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 00 - Removal and Installation of Components
Group 05 - Transmission Shift Controls
Group 10 - PowrQuad Module
Group 15 - Creeper Transmission
Group 20 - Range Transmission
Section 56 - DRIVE SYSTEMS
Group 00 - Removal and Installation of Components
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
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TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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 00 - Removal and Installation of Components
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 00 - Removal and Installation of Components
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)
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TM4756-REPAIR MANUAL
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TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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.
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TM4756-REPAIR MANUAL
SAFETY
(g) by Belgreen
Version Date
01 December 2005
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TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
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TM4756-REPAIR MANUAL
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
your telephone.
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Section 05 - SAFETY
Group 05: Safety Information
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.
2.
3.
4.
5.
Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.
If you spill acid on yourself:
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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.
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Section 05 - SAFETY
Group 05: Safety Information
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
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TM4756-REPAIR MANUAL
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.
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TM4756-REPAIR MANUAL
(g) by Belgreen
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
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TM4756-REPAIR MANUAL
(g) by Belgreen
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
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TM4756-REPAIR MANUAL
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”
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Section 10 page 1
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Section 10 - GENERAL INFORMATION
Group 05: Specifications
”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”
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Section 10 - GENERAL INFORMATION
Group 05: Specifications
Engine Specifications
Type
- 6820
with Bosch VP-44 injection pump .......... 6068HLA71
with Denso HPCR injection pump .......... 6068HL472
- 6920
with Bosch VP-44 injection pump .......... 6068HLA72
with Denso HPCR injection pump .......... 6068HL473
- 6920S
with Bosch VP-44 injection pump .......... 6068HLA73
with Denso HPCR injection pump .......... 6068HL474
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
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Section 10 - GENERAL INFORMATION
Group 05: Specifications
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
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Group 05: Specifications
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
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Group 05: Specifications
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
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Group 05: Specifications
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
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Group 05: Specifications
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.)
AutoPowr/IVT transmission
- 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.
<- Go to Section TOC
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Group 05: Specifications
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)
- axle housing .......... 7.0 L (1.8 U.S. gal.)
- final drive housing (each) .......... 1.7 L (0.4 U.S. gal.)
6920/6920S (045JD)
- axle housing .......... 9.5 L (2.5 U.S. gal.)
- final drive housing (each) .......... 2.0 L (0.53 U.S. gal.)
Front-wheel drive axle with TLS
6820 (AS 2045)
- axle housing .......... 8.0 L (2.11 U.S. gal.)
- final drive housing (each) .......... 1.7 L (0.4 U.S. gal.)
6920/6920S (AS 2060)
- axle housing .......... 9 L (2.4 U.S. gal.)
- final drive housing (each) .......... 2.2 L (0.6 U.S. gal.)
6920/6920S (045JDS20)
- axle housing .......... 10.6 L (2.8 U.S. gal.)
- final drive housing (each) .......... 2.0 L (0.53 U.S. gal.)
Front-wheel drive axle with TLS and disk brake
6820 (AS 2045)
- axle housing .......... 8.0 L (2.11 U.S. gal.)
- final drive housing (each) .......... 1.0 L (0.3 U.S. gal.)
6920/6920S (AS 2060)
- axle housing .......... 9.0 L (2.4 U.S. gal.)
- final drive housing (each) .......... 1.8 L (0.5 U.S. gal.)
6920/6920S (045JDS20)
- axle housing .......... 10.6 L (2.8 U.S. gal.)
- final drive housing (each) .......... 2.0 L (0.5 U.S. gal.)
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.
<- Go to Section TOC
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Group 05: Specifications
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.
<- Go to Section TOC
Section 10 page 10
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Group 05: Specifications
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.
<- Go to Section TOC
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Group 05: Specifications
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.
<- Go to Section TOC
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Section 10 - GENERAL INFORMATION
Group 05: Specifications
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
<- Go to Section TOC
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Group 05: Specifications
engine oil as recommended in this manual.
<- Go to Section TOC
Section 10 page 14
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Section 10 - GENERAL INFORMATION
Group 05: Specifications
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
<- Go to Section TOC
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Group 05: Specifications
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%.
<- Go to Section TOC
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Group 05: Specifications
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 ™
Other oils may be used if they meet one or more of the following:
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:
<- Go to Section TOC
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Group 05: Specifications
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.
<- Go to Section TOC
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Group 05: Specifications
Transmission and Hydraulic Oil
Use oil with a viscosity based on the expected air temperature range during the period
between oil changes.
The following oils are preferred:
John Deere HY-GARD ™
John Deere HY-GARD ™ with low viscosity
Other oils may be used if they meet one or more of the following:
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
<- Go to Section TOC
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Group 05: Specifications
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 ™
[ 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. ]
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.
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Group 05: Specifications
Front-Wheel Drive Axle Oil
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 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 ™
[ 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
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Group 05: Specifications
mineral oils because this reduces the biodegradability and makes proper oil recycling impossible. ]
or BIO-HY-GARD ™
[ 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. ]
→NOTE:
Do NOT use BIO-HY-GARD on braked axles.
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Group 05: Specifications
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.
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Group 05: Specifications
Supplemental Coolant Additives
Some coolant additives will gradually deplete during engine operation. For John Deere COOLGARD ™ 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
<- Go to Section TOC
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Group 05: Specifications
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.
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Group 05: Specifications
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).
<- Go to Section TOC
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Group 05: Specifications
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.
<- Go to Section TOC
Section 10 page 27
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
Unified Inch Bolt and Screw Torque Values
SAE Grade 2
Bolt
or
Screw
[ Grade 2 applies for hex cap
screws (not hex bolts) up to 6.
in (152 mm) long. Grade 1
applies for hex cap screws
over 6 in. (152 mm) long, and
for all other types of bolts and
screws of any length. ]
SAE Grade 1
Lubricated
Lubricated
[
“Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners with
JDM F13C zinc
flake coating.
]
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
1/4 to 3/4 in.
fasteners with
JDM F13B zinc
flake coating.
]
[
“Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners with
JDM F13C zinc
flake coating.
]
Dry
SAE Grade 5, 5.1 or 5.2
SAE Grade 8 or 8.2
Lubricated
Lubricated
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
1/4 to 3/4 in.
fasteners with
JDM F13B zinc
flake coating.
]
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners with
JDM F13C zinc
flake coating.
]
Dry
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
1/4 to 3/4 in.
fasteners with
JDM F13B zinc
flake coating.
]
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
7/8 in. and
larger
fasteners with
JDM F13C zinc
flake coating.
]
Dry
Dry
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
1/4 to 3/4 in.
fasteners with
JDM F13B zinc
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.
28
20.5
35
26
5/16
3/8
7/16
7.7
13.5
68
120
9.8
86
12
106
15.5
137
19.5
172
25
221
N˙m
lb.-ft.
N˙m
lb.-ft.
35
26
44
32.5
49
36
63
46
17.5
155
22
194
27
240
N˙m
lb.-ft.
N˙m
lb.-ft.
N˙m
lb.-ft.
28
20.5
35
26
44
32.5
56
41
70
52
80
59
100
74
22
194
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
of the bolt or screw. DO NOT use these values if a different torque
value or tightening procedure is given for a specific application. For
plastic insert or crimped steel type lock nuts, for stainless steel
fasteners, or for nuts on U-bolts, see the tightening instructions for
the specific application. Shear bolts are designed to fail under
predetermined loads. Always replace shear bolts with identical grade.
<- Go to Section TOC
Replace fasteners with the same or higher grade. If higher
grade fasteners are used, tighten these to the strength of the
original. Make sure fastener threads are clean and that you
properly start thread engagement. When possible, lubricate
plain or zinc plated fasteners other than lock nuts, wheel
bolts or wheel nuts, unless different instructions are given for
the specific application.
Section 10 page 28
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
Metric Bolt and Screw Torque Values
Bolt
or
Screw
Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricated
Lubricated
Lubricated
Lubricated
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
M20 and
larger
fasteners with
JDM F13C zinc
flake coating.
]
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
M6 to M18
fasteners with
JDM F13B zinc
flake coating.
]
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
M20 and
larger
fasteners with
JDM F13C zinc
flake coating.
]
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
M6 to M18
fasteners with
JDM F13B zinc
flake coating.
]
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
M20 and
larger
fasteners with
JDM F13C zinc
flake coating.
]
Dry
Dry
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
M6 to M18
fasteners with
JDM F13B zinc
flake coating.
]
[ “Lubricated”
means coated
with a
lubricant such
as engine oil,
fasteners with
phosphate
and oil
coatings, or
M20 and
larger
fasteners with
JDM F13C zinc
flake coating.
]
Dry
Dry
[ “Dry” means
plain or zinc
plated without
any
lubrication, or
M6 to M18
fasteners with
JDM F13B zinc
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.
32
23.5
40
29.5
37
27.5
47
35
M8
M10
11.5
102
14.5
128
22
194
27.5
243
N˙m
lb.-ft.
N˙m
lb.-ft.
N˙m
lb.-ft.
29
21
43
32
55
40
63
46
80
59
75
55
95
70
23
204
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
strength of the bolt or screw. DO NOT use these values if a
different torque value or tightening procedure is given for a
specific application. For stainless steel fasteners or for nuts
on U-bolts, see the tightening instructions for the specific
application. Tighten plastic insert or crimped steel type lock
nuts by turning the nut to the dry torque shown in the chart,
unless different instructions are given for the specific
application.
<- Go to Section TOC
Shear bolts are designed to fail under predetermined loads. Always
replace shear bolts with identical property class. Replace fasteners
with the same or higher property class. If higher property class
fasteners are used, tighten these to the strength of the original. Make
sure fastener threads are clean and that you properly start thread
engagement. When possible, lubricate plain or zinc plated fasteners
other than lock nuts, wheel bolts or wheel nuts, unless different
instructions are given for the specific application.
Section 10 page 29
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
Hydraulic system inch fitting torques
LEGEND:
A
B
C
D
Bulkhead fitting
Lock nut
Collar nut
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.
<- Go to Section TOC
Section 10 page 30
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
Hydraulic system metric fitting torques
LEGEND:
A
B
C
D
Stud-end fitting
Groove for metric spec.
Lock nut
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.
<- Go to Section TOC
Section 10 page 31
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
Product identification and component serial
numbers
<- Go to Section TOC
Section 10 page 32
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
LEGEND:
DT-1
<- Go to Section TOC
Group 05: Specifications
PowrQuad module
Section 10 page 33
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
DT-2
EN-1
FA-1
FI-1
FI-2
FI-3
HY-1
OS-1
OS-2
OS-3
OS-4
OS-5
OS-6
RA-1
RA-3
RI-1
RI-2
RI-3
RI-4
RI-5
RI-6
Group 05: Specifications
SyncroPlus module
Motor
Front axle
Front PTO
Front hitch
Front loader
Hydraulic pump
Operator′s cab
ROPS
Seat
Brake valve
Steering valve
Compressor, air conditioning
Transmission assembly
Transmission ratios, differential - FWD
Inlet priority valve
Hydraulic pick-up hitch
Wagon hitch
Swinging drawbar
Holder for pick-up hitch
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.
<- Go to Section TOC
Section 10 page 34
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
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
<- Go to Section TOC
Section 10 page 35
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 05: Specifications
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
B
Designation
Part number (needed when ordering)
<- Go to Section TOC
Section 10 page 36
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
C
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 37
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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”
<- Go to Section TOC
Section 10 page 38
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 39
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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 tuneup. 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”.
<- Go to Section TOC
Section 10 page 40
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Tractor Tune-Up
Fuel system components (Bosch VP44)
LEGEND:
A
B
C
D
E
F
G
H
I
Fuel tank
Primary fuel filter
Fuel filter
Injection pump (Bosch VP-44)
Cooling element with integrated fuel cooler
Fuel injection nozzle
Fuel gauge sending unit
Fuel transfer pump
Control unit (ECU)
<- Go to Section TOC
Section 10 page 41
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Denso/Stanadyne fuel system (Stage II engines according to 97/68/EC)
LEGEND:
A
B
C
D
E
F
G
H
I
<- Go to Section TOC
Fuel tank
Primary fuel filter
Fuel filter
Injection pump
Fuel cooler
Fuel transfer pump
Fuel gauge sending unit
Control unit
Check valve
Section 10 page 42
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 43
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 44
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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
<- Go to Section TOC
Section 10 page 45
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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,
<- Go to Section TOC
Section 10 page 46
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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
<- Go to Section TOC
Section 10 page 47
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 48
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 49
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Bleeding at the Fuel Transfer Pump
LEGEND:
A
B
C
Bleed orifice in filter base
Overflow valve
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
<- Go to Section TOC
Section 10 page 50
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
[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.
<- Go to Section TOC
Section 10 page 51
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Checking the fuel filter (with Bosch VP44 injection
pump)
LEGEND:
A
B
C
Drain screw
Plastic ring
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).
Item
Measurement
Specification
Drain screw (fuel tank)
Torque
12 N˙m
9 lb-ft
<- Go to Section TOC
Section 10 page 52
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Cleaning the water trap
LEGEND:
A
B
<- Go to Section TOC
Drain plug
Breather hole
Section 10 page 53
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Checking the Fuel Filter (with Denso/Stanadyne
Injection Pump; Stage II Engines According to
97/68/EC)
LEGEND:
A
B
C
Drain screw
Bleed screw
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).
Item
Measurement
Specification
Drain plug (fuel tank)
Torque
12 N˙m
9 lb-ft
<- Go to Section TOC
Section 10 page 54
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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!
<- Go to Section TOC
Section 10 page 55
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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
<- Go to Section TOC
Section 10 page 56
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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.
<- Go to Section TOC
Section 10 page 57
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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
[1] - Depress the clutch pedal.
[2] - Move range-shift lever (A) to neutral.
[3] - Move reverse drive lever (B) to any travel direction (forward or reverse).
[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 the other direction of travel.
<- Go to Section TOC
Section 10 page 58
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Tractors with PowrQuad transmission
[1] - Depress the clutch pedal.
[2] - Move range-shift lever (A) to neutral.
[3] - Move reverse drive lever (B) to forward position.
[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 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
<- Go to Section TOC
Section 10 page 59
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
Charging Circuit.
Tractors with AutoPowr/IVT transmission
[1] - Move reverse drive lever (A) to forward or reverse.
[2] - 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.
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.
<- Go to Section TOC
Section 10 page 60
TM4756-REPAIR MANUAL
Section 10 - GENERAL INFORMATION
Group 10: Tune-Up
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
<- Go to Section TOC
Section 10 page 61
TM4756-REPAIR MANUAL
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.
<- Go to Section TOC
Section 10 page 62
TM4756-REPAIR MANUAL
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 subassembly 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).
<- Go to Section TOC
Section 10 page 63
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Section 20 - ENGINE
Table of contents
Group 00 - Removal and Installation of Components .......................................................... 1
Specifications ......................................................................................................................... 1
Removing the Engine ............................................................................................................. 2
Installing the Engine ............................................................................................................ 20
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
Group 00 - Removal and Installation of Components
Specifications
Item
Measurement Specification
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
<- Go to Section TOC
Section 20 page 1
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
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
B
C
Battery terminal (polarity as indicated on the battery)
Battery terminal (polarity as indicated on the battery)
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] -
<- Go to Section TOC
Section 20 page 2
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
D
Connector
Hinge
Damper connecting point
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.
<- Go to Section TOC
Section 20 page 3
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 20 page 4
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[5] -
LEGEND:
A
Input flange of transmission
Disconnect the u.j. shaft at flange (A).
[6] -
LEGEND:
A
B
C
D
E
Clamps on muffler pipe
Wiring harness
Wiring harness
Ground cable
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.
<- Go to Section TOC
Section 20 page 5
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[7] -
LEGEND:
A
B
Fitting on compressed-air line
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.
<- Go to Section TOC
Section 20 page 6
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[8] -
LEGEND:
A
B
C
D
E
F
H
J
Connector
Connector
Bracket for fuel transfer pump
Connector for water-in-fuel sensor
Fuel hose
All starting motor cables
Fuel filter
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.
<- Go to Section TOC
Section 20 page 7
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[9] -
LEGEND:
A
B
C
Air-intake hose
Coolant hose
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.
<- Go to Section TOC
Section 20 page 8
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[11] -
LEGEND:
A
B
C
Air-intake hose
Air-intake hose
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.
<- Go to Section TOC
Section 20 page 9
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[13] -
LEGEND:
A to F
Coolant hoses
Disconnect coolant hoses (A), (B), (C), (D), (E) and (F).
→NOTE:
Trap the coolant as it emerges.
<- Go to Section TOC
Section 20 page 10
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[14] -
LEGEND:
A
B
C
D
Connector
Connector
Screw
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] -
<- Go to Section TOC
Section 20 page 11
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
D
E
F
G
Screws on the cross-member (with battery cut-off switch only)
Screws on the bracket for the air cleaner
Screws on the bracket for the fuel cooler
Bracket for the fuel cooler
Cross-member (with battery cut-off switch only)
Fuel cooler
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:
Comply with relevant safety instructions when working on the fuel system.
[16] - On tractors with air-conditioning, doNOT disconnect refrigerant lines (G); instead,
disassemble as follows:
<- Go to Section TOC
Section 20 page 12
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
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
B
Drive belt
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.
<- Go to Section TOC
Section 20 page 13
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 20 page 14
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[17] -
LEGEND:
A
B
C
Screws for attaching the front frame at the side
Plug
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.
<- Go to Section TOC
Section 20 page 15
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 20 page 16
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[20] -
LEGEND:
A
B
D01042AA
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] -
<- Go to Section TOC
Section 20 page 17
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
LEGEND:
A
B
Attaching screws on front engine mounting
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.
<- Go to Section TOC
Section 20 page 18
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 20 page 19
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 20 page 20
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
D
E
F
G
H
Engine mounting screw (rear)
Washer
Rubber bearing
Rubber bearing with bushing
Supporting cup
Engine mounting screw (front)
Nut
Engine mounting screw
Locate the engine mountings as shown and tighten the engine mounting screws to the torque
prescribed.
<- Go to Section TOC
Section 20 page 21
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
Item
Measurement
Specification
Engine mounting screws
Torque
100 N˙m
74 lb-ft
Item
Measurement Specification
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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 20 page 22
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 20 page 23
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[7] -
LEGEND:
A
Mounting at side of front frame
Install and tighten attaching screws (A).
