Cap Screws, Main Frame to Cross-Member Torque 550 N˙m
405 lb.-ft.
Cap Screws, Front Axle to Support Torque 550 N˙m
400 lb.-ft.
Cap Screws, Housing to Front-Wheel Drive Axle with TLS Torque 310 N˙m
230 lb.-ft.
Cap Screws, TLS Support to Cross-Member Torque 610 N˙m
450 lb.-ft.
TLS Control Block, Valve Screws Torque 7 N˙m
5.2 lb.-ft.
Remove and Install the Main Frame (Summary of

References)
Remove the Main Frame
Install the Main Frame

Remove the Main Frame

Remove front PTO (if equipped). See Remove Front PTO in Section 56, Group 00.
Remove front weights (if equipped).
Remove front loader (if equipped).
CAUTION:
Never attempt to take both halves of the main frame off at the same time.
IMPORTANT:
Place tractor on firm, level ground.
→NOTE:
The main frame consists of two halves, which can be removed separately
without previous removal of any tractor components.
The steps below describe removal of the left half of the main frame.
Remove the right half of the main frame in the same way.
In addition to the steps described, however, bowden cable brackets, brake and steering line
brackets (A) and (C) and, if equipped, front control valve (B) must be removed.

Apart from this, when removing the right main frame, you must also remove the additional oil
reservoir (A) and the compressed air tank (if equipped). See Changing the Compressed Air
Tank in Section 60, Group 30 or 31.
Before the left half of the main frame can be removed, the fuel tank first must be taken off.
See Removing the Fuel Tank in Section 30, Group 10.
CAUTION:
05).

[2] -
LEGEND:
A Screw for relieving pressure in lower cylinder chamber SP R
B Screw for relieving pressure in upper cylinder chamber SP Z
Relieving pressure in the hydraulic system (tractors with TLS front-wheel drive axle):
IMPORTANT:
Place tractor on firm, level ground.
Open and close both valves (A) and (B) at the control valve block several times to relieve
accumulator pressure.
CAUTION:
During this procedure, front end of the tractor will be raised and lowered
until the front axle support is finally resting on the front axle. Stay clear of
the danger area. Danger of pinching!
The engine must be shut off.

Slacken off the two hex. socket screws (A; 4 mm across flats) on the control valve block
by approx. half a turn.
Wait a little while until all the hydraulic pressure has been relieved.
→NOTE: Leave the two hex. socket screws (A) open until this work is
completed.
Retighten the hex. socket screws.

→NOTE: When the hydraulic system is pressure-free, it takes approx. 5
- 6 seconds for the axle to level itself after the engine has been
started. If the transmission oil is cold, or if there is a heavy load at the
front end, it may take approx. 60 seconds for the axle to level itself.

[3] -
Tractors without TLS

Position a wedge on right-hand side of front axle (A).
Place a wooden block (B) between front axle and front axle support on left-hand side. Make
sure that the block is firmly seated.
CAUTION:
When removing the right main frame, note the difference concerning
removal of parts (left and right).

[4] -
Tractors with TLS

Place universal support stand JT05725 (A) under front end of tractor.
Support stand
JT05725

[5] -
Tractors with TLS

Raise tractor front end until there is a gap between stop (A) and main frame.
[6] -
Tractors with TLS

Support bracket (A) as shown.
[7] -
Tractors with TLS

As shown, put a suitable wooden block between the oil pan and front axle.

[8] -
Tractors without TLS

Support engine SECURELY, using support stand JT05725 (A).
Support stand
JT05725

[9] -
Remove rear wheel and support the tractor at the wheel flange.
[10] -
Support the housing of the front-wheel drive clutch.

[11] -
Support rear of tractor as shown.

IMPORTANT:
Make sure that the tractor is safely supported. Wooden blocks and wedges
must be firmly seated (without any play).

[12] -
Bolt universal support stand JT05724 to the main frame.

Support stand
JT05724
Installing and removing tractor components. Also required: 2 commercial 5-metric ton vehicle
jacks

[13] -
LEGEND:
A Screws on Cross-Member
B Cab Mounting Screws
CAUTION:
Make sure that everyone is clear of the danger area. Avoid vibrations when
loosening the cap screws.
[14] -
LEGEND:
A Screws on the Support
B Engine Mounting Screws
[15] -

Remove cap screws (A) using special tools JDG749 (B) and JDG750 (C).
Swivel Socket Extension
JDG749
Taking screws out at rear of main frame. Used in conjunction with swivel socket JDG750.
Swivel Socket
JDG750
Taking screws out at rear of main frame. Used in conjunction with extension JDG749.

[16] -
LEGEND:
A JT05724
Roll out the main frame.
CAUTION:
Immediately after frame removal, check if all tractor components are still
safely supported. When doing so, stay clear of the danger area and do not
use excessive force to check stability of the supports.
With frame removed, do not perform any other work on the tractor.

Install the Main Frame

[1] -
Secure JT05724 universal support stand (A) and install main frame on tractor.
Support stand
JT05724
Raising and supporting the tractor front end. Also requires: 2 commercial 5-metric ton vehicle
jacks

[2] -
Use special tools JDG749 (B) and JDG750 (C) to tighten cap screws (A).
Swivel Socket Extension
JDG749
Taking screws out at rear of main frame. Used in conjunction with swivel socket JDG750.
Swivel Socket
JDG750
Taking screws out at rear of main frame. Used in conjunction with extension JDG749.
Cap Screws, Main Frame to Differential Housing Torque 525 N˙m
385 lb.-ft.
IMPORTANT:
Before installing the screws, clean the threads and coat the underside of
the screw heads with MOLYCOTE grease (L59040).

[3] -
LEGEND:
A Screws on the Support
B Engine Mounting Screws
Tighten cap screws (A) and (B) to the specified torque. Install bracket (C) (with TLS only).
Cap Screws, Main Frame to Engine Mountings Torque 95 N˙m
70 lb.-ft.
405 lb.-ft.
[4] -
LEGEND:
A Screws on Cross-Member
B Cab Mounting Screws
Tighten cap screws (A) and (B) to the specified torque.
Cap Screws, Main Frame to Cab Support Torque 240 N˙m
175 lb.-ft.
Cap Screws, Main Frame to Cross-Member Torque 550 N˙m
405 lb.-ft.

[5] - Install the wheels. See Installing the Front and Rear Wheels in Section 80, Group 10.
[6] - After assembly:
CAUTION:
After installing right main frame, bleed the brakes. See Bleeding the
Brakes (Power-Fill Brakes and MFWD and Disk Brake) in Section 60, Group
20.
IMPORTANT:
On tractors with TLS, close the front axle control valves.
Remove and Install the Front Axle or Front-Wheel

Drive Axle (Summary of References)
Remove the Front-Wheel Drive Axle
Install the Front-Wheel Drive Axle
Remove the Front-Wheel Drive Axle with TLS
Install the Front-Wheel Drive Axle with TLS


CAUTION:
05).

[2] -
Secure universal support stand JT05724 (A) to both sides of main frame (B).
Support stand
JT05724
jacks
[3] - Take off the front wheels. See Removing the Front and Rear Wheels in Section 80,
Group 15.

[4] -
Secure universal support stand D05007ST (A), together with holding tool (B) (dealer-
fabricated) and one T25671 retaining plate (C) to the front-wheel drive axle.
Support stand
D05007ST

[5] -
Disconnect hydraulic lines (A) at the steering cylinder.

→NOTE:
Seal the open ends with plastic stoppers.
[6] -
Take out special cap screws (A).

[7] - Roll the front-wheel drive axle away to the rear.


[1] -
Move front-wheel drive axle to installation position and slide it onto bearing pins (A).
[2] -
Install the retaining elements as shown.

[3] -
Put washers on the cap screws and tighten the screws to the specified torque.
Cap Screws, Front Axle to Support Torque 550 N˙m
400 lb.-ft.
[4] -
Connect hydraulic lines (A) to the steering cylinder.

[5] -
Install the front wheel and tighten the wheel nuts to the prescribed torque. See Installing the

[6] - Check and adjust toe-in, see Checking and Adjusting Toe-In in Section 80, Group 10.


[1] -
Open the hood. Disconnect battery terminals (A) and (B).
CAUTION:
Disconnect the negative terminal first. When reconnecting, do the positive
05).

[2] -
LEGEND:
Relieving pressure in the hydraulic system: Open and close both valves (A) and (B) at
the control valve block several times to relieve accumulator pressure.
CAUTION:
During this procedure, front end of the tractor will be raised and lowered
until the front axle support is finally resting on the front axle. Stay clear of
the danger area. Danger of pinching!
IMPORTANT:
During the subsequent disassembly steps, leave both valves open.

[3] -
Attach universal support stand (A) JT05724 to main frame.

Support stand
JT05724
jacks
Group 15.

[5] -
Remove shields (A), (B) and (C).

[6] -
Loosen screws (B) and pull out u.j. shaft (A).

[7] -
Disconnect steering hoses (A) and (B) and pull off plugs. Disconnect brake hose (C).
→NOTE:
penetrate.

CAUTION:
After reassembly, it is imperative to bleed the brake system.
[8] -
Secure jack and adapter (A) (dealer-fabricated) to drive shaft housing.

Holding fixture
dealer fabricated

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)

Attach axle housing to a suitable hoist (B).

[9] -
Remove cap screws (A) from support.

[10] -
Remove pins (A), (B) and (C).
CAUTION:
Proceed with care; with these components, there is a danger of accidental
crushing.
IMPORTANT:
Disengage position sensor linkage.
→NOTE:
To enable pin (A) to be removed, slightly lower the front axle.

[11] -
Cautiously lower front axle or drive shaft housing and remove from the front.
→NOTE:
A second person is required to perform this job.
[12] -
Place front axle on two wooden blocks and support in the middle as shown. Attach a suitable
hoist to the drive shaft housing.

[13] -
Take out cap screws (A) and remove housing.
CAUTION:
Support the front-wheel drive axle as shown in the illustration.


[1] -
Install the drive shaft housing on the front-wheel drive axle and tighten all the cap screws (A)
in cross-wise fashion to the prescribed torque.
Cap Screws, Housing to Front-Wheel Drive Axle with TLS Torque 310 N˙m
230 lb.-ft.
[2] -
Suspend the front axle as shown and place a jack under the drive shaft housing using the
adapter (dealer-fabricated).
Holding fixture
dealer fabricated

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)

Position the front axle on the axle support.

[3] -
Install pins (A), (B) and (C).
CAUTION:
Proceed with care; with these components, there is a danger of accidental
crushing.
IMPORTANT:
Engage position sensor linkage.
[4] -
Tighten cap screws (A) on the support in cross-wise fashion to the torque prescribed.
Cap Screws, Support to Crossmember Torque 610 N˙m
450 lb.-ft.

[5] -
LEGEND:
Close screws (A) and (B), and observe the maximum authorized torque value when
tightening.
TLS Control Block, Valve Screws Torque 7 N˙m
5.2 lb.-ft.
Install the front wheels and tighten the wheel nuts to the prescribed torque. See Installing the
[6] - Check and adjust toe-in, see Checking and Adjusting Toe-In in Section 80, Group 10.
CAUTION:
Bleed air from brake system; see Bleeding the Brakes (Brake Valve, Power-
Fill Brakes and MFWD and Disk Brake) in Section 60, Group 15.
Remove and Install the Front Axle Support

Remove Front Axle Support
Install Front Axle Support

Remove Front Axle Support

[1] - If any or all of the following are installed, take them off: front-mounted implement, front
PTO, front weights and basic weight.
[2] -
Disconnect battery terminals (A) and (B).
CAUTION:
Disconnect the negative terminal first. When reconnecting, do the positive
05).

[3] -
Take out the two cap screws (A).

[4] -
At both sides, take out cap screws (A). Disconnect connector (B), if equipped.

[5] -
Attach universal support stand (A) JT05724 to main frame.

Support stand
JT05724
jacks
Group 15.
[7] -

Support stand
D05007ST

Holding fixture
dealer fabricated

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)

On front-wheel drive axles with TLS, also place a jack and holding tool (D; dealer-fabricated)
underneath the drive shaft housing.
[8] - Remove the u.j. shaft, see Remove the U.J. Shaft (Front-Wheel Drive Axle) in Section 56,
Group 05.
[9] -
On front-wheel drive axles without TLS, slacken off screws (A) but donot take them out at
this stage.
→NOTE:
Due to the high torque involved, it is advisable to slacken off these screws
before removing the axle support.
CAUTION:
Do not remove the two screws yet.

[10] -
On front-wheel drive axles without TLS, disconnect steering hoses (A).

→NOTE:
penetrate.
a.
On front-wheel drive axles with TLS: Disconnect steering hoses (A) and (B) from the
fittings. Disconnect brake hose (C).
→NOTE:
penetrate.
CAUTION:
After reassembly, it is imperative to bleed the brake system.

b.
Remove cap screws (A) from support.
c.
Disconnect line (A) from pressure accumulator. Disconnect lines (B), (C) and (D) at the
pilot valve.

CAUTION:
The TLS system must be pressure-free before the lines are
disconnected.
→NOTE:
Trap oil as it emerges. Seal the openings so that no dust can
penetrate.
[11] -
Support front frame using suitable pads (A) on the main frame.
[12] -
Remove screws (A) on both sides.

[13] -
Pull the front-wheel drive axle and support out of the main frame.
CAUTION:
When the support is half-way out of the main frame, use appropriate hoist
to secure it.
→NOTE:
The illustration opposite shows a front-wheel drive axle with TLS that is
supported by a jack underneath the drive shaft housing.
A second person is required to perform this job.
[14] -
Suspend the support as shown, and separate it from the front axle or front-wheel drive axle.
The necessary steps are described in this Group:

→NOTE:
The illustration opposite shows a front-wheel drive axle with TLS.

Install Front Axle Support

[1] - Install the front axle on the support. The necessary steps are described in this Group:

[2] -
Support stand
D05007ST

On front-wheel drive axles with TLS, also place a jack and holding tool (D; dealer-fabricated)
underneath the drive shaft housing.
Holding fixture
dealer fabricated

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)
IMPORTANT:
Additionally, secure the support with a hoist (see illustration).
Then install the support and front axle on the main frame.

Section 80 - MISCELLANEOUS Group 05: Main Frame
[3] -
Tighten the screws on the support to the specified torque.

405 lb.-ft.

[5] - On front-wheel drive axles with TLS, check that the TLS is functioning properly.
See Section 280, Group 10 of the Operation and Tests manual, Reference 280-10-001 ,
(Front-Wheel drive Axle with TLS - Operational Checkout).
CAUTION:
Bleed air from brake system; see Bleeding the Brakes (Brake Valve, Power-
Fill Brakes and MFWD and Disk Brake) in Section 60, Group 15.

Group 05 - Main Frame

Main frame to differential housing, mounting screws Torque 525 N˙m
385 lb-ft
Main frame to cross-member, mounting screws Torque 550 N˙m
405 lb-ft
Main frame to front axle support, mounting screws Torque 550 N˙m
405 lb-ft
Basic weight to main frame, mounting screws Torque 600 N˙m
445 lb-ft

Repairing the main frame
CAUTION:
Take heed of safety measures! See section 05, group 05.
Removing and installing main frame. See “Removing main frame” and “Installing main
frame” .
Exploded view, main frame without TLS FWD axle
Main frame without TLS FWD axle
LEGEND:
A Side frame, left
B Cross-members
C Special screw (8 used)
D Special washer (8 used)
F Side frame, right
G Mounting screw (10 used)
H Mounting screw (12 used)
I Pins, front axle
J Front axle support
K Basic weight

L Washer (4 used)
M Mounting screw (4 used)
Repair or assemble the various parts of the main frame as required, using the illustration as a
guide.
Tighten the mounting screws to the specified torque values.
385 lb-ft
405 lb-ft
405 lb-ft
445 lb-ft
Exploded view, main frame with TLS FWD axle
Main frame with TLS FWD axle
LEGEND:
A Side frame, left

Section 80 - MISCELLANEOUS Group 10: Front Wheels, Rear Wheels and Fenders
B Cross-members
C Special screw (8 used)
D Special washer (8 used)
F Side frame, right
G Mounting screw (10 used)
H Mounting screw (12 used)
I Front axle support
J Basic weight
K Washer (4 used)
L Mounting screw (4 used)
Repair or assemble the various parts of the main frame as required, using the illustration as a
guide.
Tighten the mounting screws to the specified torque values.
385 lb-ft
405 lb-ft
405 lb-ft
445 lb-ft

Group 10 - Front Wheels, Rear Wheels and Fenders

Front Wheels, Rear Wheels and Fenders -
”Special tools”
”Pivoting (front) fender”
”Removing the front and rear wheels”
”Reconditioning the front and rear wheels”
”Installing the front and rear wheels”
Special tools
→NOTE:

Universal support stand
JT05725
Supporting tractor

Pivoting front fender

Base to knuckle housing, hex. socket screw Torque 190 N˙m
140 lb-ft
Adjusting arm to pivot plate, cap screw Torque 300 N˙m
220 lb-ft
Support to adjusting arm, cap screw Torque 140 N˙m
105 lb-ft
Pivot plate to base, cap screw Torque 140 N˙m
105 lb-ft
Front wheels
Wheel rim to wheel hub, hex. nut (6820) Torque 300 N˙m
220 lb-ft
Wheel rim to wheel hub, hex. nut (6920 and 6920S) Torque 480 N˙m
355 lb-ft
Steel disk to wheel rim, screw Torque 310 N˙m
230 lb-ft
Rear wheels
Wheel dish to flanged axle, cap screw Torque 500 N˙m
370 lb-ft
Wheel dish to flanged axle, cap nut Torque 500 N˙m
370 lb-ft
Wheel dish to rim, hex. nut Torque 310 N˙m
230 lb-ft

Pivoting Front Fender
LEGEND:
A Support to adjusting arm (l.h.)
B Support to adjusting arm (r.h.)
C Pivot plate turned inward
D Pivot plate turned outward
The fenders may be adjusted individually. Several adjusting positions are possible. Tilt, width
and height of the fenders can be adjusted depending on tire size, tread width and steering
angle. To do so, proceed as follows:

[1] -
Raise front of tractor so that the front wheel drive axle can pivot freely.
[2] - Turn steering wheel in both directions and pivot the axle to determine the most suitable
fender mounting position.
[3] - Adjust fender position so that the minimum specified clearances (A = 40 mm ; 1.57 in.)
and (B = 60 mm ; 2.36 in.) are met. There must not be any contact with the tractor frame.
[4] - Adjust fender stop to prevent it from being seized at the edges with steering wheel fully
turned and axle pivoting. Make sure that the stop contacts the tractor frame before the
fender can hit the frame.
[5] - Also adjust the steering stops to make sure that the wheel does not come into contact
with the tractor frame.

Tighten screws to following torques:
Cap screws (A), support to adjusting arm Torque 140 N˙m (105 lb-ft)
Cap screw (B), adjusting arm to joint Torque 300 N˙m (220 lb-ft)
Cap screws (C), pivot plate to base Torque 140 N˙m (105 lb-ft)
Hex. socket screws (D), base to knuckle housing Torque 190 N˙m (140 lb-ft)

Removing the Front and Rear Wheels
CAUTION:
Before taking off the front and rear wheels, take note of the following
safety instructions.
Remove a wheel on level ground only. The other wheels must be secured
by means of chock blocks to prevent tractor runaway.
The tractor must be supported safely (to avoid accidents).
Raise tractor and support safely using support stand JT05725 (A).
JT05725

Supporting tractor
Removing front wheel
Take off the wheel nuts.
Take the front wheel off the hub.
Removing rear wheel (rear wheel attached with wheel retaining bolts)
Remove wheel bolts (A).
Take the rear wheel off the axle.
Removing rear wheel (rear wheel attached with wheel nuts)

Take off wheel nuts (A).
Remove the reinforcing ring (B).
IMPORTANT:
When installing, take care not to damage the threads on the studs.
Take the rear wheel off the axle.

Reconditioning the Front and Rear Wheels

Preliminary work: See ”Removing the Front and Rear Wheels” .
Reconditioning the front rim (with FWD axle)
Exploded view of adjustable front rim (with FWD axle)
LEGEND:
A Hex. nut
B Washer
C Wheel dish
D Rim
E Special screw
Recondition or assemble the front rim as required, using the illustration as a guide.
185 lb-ft
Reconditioning the rear rim (with flanged axle)

Exploded view of adjustable rear rim (with flanged axle)
LEGEND:
A Wheel dish
B Hex. nut
C Washer
D Rim
E Special screw
Recondition or assemble the rear rim as required, using the illustration as a guide.
185 lb-ft

Installing the Front and Rear Wheels

Installing the Front Wheel
Tighten wheel nuts (A) evenly.
Tighten the wheel dish attaching nuts (B) evenly.
Front wheels
Wheel rim to wheel hub, hex. nut (6820) Torque 300 N˙m
220 lb-ft
Wheel rim to wheel hub, hex. nut (6920 and 6920S) Torque 480 N˙m
355 lb-ft
[ Steel disk to wheel rim with old wheel rim ]
Torque 310 N˙m
, screw
230 lb-ft
[ Steel disk to wheel rim with new wheel rim ]
Torque 250 N˙m
, screw
185 lb-ft

Installing rear wheel (rear wheel attached with wheel bolts)
Tread-extending rim (16-position)
Tread-extending rim (8-position)
Install the rear wheel on the axle.
Tighten wheel bolts (A) evenly.
Rear wheels
Wheel dish to flanged axle, cap screw Torque 500 N˙m
370 lb-ft
230 lb-ft

Installing rear wheel (rear wheel attached with wheel nuts)
IMPORTANT:
When installing the rear wheel, take care not to damage the threads on the
studs.
Rear wheels
Wheel dish to flanged axle, hex. nut Torque 500 N˙m
370 lb-ft
185 lb-ft

Installing rear wheel (rear wheel attached with wheel nuts)
IMPORTANT:
When installing the rear wheel, take care not to damage the threads on the
studs.
Rear wheels
Wheel dish to flanged axle, hex. nut Torque 500 N˙m
370 lb-ft
Tractors with reinforced rear wheels

LEGEND:
A Reinforcing ring
B Hex. nut
C Washer
Install and tighten the reinforced rear wheel.
Reinforced rear wheel to flanged axle, cap screw or hex. nut Torque 500 N˙m
370 lb-ft
Tractors with reinforced rear wheels (heavy-duty)
LEGEND:
A Cap screw
B Washer
C Re-inforcing disk
D Hex. nut
Section 80 - MISCELLANEOUS Group 15: Trailer Mounting and Swinging Drawbar
E Cap screw
F Washer
Install and tighten the reinforced rear wheel.
Reinforced rear wheel to flanged axle, hex. nut Torque 500 N˙m
370 lb-ft
Reinforcing disk to wheel dish, hex. nut Torque 250 N˙m
185 lb-ft

Group 15 - Trailer Mounting and Swinging Drawbar

Trailer Mounting and Swinging Drawbar —
Before reconditioning the trailer mounting and swinging drawbar, refer to the following:
”Repair Specifications”
”Checking the Manually-Operated Hitch for Wear”
”Checking the Remote Controlled Hitch for Wear”
”Checking the Tow-Hook for Wear”
”Checking the Hitch Ball for Wear”
”Checking the Swinging Drawbar for Wear”
”Installing the Trailer Mounting for Center Link”
”Installing Guide Rails”
”Repairing the Automatic Trailer Hitch (One-Lever Operation)”
”Repairing the Automatic Trailer Hitch (Two-Lever Operation)”
”Remote Control for Automatic Trailer Hitch”
”Repairing the Height-Adjustable Trailer Hitch (Italy and Spain only)”
”Swinging Drawbar”
”Swinging Drawbar (with Pick-Up Hitch)”

Specifications
Trailer mounting (center link) to PTO housing, cap screw Torque 340 N˙m
250 lb-ft
Guide rails to PTO housing, cap screw Torque 610 N˙m
450 lb-ft
Guide rail spacer pins, hex. nut Torque 230 N˙m
170 lb-ft
Trailer hitch in guide rails Play 1 mm max.
0.04 in. max.
Cover to hitch body, cap screw (one-lever operation) Torque 28 N˙m
20 lb-ft
Cover to hitch body, cap screw (two-lever operation) Torque 11 N˙m
8.5 lb-ft
End plate to hitch body, cap screw Torque 17 N˙m
12 lb-ft
Hitch pivot, hex. socket screw Torque 35 to 50 N˙m
26 to 37 lb-ft
Wear plate Minimum thickness 6 mm
0.24 in.
Swinging drawbar, special nut Torque 435 N˙m
320 lb-ft
Swinging drawbar, cap screw on plate Torque 435 N˙m
320 lb-ft
Swinging drawbar, cap screw on rear PTO Torque 320 N˙m
235 lb-ft
Swinging drawbar, cap screw on differential housing Torque 310 N˙m
230 lb-ft
Swinging drawbar, plug in drawbar support Torque 310 N˙m
230 lb-ft
Swinging drawbar with hydraulic pick-up hitch, nut Torque 375 N˙m
275 lb-ft

Check the Manually-Operated Trailer Hitch for Wear
CAUTION:
Parts that have reached or exceeded their wear limit must be replaced
with new parts.
Check diameter (a) of the hitch pin.
Hitch pin Wear limit or diameter min. 29.0 mm
min. 1.14 in.
Check permissible vertical play of the hitch pin.

Hitch pin Play max. 6 mm
max. 0.24 in.
Check diameter (b) of the receiver hole.
Top and bottom receiver holes (measured in direction of travel) Wear limit or diameter max. 35.0 mm (oval)
max. 1.38 in. (oval)

Determine play (c) between trailer hitch and receiver.
Trailer hitch and receiver Play max. 3.0 mm
max. 0.12 in.

Determine play (d) and wear (e + f) at the guide rails.
Guide components in pull/push direction (d) Play max. 2.4 mm
max. 0.09 in.
Guide rails, groove (e) in trailer mounting Wear max. 1.2 mm
max. 0.05 in.
Guide rails, trailer hitch guide (f) Wear max. 0.8 mm
max. 0.03 in.

Check Remote Controlled Trailer Hitch for Wear
CAUTION:
Straight-Sided Hitch Pin
Ball-Shaped Hitch Pin
with new parts.
Check diameters (a, b and c) of the hitch pin.
Straight-sided hitch pin Wear limit or diameter (a) min. 29 mm
min. 1.14 in.
Ball-shaped hitch pin Wear limit or diameter (b) min. 36.5 mm

min. 1.44 in.
Ball-shaped hitch pin Wear limit or diameter (c) min. 27 mm
min. 1.06 in.
Check vertical play (d) of the hitch pin.
Hitch pin Play max. 2.5 mm
max. 0.1 in.
Check diameter (c) of the receiver hole.
Bottom receiver hole (in direction of travel) Wear limit or diameter max. 34.0 mm (oval)
max. 1.33 in. (oval)

Check thickness (e) of wear plate.
Wear plate Thickness min. 6 mm
min. 0.24 in.
Check play in the bottom pin guide.
Pin in the bottom pin guide Play max. 2.5 mm
max. 0.1 in.
Check wear of hitch pin or bore.
Hitch pin and bore Wear max. 1.5 mm
max. 0.06 in.

Determine play (f) between trailer hitch and receiver.
Trailer hitch and receiver Play max. 3.0 mm
max. 0.12 in.