Item
Measurement
Specification
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).
Item
Measurement
Specification
Mounting at front of front frame, screws
Torque
55 N˙m
40 lb-ft
<- Go to Section TOC
Section 20 page 24
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
[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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 20 page 25
TM4756-REPAIR MANUAL
Section 20 - ENGINE
Group 00: Removal and Installation of Components
IMPORTANT:
Lay out the hoses and lines so that they are not subject to any
mechanical or thermal forces.
[11] -
LEGEND:
A
B
C
Air cleaner housing
Strut attaching screws
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:
Comply with relevant safety instructions when working on the fuel system.
[12] - For further assembly, reverse disassembly procedure. See ”Removing the Engine” in
this Group.
<- Go to Section TOC
Section 20 page 26
TM4756-REPAIR MANUAL
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 heatshields on the exhaust) are all installed properly.
<- Go to Section TOC
Section 20 page 27
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
General Information ............................................................................................................. 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
General Information ............................................................................................................. 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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
General Information ............................................................................................................. 62
Specifications ....................................................................................................................... 62
Installing the Muffler ............................................................................................................ 63
Exhaust Pipe or Intermediate Exhaust Pipe ......................................................................... 66
Exhaust Pipe or Intermediate Exhaust Pipe —Upright .......................................................... 67
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
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
Item
Measurement Specification
Voltage output of hand throttle sensor and accelerator pedal
sensor (electronic speed control)
Voltage
<- Go to Section TOC
Section 30 page 1
0.5 to 4.5 volts (over entire range)
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
Accelerator Pedal, with Mechanical Speed Control
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
<- Go to Section TOC
Pedal plate
Bushing
Spring
M6x16 self-tapping screw (3 used)
Stop
Lever
Snap ring (5 used)
Hex. nut (6 used)
Spring pin (4 used)
Ball socket
Pivot (2 used)
Retaining wire
Section 30 page 2
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
13
14
15
16
17
18
19
20
Group 05: Speed Control
Threaded rod
Bushing (4 used)
Lever
Lever
Spring
Lever
Shaft
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.
<- Go to Section TOC
Section 30 page 3
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
Replacing the Accelerator Pedal Assembly
(AutoPowr/IVT)
LEGEND:
A
B
C
Accelerator pedal assembly
Hex. socket screws (3 used)
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.
<- Go to Section TOC
Section 30 page 4
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
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.
<- Go to Section TOC
Section 30 page 5
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
[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).
<- Go to Section TOC
Section 30 page 6
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
[3] -
LEGEND:
A
B
C
D
E
Potentiometer with holder
Toothed segment with spring
Accelerator pedal housing
Punch
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).
<- Go to Section TOC
Section 30 page 7
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
[4] -
Install hex. socket screws (A) on the housing.
→NOTE:
Install the stopper on the housing.
<- Go to Section TOC
Section 30 page 8
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 05: Speed Control
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
<- Go to Section TOC
Section 30 page 9
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
[1] -
When the segment is installed properly, the two arrows (A) are in perfect alignment.
[2] - For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 30 page 10
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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.
<- Go to Section TOC
Section 30 page 11
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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
B
C
D
Cover
Plug connection
Fuel hoses
Mounting plate
Take off cover (A), disconnect fuel lines (C) and pull off plug (B).
<- Go to Section TOC
Section 30 page 12
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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.
<- Go to Section TOC
Section 30 page 13
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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.
<- Go to Section TOC
Section 30 page 14
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
IMPORTANT:
Do not mix up connections!
Install the retaining plate.
Bleed fuel system.
<- Go to Section TOC
Section 30 page 15
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
Replace the Fuel Transfer Pump
LEGEND:
A
B
C
D
E
F
Fuel transfer pump
Screen
Connecting hose
Hose clip
Fuel level sending unit and float system linkage
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
<- Go to Section TOC
Section 30 page 16
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
LEGEND:
A
Group 10: Fuel System
Fuel transfer pump
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
B
C
<- Go to Section TOC
Cap screw
Retainer
Fuel hose
Section 30 page 17
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
D
E
F
G
Group 10: Fuel System
Fuel hose
Fuel transfer pump
Connector
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.
<- Go to Section TOC
Section 30 page 18
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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.
<- Go to Section TOC
Section 30 page 19
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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.
<- Go to Section TOC
Section 30 page 20
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
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
<- Go to Section TOC
Section 30 page 21
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 10: Fuel System
to 97/68/EC)
LEGEND:
A
B
C
D
E
F
G
H
I
Fuel tank
Primary fuel filter
Fuel filter
Injection pump
Fuel cooler
Fuel transfer pump
Fuel gauge sender
Control unit
Check valve
Use two clips (B) to install the check valve (I) approx. 100 mm (4 in.) in front of the fuel filter.
<- Go to Section TOC
Section 30 page 22
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 15: Air Intake System
IMPORTANT:
The arrow on the valve must point towards the fuel filter!
<- Go to Section TOC
Section 30 page 23
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 15: Air Intake System
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:
<- Go to Section TOC
Section 30 page 24
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
A
B
C
D
E
F
G
Group 20: Cooling System
Air intake openings
Air filter housing
Outlet
Primary filter element
Secondary (safety) filter element
Outlet support
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”.
<- Go to Section TOC
Section 30 page 25
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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
Item
Measurement Specification
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)
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
Fan console to engine
52 lb-ft
Coolant drain plug
Torque
4 – 5 N˙m
3 – 3.7 lb-ft
<- Go to Section TOC
Section 30 page 26
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Removing and Installing the Ring-Shaped Cooler
See reference ”Removing and Installing the Ring-Shaped Cooler” in Section 56, Group 05.
<- Go to Section TOC
Section 30 page 27
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Remove the Radiator
[1] - Draining the coolant ontractors up to serial no. 425328 .
Illustration shows a tractor up to serial no. 425328
LEGEND:
A
B
C
<- Go to Section TOC
Drain plug
Filler cap
Connect/disconnect control
Section 30 page 28
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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.
Item
Measurement
Specification
Coolant drain plug
Torque
4 – 5 N˙m
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] -
<- Go to Section TOC
Section 30 page 29
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
LEGEND:
A
B
C
Drain plug
Filler cap
Connect/disconnect control
Draining the coolant ontractors from serial no. 425329 .
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.
Item
Measurement
Specification
Coolant drain plug
Torque
4 – 5 N˙m
3 – 3.7 lb-ft
Turn the connect/disconnect control (C) as far as it will go in direction ”b” (open).
→NOTE:
The connect/disconnect control is used to connect or disconnect chambers
within the radiator.
On tractors with cab, fully open heater control.
<- Go to Section TOC
Section 30 page 30
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
[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.
<- Go to Section TOC
Section 30 page 31
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
[4] - Remove engine hood.
IMPORTANT:
The hood is heavy and awkward to move; you will require the assistance of
a second person.
Disconnect safety cable (A) at the screw.
Disconnect plug (B).
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.
<- Go to Section TOC
Section 30 page 32
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
[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] -
<- Go to Section TOC
Section 30 page 33
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Take out attaching screws (A), (B) and (E).
Take off retainer (C) and pull out dust screen (D).
<- Go to Section TOC
Section 30 page 34
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Take off the two frame parts and use a cable binder to secure condenser (A) to the side of
the engine.
<- Go to Section TOC
Section 30 page 35
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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.
<- Go to Section TOC
Section 30 page 36
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
→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).
Item
Measurement
Specification
Securing the drive to the pulley
Torque
50 N˙m
37 lb-ft
Item
Measurement
Specification
Securing the drive to the fan
Torque
50 N˙m
37 lb-ft
<- Go to Section TOC
Section 30 page 37
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Remove and Install the Intercooler
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
<- Go to Section TOC
Hose clamp
Air intake hose
Intercooler
Hose clamp
Air intake hose
Flanged screw
Console
Gasket
Retainer
Cap screw, 45—55 N˙m (33—41 lb-ft)
Flanged screw, 13—17 N˙m (10—12 lb-ft)
Ground strap
Flange nut
Section 30 page 38
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
N
Group 20: Cooling System
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).
For installation, follow removal procedure in reverse order.
When installing, tighten to the appropriate torque (see below):
Item
Measurement
Specification
Ground strap to intercooler
Torque
13—17 N˙m
10—12 lb-ft
<- Go to Section TOC
Section 30 page 39
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Remove and Install the Intercooler (Stage II engines
to 97/68/EC)
<- Go to Section TOC
Section 30 page 40
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
LEGEND:
A
B
C
D
E
F
G
H
I
Group 20: Cooling System
Hose clamp
Air-intake hose
Cap screw (3 used)
Bushing
Intercooler
Insulating pad
Seal
Contact plate
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).
For installation, follow removal procedure in reverse order.
When installing, tighten to the appropriate torque (see below):
Item
Measurement
Specification
Intercooler to engine block attaching screw
Torque
16 - 20 N˙m
11.5 - 14.5 lb-ft
Removing and Installing the Expansion Tank
<- Go to Section TOC
Section 30 page 41
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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.
<- Go to Section TOC
Section 30 page 42
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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.
<- Go to Section TOC
Section 30 page 43
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
On tractors from serial no. 425329
Removal:
LEGEND:
A
B
C
Hose (inlet from radiator)
Hose clamp
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
<- Go to Section TOC
Section 30 page 44
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
following specification.
Item
Measurement
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” .
<- Go to Section TOC
Section 30 page 45
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Filling the Cooling System with Coolant
On tractors up to serial no. 425328
LEGEND:
A
B
C
D
<- Go to Section TOC
Drain plug
Connect/disconnect control
Filler cap
Relief valve cap
Section 30 page 46
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
IMPORTANT:
Radiator repairs should be carried out only by experienced mechanics or in
specialist workshops.
[1] - Tighten coolant drain plug (A) to the torque value quoted below, and remove filler cap
(C) from the expansion tank.
Item
Measurement
Specification
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
within the radiator.
[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.
[8] - Shut down the engine and add coolant up to the "max." mark.
[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
<- Go to Section TOC
Section 30 page 47
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
LEGEND:
A
B
C
Group 20: Cooling System
Drain plug
Filler cap
Connect/disconnect control
IMPORTANT:
Radiator repairs should be carried out only by experienced mechanics or in
specialist workshops.
<- Go to Section TOC
Section 30 page 48
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
[1] - Tighten coolant drain plug (A) to the torque value quoted below, and remove filler cap
(b) from the expansion tank.
Item
Measurement
Specification
Coolant drain plug
Torque
4—5 N˙m
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.
[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.
[8] - Shut down the engine and add coolant up to the "max." mark.
[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.
<- Go to Section TOC
Section 30 page 49
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Relieve the Tension on the Drive Belt
LEGEND:
A
B
C
Bore (cam)
Bore (base plate)
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.
<- Go to Section TOC
Section 30 page 50
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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.
<- Go to Section TOC
Section 30 page 51
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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
B
C
Corrugated-head screws
Drive belt
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.
<- Go to Section TOC
Section 30 page 52
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Item
Measurement
Specification
Attachment to fan
Torque
22 – 28 N˙m
16 – 21 lb-ft
LEGEND:
A
B
C
D
E
F
G
H
Crankshaft
Coolant pump
Tensioner roll
Fan pulley
Alternator
Deflector roll
Compressor (air conditioning system)
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
<- Go to Section TOC
Section 30 page 53
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Slacken drive belt and remove the three cap screws (A).
When installing, tighten the three cap screws (A) to the following torque:
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 30 page 54
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
Repairing the Fan Console
LEGEND:
A
B
C
D
Hub
Snap ring
Bearing
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).
<- Go to Section TOC
Section 30 page 55
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 20: Cooling System
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
<- Go to Section TOC
Section 30 page 56
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 25: Cold-Weather Starting Aids
Coolant Pump)
LEGEND:
A
B
C
Cap screws
Fan console
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.
For installation, follow removal procedure in reverse order.
When installing, tighten to the appropriate torque (see below):
Item
Measurement Specification
Cap screws at fan console with integrated coolant pump
Torque
70 N˙m
52 lb-ft
<- Go to Section TOC
Section 30 page 57
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 25: Cold-Weather Starting Aids
Group 25 - Cold-Weather Starting Aids
Fuel Preheater
LEGEND:
A
B
C
D
<- Go to Section TOC
Cap
Heating element
Seal
Fuel filter head
Section 30 page 58
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 25: Cold-Weather Starting Aids
With Bosch VP44 injection pump and Denso/Stanadyne
LEGEND:
A
B
Heater coil
O-rings
Electrical Starting Aid
<- Go to Section TOC
Section 30 page 59
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
LEGEND:
A
B
C
D
E
F
Group 25: Cold-Weather Starting Aids
Air intake pipe
Cap screw
Seal
Heating element
Seal
Hex. nut
Coolant Heater
<- Go to Section TOC
Section 30 page 60
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
LEGEND:
A
B
C
D
E
F
G
H
<- Go to Section TOC
Group 30: Exhaust System
Heating element
Seal ring
O-ring
Adapter
Collar nut
Connecting cable
Cable binder
Clamp
Section 30 page 61
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 30: Exhaust System
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
Item
Measurement
Specification
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
Item
Measurement
Specification
Pipe clamp (items 3 and 7)
Torque
48—60 N˙m
32—44 lb-ft
<- Go to Section TOC
Section 30 page 62
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 30: Exhaust System
Installing the Muffler
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Muffler
Retaining strap
M8x70 hex. socket screw
Bracket
Washer
Cap screw
Bracket
Hex. nut
Heat shield
Washer
Cap screw
Cap screw
Clamp
M8x35 hex. socket screw
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.
<- Go to Section TOC
Section 30 page 63
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 30: Exhaust System
Item
Measurement
Specification
Clamp, muffler
Torque
10 to 14 N˙m
8 to 10 lb-ft
Stage II engines to 97/68/EC
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Muffler
Retaining strap
M8x70 hex. socket screw
Bracket
Washer
Cap screw
Bracket
Washer
Hex. nut
Cap screw
Heat shield
Cap screw
Clamp
M8x35 hex. socket screw
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
<- Go to Section TOC
Section 30 page 64
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 30: Exhaust System
value given in the table.
Item
Measurement
Specification
Clamp, muffler
Torque
10 to 14 N˙m
8 to 10 lb-ft
<- Go to Section TOC
Section 30 page 65
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
Group 30: Exhaust System
Exhaust Pipe or Intermediate Exhaust Pipe
LEGEND:
1
2
3
4
5
<- Go to Section TOC
Exhaust pipe
Clamp
Clamp
Hex. nut (2 used)
Washer (2 used)
Section 30 page 66
TM4756-REPAIR MANUAL
Section 30 - FUEL, AIR INTAKE, COOLING AND
EXHAUST SYSTEMS
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Group 30: Exhaust System
Sheet-metal nut (8 used)
Cap screw (2 used)
Hex. nut (4 used)
Washer (2 used)
Washer (2 used)
Washer (4 used)
Rubber bearing (2 used)
Console
Bushing (2 used)
Cap screw (2 used)
Console
Washer (3 used)
Hex. socket screw (3 used)
Pan-head screw (3 used)
Pipe clamp (2 used)
Flexible pipe
Heat shield (assembly)
Spring
Hex. nut
Pipe clamp (2 used)
Intermediate exhaust pipe
Heat shield
Tighten pipe clamps (20) and (25) as specified.
Pipe clamp (spherical)
.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 30 page 67
TM4756-REPAIR MANUAL
ELECTRICAL SYSTEM
(g) by Belgreen
Exhaust Pipe or Intermediate Exhaust Pipe
—Upright
LEGEND:
1
2
3
4
5
6
7
8
9
Exhaust pipe
Clamp
Clamp
Intermediate exhaust pipe
Flanged screw
Console
Clamp
Pan-head screw
Protective panel
Items 3 and 7 (pipe clamps) must be tightened to the torque values given in the table below.
Item
Measurement
Specification
Pipe clamps (3) and (7)
Torque
48—60 N˙m
32—44 lb-ft
<- Go to Section TOC
Section 30 page 68
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
....................................................................................................................................... 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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
Disconnecting Electrical Circuits ........................................................................................ 208
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
Disconnecting Electrical Circuits ........................................................................................ 215
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Monitoring Systems - Recondition (Summary of References) ............................................ 396
General Information ........................................................................................................... 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
General Information ........................................................................................................... 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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Group 05 - Electrical Connectors
Connectors - Summary of References
”Special tools”
”General information”
”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”
<- Go to Section TOC
Section 40 page 1
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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
Repairing wiring harnesses
Extraction tool
JDG364
<- Go to Section TOC
Section 40 page 2
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Removing electrical connectors
Extraction tool
JDG776
Removing electrical connectors
Extraction tool
JDG777
Removing electrical connectors
Crimping pliers
FKM10427
Installing a terminal
Crimping pliers
<- Go to Section TOC
Section 40 page 3
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
FKM10469
Installing a terminal
Wiring harness repair kit
JDG359
Repairing DEUTSCH connectors
Terminal puller
JDG1369
JDG1369
For pulling terminals off the injection pump connector.
AMP crimping pliers
JDG708
<- Go to Section TOC
Section 40 page 4
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
JDG708
Installing a terminal
<- Go to Section TOC
Section 40 page 5
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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
<- Go to Section TOC
Section 40 page 6
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
<- Go to Section TOC
Section 40 page 7
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
→NOTE:
Special pliersKLM10019-1are included in electrical repair tool kitFKM10461
Electrical repair tool kit
FKM10461
Repairing wiring harnesses
.
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
<- Go to Section TOC
Section 40 page 8
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
To open the pliers, pull the release lever.
<- Go to Section TOC
Section 40 page 9
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
WEATHER PACK Connectors
→NOTE:
WEATHER PACK ™ connector
→NOTE:
1- to 6-pin connectors are used on the tractor.
LEGEND:
A
B
Male Terminal Body
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.
<- Go to Section TOC
Section 40 page 10
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical 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.
<- Go to Section TOC
Section 40 page 11
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 12
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
METRI PACK Connectors
with Terminal Lock at the Rear
→NOTE:
METRI PACK
[ METRI PACK is a trademark of Packard Electric ]
connector
→NOTE:
1- to 10-pin connectors are used on the tractor.
LEGEND:
A
B
<- Go to Section TOC
Male Terminal Body
Female Terminal Body
Section 40 page 13
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[1] - Remove terminal
→NOTE:
The terminals and wire seals are held in place on the terminal body by a
locking cap. This must be removed before removing the terminal.