Determine play (g) and wear (h + i) at the guide rails.
Guide components in pull/push direction (g) Play max. 2.4 mm
max. 0.09 in.
Guide rails, groove (h) in trailer mounting Wear max. 1.2 mm
max. 0.05 in.
Guide rails, trailer hitch guide (i) Wear max. 0.8 mm
max. 0.03 in.
Checking the Tow-Hook for Wear
CAUTION:
with new parts.
Check gap (b) at catch.
Gap at catch Maximum permissible clearance 10.0 mm
0.39 in.
Check diameter (a) of the pin.
Pin Wear limit or minimum diameter 41.5 mm
1.63 in.

Checking the Hitch Ball for Wear
CAUTION:
with new parts.
Check gap (a) at catch.
0.16 in.
Check diameter (b) of the ball.
Ball diameter Wear limit or minimum diameter 78.0 mm
3.07 in.

Checking the Swinging Drawbar for Wear
CAUTION:
with new parts.
Check diameter (a) of the pin.
Swinging drawbar, pin Wear limit or minimum diameter 29.5 mm
1.16 in.
Check diameter (b) of the pin receiver hole.
Top and bottom receiver holes (measured in

Wear limit or maximum permitted diameter 35.0 mm (oval)
direction of travel)
1.38 in. (oval)

Installing trailer mounting for center link
Tighten screws (A).
Trailer mounting (center link) to PTO housing, cap screw Torque 340 N˙m
250 lb-ft

Installing the Guide Rails

With height-adjustable trailer hitch
Tighten guide rail cap screws (A).
Guide rails to PTO housing, cap screw Torque 610 N˙m
450 lb-ft
Tighten spacer bolt hex. nuts (B).
Guide rail spacer bolts, hex. nut Torque 230 N˙m
170 lb-ft
Lateral play of the trailer hitch in the guide rails should not exceed the amount specified. If
necessary, adjust the spacer bolts.
Trailer hitch in guide rails Play 1 mm max.
0.04 in. max.
Trailer Mounting (Height-Adjustable, 4-Position) up to Serial No.

369175

LEGEND:
1 Belleville spring (16 used)
2 Cover
3 Hex. nut
4 Guide rail (left)
5 Guide rail (right)
6 Threaded rod
7 Bracket (2 used)
8 Washer
9 Cap screw
10 Shield (2 used)

Trailer Mounting (Height-Adjustable, 4-Position) from Serial No.

369176
LEGEND:
1 Hex. nut
2 Threaded rod
3 Shield
4 Cover
6 Guide rail (left)
7 Hex. socket screw
8 Spring
10 Washer (4 used)
Trailer Mounting (Height-Adjustable, 9-Position) up to Serial No.

368006

LEGEND:
1 Belleville spring (16 used)
2 Cover
3 Hex. nut
4 Guide rail (left)
6 Threaded rod
7 Bracket
8 Cap screw
9 Cap screw
10 Type plate
11 Rivet (4 used)
12 Stop
13 Shield

Trailer Mounting (Height-Adjustable, 9-Position) from Serial No.

368007
LEGEND:
1 Hex. nut (4 used)
2 Threaded rod (2 used)
3 Shield
4 Cover
6 Guide rail (left)
7 Spring
8 Spring pin
9 Cotter pin
10 Pin

Reconditioning the Automatic Trailer Hitch (One-

Lever Operation)
→NOTE:
Trailer hitch with cylindrical pin up to serial no. 375631. Trailer hitch with
spherical pin up to serial no. 376842.
LEGEND:
1 Grease fitting
2 Hitch body
3 Bushing
4 Hitch pin
5 Cover
7 Spring
8 Indicator pin
9 Cover
10 Grease fitting
11 Protective cap
12 Lever grip
13 Control lever
14 Torsion spring
15 Release lever
16 Locking catch

17 Shim
18 Spring
19 Detent pin
20 Control plate
21 Spring
22 Spring pin
23 Return spring
24 Cable lever
25 Spring pin
26 Snap ring
27 Shaft
28 Shim
29 Pin-raising lever
30 Torsion spring
31 Bearing plate
32 Bearing pin
33 Locking bolt
34 Cylindrical pin
35 Cam plate with handle
36 Torsion spring
37 End plate
One-lever operation
[1] - Open the trailer hitch, pull the bowden cable out of cover (5) and disengage the bowden
cable eye from cable lever (24).
[2] - Close the hitch and take the hitch out of the guide rails.
[3] - Clean all parts and coat them lightly with grease.
Changing the hitch pin
[1] - Remove cover (5). Open the hitch with control lever (13).
[2] - From the outside, use pliers to hold indicator pin (8) securely, preventing the indicator
pin and spring (7) from falling into the hitch.
[3] - Turn locking catch (16) upward until hitch pin (4) can be removed from above. Hold the
locking catch securely and insert the new pin.
[4] - Guide the lug on the locking catch into the shaped recess in the hitch pin, and then
release. Remove the pliers from the indicator pin.
[5] - Put on cover (5) and tighten hex. socket screws (6).
Cover to hitch body, cap screw (one-lever operation) Torque 28 N˙m
20 lb-ft

[6] -
→NOTE:
Before returning the tractor to operation, check that the mechanism
functions automatically.
Open the hitch with control lever (13). Indicator pin (8) must not protrude out of the sleeve!
Vertical play at the hitch pin is approx. 2 mm (0.08 in.).
Changing the lower bushing
[1] - From below, knock out the lower bushing (3).

[2] - Insert a new bushing and secure it from below to the bore of the hitch body by peening.
Disassembling the automatic mechanism
[1] - Knock out spring pin (25) and pull off cable lever (24) and return spring (23).
[2] - Remove cover (5). Remove snap ring (26) and slide out shaft (27).
[3] - Take out the pin-raising lever (29), torsion spring (30) and shims (28; if equipped).
→NOTE:
Note the position of the shims.
[4] - Knock out spring pin (22) from above.

[5] - Pull out control lever (13) and take out parts 14 to 21. Take out hitch pin (4); indicator
pin (8) and spring (7) fall into the hitch.
Installing the automatic mechanism
[1] - Install the parts in reverse order.

[2] - Check that detent pin (19) operates smoothly at release lever (15).
[3] - Install the release lever, locking catch (16), control plate (20) and spring (14) on an
assembly tool (17.8 mm dia., 46 mm length), and insert.
[4] - Re-install shim(s) (17) as they were before.
[5] - Insert shaft of control lever (13) through the bores of the parts centered on the
assembly tool, and include shim(s) (17).
→NOTE:
Make sure that control plate (20) is in contact with the flattened surface of
the hitch body. The lug on which spring (21) is inserted must be
uppermost.

[6] - Align the bore of locking catch (16) with that of control lever (13), and knock in a new
spring pin (22) from above.
[7] - Insert spring (21) between control plate (20) and the spring retainer on the hitch body.
→NOTE:
Make sure that the spring is seated securely and the control plate moves
smoothly.
[8] - From the inside, insert indicator pin (8) and spring (7), and hold them securely from the
outside with a pair of pliers.
[9] - Insert hitch pin (4) from above, and remove the pliers.
[10] - Insert the pin-raising lever (29) and torsion spring (30).
[11] - Insert shaft (27) and secure it with snap ring (26).
[12] - To do this, push down the locking catch against the pressure of the spring until the
bore in the hitch body is aligned with the bore in the locking catch.
[13] - Install shim(s) (28) as they were before.
→NOTE:
Shims (17) and (28) are required to center the components.
Automatic mechanism functional check
[1] -
CAUTION:
Do NOT open the release lever by hand.
Use a suitable tool (NOT your hand!) to hold release lever (15) in the recess in the base of the
jaws and at the same time open the hitch by means of the control lever.
[2] - It must be possible to push the control lever to its final position (roughly vertical), and to
engage it positively.
[3] - Let go the release lever again.
[4] - The lever must move to the stand-by position, where it can be heard to lock into
position.
[5] -
CAUTION:
Do NOT close the release lever by hand.
Close the hitch by pushing back the release lever (NOT by hand!).
[6] - Indicator pin (8) must not protrude out of the sleeve! To make sure the hitch is
operating safely, repeat the hitching procedure.
[7] - Install cover (5) and tighten hex. socket screws (6).
[8] - Put the cable lever (24) and return spring (23) on the shaft of the control lever, and
knock in spring pin (25).
[9] - Check that the cable lever moves smoothly.
Adjustment unit repair (parts 31 to 38)
[1] - Remove the four cap screws (38) from end plate (37).
[2] - Turn the end plate in the direction that torsion spring (36) turns.
[3] - The end plate, bearing pin (32), torsion spring (36), cylindrical pins (34), cam plate (35),
locking bolts (33) and bearing plate (31) can all be removed.
[4] - Clean and check all components.
[5] - Apply grease to new parts and install in reverse order.
[6] - Insert end of torsion spring (36) into the shaped recess in end plate (37).
[7] - Turn the end plate against the pressure of the torsion spring and at the same time slide
the bearing bore (in the end plate) over the spigot on the end of bearing pin (32).
[8] - Insert cap screws (38), and tighten.
12 lb-ft
Adjustment unit functional check
[1] - Turn the handle on cam plate (35) up and push it to the left.
[2] - Locking bolts (33) move inward.
[3] - When the handle is released, the cam plate returns to its initial position. The locking
bolts are extended again.
[4] - Because the handle and locking cam turn back automatically, the cam plate cannot be
displaced unintentionally.
[5] - In the locked position, the handle on the cam plate can be moved by only about 4 mm
(0.16 in.) to the left.

Reconditioning the Automatic Trailer Hitch (Two-

Lever Operation)
→NOTE:
Trailer hitch for Switzerland up to serial no. 358807
LEGEND:
1 Grease fitting
2 Hitch body
3 Bushing
4 Hitch pin
5 Spring
6 Cover
8 Release lever
9 Spring
10 Locking lever
11 Washer
12 Cotter pin
13 Spring
14 Indicator pin
15 Cover
16 Grease fitting
17 Lever grip

18 Control lever
19 Torsion spring
20 Shim
21 Locking catch
22 Spring pin
23 Return spring
24 Cable lever
25 Spring pin
26 Washer
27 Rubber stopper
28 Adjusting screw
29 Bearing plate
30 Bearing pin
31 Locking bolt
32 Cylindrical pin
33 Cam plate with handle
34 Torsion spring
35 End plate
37 Closure cap
Two-lever operation
cable eye from cable lever (24). Close the hitch again using release lever (8). Take the hitch
out of the guide rails.
[2] - Remove spring pin (25), and pull off cable lever (24) and return spring (23).
[3] - Remove cover (6). From the inside, knock out closure cap (37). Lift up control lever (18)
and knock spring pin (22) out from the outside through the opening for closure cap (37) - do
not approach it from above, otherwise the pin will stick. Pull out the control lever.
[4] - Hitch pin (4) is held loosely by release lever (8). Press the hitch pin all the way down
and take out locking catch (21) and the shim (if equipped). Take out the hitch pin from
above. Indicator pin (14) and its spring will fall out through the hitch pin bore. Remove cotter
pin (12) and the washer. Pull out locking lever (10) and take out release lever (8) from above.
Spring (9) will fall out.
[5] - Clean the components and apply multi-purpose grease.
[6] - From below, knock out lower bushing (3). Insert a new bushing and secure it from below
to the bore of the hitch body by peening.
[7] - Re-install all the components in reverse order.
Tighten the cap screws (7).
Cover to hitch body, cap screw (two-lever operation) Torque 11 N˙m
8.5 lb-ft

[8] - To prevent indicator pin (14) from falling to the inside when hitch pin (4) is being
installed, the indicator pin must be held securely with pliers from the outside. Lift the hitch
pin slightly to insert locking catch (21). To do this, press locking lever (10). The lower finger
of the locking lever must engage in the shaped recess in the hitch pin. If required, center the
locking lever in relation to the hitch pin by inserting shim (20).
[9] - When the bores in the control lever and the locking catch are aligned, knock in a new
spring pin (22) from above.
[10] - After assembly, apply more grease to the hitch.
[11] - The axial torque of the hitch can be increased at adjusting screw (28).
CAUTION:
Before returning the tractor to operation, check that the hitch closes
properly. Indicator pin (14) must no longer protrude from its bore; if it
does protrude, the hitch pin has not reached its lowest position and is NOT
double-locked.
Adjustment unit repair (parts 29 to 36)
[1] - Remove the four cap screws (36) from end plate (35). Turn the end plate in the
direction that torsion spring (34) turns.
[2] - End plate (35), bearing pin (30), torsion spring (34), cylindrical pins (32), cam plate (33),
locking bolts (31) and bearing plate (29) can all be removed.
[3] - Clean and check all components. Apply grease to new parts and install in reverse order.
[4] - Insert end of torsion spring into the shaped recess in the end plate. Turn the end plate
against the pressure of the torsion spring and at the same time slide the bearing bore (in the
end plate) over the spigot on the end of bearing pin (30). Insert cap screws (36), and tighten.
12 lb-ft
[1] - Turn the handle on cam plate (33) up and push it to the left. Locking bolts (31) move
inward.
bolts are extended again.
Reconditioning the Automatic Trailer Hitch (One-

Lever Operation)
→NOTE:
Trailer hitch with cylindrical pin from serial no. 375632. Trailer hitch with
spherical pin from serial no. 376843. Trailer hitch for Switzerland from
serial no. 358808

LEGEND:
1 Grease fitting
2 Hitch body
3 Spring pin
4 Hitch pin
5 Cover
6 Cap screw
7 Spring
8 Pin-raising lever
9 Locking catch
10 Hex. socket screw
11 Snap ring
12 Pin
13 Release lever
14 Pin
15 Spring
16 Roll
17 Spring pin
18 Spring
19 Washer
20 Locking pin
21 Spring
22 Snap ring
23 Spring pin
24 Control lever
25 Washer
26 Spring
27 Cable lever
28 Threaded pin
29 Rubber stopper
30 Washer
31 Locking pin
32 Pin
33 Connecting lever
34 Pin
35 Lever grip
36 Spring
37 Retaining lever
38 Spring pin
39 Adjusting ring
40 End plate
41 Cap screw
42 Cap screw
43 Snap ring
44 Threaded plug
45 Threaded plug
46 Spring
47 Wear plate
48 Washer
49 Spring

Automatic trailer hitch
cable eye from cable lever (27).
[2] - Close the hitch and take the hitch out of the guide rails.
[3] - Clean all parts and coat them lightly with grease.
Remove hitch pin and wear plate
[1] -
LEGEND:
A Snap ring
B Wear plate
Open the trailer hitch. Remove snap ring (A or 43). Drive out wear plate (B or 47) from below.
[2] -
LEGEND:
A Punch
Close the trailer hitch. Remove the two plugs (44) and (45) from the r.h. and l.h. sides of the
hitch body (2). Using a suitable punch (A) drive out pin (44) through the smaller bore. From
underneath, take off the hitch pin (4).

Disassembling the automatic mechanism
[1] -
LEGEND:
A Snap ring
B Pin
C Spring
D Cover
Remove cover (D or 5). Remove snap ring (A or 26) and disconnect spring (C or 46). Remove
pin (B or 12).
[2] - Take out the pin-raising lever (8) and the spring (7).
[3] - Knock out spring pin (23).
[4] - Pull out control lever (24), remove release lever (13), locking catch (9) and washer (48).
Installing the automatic mechanism
[1] - Install the parts in reverse order.

[2] -
LEGEND:
A Locking catch
B Release lever
C Washer
D Control lever
Insert control lever (D or 24) into hitch body and install washer (C or 48), release lever (B or
13) and locking catch (A or 9).
[3] -
LEGEND:
A Wire
B Pin
C Pin-raising lever
D Spring ends
E Spring
Install pin-raising lever (C or 8), spring (E or 7) and pin (B or 12).
→NOTE:
When installing pin-raising lever and spring, use a wire (A) to pull spring
ends (C) upwards until they engage in the cutouts of the housing.

Install hitch pin and wear plate
[1] - Slide hitch pin (4) into hitch body from below and, using a screwdriver, push locking pin
(20) outward.
[2] - Using a suitable punch (A), drive in pin (44) through the larger bore.
[3] - Install wear plate (47) and the snap ring.
Automatic mechanism functional check
[1] - It must be possible to push the control lever to its final position (roughly vertical), and to
engage it positively.
[2] - The locking pin (20) will protrude by approximately 10 mm (0.40 in.) from the housing.
[3] -
CAUTION:
Do NOT close the release lever by hand.
When the trailer towing eye enters the hitch, the release lever is moved and the hitch pin (4)
will close. Locking pin (20) must not protrude from the housing!
[4] - Install cover (5).
[5] - Place cable lever (27), spring (46) and washer (48) on the control lever shaft and knock
in spring pin (23).
[6] - Check that the cable lever moves smoothly.
Adjustment unit repair

[1] -
LEGEND:
A Adjusting ring
B Spring
C Locking pin
Remove the eight cap screws (41) and (42) from end plate (40).
[2] - Disconnect both springs (B or 49) and remove adjusting ring (A or 39).
[3] - Push locking pin (C or 31) outward until pins (32) can be removed.
[4] - Clean and check all components.
[5] - Apply grease to new parts and install in reverse order.
[1] - Turn the handle on adjusting ring up and push it to the left.
[2] - The locking pins move inward.
pins are extended again.
Check that trailer hitch turns

[1] -
LEGEND:
A Hex. socket screw
Slacken off hex. socket screw (A).
[2] - Lubricate the trailer hitch.
[3] - Rotate hitch through one revolution and tighten hex. socket screw (A).
Hitch pivot, hex. socket screw Torque 35 to 50 N˙m
26 to 37 lb-ft

Remote Control for Automatic Trailer Hitch

Changing the bowden cable
LEGEND:
1 Control lever
2 Snap ring
3 Lever shaft
4 Bushing
5 Base plate and bracket
6 Bowden cable
7 Retainer
8 Retaining clip
9 Rubber grommet
10 Clip
11 Cover

12 Cable lever
[1] - Lay out bowden cable (6) so that it does not get bent or squashed.
[2] - Engage yoke in control lever (1), and secure.
[3] - Use retaining clip (8) to attach the bowden cable to base plate (5).
[4] - Use the control lever to open the hitch. Engage the eye in cable lever (12) and then
insert the bowden cable in cover (11).
[5] - Close the trailer hitch and adjust the remote control.
→NOTE:
The bowden cable must not catch when the trailer hitch is adjusted
vertically.
Adjusting the remote control
→NOTE:
spherical pin up to serial no. 376842. Trailer hitch for Switzerland up to
serial no. 358807
[1] -
Move control lever (A) to the position shown.

[2] -
One-lever operation shown

Use lever (C) to close the trailer hitch.
[3] - There must be a gap (a) of at least 1 mm (0.04 in.) between cable hook (D) and spring
pin (E).
[4] - Adjust the bowden cable at hex. nuts (B) as appropriate.
[5] - Use the control lever in the cab to open the trailer hitch. The hitch must positively
engage in the open position. When the control lever is released, this lever must return
automatically to its (locked) initial position.
[6] - Close the trailer hitch with the locking lever and check the clearance between cable
hook (D) and spring pin (E) once again.
Adjusting the remote control
→NOTE:
serial no. 358808

[1] -
Move control lever (A) to the position shown.

[2] -
LEGEND:
B Control lever
C Tow hook
D Hitch housing
Use control lever (B) to close the trailer hitch.
[3] - There must be a gap (a) of at least 4 mm (0.16 in.) between tow hook (C) and hitch
housing (D).
[4] - Adjust the bowden cable at hex. nuts as appropriate.
[5] - Use the control lever in the cab to open the trailer hitch. The hitch must positively
engage in the open position. When the control lever is released, this lever must return
automatically to its (locked) initial position.
[6] - Close the trailer hitch with the control lever and check the clearance between tow hook
(C) and hitch housing (D) once again.
Functional check

→NOTE:
spherical pin up to serial no. 376842. Trailer hitch for Switzerland up to
serial no. 358807
[1] -
Use remote control lever (A) to pull the hitch pin into the detent position, then release the
control lever. The hitch pin must engage positively in the open position.
[2] -
One-lever operation
The cable lever return spring must pull the control lever back to the closed position.

[3] -
Two-lever operation
Use lever (B) to close the trailer hitch.
CAUTION:
Use lever (B) to close the trailer hitch. Check that the trailer hitch is closed
properly. When a trailer is hitched (hitch closed), indicator pin (C) must not
protrude out of the guide bushing. If the indicator pin does protrude, this
indicates that the hitch is not closed properly and that there is the risk of
an accident.
IMPORTANT:
Do not apply too much grease to the trailer hitch.
Functional check
→NOTE:
serial no. 358808

[1] -
Use remote control lever (A) to pull the hitch pin into the detent position, then release the
control lever. The hitch pin must engage positively in the open position.
[2] -
LEGEND:
B Control lever
C Locking pin
The cable lever return spring must pull the control lever back to the closed position.
[3] - Use control lever (B) to close the trailer hitch.
CAUTION:
Use control lever (B) to close the trailer hitch. Check that the trailer hitch
is closed properly. When the hitch is closed, locking pin (C) must not
protrude from the hitch housing. If the locking pin does protrude, this
indicates that the hitch is not closed properly and that there is the risk of
an accident.
IMPORTANT:
Do not apply too much grease to the trailer hitch.

Reconditioning the height-adjustable trailer hitch

(Italy and Spain only)
LEGEND:
A Guide rail (left)
B Spring
C Shield
D Guide rail (right)
E Cap screw (4 used)
G Cap screw (2 used)
H Bushing (2 used)

I Bushing (2 used)
J Snap ring (2 used)
K Pin (2 used)
L Handle
M Spring
N Hitch pin
O Pin (2 used)
P Grease fitting (2 used)
Q Lock nut (2 used)
R Set screw (2 used)
S Stop
T Hitch jaw
U Self-locking nut
V Plate
W Cap screw (4 used)
X Hex. socket screw

Swinging Drawbar - Exploded View
LEGEND:
A Special nut
B Cap screw
C Cap screw
D Cap screw
E Plug
For correct torques, refer to the following specifications.
Swinging drawbar, special nut Torque 435 N˙m

Group 20: Triple Link Suspension (TLS) of Front-
Wheel Drive Axle
320 lb-ft
Swinging drawbar, cap screw on plate Torque 435 N˙m
320 lb-ft
Swinging drawbar, cap screw on rear PTO Torque 320 N˙m
235 lb-ft
Swinging drawbar, cap screw on differential housing Torque 310 N˙m
230 lb-ft
Swinging drawbar, plug in drawbar support Torque 310 N˙m
230 lb-ft
Swinging drawbar (with pick-up hitch)
Tighten hex. nut (A).
Swinging drawbar with hydraulic pick-up hitch, nut Torque 375 N˙m
275 lb-ft

Wheel Drive Axle
Group 20 - Triple Link Suspension (TLS) of Front-

Wheel Drive Axle
Triple Link Suspension (TLS) of Front-Wheel Drive
Axle - Summary of References
Special Tools
Specifications
Relieve Pressure in the Hydraulic System
Remove/Install the Oscillation Limiter
Remove the Panhard Link
Install the Panhard Link
Remove and Install the Sensor Rod
Remove the Sensor for TLS Position
Recondition the Sensor for TLS Position
Install the Sensor for TLS Position
Remove the Hydraulic Cylinder
Recondition the Hydraulic Cylinder
Install the Hydraulic Cylinder
Remove the Control Block
Recondition the Valves in the Control Valve Block
Install the Control Valve Block
Remove the Accumulator
Recondition the Accumulator
Install the Accumulator
Remove and Recondition the Bearing Support
Install the Bearing Support

Wheel Drive Axle
→NOTE:

Splitting stand
JT05724
Raising and supporting tractor front end. Also required: 2 commercial 5-metric ton vehicle
jacks
Splitting stand
D05007ST

Wheel Drive Axle
Removing and installing suspension components on FWD axle with TLS
Splitting stand
JT05725
Supporting the FWD axle. Also required: 1 commercial 12-metric ton vehicle jack
Slide hammer puller
D01210AA

Wheel Drive Axle
Removing the ball bearing from quill
Single-acting hydraulic ram
FKM10464
Pressing the pin out of the front axle support. Also required: expulsion pin (dealer-fabricated)
Adapter (on hydraulic ram)
L38860
Pressing the pin out of the front axle support.
Manually-operated hydraulic pump
D01019AA

Wheel Drive Axle
Adapter (on manually-operated pump)
JT03248
Adapter
JDG1182
[ Used with slide hammer from JDG1072 ]
Extracting pin from hydraulic ram and Panhard link
Special socket
JDG1225
Removing and installing plugs on the control valve block

Wheel Drive Axle
Other material
Number Name Use

• L41476 (us) Thread lock and sealer (high
Repairing the hydraulic cylinder
• 270 LOCTITE ™ (loctite) strength)
• L59040 (us)
Grease Bearings and moving parts
• MOLYKOTE BR2 PLUS (us)

Wheel Drive Axle
Retaining pin, M10 screw Torque 55 N˙m
40 lb-ft
70 lb-ft
Clamp on accumulator, M10 screw Torque 55 N˙m
40 lb-ft
Base plate, screw Torque 55 N˙m
40 lb-ft
Hydraulic hose or line, collar nut (19 mm across flats) Torque 33 N˙m
24 lb-ft
30 lb-ft
37 lb-ft
50 lb-ft
Position sensor assembly to front axle support, M10 screw Torque 55 N˙m
40 lb-ft
Bearing eye in piston rod Torque 200 N˙m
147 lb-ft
Rod guide in hydraulic cylinder Torque 200 N˙m
147 lb-ft
Bleed valve Torque 5 ± 1 N˙m
3.7 ± 0.7 lb-ft
Electro-hydraulic control valve plug Torque 20 N˙m
15 lb-ft
Pressure limiting valve Torque 40 N˙m
30 lb-ft
Preload valve plug Torque 20 N˙m
15 lb-ft
Pressure-regulating valve plug Torque 35 N˙m
26 lb-ft
Solenoid valve, valve Torque 35 N˙m
26 lb-ft
Solenoid valve, nut Torque 5,5 N˙m
4 lb-ft
Shuttle valve plug Torque 25 N˙m

Wheel Drive Axle
18 lb-ft
Manifold block, screw Torque 50 N˙m
37 lb-ft
Control valve block to front axle support, screw Torque 40 ± 2 N˙m
30 ± 1.5 lb-ft
Accumulator, special screw Torque 20 N˙m
15 lb-ft
Cover to bearing block, hex. socket screw Torque 35 N˙m
26 lb-ft
Bearing quill to housing, hex. socket screw Torque 35 N˙m
26 lb-ft
Support to cross-member, cap screw Torque 610 N˙m
450 lb-ft
Housing to front wheel drive axle, cap screw Torque 310 N˙m
229 lb-ft
Bracket to front wheel drive axle, cap screw Torque 35 N˙m
26 lb-ft
Drive shaft, retaining nut Torque 450 N˙m
330 lb-ft
U.j. shaft to drive flange, cap screw Torque 125 N˙m
92 lb-ft
Drive shaft in FWD axle: MOLYKOTE BR2 PLUS Capacity 1 cm 3
0.061 cu in.

Wheel Drive Axle
Relieving Pressure in the Hydraulic System
CAUTION:
When pressure is relieved from the hydraulic system, the front axle carrier
will drop until it rests on the front wheel drive axle (axle oscillation stop).
Keep parts of your body, items of clothing and tools well clear.
[1] -
LEGEND:
A Screw for relieving pressure in lower cylinder chamber (SP R )
B Screw for relieving pressure in upper cylinder chamber (SP Z )
CAUTION:
When screw (A) is slackened, the front axle carrier drops.
[2] - Slacken off screw (A) by approx. 1/2 turn.

[3] - Slacken off screw (B) by approx. 1/2 turn.
[4] - Allow time for all hydraulic pressure to dissipate.
→NOTE:
Leave the two screws (A) and (B) open until this work is completed.
[5] - Tighten the two screws (A) and (B).

Control block, screws Torque 5 ± 1 N˙m
3.7 ± 0.7 lb-ft

Wheel Drive Axle
→NOTE:
When the hydraulic system is pressure-free, it takes approx. 5 - 6 seconds
for the cab to level itself after the engine has been started. If the
transmission oil is cold, or if there is a heavy load at the front end, it may
take approx. 60 seconds for the axle to level itself.

Wheel Drive Axle
Removing/Installing the oscillation limiter

[1] -
Relieve hydraulic system pressure. See “Relieving hydraulic system pressure” in this group.
[2] - Take off collar nut (A).
[3] -
CAUTION:
Accumulator (C) is very heavy; when slackening off screw (D), make sure
that it does not drop off.
Take out screw (D) and remove accumulator (C).

[4] - Take out screw (B).
[5] -
Take out pins (A). Take out screw (D) and remove the washer.
[6] - Pull out pins (C) and take off the oscillation limiter (B).
[7] - Replace parts as necessary.

Wheel Drive Axle
[8] - Reinstall the oscillation limiter in reverse order to removal procedure. Tighten retaining
pin screw.
70 lb-ft
Tighten the cap screw and hex. socket screw on the clamp.
Clamp on accumulator, M10 screw Torque 55 N˙m
40 lb-ft
Tighten the collar nut on the accumulator.

Collar nut (27 mm across flats) Torque 70 N˙m
50 lb-ft

Wheel Drive Axle
Removing the Panhard link

[1] -
Install universal support stand JT05724 (A) at both sides of the main frame.
JT05724
Raising and supporting tractor front end. Also required: two commercial 5-metric ton vehicle
jacks
[2] - Relieve hydraulic system pressure. See “Relieving hydraulic system pressure” in this
group.
[3] - Use the two vehicle jacks to raise the main frame.

Wheel Drive Axle
[4] -
Take out screw (A).

[5] -
Remove line (A).

[6] -
Disconnect the sensor rod (A) from ball end (B).

Wheel Drive Axle
[7] -
Remove screw (A) and its washer, then use a slide hammer and adapter JDG1182 to pull out
pins (B) and (C).
Adapter
JDG1182<@ftnoteref id=2>
Extracting pin from hydraulic ram and Panhard link

Wheel Drive Axle
Installing the Panhard Link
→NOTE:
Remove the Panhard link stop (A). The stop is required on 10 Series
tractors only.
[1] - Install Panhard link in reverse order (with regard to removal procedure).
Tighten the cap screw on the retaining pin.
40 lb-ft
70 lb-ft
Tighten the collar nut on the accumulator.

50 lb-ft

Wheel Drive Axle
[2] -
Press sensor rod (C) onto ball end (B).

[3] - For calibrating front axle, see Reference 245-SFA-001 , Calibration and input addresses
(front-wheel drive axle with TLS).
Removing and Installing the Sensor Rod

[1] -
CAUTION:
The front axle support and front-wheel drive axle must be secured in such
a way that no parts of the body are at risk from pinching.
Disconnect the top end of sensor rod (A) from the position sensor and its bottom end from
the ball spigot on the Panhard link.
[2] - Inspect all parts for wear and damage and replace as necessary.
[3] - Connect the top end of sensor rod (A) to the position sensor and its bottom end to the
ball spigot on the Panhard link.
[4] - For calibrating front axle, see Reference 245-SFA-001 , Calibration and input addresses
(front-wheel drive axle with TLS).

Wheel Drive Axle
Removing the Position Sensor

[1] -
Open the hood.

[2] -
CAUTION:
When disconnecting the battery, remove the negative terminal cable first.
05).
Remove battery cables (A) and (B).

[3] - Release retaining strap (C) and remove the battery.
[4] - Relieve hydraulic system pressure. Refer to ”Relieving Pressure in the Hydraulic
System” in this Group.
[5] -
Remove screws (A).

Wheel Drive Axle
[6] -
IMPORTANT:
Do not raise the baseplate much. Make sure no components (e.g. fan
shroud) are damaged.
Raise the baseplate slightly and secure it (e.g. with wooden wedges).
[7] -
Disengage linkage (A).

[8] -
→NOTE:
For the sake of clarity, the baseplate is not installed.
Take out screws (A) and remove the position sensor assembly through the opening.
[9] - Remove retaining strap (B).
[10] - Disconnect plug (C) from the position sensor.
[11] - If necessary, recondition the position sensor. See ”Reconditioning the Position Sensor”
in this Group.

Wheel Drive Axle
Reconditioning the Position Sensor
LEGEND:
A Screw (2 used)
B Washer (2 used)
C Sensor
D O-ring
E Shaft
F Screw (2 used)
G Bushing
H Screw (2 used)
I Washer (2 used)
J Washer
K Bracket
L Nut
M Retaining ring
N Lever
O Nut
P Sensor rod
[1] - Remove the position sensor. See “Removing the Position Sensor” in this Group.
[2] - Dismantle, and replace defective parts.
[3] - Install parts as shown in the illustration.
→NOTE:
When fully assembled, shaft (E) must turn freely.

Wheel Drive Axle
[4] - Install the position sensor. See “Installing the Position Sensor” in this Group.

Wheel Drive Axle
Installing the Position Sensor

[1] -
→NOTE:
For the sake of clarity, the baseplate is not installed.
Connect plug (C) to the position sensor.

[2] - Install retaining strap (B).
[3] - Install the position sensor assembly through the opening. Install and tighten screws (A).
Position sensor assembly to front axle support, M10 cap screw Torque 55 N˙m
40 lb-ft
[4] -
Install linkage (A).

Wheel Drive Axle
[5] -
Lower the baseplate. Install and tighten screws (A).

40 lb-ft
[6] -
CAUTION:
When reconnecting the battery, be sure to connect the positive terminal
first, and then the negative terminal. Note identifying marks on battery
and cables carefully.
05).
Install battery.
[7] - For calibrating front axle; see Reference 245-SFA-001 , Calibration and input addresses
(FWD axle with TLS).

Wheel Drive Axle
Removing Hydraulic Cylinder

[1] -
→NOTE:
The sealing elements can be changed without removing the hydraulic
cylinder. See ”Repairing the Hydraulic Cylinder” in this Group.
Open the hood.

[2] -
CAUTION:
When disconnecting the battery, remove the negative terminal cable first.
05).
Remove battery cables (A) and (B).

[3] - Release retaining strap (C) and remove the battery.
[4] - Relieve hydraulic system pressure. Refer to ”Relieving Pressure in the Hydraulic
System” in this Group.

Wheel Drive Axle
[5] -
LEGEND:
A Safety cable
B Connector
C Cable strap
D Screws
E Screws
IMPORTANT:
a second person.
Disconnect safety cable (A) at the screw.

Remove connector (B).
Cut tie strap (C), take out screws (D) and (E) and remove hood.

Wheel Drive Axle
[6] -
Open the cover on the radiator expansion tank. Unscrew drain valve (A) halfway and drain
coolant (approx. 14 to 25 liters; 3.7 to 6.6 US gal)
[ depending on tractor equipment ]
into suitable container.
[7] -

[8] - Remove cable (B).
[9] - Remove main fuse (C) with wiring harness and support.

Wheel Drive Axle
[10] -
Disconnect coolant hoses (A) to (C) and seal the open ends.
[11] -

[12] - If provided, disconnect hose (B) of the air brake compressor.
[13] - Disconnect hose (C) of turbocharger.
[14] - Remove negative cable (D) of battery.

Wheel Drive Axle
[15] -
Pull off seal (A) and disconnect hoses (B) and (D) from air cleaner housing (C).
→NOTE:
Cap or plug the openings so that no dust can penetrate.
[16] - Remove the air cleaner housing.

[17] -
CAUTION:
On tractors with fuel cooler, disconnect the two hoses (A) and (B) from the cooler. Seal
the ends of the hoses and the hose fittings.

Wheel Drive Axle
[18] -
CAUTION:
On tractors with air-conditioning, do not disconnect refrigerant lines; instead,

disassemble as follows:
a. Disconnect springs (A) on both sides of condenser.

b. Remove all the clamps on the refrigerant hoses.
IMPORTANT:
Use suitably folded cardboard to protect the fins on the condenser
from damage. Do not bend the refrigerant hoses or subject them to
tension.

Wheel Drive Axle
Remove the condenser and place it temporarily on top of the engine.
[19] -
Disconnect coolant hose (A) from the hose fitting. Trap coolant as it emerges, and seal the
open ends.
[20] - Take out screws (B) on both sides.

Wheel Drive Axle
[21] -
Remove screws (A). To enable the cables to be passed through the baseplate when the front
frame is raised, slacken off fitting (B).
[22] -
→NOTE:
One at a time, cut through all the retaining straps (number varies
depending how tractor is equipped) before you raise the front frame.
Suspend the front frame as shown, and remove it.

Wheel Drive Axle
[23] -
Install splitting stand JT05724 (A) at both sides of the main frame.
Splitting stand
JT05724
jacks

Wheel Drive Axle
[25] -
Remove hydraulic hoses (A) and (B) from the hydraulic cylinder.
[26] - Take out screw (C) and remove the washer.
[27] - Use a slide hammer and adapter JDG1182 to pull out pin (D).
Adapter
JDG1182
[ used with slide hammer from JDG1072 ]
Extracting pin from hydraulic cylinder and Panhard link

Wheel Drive Axle
[28] -
Remove the screw (A) and washer (B) that secure the pin. If the pin does not come out of its
guide easily, use hydraulic ram FKM10464
Hydraulic cylinders
FKM10464
Pressing the pin out of the front axle support. Also required: expulsion pins (dealer-
fabricated)
Adapter (on hydraulic cylinder)
L38860
[ available as spare part ]

and manually-operated pump D01019AA
Hydraulic hand pump
D01019AA

Wheel Drive Axle

Adapter (on manually-operated pump)
JT03248

.
[29] - Use dealer-fabricated spacers to press the pin out of the guide.
[30] - Remove the hydraulic cylinder from below.
[31] - If necessary, repair the hydraulic cylinder. See ”Repairing the Hydraulic Cylinder” in
this Group.

Wheel Drive Axle
Repairing the Hydraulic Cylinder
→NOTE:
The sealing elements can be changed without removing the hydraulic

cylinder. If other parts are defective, the hydraulic cylinder must be
removed. See reference ”Removing the Hydraulic Cylinder” in this Group.
CAUTION:
Ensure an adequate supply of fresh air. Paint and sealant material may
catch fire.
IMPORTANT:
Seals on the rod guide must be replaced after they have been warmed up.
→NOTE:
When warming up the hydraulic cylinder, take care not to heat up

surrounding components. Always cover them up with a suitable material.
Heating destroys the adhesive that secures the screws. New

adhesive/locking material must be used on the hardware affected.
Removing the piston rod and rod guide

Wheel Drive Axle
[1] -
Install universal support stand JT05724 (A) at both sides of the main frame.
JT05724
jacks
[2] - Relieve hydraulic system pressure. See reference ”Relieving Hydraulic System
Pressure” in this Group.

Wheel Drive Axle
[4] -
Using a hot air blower, heat cylinder tube (A) at the thread on rod guide (B) to approx. 300°C
(580°F).
[5] - Slacken off rod guide (B) by means of a pin-type face wrench.
[6] - Take out screw (C) and remove the washer.
[7] - Use a slide hammer and reducing adapter JDG1182 to pull out pin (D).
Adapter
JDG1182
[ used with slide hammer from JDG1072 ]
Extracting pin from hydraulic cylinder and Panhard link

[8] - Pull the piston rod and rod guide out of the cylinder tube (A).
Replacing the sealing elements
LEGEND:
A Bearing eye

Wheel Drive Axle
B Rod guide with sealing elements

C Piston with sealing elements
D Cylinder tube
E Piston rod
[1] -
IMPORTANT:
Use blocks to prevent the vise damaging the end of the rod.
LEGEND:
A End of piston rod
B Bearing opening
C Piston rod
D Bearing eye
E Monkey wrench
F Rod guide
Clamp the end (A) of the piston rod in a vise.

Wheel Drive Axle
[2] -
IMPORTANT:
The bearing eye is tightened to 200 N˙m (147 lb-ft), and adhesive/locking
material is used. To destroy the adhesive/locking material, use a hot-air
blower to heat the area around the thread to approx. 300°C (580°F). Do
NOT use bearing opening (B) to open the bearing eye.
Heat the area around the thread on piston rod (C) and use a large monkey wrench (E) to
open bearing eye (D).
[3] - Pull rod guide (F) from the piston rod (C).
[4] -
IMPORTANT:
Take care not to damage the base of the groove.
LEGEND:
A Guide band
B Piston seal
C Piston with piston rod
D O-ring
E Rod guide
F Rod seal
G Grooved ring
H Wiper seal
I Bearing eye
Use a blunt instrument to remove all sealing elements.
[5] -
IMPORTANT:
There must be no residual sealant on the sealing grooves. Apply a light
coating of grease to the sealing elements before you install them.

Wheel Drive Axle
LEGEND:
A Wiper seal
B Grooved ring
C Rod seal
D O-ring
E Guide band (2 used)
F Piston seal
Install the sealing elements.
a. Apply a small amount of grease to parts (A) to (C) before installing them in the rod
guide.
b. Apply a small amount of grease to O-ring (D) before installing it on the rod guide.
IMPORTANT:
Do NOT use any sharp instruments.
Apply a small amount of grease to piston seal (F) before installing it on the piston. To
facilitate assembly, plunge the piston seal into a bath of water or oil or use a hot-air
blower to heat it to approx. 80-100°C (176-212°F).

Wheel Drive Axle
d. Install the guide bands (E) on the piston, applying a little grease to them and sticking
them into the grooves.
[6] -
Slide rod guide (B) onto the piston rod.

[7] - Make the thread of bearing eye (C) free of grease, then coat it with L41476 (LOCTITE ™
270) and screw the eye into the piston rod.
Number Name Use
• L41476 (us) Thread Lock and Sealer (High Repairing the hydraulic
• 270 LOCTITE ™ (loctite) Strength) cylinder
[8] - Tighten the bearing eye.
147 lb-ft
Replacing the sealing elements up to tractor serial no. 434529
LEGEND:
A Bearing eye
D Cylinder tube
E Piston rod

Wheel Drive Axle
[1] -
IMPORTANT:
LEGEND:
A End of piston rod
B Bearing opening
C Piston rod
D Bearing eye
E Monkey wrench
F Rod guide
Clamp the end (A) of the piston rod in a vise.
[2] -
IMPORTANT:
The bearing eye is tightened to 200 N˙m (147 lb-ft), and adhesive/locking
material is used. To destroy the adhesive/locking material, use a hot-air
blower to heat the area around the thread to approx. 300°C (580°F). Do
NOT use bearing opening (B) to open the bearing eye.
Heat the area around the thread on piston rod (C) and use a large monkey wrench (E) to
open bearing eye (D).
[3] - Pull rod guide (F) from the piston rod (C).
Wheel Drive Axle
[4] -
IMPORTANT:
Take care not to damage the base of the groove.
LEGEND:
A Guide band
B Piston seal
C Piston with piston rod
D O-ring
E Rod guide
F Rod seal
G Grooved ring
H Wiper seal
I Bearing eye
[5] -
IMPORTANT:

Wheel Drive Axle
LEGEND:
A Wiper seal
B Grooved ring
C Rod seal
D O-ring
E Guide band (2 used)
F Piston seal
Install the sealing elements.
a. Apply a small amount of grease to parts (A) to (C) before installing them in the rod
guide.
b. Apply a small amount of grease to O-ring (D) before installing it on the rod guide.
IMPORTANT:

Wheel Drive Axle
d. Install the guide bands (E) on the piston, applying a little grease to them and sticking
[6] -
Slide rod guide (B) onto the piston rod.

[7] - Make the thread of bearing eye (C) free of grease, then coat it with L41476 (LOCTITE ™
270) and screw the eye into the piston rod.
Number Name Use
[8] - Tighten the bearing eye.
147 lb-ft
Replacing the sealing elements from tractor serial no. 434530
LEGEND:
A Bearing eye
D Cylinder tube
E Piston rod

Wheel Drive Axle
[1] -
IMPORTANT:
IMPORTANT:
To destroy the adhesive/locking material, use a hot-air blower to heat the
area around the thread to 300°C (580°F) maximum. Pay attention to the
following: Ensure an adequate supply of fresh air. Paint and sealant
material may catch fire. Seals and rod guide must be replaced after they
have been warmed up. Peform the heating process in several stages,
checking from time to time whether the rod guide can be loosened. Use a
suitable wrench for this purpose.
LEGEND:
A Hydraulic cylinder
B Wrench
C Rod guide
D Piston rod
Clamp the end of hydraulic cylinder (A) in a vise.
[2] - Heat the thread area of rod guide (C) and loosen it using a suitable wrench (B).
[3] - Pull out rod guide (C) with piston rod (D).

Wheel Drive Axle
[4] -
LEGEND:
A Screw
B Lower guide
C Bushing
D Upper guide
Remove screw (A) and pull out lower guide (B), bushing (C) and upper guide (D).

Wheel Drive Axle
[5] -
LEGEND:
A Piston rod
B Wiper seal
C Grooved ring
D Rod seal
E O-ring
F Rod guide
G O-ring
H O-ring
I Rod guide
J Screw
K Guide band
L Piston seal
M Guide band
N Bushing
O O-ring
P O-ring
[6] -
IMPORTANT:

Wheel Drive Axle
a.
LEGEND:
A Wiper seal
B Grooved ring
C Rod seal
D Guide bands (2 used)
E O-rings (2 used)
F Piston seal
Apply a small amount of grease to parts (A) to (F) before installing them in the rod
guide.
b. Install O-rings (C) and (E) (lightly coated with grease) on lower and upper guide.
IMPORTANT:
d. Install the guide bands (D) on the piston, applying a little grease to them and sticking

Wheel Drive Axle
[7] -
LEGEND:
A Screw
B Lower guide
C Bushing
D Upper guide
Slide upper guide (D) on piston rod, install bushing (C) and lower guide (B) and secure parts
by means of screw (A).
[8] - Make the thread of upper guide free of grease, then coat it with L41476 (LOCTITE ™
270) and screw into the hydraulic cylinder.
Number Name Use

Wheel Drive Axle
[9] -
LEGEND:
A Hydraulic cylinder
B Wrench
C Rod guide
D Piston rod
Insert piston rod into hydraulic cylinder and tighten rod guide (C) to the following torque:
148 lb-ft
Installing the piston rod and rod guide
[1] -
Install the piston rod and rod guide (B). Make the thread on the rod guide free of grease, then
coat it with L41476 (LOCTITE ™ 270) and install the rod guide on cylinder tube (A).
Number Name Use
[2] - Put the bearing eye into position. Make sure the grease fitting is on the outside.

Wheel Drive Axle
[3] - Install pin (D).

[4] - Install screw (C) with washer and tighten.
70 lb-ft
[5] - Tighten rod guide (B) with a pin-type face wrench.

147 lb-ft
→NOTE:
If the hydraulic cylinder was removed, re-install it. See reference

”Installing the Hydraulic Cylinder” in this Group.

Wheel Drive Axle
Installing Hydraulic Cylinder

[1] -
Locate the hydraulic cylinder and install pins. Install and tighten screw (A), remembering to
include washer (B).
70 lb-ft
[2] -
Install and tighten hydraulic hose (A).

30 lb-ft
[3] - Install and tighten hydraulic hose (B).

37 lb-ft

Wheel Drive Axle
[4] - Install pin (D) and screw (C), remembering to include a washer.
70 lb-ft
[5] -
Install front frame as shown in the illustration.

[6] - While the front is being set down, feed the electrical leads into the baseplate.
[7] - Connect all the hoses to the relevant hose fittings.
[8] -

40 lb-ft

Wheel Drive Axle
[9] -

40 lb-ft
[10] - Connect the two ends of the positive cable (B).
CAUTION:
Install the battery only when assembly is completed.
[11] -
CAUTION:
On tractors with air-conditioning:

Wheel Drive Axle
IMPORTANT:
Lay out the lines so that they are not subject to any mechanical or
thermal forces.
Install condenser and engage springs (A) on both sides.
b. Install all the clamps on the refrigerant hoses, and secure all the lines.
[12] -
CAUTION:
Tractors with fuel cooler:
IMPORTANT:
Lay out the hoses so that they are not subject to any mechanical or
thermal forces.
Connect fuel hoses (A) and (B) to the fuel cooler.
b. Install all brackets of fuel cooler hoses and fasten hoses to them.

Wheel Drive Axle
[13] -
Install the air cleaner housing (C).

[14] - Install hoses (B) and (D) on the air cleaner housing.
[15] - Install seal (A).
[16] -
Install screws (A).

[17] - If provided, connect hose (B) of the air brake compressor.
[18] - Install hose (C) of turbocharger.
[19] - Install negative cable (D) of battery.

Wheel Drive Axle
[20] -
Install screws (A).

[21] - Install cable (B).
[22] - Install main fuse (C) with wiring harness and support.

Wheel Drive Axle
[23] -
LEGEND:
A Safety cable
B Connector
C Cable straps
D Screws
E Screws
Install the hood.
IMPORTANT:
a second person.
[24] - Tighten bolts (D) and (E).

[25] - Secure the leads with tie straps (C).
[26] - Connect plug (B) and install safety cable (A) with screw.
[27] -
CAUTION:
05).

Wheel Drive Axle
Install battery.
[28] - Install retainer (C).
[29] -
CAUTION:
When reconnecting the battery, be sure to connect the positive terminal
first, and then the negative terminal. Note identifying marks on battery
and cables carefully.
Install battery cables (A) and (B).

[30] - Check all fluid levels, connections and routings. Install new tie straps.
[31] - Remove all equipment.

Wheel Drive Axle
Removing the Control Valve Block

[1] -
Install splitting standJT05724(A) at both sides of the main frame.

[2] - Relieve hydraulic system pressure. See reference ”Relieving Hydraulic System
Pressure” in this Group.
[4] -
Remove hydraulic lines (A) to (D) from the control valve block.

Wheel Drive Axle
[5] -
Remove hydraulic line (E) from the control valve block.

[6] -
Remove hydraulic hoses (A) and (B) from the manifold block.
[7] -
→NOTE:
Mark plugs of solenoid valves and TLS pressure sensor before
disconnecting them.
Pull plugs (A) and (B) out of the solenoid valves.

Wheel Drive Axle
[8] -
Take screws (A) out of the control valve block.

[9] - Move the control valve block downward and then take it out between the main frame
and the FWD axle.
[10] - If necessary, recondition the valves in the control valve block. See reference
”Repairing the Valves in the Control Valve Block” in this Group.

Wheel Drive Axle
Repairing the Valves in the Control Valve Block
Control valve block, exploded view
LEGEND:
A Electro-hydraulic control valve
B Pressure relief valve
C Preload valve
D Flow control valve
E Electro-hydraulic control valve
F Pressure-regulating valve
G Bleed valve (2 used)
H Solenoid valve (2 used)
I Restriction valve
J Manifold block
K Screw (2 used)
L Screw (2 used)
M Shuttle valve
N Control valve block

Wheel Drive Axle
CAUTION:
Before you start, relieve all pressure in the hydraulic system. Refer to
”Relieving Pressure in the Hydraulic System” in this Group.
Electro-hydraulic control valve (A)
[1] -
Remove the control valve block. See ”Removing the Control Valve Block” in this Group.
[2] - Use special tool JDG1225 to open plugs (A) and (B), and remove the electro-hydraulic
control valve.
Special socket
JDG1225

Wheel Drive Axle
[3] - Replace any defective components.

→NOTE:
[4] -
→NOTE:
For installation, refer to the exploded view.
Install the electro-hydraulic control valve and tighten plugs (A) and (B).
15 lb-ft
[5] - Install the control valve block. See ”Installing the Control Valve Block” in this Group.
Pressure relief valve (B)
[1] -
[2] - Remove the pressure relief valve (A).
→NOTE:
[4] -
→NOTE:
Install and tighten pressure relief valve (A).

Pressure relief valve Torque 40 N˙m

Wheel Drive Axle
30 lb-ft
Preload valve (C)
[1] -
[2] - Use special tool JDG1225 to open plugs (A) and (B), and remove the preload valve.
Special socket
JDG1225

→NOTE:

Wheel Drive Axle
[4] -
→NOTE:
Install the preload valve and tighten plugs (A) and (B).
Preload valve plug Torque 20 N˙m
15 lb-ft
Electro-hydraulic control valve (E)
[1] -
[2] - Use special tool JDG1225 to open plug (A), and remove the electro-hydraulic control
valve.
Special socket
JDG1225

→NOTE:

Wheel Drive Axle
[4] -
→NOTE:
Install the electro-hydraulic control valve and tighten plug (A).

15 lb-ft
Pressure-regulating valve (F)
[1] -
Open plug (A) and remove the pressure-regulating valve.

→NOTE:
[3] -
→NOTE:
Install the pressure-regulating valve and tighten plug (A).

Pressure-regulating valve plug Torque 35 N˙m
26 lb-ft
Bleed valve (2 used) (G)

Wheel Drive Axle
[1] -
Remove the relevant bleed valve (A).

→NOTE:
[3] -
→NOTE:
Install and tighten the relevant bleed valve (A).

Bleed valve Torque 5 ± 1 N˙m
3.7 ± 0.7 lb-ft
Solenoid valve (2 used) (H)
→NOTE:
What follows applies to both of the solenoid valves.

Wheel Drive Axle
[1] -
Disconnect plug (A) from coil (C).

[2] - Take off nut (B) and remove coil (C).
[3] - Remove valve (D).
→NOTE:
[5] -
→NOTE:
Install and tighten valve (D).

Solenoid valve, valve Torque 35 N˙m
26 lb-ft
[6] - Install coil (C). Put on nut (B) and tighten.

Solenoid valve, nut Torque 5.5 N˙m
4 lb-ft
[7] - Connect plug (A) to coil (C).
Shuttle valve (M)
[1] -
→NOTE:
The shuttle valve is located behind the manifold block.

Wheel Drive Axle
Take off line (B).

[2] - Take out screws (A) and remove the manifold block.
[3] - Remove shuttle valve (C).
→NOTE:
[5] -
→NOTE:
Install and tighten the plug of shuttle valve (C).

Shuttle valve plug Torque 25 N˙m
18 lb-ft
[6] - Re-install the manifold block. Install and tighten screws (A).
Manifold block, screw Torque 50 N˙m
37 lb-ft
[7] - Install and tighten line (B).

37 lb-ft

Wheel Drive Axle
Installing the Control Valve Block

[1] -
From below, move the control valve block into position between the main frame and the FWD
axle.
[2] - Install and tighten screws (A).
Control valve block to front axle support, screw Torque 40 ± 2 N˙m
30 ± 1.5 lb-ft
[3] -
Put plugs (A) and (B) onto the relevant solenoid valves.

Wheel Drive Axle
[4] -
Install and tighten hydraulic hoses (A) and (B).

30 lb-ft
37 lb-ft
[5] -
Install and tighten hydraulic line (E).

50 lb-ft

Wheel Drive Axle
[6] -
Install and tighten hydraulic lines (A) to (D).

30 lb-ft
37 lb-ft
Removing the Accumulator

[1] -
→NOTE:
What follows applies to all accumulators on the front-wheel drive axle with
TLS.
Relieve hydraulic system pressure. See “Relieving Hydraulic System Pressure” in this Group.
[2] -
Remove pressure line (A) at accumulator (B). Release tensioning strap (C).
[3] - Remove accumulator (B).
[4] - If necessary, recondition the accumulator. See “Reconditioning the Accumulator” in this
Group.