Extraction toolJDG776(A) for METRI PACK connectors, Series 280 and 630.
[2] - Remove terminal
→NOTE:
The terminals and wire seals are held in place on the terminal body by a
locking cap. This must be removed before removing the terminal.
Extraction toolJDG777(A) for METRI PACK connectors, Series 150.
<- Go to Section TOC
Section 40 page 14
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install wire seal
→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)
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.
<- Go to Section TOC
Section 40 page 15
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1.
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
[5] - Install terminal
Before installing a male or female terminal, bend locking tang (A) back to its original position.
From the back, insert the male terminal into the terminal body.
Put on the locking cap.
<- Go to Section TOC
Section 40 page 16
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
METRI PACK Connectors
with Terminal Lock at the Front
→NOTE:
METRI PACK
[ METRI PACK is a trademark of Packard Electric ]
connector
→NOTE:
2- to 4-pin connectors are used on the tractor.
[1] - Remove terminal lock
Use a small screwdriver to disengage terminal lock (A) at the points indicated, and pull it out.
[2] - Remove terminal
JDG777extraction tool (A) for METRI PACK connectors.
<- Go to Section TOC
Section 40 page 17
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install wire seal
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.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 18
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
Put on the locking cap.
<- Go to Section TOC
Section 40 page 19
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
METRI PACK Connectors
→NOTE:
METRI PACK
[ METRI PACK is a trademark of Packard Electric ]
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.
Strip insulation from wire to expose 4 mm (0.16 in.) length of wire.
<- Go to Section TOC
Section 40 page 20
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Replace female terminal
Place the female terminal in the matching recess in crimping pliersKLM10019-1.
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
Place the stripped portion of the wire in the recess in the female terminal, and squeeze the
pliers until they engage.
To open the pliers, pull the release lever.
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
<- Go to Section TOC
Section 40 page 21
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[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).
[2] - Remove terminal lock
Use a small screwdriver (E) to disengage terminal lock (D), then push it out and take it off.
[3] - Extract female terminal
Using a pointed tool (F), depress the locking tang and pull the female terminal out of the
body.
<- Go to Section TOC
Section 40 page 22
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[4] - Install wire seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[5] - Replace terminal
Place male or female terminal in matching recess of crimping pliersJDG1727(JDG783).
→NOTE:
Special pliersJDG1727are included in harness repair tool kitJDG1744.
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.
<- Go to Section TOC
Section 40 page 23
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the female or male terminal into the terminal body.
Put the terminal lock back on.
<- Go to Section TOC
Section 40 page 24
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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
Removing electrical connectors
to press in the locking tang, and pull the female terminal out from the rear.
<- Go to Section TOC
Section 40 page 25
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Installing a wire seal
Slip the correct size seal onto the wire.
IMPORTANT:
The seal must fit snugly against the wire 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. Align seal with edge of
insulation.
<- Go to Section TOC
Section 40 page 26
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[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.
Wiring harness repair kit
FKM10461
Repairing wiring harnesses
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.
To open the pliers, pull the release lever.
Before installing a female terminal, bend the locking tang back to its original position.
From the back, insert the female terminal into the terminal body.
Insert the terminal lock.
<- Go to Section TOC
Section 40 page 27
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Connectors for Electronic Control Units
45-pin or 68-pin connectors
[1] - Remove cover
Remove the cable binder.
Press up locking tang and slide cover (A) to the left.
[2] - Extract female terminal
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
<- Go to Section TOC
Section 40 page 28
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install wire seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 29
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
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.
Strip insulation from wire to expose 4 mm (0.16 in.) length of wire.
<- Go to Section TOC
Section 40 page 30
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Replace Female Terminal
Place female terminals in the matching recess in crimping pliersKLM10019-1.
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
Place the stripped portion of the wire in the recess in the female terminal, and squeeze the
pliers until they engage.
To open the pliers, pull the release lever.
Before installing a female terminal, bend the locking tang back to its original position.
Pull the female terminal back into the terminal body.
32-pin or 48-pin connectors
[1] - Remove cover
Press the two locking tangs (A) outward and slide cover (B) away to the front.
<- Go to Section TOC
Section 40 page 31
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[2] - Remove terminal lock
Pull terminal lock (A) out of terminal body.
[3] - Extract Female Terminal
LEGEND:
A
B
Chamber
Openings
Use extraction toolJDG1725to press in the locking tangs in openings (B) and extract the
female terminal from the rear of the chamber.
→NOTE:
Special pliersJDG1725are included in harness repair tool kitJDG1744.
<- Go to Section TOC
Section 40 page 32
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[4] - Replace terminal
Place male or female terminal in matching recess of the crimping pliersJDG1727.
→NOTE:
Special pliersJDG1727are included in harness repair tool kitJDG1744.
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.
From the back, insert the female or male terminal into the terminal body.
Insert the terminal lock.
Slide on the cover and install the cable binder.
<- Go to Section TOC
Section 40 page 33
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Connectors
10-, 16- and 24-pin connectors
[1] - Remove terminal lock
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.
<- Go to Section TOC
Section 40 page 34
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install Wire Seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 35
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
Insert the terminal lock.
42-pin connector
[1] - Remove terminal lock
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.
<- Go to Section TOC
Section 40 page 36
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install Wire Seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 37
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
Insert the terminal lock.
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.
<- Go to Section TOC
Section 40 page 38
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install wire seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1(JDG783).
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 39
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
Insert the terminal lock.
<- Go to Section TOC
Section 40 page 40
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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
<- Go to Section TOC
Section 40 page 41
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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
Strip insulation from wire to expose 4 mm (0.16 in.) length of wire.
<- Go to Section TOC
Section 40 page 42
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Place female terminals in the matching recess in crimping pliers “FKM10427”
Crimping pliers
FKM10427
Installing a terminal
.
Insert the stripped portion of the wire into the female terminal.
Squeeze the pliers together.
Before installing a female terminal, bend the locking tang back to its original position.
From the back, insert the female terminal into the terminal body.
Insert the terminal lock.
Put on the cap and install the cable binder.
<- Go to Section TOC
Section 40 page 43
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
[2] - Extract female terminal
Use extraction toolKLM10019-4(A) to extract the female terminal.
→NOTE:
Extraction toolKLM10019-4is included in harness repair tool kitFKM10461.
<- Go to Section TOC
Section 40 page 44
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install wire seal
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 4 mm (0.16 in.) length of wire. Move the seal all the way
to the edge of the insulation.
[4] - Replace terminal
Place male or female terminal in matching recess of crimping pliersKLM10019-1.
→NOTE:
Special pliersKLM10019-1are included in harness repair tool kitFKM10461.
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.
<- Go to Section TOC
Section 40 page 45
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
From the back, insert the male terminal into the terminal body.
<- Go to Section TOC
Section 40 page 46
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
DEUTSCH Connectors
→NOTE:
DEUTSCH ™ connectors
[1] - Extract male or female terminals
Position extraction toolJDG362against wire as shown in the illustration.
<- Go to Section TOC
Section 40 page 47
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
→NOTE:
Extraction toolJDG362is included in wiring harness repair tool kitJDG359
Wiring harness repair kit
JDG359
Repairing DEUTSCH connectors
.
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.
<- Go to Section TOC
Section 40 page 48
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[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
Wiring harness repair kit
JDG359
Repairing DEUTSCH connectors
.
Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
IMPORTANT:
Select proper size of male or female terminal.
<- Go to Section TOC
Section 40 page 49
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
<- Go to Section TOC
Section 40 page 50
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[3] - Install terminal
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.
<- Go to Section TOC
Section 40 page 51
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
<- Go to Section TOC
Section 40 page 52
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[2] - Change a terminal
Strip insulation from wire to expose 6 mm (0.24 in.) length of wire.
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
Repairing wiring harnesses
.
Place the stripped portion of the wire in the recess in the terminal, and squeeze the pliers
until they engage.
To open the pliers, pull the release lever.
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.
<- Go to Section TOC
Section 40 page 53
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
Connector for Bosch VP44 Injection Pump
How to use AMP crimping pliers
LEGEND:
A
B
C
D
E
F
G
H
Locator assembly
Locator
Wire
Crimping slot
Crimping slot
Terminal
Insulation barrel
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.
<- Go to Section TOC
Section 40 page 54
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[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.
<- Go to Section TOC
Section 40 page 55
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[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.
<- Go to Section TOC
Section 40 page 56
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
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.
[2] - Extracting a female terminal
Use a small screwdriver to press in the locking tang and extract the female terminal from the
rear.
Before installing a female terminal, bend the locking tang back to its original position.
Extracting a female terminal from relay boxes (K02, K08 and K09)
<- Go to Section TOC
Section 40 page 57
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[1] - Removing a terminal lock
Pull terminal lock (A) out at the front.
[2] - Extracting a female terminal
Use a small screwdriver to press in the locking tang and extract the female terminal from the
rear.
Before installing a female terminal, bend the locking tang back to its original position.
Extracting female terminals from fuse boxes (F03, F04, F05, F06 and
F07)
<- Go to Section TOC
Section 40 page 58
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 05: Electrical Connectors
[1] - Removing a terminal lock
Pull terminal lock (A) out from underneath.
[2] - Extracting a female terminal
Use a small screwdriver to press in the locking tang and extract the female terminal from the
rear.
Before installing a female terminal, bend the locking tang back to its original position.
Replacing a female terminal
Strip insulation from wire to expose 6 mm (0.24 in.) length of wire.
<- Go to Section TOC
Section 40 page 59
TM4756-REPAIR MANUAL
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
Wiring harness repair kit
FKM10461
Repairing wiring harnesses
.
Place the stripped portion of the wire in the recess in the terminal, and squeeze the pliers
until they engage.
To open the pliers, pull the release lever.
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.
<- Go to Section TOC
Section 40 page 60
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
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 W31 — 7-terminal power outlet socket” .
<- Go to Section TOC
Section 40 page 61
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
”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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
<- Go to Section TOC
Section 40 page 62
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Wiring Harnesses for Tractors with PowrQuad Plus
or AutoQuad Transmissions and Stage II 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 II engine to
97/68/EC (Level 11 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 II engine to 97/68/EC”.
”Removing and installing harness W09 — Cowl, for Stage II 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 II engines to 97/68/EC (Level 11
ECU)”.
”Removing and installing harness W16 — SIC with Stage II 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 II 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 W31 — 7-terminal power outlet socket” .
”Removing and installing harness W32 — Stepper motors for Stage II engine to
97/68/EC”.
<- Go to Section TOC
Section 40 page 63
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
”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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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)”.
”Removing and installing harness W39 — GreenStar with tractor equipment interface
controller (cab)”.
”Removing and installing harness W40 — GreenStar (cab roof)”.
”Removing and installing harness W41 — JDLink”.
”Removing and installing harness W42 — Battery cut-off switch, version 1”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
<- Go to Section TOC
Section 40 page 64
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Wiring Harnesses for Tractors with PowrQuad Plus
or AutoQuad Plus Transmission from Serial No.
398656 — Recondition (Summary of References)
”Disconnecting electrical circuits” .
”Ground point locations” .
”Removing and installing harness W01 — Power supply” .
”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 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 from serial no. 398656”.
”Removing and installing harness W09 — Cowl from serial no. 398656”.
”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 — Engine control unit (Level 11 ECU) from serial
no. 398656”.
”Removing and installing harness W16 — SIC with Stage II 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 II 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 from serial no.
398656”.
”Removing and installing harness W26 — ClimaTrak (cab)”.
”Removing and installing harness W28 — Front end of transmission” .
”Removing and installing harness W30 — Rear end of transmission”.
”Removing and installing harness W31 — 7-terminal power outlet socket” .
<- Go to Section TOC
Section 40 page 65
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
”Removing and installing harness W32 — Stepper motors for Stage II 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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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)”.
”Removing and installing harness W39 — GreenStar with tractor equipment interface
controller (cab)”.
”Removing and installing harness W40 — GreenStar (cab roof)”.
”Removing and installing harness W41 — JDLink”.
”Removing and installing harness W42 — Battery cut-off switch, version 1”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
”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)”.
<- Go to Section TOC
Section 40 page 66
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Wiring Harnesses for Tractors with AutoPowr/IVT
Transmission 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) (AutoPowr/IVT transmission)”.
”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, 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
(AutoPowr/IVT transmission)” .
”Removing and installing harness W10 — Shift console” .
”Removing and installing harness W11 — Speed control lever and hand throttle
(AutoPowr/IVT transmission)” .
”Removing and installing harness W12 — Command Arm (AutoPowr/IVT transmission)” .
”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 (AutoPowr/IVT
<- Go to Section TOC
Section 40 page 67
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
transmission)” .
”Removing and installing harness W29 — Valve block (AutoPowr/IVT transmission)” .
”Removing and installing harness W30 — Rear end of transmission”.
”Removing and installing harness W31 — 7-terminal power outlet socket” .
”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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
<- Go to Section TOC
Section 40 page 68
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Wiring Harnesses for Tractors with AutoPowr/IVT
Transmission and Stage II 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 II engine to
97/68/EC (Level 11 ECU)”.
”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)”.
”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, 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
(AutoPowr/IVT transmission)”.
”Removing and installing harness W10 — Shift console” .
”Removing and installing harness W11 — Speed control lever and hand throttle
(AutoPowr/IVT transmission)” .
”Removing and installing harness W12 — Command Arm (AutoPowr/IVT transmission)” .
”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 II engines to 97/68/EC (Level 11
ECU)”.
”Removing and installing harness W16 — SIC with Stage II 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 II 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 (AutoPowr/IVT
<- Go to Section TOC
Section 40 page 69
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
transmission)” .
”Removing and installing harness W29 — Valve block (AutoPowr/IVT transmission)” .
”Removing and installing harness W30 — Rear end of transmission”.
”Removing and installing harness W31 — 7-terminal power outlet socket” .
”Removing and installing harness W32 — Stepper motors for Stage II 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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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)”.
”Removing and installing harness W39 — GreenStar with tractor equipment interface
controller (cab)”.
”Removing and installing harness W40 — GreenStar (cab roof)”.
”Removing and installing harness W41 — JDLink”.
”Removing and installing harness W42 — Battery cut-off switch, version 1”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
<- Go to Section TOC
Section 40 page 70
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Wiring Harnesses for Tractors with AutoPowr/IVT
transmission from Serial No. 398656 — Recondition
(Summary of References)
”Disconnecting electrical circuits” .
”Ground point locations” .
”Removing and installing harness W01 — Power supply” .
”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 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, with Stage I engine to 97/68/EC
(AutoPowr/IVT transmission)”.
”Removing and installing harness W09 — Cowl (AutoPowr/IVT transmission) from serial
no. 398656”.
”Removing and installing harness W10 — Shift console” .
”Removing and installing harness W11 — Speed control lever and hand throttle
(AutoPowr/IVT transmission)” .
”Removing and installing harness W12 — Command Arm (AutoPowr/IVT transmission)” .
”Removing and installing harness W13 — Clutch sending unit” .
”Removing and installing harness W14 — 3-terminal power outlet socket” .
”Removing and installing harness W15 — Engine control unit (Level 11 ECU) from serial
no. 398656”.
”Removing and installing harness W16 — SIC with Stage II 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 II 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 from serial no.
398656”.
<- Go to Section TOC
Section 40 page 71
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
”Removing and installing harness W26 — ClimaTrak (cab)”.
”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 W30 — Rear end of transmission”.
”Removing and installing harness W31 — 7-terminal power outlet socket” .
”Removing and installing harness W32 — Stepper motors for Stage II 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)”.
”Removing and installing harness W35 — Access step lighting and battery cut-off switch
(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)”.
”Removing and installing harness W39 — GreenStar with tractor equipment interface
controller (cab)”.
”Removing and installing harness W40 — GreenStar (cab roof)”.
”Removing and installing harness W41 — JDLink”.
”Removing and installing harness W42 — Battery cut-off switch, version 1”.
”Removing and installing harness W42 — Battery cut-off switch, version 2”.
”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)”.
Disconnecting electrical circuits
<- Go to Section TOC
Section 40 page 72
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Before working on the electrical system, always disconnect battery ground strap (-).
<- Go to Section TOC
Section 40 page 73
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Ground Point Locations
<- Go to Section TOC
Section 40 page 74
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
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
<- Go to Section TOC
Section 40 page 75
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
G01
F13
F14
X473
<- Go to Section TOC
Group 10: Wiring Harnesses
Terminal with ring, for positive terminal of battery
Main fuse
Main fuse
Connecting point — power supply harness (W08)
Section 40 page 76
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W02 — Engine
Wiring Harness for Stage I Engine to 97/68/EC (ECU
Level 4)
LEGEND:
G02
K40
M01
<- Go to Section TOC
Alternator
Injection pump relay
Starting motor
Section 40 page 77
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X02
X66/1
X66/2
X70
X79
X130
X205
X261
X262
X305
X351
X356
X357
X358
X359
X364
X411
X450
X451
X547
XGND9
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — front PTO harness (W07)
Horn plug
Horn plug
Plug for sending unit (air cleaner restriction warning light)
Plug for fuel preheater element
Plug for compressor clutch (air conditioning)
Connecting point — wiring harness W06 (FWD axle with TLS)
Plug for sending unit (coolant temperature)
Plug for sending unit (coolant temperature gauge)
Plug for voltage-to-ground on radiator
Plug for injection pump
Plug for sending unit (crankshaft speed)
Plug for fuel transfer pump
Plug for sending unit (engine oil pressure)
Plug for sending unit (camshaft speed)
Plug for sending unit (fuel pressure)
Connecting point — headlight harness (W04)
Connecting point — engine harness (W08)
Connecting point — engine harness (W15)
Connecting point — starting aid harness (W03)
Ground point
Section 40 page 78
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W02 — Engine
Wiring Harness for Stage II Engine to 97/68/EC (ECU
Level 11)
LEGEND:
G02
M01
X02
<- Go to Section TOC
Alternator
Starting motor
Connecting point — front PTO harness (W07)
Section 40 page 79
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X66/1
X66/2
X70
X79
X130
X205
X261
X262
X301
X305
X356
X358
X359
X411
X450
X451
X547
X550
X566
X567
X568
X569
X575
X610
X625
XGND9
<- Go to Section TOC
Group 10: Wiring Harnesses
Horn plug
Horn plug
Plug for sending unit (air cleaner restriction warning light)
Plug for fuel preheater element
Plug for compressor clutch (air conditioning)
Connecting point — wiring harness W06 (FWD axle with TLS)
Plug for sending unit (coolant temperature)
Plug for sending unit (coolant temperature gauge)
Plug for sending unit (intake air temperature)
Plug for voltage-to-ground on radiator
Plug for sending unit (crankshaft speed)
Plug for sending unit (engine oil pressure)
Plug for sending unit (camshaft speed)
Connecting point — headlight harness (W04)
Connecting point — engine harness (W08)
Connecting point — engine harness (W15)
Connecting point — starting aid harness (W03)
Plug for sending unit (fuel temperature)
Plug for fuel valve
Plug for water separator sender in fuel filter
Plug for injection valves
Plug for fan valve
Plug for fuel transfer pump
Ground connection for screening of wires
Plug for sending unit (injection pressure)
Ground point
Section 40 page 80
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W02 — Engine
(Level 11 ECU) from Serial No. 398656
LEGEND:
G02
M01
X02
X66/1
X66/2
<- Go to Section TOC
Alternator
Starting motor
4-pin plug — Connection point for front PTO wiring harness (W07)
1-pin plug, horn
1-pin plug, horn
Section 40 page 81
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X70
X79
X130
X205
X261
X301
X305
X356
X358
X359
X411
X450
X451
X547
X550
X566
X567
X568
X575
X604
X610
X625
XGND9
Group 10: Wiring Harnesses
2-pin plug, sender for restricted air cleaner warning light
2-pin plug, fuel preheater element
1-pin plug for air-conditioner compressor clutch
8-pin plug — Connection point of harness for front-wheel drive axle
with TLS (W06)
2-pin plug, coolant temperature sender
2-pin plug, manifold air temperature sender
1-pin plug, voltage-to-ground on radiator
2-pin plug, crankshaft speed sender
3-pin plug for engine oil pressure sender
2-pin plug for camshaft speed sender
8-pin plug — Connection point for headlight wiring harness (W04)
42-pin plug — Connection point for engine wiring harness (W08)
42-pin plug — Connection point for engine wiring harness (W08)
10-pin plug — Connection point for starting aid wiring harness (W03)
2-pin plug for fuel temperature sender
2-pin plug for fuel valve
2-pin plug for sender of water separator in fuel filter
12-pin plug for injection valves
2-pin plug for fuel transfer pump
2-pin plug for front ambient air temperature sensor (ClimaTrak)
Ground connection for screening of wires
3-pin plug for injection pressure sender
Ground point
Removing and Installing Harness W03 — Starting
Aid for Stage I and II engines to 97/68/EC (Level 4 or
11 ECUs)
<- Go to Section TOC
Section 40 page 82
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
D31
F09
F10
F11
G02
Group 10: Wiring Harnesses
Diode for electrical starting aid
Fuse for heater element (electrical starting aid)
Fuse for fuel injection pump (with Stage I engines to 97/68/EC only
(Level 4 ECU))
Fuse for electrical starting aid
Terminal with ring, for alternator
<- Go to Section TOC
Section 40 page 83
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K01
K36
R15
X547
Group 10: Wiring Harnesses
Starting motor relay
Relay for electrical starting aid
Terminal with ring, for heater element (electrical starting aid)
Connecting point — starting aid harness (W02)
Removing and Installing Harness W03 — Starting
Aid (Level 11 ECU) from Serial No. 398656
LEGEND:
F09
F11
G02
K01
K36
Glow plug fuse
Fuse for electrical starting aid
Terminal with ring, for alternator
Starting motor relay
Relay for electrical starting aid
<- Go to Section TOC
Section 40 page 84
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X547
X630
Group 10: Wiring Harnesses
10-pin plug — Connection point for starting aid wiring harness (W02)
1-pin plug — Connection point for glow plug wiring harness
<- Go to Section TOC
Section 40 page 85
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
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)
LEGEND:
D31
Diode for electrical starting aid
<- Go to Section TOC
Section 40 page 86
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F09
F10
F11
F22
G02
K01
K36
R15
X528
X547
Group 10: Wiring Harnesses
Fuse for heater element (electrical starting aid)
Fuse for fuel injection pump (with Stage I engines to 97/68/EC only
(Level 4 ECU))
Fuse for electrical starting aid
Fuse for LTC coolant pump
Terminal with ring, for alternator
Starting motor relay
Relay for electrical starting aid
Terminal with ring, for heater element (electrical starting aid)
Plug for LTC coolant pump
Connecting point — starting aid harness (W02)
Removing and Installing Harness W03 — Starting
Aid (Level 11 ECU) (AutoPowr/IVT transmission)
from Serial No. 398656
<- Go to Section TOC
Section 40 page 87
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
F09
F11
F22
G02
K01
K36
X528
X547
X630
Group 10: Wiring Harnesses
Glow plug fuse
Fuse for electrical starting aid
Fuse for LTC coolant pump
Terminal with ring, for alternator
Starting motor relay
Relay for electrical starting aid
3-pin plug for LTC coolant pump
10-pin plug — Connection point for starting aid wiring harness (W02)
1-pin plug — Connection point for glow plug wiring harness
Removing and Installing Harness W04 — Headlights
<- Go to Section TOC
Section 40 page 88
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W04 - Harness for headlights, with worklights on front corner
<- Go to Section TOC
Section 40 page 89
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W04 - Headlight wiring harness
LEGEND:
X67
X68
X69/1
X69/2
X411
Plug for r.h. headlight
Plug for l.h. headlight
Plug for front corner worklight, r.h.
Plug for front corner worklight, l.h.
Connecting point — Headlight harness (W02)
Removing and Installing Harness W06 — FrontWheel Drive Axle with TLS
LEGEND:
X205
X206
X207
X209
Connecting point — Wiring harness W02 (front-wheel drive axle with
TLS)
Plug for solenoid valve on front-wheel drive axle with TLS
Plug for solenoid valve on front-wheel drive axle with TLS
Plug for position sensor on front-wheel drive axle with TLS
Removing and Installing Harness W07 — Front PTO
<- Go to Section TOC
Section 40 page 90
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X02
X166
X167
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — front PTO harness (W02)
Plug for front PTO solenoid valve
Plug for sending unit (front PTO speed)
Section 40 page 91
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab, with
Stage I Engine to 97/68/EC
LEGEND:
X34
X35
X37
X40
X44
X50
X106
X107
X113/1
X113/2
<- Go to Section TOC
Plug for the remote-control switch of the rockshaft control, left
Plug for the remote-control switch of the rockshaft control, right
Plug for front loader
Connecting point — rear window wiper harness (W24)
Plug for rear window washer pump
Connecting point — harness for air-conditioning and fan (W26)
Plug for tail, brake and turn signal lights (right)
Plug for tail, brake and turn signal lights (left)
Plug for license plate or worklight on left fender
Plug for license plate or worklight on right fender
Section 40 page 92
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X122
X128
X132
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X245
X247
X248
X260
X285
X371
X400
X403
X404
X409
X409/1
X422
X423
X430
X440
X441
X450
X472/1
X472/2
X473
X483/1
X483/2
X485
X488
X489
X489/1
X500
X501
X503
X522
X540
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for differential lock switch
Plug for cigarette lighter
Signal socket
Connecting point — worklights on fender
Connecting point — license plate or worklight on right fender
Connecting point — license plate light
Connecting point — license plate or worklight on left fender
Plug for remote-control switch of rear PTO, left
Plug for seat switch
Plug for handbrake switch
Plug for cruise control potentiometer
Connecting point — harness for 3-terminal power outlet socket
(W14)
Plug for HMS switch
Plug for rear PTO preselector switch
Plug for front-wheel drive switch
Plug for monitor unit
Plug for lighting system monitor unit
Plug for worklight switch
Plug for windshield washer pump
Plug for accelerator pedal potentiometer
Connecting point — cab roof harness (W19)
Connecting point — cowl harness (W09)
Connecting point — cowl harness (W09)
Connecting point — ECU harness (W15)
Connecting point — ECU harness (W15)
Connecting point — shift console harness (W10) or Command Arm
harness (W12)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W16)
Connecting point — harness at rear end of transmission (W30)
Plug for record/save switch
Connecting point — transmission shift and hand throttle harness
(W11) or Command Arm harness (W12)
Connecting point — engine harness (W02)
Plug for switch that operates the worklights at the rear of the cab
roof
Plug for switch that operates the worklights at the front of the cab
roof
Connecting point — power supply harness (W01)
Plug for basic control unit (BCU)
Plug for basic control unit (BCU)
Plug for SFA control unit
Plug for operator′s seat
Plug for electronic PowrQuad controller (EPC)
Prewiring for electrical range shift
Connecting point — harness at front end of transmission (W28)
Connecting point — wiring harness of GreenStar port (W37)
Plug for park lock switch
Connecting point — service harness (W33)
Connecting point — wiring harness, GreenStar (cab) (W39)
Section 40 page 93
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X544
X545
X551
XGND 1
XGND 5
XGND43
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — wiring harness, access-step light and battery
cut-off switch (W35)
Plug for implement switch
Plug for creeper switch
Ground point
Ground point
Ground point for electronics
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 94
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab, with
Stage II Engine to 97/68/EC
LEGEND:
X14/1
X14/2
X34
X35
X37
X40
X44
X50
X106
X107
<- Go to Section TOC
Plug for position feedback unit
Plug for sensitivity potentiometer
Plug for the remote-control switch of the rockshaft control, left
Plug for the remote-control switch of the rockshaft control, right
Plug for front loader
Connecting point — rear window wiper harness (W24)
Plug for rear window washer pump
Connecting point — harness for air-conditioning and fan (W26)
Plug for tail, brake and turn signal lights (right)
Plug for tail, brake and turn signal lights (left)
Section 40 page 95
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X113/1
X113/2
X122
X125
X127
X128
X132
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X244
X245
X247
X248
X249
X260
X285
X371
X400
X403
X404
X409
X409/1
X409/2
X423
X430
X440
X450
X460/1
X471
X472/1
X472/2
X473
X483/1
X483/2
X485
X488
X489
X500
X503
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for license plate or worklight on left fender
Plug for license plate or worklight on right fender
Plug for differential lock switch
Plug for rear PTO switch
Plug for front PTO switch
Plug for cigarette lighter
Signal socket
Connecting point — worklights on fender
Connecting point — license plate or worklight on right fender
Connecting point — license plate light
Connecting point — license plate or worklight on left fender
Plug for remote-control switch of rear PTO, left
Plug for seat switch
Plug for handbrake switch
Plug for cruise control potentiometer
Connecting point — harness for 3-terminal power outlet socket
(W14)
Plug for HMS switch
Plug for rear PTO preselector switch
Plug for ECO/power mode switch
Plug for front-wheel drive switch
Plug for monitor unit
Plug for lighting system monitor unit
Plug for gear selector switch
Plug for worklight switch
Plug for windshield washer pump
Plug for accelerator pedal potentiometer
Connecting point — cab roof harness (W19)
Connecting point — cowl harness (W09)
Connecting point — cowl harness (W09)
Connecting point — ECU harness (W15)
Connecting point — ECU harness (W15)
Connecting point — ECU harness (W15)
Connecting point — E-SCV / E-ICV controller (SIC) harness
Connecting point — harness at rear end of transmission (W30)
Plug for record/save switch
Connecting point — engine harness (W02)
Plug for hand throttle potentiometer
Plug for program selector switch
Plug for switch that operates the worklights at the rear of the cab
roof
Plug for switch that operates the worklights at the front of the cab
roof
Connecting point — power supply harness (W01)
Plug for basic control unit (BCU)
Plug for basic control unit (BCU)
Plug for SFA control unit
Plug for operator′s seat
Plug for electronic PowrQuad controller (EPC)
Connecting point — harness at front end of transmission (W28)
Plug for park lock switch
Section 40 page 96
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X522
X544
X545
X571
XGND1
XGND5
XGND43
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — GreenStar harness (W39)
Connecting point — wiring harness, access-step light and battery
cut-off switch
Plug for implement switch
Service socket (CAN BUS)
Ground point
Ground point
Ground point for electronics
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 97
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab from
Serial No. 398656
LEGEND:
F03
F04
F05
F06
F07
K01
K02
K08
K09
K10
<- Go to Section TOC
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays and diodes (fuse and relay boxes)
Relays (fuse and relay boxes)
Section 40 page 98
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X14/1
X14/2
X34
X35
X37
X37/3
X40
X44
X106
X107
X113/1
X113/2
X122
X125
X127
X128
X132
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X245
X247
X248
X260
X285
X371
X400
X403
X404
X409
X409/1
X409/2
X423
X430
X440
X450
X460/1
X471
X472/1
<- Go to Section TOC
Group 10: Wiring Harnesses
8-pin plug for feedback unit
3-pin plug for sensitivity potentiometer
6-pin plug for remote-control switch of rockshaft control, right
6-pin plug for remote-control switch of rockshaft control, left
2-pin plug for front loader
2-pin plug for accessories
6-pin plug — Connection point for rear window wiper harness (W24)
2-pin plug for rear window washer pump
4-pin plug for right tail, brake and turn signal lights
4-pin plug for left tail, brake and turn signal lights
2-pin plug for license plate/fender worklight, left
2-pin plug for license plate/fender worklight, right
2-pin plug for differential lock switch
3-pin plug for rear PTO switch
3-pin plug for front PTO switch
2-pin plug for cigarette lighter
7-pin signal socket
1-pin plug — Connection point, fender-mounted worklights
1-pin plug — Connection point for license plate/fender worklight,
right
1-pin plug — Connection point for license plate light
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
l.h. side)
2-pin plug for seat switch
2-pin plug for handbrake switch
4-pin plug for cruise control potentiometer
3-pin plug — Connection point of harness for 3-terminal power
outlet socket (W14)
3-pin plug for HMS switch
3-pin plug for rear PTO preselector switch
3-pin plug for front wheel drive switch
26-pin plug for monitor unit
26-pin plug for lighting monitor unit
10-pin plug for worklight switch
2-pin plug for windshield washer pump
6-pin plug for accelerator pedal potentiometer
42-pin plug — Connection point for cab roof wiring harness (W19)
42-pin plug — Connection point for cowl wiring harness (W09)
42-pin plug — Connection point for cowl wiring harness (W09)
24-pin plug — ECU wiring harness connection point (W15)
1-pin plug — ECU wiring harness connection point (W15)
6-pin plug — ECU wiring harness connection point (W15)
16-pin plug — SIC harness connection point (W16)
42-pin plug — Connection point for harness at rear of transmission
(W30)
3-pin plug for record/save switch
42-pin plug — Connection point for engine wiring harness (W02)
3-pin plug for hand throttle potentiometer
4-pin plug for program selector switch
4-pin plug, switch for worklights on rear of cab roof
Section 40 page 99
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X472/2
X473
X483/1
X483/2
X485
X488
X500
X503
X522
X544
X545
X571
X577
X577/1
X623
X651
X653
X657
X660
XGND1
XGND4
XGND5
XGND6
XGND43
XGND44
XGND45
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
4-pin plug, switch for worklights on front of cab roof
2-pin plug — Connecting point for power supply wiring harness
(W01)
68-pin plug for BCU
45-pin plug for BCU
45-pin plug for the SFA controller
2-pin plug for operator′s seat
42-pin plug, connection point for harness at front end of
transmission (W28)
2-pin plug for park lock switch
10-pin plug — Connection point for GreenStar wiring harness (cab);
W39
2-pin plug — Connection point for harness of access-step light and
battery cut-off switch (W35)
2-pin plug for implement switch
9-pin service socket (CAN BUS)
7-pin plug — Connection point for fan and air-conditioning harness
(W26)
2-pin plug — Connection point for ClimaTrak harness (cab), W26
3-pin plug for the remote-control switch of the rear PTO (switch on
r.h. side)
4-pin plug for switches on shift lever
3-pin plug for Auto-mode potentiometer
68-pin plug for Electronic PowrQuad Controller (EPC)
3-pin plug for gear selector switch
Ground point
Collective ground point for XGND43
Ground point
Collective ground point for XGND43
Ground point for electronics
Collective ground point for XGND5
Collective ground point for XGND1
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 100
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab, with
Stage I engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
R18
X34
X35
X37
X40
X44
X50
X106
X107
<- Go to Section TOC
Resistor for brake sensors
Plug for the remote-control switch of the rockshaft control, left
Plug for the remote-control switch of the rockshaft control, right
Plug for front loader
Connecting point — rear window wiper harness (W24)
Plug for rear window washer pump
Connecting point — harness for air-conditioning and fan (W26)
Plug for tail, brake and turn signal lights (right)
Plug for tail, brake and turn signal lights (left)
Section 40 page 101
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X113/1
X113/2
X122
X128
X132
X133
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X245
X247
X248
X260
X285
X332
X367
X371
X382
X400
X403
X404
X409
X409/1
X422
X423
X430
X440
X450
X472/1
X472/2
X473
X481
X482
X483/1
X483/2
X484
X485
X488
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for license plate or worklight on left fender
Plug for license plate or worklight on right fender
Plug for differential lock switch
Plug for cigarette lighter
Signal socket
Plug for UIC controller
Connecting point — worklights on fender
Connecting point — license plate or worklight on right fender
Connecting point — license plate light
Connecting point — license plate or worklight on left fender
Plug for remote-control switch of rear PTO, left
Plug for seat switch
Plug for handbrake switch
Plug for cruise control potentiometer
Connecting point — harness for 3-terminal power outlet socket
(W14)
Plug for HMS switch
Plug for rear PTO preselector switch
Plug for front-wheel drive switch
Plug for monitor unit
Plug for lighting system monitor unit
Plug for worklight switch
Plug for windshield washer pump
Plug for transmission control unit (TCU)
Plug for AutoPowr selector
Plug for accelerator pedal potentiometer
Plug for park lock controller (PLC)
Connecting point — cab roof harness (W19)
Connecting point — cowl harness (W09)
Connecting point — cowl harness (W09)
Connecting point — ECU harness (W15)
Connecting point — ECU harness (W15)
Connecting point — shift console harness (W10) or Command Arm
harness (W12)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W16)
Connecting point — harness at rear end of transmission (W30)
Plug for record/save switch
Connecting point — engine harness (W02)
Plug for switch that operates the worklights at the rear of the cab
roof
Plug for switch that operates the worklights at the front of the cab
roof
Connecting point — power supply harness (W01)
Connecting point — harness at front end of transmission (W28)
Connecting point — valve block harness (W29)
Plug for basic control unit (BCU)
Plug for basic control unit (BCU)
Connecting point — speed control lever and hand throttle harness
(W11) or Command Arm harness (W12)
Plug for SFA control unit
Plug for operator′s seat
Section 40 page 102
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X522
X540
X544
X545
XGND1
XGND5
XGND43
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — service harness (W33)
Connecting point — wiring harness, GreenStar (cab) (W39)
Connecting point — wiring harness, access-step light and battery
cut-off switch (W35)
Plug for implement switch
Ground point
Ground point
Ground point for electronics
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 103
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab, with
Stage II engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
R18
X34
X35
X37
X40
X44
X50
X106
X107
<- Go to Section TOC
Resistor for brake sensors
Plug for the remote-control switch of the rockshaft control, left
Plug for the remote-control switch of the rockshaft control, right
Plug for front loader
Connecting point — rear window wiper harness (W24)
Plug for rear window washer pump
Connecting point — harness for air-conditioning and fan (W26)
Plug for tail, brake and turn signal lights (right)
Plug for tail, brake and turn signal lights (left)
Section 40 page 104
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X113/1
X113/2
X122
X128
X132
X133
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X245
X247
X248
X260
X285
X332
X367
X371
X382
X400
X403
X404
X409
X409/1
X422
X423
X430
X440
X450
X472/1
X472/2
X473
X481
X482
X483/1
X483/2
X484
X485
X488
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for license plate or worklight on left fender
Plug for license plate or worklight on right fender
Plug for differential lock switch
Plug for cigarette lighter
Signal socket
Plug for UIC controller
Connecting point — worklights on fender
Connecting point — license plate or worklight on right fender
Connecting point — license plate light
Connecting point — license plate or worklight on left fender
Plug for remote-control switch of rear PTO, left
Plug for seat switch
Plug for handbrake switch
Plug for cruise control potentiometer
Connecting point — harness for 3-terminal power outlet socket
(W14)
Plug for HMS switch
Plug for rear PTO preselector switch
Plug for front-wheel drive switch
Plug for monitor unit
Plug for lighting system monitor unit
Plug for worklight switch
Plug for windshield washer pump
Plug for transmission control unit (TCU)
Plug for AutoPowr selector
Plug for accelerator pedal potentiometer
Plug for park lock controller (PLC)
Connecting point — cab roof harness (W19)
Connecting point — cowl harness (W09)
Connecting point — cowl harness (W09)
Connecting point — ECU harness (W15)
Connecting point — ECU harness (W15)
Connecting point — shift console harness (W10) or Command Arm
harness (W12)
Connecting point — E-SCV / E-ICV controller (SIC) harness
Connecting point — harness at rear end of transmission (W30)
Plug for record/save switch
Connecting point — engine harness (W02)
Plug for switch that operates the worklights at the rear of the cab
roof
Plug for switch that operates the worklights at the front of the cab
roof
Connecting point — power supply harness (W01)
Connecting point — harness at front end of transmission (W28)
Connecting point — valve block harness (W29)
Plug for basic control unit (BCU)
Plug for basic control unit (BCU)
Connecting point — speed control lever and hand throttle harness
(W11) or Command Arm harness (W12)
Plug for SFA control unit
Plug for operator′s seat
Section 40 page 105
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X522
X544
X545
X571
XGND1
XGND5
XGND43
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — GreenStar harness (W39)
Connecting point — wiring harness, access-step light and battery
cut-off switch
Plug for implement switch
Service socket (CAN BUS)
Ground point
Ground point
Ground point for electronics
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 106
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W08 — Cab
(AutoPowr/IVT Transmission) from Serial No.