Wheel Drive Axle
Reconditioning the Accumulator

[1] - If necessary, remove the accumulator. See “Removing the Accumulator” in this Group.
[2] -
→NOTE:
What follows applies to all accumulators on the front-wheel drive axle with
TLS.
Relieve hydraulic system pressure. See “Relieving Hydraulic System Pressure” in this Group.
[3] -
Remove lock nut (D) from accumulator (A).

[4] - Take out the special screw (C).Nitrogen escapes at this point.
[5] - Remove seal ring (B).
[6] - Clean all sealing surfaces and use a new seal ring.
[7] - Re-install special screw (C) in accumulator (A).
Accumulator, special screw Torque 20 N˙m
15 lb-ft
IMPORTANT:
The accumulator must be charged with nitrogen. See Reference 280-15-002
in the relevant technical manual, Section 280, Group 15.
[8] - Once charging is completed, screw lock nut (D) back onto the accumulator (A).
[9] - If necessary, install the accumulator. See “Installing the Accumulator” in this Group.
Installing the Accumulator

Wheel Drive Axle
→NOTE:
Never install an accumulator unless you know its nitrogen pressure. See
Reference 280-15-002 in the relevant technical manual, Section 280,
Group 15.
[1] -
Install accumulator (B).

[2] - Secure the tensioning strap with screw (C).
[3] - Install and tighten pressure line (A).
37 lb-ft

Wheel Drive Axle
Removing and repairing the bearing support
LEGEND:
1 Input shaft
2 O-ring
3 Housing
4 Screw (14 used)
5 Holder
6 Screw (2 used)

Wheel Drive Axle
7 Dowel pin (4 used)

8 Seal (2 used)
9 Screw (4 used)
10 Support
11 Grease fitting
12 Spherical bearing
13 O-ring
14 Cover
15 Screw (16 used)
16 Bearing quill
17 Grease fitting
18 Snap ring (2 used)
19 Ball bearing
20 Seal ring
21 Sleeve
22 Flange
23 Washer
24 Nut
Removing the bearing support
[1] - Relieve hydraulic system pressure. See “Relieving hydraulic system pressure” in this
group.
→NOTE:
To disconnect the support from the housing, it is necessary to remove the
entire assembly (support to FWD axle).
Some illustrations show the front wheel still in place. In other illustrations,
it has been removed for the sake of clarity.
[2] -
Remove shields (A), (B) and (C).

Wheel Drive Axle
[3] -
Unfasten screws (B) and pull out u.j. shaft (A).

[4] -
CAUTION:
The tractor must be supported on all four wheels and park lock must be
engaged, since the tractor may begin to move when the retaining nut is
slackened or tightened.
Unfasten retaining nut (A),but do not remove it .

Wheel Drive Axle
[5] -
Put a standard movable vehicle jack in position as shown, and raise the front end of the
tractor approx. 90 mm (3.55 in.).
[6] - At a suitable point, support the front of the tractor so that it cannot fall.
[7] - Lower the front axle and remove the movable vehicle jack.
[8] -
LEGEND:
A Special tool D05007ST
B Special tool JT05725
Attach special tools (A) and (B) at the points shown.
D05007ST

Wheel Drive Axle
Removing and installing suspension components on FWD axle with TLS

Splitting stand<@ftnoteref id=5>
JT05725
Supporting the FWD axle

Wheel Drive Axle
[9] -
Take off collar nut (A) and seal the connections.

[10] - Take out screw (B).
[11] -
Take out screws (A) at the support.

[12] - Take out screws (B) at the housing.
[13] -
Move the complete housing assembly out from underneath the tractor.

Wheel Drive Axle
[14] -
Take out retaining nut (A) and pull off flange (B).

[15] -
Remove seal ring (A).

[16] -
Pull out drive shaft (A).

[17] - Remove front snap ring (B).

Wheel Drive Axle
[18] -
LEGEND:
A Ball bearing
B Special tool D01210AA
Use special tool (B) to pull off ball bearing (A).
Puller
D01210AA
Removing the ball bearing from quill

Wheel Drive Axle
[19] -
Remove rear snap ring (A).

[20] - Take hex. socket screws (B) out of bearing quill (C), and remove the quill.
[21] -
Take hex. socket screws (A) out of cover (B), and remove the cover.
[22] -
Pull support (A) together with spherical bearings (B) downward and out of the housing (C).

Wheel Drive Axle
[23] -
Remove spherical bearings (A) from support (B).
Repairing the cover
[1] -
Remove seal ring (A) as shown.

Wheel Drive Axle
[2] -
Install a new seal ring using an appropriate tool.

D01045AA
Installing bearings and seal rings
[3] -
Remove O-ring (A). Coat the new O-ring with oil before inserting it.
Repairing the spherical bearings

Wheel Drive Axle
[1] -
Remove seal ring (A) as shown.

[2] -
Install a new seal ring using an appropriate tool.

D01045AA

Wheel Drive Axle
Installing the bearing support

[1] -
Apply L59040 (MOLYKOTE BR2 PLUS) to spherical bearing (A), and install.
Number Name Use
• L59040 (us)
Grease Bearings and moving parts
• MOLYKOTE BR2 PLUS (us)
[2] -
Install cover (A) on support (B).

Cover to bearing support, M8 screw Torque 35 N˙m
26 lb-ft

Wheel Drive Axle
[4] -
Slide support assembly (A) onto housing (B).

[5] -
Install bearing quill (A) in the spherical bearing, and bolt it to the housing.
Bearing quill to housing, M8 screw Torque 35 N˙m
26 lb-ft

Wheel Drive Axle
[7] -
Install snap ring (A) in rear groove.

[8] -
Install ball bearing (A) in bearing quill (B) using an appropriate tool.
D01045AA
[9] -
Install front snap ring (B) and insert the drive shaft (A).

Wheel Drive Axle
[10] -

[11] -
Press the shaft protector sleeve (A) onto the flange.

[12] -
Put on flange (B) and screw on retaining nut (A).

Wheel Drive Axle
[13] -
IMPORTANT:
Before installing the housing on the FWD axle, apply the required amount
of MOLYKOTE BR2 PLUS to the (cleaned!) outer splines of drive shaft (A)
and to the (cleaned!) inner splines of the FWD axle.
Drive shaft in FWD axle System capacity 1 cm 3
0.061 in 3
Make sure that O-ring (B) is in the correct position.

[14] -
Install the housing assembly.

Wheel Drive Axle
[15] -
Tighten the cap screws.

Bearing support to crossmember, M20 screw Torque 610 N˙m
450 lb-ft
[16] -
→NOTE:
The cylindrical pins in the FWD axle are there to facilitate installation.
Tighten the cap screws.

Housing to FWD axle, M16 screw Torque 310 N˙m
229 lb-ft

Wheel Drive Axle
[17] -
Install bracket (B). Tighten cap screw.

Bracket to FWD axle, M8 screw Torque 35 N˙m
26 lb-ft
[18] - Tighten collar nut (A).

37 lb-ft
[19] -
CAUTION:
The tractor must be supported on all four wheels and park lock must be
engaged, since the tractor may begin to move when the retaining nut is
slackened or tightened.
Tighten retaining nut (A).

Drive shaft, M24 retaining nut Torque 450 N˙m

Section 80 - MISCELLANEOUS Group 25: Pick-Up Hitch
330 lb-ft
[20] -
Install the u.j. shaft and tighten the flange screws.

U.j. shaft to drive flange, M12 screw Torque 125 N˙m
92 lb-ft

Group 25 - Pick-Up Hitch

Pick-Up Hitch - Summary of References
Before reconditioning the pick-up hitch, see the following references:
Specifications
Pick-Up Hitch - General Safety and Repair Information
Check Tow Hook on Pick-Up Hitch for Wear
Remove and Install the Pick-Up Hitch
Pick-Up Hitch - Exploded View
Pick-Up Hitch - Control Lever and Lift Links
Pick-Up Hitch - Hydraulic Parts
Electro-Hydraulically-Controlled Pick-Up Hitch - Electrical/Hydraulic Parts
Recondition the Retainer Spring
Recondition the Latch Housing
Adjust the Lift Links
Adjust the Guide Stop
Adjust the Locking Pin
Pick-Up Hitch - Operational Check

Specifications
Upper frame to bottom of differential housing, cap screws Torque (initial) 30 N˙m
22 lb-ft
Upper frame to rear of PTO housing, cap screws Torque 450 N˙m
330 lb-ft
Upper frame to bottom of differential housing, cap screws Torque (final) 265 N˙m
190 lb-ft
Retainer spring with stop, cap screw Torque 30 N˙m
22 lb-ft
Latch housing to stop, cap screw Torque 35 N˙m
26 lb-ft
Piston to piston rod Torque 320 N˙m
240 lb-ft
Union to cylinder Torque 300 N˙m
220 lb-ft
Guide stop, hex. nut Torque 300 N˙m
221 lb-ft
Locking pin, distance it sticks out Dimension min. 3 mm
min. 0.12 in.
Other material
Number Name Use
• L41475 (us)
Applied when screwing Install stop screw and
• 243 LOCTITE ™ Thread lock
fitting into cylinder. lock nut of guide.
(loctite)

Pick-Up Hitch — General Safety and Repair

Information
CAUTION:
You should comply with the safety measures at the beginning of this
manual as well as the ones mentioned below. See ”Safety Measures”,
Repair Manual, Section 05, Group 05.
CAUTION:

injury from high-pressure oil by relieving system pressure before
CAUTION:
When testing the rockshaft, the lift arms pose a risk of injury as they rise.
Danger of accidents! Therefore stay outside the working area of lift and
draft links.
The following, together with other information, can be found in part 1 of the Repair
Manual, Section 10, Group 05 under ”Specifications”.
For all capacities, see ”Capacities” .

For different types of oil, see ”Transmission and Hydraulic Oil” .
For grease, see ”Grease” .
For general information on tightening torques, see ”Unified Inch Bolt and Cap Screw
Torque Values” .
For general information on tightening torques, see ”Metric Bolt and Cap Screw Torque
Values” .
For general information on tightening torques, see ”Torques for Inch Fittings used in the
Hydraulic System” .
For general information on tightening torques, see ”Torques for Metric Fittings used in
the Hydraulic System” .

Check Tow Hook on Pick-Up Hitch for Wear
CAUTION:
with new parts.
Check gap (a) at catch.
0.39 in.

Read the “D” value (unit of measurement = kN) from pick-up hitch type plate.
If the “D” value indicated on the type plate is 65 or less, observe the following minimum
dimensions (A).
Tow hook, hook diameter (D = 65 or less) Minimum value (A), diameter 1 43.5 mm
1.71 in.
Minimum value (A), diameter 2 42.0 mm
1.65 in.
1.59 in.
If the “D” value indicated on the type plate exceeds 65, observe the following minimum
dimensions (A).
Tow hook, hook diameter (D = more than 65) Minimum value (A), diameter 1 45.0 mm
1.77 in.
1.71 in.

1.65 in.

Removing and Installing Pick-Up Hitch
CAUTION:
Comply with repair instructions. See ”Pick-Up Hitch — General Safety and
Repair Information” in this Group.
Removing hitch
Remove hitch using component diagrams, refer to:
”Pick-Up Hitch — Exploded View”

”Pick-Up Hitch — Control Lever and Lift Links”
”Pick-Up Hitch — Hydraulic Parts”
Installing hitch

LEGEND:
A M16x50 cap screw (4 used)
B M16x50 cap screw (2 used)
C M20x45 cap screw (4 used)
D Washer
E Spacer plate
[1] - Install washer (D) and spacer plate (E) on upper frame.
[2] - Position upper frame to differential housing and initially tighten the cap screws (A) and
(B) to the temporary torque.
Upper frame to bottom of differential housing, cap screws Torque (temporary) 30 N˙m
22 lb-ft
[3] - Tighten the four cap screws (C).

Upper frame to rear of PTO housing, cap screws Torque 450 N˙m
330 lb-ft
[4] - Tighten cap screws (A) and (B) to their final torque value.
Upper frame to bottom of differential housing, cap screws Torque (final) 265 N˙m
190 lb-ft
[5] - Complete hitch using component diagrams, refer to:
”Pick-Up Hitch — Exploded View”

”Pick-Up Hitch — Control Lever and Lift Links”
”Pick-Up Hitch — Hydraulic Parts”
[6] - Perform operational check, see reference: ”Pick-Up Hitch — Operational Check” in this
Group.

Pick-Up Hitch — Exploded View
LEGEND:
1 Upper frame
2 Locking pin
3 Lever
4 Spring clip
5 Compression spring
6 Housing
7 Lever

8 Grease fitting
9 Fitted screw (2 used)
10 Spring pin
11 Hydraulic cylinder
12 Lower frame
13 Guide
14 Hook
15 Pin (2 used)
16 Hex. nut (12 used)
17 Guide rail (4 used)
18 Stop screw
19 Hex. nut
20 Countersunk screw (12 used)
21 Limit stop
22 Retainer spring
23 Safety decal
24 Product identification plate
25 Shaft
26 PTO guard
27 Mounting bracket
28 Spacer plate
29 Cap (2 used)
30 Hex. nut (2 used)
31 Rubber stop (2 used)

Pick-Up Hitch — Control Lever and Lift Links


LEGEND:
1 Cover
2 Lever
3 Protective cap
4 Hex. nut
5 Washer
6 Bushing
7 Snap-ring
8 Plate
9 Rubber grommet
10 Pin
11 Bowden cable
12 Retaining clip
13 Locking pin
14 Pin
15 Cotter pin
16 Washer
17 Washer
18 Pin
19 Lift link rod
20 Washer
21 Rivet
22 Lift link tube
23 Stop
24 Cap screw
25 Special nut
26 Lift arm extension (earlier version)
27 Pin (earlier version; 2 used)
28 Washer (earlier version; 2 used)
29 Lift link rod (earlier version; 2 used)

Pick-Up Hitch — Hydraulic Parts
LEGEND:
1 Connection (2 used)
[ On earlier tractor series ]
2 O-ring (2 used)
3 Hydraulic hose (2 used)
4 Protective coil (2 used)
5 Connection (2 used)
[ On the latest tractor series ]
6 Dust protection (3 used)
7 Bracket
8 Cap screw

10 Connector (2 used)
11 O-ring (2 used)
12 Clamp
13 Shield

16 Fitting (2 used)

Electro-Hydraulically-Controlled Pick-Up Hitch —

Electro-Hydraulic Parts
LEGEND:
1 Protective coil (2 used)
2 Hydraulic hose
3 Hydraulic hose
4 Special screw
5 Bracket

6 Hex. nut
7 Clamp (2 used)
8 Cheese-head screw
9 O-ring (4 used)
10 Fitting (2 used)
11 Mounting bracket
12 Control block
13 O-ring (2 used)
14 Elbow fitting
15 Hose clamp (2 used)
16 Washer (2 used)
18 Elbow fitting
19 O-ring (4 used)
20 O-ring
21 Elbow fitting
22 Oil line
23 Hose
24 Elbow fitting (2 used)
25 O-ring (2 used)
26 Oil line
28 Hose clamp (2 used)
29 T-fitting
30 T-fitting
31 T-fitting
32 Oil line

Repairing the Retainer Spring
CAUTION:
Removing the retainer spring
[1] -
Lower the hitch and fold up the PTO guard.

[2] -
CAUTION:
Do NOT use your fingers to release the locking pin. Risk of injury!
Disengage locking pin (B) by pressing against stop (A). Be sure to use a screwdriver!

[3] -
Take out the two cap screws (A).

[4] - Disengage retainer spring (B) together with the stop.
Installing the retainer spring
[1] -
Insert the retainer spring and stop as shown.

[2] - Place the two self-locking nuts (each with one washer) in recesses (A).
[3] - Insert the two cap screws (B), including one washer for each.
[4] - Move the spring to the center position.
[5] - Tighten the cap screws.
Retainer spring with stop, cap screw Torque 30 N˙m
22 lb-ft
Checking and adjusting the retainer spring

[1] -
Using the control lever in the cab, open the locking pin. Hold the lever tight so that the pin
cannot exert pressure on the stop.
[2] -
Check the position of the retainer spring: Retainer spring (A) must not be touching the
housing; it must be centered relative to guide hole (B).
[3] -
CAUTION:
Do not align the retainer spring by hand! Risk of injury!
If it is not centered, use a screwdriver to bend the spring back to the appropriate position.
Group.

Repairing the Latch Housing
CAUTION:
Removing the latch housing
[1] -
Disengage bowden cable at yoke (A).

[2] -
CAUTION:
Do NOT use your fingers to release the locking pin. Risk of injury!
Disengage the locking pin by pressing against stop (B). Be sure to use a screwdriver!
[3] - Remove the right-hand lift link (C).
[4] - Remove the two hex.-fitted screws (D) and take off the latch housing and locking pin.
[5] - Disassemble the latch housing.
Assembling the latch housing

[1] -
Clean the various parts, inspect them for wear or damage and replace as necessary.
[2] - Apply grease to all the components.
[3] - Place the stop (B; if equipped) in the spring (A), and install it in the housing.
[4] -
Turn and hold the lever shaft (A) so that spring clip (B) is located in front of spring (C) (see
illustration).
[5] - Guide the locking pin (D) into the housing and press it in while at the same time rotating
the lever shaft (A). The lug on the lever must engage in the recess in the pin.
Installing the latch housing
[1] -
CAUTION:
Make sure that the punch cannot slip out.

Use a 6 mm (15/64 in.) punch to jam the lever shaft (A) as shown.
[2] -
Put the housing in position and tighten the fitted screws (A).
Latch housing to stop, cap screw Torque 35 N˙m
26 lb-ft
[3] - Remove the punch and secure the bowden cable yoke (B) to the lever shaft by means of
retaining pins.
[4] - Re-install the lift link.
[5] - Adjust locking pin, see ”Adjusting the Locking Pin”” in this Group.

CAUTION:
Comply with repair instructions. See Pick-Up Hitch - General Safety and
Repair Information in this Group.
→NOTE:
Disassemble hydraulic cylinder using the exploded view drawing; see Pick-
Up Hitch - Exploded View in this Group.
→NOTE:
Threaded pin (C) is located under back-up ring of piston (B).
[1] -
LEGEND:
A Cylinder
B Piston
C Threaded Pin
D Guide Bushing
E Fitting
F Piston Rod
Disassemble hydraulic cylinder.

[2] -
LEGEND:
A Piston
B Threaded Pin
C Back-Up Ring
D Back-Up Ring
E Piston Ring
Replace piston seals.
[3] -
LEGEND:
A Wiper Seal
B Seal Ring
C O-Ring
Replace guide bushing seals.
[4] - Sealing lip of wiper seal (A) must face to the outside.
[5] - The sealing lip on seal ring (B) must face inward.

[6] -
Apply L41475 ( LOCTITE ™ 243) to threads of piston rod (C).

Number Name Use
• L41475 (us)
Thread Lock Applied when screwing the fitting into the cylinder
[7] - Tighten piston (A).
Piston to Piston Rod Torque 320 N˙m
240 lb.-ft.
[8] - Secure piston by means of threaded pin (B); peen threaded pin head with a center-
punch.
[9] - Tighten the fitting (D) of the cylinder.
Fitting to Cylinder Torque 300 N˙m
220 lb.-ft.
[10] - Install hydraulic cylinder using the exploded view drawing; see Pick-Up Hitch -
Exploded View in this Group.
[11] - Perform operational check, see Pick-Up Hitch - Operational Check in this Group.

Adjusting the Lift Links
CAUTION:
[1] - Move lift arms to highest position (do not use remote control).
[2] - Using a jack, press lower frame (A) slightly against console until hook bore (D) reaches
the horizontal and vertical position shown on the drawing.
[3] - Turn lift link tube (B) until bore is aligned with pin (C).
[4] - Install washer and secure with cotter pin.

Group.

Adjusting the Guide Stop
CAUTION:
CAUTION:
NEVER reach into the receiver opening (A) when the hitch is lowered. Risk
of injury!

[1] - With the trailer hook retracted, locking pin (A) must engage easily in the corresponding
hole (E) in the hook.
[2] - Extend the trailer hook and lower the pick-up hitch.
[3] - Shut off engine.
[4] -
IMPORTANT:
Apply L41475 ( LOCTITE ™ 243) to cap screw and hex. nut.
Remove lift link (D), adjust stop screw (C) as necessary and tighten hex. nut.
Guide stop, hex. nut Torque 300 N˙m
221 lb-ft
[5] -
→NOTE:
To obtain the desired torque, align hex. nut (F) with the housing and apply
a mark to the housing where one edge of the nut is located (see
illustration). Turn nut until the center line of the next side of the nut is
aligned with the housing mark.
Re-check the adjustment.

Group.

Adjusting the Locking Pin
CAUTION:
CAUTION:
NEVER reach into the receiver opening (A) when the hitch is lowered. Risk
of injury!

[1] - Open and close the hitch several times.

[2] - When locked:
a. Locking pin (A) must stick out (see arrow).

Locking pin, distance it sticks out Measurement min. 3 mm
min. 0.12 in.
b. Operating lever (D) in the cab must be in detent position.
[3] - When unlocked:
a. The operating lever must be pulled to its limit position and held there. In this position,
locking pin (A) must not stick out beyond surface (C).
b. Whenever the actuating lever is released, it should be held firmly by stop (B).
[4] - If necessary, carry out the appropriate adjustment to the bowden cable at the two
adjusting nuts (E). Repeat the check.
Group.
Pick-Up Hitch — Operational Check
CAUTION:
[1] - Check hitch function by opening and closing hitch several times.

OPERATOR′S CAB (g) by Belgreen
[2] - Make sure that hitch is completely locked. If this is the case, the hitch will not lower
when the draft links are lowered and not extend when the selective control valve is operated.
[3] - In case the hitch does not function without fault: Check or perform the following
adjustments; see:
”Adjusting the Lift Links”

”Adjusting the Guide Stop”
”Adjusting the Locking Pin”

Section 90 - OPERATOR′S CAB

Table of contents
Special Tools .......................................................................................................................... 1
Dealer-Manufactured Special Tools ........................................................................................ 3
Repair specifications .............................................................................................................. 4
Tilting operator′s cab and removal and installation ............................................................... 4
Tilt Operator′s Cab Upward .................................................................................................... 6
Tilting the operator′s cab downward .................................................................................... 19
Removing the operator′s cab ............................................................................................... 26
Installing the operator′s cab ................................................................................................. 38
Checking and adjusting shift units ....................................................................................... 46
Group 05 - Controls and Instruments ................................................................................... 47
Controls and Instruments (Summary of References) ........................................................... 47
Replacing Bulbs on the Instrument Unit ............................................................................... 47
Removing Control Unit ......................................................................................................... 47
Removing Control Unit for the Lighting System ................................................................... 48
Instructions when Replacing a Control Unit ......................................................................... 49
Replacing the UIM Control Unit ............................................................................................ 50
Replacing a VTI Display ........................................................................................................ 51
Replacing a BCU Control Unit ............................................................................................... 52
Replacing a TCU Control Unit ............................................................................................... 53
Replacing an SFA Control Unit ............................................................................................. 55
Replacing an SIC Control Unit .............................................................................................. 57
Replacing an ECU Control Unit ............................................................................................. 58
Replacing an UIC/PLC Control Unit ....................................................................................... 58
Replacing the Terminating Resistors .................................................................................... 60
Replacing the Performance Monitor (PRF) ............................................................................ 66
Replace the Basic Informator (BIF) ....................................................................................... 68
Replace Operation Unit ........................................................................................................ 69
Group 10 - Air-Conditioning System ..................................................................................... 71
Air-conditioning system (summary of references) ............................................................... 71
Special Tools ........................................................................................................................ 72
Specifications ....................................................................................................................... 79
Torques for Tightening Refrigerant Hoses ............................................................................ 80
Safety At Work ..................................................................................................................... 81
Handling Refrigerant ............................................................................................................ 81
In an Emergency .................................................................................................................. 82
Safety Equipment ................................................................................................................. 82
Storage of Refrigerant Containers ........................................................................................ 83
R134A Refrigerant ................................................................................................................ 83
Important Note ..................................................................................................................... 84
Discharging the System ....................................................................................................... 85
Evacuating the system ......................................................................................................... 87
Filling with Refrigerant Oil .................................................................................................... 89
Instructions for Starting Up the DENSO Air-Conditioning Compressor ................................. 90
Filling the System ................................................................................................................. 92
Topping up a partly discharged system ............................................................................... 95

Leak test .............................................................................................................................. 95

Removing the Compressor ................................................................................................... 96
Checking Level in the Compressor ....................................................................................... 97
Disassembling the Compressor Clutch ................................................................................. 99
Checking Clutch Hub Clearance ......................................................................................... 100
Checking the Compressor Manifold .................................................................................... 101
Installing the Compressor .................................................................................................. 102
Removing and Installing the Condenser ............................................................................. 103
Removing and Installing the Receiver-Drier ....................................................................... 104
Removing and Installing the Evaporator and Expansion Valve .......................................... 105
Replacing the Expansion Valve .......................................................................................... 106
Installing Condensation Water Drain Hoses ....................................................................... 106
Removing and Installing the Thermostat Switch ................................................................ 107
Adjusting Thermostat Switch Bowden Cables .................................................................... 108
Removing and Installing the High/Low Pressure Switch ..................................................... 109
Group 11 - ClimaTrak ............................................................................................................ 110
ClimaTrak - Summary of References .................................................................................. 110
Removing and Installing the ATC Controller (ClimaTrak) ................................................... 110
Removing and Installing the Driver Unit for Fan Motor (A59) ............................................. 110
Removing and Installing the Sending Unit for Ambient Temperature (Front) (B125) ......... 111
Removing and Installing the Sending Unit for Ambient Temperature (Rear) (B126) .......... 112
Removing and Installing the Sending Unit for Inside Air Temperature (B127) ................... 113
Removing and Installing the Sending Unit for Actual Outlet Air Temperature (B128) ........ 114
Removing and Installing the Sending Unit for Evaporator Core Temperature (B129) ........ 114
Removing and Installing Sending Unit for Refrigerant Pressure (B130) ............................. 115
Water Valve (B131) Removal and Installation .................................................................... 116
Mode Control for Position of Air Distribution Flaps (B132), Removal and Installation ........ 118
Remove and Install the Defog sensor (B143) ..................................................................... 120
Group 15 - Heating System .................................................................................................. 122
Heating System (Summary of References) ........................................................................ 122
Removal and Installation of Components ........................................................................... 123
Adjusting Air Flow Bowden Cables ..................................................................................... 127
Group 20 - Seats .................................................................................................................... 130
Operator′s Seats (Summary of References) ....................................................................... 130
Comfort seat MSG85 .......................................................................................................... 131
Air Comfort Seat MSG95, Lower Section ............................................................................ 148
Exploded View of the Instructional Seat ............................................................................. 155
Command Arm Repair ........................................................................................................ 158
Group 25 - Operator′s Cab .................................................................................................... 162
Operator′s Cab (Summary of References) .......................................................................... 162
Removing Cab Frame ......................................................................................................... 162
Cab mounting torques ....................................................................................................... 164
Removing the Outer Roof ................................................................................................... 165
Removing and Installing the Windshield ............................................................................ 167
Removing and Installing the Rear Window ......................................................................... 169
Removing and Installing the Roof Hatch ............................................................................ 171
Removal and Installation of Panoramic Windshield ............................................................ 173
Installing Door Lock ............................................................................................................ 181
Adjusting Windshield and Rear Window Contact Pressure ................................................. 183

Operator′s Cab Door Removal and Installation .................................................................. 184

Roller Sun-Visor Removal and Installation .......................................................................... 185
Removing Inner Roof Trim ................................................................................................. 186
Group 30 - Cab Suspension .................................................................................................. 187
Cab Suspension — Summary of References ....................................................................... 187
Important Instructions ........................................................................................................ 187
Specifications ..................................................................................................................... 188
Relieving Hydraulic System Pressure ................................................................................. 189
Installing and Removing the Cab Suspension Shields ........................................................ 190
Removing and Installing the Sensor Rod ............................................................................ 190
Adjusting the Sensor Rod ................................................................................................... 192
Removing the Position Sensor ............................................................................................ 192
Reconditioning the Position Sensor .................................................................................... 194
Installing the Position Sensor ............................................................................................. 194
Removing the Accumulator ................................................................................................ 195
Reconditioning the Accumulator ........................................................................................ 197
Installing the Accumulator ................................................................................................. 198
Removing Hydraulic Cylinder ............................................................................................. 198
Installing Hydraulic Cylinder .............................................................................................. 199
Removing the Control Valve Block ..................................................................................... 200
Reconditioning the Valves in the Control Valve Block ........................................................ 201
Installing the Control Valve Block ....................................................................................... 206
Panhard Link Removal and Installation .............................................................................. 207
Bleeding Cab Suspension Hydraulic Cylinders ................................................................... 208

Section 90 - OPERATOR′S CAB Group 00: Removal and Installation of Components

Special Tools
→NOTE:

Cab tilting device
KJD10178C
[ This tool kit may be used on 6020 to 6920, 6010 to 6910 and 6000 to 6900 tractors. ]
LEGEND:
4 Support rod KJD10178-4A (including joints and pins)
5 Hinge pin KJD10178-5 (including retaining pin)
8 Strut KJD10178-8B (replaces KJD10178-8 and KJD10178-8A)
10 Spindle KJD10178-10 (assembly with crank)
12 Rod KJD10178-12 (including retaining pins)
13 Bracket KJD10178-13 (including attaching screws)
14 Rear tilt bracket KJD10178-14 (with suspended cab)
Tilting the operator′s cab up and down (replaces tilting devices KJD10178, KJD10178A and

KJD10178B). For conversion of the old tilting devices, all parts can be ordered separately.
Strut KJD10178-8B
LEGEND:
(A+B) KJD10178-8B
Used for: tilting all operator′s cabs equipped with tubes inside their frames.
→NOTE:
This part is included in cab tilting device KJD10178C. If you intend using
older tilting devices on cabs with inner tubes, you will have to order this
part separately.
Location: On the front of the cab frame, r.h. side. Bushing (B) must be installed and secured
by means of a retaining pin at the appropriate position on part (A).
DEFINITIONS:
1 Installation for cab frameswith inner tube
2 Installation for cab frameswithout inner tube
Snap ring tool
JDG18

Removing and installing snap rings on rack-and-pinion axles
JT05725
Supporting tractor during rear wheel removal. One commercial 12-ton vehicle jack is also
required.
Lifting sling
JDG23
Operator′s cab removal and installation
Dealer-Manufactured Special Tools

Suspension eyes (2 used)

LEGEND:
A Commercial M16, DIN 582 lifting eye nut
B M16 nut
C Threaded rod M16 x 100 mm (4 in.), Grade 8.8
Coat threaded rod (C) with LOCTITE ™ 270 (L41476), screw it into the eye nut (A) until it is
flush, and lock it with nut (B).
Front cab mounting, cap screw Torque 220 N˙m
160 lb-ft
Rear cab mounting, cap screws Torque 200 N˙m
150 lb-ft
Baseplate at rear cab mountings, cap screws Torque 400 N˙m
300 lb-ft
Tilting operator′s cab and removal and installation

Summary of references, section 90, group 00:
“Tilting the operator′s cab upward”

“Tilting operator′s cab downward”
“Removing operator′s cab”
“Installing operator′s cab”

Tilt Operator′s Cab Upward
IMPORTANT:
Remove all loose objects from cab to prevent the windows from being
damaged.
CAUTION:
Always be careful to observe the correct battery terminals.
05).