398656
LEGEND:
F03
F04
F05
F06
F07
K01
K02
K08
K09
<- Go to Section TOC
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Fuses (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays (fuse and relay boxes)
Relays and diodes (fuse and relay boxes)
Section 40 page 107
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K10
R18
X34
X35
X37
X37/3
X40
X44
X106
X107
X113/1
X113/2
X122
X128
X132
X133
X171/1F
X171/1M
X171/2F
X171/2M
X174
X230
X235
X236
X239
X242
X243
X245
X247
X248
X260
X285
X332
X367
X371
X382
X400
X403
X404
X409
X422
X423
X430
X440
X450
X472/1
<- Go to Section TOC
Group 10: Wiring Harnesses
Relays (fuse and relay boxes)
Resistor for brake sensors
6-pin plug for remote-control switch of rockshaft control, left
6-pin plug for remote-control switch of rockshaft control, right
2-pin plug for front loader
2-pin plug for accessories
6-pin plug — Connection point for rear window wiper harness (W24)
2-pin plug for rear window washer pump
4-pin plug for right tail, brake and turn signal lights
4-pin plug for left tail, brake and turn signal lights
2-pin plug for license plate/fender worklight, left
2-pin plug for license plate/fender worklight, right
2-pin plug for differential lock switch
2-pin plug for cigarette lighter
7-pin signal socket
68-pin plug for user interface controller (UIC)
1-pin plug — Connection point, fender-mounted worklights
1-pin plug — Connection point for license plate/fender worklight,
right
1-pin plug — Connection point for license plate light
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
l.h. side)
2-pin plug for seat switch
2-pin plug for handbrake switch
4-pin plug for cruise control potentiometer
3-pin plug — Connection point of harness for 3-terminal power
outlet socket (W14)
3-pin plug for HMS switch
3-pin plug for rear PTO preselector switch
3-pin plug for front wheel drive switch
26-pin plug for monitor unit
26-pin plug for lighting monitor unit
10-pin plug for worklight switch
2-pin plug for windshield washer pump
68-pin plug for TCU
3-pin plug for AutoPowr selector
6-pin plug for accelerator pedal potentiometer
45-pin plug for PLC
42-pin plug — Connection point for cab roof wiring harness (W19)
42-pin plug — Connection point for cowl wiring harness (W09)
42-pin plug — Connection point for cowl wiring harness (W09)
24-pin plug — ECU wiring harness connection point
24-pin plug — Connection point for shift console harness (W10) or
Command Arm harness (W12)
16-pin plug — SIC harness connection point (W16)
42-pin plug — Connection point for harness at rear of transmission
(W30)
3-pin plug for record/save switch
42-pin plug — Connection point for engine wiring harness (W02)
4-pin plug, switch for worklights on rear of cab roof
Section 40 page 108
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X472/2
X473
X481
X482
X483/1
X483/2
X484
X485
X488
X522
X544
X545
X571
X577
X577/1
X623
XGND1
XGND4
XGND5
XGND6
XGND43
XGND44
XGND45
XGND47
XGND48
XGND49
XGND50
XGND52
<- Go to Section TOC
Group 10: Wiring Harnesses
4-pin plug, switch for worklights on front of cab roof
2-pin plug — Connecting point for power supply wiring harness
(W01)
42-pin plug, connection point for harness at front end of
transmission (W28)
42-pin plug — Connection point for valve block wiring harness
(W29)
68-pin plug for BCU
45-pin plug for BCU
24-pin plug — connecting point for speed control lever and hand
throttle harness (W11) or for Command Arm harness (W12)
45-pin plug for the SFA controller
2-pin plug for operator′s seat
10-pin plug — Connection point for GreenStar wiring harness (cab);
W39
2-pin plug — Connection point for harness of access-step light and
battery cut-off switch (W35)
2-pin plug for implement switch
9-pin service socket (CAN BUS)
7-pin plug — Connection point for fan and air-conditioning harness
(W26)
2-pin plug — Connection point for ClimaTrak harness (W26)
3-pin plug for the remote-control switch of the rear PTO (switch on
r.h. side)
Ground point
Collective ground point for XGND43
Ground point
Collective ground point for XGND43
Ground point for electronics
Collective ground point for XGND5
Collective ground point for XGND1
Ground point
Ground point
Ground point
Ground point
Ground point
Section 40 page 109
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl, with
Stage I Engine to 97/68/EC
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
X238
Plug for main (key) switch
Plug for light switch
Connecting point — windshield wiper harness (W23)
Connecting point — windshield wiper harness (W18)
Plug for basic informator (BIF)
Plug for basic informator (BIF)
Plug for air-brake pressure gauge
Plug for air-brake pressure gauge
Plug for hazard warning light switch
Plug for accelerator pedal potentiometer
<- Go to Section TOC
Section 40 page 110
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X270
X322
X324
X403
X404
X487
X490/1
XGND40
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for CAN BUS terminator (29-bit)
Connecting point — clutch sender harness (W13)
Plug for brake switch
Connecting point — cowl harness (W08)
Connecting point — cowl harness (W08)
Connecting point — multi-function lever harness (W17)
Plug for electrical reverser control
Ground point
Section 40 page 111
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl, with
Stage II Engine to 97/68/EC
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
X238
Plug for main (key) switch
Plug for light switch
Connecting point — windshield wiper harness (W23)
Connecting point — windshield wiper harness (W18)
Plug for basic informator (BIF)
Plug for basic informator (BIF)
Plug for air-brake pressure gauge
Plug for air-brake pressure gauge
Plug for hazard warning light switch
Plug for accelerator pedal potentiometer
<- Go to Section TOC
Section 40 page 112
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X322
X324
X403
X404
X487
X490/1
X615
XGND40
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — clutch sender harness (W13)
Plug for brake switch
Connecting point — cowl harness (W08)
Connecting point — cowl harness (W08)
Connecting point — multi-function unit harness (W17)
Plug for electrical reverser control
Plug for CAN BUS terminator (29-bit)
Ground point
Section 40 page 113
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl from
Serial No. 398656
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
X238
<- Go to Section TOC
8-pin plug for main (key) switch
5-pin plug for light switch
1-pin plug — Connection point for windshield wiper harness (W23)
3-pin plug — Connection point for windshield wiper harness (W18)
26-pin plug for basic informator (BIF)
26-pin plug for basic informator (BIF)
1-pin plug for air-brake pressure gauge
1-pin plug for air-brake pressure gauge
3-pin plug for hazard warning light switch
3-pin plug for accelerator pedal potentiometer
Section 40 page 114
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X322
X324
X403
X404
X487
X615
X654
XGND40
<- Go to Section TOC
Group 10: Wiring Harnesses
6-pin plug — Connection point for clutch sending unit harness (W13)
8-pin plug for brake switches
42-pin plug — Connection point for cowl wiring harness (W08)
42-pin plug — Connection point for cowl wiring harness (W08)
10-pin plug — Connection point for multi-function unit harness
(W17)
6-pin plug for CAN BUS terminator (29-bit)
8-pin plug for electrical reverser control
Ground point
Section 40 page 115
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl, with
Stage I engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
Plug for main (key) switch
Plug for light switch
Connecting point — windshield wiper harness (W23)
Connecting point — windshield wiper harness (W18)
Plug for basic informator (BIF)
Plug for basic informator (BIF)
Plug for air-brake pressure gauge
Plug for air-brake pressure gauge
Plug for hazard warning light switch
<- Go to Section TOC
Section 40 page 116
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X270
X322
X323
X324
X343
X403
X404
X487
XGND40
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for CAN BUS terminator (29-bit)
Connecting point — clutch sender harness (W13)
Plug for reverse drive lever
Plug for brake switch
Plug for neutral start switch
Connecting point — cowl harness (W08)
Connecting point — cowl harness (W08)
Connecting point — multi-function unit harness (W17)
Ground point
Section 40 page 117
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl, with
Stage II engine to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
Plug for main (key) switch
Plug for light switch
Connecting point — windshield wiper harness (W23)
Connecting point — windshield wiper harness (W18)
Plug for basic informator (BIF)
Plug for basic informator (BIF)
Plug for air-brake pressure gauge
Plug for air-brake pressure gauge
Plug for hazard warning light switch
<- Go to Section TOC
Section 40 page 118
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X322
X323
X324
X343
X403
X404
X487
X615
XGND40
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — clutch sender harness (W13)
Plug for reverse drive lever
Plug for brake switch
Plug for neutral start switch
Connecting point — cowl harness (W08)
Connecting point — cowl harness (W08)
Connecting point — multi-function unit harness (W17)
Plug for CAN BUS terminator (29-bit)
Ground point
Section 40 page 119
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W09 — Cowl
(AutoPowr/IVT Transmission) from Serial No.
398656
LEGEND:
S01
S09
X20A
X20B
X25
X26
X120/1
X120/2
X126
<- Go to Section TOC
8-pin plug for main (key) switch
5-pin plug for light switch
1-pin plug — Connection point for windshield wiper harness (W23)
3-pin plug — Connection point for windshield wiper harness (W18)
26-pin plug for basic informator (BIF)
26-pin plug for basic informator (BIF)
1-pin plug for air-brake pressure gauge
1-pin plug for air-brake pressure gauge
3-pin plug for hazard warning light switch
Section 40 page 120
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X322
X323
X324
X343
X403
X404
X487
X615
XGND40
Group 10: Wiring Harnesses
6-pin plug — Connection point for clutch sending unit harness (W13)
10-pin plug for reverse drive lever
8-pin plug for brake switches
2-pin plug for neutral start switch
42-pin plug — Connection point for cowl wiring harness (W08)
42-pin plug — Connection point for cowl wiring harness (W08)
10-pin plug — Connection point for multi-function unit harness
(W17)
6-pin plug for CAN BUS terminator (29-bit)
Ground point
Removing and Installing Harness W10 — Shift
Console
LEGEND:
X14/1
X14/2
X125
X127
X422
X471
<- Go to Section TOC
Plug for position feedback unit
Plug for sensitivity potentiometer
Plug for rear PTO switch
Plug for front PTO switch
Connecting point — switch console harness (W08)
Plug for program selector switch
Section 40 page 121
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W11 —
Transmission Shift and Hand Throttle
LEGEND:
X244
X249
X441
X460/1
X477
Plug for ECO/power mode switch
Plug for gear selector switch
Connecting point — harness for transmission shift and hand throttle
(W08)
Plug for hand throttle potentiometer
Plug for range selector switch
Removing and Installing Harness W11 — Speed
Control Lever and Hand Throttle (AutoPowr/IVT
transmission)
<- Go to Section TOC
Section 40 page 122
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X334
X349
X370
X484
Group 10: Wiring Harnesses
Plug for speed control lever
Plug for potentiometer of speed control lever
Plug for hand throttle potentiometer
Connecting point — harness for speed control lever and hand throttle
(W08)
<- Go to Section TOC
Section 40 page 123
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W12 — Command
Arm (AutoPowr/IVT transmission)
LEGEND:
X125
X127
X334
X349
X370
X422
X428
X436
X437
X438
Plug for rear PTO switch
Plug for front PTO switch
Plug for speed control lever
Plug for potentiometer of speed control lever
Plug for hand throttle potentiometer
Connecting point — Command Arm harness (W08)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W16)
Plug for E-SCV 1 switch
Plug for E-SCV 2 switch
Plug for E-SCV 3 switch
<- Go to Section TOC
Section 40 page 124
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X439
X468
X469
X470
X471
X484
Group 10: Wiring Harnesses
Plug for E-SCV 4 switch
Plug for depth-setting regulator
Plug for position feedback unit
Plug for rapid withdrawal switch
Plug for program switch
Connecting point — Command Arm harness (W08)
Removing and Installing Harness W13 — Clutch
Sending Unit
LEGEND:
S72
X322
X328
Clutch switch
Connecting point — clutch switch harness (W08)
Plug for clutch pedal potentiometer
Removing and Installing Harness W14 — 3-Terminal
<- Go to Section TOC
Section 40 page 125
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Power Outlet Socket
LEGEND:
X06-15
X06-31
X06-82
X239
Plug for 3-terminal power outlet socket
Plug for 3-terminal power outlet socket
Plug for 3-terminal power outlet socket
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)
<- Go to Section TOC
Section 40 page 126
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X361
X409
X451
XGND1
Group 10: Wiring Harnesses
Plug, ECU for Stage I engine to 97/68/EC (Level 4 ECU)
Connecting point — ECU harness (W08)
Connecting point — engine harness (W02)
Ground point
Removing and Installing Harness W15 — ECU for
Stage II engines to 97/68/EC (Level 11 ECU)
<- Go to Section TOC
Section 40 page 127
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X409
X451
X570/1
X570/2
X610
Group 10: Wiring Harnesses
Connecting point — ECU harness (W08)
Connecting point — engine harness (W02)
Plug, ECU for Stage II engine to 97/68/EC (Level 11 ECU)
Plug, ECU for Stage II engine to 97/68/EC (Level 11 ECU)
Ground connection for screening of wires
Removing and Installing Harness W15 — Engine
Control Unit (Level 11 ECU) from Serial No. 398656
<- Go to Section TOC
Section 40 page 128
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X409
X451
X570/1
X570/2
X610
Group 10: Wiring Harnesses
24-pin plug — ECU wiring harness connection point (W08)
42-pin plug — Connection point for engine wiring harness (W02)
30-pin plug for control unit (ECU)
30-pin plug for control unit (ECU)
Ground connection for screening of wires
Removing and Installing Harness W16 — SIC with
Stage I engine to 97/68/EC
<- Go to Section TOC
Section 40 page 129
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X219
X220
X226
X423
X428
X456
X552
X553
X554
Group 10: Wiring Harnesses
Plug for multi-function lever
Plug for multi-function lever
Plug for CAN BUS terminator (11-bit)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W12)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W08)
Plug for E-SCV / E-ICV controller (SIC)
Plug for E-SCV encoder
Plug for E-SCV transport lock
Plug for E-SCV indicator light
<- Go to Section TOC
Section 40 page 130
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W16 — SIC with
Stage II engine to 97/68/EC
W16 - Wiring harness, SIC with E-SCV / E-ICV
<- Go to Section TOC
Section 40 page 131
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W16 - Wiring harness, SIC with E-ICV
LEGEND:
X219
X220
X423
X428
X456
X552
X553
X554
X619
Plug for multi-function lever
Plug for multi-function lever
Connecting point — E-SCV / E-ICV controller (SIC) harness (W12)
Connecting point — E-SCV / E-ICV controller (SIC) harness (W08)
Plug for E-SCV / E-ICV controller (SIC)
Plug for E-SCV encoder
Plug for E-SCV transport lock
Plug for E-SCV indicator light
Plug for CAN BUS terminator (11-bit)
<- Go to Section TOC
Section 40 page 132
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W17 — Multifunction Unit
LEGEND:
S08/LH
S08/RH
S10
X59
X60
X61
X62
X487
Left-turn signal switch
Right-turn signal switch
Full/dipped-beam switch
Plug for horn switch
Plug for horn switch
Plug for flash-to-pass switch
Plug for flash-to-pass switch
Connecting point — multi-function lever harness (W09)
Removing and Installing Harness W18 — Windshield
Wiper Switch (Without Intermittent Wipe)
<- Go to Section TOC
Section 40 page 133
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
S15
S31
X20B
X39
X63
X64
Group 10: Wiring Harnesses
Plug for windshield wiper switch
Digital instrument set switch
Connecting point — washer switch harness (W09)
Connecting point — windshield wiper harness (W23)
Plug for windshield washer switch
Plug for windshield washer switch
Removing and Installing Harness W18 — Windshield
Wiper Switch (with Intermittent Wipe)
<- Go to Section TOC
Section 40 page 134
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
K26
S15
S31
X20B
X39
X63
X64
<- Go to Section TOC
Group 10: Wiring Harnesses
Intermittent-wipe relay
Plug for windshield wiper switch
Digital instrument set switch
Connecting point — washer switch harness (W09)
Connecting point — windshield wiper harness (W23)
Plug for windshield washer switch
Plug for windshield washer switch
Section 40 page 135
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W19 — Cab Roof,
with Stage I Engine to 97/68/EC
LEGEND:
B28/LH
B28/RH
X43
X105
X121
X142/1
X142/2
X158
X227
X400
<- Go to Section TOC
Door switch for dome light, l.h.
Door switch for dome light, r.h.
Plug for rear window wiper motor
Plug for radio
Plug for dome and console lights
Prewiring for beacon light
Ground terminal with ring, for beacon light
Plug for radio antenna ground
Plug for CAN BUS terminator (29-bit)
Connecting point — cab roof harness (W08)
Section 40 page 136
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X401
X433
X434
X442
X443
X475
X486
X530
X531/1
X531/2
X531/3
X532/1
X532/2
XGND10
XGND14
XGND41
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — harness for electric rear-view mirror (W34)
Connecting point — harness for worklights at rear of cab roof (W22)
Connecting point — harness for worklights at front of cab roof (W21)
Connecting point — harness for r.h. turn-signal and clearance lights
(W20)
Connecting point — harness for l.h. turn-signal and clearance lights
(W20)
Connecting point — not used
Plug for performance monitor (PRF)
Connecting point — JDLink harness (W41)
Plug for heated rear window switch
Plug for heated rear window switch
Plug for heated rear window switch
Plug for heated rear window resistor
Plug for heated rear window resistor
Ground point
Ground point
Ground point
Section 40 page 137
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W19 — Cab Roof,
with Stage II Engine to 97/68/EC
LEGEND:
B28/LH
B28/RH
X43
X121
X142/1
X142/2
X158/1
X158/2
X400
X401
<- Go to Section TOC
Door switch for dome light, l.h.
Door switch for dome light, r.h.
Plug for rear window wiper motor
Plug for dome and console lights
Prewiring for beacon light
Ground terminal with ring, for beacon light
Plug for radio antenna ground
Plug for radio antenna
Connecting point — cab roof harness (W08)
Connecting point — harness for electric rear-view mirror (W34)
Section 40 page 138
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X433
X434
X442
X443
X475
X486
X530
X531/1
X531/2
X531/3
X532/1
X532/2
X613
X614
XGND10
XGND14
XGND41
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — harness for worklights at rear of cab roof (W22)
Connecting point — harness for worklights at front of cab roof (W21)
Connecting point — harness for r.h. turn-signal and clearance lights
(W20)
Connecting point — harness for l.h. turn-signal and clearance lights
(W20)
Connecting point — not used
Plug for performance monitor (PRF)
Connecting point — JDLink harness (W41)
Plug for heated rear window switch
Plug for heated rear window switch
Plug for heated rear window switch
Plug for heated rear window resistor
Plug for heated rear window resistor
Plug for radio
Plug for CAN BUS terminator (29-bit)
Ground point
Ground point
Ground point
Section 40 page 139
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W20 — Turn Signal
and Clearance Lights
W20 - Harness for l.h. turn-signal and clearance lights
<- Go to Section TOC
Section 40 page 140
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W20 - Harness for r.h. turn-signal and clearance lights
<- Go to Section TOC
Section 40 page 141
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W20 - Harness for l.h. turn-signal and clearance lights
<- Go to Section TOC
Section 40 page 142
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W20 - Harness for r.h. turn-signal and clearance lights
LEGEND:
X108
X109
X110
X115
X162/1
X162/2
X111
X116
X442
<- Go to Section TOC
Plug for r.h. turn signal and clearance lights
Plug for l.h. turn signal and clearance lights
Plug for light on left of cab frame
Plug for light on right of cab frame
Plug for worklight on left side of cab frame
Plug for worklight on right side of cab frame
Plug for light on left of cab frame
Plug for light on right of cab frame
Connecting point — harness for r.h. turn-signal and clearance lights
(W19)
Section 40 page 143
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X443
Group 10: Wiring Harnesses
Connecting point — harness for l.h. turn-signal and clearance lights
(W19)
Removing and Installing Harness W21 — Worklights
on Front of Cab Roof
LEGEND:
X434
X452/1F1
X452/1F2
X452/2F1
X452/2F2
Connecting point — harness for worklights at front of cab roof
(W19)
Plug for outer right worklight on front of cab roof
Plug for inner right worklight on front of cab roof
Plug for outer left worklight on front of cab roof
Plug for inner left worklight on front of cab roof
Removing and Installing Harness W22 — Worklights
on Rear of Cab Roof
<- Go to Section TOC
Section 40 page 144
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X433
X114/1F1
X114/1F2
X114/2F1
X114/2F2
Group 10: Wiring Harnesses
Connecting point — harness for worklights at rear of cab roof (W19)
Plug for outer right worklight on rear of cab roof
Plug for inner right worklight on rear of cab roof
Plug for outer left worklight on rear of cab roof
Plug for inner left worklight on rear of cab roof
Removing and Installing Harness W22 — Xenon
(HID) Worklights on Rear of Cab Roof
<- Go to Section TOC
Section 40 page 145
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X433
X542/1
X542/2
Group 10: Wiring Harnesses
Connecting point — harness for worklights at rear of cab roof (W19)
Plug of ballast unit for Xenon (HID) worklights at rear of cab roof, left
Plug of ballast unit for Xenon (HID) worklights at rear of cab roof, right
Removing and Installing Harness W23 — Windshield
Wiper Switch (Without Switch for Windshield)
<- Go to Section TOC
Section 40 page 146
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
<- Go to Section TOC
Group 10: Wiring Harnesses
Section 40 page 147
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X20A
X38
X39
Group 10: Wiring Harnesses
Connecting point — windshield wiper harness (W09)
Plug for windshield wiper motor
Connecting point — windshield wiper harness (W18)
Removing and Installing Harness W23 — Windshield
Wiper (With Switch for Windshield)
<- Go to Section TOC
Section 40 page 148
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
<- Go to Section TOC
Group 10: Wiring Harnesses
Section 40 page 149
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X20A
X38
X39
X583F
X583M
S17
Group 10: Wiring Harnesses
Connecting point — windshield wiper harness (W09)
Plug for windshield wiper motor
Connecting point — windshield wiper harness (W18)
Plug of harness for windshield switch
Plug of harness for windshield switch
Windshield switch
Removing and Installing Harness W24 — Rear
Window Wiper
LEGEND:
S20
X40
X42M
Rear window switch
Connecting point — rear window wiper harness (W08)
Connecting point — harness for rear window wiper switch (W25)
Removing and Installing Harness W25 — Rear
Window Wiper Switch
<- Go to Section TOC
Section 40 page 150
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X42
X42F
Group 10: Wiring Harnesses
Plug for rear window wiper switch
Connecting point — rear window wiper harness (W24)
Removing and Installing Harness W26 — Fan and
Air-Conditioner
<- Go to Section TOC
Section 40 page 151
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X28
X46
X47
X48
X50
X73/1
X73/2
X100
X448
X449/1
X449/2
XGND15
Group 10: Wiring Harnesses
Plug for pressure switch (air-conditioning)
Plug for fan motor
Plug for fan motor
Plug for resistors
Connecting point — fan harness (W08)
Plug for thermostat switch
Plug for thermostat switch
Plug for fan switch
Plug for air-conditioning switch
Plug for de-icer switch
Plug for de-icer switch
Ground point
Removing and Installing Harness W26 — Fan and
Air-conditioner from Serial No. 398656
<- Go to Section TOC
Section 40 page 152
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X28
X46
X47
X48
X73/1
X73/2
X100
X448
X449/1
X449/2
X577
X665
XGND15
Group 10: Wiring Harnesses
2-pin plug for air-conditioner pressure switch
2-pin plug for fan motor
2-pin plug for fan motor
4-pin plug for resistors
1-pin plug for thermostat switch
1-pin plug for thermostat switch
6-pin plug for fan switch
3-pin plug for air conditioner switch
1-pin plug for de-icer switch
1-pin plug for de-icer switch
7-pin plug — Connection point for fan wiring harness (W08)
1-pin plug, voltage-to-ground on evaporator
Ground point
Removing and Installing Harness W26 — ClimaTrak
(Cab)
<- Go to Section TOC
Section 40 page 153
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
LEGEND:
X577
X577/1
X595
X599
X600
X602
X655
<- Go to Section TOC
7-pin plug — Connection point for fan and air-conditioning harness
(W08)
2-pin plug — Connection point for ClimaTrak harness (cab) (W08)
42-pin plug — Connection point for ClimaTrak harness (cab roof)
(W47)
8-pin plug — Connection point for ClimaTrak harness (cowl) (W48)
3-pin plug for refrigerant pressure sending unit
2-pin plug for inside air temperature sender
6-pin plug for water valve
Section 40 page 154
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X664
XGND15
<- Go to Section TOC
Group 10: Wiring Harnesses
7-pin plug — Connection point for ClimaTrak harness (evaporator
housing) (W49)
Ground point
Section 40 page 155
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W28 — Front End
of Transmission
LEGEND:
X30
X80
X83
X86
X91
<- Go to Section TOC
Prewiring for radar connection
Plug for switch that warns of a restriction at the transmission oil filter
Plug for sending unit (engagement oil warning light)
Plug for sending unit (fuel gauge and fuel transfer pump)
Plug for solenoid valve (front-wheel drive)
Section 40 page 156
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X307
X420
X459
X492
X493
X494
X495
X496
X497
X499/1
X499/2
X500
X546
<- Go to Section TOC
Group 10: Wiring Harnesses
Plug for sending unit (transmission oil temperature)
Plug for air brake system solenoid valve
Plug for sending unit (transmission enable pressure)
Plug for K3 solenoid (Y32)
Plug for forward solenoid valve (Y33)
Plug for reverse solenoid valve (Y36)
Plug for proportional valve (Y38)
Plug for K2 solenoid valve (Y39)
Plug for K1 solenoid valve (Y40)
Plug for transmission speed sender
Plug for transmission speed sender
Connecting point — harness at front end of transmission (W08)
Plug for switch that warns of a restriction at the hydraulic oil filter
Section 40 page 157
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W28 — Front End
of Transmission (AutoPowr/IVT transmission)
LEGEND:
X30
X86
X91
X336
X337
<- Go to Section TOC
Prewiring for radar connection
Plug for sending unit (fuel gauge and fuel transfer pump)
Plug for solenoid valve (front-wheel drive)
Plug for transmission speed sender
Plug for switch at transmission oil filter
Section 40 page 158
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X338
X339
X340/1
X340/2
X341
X375
X397
X410
X413
X420
X481
X546
Group 10: Wiring Harnesses
Plug for transmission oil pressure switch
Plug for sending unit (hydrostatic speed)
Plug for park lock solenoid valve
Plug for park lock solenoid valve
Plug for sending unit (transmission input speed)
Plug for sending unit (transmission output speed)
Plug for cold-weather starting pressure switch
Plug for sending unit (front-wheel drive speed)
Plug for sending unit (park lock pressure)
Plug for air brake system solenoid valve
Connecting point — harness at front end of transmission (W08)
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)
<- Go to Section TOC
Section 40 page 159
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W29 - Valve block harness with GreenStar port, for Stage I engines to 97/68/EC (AutoPowr/IVT
transmission)
LEGEND:
X482
X482/1
X543
X543/1
<- Go to Section TOC
Connecting point — valve block harness (W08)
Plug for valve block
Connecting point — Harness for 60-amp GreenStar socket (W36)
Connecting point — Harness for 60-amp GreenStar socket (W36)
Section 40 page 160
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W30 — Rear End
of Transmission
W30 - Wiring Harness - Rear End of Transmission
<- Go to Section TOC
Section 40 page 161
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W30 - Wiring Harness - Rear End of Transmission (with E-SCV / E-ICV)
LEGEND:
X71
X87
X88/1
X88/2
X92
X94
X95
X96
Plug for draft potentiometer
Plug for differential lock solenoid
Plug for sending unit (wheel speed)
Plug for sending unit (wheel speed)
Plug for stepper motor (hitch control)
Plug for sending unit (rear PTO speed)
Plug for rear PTO solenoid valve
Plug for position sensor (hitch control)
<- Go to Section TOC
Section 40 page 162
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X234
X430
X462
X524
X525
X526
Group 10: Wiring Harnesses
Connecting point — harness for -7-terminal power outlet socket (W31)
Connecting point — harness at rear end of transmission (W08)
Connecting point — stepper motor harness (W32)
Plug for cab suspension solenoid
Plug for cab suspension solenoid
Plug for position sensor (cab suspension)
Removing and Installing Harness W31 — 7-Terminal
Power Outlet Socket
LEGEND:
X05
X234
Plug for 7-terminal power outlet socket
Connecting point — harness for 7-terminal power outlet socket (W30)
<- Go to Section TOC
Section 40 page 163
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
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
<- Go to Section TOC
Section 40 page 164
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W32 - Wiring harness, stepper motors with E-ICV
LEGEND:
X251
X252
X258
X318
X462
X464
X465
X466
X467
<- Go to Section TOC
Plug for E-ICV 2 stepper motor
Plug for E-ICV 3 stepper motor
Plug for CAN BUS terminator (11-bit)
Plug for E-ICV 1 stepper motor
Connecting point — stepper motor harness (W30)
Plug for E-SCV 1 stepper motor
Plug for E-SCV 2 stepper motor
Plug for E-SCV 3 stepper motor
Plug for E-SCV 4 stepper motor
Section 40 page 165
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
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
<- Go to Section TOC
Section 40 page 166
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W32 - Wiring harness, stepper motors with E-ICV
<- Go to Section TOC
Section 40 page 167
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
W32 - Wiring harness, stepper motors with E-SCV
LEGEND:
X251
X252
X318
X462
X464
X465
X466
X467
X622
<- Go to Section TOC
Plug for E-ICV 2 stepper motor
Plug for E-ICV 3 stepper motor
Plug for E-ICV 1 stepper motor
Connecting point — stepper motor harness (W30)
Plug for E-SCV 1 stepper motor
Plug for E-SCV 2 stepper motor
Plug for E-SCV 3 stepper motor
Plug for E-SCV 4 stepper motor
Plug for CAN BUS terminator (11-bit)
Section 40 page 168
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W33 — Service
LEGEND:
X522
X571
Connecting point — service harness (W08)
Service plug (CAN BUS)
Removing and Installing Harness W34 — Electric
Rear-View Mirrors
<- Go to Section TOC
Section 40 page 169
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X401
X556/1
X556/2
X557
X558
X559
Group 10: Wiring Harnesses
Connecting point — harness for electric rear-view mirror (W19)
Plug for adjusting motor (left)
Plug for adjusting motor (right)
Plug for mirror adjusting switch
Plug for mirror support adjusting switch
Plug for mirror heater switch
Removing and Installing Harness W35 — Access
Step Lighting and Battery Cut-off Switch (Version 1)
<- Go to Section TOC
Section 40 page 170
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
LEGEND:
X544
X593
X606/1
X606/2
X607
Connecting point — wiring harness, access-step light and battery cutoff switch (W08)
Plug for switch that operates the battery cut-off switch
Plug for r.h. access-step light
Plug for l.h. access-step light
Connecting point — harness for battery cut-off switch (W42)
Removing and Installing Harness W35 — Access
<- Go to Section TOC
Section 40 page 171
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Step Lighting and Battery Cut-off Switch (Version 2)
LEGEND:
X544
X606/1
X606/2
X696
X697
<- Go to Section TOC
Connecting point — wiring harness, access-step light and battery cutoff switch (W08)
Plug for r.h. access-step light
Plug for l.h. access-step light
Plug for the switch that operates the battery cut-off switch
Connecting point — harness for battery cut-off switch (W42)
Section 40 page 172
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W36 — 60-amp
GreenStar Socket for Stage I Engine to 97/68/EC
LEGEND:
F16
F17
K46
K47
<- Go to Section TOC
Fuse for 60-amp socket
Fuse for 60-amp socket
Relay for 60-amp socket
Relay for 60-amp socket
Section 40 page 173
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
R20
R21
X533/1
X533/2
X533/3
X541
X543
X543/1
X574
XGND51
Group 10: Wiring Harnesses