[2] -
Stop the tractor on level ground, engage the park lock and remove the right rear wheel.
Support the tractor underneath the r.h. final drive housing.
[3] -
Mechanically actuated clutch: Remove the cowl trim. Slacken off locknut (B), and remove
retainers (A) and (C). Then take the yoke off the cable.
→NOTE:
As the cab tilts up, feed the cable through the hole in the cab floor.

Emergency park lock release on tractors with AutoPowr/IVT transmission:

Take off retainers (A) and (B), and disengage the yoke. Take screw out of clamp (C).
→NOTE:
As the cab tilts up, make sure that the bowden cable does not get caught.

[4] -
Disengage bowden cable (A) of the handbrake at the yoke and counter-bearing.
→NOTE:
[5] -
Tractors with muffler pipe to top right: Remove shield (A) and loosen the pipe clamp
located underneath. Disconnect clamp (B) from the engine block and slacken off pipe clamp
(C). Remove muffler pipe (D).

[6] -
Remove the r.h. access step and front bracket (E). This is done by taking out screws (A) and
hex. socket screw (B), disconnecting hoses (C) from the windshield washer reservoir and
disconnecting cable (D).
→NOTE:
If you intend to remove transmission sub-assemblies after the cab has been
tilted, you will also have to take off the l.h. access step; this will allow
lifting tackle to be attached without undue difficulty.
[7] -

Remove the toolbox retainer if necessary.

As shown, attach theKJD10178Dtilting device to the main frame and cab. Secure part (A) with
a hex. socket screw (see B in step 7). See also Special Tools (Available as Spare Part), Section
99, Group 10.
CAUTION:
Install quick-lock pins (E) and (F).
→NOTE:
Part (A; KJD10178-8) of the old tilting device KJD10178 cannot be installed
on cabs equipped with a tube inside the frame. Refer to the relevant
instructions at Special Tools in this Group.

[8] -
Take cover (A) off the l.h. cab air filter (not equipped on suspended operator′s cabs
[ HCS cab ]
).
[9] -
Disengage the PTO control cable (A; if equipped) and the trailer hitch release cable (B; if
equipped). If equipped, disconnect the stabilizer rod chains (draft links).
[10] -
On tractors with air-conditioning, take out the two screws (A).

[11] - Cab NOT suspended:
Front tilt joint
Rear tilt joint

Install the tilt joint pins (A), and secure.
→NOTE:
If the tilt joint pins cannot be installed easily, slacken off the cab mounting
screws.
Remove cap screws (A) on both sides of the cab.

With suspended cab (HCS):
a. Remove the two rear screws (A) from the r.h. baseplate.
b.
LEGEND:
A Bracket KJD10178-14 (included in cab tilting device KJD10178D)
Locate bracket (A) as shown and secure with cap screws (B). Install screws (C) and (D).
Insert and secure tilt joint pin (E).
→NOTE:
If the hydraulic pressure at the two cylinders is not sufficient to hold
the cab in its initial position, use a suitable tool to raise it.

c.
Remove cap screw (A) from Panhard link attachment.
d.
Disengage position sensor linkage (B) and then take out screws (A) on both sides of the
cab.
[12] -

[13] -
Tilt the operator′s cab upward. As soon as bracket (A) can be reached, unbolt it; do not tilt
the cab higher until the bracket has been unbolted.
CAUTION:
Never use a powered tool (electric or pneumatic) to drive the tilting
device. This would damage the threaded spindle of the tilting device and
could result in personal injury.
IMPORTANT:
When tilting the cab upward, watch out for lines and hoses, plus all the
bowden cables. There is a risk of them getting caught on other
components. The same applies to wiring harnesses.
Pay attention to cable binders and other items that may have been
attached to the cab′s harnesses or components later on.

[14] -
As soon as the cab is tilted up, install retaining strut (A). The strut may be installed either at
the front or at the rear cab mounting, depending on requirements.
With suspended cab (HCS), remove the cab suspension′s Panhard link and install retaining
strut (A) as shown.
CAUTION:
Repair or maintenance work must not be carried out under the tilted cab
until the retaining strut has been attached. Repair work inside a tilted cab
is NOT permitted.
Take particular care when opening the r.h. cab door; due to its angle, it
could swing open of its own accord as soon as the catch is released.
[15] -
CAUTION:
If any work is to be done on the hydraulic cab suspension
[ If equipped ]
, remember to relieve the hydraulic pressure first.
Do NOT reach into the hazardous area while pressure is still being relieved.

If any subsequent work is to be done on the hydraulic cab suspension, relieve the oil
pressure of both hydraulic cylinders. Install a suitable hose (A) on bleed valve (B) and put the
other end of the hose in the oil filler neck. Open the bleed valve until the oil stops flowing;
then close the bleed valve. Repeat this procedure on the l.h. hydraulic cylinder.

Tilting the operator′s cab downward

[1] - Cab not suspended:
LEGEND:
A Cap screw
B Washer
C Rubber washer
D Bushing
E Rubber bearing
F Washer
G Nut
H Cap screw
I Washer
J Nut
The illustration opposite shows where the various parts of the cab mountings are located.
IMPORTANT:

On suspended cab (HCS):
Install the supports of the front cab bearings (A) on the spherical bearings as shown. When
the cab is tilted down, the dowel pins in these supports must locate in the relevant holes in
the cab.
[2] - Remove the retaining strut. Carefully tilt the cab by turning the threaded spindle to the
left (counter-clockwise). Ensure that none of the hoses, bowden cables or electrical cables
become trapped.
Before the cab is completely tilted, carefully check the position of all bowden cables. Comply
with the following guidelines:

The bowden cable must not chafe against other components.
Make sure that the wiring harnesses are all routed correctly. Put the steering system oil
hoses back in the brackets provided for them.
On tractors with air-conditioning, connect the condensation drain hoses between the main
frame and the transmission.

[3] -
Front cab mountings

Tighten the front cab mounting screws to the prescribed torque value.
160 lb-ft
IMPORTANT:
When tightening the front cab mountings on suspended cabs, take care not
to apply too much pressure to the spherical bearings.
[4] -
Rear cab mountings (cab NOT suspended)

Tighten the cap screws on the rear cab mountings to the prescribed torque value.
150 lb-ft

Install cap screws (A), and tighten the nuts by hand. Remove pins (B) and take off bracket
(C). Then tighten the cap screws to the specified torque value.
150 lb-ft
CAUTION:
Raise the cab slightly before taking off bracket (C).
→NOTE:
If the hydraulic pressure at the two cylinders is not sufficient to hold the
cab in its initial position, use a suitable tool to raise it.
Install Panhard link (D).
Tighten the screws on the baseplate to the prescribed torque.

Baseplate at rear cab mountings, cap screws Torque 400 N˙m
300 lb-ft

IMPORTANT:
Always use the original bushings when installing these screws. The use of
shorter screws is NOT permitted, as the required clamping force cannot be
obtained.
On the l.h. side, install cap screws (A) and tighten them to the specified torque. Install the
position sensor linkage.
→NOTE:
Remember to calibrate the cab suspension once cab installation has been
completed.
[5] - Engage and adjust the handbrake cable. See “Adjusting the handbrake” , section 60,
group 25.
[7] -
Install the r.h. rear wheel. See “Installing the front and rear wheels” , section 80, group 15.
Tighten the wheel screws to the prescribed torque. Drive the tractor for a distance of approx.
50 m (150 ft), then retighten the cap screws to the specified torque value.

[8] - Once installation has been completed:
Check the adjustment of all shift mechanisms/linkages.

Check engine idle speed adjustment.
Check the setting of the handbrake.
Check clutch adjustment
Calibrate the cab suspension (with suspended cab only)
See “Checking and adjusting the shift mechanisms/linkages” in this group.

See “Speed control linkage (summary of references)” , section 30, group 05.
See “Checking the handbrake” , section 60, group 25.
See “Calibrating the cab suspension”, section 290, group 25.
IMPORTANT:
Check and adjust the pneumatic trailer brake valve (if equipped). See
“Adjusting the handbrake (with air brake system)”, section 60, group 35.

Removing the operator′s cab

[1] - Drain coolant.
Disconnect the negative terminal (—) on the battery. The version shown here has its negative
CAUTION:
Always take note of battery terminals.
Comply with safety instructions on how to handle batteries (see section
05).
[3] - Tractors with air-conditioning: Before extracting the refrigerant, see “Discharging
the system” in section 90, group 10.
[4] -
For mechanically actuated clutch: Remove the cowl trim. Slacken off locknut (B), and
remove retainers (A) and (C). Then take the yoke off the cable.
→NOTE:
As the cab tilts up, feed the cable through the hole in the cab floor.

[5] -
Emergency park lock release on tractors with AutoPowr/IVT transmission:

Take off retainers (A) and (B), and disengage the yoke. Take screw out of clamp (C).

→NOTE:
As the cab is being removed, make sure that the bowden cable does not
get caught.
[6] -
With muffler pipe to top right: Remove metal shield (A) and slacken the pipe clamp
located beneath. Disconnect clamp (B) from the engine block and slacken off pipe clamp (C).
Remove muffler pipe (D).
[7] -
Remove the access steps on both sides. Do this by taking out screws (A). If a windshield
washer reservoir is equipped, disconnect the electrical cable and hoses and take out the
reservoir.

[8] -
If equipped, disengage bowden cables (A) of the front control valves and disconnect
pressure-gauge hose (B) of the air brake system from the air tank.
CAUTION:
It is vitally important to relieve air pressure before disconnecting the air
lines.
→NOTE:
Mark the bowden cables to facilitate their reinstallation. Seal the open
ends of the air tank and air line so that no dust can penetrate.
On electrically actuated independent control valves, the relevant electrical
connector must be disconnected instead of the bowden cables (A).
[9] -
Disconnect steering hoses (A) and brake hoses (B).

→NOTE:
Trap oil as it emerges. Seal the openings so that no dust can penetrate.

[10] -
Mark all the transmission shift bowden cables to assist with reinstallation, then disengage. If
bowden cable (A) is equipped, disengage it at the yoke and counter-bearing.
→NOTE:
Depending on transmission type, differences will occur with regard to the
illustration opposite.
Disconnect heater hoses (B).

IMPORTANT:
It is essential to mark the heater hoses before disconnecting, as they must
not be mixed up. Incorrect installation of hoses will impair the functioning
of the air-conditioning system.
→NOTE:
Drain escaping coolant into a suitable container.

[11] -
On tractors with air conditioning system: Disconnect the refrigerant line at fitting (A) on the
receiver-drier.
Disconnect the refrigerant line at fitting (B) on the compressor. This line is removed together
with the cab.
CAUTION:
It is vitally important to extract the refrigerant BEFORE disconnecting any
refrigerant lines.
IMPORTANT:
Seal the air-conditioning system disconnection points immediately so that
no air can get in.

[12] -
Underneath the front right corner of the operator′s cab, disconnect ground strap (A).
[13] -
Disengage all the SCV bowden cables (A). Disconnect line (B).
If bowden cables (C) and (D) are equipped, disengage them at the counter-bearing and yoke.

[14] -
Pull out connector (A). On both sides of the cab, take off covers (B) and pull out the
connectors (C) that lie behind the covers.
[15] -
Disengage bowden cable (A) of the handbrake at the yoke and counter-bearing.
→NOTE:
If equipped, disconnect release chains of stabilizer struts.

[16] -
Remove Panhard link (A).

[17] -
Take the two cap screws out of the top of the roof.
Screw in the two (dealer fabricated) lifting eyes (B) as far as the collar, and tighten.
dealer fabricated
Threaded rod (C) coated with LOCTITE ™ 270 (L41476), screw into ring nut (A) until it
bottoms and lock with nut (B).
CAUTION:
The cab weighs approx. 800 kg (1765 lb). This fact must be borne in mind
when fabricating the two lifting eyes and selecting an appropriate hoist.
(RISK OF ACCIDENT).
IMPORTANT:
Adjust the width of sling (A) (JDG23) to match the distance between the
two lifting eyes (B). Only with the weight distributed in this way can the
maximum load capacity of the lifting eyes be achieved.
Suspend the operator′s cab from the suitable hoist by means of lifting sling JDG23.

Suspension sling
JDG23
Removing and installing the operator′s cab and other tractor components.
[18] -

[19] -

Raise the cab, and disconnect return hose (A) as soon as it can be reached. On models with
Power-Fill brake valve, also disconnect LS hose (B).
On tractors with Power-Fill brake valve, disconnect hose (A) from attenuator (B).
→NOTE:
Trap oil as it emerges. Seal the openings so that no dust can penetrate.
To facilitate their reinstallation, mark all the plug connections between the cab and the
tractor, and then disconnect them.
Raise the cab carefully.

IMPORTANT:
When raising the operator′s cab, watch out for lines and hoses, plus all the
bowden cables. There is a risk of them getting caught on other
components. The same applies to wiring harnesses.
Pay attention to cable binders and other items that may have to be
attached to the cab′s harnesses or components later on.
Lower the operator′s cab onto mounting blocks. AVOID ACCIDENTS!

[20] -
CAUTION:
If any work is to be done on the hydraulic cab suspension, remember to
relieve the hydraulic pressure first.
Do NOT reach into the hazardous area while pressure is still being relieved.
If any work is to be done on the hydraulic cab suspension, relieve the oil pressure at
the two hydraulic cylinders. Install a suitable hose (A) on bleed valve (B) and put the other
end of the hose in the oil filler neck. Open the bleed valve until the oil stops flowing; then
close the bleed valve. Repeat this procedure on the l.h. hydraulic cylinder.

Installing the operator′s cab

[1] - Cab not suspended:
LEGEND:
A Cap screw
B Washer
C Rubber washer
D Bushing
E Rubber bearing
F Washer
G Nut
H Cap screw
I Washer
J Nut
The illustration opposite shows where the various parts of the cab mountings are located.
IMPORTANT:

Install the supports of the front cab bearings (A) on the spherical bearings as shown. When
the cab is lowered, the dowel pins in these supports must locate in the relevant holes in the
cab.

[2] -
Lower the cab, and connect return hose (A) as soon as possible. With Power-Fill brake valve,
also connect LS hose (B).
On tractors with Power-Fill brake valve, connect hose (A) to attenuator (B).

[3] - Lower the cab onto its mountings and ensure that none of the hoses, bowden cables or
electrical cables become trapped.
Before the cab is completely mounted, carefully check the position of all bowden cables.
Comply with the following guidelines:

The bowden cable must not chafe against other components.
Make sure that the wiring harnesses are all routed correctly. Put the steering system oil
hoses back in the brackets provided for them.
On tractors with air-conditioning, connect the condensation drain hoses between the main
frame and the transmission.
[4] -
Rear cab mountings (cab NOT suspended)

Tighten the cap screws on the rear cab mountings to the prescribed torque value.
150 lb-ft

[5] -
Front cab mountings

Tighten the front cab mounting screws to the prescribed torque value.
160 lb-ft
[6] -
Install Panhard link (A).


[8] -
Connect the negative terminal (—) on the battery. The version shown here has its negative
CAUTION:
If both battery terminals have been disconnected, reconnect positive
terminal first.
CAUTION:
For instructions on how to handle batteries safely, see section 05, group
05.
→NOTE:
Location of battery terminals may be different depending on battery type.
Always take note of the markings on the battery.

[9] - Once installation has been completed:
Check the adjustment of all shift mechanisms

Check the adjustment of hand throttle
Check the brake system
Check the handbrake adjustment
Check the setting of the clutch pedal
Calibrate the cab suspension (with suspended cab only)
Check the trailer brake valves (if equipped)
Recharge the air-conditioning system (if equipped)
See “Checking and adjusting the shift mechanisms/linkages” in this group.

See “Speed control linkage (summary of references)” , section 30, group 05.
See “Checking the handbrake” , section 60, group 25.
See “Calibrating the cab suspension”, section 290, group 25.
See “Bleeding the brakes (Power-Fill brake valve, with FWD and disk brake)” , section 60,
group 20, and “Bleeding the trailer brake valve” , section 60, group 30.
See “Checking the hydraulic trailer brake valve” , section 60, group 30.
See “Checking” at the air-brake system, and “Adjusting the handbrake (with air brake
system)” , section 60, group 35.
Before recharging the air-conditioning system, see “Charging the system” , section 90, group
10.
Check all functions and rectify any faults (refer to corresponding Technical Manual).

Section 90 - OPERATOR′S CAB Group 05: Controls and Instruments
Checking and adjusting shift units
→NOTE:
Once the operator′s cab or open station has been installed, check the
setting of the shift mechanisms/linkages.
AutoPowr/IVT transmission (group 53-05)
See “Manual release of park lock”

“253-10-001” , AutoPowr/IVT transmission — For operational checks, see “Operation
and Tests” manual, section 253, group 10.
PowrQuad transmission (group 55-05)
“Checking and adjusting the shift mechanisms/linkages (reverser control on steering

column)”
“Shift units, checking and adjusting (PowrQuad Plus and AutoQuad transmission)”
“Adjusting reverse drive lever (on steering column)”
“Adjusting clutch pedal (PowrQuad transmission)”
All tractors
IMPORTANT:
See “Checking the neutral start circuit” , section 10, group 10.

Group 05 - Controls and Instruments

Controls and Instruments (Summary of References)
”Replacing bulbs on the instrument unit”
”Removing control unit”
”Removing control unit for the lighting system”
”Instructions when replacing a control unit”
”Replacing control unit (UIM)”
”Replacing a VTI display”
”Replacing control unit (BCU)”
”Replacing control unit (TCU)”
”Replacing control unit (SFA)”
”Replacing control unit (SIC)”
”Replacing control unit (ECU)”
”Replacing control unit (UIC/PLC)”
”Replacing terminating Bus resistors”
”Replacing the performance monitor (PRF)”
”Replacing the basic informator (BIF)”
”Replacing the operation unit”
Replacing Bulbs on the Instrument Unit
Remove instrument unit.
See "Replacing Instrument Unit (BIF)" , Section 90, Group 05.
Turn socket with bulb counterclockwise and remove.
Removing Control Unit

Carefully pry out the console using a screwdriver at the locations indicated (see arrows).
Pull out locking clip (A) at plug (B) and disconnect plug.
Carefully press on areas indicated and push out control unit to the front.
Removing Control Unit for the Lighting System

IMPORTANT:
Do not use a test lamp when working with electronic control units. When
carrying out welding jobs on the tractor disconnect the battery to protect
the electronic system.
Carefully pry out the console using a screwdriver at the locations indicated (see arrows).
Pull out locking clip (A) at plug (B) and disconnect plug.
Carefully press on areas indicated and push out control unit to the front.
Instructions when Replacing a Control Unit

Do not replace a control unit with another one unless it is necessary.
Follow relevant diagnostic procedures to determine cause of problem.
Specific diagnostic trouble codes will be displayed if control unit is defective.

→NOTE:
As far as possible, read the following data out from the control unit before
you replace it with another one.
To make sure that the correct replacement unit is used, determine the
software version (for software information, see”Reference
245-05-006, Approved Software for Control Units”).
Read out the input addresses that are typical for the tractor, and
make a note of them (see the calibration and input addresses for the
relevant control unit in Section 245).
Once the control unit has been replaced with another one, key in the
input addresses and calibrate the following control units: SFA, SIC,
BCU, SSU, TCU, EPC and ATC (and PRF too if a radar sensor is
equipped).
Replacing the UIM Control Unit
→NOTE:
See reference”Instructions when Replacing a Control Unit”, before

replacing the control unit with another one.
Remove the monitor unit, see ”Removing the Monitor Unit” .
Break the plug connections.
Take out hex. socket screws (A) and remove the control unit (UIM).
To install, follow disassembly procedure in reverse order and comply with the following
torque values:

Control unit (UIM) to cab post

Hex. socket screw Torque 18 N˙m
13.3 lb-ft
Replacing a VTI Display
→NOTE:

Remove cap screws (A) and move display (B) slightly forward, disconnect plug and remove
display (B).

Replacing a BCU Control Unit
→NOTE:

The basic control unit (BCU) is located on the right-hand side (seen in the direction of forward
travel) below the TCU/EPC control unit (if equipped).
Take out attaching screws (A) and remove control unit (B).
→NOTE:
Put an identifying mark on the plugs before disconnecting them.
Disconnect plugs (A) and (C) and remove control unit (B).

IMPORTANT:
carrying out welding jobs on the tractor, disconnect the battery to protect
A new electronic control unit (BCU) has to be calibrated.
See Reference 245-BCU-001 , Calibration and Input Addresses of Basic Functions.
See Reference 245-BCU-002 , Calibration and Input Addresses of Hitch Control.
Replacing a TCU Control Unit
→NOTE:

The hitch control unit is located on the right-hand side of the tractor (viewed in direction of
travel).
Disconnect plug (A) and remove attaching screws (B).
Remove control unit (C).
IMPORTANT:
carrying out welding jobs on the tractor, disconnect the battery to protect

A new electronic control unit (TCU) has to be calibrated.
See reference245-TCU-001, Calibration and Input Addresses.

Replacing an SFA Control Unit
→NOTE:

Remove cover (A).
Take out hex. socket screws (B) and remove panel.

Disconnect plug, remove hex. socket screws (A) and control unit (B).
A new electronic control unit has to be calibrated.
See Reference 245-SFA-001 , Calibration and Input Addresses, Front-Wheel Drive Axle with
TLS.
See Reference 245-SFA-002 , Calibration and Input Addresses, Hydraulic Cab Suspension.

Replacing an SIC Control Unit
→NOTE:

Remove cover (A).
Take out hex. socket screws (B) and remove panel.

Remove cap screws (A) and disconnect plug (B).
See Reference 245-SIC-001 , Calibration and Input Addresses for E-SCVs and E-ICVs.
Replacing an ECU Control Unit
→NOTE:

Remove hex. nuts (A), disconnect plug and remove control unit (B).
Replacing an UIC/PLC Control Unit

→NOTE:

Remove hex. nuts (A) and control unit (B).
Disconnect both plugs and remove control unit (C).
Reference 245-UIC-001 , Calibration and Input Addresses.
Reference 245-PLC-001 , Calibration and Input Addresses.

Replacing the Terminating Resistors

29-bit CAN BUS system
Terminating resistor, instruments, 6-terminal (A14)
Remove trim panels from cowl.
Remove cap screws (A) and take out terminating resistor (B).
Disconnect plug.
Terminating resistor, instruments, 6-terminal (A62) up to tractor serial no. 398655

LEGEND:
A Hex. nut
B Panel
C Terminating resistor, instruments (A62)
Remove trim panels from cowl.
Remove hex. nut (A) and lift off panel (B).
Carefully remove wiring harness and terminating resistor (C).
Terminating resistor, instruments, 6-terminal (A62) from tractor serial no. 398656
with CommandARM™ shown

LEGEND:
A Side panel
B Side panel
C Hex. nuts
D Terminating resistor, instruments (A62)
The instruments terminating resistor (A62) is located under the panel on the right-hand side
(seen in direction of forward travel).
Remove side panels (A) and (B), hex. nuts (C) and disconnect plugs.
Carefully remove wiring harness and terminating resistor (D).
Terminating resistor in cab roof, 6-terminal (A61)

Carefully remove panel (A) and pull out plastic ring (B).
Take out screws (C) and remove loudspeaker (D).
Pull off terminating resistor (E).
Terminating resistor in cab roof, 4-terminal (A15)

Remove panel (A) and hex. socket screws (B).
Carefully pry out first aid kit compartment (C) across edge (arrows).
Remove bus resistor rivets.
Install new terminating resistor (D) with rivets.
11-bit CAN-BUS System (6-terminal; A17)

Terminating resistor
Disengage gas-filled strut (A).
Remove covers (B) and (C).
Remove terminating resistor (D).
Terminating resistor
Remove terminating resistor (B)
[ 4-terminal; A18 ]
from control units.
11-bit CAN-BUS System (6-terminal: A63)
→NOTE:
On the latest tractors, the terminating resistor is located behind the seat
on the r.h. side (viewed in direction of travel).
LEGEND:
A Terminating resistor
Detach the SIC control unit from the baseplate; see reference ”Replacing an SIC Control Unit”
. Carefully pull out wiring harness and terminating resistor (A).
Replacing the Performance Monitor (PRF)
→NOTE:


The performance monitor is located at the right-hand front cab post (seen in direction of
forward travel).
Disconnect plug (A) and remove attaching screws (B).
Remove the attaching screws (C).

Replace the Basic Informator (BIF)
→NOTE:

[1] - The basic informator is located in the cowl.
Move steering wheel to vertical position and pull off knob (A).

Remove four Phillips-head screws (B) and cover (C).
[2] -
Remove attaching screws (D).

[3] -
Pull out clips and disconnect plugs (E).

[4] - Remove instrument unit.
A new electronic control unit (BIF) requires adjustments to be made.
See reference 245-BIF-001 , Calibration and Input Addresses.
Replace Operation Unit
LEGEND:
A Attaching screws
B Grips
Remove attaching screws (A) and grips (B) from selective control valve levers.
Remove operation unit from console and disconnect wiring harnesses at connectors.
Install the same operation unit by following removal procedure in reverse order.
If a new operation unit is installed, it has to be calibrated. See Reference 245-BCU-001 ,

Section 90 - OPERATOR′S CAB Group 10: Air-Conditioning System
Calibration and Input Addresses of Basic Functions.
See Reference 245-BCU-002 , Calibration and Input Addresses of Hitch Control.

Group 10 - Air-Conditioning System

Air-conditioning system (summary of references)
”Special tools“
“Repair specifications”
“When tightening refrigerant hoses, pay heed to the following torques”
“Safety at work”
“Handling refrigerant”
“In an emergency”
“Safety equipment”
“Storage of refrigerant cans”
“Refrigerant R134A”
“Important note”
“Discharging the system”
“Evacuating the system”
“Filling with refrigerant oil”
“Instructions for starting up the DENSO air-conditioning compressor”
“Filling the system”
“Topping up a partly discharged system”
“Leak test”
“Removing the compressor”
“Checking oil level in compressor”
“Disassembling the magnetic compressor clutch”
“Checking clutch hub clearance”
“Checking compressor manifold”
“Installing the compressor”
“Removing and installing condenser”
“Removing and installing the receiver-drier”
“Removing and installing the evaporator and expansion valve”
“Replacing the expansion valve”
“Installing the condensation water drain hoses”
“Removing and installing the thermostat switch”
“Adjusting the thermostat switch bowden cables”
“Removing and installing the high/low pressure switch”

Special Tools
→NOTE:

Service unit
FKM10478
Used to discharge, evacuate, fill, clean and check the air conditioning system
IMPORTANT:
Use only service units suitable for handling R134a refrigerant.
→NOTE:
All work performed with this unit must be carried out in accordance with
the service unit operator′s manual.

Leak tester
FKM10444
Identifying refrigerant leaks.
→NOTE:
Leak tester can be used with R12 as well as R134a refrigerant.
Discharging unit
FKM10442
Discharging refrigerant from the system.

IMPORTANT:
Gauge set
FKM10445
Evacuating, filling and checking the air conditioning system
IMPORTANT:
Vacuum pump
FKM10440

Evacuating the system
→NOTE:
The vacuum pump is suitable for both R12 and R134a refrigerant.
Oil injector
FKM10436
Filling with refrigerant oil

IMPORTANT:
Use PAG oil (ND-Oil8) only.
Refrigerant can (R134a; 920g; 750 ml)
FKM10447
Filling the system
IMPORTANT:
Charging valve
FKM10443

Filling the system
IMPORTANT:
PAG refrigerant oil (ND-Oil8; 250 ml)
FKM10446
IMPORTANT:
Use PAG oil (ND-Oil8) only.

Clutch hub holding tool
OTC7062A
Removing the clutch hub

Specifications
Air-conditioning system Cooling output 7 kW
Pressure side of system Refrigerant pressure 1500-2000 kPa (15-20 bar; 218-290 psi)
Vacuum side of system Refrigerant pressure 50-200 kPa, (0.5-2 bar; 7.5-29 psi)
Refrigerant circuit Oil volume (PAG-oil) 220 ml (7.44 fl. oz.)
R134a Refrigerant quantity 1450-1500 g (3.2- 3.3 lb)
Hub to pulley Distance 0.35-0.65 mm (0.014-0.025 in.)
Compressor clutch coil Current draw at 12 V, 20°C (68°F) 2.2 amps., 40 W power
Compressor clutch Resistance 3.5 to 4 ohms
Opening pressure (low; pressure

High and low pressure switches 150-90 kPa (1.5-0.9 bar) (22-13 psi)
dropping)
Closing pressure (low; pressure

High and low pressure switches 240 kPa (2,4 bar) (35 psi)
rising)
Opening pressure (high: pressure 2420-2780 kPa (24.2-27.8 bar) (355-405

High and low pressure switches
rising) psi)
Closing pressure (high; pressure 1880-1520 kPa (18.8-15.2 bar) (275-220

High and low pressure switches
dropping) psi)
Clutch hub attaching screw Torque 15 N˙m (11 lb-ft)
High and low pressure switches Torque 16 N˙m (12 lb-ft)
Hex. socket screw on compressor

manifold
High/low pressure lines—hex. socket

Torque 21—25 N˙m
screws
15.5—18.4 lb-ft
Hose clamp at evaporator housing Torque 3—4 N˙m
2.2—3.0 lb-ft

Torques for Tightening Refrigerant Hoses

Screw size Width across flats Tightening torque
5/8“ .......... 19 mm (3/4”) .......... 17 N˙m (13 lb-ft)
3/4“ .......... 22 mm (7/8”) .......... 35 N˙m (26 lb-ft)
7/8“ .......... 27 mm (1 1/16”) .......... 40 N˙m (29 lb-ft)

Safety At Work
CAUTION:
Certain basic safety regulations apply when dealing with air conditioning
systems, and must be observed at all times. They are backed up by
legislation covering safety precautions for air conditioning systems. The
following excerpts are particularly important:
Air conditioning systems may be operated, serviced or repaired by

authorized, trained personnel only.
Adolescents should not be allowed to carry out service work on air

conditioning systems involving the discharge of Category 2 or 3
refrigerants, unless trade training of adolescents over 16 years old
requires such work. In this case, the adolescent must be supervised by a
trained adult.
Before repairing components carrying refrigerant, remove refrigerant as

far as necessary to ensure that the work can be carried out safely.
Refrigerant should be extracted by suction and re-used. When refrigerant

is discharged into the air, there is the danger of asphyxiation, especially if
work is being performed in an inspection pit, since refrigerant is heavier
than air and concentrates at the lowest level. Moreover, refrigerant is
odorless and colorless, so small quantities emerging from a leak cannot be
detected. In such a case, ensure that there is adequate ventilation at the
place of work.
Smoking and naked flames are not permitted in enclosed spaces where
refrigerant has been released. High temperatures cause chemical reactions
in the refrigerant gas, and highly poisonous substances can form. If
inhaled, these substances have serious effects on health.
High temperatures produced by welding and soldering cause very high

pressures inside components of the air conditioning system, and these
pressures may result in an explosion.
Handling Refrigerant

CAUTION:
When handling refrigerant, always wear safety glasses and leather gloves.
Contact with escaping refrigerant may result in serious frostbite, or even
blindness if the refrigerant strikes the eye.
Whenever there is the risk of refrigerant encountering high temperatures,

wear a suitable breathing mask while working. The breathing mask is not a
suitable means of protection against asphyxiation caused by large volumes
of escaping refrigerant.
In an Emergency
Rinse eye with cold water; preferably use a 1% boric acid solution.
Wash affected parts of the body with water, or preferably with a solution
consisting of one part essence of vinegar and five parts water.
See a doctor as soon as first aid has been administered.
Safety Equipment
This equipment consists of safety glasses, safety gloves and, where appropriate, a breathing
mask (if there is the risk of poisonous gases being released).

CAUTION:
A breathing mask provides NO protection against lack of oxygen.
Prepare a 1% boric acid solution for rinsing the eyes and a solution consisting of 1 part
essence of vinegar and 5 parts water for washing affected parts of the body. Also provide a
first aid kit.
Storage of Refrigerant Containers
CAUTION:
Refrigerant containers are under pressure, and this pressure increases

rapidly when the temperature of the container rises. The thin-walled refill
containers are particularly at risk in this respect. Refrigerant containers
must never be exposed to temperatures over 52°C (120°F).
Never store pressurized containers in the vicinity of heat sources or in

places exposed to direct sunlight. Never open pressurized containers by
force or damage them in any way.
R134A Refrigerant

IMPORTANT:
The air conditioning system operates using R134a refrigerant (tetra-

fluorethane). This substance does not contain any chlorine atoms, so it
does not have a detrimental effect on the ozone in the Earth′s atmosphere.
Even so, the refrigerant must never be discharged straight into the air. It
must be trapped in a recycling unit. Refrigerant stored in a recycling unit
may be re-used at any time.
The recycling unit used to do this must be of a type suitable for handling
R134a refrigerant.
The boiling point of R134a is minus 26.5°C (minus 15.7°F) and its freezing
point is minus 101°C (minus 149.8°F).
Before replacing any component make sure it is compatible with the

refrigerant being used.
Additionally, make sure the proper refrigerant oil is being used. R12
systems are lubricated with petroleum oil which should never be used for
R134a systems. PAG oil should be used for this purpose as it preferentially
binds to the refrigerant and thus assures adequate lubrication of the entire
system.
Important Note
Refrigerant
Use R134a refrigerant only. Any other refrigerant will impair the function of the air-
conditioning system and render all claims for damages made against the manufacturer null
and void.
PAG Refrigerant Oil
Use prescribed refrigerant oil only. Failure to do so will result in damage to the compressor.

Discharging the System
LEGEND:
A Discharge unit (FKM10442)
B Low pressure valve
C Oil separator
D Connector for recycling container
E Service valve
CAUTION:
To prevent the risk of injury, always wear protective goggles and gloves
when working on the air conditioning system.
Run the tractor at 2000 rpm. Operate the a/c system with compressor on at full cooling
output and max. fan speed for approx. 10 min.
→NOTE:
For this task, refer also to the operator′s manual of the relevant discharge
unit.
Shut down the tractor and perform the following procedure.
Connect the red hose to the pressure connection and the blue hose to the suction connection
(oil separator) of discharge unit FKM10442 (A).
Connect the other ends of the hoses as follows:
Use service valve (E) to connect the blue hose from pressure gauge kit FKM10445 to the low-

side valve (B) of the compressor. Use connector (D) from pressure gauge kit FKM10445 to
connect the red hose to a commercially available R134a recycling container.
→NOTE:
Comply with data on recycling container (e.g. weight when empty, max.
weight).
The recycling container must be weighed repeatedly before and during the
discharging process to make sure that it is not over-filled.
Tighten all screw connections, switch on the discharge unit and open the valves.
The discharge unit discharges the system until the suction-pressure switch trips and switches
the unit off at a pressure of approx. -30 kPa (-0.3 bar; -4.5 psi). Then close the valves.
→NOTE:
If the system is already discharged, do not attempt to discharge the

system further. Avoid air ingestion.
At the sight-glass in the oil separator, observe how much oil has been sucked out. When the
system is subsequently recharged, remember to top up with the same quantity of fresh oil.

Evacuating the system
LEGEND:
A High-pressure valve
B Low-pressure valve
C Vacuum pump FKM10440
D Dual gauge set FKM10445
CAUTION:
→NOTE:
Bleeding the system means sucking all the air out of the system until a
vacuum is obtained. Every time the system is discharged, it must then be
evacuated, otherwise air and moisture will enter the openings before they
can be capped.

Connect dual gauge set FKM10445 (D) as follows:
Open the two manual valves on the test equipment. Connect the red hose to high-pressure
valve (A) and the blue hose to low-pressure valve (B) of the compressor.
Connect the yellow hose to vacuum pump FKM10440 (C) and switch on the pump.
The system should reach a low pressure of 100 kPa; 1 bar; 14.5 psi (1000 mbar; 75 cm QS;
29 in. Hg) within 5 minutes.
→NOTE:
If this low pressure is not reached within 5 minutes, all joints must be
checked, and it may be necessary to perform a leak test as well.
Close the valves and switch off the pump. Wait 5 minutes. The gauge should not rise by more
than 3.4 kPa; 0.034 bar; 0.5 psi (34 mbar; 2.5 cm QS; 1 in. Hg).
Switch on the pump again and open the valves.
Extract air from the system for at least 30 minutes.
Close the valves and disconnect the pump.
→NOTE:
Do not open the system; the vacuum must remain until the system is filled.

Filling with Refrigerant Oil
LEGEND:
A Charging valve
B Refrigerant oil injector FKM10436
C Gauge set FKM10445
CAUTION:
Connect dual gauge set FKM10445 (C) as described in ”Evacuating the System”.
Evacuate the system as described in ”Evacuating the System”.
Close the valves and disconnect the pump.
Read how much oil is extracted during the evacuation process at the sight-glass in the oil
separator. Add the same amount of new oil plus 10 ml to the oil injector. Whenreplacing a
sub-assembly, the requisite amount of fresh oil must be added (see "Oil Capacities in Air-
Conditioning Components").
IMPORTANT:
Refrigerant oil is extremely hygroscopic. This means it attracts moisture in

large amounts from the atmosphere. For this reason, do not open the
system and oil can any longer than necessary.
Connect refrigerant oil injector FKM10436 (B) to the low side of gauge set.

Open charging valve (A) of oil injector. Open low-side valve.
→NOTE:
The vacuum within the system will draw oil into the system.
Oil capacities in air conditioning components
If one of the air conditioning components has been removed, the oil drained and the
component cleaned (separately), add the following amounts of oil to the cooling circuit.
Condenser: 40 ml (1.4 fl. oz.)

Evaporator: 40 ml (1.4 fl. oz.)
Receiver-drier: 10 ml (0.35 fl. oz.)
Refrigerant lines: 20 ml (0.7 fl. oz.)
Compressor: 50 ml (1.7 fl. oz.)
→NOTE:
Hoses = 3 ml per 30 cm (0.1 oz per ft)
If a hose damage has occured, measure length of hose and use the formula to determine
correct amount of oil to be added. Determine quantity of missing compressor oil by removing
and discharging it. Fill the calculated amount of oil into the compressor.
If only a new compressor must be installed, reduce the compressor charge to only 50 ml (1.7
fl. oz.).
If the entire system is disassembled and all the lines and components (including compressor)
are discharged and cleaned individually, add the full capacity of 160 ml (5.4 fl. oz.) to the
system after re-assembly.
— On all tractors, add60 ml (2.02 fl. oz.) to the low-side line (bringing the total amount
to 220 ml; 7.44 fl. oz.).
→NOTE:
The extra 60 ml (2.02 fl.oz.) in the low-side line is used to provide the
compressor with lubrication during its start-up phase.

Instructions for Starting Up the DENSO Air-

Conditioning Compressor
IMPORTANT:
This procedure MUST be carried out whenever the air-conditioning system

has been replaced or completely cleaned, and if the system has not been in
use for a lengthy period of time (about 4 weeks).
CAUTION:
Do NOT switch on the compressor while the engine is running until you
have reached step 4.
[1] - Open all the air vents/louvers.

[2] - Start the engine and allow the idle speed to stabilize (about 5 seconds).
[3] - Set the fan to at least 75% of its maximum possible output.
[4] - Switch on the air-conditioning system and continuously run the compressor at idle
speed for at least 10 minutes.
When this time is up, the compressor will have spread the oil throughout the refrigerant
system.

Filling the System
LEGEND:
A Charging valve FKM10443
B Refrigerant can FKM10447
C Dual gauge set FKM10445
D High pressure valve
E Low pressure valve
CAUTION:
CAUTION:
To avoid damaging the compressor while putting refrigerant into the high-
side section of the system, it is VITAL to shut off the engine first.

Connect dual gauge set FKM10445 (C) and evacuate the system as described in ”Evacuating
the System”.
Screw charging valve FKM10443 (A) into refrigerant can FKM10447 (B) and connect the
yellow hose.
IMPORTANT:
Never attempt to fill an R134a system with R12 refrigerant.
To fill with fluid refrigerant, turn can upside down as shown.
Open charging valve (A) and high-side valve (D). Neither of the two gauges should indicate a
pressure vacuum.
→NOTE:
If the low-side pressure gauge fails to rise, there must be a blockage in the
system. Any blockages must be cleared.
Wait till the pressure has stopped rising, then close the high-side valve (D).
IMPORTANT:
With air-conditioning switched on, run the tractor engine for 10 minutes at
low idle speed; see ”Engine Specifications” in Section 10, Group 05.
Then run the engine at 2000 rpm with the system set to maximum cooling effect.
CAUTION:
The temperature of the refrigerant must never exceed 50°C (120°F),

otherwise the refrigerant can may explode.
Turn the refrigerant can upright and open the low-side valve (E) to fill in gaseous refrigerant.

IMPORTANT:
Liquid refrigerant must not enter the compressor. Liquid refrigerant will
damage the compressor.
Prescribed capacity:
All tractors Refrigerant capacity 1450-1500g (3.2-3.3 lb)
When the filling process is completed, close charging valve (A).
Check if enough refrigerant is in the system by looking at the sight-glass on the receiver-
drier. If bubbles occur, top up with more refrigerant.

Topping up a partly discharged system
Refilling the system with small amounts of refrigerant can be necessary to compensate for
leaks or losses owing to repair work.
Connect dual gauge set FKM10445 as described in “FILLING THE SYSTEM”.
Connect the yellow hose to refrigerant can FKM10447.
IMPORTANT:
Never attempt to fill an R134a system with R12 refrigerant.
Unfasten the hose connection at the pressure gauge kit. Briefly open the charging valve, so
that air can escape from the yellow hose. Tighten the hose connection.
Run the engine at not more than 2000 rpm and set the system to maximum cooling effect.
Hold the refrigerant can upright and open the low-side valve (E).
Observe the sight-glass at the receiver-drier. When no more air bubbles are visible, add a
further 0.2 to 0.4 kg (7 to 14 oz.) of refrigerant.
CAUTION:
The temperature of the refrigerant must never exceed 50°C (120°F),

otherwise the refrigerant might explode.

Leak test
Perform a leak test only on systems that are in an operational condition. If the system has
already lost some of its refrigerant, top it up with refrigerant before testing for leaks.
Go over the entire system with the probe of the electronic leak detector (also see 290-15-065
, “Explanation of checks”, section 290, group 15, at "Leak test".
Leak tester
FKM10444
Locating leaks
→NOTE:
If possible, probe underneath each potential leak, as R134a refrigerant is

heavier than air. Dense concentrations of R134a in the air may affect the
result of the test.
Removing the Compressor

Discharge the system (see “Discharging the Air-Conditioning System” in this Group).
Take off the drive belt. See “Relieving Tension on the Drive Belt” and “Replacing the Drive
Belt” in Section 30, Group 20.
Slacken off the retaining screws (A) on the line clamping plate and remove the lines.
Seal all openings and lines so that no dirt can get in.
Remove the compressor.
Checking Level in the Compressor
Remove the compressor manifold (see “Checking the Compressor Manifold”).
Drain the refrigerant oil from the compressor through the suction line connection and into a
graduated container. Note the quantity of oil drained from the compressor.
Dispose of the oil in an environmentally friendly way.

Fill with refrigerant oil as described in “Filling with Refrigerant Oil”.
→NOTE:
Replace the receiver-drier every time the system is interrupted.

Disassembling the Compressor Clutch
→NOTE:
There is no need to disconnect any refrigerant lines before disassembling

the compressor clutch.
Removing the clutch hub
Hold the clutch hub securely using holder OTC7062A, and take the bolt out of the clutch
shaft.
Removing the clutch plate

Remove shims (A) from clutch hub and keep them ready for re-installation.
Remove snap ring and take off clutch plate.
Removing magnetic coil
Remove snap ring.
Disconnect magnetic coil cable at compressor and take off the magnetic coil.
→NOTE:
When re-installing the snap ring, ensure that the chamfered side of the
snap ring is uppermost.
Checking Clutch Hub Clearance

Use a feeler gauge to measure the clearance between the clutch hub and clutch plate at
three different points.
Turn the clutch plate through half a revolution and measure the clearance again at three
different points.
Specified clearance is 0.35-0.65 mm (0.014-0.025 in.). Add or remove shims as required.
Tighten the clutch hub retaining bolt to 15 N˙m (11 ft-lb).
Checking the Compressor Manifold
LEGEND:
A Hex. socket screw
B Manifold
C Manifold gasket
Take out hex. socket screws (A) and remove manifold (B).
Remove and discard gasket (C). Check the contact surfaces.

Apply PAG oil to new gasket (C), and install.
Install manifold.
Tighten hex. socket screws to 25 N˙m (18 lb-ft).
Installing the Compressor
CAUTION:
The battery negative (—) cable must be disconnected.
Before installing, ensure that the compressor contains the specified amount of oil.
→NOTE:
A new compressor takes 160 ml (5.4 fl. oz.)
Install the compressor and secure the high- and low-pressure hoses (A) to the compressor.
High and low pressure line, hex. socket screws Torque 21—25 N˙m
15.5—18.4 lb-ft
Install the drive belt. See “Drive Belt” , Section 30, Group 20).

Removing and Installing the Condenser
LEGEND:
A Refrigerant lines
B Retaining spring
[1] - Discharge the cooling and air-conditioning system.

[2] - Disconnect refrigerant lines (A) at the cooler.
[3] - Disengage the two retaining springs (B) at the frame of the condenser.
[4] - Seal all openings with plastic caps.
[5] - Pull out the condenser. Drain refrigerant oil and dispose of it in an environmentally
friendly way.
[6] - Install the new (or cleaned) condenser.
→NOTE:
Replace the receiver-drier every time the system is opened.
[7] - Evacuate the system, add new refrigerant oil and refrigerant.
→NOTE:

Removing and Installing the Receiver-Drier

[1] -
Discharge the air-conditioning system.

[2] - Disconnect the refrigerant lines.
[3] - Seal the open ends with plastic caps.
[4] - Remove receiver-drier (A).
[5] -
IMPORTANT:
As soon as the dessicant material reaches its saturation level, the receiver-
drier must be replaced, otherwise the system will become contaminated
with moisture. Replace the receiver-drier every time an air conditioning
component is removed or replaced.
Install the receiver-drier horizontally. The inscription “Top” or “This side
up” must be uppermost.
Install the receiver-drier.

[6] - Evacuate the system, add new refrigerant oil and refrigerant.
→NOTE:

Removing and Installing the Evaporator and

Expansion Valve
LEGEND:
A Heater hoses
B Evaporator
C Refrigerant lines
D Expansion valve
[1] - Discharge the air-conditioning and cooling systems.

[2] - Remove seat.
[3] - Remove the cover from the heater/evaporator housing.
[4] - Disconnect heater hoses (A) and refrigerant lines (C) at evaporator.
[5] - Seal the open ends with plastic caps.
[6] - Pull the capillary tube out of the evaporator.
[7] - Remove evaporator (B) and expansion valve (D). Drain refrigerant oil and dispose of it
in an environmentally friendly way.
→NOTE:
Replace the receiver-drier every time the system is opened.

[8] - Install and reassemble in reverse order.

[9] -
→NOTE:
Evacuate the system, fill with refrigerant and check.
Replacing the Expansion Valve
Follow the procedure set out above in “Removing and Installing the Evaporator and
Expansion Valve”.
Remove the two slotted screws (A).
Take off expansion valve (C).
Coat the new O-rings (B) with refrigerant oil and install them on the evaporator.
Secure the new expansion valve.
Installing Condensation Water Drain Hoses

IMPORTANT:
Check if both condensation water drain hoses are provided with a loop.
Form a loop with hose (A), fix it with strap (B) and place it in the opening in the tractor frame
(see arrow).
Secure drain hose (A) to the evaporator housing.
Hose clamp
Torque 3—4 N˙m
2.2—3.0 lb-ft
Removing and Installing the Thermostat Switch
LEGEND:
A Sensing bulb (gas-filled capillary tube)
B Thermostat switch
C Bowden cable
D Evaporator

Remove seat.
Remove the cover from the heater/evaporator housing.
Remove side panel.
Disconnect both cables on thermostat switch.
Remove sensing bulb (A) from the evaporator web.
Remove thermostat switch (B).
IMPORTANT:
Never bend or squash the capillary tube. Re-install capillary tube at the
same point from which it was removed.
→NOTE:
When installing, make sure bowden cables are not tensioned or bent.
Adjusting Thermostat Switch Bowden Cables
LEGEND:
A Bowden cable
B Heater valve
C Bowden cable
Turn heater and air conditioning system regulator to neutral position.
Heater valve (B) must be closed completely. Adjust bowden cable (C), if necessary.
Reset heater and air conditioning system regulator to “cooling” (blue) position.
Thermostat switch must be fully open. Re-adjust bowden cable (A), if necessary.

Section 90 - OPERATOR′S CAB Group 11: ClimaTrak
Removing and Installing the High/Low Pressure

Switch
→NOTE:
There is no need to discharge the system when removing or installing

high/low pressure switch (A) as the line connection is equipped with a
check valve.
Carefully remove remains of O-ring from both ends of connection.
Always install a new O-ring which has been coated with PAG-oil beforehand.
IMPORTANT:
Slowly screw in new switch (A) and tighten to 16 N˙m (12 ft-lb).

Group 11 - ClimaTrak
ClimaTrak - Summary of References
”Removing and installing the ATC controller (ClimaTrak)”
”Removing and installing the driver unit for fan motor (A59)”
”Removing and installing the sending unit for ambient temperature (front) (B125)”
”Removing and installing the sending unit for ambient temperature (rear) (B126)”
”Removing and installing the sending unit for inside air temperature (B127)”
”Removing and installing the sending unit for actual outlet air temperature (B128)”
”Removing and installing the sending unit for evaporator core temperature (B129)”
”Removing and installing the sending unit for refrigerant pressure (B130)”
”Removing and installing the water valve (B131)”
”Removing and installing the mode control for position of air distribution flaps (B132)”
”Removing and installing the defog sensor (B143)”
Removing and Installing the ATC Controller

(ClimaTrak)
LEGEND:
A Controller
B Wiring connector
Carefully force controller (A) out of the console.
Disconnect wiring connector (B).
After the controller has been replaced with a new one, it must be calibrated, seeReference
245-ATC-001, Calibration and Input Addresses (ClimaTrak ™ ).

Removing and Installing the Driver Unit for Fan

Motor (A59)
LEGEND:
X603 Plug
A59 Fan motor
Remove the operator′s seat and take the covering plate off the evaporator housing.
Pull out plug (X603) and remove the driver unit for fan motor (A59).
Removing and Installing the Sending Unit for

Ambient Temperature (Front) (B125)
LEGEND:
X604 Plug
B125 Sending unit
Open the hood.
Pull out plug (X604) and remove sending unit (B125) for ambient temperature.


Ambient Temperature (Rear) (B126)
LEGEND:
B126 Sending unit for ambient temperature at the rear
X594 Plug
Sending unit (B126; for ambient temperature at the rear) is located on the r.h. side (viewed
in direction of travel) underneath the outer section of the roof.
Before removing the outer section of the roof, see reference ”Removing the Outer Roof” .
Pull out plug (X594) and remove the sensor for ambient temperature at the rear (B126).