Resistor
Resistor
Plug for 60-amp socket
Plug for 60-amp socket
60-amp socket
Terminal with ring for battery power
Connecting point — wiring harness of GreenStar port (W37 or W29)
Connecting point — wiring harness of GreenStar port (W37 or W29)
Plug for implement switch
Ground point
Removing and Installing Harness W36 — 60-amp
GreenStar Implement Socket
<- Go to Section TOC
Section 40 page 174
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
F16
F17
K46
K47
R20
R21
X533/1
X533/2
X533/3
<- Go to Section TOC
Group 10: Wiring Harnesses
Fuse for implement BUS (components)
Fuse for implement BUS (CAN BUS)
Relay for implement BUS (components)
Relay for implement BUS (CAN BUS)
Resistor
Resistor
2-pin plug for 60-amp implement socket
4-pin plug for 60-amp implement socket
60-amp implement socket
Section 40 page 175
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X541
X543
X574
XGND51
Group 10: Wiring Harnesses
Terminal with ring for battery power
10-pin plug — Connection point for GreenStar (60-amp implement
socket) (W39)
2-pin plug for implement switch
Ground point
Removing and Installing Harness W37 — GreenStar
Port
LEGEND:
X482
X543
X543/1
Connecting point — valve block harness (W08)
Connecting point — Harness for 60-amp GreenStar socket (W36)
Connecting point — Harness for 60-amp GreenStar socket (W36)
Removing and Installing Harness W39 — GreenStar
(Cab), for Stage I Engine to 97/68/EC
<- Go to Section TOC
Section 40 page 176
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
K51
X522
X522/1
X535
X540
<- Go to Section TOC
Group 10: Wiring Harnesses
Timer
Connecting point — service harness (W08)
Connecting point — service harness (W33)
Connecting point — wiring harness, GreenStar (cab roof) (W40)
Connecting point — wiring harness, GreenStar (cab) (W08)
Section 40 page 177
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X591F
X591M
Group 10: Wiring Harnesses
Connecting point — CAN BUS (GreenStar)
Connecting point — CAN BUS (GreenStar)
Removing and Installing Harness W39 — GreenStar
(Cab)
LEGEND:
K51
X522
5-pin plug for timer
10-pin plug — Connection point for GreenStar (cab) (W08)
<- Go to Section TOC
Section 40 page 178
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X535
X543
X571F
X571M
X591F
X591M
Group 10: Wiring Harnesses
10-pin plug — Connection point for GreenStar (cab roof) (W40)
10-pin plug — Connection point for GreenStar harness (60-amp
implement socket) (W36)
9-pin plug for CAN BUS connection
9-pin service socket (CAN BUS)
4-pin plug — Connection point for CAN BUS (GreenStar)
4-pin plug — Connection point for CAN BUS (GreenStar)
Removing and Installing Harness W39 — GreenStar
with TEC (Cab), for Stage I Engine to 97/68/EC
<- Go to Section TOC
Section 40 page 179
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X522
X522/1
X535
X540
X572
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — service harness (W08)
Connecting point — service harness (W33)
Connecting point — wiring harness, GreenStar (cab roof) (W40)
Connecting point — wiring harness, GreenStar (cab) (W08)
Plug for TEC
Section 40 page 180
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X591F
X591M
<- Go to Section TOC
Group 10: Wiring Harnesses
Connecting point — CAN BUS (GreenStar)
Connecting point — CAN BUS (GreenStar)
Section 40 page 181
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W39 — GreenStar
with Tractor Equipment interface Controller (Cab)
LEGEND:
X522
X535
X543
X571F
X571M
X572
X591F
<- Go to Section TOC
10-pin plug — Connection point for GreenStar wiring harness (cab);
W39
10-pin plug — Connection point for GreenStar harness (cab roof)
(W40)
10-pin plug — Connection point for GreenStar harness (60-amp
implement socket) (W36)
9-pin plug for CAN BUS connection
9-pin service socket (CAN BUS)
68-pin plug for tractor equipment interface controller (TEC)
4-pin plug — Connection point for CAN BUS (GreenStar)
Section 40 page 182
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X591M
X615F/2
X615M/1
X636
X641
X656
X659
Group 10: Wiring Harnesses
4-pin plug — Connection point for CAN BUS (GreenStar)
6-pin plug for CAN BUS terminator (29-bit)
6-pin plug for CAN BUS connection (29-bit)
3-pin plug for AutoTrac switch or connection point, harness for
AutoTrac Command Arm (W53)
4-pin plug — Connection point for AutoTrac wiring harness (cab)
(W51)
24-pin plug (GSD 2100)
3-pin plug (GSD 2100)
Removing and Installing Harness W40 — GreenStar
(Cab Roof), for Stage I Engine to 97/68/EC
LEGEND:
<- Go to Section TOC
Section 40 page 183
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X535
X536
X538
X539
X565
Group 10: Wiring Harnesses
Connecting point - wiring harness, GreenStar (cab roof) (W39)
Plug for CAN BUS terminator (GreenStar)
Plug for mapping processor
Plug for GreenStar display
Plug for GPS position receiver
Removing and Installing Harness W40 — GreenStar
(Cab Roof)
LEGEND:
X535
X536
X538
X539
X565
10-pin plug — Connection point for GreenStar wiring harness (cab roof)
(W39)
6-pin plug for CAN BUS terminator (GreenStar)
10-pin plug for mapping processor
10-pin plug for GreenStar display
12-pin plug, connection point for position receiver (GPS)
<- Go to Section TOC
Section 40 page 184
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W41 — JDLink
LEGEND:
X529
X530
Plug for JDLink control unit (JDL)
Connecting point — JDLink harness (W19)
Removing and Installing Harness W42 — Battery
Cut-Off Switch, Version 1
<- Go to Section TOC
Section 40 page 185
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
K48
X607
X86
X86/1
XGND56
XGND57
<- Go to Section TOC
Group 10: Wiring Harnesses
Relay for battery cut-off switch
Connecting point — wiring harness, access-step light and battery
cut-off switch (W35)
Connecting point - harness at front end of transmission (W28)
Plug for fuel gauge and fuel pump
Ground point
Ground terminal with ring, for battery cut-off relay
Section 40 page 186
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W42 — Battery
Cut-Off Switch, Version 2
LEGEND:
K56
K57
X86
X86/1
<- Go to Section TOC
Battery cut-off relay
Relay for battery cut-off switch
Connecting point — harness at front end of transmission (W28)
Plug for fuel gauge and fuel pump
Section 40 page 187
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X697
XGND56
Group 10: Wiring Harnesses
Connecting point — wiring harness, access-step light and battery
cut-off switch (W35)
Ground point
Removing and Installing Harness W47 — ClimaTrak
(Cab Roof)
LEGEND:
X594
<- Go to Section TOC
2-pin plug for rear ambient air temperature sensor
Section 40 page 188
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
X595
X597
X614F/1
X614M/1
X652
Group 10: Wiring Harnesses
42-pin plug — Connection point for ClimaTrak harness (cab roof)
(W26)
32-pin plug — Connection point for ClimaTrak control unit (ATC)
6-pin plug for CAN BUS terminator (29-bit)
6-pin plug for CAN BUS connection (29-bit)
2-pin plug of defog sensor for windshield
Removing and Installing Harness W48 — ClimaTrak
(Cowl)
<- Go to Section TOC
Section 40 page 189
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X599
X601
X605
Group 10: Wiring Harnesses
8-pin plug — Connection point for ClimaTrak harness (cowl) (W26)
2-pin plug for sending unit for actual outlet air temperature
6-pin plug of adjusting motor for air distribution
Removing and Installing Harness W49 — ClimaTrak
<- Go to Section TOC
Section 40 page 190
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
(Evaporator Housing)
LEGEND:
X46
X47
X598
X603
X664
X665
2-pin plug for fan motor
2-pin plug for fan motor
2-pin plug, sending unit for evaporator core temperature
6-pin plug for the fan motor driver unit
7-pin plug — Connection point for ClimaTrak harness (evaporator
housing) (W26)
1-pin plug, voltage-to-ground on evaporator
<- Go to Section TOC
Section 40 page 191
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W50 — GreenStar
(CAN BUS Terminator)
LEGEND:
X543
X658
10-pin plug — Connection point for GreenStar harness (60-amp
implement socket) (W36)
6-pin plug for CAN BUS terminating resistor
Removing and Installing Harness W51 — AutoTrac
(Cab)
<- Go to Section TOC
Section 40 page 192
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X615F/2
X615M/2
X631/1
X631/2
X631/3
X632/1
X632/2
X635
<- Go to Section TOC
Group 10: Wiring Harnesses
6-pin plug for CAN BUS terminator (29-bit)
6-pin plug for CAN BUS connection (29-bit)
32-pin plug for AutoTrac control unit (SSU)
48-pin plug for AutoTrac control unit (SSU)
32-pin plug for AutoTrac control unit (SSU)
4-pin plug for steering input device
4-pin plug for steering input device
4-pin plug for steering valve
Section 40 page 193
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Section 40 - ELECTRICAL SYSTEM
X637
X641
XGND60
Group 10: Wiring Harnesses
6-pin plug — Connection point for AutoTrac wiring harness (steering
angle sensor) (W52)
4-pin plug — Connection point for AutoTrac wiring harness (cab)
(W39)
Ground point
Removing and Installing Harness W52 — AutoTrac
(Steering Angle Sensor)
<- Go to Section TOC
Section 40 page 194
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X633
X637
Group 10: Wiring Harnesses
6-pin plug for steering angle sensor
6-pin plug — Connection point for AutoTrac wiring harness (steering
angle sensor) (W51)
Removing and Installing Harness W53 — AutoTrac
(Command Arm)
LEGEND:
X636
X636/1
<- Go to Section TOC
3-pin plug — Connection point for AutoTrac wiring harness (Command
Arm) (W39/1)
3-pin plug for AutoTrac switch
Section 40 page 195
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 10: Wiring Harnesses
Removing and Installing Harness W55 — Display
LEGEND:
X656
X692
X693
X698
Connecting point - GreenStar wiring harness with TEC (Cab); W39/1
Plug for UIM controller
Plug for RCD display
Connecting point - serial interface harness, adapter (W56)
Removing and Installing Harness W56 — Serial
Interface, Adapter
<- Go to Section TOC
Section 40 page 196
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X698
X699
X712
Group 10: Wiring Harnesses
Connecting point - serial interface harness, adapter (W55)
Plug for serial interface 1
Plug for serial interface 2
Removing and Installing Harness W57 — Electrohydraulic Pick-up Hitch (Cab)
<- Go to Section TOC
Section 40 page 197
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X37F
X37M
X644
X645
Group 10: Wiring Harnesses
Plug for front loader
Connecting point — front loader (W08)
Connecting point — wiring harness for electro-hydraulic pick-up hitch
(valves) (W58)
Plug for switch that operates the pick-up hitch
Removing and Installing Harness W58 — Electrohydraulic Pick-up Hitch (Valves)
<- Go to Section TOC
Section 40 page 198
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
X642
X643
X644
Group 15: Charging Circuit
Plug for solenoid valve of electro-hydraulic pick-up hitch (on/off switch)
Plug for solenoid valve of electro-hydraulic pick-up hitch
(retract/extend)
Connecting point — wiring harness for electro-hydraulic pick-up hitch
(cab) (W57)
<- Go to Section TOC
Section 40 page 199
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
Group 15 - Charging Circuit
Charging Circuit - Summary of References
”Special tools”
”Specifications”
”Repairing the alternator”
”Disconnecting electrical circuits”
”Relieving tension on the drive belt”
”Removing/installing the alternator”
”Pulley removal and installation”
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
KJD10227- Special tool
KJD10278- Special tool
Specifications
Item
Measurement Specification
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
<- Go to Section TOC
Section 40 page 200
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
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
<- Go to Section TOC
Section 40 page 201
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Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
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.
<- Go to Section TOC
Section 40 page 202
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
Remove/Install the Alternator
LEGEND:
A
B
C
Wire (terminal 30)
Wire (terminal D+)
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.
<- Go to Section TOC
Section 40 page 203
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
Take out the two attaching screws (C).
Replace the alternator.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement Specification
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
<- Go to Section TOC
Section 40 page 204
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 15: Charging Circuit
Remove and Install the Pulley
LEGEND:
A
Pulley
Tools for pulley removal
LEGEND:
[ Torque wrench Commercially-available tool ]
A
B
KJD10227Special tool
C
KJD10278Special tool
[ Extension with 1/2 in. drive (50 mm, 2 in. in length) Commercially-available tool ]
D
[ Ratchet with 1/2 in. drive Commercially-available tool ]
E
Open the hood.
<- Go to Section TOC
Section 40 page 205
TM4756-REPAIR MANUAL
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:
Item
Measurement
Specification
Pulley on alternator shaft
Torque
80 N˙m
60 lb-ft
<- Go to Section TOC
Section 40 page 206
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 20: Starter Motor Circuit
Group 20 - Starter Motor Circuit
Starter Motor Circuit - Summary of References
”Special tools”
”Specifications”
”Repairing the starter motor”
”Disconnecting electrical circuits”
”Removing and installing the starter motor”
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
KJD10213
Special wrench
Removing and installing the starter motor
Specifications
Item
Measurement
Specification
Hex. nut (A) at terminal 30
Torque
30 N˙m
23 lb-ft
Cheese-head screw (C) at terminal 50
Torque
1 - 1.3 N˙m
9 - 11 lb-in.
Repairing the Starter Motor
<- Go to Section TOC
Section 40 page 207
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 20: Starter Motor Circuit
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.
Disconnecting Electrical Circuits
Before working on the electrical system, always disconnect battery ground cable (-).
<- Go to Section TOC
Section 40 page 208
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 20: Starter Motor Circuit
Removing and installing the starter motor
LEGEND:
A
B
C
D
Hex. nut
Cover
Wire and fillister-head screw
Special box wrench KJD10213
Open the hood and take off the l.h. side panel.
CAUTION:
Disconnect negative (-) cable from battery.
Remove hex. nut (A).
Disconnect the wires at the connecting pins.
Remove cover (B).
<- Go to Section TOC
Section 40 page 209
TM4756-REPAIR MANUAL
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
Removing and installing the starter motor
to remove the starter motor.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement
Specification
Hex. nut (A) at terminal 30
Torque
30 N˙m
23 lb-ft
Fillister-head screw (C) at terminal 50
Torque
1 - 1,3 N˙m
9 - 11 lb-in.
<- Go to Section TOC
Section 40 page 210
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Group 25 - Fuses, Relays and Switches
Fuses, Relays and Switches — Recondition
(Summary of References)
”Removing trim panels from cowl”.
”Disconnecting electrical circuits” .
”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)
(AutoPowr/IVT transmission)”.
”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” .
<- Go to Section TOC
Section 40 page 211
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
”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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
<- Go to Section TOC
Section 40 page 212
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Extraction tool
JDG777
Removing electrical connectors
<- Go to Section TOC
Section 40 page 213
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Specifications
Item
Measurement Specification
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
Battery cable to battery cut-off relay (version 2), M10 hex. nut
Torque
15 to 20 N˙m
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).
<- Go to Section TOC
Section 40 page 214
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
B
C
Group 25: Fuses, Relays and Switches
Screw
Trim panel
Remove screws (B).
Remove panels (C).
Disconnecting Electrical Circuits
<- Go to Section TOC
Section 40 page 215
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Before working on the electrical system, always disconnect battery ground cable (-).