Removing and Installing the Sending Unit for Inside

Air Temperature (B127)
LEGEND:
A Cover
B Recirculated air filter
X602 Plug
B127 Sending unit for inside air temperature
Take off cover (A) and remove recirculated air filter (B).
Pull out plug (X602) and remove sending unit (B127) for inside air temperature.

Removing and Installing the Sending Unit for Actual

Outlet Air Temperature (B128)
LEGEND:
A Cover plate
X601 Plug
B128 Sending unit for actual outlet air temperature
Disconnect the cup-holder and remove cover plate (A) from the cowl.
Pull out plug (X601) and remove sending unit (B128) for actual outlet air temperature.

Evaporator Core Temperature (B129)

LEGEND:
X598 Plug
B129 Sending unit for evaporator core temperature
Remove the operator′s seat and take the covering plate off the evaporator housing.
Pull out plug (X598) and carefully extract sending unit (B129; for evaporator core
temperature).
Removing and Installing Sending Unit for

Refrigerant Pressure (B130)
LEGEND:
X600 Plug
B130 Refrigerant pressure sending unit
Pull out plug (X600) and unscrew sending unit (B130; for refrigerant pressure).
Before installing, carefully remove remains of O-ring from both ends of connection.
Always install a new O-ring which has been coated with PAG oil beforehand.

IMPORTANT:
Slowly screw in new sending unit for refrigerant pressure, and tighten to
16 N˙m (12 ft-lb).
Put the plug back in.
Water Valve (B131) Removal and Installation
LEGEND:
X655 Connector
B131 Water valve
→NOTE:
Water valve (B131) is located underneath the operator′s seat.
Pull out plug (X655).
→NOTE:
To prevent coolant from entering the evaporator housing, trap it in a

suitable container.
Disconnect the coolant hoses and take off the hose clamps.
Remove water valve (B131).

→NOTE:
A new water valve must be calibrated; see”ATC – Calibration and Input

Addresses”and also AddressATC022.

Mode Control for Position of Air Distribution Flaps

(B132), Removal and Installation
Take off the panels on the r.h. side (viewed in direction of travel); see reference”Steering
Valve - Removal (Tractors with Cab)”for assistance.
LEGEND:
A Top end of bowden cables
B Bottom end of bowden cables
Disengage bowden cables (A) and (B).

LEGEND:
A Screws
B132 Mode control for position of air distribution flaps
X605 Connector
Pull out plug (X605) and take out screws (A).
Remove the mode control.
→NOTE:
A new water valve must be calibrated; see”ATC – Calibration and Input

Addresses”and also AddressATC023.

Remove and Install the Defog sensor (B143)
1.
LEGEND:
A Defog sensor with cover (seen in direction of travel)
B Defog sensor
Remove cover (A), disconnect cable and carefully pull defective defog sensor from the
windshield.
2. Remove remaining adhesive patches from the windshield.
3. Clean area where adhesive for the defog sensor is to be applied using the towels
provided for this purpose.
→NOTE: At room temperature (20°C; 68°F), the adhesive requires
approximately 72 hours to dry.
→NOTE: When installing defog sensor, make sure that the plug fits into
the cover properly.
Pull off backing film from defog sensor (C) and attach sensor at the location indicated
(see table). Press it against the windshield for approx. 10 seconds.

Section 90 - OPERATOR′S CAB Group 15: Heating System
LEGEND:
A Windshield
B Frame
C Defog sensor
→NOTE: Depending on the condition of the plastic frame for the defog
sensor, it may be necessary to replace it by following the same
procedure.
Panoramic windshield Hinged windshield with long wiper Hinged windshield with short wiper
”a” 10 mm 3 mm (0.12 inch.) 10 mm (0.39 inch.)
”b” 210 mm 176 mm (6.93 inch.) 210 mm (8.27 inch.)
5. Carefully connect cable and attach the defog sensor and its cover.

Group 15 - Heating System

Heating System (Summary of References)
“Removal and Installation of Components”
”Adjusting Air Flow Bowden Cables”

Removal and Installation of Components

Removing and installing fan and radiator
[1] -
Remove the operator′s seat.

Remove cover from heater/evaporator housing.
[2] - Disconnect and remove the fan motors (A).
[3] - Empty cooling system and air conditioning system
[ Tractors with air conditioning system only ]
.
Disconnect the hot coolant hoses (B) at the radiator and the refrigerant lines
[ Tractors with air conditioning system only ]
at the expansion valve.
Removing and installing the heater valve
[1] -
Remove the side panel.

Drain cooling system.
[2] - Disconnect hot coolant hoses at heater valve (A) and disengage heating cable at valve.

[3] - Remove the heater valve.
Adjusting heater valve bowden cables
[1] -
LEGEND:
A Bowden cable
B Heater valve
C Bowden cable
Turn heater and air conditioning system regulator to neutral position.
[2] - Heater valve (B) must be closed completely. Adjust bowden cable (C), if necessary.
[3] - Reset heater and air-conditioning system regulator to “cooling” (blue) position.
Thermostat switch must be fully open. Re-adjust bowden cable (A), if necessary.
Removing the cab air filter
→NOTE:
For cleaning the cab air filter, see the Operator′s Manual.

Fold handle (A) up and pull filter cover (B) forward.
Remove filter (C).
→NOTE:
For cleaning the cab air filter, see the Operator′s Manual.
Replacing recirculating air filter

→NOTE:
Tractors without air conditioning system only
Pull out filter (A).
Clean or replace filter.

Adjusting Air Flow Bowden Cables

[1] -
Fold back the cup holder (A), use a Phillips-head screwdriver to take out retaining screws (B)
and lift off trim (C).
[2] -
Remove screws (A) and (B) and tilt base plate to the side
[3] -
Remove cover (B).

[4] - Adjusting air flow to footwell:
Adjust control knob to "footwell" position.

[5] -
Take out attaching clamp (A).

[6] - Move lever to upper end position and re-install clamp (A).
To check correct function, operate control knob several times after adjustment has been
completed.
[7] - Adjusting air flow to operator:
Adjust control knob to "operator" position.

Section 90 - OPERATOR′S CAB Group 20: Seats
[8] -
Carefully loosen clamp (A).

[9] - Move lever (B) to upper end position and re-install clamp (A).
[10] - To check correct function, operate control knob several times after adjustment has
been completed.

Group 20 - Seats
Operator′s Seats (Summary of References)
“Repair Specifications”
“Comfort Seat MSG85”
“Air Comfort Seat MSG95, Lower Section”
“Exploded View of the Passenger Seat”
“Command Arm Repair”
Air comfort seat MSG95, lower section

Level control, hex. nuts Torque 25 N˙m (18 ft-lb)
Horizontal suspension, cap screws Torque 25 N˙m (18 ft-lb)
Air spring, hex. socket screws Torque 10 N˙m (7 ft-lb)

Comfort seat MSG85

Removing and installing lumbar support
Remove back cushion and storage pocket.
Knock out rivets (1), then disengage spring tabs (2) from bracket (3) and remove.
Disengage bracket (3) from carrier (4).
Take out hex. socket screw (5) and lift off adjusting knob (6) together with gear (7).
Knock out rivets (8) and remove loop-spring brake (9) and carrier (4).
Install and reassemble in reverse order.
Removing and installing the lap-strap

Take off covers (1).
Take off the hex. nut (2).
Remove lap-strap (3) and washer (4).
Remove parts 5 to 7 in the same way as described in sections 2 and 3.
IMPORTANT:
Tightening torque on hex. nuts (2 and 5) is 50 N˙m (37 lb-ft)
Removing and installing the backrest

Remove backrest cushion and covers (1).
Tilt backrest (2) to the front.
Take off the two armrests (5).
Take off hex. nuts (6) and washers (7).
Take out cap screws (8). Remove washers (9) and spacers (10).
Drill out rivets (12) and take out reinforcing tube (13).
CAUTION:
Injury hazard! The helical coiled spring is strongly tensioned!
Remove backrest (2), washers (14) and (15) and helical coiled spring (16).

IMPORTANT:
Tightening torque on hex. nuts (3, 6) is 25 N˙m (18 lb-ft).
When installing: Engage helical coiled spring (16) in lug (see arrow).
Removing and installing the seat tilt- and height-adjusting levers
Remove the seat cushion.
Press spring tab (1) inwards. Actuate the lever for adjusting seat tilt (2).
Fold up rocker panel (3), and remove.
Drill out rivet (18) and remove spring tab (1).

Take out hex. socket screws (5) and remove cover (6), adjusting levers (2, 7), linkage (4) and
detent lever (8).
Disengage spring (9).
Turn lever (10) clockwise as far as it will go, pull plate (11) all the way forward, and remove.
Remove covers at left and right.
Unscrew nut (12), and remove lever (10) and screw (13).
Drill out rivet (16) and remove detent (17).
Removing and installing the integral turntable and baseplate

Remove upholstery from seat and backrest.
Remove backrest (only necessary if the baseplate is to be replaced).
Turn integral turntable (1) together with baseplate (3) to one side, and take out screws (2).
Remove baseplate (3) together with integral turntable (1). Remove hex. nuts (6) and washers
(7).

Take off hex. nuts (8). Remove washers (9) and hex. socket screws (10).
→NOTE:
Replace the hex. socket screws with new ones; torque is 25 N˙m (18 lb-ft).
It must be possible to move the turntable at a torque of 30 N˙m (22 lb-ft) or
less.
Remove baseplate (3) and washers (12). Remove bushing (11) and friction washers (13), and
disengage spring (14).
Take off hex. nut (15) and cap screw (16). Disengage lever (17) from linkage (18), and
remove.
Take out linkage (18) and grip (19).
Removing and installing the horizontal shock absorber

Remove upper part of seat.
Take off snap ring (1) and pull horizontal shock absorber (2) off the upper part of spring
assembly (3).
Take the horizontal shock absorber (2) off the rocker (4).
Removing and installing the horizontal spring assembly
Remove hook (1).
Remove snap rings (2).
Pull off spring (3) together with bushings (4), buffers (5) and clip (6).

Removing and installing the upper section of the spring assembly
Remove horizontal shock absorber.
Disengage clip (1) at rocker (2).
Take off hex. nut (3), and remove screw (4) and stop (5).
Push upper section of spring assembly (6) to the rear, and remove it by turning rocker (2).
Remove the horizontal spring assembly and linkage.
→NOTE:
Apply grease to the slides.

Removing and installing the vertical shock absorber
Remove the boot.
Remove upper section of spring assembly.
Take off snap rings (1) and pull out pins (2).
Remove the vertical shock absorber (3).
→NOTE:
The decal on the vertical shock absorber must face upward.

Removing and installing the lower section of the spring assembly
Remove upper section of seat and take off the boot.
Take off snap ring (1) and pull out pin (2).
Unlock bolt (3), and remove.
→NOTE:
The vertical shock absorber remains on the rocker.
Release and disengage spring (4).
Twist upper section of spring assembly (5) together with the rocker, and lift it out of the lower
section of the spring assembly (6).
Remove weight-adjusting mechanism.
Remove rubber buffers (7).

Drill out rivets (8).
Remove U-section rail (9) and rubber plate (10).
→NOTE:
Apply grease to the slides.
Removing and installing the weight-adjusting mechanism
Removing the weight-adjusting mechanism:
Remove upper section of seat and lower section of spring assembly.
Disengage spring (1) from display strip (2).
Remove window (3) and roller (4).

Knock out spring pin (5) and remove yoke (6).
Lift up spring yoke (8) and remove threaded bushing (9), axial ball bearings (10), plastic
washer (11) and tube (14).
Unscrew adjusting spindle (7) and disengage springs (12) and (13).
Remove display strip (2) from spring yoke (8).
Remove bushing (15) from lower section of spring assembly.
Installing the weight-adjusting mechanism:
Press bushing (15) into lower section of spring assembly.
Install display strip (2) in spring yoke (8).
Engage springs (12) and (13) in spring yoke (8).
Engage spring (12) in the pin (see arrow).
Insert threaded bushing (9), screw in adjusting spindle (7) and put on tube (14), axial ball
bearings (10) and plastic washer (11).
Engage spring (13).
Place yoke (6) on adjusting spindle (7) and force in spring pin (5).
Install display strip (2) together with window (3) and roller (4).
Engage spring (1) in display strip (2).
Install upper section of seat.
Removing and installing the rocker

Remove horizontal shock absorber.
Remove upper section of spring assembly.
Remove vertical shock absorber.
Unlock bolt (1), and remove.
Twist rocker (2) and remove it from the lower section of the spring assembly (3).
Remove bushings (4).
Remove rollers (5), washers (6) and detent levers (7).
Disengage springs (8).
Lift off plate (9).
Raise detent plates (12) and lower the curved lever (11).

Pull out hex. pin (10).
Remove detent plates (12).
Removing and installing pneumatic lumbar support
Remove back cushion and storage pocket
[ If equipped ]
.
Pull air hoses (1, 2 and 3) off valve ports (A, B and C).
Pull connector (4) off connecting cable (5).

Pull terminals (6) off the compressor.
Remove switch (8) and switch housing (9).
Remove dummy rivets (10).
Remove plate (11) together with lumbar support (12).
Take out the two plastic rivets (13) and lift off the lumbar support (12).
Take compressor (7) off plate (11).
Remove rubber buffers (14).
Take off cable binder (15) and remove connecting cable (5) from plate (11).
Removing and installing the seat switch
LEGEND:
1 Blind rivet
2 Spring
3 Terminal
4 Seat switch
Disconnect plug-in connection from seat switch (4).
Remove the seat upholstery.

Take out dummy rivets (1) and replace seat switch (4) with a new switch.

Air Comfort Seat MSG95, Lower Section
→NOTE:
Always use LOCTITE ™ 248 on hose connectors.
Disassembly
LEGEND:
A Plastic cover
B Boot
C Grooved pins (22 used)
D Wooden block (2 used)
Remove adjusting rails.
Remove grooved pins (C) and boot (B).
Remove plastic cover (A).

→NOTE:
For easier disassembly of lower seat section, place two wooden blocks (D),
length approx. 80 mm (3.15 in.), into U-rails of frame.
Replacing extra tank
→NOTE:
If equipped
Remove clamp (A) and cable binders (B)
Remove extra tank (C).
Removing level control components

LEGEND:
A Bowden cable
B Bowden cable
C Connector
D Screw
E Bowden cable bracket
F Phillips-head screw
G Locking pin
H Hex. nuts
J Belt retractor
Disconnect bowden cables (A and B) and connectors (C).
Loosen screw (D) and disconnect bowden cable bracket (E).
Loosen hose and cable clamps. Disconnect hoses.
Loosen screw (F) and remove locking pin (G).
IMPORTANT:
Retract belt slowly.
Loosen hex. nuts (H) and remove belt retractor (J).
Removing shock absorbers

LEGEND:
A Snap ring
B Horizontal shock absorber
C Hook
D Bowden cable
E Shock absorber
F Snap rings
Remove snap ring (A) and disconnect horizontal shock absorber (B) at hook (C).
Disonnect bowden cable (D) at shock absorber (E).
Remove snap rings (F) from bearing pins and remove shock absorber.
Installation:
After installation check that adjusting pin on shock absorber (E) is seated securely.
Removing horizontal spring assembly

LEGEND:
A Phillips-head screw
B Adjusting handle
C Rivets (2 used)
D Emergency stop (2 used)
E Frame
F Cap screws
G Horizontal spring assembly
H Spring
J Snap ring
K Locking lever
Remove Phillips-head screw (A) from adjusting handle (B) and disconnect handle with
linkage.
Drill out rivets (C) of emergency stops (D) and remove stops from frame (E).
Move frame to recess and remove it by tilting it laterally.
Remove cap screws (F) and horizontal spring assembly (G).
Disconnect spring (H). Remove snap ring (J) from bearing pin. Remove locking lever (K).

Removing weight and height adjuster
LEGEND:
A Phillips-head screws (3 used)
B Bowden cable
C Bowden cable
D Support
Remove the three Phillips-head screws (A). Disconnect bowden cables (B and C) and replace
support (D).
Removing the compressor
LEGEND:
A Hex. socket screw
B Compressor
C Hose
Remove hex. socket screw (A) from compressor (B).
Disconnect hose (C) and connector. Replace compressor

Replacing the air hoses
LEGEND:
A Air hose
B Air hose
C Level control
D Hose clamps
E Hose connectors
Pull off hoses at compressor and air spring.
Cut off existing hoses (A and B) at level control unit (C). Connect new hoses to remaining
hose sections of level control unit, using hose clamps (D) and hose connectors (E).
Before installing hoses on air spring and compressor, shorten them to the length of the old
hoses.

Exploded View of the Instructional Seat
LEGEND:
A Backrest
B Hex. socket screw (2 used)
C Hex. nut (3 used)
D Seat cushion
E Bearing plate
F Sleeve (2 used)
G Shims (2 used)
H Washer (2 used)
I Pin
J Turntable
K Pin
L Snap ring (6 used)
M Seat support
N Pin
O Lever
P Grip
Q Tension spring
R Seat rocker
S Washer (2 used)
T Retaining strap
U Bushing
V Hex. socket screw
W Mushroom-head screw (4 used)
X Shim (4 used)
Y Hex. nut (4 used)
Z Washer (4 used)
Remove and install the seat belt
LEGEND:
A Cap screw (2 used)
B Seat belt (retractor and buckle)
C Spring washer
D Bracket
E Lock Nut (2 used)
F Bracket

CAUTION:
The belt retractor (B) must be installed as shown and tightened properly to
the bracket.
Belt retractor and buckle must be installed at an angle of 45°.

Command Arm Repair

[1] -
LEGEND:
A Side panel
B Side panel
C Hex. nuts
Removal:
Remove side panels (A) and (B), hex. nuts (C) and disconnect plugs.

[2] -
Remove cap screws (C) and command arm.

[3] -
Turn knob (A) until the two cap screws (B) are visible.
[4] - Remove the cap screws and lift off mounting block.
[5] -
Loosen flange nut (A) and remove tensioner roll.

[6] - Remove snap ring (B), knob (C) and locking element (D).

[7] -
Take out toothed belt (A).

[8] -
Installation:
Before re-installing the toothed belt, bores (B) must be aligned with housing bores (A).
→NOTE:
After bores are aligned, mark gears.
[9] -
Tension toothed belt by means of roll (A) and tighten the cap screw.

Section 90 - OPERATOR′S CAB Group 25: Operator′s Cab
[10] - Install locking element and secure (see removal procedure).

[11] - Install mounting block (see removal procedure).

Group 25 - Operator′s Cab

Operator′s Cab (Summary of References)
”Removing the cab frame”
”Cab mounting torques”
”Removing outer roof”
”Removing and installing the windshield”
”Removing and installing the rear window”
”Removing and installing the roof hatch”
”Removal and installation of panoramic windshield”
”Installing door lock”
”Adjusting windshield and rear window contact pressure”
”Operator′s cab door removal and installation”
”Removing and installing roller sun-visor”
”Removing inner roof trim”
Removing Cab Frame

Remove the operator′s cab.
See “Removing the Operator′s Cab” , Section 90, Group 00.
CAUTION:
If frame attaching screws are loosened or frame is removed, make certain

all parts are reinstalled correctly to maintain adequate protection of the
operator. Tighten attaching screws to specified torque.
A tractor roll-over may place a severe stress on the frame structure. Therefore, replace frame
if structural members have been bent, buckled or stretched to maintain adequate protection
of the operator.
No welding, grinding, drilling or cutting of any type should be done on the frame structural
members. Doing so may weaken the members sufficiently to limit their effectiveness in
protecting the operator if a roll-over or upset should occur.

Cab mounting torques
Cab mounting without hydr. suspension
LEGEND:
A Cap screw (4 used)/220 N˙m (160 lb-ft)
B Cap screw (4 used)/220 N˙m (160 lb-ft)
C Rear mounting bracket (2 used)
D Front mounting bracket (2 used)
E Cap screw (6 used)/220 N˙m (160 lb-ft)
Cab mounting with hydr. suspension
LEGEND:
A Cap screw (2 used)/220 N˙m (160 lb-ft)
B Hex. nut (4 used)/200 N˙m (145 lb-ft)
C Cap screw (8 used)/ 450 N˙m (332 lb-ft)
D Cap screw (6 used)/ 200 N˙m (145 lb-ft)
E Cap screw on spherical bearing (4 used)/ 90 N˙m (66 lb-ft)
F Front mounting bracket (2 used)
G Base plate, rear (left)
H Rear mounting bracket (right)
I Rear mounting bracket (left)
J Base plate, rear (right)
Tighten all other screws according to torque table, see “Torques for metric measurements” ,
section 10, group 05.

Removing the Outer Roof
Remove cap screws (A).
Open roof hatch, remove hinge pins and roof hatch.
Remove cap screws (B) and thirteen oval-head screws (C).
Carefully take off the outer roof.

Removing and Installing the Windshield
Remove four cap screws (A) and wiper arm (B).
Lift out windshield (C).
Installation of windshield
LEGEND:
A Bracket
B Cap screw (4 used)
C Cap screw (4 used)
→NOTE:
Tighten cap screws (B) and (C) until some effort is needed to pull out paper
strips placed between cab frame and seal.
Loosen and raise outer roof (see " Removing the Outer Roof ").
Attach preassembled windshield to bracket (A) and align with cab frame.

Press windshield against cab frame.
Tighten cap screws (B).

Removing and Installing the Rear Window
LEGEND:
A Hex. nut (4 used)
B Wiper arm
C Bracket
D Cap screws (4 used)
Remove wiper arm (B).
Remove four cap screws (D) and lift off rear window.
Installation of rear window
LEGEND:
A Hex. nut (4 used)
B Wiper arm
C Bracket
D Cap screws (4 used)
Loosen and raise outer roof (see " Removing the Outer Roof ").
Attach preassembled rear window to bracket (C) and align with cab frame.
Press rear window against cab frame.

Tighten cap screws (D).
Install wiper arm (B).
→NOTE:
Tighten cap screws (D) and hex. nuts (A) until some effort is needed to pull
out paper strips placed between cab frame and seal.

Removing and Installing the Roof Hatch
CAUTION:
When removing or installing roof hatch, remember its weight and secure it
to avoid tipping.
Open roof hatch (A).
Loosen retainers of both gas cylinders (B).
Disconnect top of gas cylinders (B) from supports.
Pull out both hinges (C) and carefully remove roof hatch.
Installation of roof hatch

Install both hinges (C) and carefully install roof hatch.
Install retainers on gas cylinders (B).

Removal and Installation of Panoramic Windshield
IMPORTANT:
2 people are required to convert the panoramic windshield.
→NOTE:
For the sake of clarity, the cab shown here has been taken off the tractor.
[1] -
LEGEND:
A Hex. nut
Unfasten and remove hex. nut (A). Then pull off wiper.
[2] -
LEGEND:
A Hinge
B Screw
Take screw (B) out of hinge (A).

[3] -
LEGEND:
A Bushing
B Rubber washer
Put rubber washer (B) on bushing (A).
[4] -
LEGEND:
A Bushing
B Rubber washer
C M8 hex nut
D Hinge
Remove the old bushing.
Use a screw, new nut (C) and a washer to secure bushing (A) and rubber washer (B) to hinge
(D); see specification.
Washer at hinge Torque 6 N˙m
4.4 lb-ft
[5] - Replace the bushing at the other hinge on the roof in the same way.
Then put two caps on the bushings.

[6] -
LEGEND:
A Hex. socket screws
B Attachment points
C Cap screws
D Hinge attachments
E Attachment points
Unfasten hex. socket screws (A) and remove the mounting.
[7] - Remove cap screws (C) and take off the sleeves, washers and mountings/plastic
clamps.
[8] - Detach the windshield at attachment points (B) and (E).

[9] -
Rubber washer at the front left (on inside)

LEGEND:
A Rubber washer
Pull off the rubber washer that is already in place. If any adhesive remains, use a suitable
cleaning agent to remove it.
[10] - On the inside of the windshield at bottom left and right, apply the rubber washers (A)
that are adhesive on one side only.
[11] - On the inside of the windshield level with the worklight/headlight brackets, apply the
rubber washer that is adhesive on both sides. Apply the washers to the center of rubber
washers.

[12] -
LEGEND:
A Rubber washer
B Bushing
Put rubber washer (A) on bushing (B).
→NOTE:
Illustration shows installation on l.h. side, at bottom

LEGEND:
A M6 x 30 screw
B Rubber washer
C Bushing
Do NOT tighten screws (A) at this stage.

[13] - From the outside, insert screw (A) into the bottom part of the windshield,
remembering to include a washer, bushing (C) and rubber washer (B).
→NOTE:
Illustration shows installation on l.h. side level with the worklight/headlight

bracket
LEGEND:
A M6 x 40 screw
B Rubber washer
C Bushing
Do NOT tighten screws (A) at this stage.
[14] - From the outside, insert screw (A) into the windshield level with the
worklight/headlight bracket, remembering to include a washer, bushing (C) and rubber
washer (B).
[15] - On the inside, hold the cover so that the mounting does not turn as well when the
screw is tightened.

[16] -
Illustration shows installation of mounting on r.h. side

LEGEND:
A Gasket support plate
B Washer
C Screws
D Patch
E Clamp
Pull off the rubber strip or adhesive patch that is already in place and clean the area. At left
and right and level with screws (C), apply patch (D) to the panoramic windshield.
[17] - Use washer (B) and screw (C) to bring clamp (E) and gasket support plate (A) into
contact.
[18] -
LEGEND:
A Mounting
B Cushion
Insert cushion (B) in mounting (A).

[19] -
LEGEND:
A Mounting
B Screws
Pull off the rubber strip or adhesive patch that is already in place and clean the area. Put
mounting (A) with its cushion back in position and put in screws (B) to hold it in place.
[20] -
IMPORTANT:
LEGEND:
A M8 screws
B M8 screws
C M6 x 30 screws
D M6 x 40 screws
To keep the panoramic windshield free of tension, observe the tightening
torques and do the various steps in the order in which they are listed.
Tighten screws (A).

Central screws (A), mounting above firewall Torque 10 N˙m
7.4 lb-ft

[21] - Tighten screws (B).

Screws (B), left and right clamps, next to the firewall Torque 10 N˙m
7.4 lb-ft
[22] - Tighten screws (C).

Screws (C), bushings at bottom left and right Torque 6 N˙m
4.4 lb-ft
[23] - Tighten screws (D).

Screws (D), bushings at left and right level with the worklight/headlight brackets Torque 6 N˙m
4.4 lb-ft
[24] -
Cap shown at bottom right

Install four caps (A) on bushings and light brackets.
Installing Door Lock

LEGEND:
A Door lock pin
B Shield
C Holding bracket
D Carriage bolt
E Latch
F Handle
G Spacer
H Spacer bushing
J Gasket
K Console
L Cover
M Door lock
N Spacer bushing

O Spacer
Loosen door lock pin (A) and adjust cab door tension by moving shield (B) until some effort is
needed to pull out paper strips placed between cab frame and seal.
Adjusting Windshield and Rear Window Contact

Pressure
LEGEND:
A Cover
B Hex. nut
C Piece of paper
Remove cover (A).
Adjust hex. nut (B) until windshield or rear window contact pressure makes it difficult to pull
out pieces of paper caught between the cab frame and the seal.

Operator′s Cab Door Removal and Installation
Remove plug (A) and cab frame cover (B).
Remove locking wire from gas cylinder ball socket and disconnect cylinder (C).
Take out the four attaching screws (D).
Installation of cab door

Insert the cab door in the frame and align it correctly.
Tighten the four attaching screws (D).
Install gas cylinder (C) and secure it.
Install cab frame cover (B) and plug (A).
Install door lock (see "Installing Door Lock" in Section 90, Group 25).
Roller Sun-Visor Removal and Installation

Section 90 - OPERATOR′S CAB Group 30: Cab Suspension
Rear roller sun-visor
Remove Phillips-head screws (A) and carefully take out roller sun-visor.
Installation of roller sun-visor
Install by reversing removal procedure.
Removing Inner Roof Trim
On both sides remove molded parts (see arrows).
Remove roof trim.
Remove two loudspeaker support plates and one radio support plate.

Group 30 - Cab Suspension

Cab Suspension — Summary of References
Before reconditioning the cab suspension system, refer to the following:
”Relieving Hydraulic System Pressure”

”Installing and Removing the Cab Suspension Shields”
”Removing and Installing the Sensor Rod”
”Adjusting the Sensor Rod”
”Removing the Position Sensor”
”Reconditioning the Position Sensor”
”Installing the Position Sensor”
”Removing the Accumulator”
”Reconditioning the Accumulator”
”Installing the Accumulator”
”Removing Hydraulic Cylinder”
”Installing Hydraulic Cylinder”
”Removing the Control Valve Block”
”Reconditioning the Valves in the Control Valve Block”
”Installing the Control Valve Block”
”Panhard Link Removal and Installation”
”Bleeding Cab Suspension Hydraulic Cylinders”
Important Instructions
IMPORTANT:
After adjusting or replacing the sensor rod or replacing the position sensor,
be sure to calibrate the hydro-pneumatic cab suspension. See Reference
245-SFA-002 , Calibration and Input Addresses, Hydraulic Cab Suspension.

Specifications
Control block, screws Torque 5 N˙m
3.7 lb-ft
Position sensor rod Adjusting dimension 76 mm
2.99 in.
Accumulator, filler screw Torque 20 N˙m
15 lb-ft
Accumulator seal nut Torque 30 +5 N˙m
22 +4 lb-ft
Hydraulic hose to cylinder Torque 16 N˙m
12 lb-ft
Hex. nut at valve spool Torque 5,5 +1 N˙m
4.1 +0.7 lb-ft
Valve spool Torque 35 N˙m
26 lb-ft
Service valve Torque 5 +1 N˙m
3.7 +0.7 lb-ft
Orifice at control valve block Torque 3 N˙m
2.2 lb-ft
Orifice at LS connection Torque 3 N˙m
2.2 lb-ft
Cap screw (LS line) Torque 9 +2 N˙m
6.6 lb-ft

Relieving Hydraulic System Pressure
CAUTION:
When relieving pressure in the hydraulic system, the operator′s cab will
lower. Keep parts of your body, items of clothing and tools well clear.
[1] -
LEGEND:
A Pressure relief screw (service valve)
CAUTION:
When screw (A) is slackened, the operator′s cab will lower.
[2] - Slacken off screw (A) by approx. 1/2 turn.

[3] - Allow time for all hydraulic pressure to dissipate.
→NOTE:
Leave screws (A) open until this work is completed.
[4] - Tighten screw (A).

Control block, screws Torque 5 N˙m
3.7 lb-ft

→NOTE:
When the hydraulic system is pressure-free, it takes approx. 5 - 6 seconds
for the cab to level itself after the engine has been started. If the
transmission oil is cold, it may take approx. 60 seconds for the cab to level
itself.
Installing and Removing the Cab Suspension Shields
Take out cap screws (A) and remove shield (B).
The r.h. shield is installed in the same way as the l.h. one.
Removing and Installing the Sensor Rod

[1] -
CAUTION:
The operator′s cab must be secured in such a way that no parts of the body
are at risk from pinching.

Disconnect the top end of sensor rod (A) from the position sensor and its bottom end from
the ball spigot on the support.
[2] - Replace the relevant parts, if necessary.
[3] - Connect the top end of sensor rod (A) to the position sensor and its bottom end to the
ball spigot on the support.

Adjusting the Sensor Rod

[1] -
Remove sensor rod (A).

[2] -
Measure dimension (a) between the two ball ends.

Position sensor rod Adjusting dimension 76 mm
2.99 in.
[3] -
IMPORTANT:
After adjusting or replacing the sensor rod, be sure to calibrate the hydro-
pneumatic cab suspension. See Reference 245-SFA-002 , Calibration and
Input Addresses, Hydraulic Cab Suspension.
Install sensor rod in reverse order (with regard to removal procedure).

Removing the Position Sensor

Remove hex. nut (A).
Disconnect plug (B) and remove hex. socket screws (C).

Reconditioning the Position Sensor
LEGEND:
A Screw (2 used
B Washer (2 used)
C Position sensor
D O-ring
E Shaft
F Bushing
G Hex. socket screw (2 used)
H Washer (2 used)
I Hex. nut
J Lever
K Hex. nut
L Ball-ended pin
M Hex. nut
N Ball-ended pin
O Sensor rod
P Rear mounting bracket (left)
[1] - Remove the position sensor. See“Removing the Position Sensor”in this Group.
[2] - Dismantle, and replace defective parts.
[3] - Install parts as shown in the illustration.
→NOTE:
When fully assembled, shaft (E) must turn freely.
[4] - Install the position sensor. See“Installing the Position Sensor”in this Group.

Installing the Position Sensor
Install hex. socket screws (C) and plug (B).
Install hex. nut (A).
IMPORTANT:
After adjusting or replacing the sensor rod, be sure to calibrate the hydro-
pneumatic cab suspension. See Reference 245-SFA-002 , Calibration and
Input Addresses, Hydraulic Cab Suspension.
Removing the Accumulator

[1] -
Relieve hydraulic system pressure. See“Relieving Hydraulic System Pressure”in this Group.
→NOTE:
What follows applies to both of the cab suspension accumulators.
[2] -
→NOTE:
Use a suitable container to trap all leaking hydraulic oil as it emerges.
Unfasten and remove accumulator (A).

[3] - If necessary, recondition the accumulator. See “Reconditioning the Accumulator” in this
Group.

Reconditioning the Accumulator
IMPORTANT:
For safety reasons the accumulators must be replaced every 10 years.
[1] -
If necessary, remove the accumulator. See“Removing the Accumulator”in this Group.

[2] -
→NOTE:
[3] - Remove seal nut (E) from accumulator (A).
[4] - Take out the filler screw (D).Nitrogen escapes at this point.
[5] - Remove seal ring (C).
[6] - Clean all sealing surfaces and use a new seal ring.
[7] - Re-install filler screw (D) in accumulator (A).
Accumulator, filler screw Torque 20 N˙m
15 lb-ft
IMPORTANT:
The accumulator must be charged with nitrogen. SeeReference 290-15-110,
"Hydro-Pneumatic Cab Suspension - Checking and Adjusting the Nitrogen
Precharge" in the relevant Technical Manual, Section 290, Group 15.

[8] - After charge procedure has been completed, check O-ring for damage (replace, if
necessary), re-install seal nut (E) on accumulator (A) and tighten as specified.
Accumulator seal nut Torque 30 +5 N˙m
22 +4 lb-ft
[9] - If necessary, install the accumulator. See “Installing the Accumulator” in this Group.
Installing the Accumulator
→NOTE:
Never install an accumulator unless you know its nitrogen pressure.

SeeReference 290-15-110, "Hydro-Pneumatic Cab Suspension - Checking
and Adjusting the Nitrogen Precharge" in the relevant Technical Manual,
Install accumulator (A) and secure with screws.
Removing Hydraulic Cylinder

[1] - Relieve hydraulic system pressure. See“Relieving Hydraulic System Pressure”in this
Group.
[2] -
→NOTE:
Disconnect the hydraulic hose (A) from hydraulic cylinder.

[3] - Remove locking plates (B) and pull out pins.
CAUTION:
When removing, remember that the hydraulic cylinder is heavy!
Installing Hydraulic Cylinder

[1] - Attach hydraulic cylinder using the pins and secure with locking plates (B).
→NOTE:

[2] - Tighten hydraulic hose (A) to the specified torque.

Hydraulic hose to cylinder Torque 16 N˙m
12 lb-ft
Removing the Control Valve Block
Removing control valve block (view from operator′s cab)
Disconnect pressure line (A) and load sensing line (B) from endplate and from control valve
block.
Remove hydraulic hoses (C) and (D) from the control valve block.
Remove return hose (E) from the control valve block.
Mark both plugs (F) and (G) and disconnect from control valve block.
Remove both solenoid coils.
Take out cap screws (A) and lift off control valve block (B) with support (C).

Reconditioning the Valves in the Control Valve

Block
LEGEND:
A Hex. nut
B Hex. nut
C Solenoid
D 2/2 Valve spool
E Service valve
F Straight fitting (return)
G Control valve block
H Elbow fitting (LS connection)
I Straight fitting (pressure)
J 3/2 Valve spool
K Solenoid
L Orifice
M Orifice
IMPORTANT:
Absolute cleanliness is essential when working on hydraulic components.
When installing the components pay attention to the following torques:

Hex. nuts (A) and (B) at valve spool Torque 5,5 +1 N˙m
4.1 +0.7 lb-ft
Valve spools (D) and (J) Torque 35 N˙m
26 lb-ft
Service valve Torque 5 +1 N˙m
3.7 +0.7 lb-ft
2.2 lb-ft
2.2 lb-ft
IMPORTANT:
Relieve hydraulic system pressure. See”Relieving Hydraulic System

Pressure”in this Group.
Reconditioning the service valve
Remove O-ring (A) and replace with a new one.
→NOTE:
Apply some hydraulic oil to O-ring before installation.

→NOTE:
Make sure that O-ring is not damaged during assembly.
Reconditioning 2/2 valve spool
Replace O-rings (A) and (B) as well as back-up ring (C) with new ones.
→NOTE:
Apply some hydraulic oil to O-rings and back-up ring before installation.
→NOTE:
Make sure that O-rings and back-up ring are not damaged during assembly.
Reconditioning 3/2 valve spool
Replace O-rings (A), (B) and (C) as well as back-up rings (D), (E), (F) and (G) with new ones.

→NOTE:
Apply some hydraulic oil to O-rings and back-up rings before installation.
→NOTE:
Make sure that O-rings and back-up rings are not damaged during
assembly.
Replacing the orifice (at solenoid valve for lowering)
Screw out orifice (A; at solenoid valve for lowering) on control valve block, clean or replace it
and re-tighten as specified.
2.2 lb-ft
Removing the orifice (at LS connection)

Take out hex. socket screw (A).
→NOTE:
First remove the 3/2 valve spool and then the orifice (B).
Screw out orifice (B; at LS connection) on control valve block, clean or replace it and re-
tighten as specified.
2.2 lb-ft
Hex. socket screw (A; LS line) Torque 9 +2 N˙m
6.6 lb-ft

Installing the Control Valve Block
LEGEND:
A Cap screws
B Control valve block
C Support
Secure control valve block (B) to housing using cap screws (A).
Re-install both solenoid valves
Hex. nut at valve spool Torque 5.5 +1 N˙m
4.1 +0.7 lb-ft
Installing control valve block (view from operator′s cab)
Connect pressure line (A) and load sensing line (B) to endplate and to control valve block and
tighten.
Attach hydraulic hoses (C) and (D) to the control valve block.
Attach return hose (E) to the control valve block.

Connect both plugs (F) and (G) at control valve block.
Panhard Link Removal and Installation

See "Tilting the Operator′s Cab Upward" and "Tilting the Operator′s Cab Downward" in the
relevant Technical Manual, Section 90, Group 00.

Bleeding Cab Suspension Hydraulic Cylinders

Bleeding instructions:
CAUTION:
During bleeding of cab suspension the operator′s cab is raised and

lowered. Keep parts of your body, items of clothing and tools well clear.
CAUTION:
Always follow the steps described here precisely. This ensures that the cab
suspension operates correctly.
→NOTE:
To avoid oil foaming while bleeding, the procedure should not be started
after fast driving, working with hydraulic implements or carrying out
hydraulic tests. After such operation the tractor should be allowed to stand
for one hour to allow the oil to lose any accumulated foam.
→NOTE:
The service valve at control valve block must be closed.
[1] -
As shown in the relevant illustration, slide transparent hoses over the appropriate bleed
screws (A). Place the other ends of the two bleed hoses in the oil filler neck.
[2] - Open the bleed screws by half a turn.
[3] - Start the engine.

SPECIAL TOOLS (DEALER-FABRICATED) (g) by Belgreen
[4] - Leave the bleed screws open for 80 seconds (after this period of time the raise solenoid
valve closes and oil is no longer flowing).
[5] - Shut off tractor engine, wait for 20 seconds and re-start the engine.
[6] - Leave bleed screws open until the fluid escaping from the bleed screws is free of air
bubbles.
CAUTION:
When closing the bleed screws, pressure builds up and the cab rises
quickly.
[7] - Close bleed screws and remove the hoses.

Section 99 - SPECIAL TOOLS (DEALER-

FABRICATED)
Table of contents
Group 05 - Special Tools (Dealer-Fabricated) ....................................................................... 1
Suspension Device ................................................................................................................. 1
Adapter Strut ......................................................................................................................... 1
Holding Fixture ....................................................................................................................... 3
Lifting Eyes for Operator′s Cab ............................................................................................... 3
Holding Fixture ....................................................................................................................... 4
DFLX13 - Holding Device ........................................................................................................ 6
DFLX21 - Special Wrench ....................................................................................................... 6
DFLX22 – Socket Wrench Insert ............................................................................................. 7
DFLX42 - Turning Device ........................................................................................................ 8
Driver ..................................................................................................................................... 9
DFRW29 - Housing Adapter .................................................................................................. 10
DFRW30 - Axle Jacking Tool ................................................................................................. 11
DFRW79 – Piston Holding Tool ............................................................................................. 12
Bushing ................................................................................................................................ 12
Installation Tool .................................................................................................................... 13
Tube ..................................................................................................................................... 13
Unlocking Device ................................................................................................................. 14
Suspension Device ............................................................................................................... 14
Group 10 - Special Tools (Available from the Dealer) ....................................................... 16
AR52361 - Socket ................................................................................................................. 16
D01042AA – Load-Positioning Sling ...................................................................................... 16
D01045AA - Bushing, Bearing and Seal Driver Set ............................................................... 16
D05007ST - Tractor Splitting Stand ...................................................................................... 17
FKM10002 / JT05470 - Universal Pressure Test Kit ............................................................... 17
JDE83 – Flywheel Turning Tool ............................................................................................. 18
JDG19 – Special Mounting Brackets ...................................................................................... 18
JT01673 - Installer ................................................................................................................ 18
JT05723 – Medium-Duty Rear Tractor Splitting Stand .......................................................... 19
JT05724 – Medium-Duty Front Tractor Splitting Stand ......................................................... 19
JT05725 – Universal Support Stand ...................................................................................... 20
JT02044 - Support Stand ...................................................................................................... 20
JDG23 – Lifting Sling ............................................................................................................. 21
JDG749 - 1,30 m (52 in.) Torque wrench extension ............................................................. 21
JDG750 – Swivel Socket ........................................................................................................ 21
JDG778A – Adjusting Tool ..................................................................................................... 22
JDG820 – Flywheel Turning Tool ........................................................................................... 22
KJD10173 – Shaft Puller ........................................................................................................ 22
KJD10178C – Cab Tilting Device ........................................................................................... 23
KJD10194 - Pressure Gauge Set for Air Brake System .......................................................... 23
KJD10293 – Disconnecting Tool ............................................................................................ 24

Section 99 - SPECIAL TOOLS (DEALER-FABRICATED) Group 05: Special Tools (Dealer-Fabricated)
Group 05 - Special Tools (Dealer-Fabricated)

Suspension Device
Device for suspending the PowrQuad module during removal and installation (also for
PowrQuad Plus and AutoQuad transmissions)
IMPORTANT:
Adapter Strut

LEGEND:
A 80 mm (3.2 in.)
B 45 mm (1.8 in.)
C 400 mm (16 in.)
D 360 mm (14.17 in.)
E 140 mm (5.51 in.)
H 8 mm (5/16”)
Used for removing and installing the differential housing. This adapter strut facilitates
installation of the JT05723 universal support stand on the rear PTO housing of various tractor
versions.
Made from U-shaped steel to U-80 DIN1026-St37-2 (UNP-80 EN10279) standard. When
selecting hardware, be sure to choose high-tensile attaching screws. When securing the
adapter strut, only use DIN6918 washers, which have a tilt of 8%, on the inside of the strut.
Extra hardware required:
2 M12 x 60 mm cap screws

2 M16 x 40 mm cap screws

Holding Fixture
LEGEND:
A M12x30 mm screw
Used in conjunction with support stand D05007ST during the removal of tractor components.
Also required: two M16x350 mm threaded rods.
When used to remove the final drives, screw (A) is used to support the edge of the flat piece
of metal.
a .......... 250 mm (10 in.)
b .......... 50 mm (2 in.)
c .......... 15 mm (0.6 in.)
d .......... 205 mm (8.1 in.)
e .......... 16 mm (0.6 in.)
f .......... Ø 18 mm (45/64 in.)
Lifting Eyes for Operator′s Cab

LEGEND:
B M16 Hex. Nut
→NOTE:
Two lifting eyes are required for removal and installation of the operator′s
cab.
Coat one end of threaded rod (C) with LOCTITE 270 (L41476) and screw it into eye nut (a)
until it bottoms. Lock with hex. nut (B).
Holding Fixture

LEGEND:
A 185 mm (7.5 in.)
B 185 mm (7.5 in.)
C 5 mm (0.2 in.)
D 200 mm (8 in.)
On front-wheel drive axles with TLS: For holding drive shaft housing.
→NOTE:
This tool is attached to the support of a commercial jack. The correct hole
pattern of part (E) depends on the type of jack being used.
Determine the correct hole pattern and attach tool to the support of the
jack, using at least two M8 screws.

DFLX13 - Holding Device
Removal and installation of components.
In conjunction withD05007ST- Mobile Support Stand
DFLX21 - Special Wrench

For removing the sending unit from fuel tanks that have a screw-type connection.
→NOTE:
As an alternative to cutting out the square hole, a standard 1/2 in. square
drive socket may welded to the metal fork.
DFLX22 – Socket Wrench Insert

Removing guide pieces (brake valve with power fill).
Take a standard hex. socket insert with a width across flats of 41 mm (39/64 in.), and turn
the outside diameter of the hex. end until it is 49.5 mm (1.95 in.) across for a length of 8 mm
(0.3 in.).
Remove SCV end plate
Take a standard hex. socket insert with a width across flats of 17 mm (11/16 in.) and a 1/2 in.
square drive socket, and turn the outside diameter of the hex. end until it is 22,5 mm (0.9 in.)
across for a length of 13 mm (0.5 in.).
Socket wrench insert for removing the guide piece. Can also be used to remove the screw-
plug. Take a standard hex. socket insert, with a width across flats of 41 mm (39/64 in.), and
turn the outside diameter until it is 49.5 mm (1.95 in.) for a length of 8 mm (0.3 in.).

DFLX42 - Turning Device
LEGEND:
A Brace
B Screw, M16
C Spacer Sleeve
D Nut, M16
E Screw, M16
The turning device is used to measure the rolling drag torque of the final drives.
Driver

Reworked from KJD10171 to KJD10171A.
Tool for installing the seal ring on output shaft of rear PTO (540/1000 and 540/540E/1000
rpm)
DFRW29 - Housing Adapter

LEGEND:
A 3/8 x 2 in. cap screws (2 used)
B Flat washer (2 used)
C 3/8 in. nut (5 used)
D (6.35 x 38.10 mm) (0.250 x 1.500 in.) strap
The housing adapter is used to check rolling drag torque of final drive.
DFRW30 - Axle Jacking Tool
Material required:
102 x 51 x 559 mm steel tubing (4 x 2 x 22 in.)
The axle jacking tool is made from specified tubing with 2-9/16 x 14 in. steel rods.
Use 4-9/16 in. nuts and 2-9/16 in. flat washers on the rods.
The axle jacking tool is used to remove the axle housing from the axle shaft.
DFRW79 – Piston Holding Tool
Used to hold B 2 and B 3 pistons in housing during installation.
Material required: 11.5 cm (4.5 in.) steel wire (9 to 11 Gauge)
Fabricate holding tool as illustrated.
Bushing

Removing and installing Belleville springs on the front-wheel drive clutch
Installation Tool
Removing and installing the park lock control block and the check valve.
Tube

Unlocking Device
LEGEND:
B Nut M6 (14M7272)
D Nut M6 (14M7272)
E Yoke (L80051)
F Pin (AL79051)

Section 99 - SPECIAL TOOLS (DEALER-FABRICATED) Group 10: Special Tools (Available from the Dealer)
Suspension Device
LEGEND:
A 145 mm (5.7 in.)
B 15 mm (0.6 in.)
C 15 mm (0.6 in.)
D Bore, 13 mm (1/2”)
E Bore, 11 mm (7/16”)
F 90 mm (3.54 in.)
G 15 mm (0.6 in.)
H 15 mm (0.6 in.)
I Bore, 11 mm (7/16”)
similar norms).

Group 10 - Special Tools (Available from the Dealer)

AR52361 - Socket
Checking the trailer brake valve.
Available as spare part
D01042AA – Load-Positioning Sling
Removal and installation of tractor components. This tool permits the adjustment of the angle
of the load being handled. Therefor the positioning of the attached component is optimally
aligned to its location.
D01045AA - Bushing, Bearing and Seal Driver Set

Installing bushings, bearings and seal rings.
D05007ST - Tractor Splitting Stand
→NOTE:
Tractor splitting stand D5007ST is replaced by mobile splitting

standKJD10559.
Removal and installation of front-wheel drive axles, final drives and other heavy components.
Holding toolDFLX13is also required.
FKM10002 / JT05470 - Universal Pressure Test Kit

Checking pressure on tractors with test ports. Gauges can be connected to the machine
without using any tools.
Hydraulic oil pressure: in conjunction withJT07115- Pressure Test Kit
JDE83 – Flywheel Turning Tool
To turn flywheel manually in order to turn 4-cyl. engine crankshaft.
JDG19 – Special Mounting Brackets
Used for removal and installation of tractor components.
Use in conjunction with load-positioning slingD01042AA.
JT01673 - Installer

Installing bearing cups in axle housing
JT05723 – Medium-Duty Rear Tractor Splitting Stand
Raising and supporting tractor components.
Use in conjunction with two commercial 8-tonne vehicle jacks.
→NOTE:
Alternatively, one JT07122 special tool kit may be used
JT05724 – Medium-Duty Front Tractor Splitting

Stand

Use in conjunction with two commercial 5-tonne vehicle jacks.
→NOTE:
Alternatively, one JT07122 special tool kit may be used
JT05725 – Universal Support Stand
Use in conjunction with a commercial 12-tonne vehicle jack.

JT02044 - Support Stand
Support for tractor components. Height can be varied between 863 and 1117 mm (34 and 44
in.)
JDG23 – Lifting Sling
Removal and installation of operator′s cab and other tractor components.
JDG749 - 1,30 m (52 in.) Torque wrench extension
Unscrewing and tightening the differential-housing-to-frame screws.
Use in conjunction with swivel socketJDG750.

JDG750 – Swivel Socket
Unscrewing and tightening the differential-housing-to-frame screws.
Use in conjunction withJDG749- 1,30 m (52 in.) Torque wrench extension
JDG778A – Adjusting Tool
Checking the rolling drag torque of final drive pinions
JDG820 – Flywheel Turning Tool
To turn flywheel manually in order to turn 6-cyl. engine crankshaft.
KJD10173 – Shaft Puller
Removal and installation of PTO and pump drive shafts.

KJD10178C – Cab Tilting Device
LEGEND:
4 Support rod KJD10178-4A (including joints and pins)
8 Strut KJD10178-8B (replaces KJD10178-8 and KJD10178-8A)
10 Spindle KJD10178-10 (assembly with crank)
12 Rod KJD10178-12 (including retaining pins)
13 Bracket KJD10178-13 (including attaching screws)
14 KJD10178-14 Rear tilt bracket (with suspended cab)
Tilting the operator′s cab up and down. This is the basic tool kit for 6020 Series tractors.
Also seeKJD10283supplementary kit to cab tilting device KJD10178C.
For tilting SE tractor low-profile cab (tunnel) also order AL114332.
→NOTE:
KJD10178C replaces KJD10178, KJD10178A and KJD10178B cab tilting

devices. For conversion of the old tilting devices, all parts can be ordered
separately.

KJD10194 - Pressure Gauge Set for Air Brake

System
Checking the air brake system for leaks. Checking pressure of dual-line brake.
KJD10293 – Disconnecting Tool
Disconnecting/connecting steering or brake hoses.

Repair Manual: 6820, 6920 and 6920S Tractors Repair

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Repair Manual: 6820, 6920 and 6920S Tractors Repair

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John Deere Agriculture

6820, 6920 and 6920S Tractors Repair

TM4756, August 2010

<- Go to Global Table of contents TM4756-REPAIR MANUAL

Group 05 - Hydrostatic Steering

<- Go to Global Table of contents TM4756-REPAIR MANUAL

6820, 6920 and 6920S.

This is the safety-alert symbol. It indicates that there is danger of injury.

<- Go to Global Table of contents TM4756-REPAIR MANUAL

<- Go to Global Table of contents TM4756-REPAIR MANUAL

<- Go to Global Table of contents TM4756-REPAIR MANUAL

Group 05 - Safety Information

Follow recommended precautions and safe operating practices.

Prevent Machine Runaway

<- Go to Section TOC Section 05 page 1 TM4756-REPAIR MANUAL

Avoid possible injury or death from machinery runaway.

Handle Fluids Safely—Avoid Fires

Make sure machine is clean of trash, grease, and debris.

<- Go to Section TOC Section 05 page 2 TM4756-REPAIR MANUAL

Prevent Battery Explosions

Prepare for Emergencies

Be prepared if a ﬁre starts.

<- Go to Section TOC Section 05 page 3 TM4756-REPAIR MANUAL

Keep a ﬁrst aid kit and ﬁre extinguisher handy.

<- Go to Section TOC Section 05 page 4 TM4756-REPAIR MANUAL

Prevent Acid Burns

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

If you spill acid on yourself:

<- Go to Section TOC Section 05 page 5 TM4756-REPAIR MANUAL

1. Flush your skin with water.

1. Do not induce vomiting.

Avoid High-Pressure Fluids

Service Cooling System Safely

<- Go to Section TOC Section 05 page 6 TM4756-REPAIR MANUAL

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Remove paint before heating:

<- Go to Section TOC Section 05 page 7 TM4756-REPAIR MANUAL

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Work In Ventilated Area

<- Go to Section TOC Section 05 page 8 TM4756-REPAIR MANUAL

Wear Protective Clothing

<- Go to Section TOC Section 05 page 9 TM4756-REPAIR MANUAL

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Practice Safe Maintenance

<- Go to Section TOC Section 05 page 10 TM4756-REPAIR MANUAL

Park Machine Safely

Before working on the machine:

Lower all equipment to the ground.

Use Proper Lifting Equipment

<- Go to Section TOC Section 05 page 11 TM4756-REPAIR MANUAL

Construct Dealer-Made Tools Safely

Support Machine Properly

<- Go to Section TOC Section 05 page 12 TM4756-REPAIR MANUAL

Work in Clean Area

Before starting a job:

Clean work area and machine.

<- Go to Section TOC Section 05 page 13 TM4756-REPAIR MANUAL

Make sure you have all necessary tools to do your job.

Illuminate Work Area Safely

Service Machines Safely