<- Go to Section TOC
Section 40 page 216
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Fuse and Relay Boxes on Tractors with Operator′s
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
B
C
D
E
F
<- Go to Section TOC
Relay box K01
Relay box K02
Fuse box F03
Fuse box F04
Fuse box F05
Fuse box F06
Section 40 page 217
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
G
H
I
J
Group 25: Fuses, Relays and Switches
Fuse box F07
Relay box K08
Relay box K09
Relay box K10
Relays (relay box K01) up to serial no. 398655
DEFINITIONS:
K01/1
K01/2
K01/3
K01/4
<- Go to Section TOC
Relay for accessories
Relay for power supply to electronics
Relay for accessories
Acoustic alarm
Section 40 page 218
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K02) up to serial no. 398655
DEFINITIONS:
K02/1
K02/2
K02/3
K02/4
K02/5
K02/6
K02/7
<- Go to Section TOC
Not used
Alternator relay
Not used
Not used
Relay for power supply to E-ICV
Not used
Not used
Section 40 page 219
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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)
<- Go to Section TOC
Section 40 page 220
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F03/03
F03/04
F03/05
F03/06
F03/07
F03/08
F03/09
F03/10
F03/11
F03/12
F03/13
F03/14
F03/15
F03/16
Group 25: Fuses, Relays and Switches
20-amp, right turn signal, hazard warning lights
20-amp, left turn signal
Not used
10-amp, brake light
20-amp, brake switch
10-amp, controller for suspended front axle (SFA) (battery voltage)
Not used
20-amp, power supply to E-ICV
Not used
Not used
10-amp, SIC controller (battery voltage)
10-amp, JDLink, GreenStar
10-amp, SIC controller (power supply)
20-amp, heated rear window
Fuses (fuse box F04) up to serial no. 398655
<- Go to Section TOC
Section 40 page 221
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F04/01
F04/02
F04/03
F04/04
F04/05
<- Go to Section TOC
10-amp, ECU controller (power supply)
20-amp, ECU controller (battery voltage)
Not used
15-amp, main switch (BAT)
30-amp, accessories
Section 40 page 222
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F04/06
F04/07
F04/08
F04/09
F04/10
F04/11
F04/12
F04/13
F04/14
F04/15
F04/16
Group 25: Fuses, Relays and Switches
30-amp, power supply for electronics
30-amp, accessories
20-amp, fuel preheater
10-amp, basic informator, SFA controller (power supply)
10-amp, basic informator (battery voltage)
10-amp, fuel pump, injection pump shut-off valve
10-amp, performance monitor (PRF)
10-amp, CAN BUS terminator, service socket
10-amp, electrical reverser control
10-amp, EPC controller (power supply)
10-amp, EPC controller (battery voltage)
Fuses (fuse box F05) up to serial no. 398655
<- Go to Section TOC
Section 40 page 223
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F05/01
F05/02
F05/03
F05/04
F05/05
<- Go to Section TOC
10-amp, air-conditioning system and relay for fan
10-amp, 2-pin plug for front loader
Not used
Not used
Not used
Section 40 page 224
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F05/06
F05/07
F05/08
F05/09
F05/10
F05/11
F05/12
F05/13
F05/14
F05/15
F05/16
Group 25: Fuses, Relays and Switches
Not used
Not used
10-amp, windshield wiper and washer
10-amp, rear window wiper and washer
10-amp, electrical rear-view mirror
10-amp, GreenStar, TEC controller (power supply)
10-amp, dome light, radio (battery voltage)
20-amp, fan
20-amp, fan
10-amp, 3-terminal socket, socket strip (power supply)
30-amp, 3-terminal socket, socket strip (battery voltage)
Fuses (fuse box F06) up to serial no. 398655
<- Go to Section TOC
Section 40 page 225
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F06/01
F06/02
F06/03
F06/04
F06/05
<- Go to Section TOC
10-amp, horn
10-amp, cigarette lighter
10-amp, operator′s seat
10-amp, radio (power supply)
10-amp, console light, radio lighting
Section 40 page 226
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F06/06
F06/07
F06/08
F06/09
F06/10
F06/11
F06/12
F06/13
F06/14
F06/15
F06/16
Group 25: Fuses, Relays and Switches
10-amp, beacon light
10-amp, front corner worklight
10-amp, worklights on fenders (rear-facing)
10-amp, outer worklight on rear of cab roof
10-amp, inner worklight on rear of cab roof
10-amp, outer worklight on front of cab roof
10-amp, inner worklight on front of cab roof
Fuse tester
Not used
Not used
15-amp, light switch (pin B)
Fuses (fuse box F07) up to serial no. 398655
<- Go to Section TOC
Section 40 page 227
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
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
<- Go to Section TOC
Section 40 page 228
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Section 40 - ELECTRICAL SYSTEM
F07/06
F07/07
F07/08
F07/09
F07/10
F07/11
F07/12
F07/13
F07/14
F07/15
F07/16
Group 25: Fuses, Relays and Switches
10-amp, dipped-beam headlight, left
10-amp, dipped-beam headlight, right
15-amp, full-beam headlights
30-amp, lights on cab frame
10-amp, r.h. tail light, l.h. clearance light, license plate light
10-amp, l.h. tail light, r.h. clearance light
10-amp, lighting
10-amp, dipped beam, left (lights on cab frame)
10-amp, dipped beam, right (lights on cab frame)
30-amp, headlights
15-amp, full-beam headlights
Relays (relay box K08) up to serial no. 398655
<- Go to Section TOC
Section 40 page 229
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K08/1
K08/2
K08/3
K08/4
K08/5
K08/6
K08/7
Group 25: Fuses, Relays and Switches
Relay for full-beam headlights
Relay for dipped-beam headlights
Relay for lights on cab frame
Relay for headlights and worklights on cab frame
Relay for worklights on front of cab roof
Relay for worklights on rear of cab roof
Relay for front corner/fender worklights (rear-facing)
Relays (relay box K09) up to serial no. 398655
<- Go to Section TOC
Section 40 page 230
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
DEFINITIONS:
K09/1
3-amp, lighting diode
K09/1
1-amp, diode for power supply to electronics
K09/2
3-amp, CAN BUS diode
K09/2
1-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)
<- Go to Section TOC
Section 40 page 231
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K10) up to serial no. 398655
DEFINITIONS:
K10/1
K10/2
K10/3
K10/4
<- Go to Section TOC
Fan relay
Not used
Relay for 3-terminal socket, power outlet strip
Plug for ”come home” mode
Section 40 page 232
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Fuse and Relay Boxes on Tractors with Operator′s
Cab from Serial No. 398656
Fuse and relay boxes from serial no. 398656
→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
B
C
D
E
F
<- Go to Section TOC
Relay box K01
Relay box K02
Fuse box F03
Fuse box F04
Fuse box F05
Fuse box F06
Section 40 page 233
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
G
H
I
J
Group 25: Fuses, Relays and Switches
Fuse box F07
Relay box K08
Relay box K09
Relay box K10
Relays (relay box K01) from serial no. 398656
DEFINITIONS:
K01/1
K01/2
K01/3
K01/4
<- Go to Section TOC
Relay for accessories
Relay for power supply to electronics
Relay for accessories
Acoustic alarm
Section 40 page 234
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K02) from serial no. 398656
DEFINITIONS:
K02/1
K02/2
K02/3
K02/4
K02/5
K02/6
K02/7
<- Go to Section TOC
Not used
Alternator relay
Not used
Not used
Relay for power supply to E-ICV
Not used
Not used
Section 40 page 235
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Fuses (fuse box F03) from serial no. 398656
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 and radar)
<- Go to Section TOC
Section 40 page 236
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F03/03
F03/04
F03/05
F03/06
F03/07
F03/08
F03/09
F03/10
F03/11
F03/12
F03/13
F03/14
F03/15
F03/16
Group 25: Fuses, Relays and Switches
20-amp, right turn signal, hazard warning lights
20-amp, left turn signal
Not used
10-amp, brake light
20-amp, brake switch
10-amp, controller for suspended front axle (SFA) (battery voltage)
Not used
20-amp, power supply to E-ICV
Not used
Not used
10-amp, SIC controller (battery voltage)
10-amp, service plug, JDLink, GreenStar (battery power)
10-amp, SIC controller (power supply)
20-amp, heated rear window
Fuses (fuse box F04) from serial no. 398656
<- Go to Section TOC
Section 40 page 237
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F04/01 10-amp, ECU controller (power supply)
F04/02 10-amp, ECU controller (battery voltage)
F04/03 10-amp, GreenStar (power supply)
F04/04 15-amp, main (key) switch (battery voltage)
F04/05 30-amp, accessories
<- Go to Section TOC
Section 40 page 238
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F04/06
F04/07
F04/08
F04/09
F04/10
F04/11
F04/12
F04/13
F04/14
F04/15
F04/16
Group 25: Fuses, Relays and Switches
30-amp, power supply for electronics
30-amp, accessories
20-amp, fuel preheater
10-amp, basic informator BIF, SFA controller (power supply)
10-amp, basic informator BIF (battery voltage)
10-amp, fuel pump, injection pump shut-off valve
10-amp, performance monitor PRF, JDLink (power supply)
10-amp, CAN BUS terminator
Not used
Not used
Not used
Fuses (fuse box F05) from serial no. 398656
<- Go to Section TOC
Section 40 page 239
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
10-amp, air-conditioning system, relay for fan, ClimaTrak (power
F05/01
supply)
F05/02 10-amp, 2-pin plug for front loader
F05/03 Not used
F05/04 10-amp, EPC controller (power supply)
<- Go to Section TOC
Section 40 page 240
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F05/05
F05/06
F05/07
F05/08
F05/09
F05/10
F05/11
F05/12
F05/13
F05/13
F05/14
F05/14
F05/15
F05/16
Group 25: Fuses, Relays and Switches
10-amp, EPC controller (battery voltage)
10-amp, EPC controller (gear selection)
10-amp, accessories
10-amp, windshield wiper and washer
10-amp, rear window wiper and washer
10-amp, electric rear-view mirrors, signal socket
10-amp, GreenStar, TEC controller (power supply)
10-amp, dome light, radio (battery voltage)
20-amp, fan
30-amp, ClimaTrak (fan)
20-amp, fan
10-amp, ClimaTrak (battery voltage)
10-amp, 3-terminal socket, socket strip (power supply)
30-amp, 3-terminal socket, socket strip (battery voltage)
Fuses (fuse box F06) from serial no. 398656
<- Go to Section TOC
Section 40 page 241
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F06/01 10-amp, horn
F06/02 10-amp, cigarette lighter
F06/03 15-amp, operator′s seat
F06/04 10-amp, radio (power supply)
F06/05 10-amp, shift console light, radio lighting
<- Go to Section TOC
Section 40 page 242
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F06/06
F06/07
F06/08
F06/09
F06/10
F06/11
F06/12
F06/13
F06/14
F06/15
F06/16
Group 25: Fuses, Relays and Switches
10-amp, beacon light
10-amp, front corner worklight
10-amp, worklights on fenders (rear-facing)
15-amp, outer worklight on rear of cab roof or Xenon (HID) worklight
on right rear of cab roof
15-amp, inner worklight on rear of cab roof or Xenon (HID) worklight
on left rear of cab roof
10-amp, outer worklight on front of cab roof
10-amp, inner worklight on front of cab roof
Fuse tester
10-amp, AutoTrac (power supply)
10-amp, AutoTrac (battery voltage)
15-amp, light switch (pin B)
Fuses (fuse box F07) from serial no. 398656
<- Go to Section TOC
Section 40 page 243
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
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
<- Go to Section TOC
Section 40 page 244
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F07/06
F07/07
F07/08
F07/09
F07/10
F07/11
F07/12
F07/13
F07/14
F07/15
F07/16
Group 25: Fuses, Relays and Switches
10-amp, dipped-beam headlight, left
10-amp, dipped-beam headlight, right
15-amp, full-beam headlights
30-amp, lights on cab frame
10-amp, r.h. tail light, l.h. clearance light, license plate light
10-amp, l.h. tail light, r.h. clearance light
10-amp, lighting
10-amp, dipped beam, left (lights on cab frame)
10-amp, dipped beam, right (lights on cab frame)
30-amp, headlights
15-amp, full-beam headlights
Relays (relay box K08) from serial no. 398656
<- Go to Section TOC
Section 40 page 245
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K08/1
K08/2
K08/3
K08/4
K08/5
K08/6
K08/7
Group 25: Fuses, Relays and Switches
Relay for full-beam headlights
Relay for dipped-beam headlights
Relay for lights on cab frame
Relay for headlights and worklights on cab frame
Relay for worklights on front of cab roof
Relay for worklights on rear of cab roof
Relay for front corner/fender worklights (rear-facing)
Relays (relay box K09) from serial no. 398656
<- Go to Section TOC
Section 40 page 246
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K09/1
K09/1
K09/2
K09/2
K09/3
K09/4
K09/5
K09/6
K09/7
<- Go to Section TOC
Group 25: Fuses, Relays and Switches
3-amp, lighting diode
1-amp, diode for power supply to electronics
3-amp, CAN BUS diode
1-amp, CAN BUS diode
Relay for fuel preheater
Relay for air-conditioning system
Transmission enable relay
Not used
Not used
Section 40 page 247
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K10) from serial no. 398656
DEFINITIONS:
K10/1
K10/1
K10/3
K10/4
<- Go to Section TOC
Fan relay
ClimaTrak bridging plug
Relay for 3-terminal socket, power outlet strip
Plug for ”come home” mode
Section 40 page 248
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Fuse and Relay Boxes on Tractors with Operator′s
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:
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
B
C
<- Go to Section TOC
Relay box K01
Relay box K02
Fuse box F03
Section 40 page 249
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
D
E
F
G
H
I
J
Group 25: Fuses, Relays and Switches
Fuse box F04
Fuse box F05
Fuse box F06
Fuse box F07
Relay box K08
Relay box K09
Relay box K10
Relays (relay box K01) on tractors with AutoPowr/IVT transmission up
to serial no. 398655
DEFINITIONS:
K01/1
<- Go to Section TOC
Relay for accessories
Section 40 page 250
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K01/2
K01/3
K01/4
Group 25: Fuses, Relays and Switches
Relay for power supply to electronics
Relay for accessories
Acoustic alarm
Relays (relay box K02) on tractors with AutoPowr/IVT transmission up
to serial no. 398655
DEFINITIONS:
K02/1
K02/2
K02/3
K02/4
K02/5
<- Go to Section TOC
Enable relay
Alternator relay
Relay for LTC coolant pump
Not used
Relay for power supply to E-ICV
Section 40 page 251
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K02/6
K02/7
Group 25: Fuses, Relays and Switches
Relay for power supply to E-SCV 3, E-SCV 4
Relay for power supply to E-SCV 1, E-SCV 2
Fuses (fuse box F03) on tractors with AutoPowr/IVT transmission 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.
<- Go to Section TOC
Section 40 page 252
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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 20-amp, LTC coolant pump
F03/10 20-amp, power supply to E-ICV
F03/11 10-amp, power supply to E-SCV 3, E-SCV 4
F03/12 10-amp, power supply to E-SCV 1, E-SCV 2
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
Fuses (fuse box F04) on tractors with AutoPowr/IVT transmission up to
serial no. 398655
<- Go to Section TOC
Section 40 page 253
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F04/01
F04/02
F04/03
F04/04
F04/05
<- Go to Section TOC
10-amp, ECU controller (power supply)
20-amp, ECU controller (battery voltage)
Not used
15-amp, main switch (BAT)
30-amp, accessories
Section 40 page 254
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F04/06
F04/07
F04/08
F04/09
F04/10
F04/11
F04/12
F04/13
F04/14
F04/15
F04/16
Group 25: Fuses, Relays and Switches
30-amp, power supply for electronics
30-amp, accessories
20-amp, fuel preheater
10-amp, basic informator, SFA controller (power supply)
10-amp, basic informator (battery voltage)
10-amp, fuel pump
10-amp, performance monitor (PRF)
10-amp, CAN BUS terminator, service socket
10-amp, UIC controller (power supply)
10-amp, TCU controller (power supply)
Not used
Fuses (fuse box F05) on tractors with AutoPowr/IVT transmission up to
serial no. 398655
<- Go to Section TOC
Section 40 page 255
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F05/01
F05/02
F05/03
F05/04
F05/05
<- Go to Section TOC
10-amp, air-conditioning system and relay for fan
10-amp, 2-pin plug for front loader
10-amp, PLC controller (power supply)
10-amp, PLC controller (battery voltage)
10-amp, TCU controller (battery voltage)
Section 40 page 256
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F05/06
F05/07
F05/08
F05/09
F05/10
F05/11
F05/12
F05/13
F05/14
F05/15
F05/16
Group 25: Fuses, Relays and Switches
Not used
Not used
10-amp, windshield wiper and washer
10-amp, rear window wiper and washer
10-amp, electrical rear-view mirror
10-amp, GreenStar, TEC controller (power supply)
10-amp, dome light, radio (battery voltage)
20-amp, fan
20-amp, fan
10-amp, 3-terminal socket, socket strip (power supply)
30-amp, 3-terminal socket, socket strip (battery voltage)
Fuses (fuse box F06) on tractors with AutoPowr/IVT transmission up to
serial no. 398655
<- Go to Section TOC
Section 40 page 257
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F06/01
F06/02
F06/03
F06/04
F06/05
<- Go to Section TOC
10-amp, horn
10-amp, cigarette lighter
10-amp, operator′s seat
10-amp, radio (power supply)
10-amp, shift console light, radio lighting
Section 40 page 258
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F06/06
F06/07
F06/08
F06/09
F06/10
F06/11
F06/12
F06/13
F06/14
F06/15
F06/16
Group 25: Fuses, Relays and Switches
10-amp, beacon light
10-amp, front corner worklight
10-amp, worklights on fenders (rear-facing)
10-amp, outer worklight on rear of cab roof
10-amp, inner worklight on rear of cab roof
10-amp, outer worklight on front of cab roof
10-amp, inner worklight on front of cab roof
Fuse tester
Not used
Not used
15-amp, light switch (pin B)
Fuses (fuse box F07) on tractors with AutoPowr/IVT transmission up to
serial no. 398655
<- Go to Section TOC
Section 40 page 259
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
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
<- Go to Section TOC
Section 40 page 260
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F07/06
F07/07
F07/08
F07/09
F07/10
F07/11
F07/12
F07/13
F07/14
F07/15
F07/16
Group 25: Fuses, Relays and Switches
10-amp, dipped-beam headlight, left
10-amp, dipped-beam headlight, right
15-amp, full-beam headlights
30-amp, lights on cab frame
10-amp, r.h. tail light, l.h. clearance light, license plate light
10-amp, l.h. tail light, r.h. clearance light
10-amp, lighting
10-amp, dipped beam, left (lights on cab frame)
10-amp, dipped beam, right (lights on cab frame)
30-amp, headlights
15-amp, full-beam headlights
Relays (relay box K08) on tractors with AutoPowr/IVT transmission up
to serial no. 398655
<- Go to Section TOC
Section 40 page 261
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K08/1
K08/2
K08/3
K08/4
K08/5
K08/6
K08/7
Group 25: Fuses, Relays and Switches
Relay for full-beam headlights
Relay for dipped-beam headlights
Relay for lights on cab frame
Relay for headlights and worklights on cab frame
Relay for worklights on front of cab roof
Relay for worklights on rear of cab roof
Relay for front corner/fender worklights (rear-facing)
Relays (relay box K09) on tractors with AutoPowr/IVT transmission up
to serial no. 398655
<- Go to Section TOC
Section 40 page 262
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K09/1
K09/1
K09/2
K09/2
K09/3
K09/4
K09/5
K09/6
K09/7
<- Go to Section TOC
Group 25: Fuses, Relays and Switches
3-amp, lighting diode
1-amp, diode for power supply to electronics
3-amp, CAN BUS diode
1-amp, CAN BUS diode
Relay for fuel preheater
Relay for air-conditioning system
Not used
Not used
Not used
Section 40 page 263
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K10) on tractors with AutoPowr/IVT transmission up
to serial no. 398655
DEFINITIONS:
K10/1
K10/2
K10/3
K10/4
<- Go to Section TOC
Fan relay
Acoustic alarm for park lock
Relay for 3-terminal socket, power outlet strip
Plug for ”come home” mode
Section 40 page 264
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Fuse and Relay Boxes on Tractors with Operator′s
Cab and AutoPowr/IVT Transmission from Serial No.
398656
Fuse and relay boxes on tractors with AutoPowr/IVT transmission from
serial no. 398656
→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
B
C
<- Go to Section TOC
Relay box K01
Relay box K02
Fuse box F03
Section 40 page 265
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
D
E
F
G
H
I
J
Group 25: Fuses, Relays and Switches
Fuse box F04
Fuse box F05
Fuse box F06
Fuse box F07
Relay box K08
Relay box K09
Relay box K10
Relays (relay box K01) on tractors with AutoPowr/IVT transmission
from serial no. 398656
DEFINITIONS:
K01/1
<- Go to Section TOC
Relay for accessories
Section 40 page 266
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K01/2
K01/3
K01/4
Group 25: Fuses, Relays and Switches
Relay for power supply to electronics
Relay for accessories
Acoustic alarm
Relays (relay box K02) on tractors with AutoPowr/IVT transmission
from serial no. 398656
DEFINITIONS:
K02/1
K02/2
K02/3
K02/4
K02/5
<- Go to Section TOC
Enable relay
Alternator relay
Not used
Not used
Relay for power supply to E-ICV
Section 40 page 267
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
K02/6
K02/7
Group 25: Fuses, Relays and Switches
Relay for power supply to E-SCV 3, E-SCV 4
Relay for power supply to E-SCV 1, E-SCV 2
Fuses (fuse box F03) on tractors with AutoPowr/IVT transmission from
serial no. 398656
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
<- Go to Section TOC
Section 40 page 268
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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 and 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 10-amp, power supply to E-SCV 3, E-SCV 4
F03/12 10-amp, power supply to E-SCV 1, E-SCV 2
F03/13 10-amp, SIC controller (battery voltage)
F03/14 10-amp, service plug, JDLink, GreenStar
F03/15 10-amp, SIC controller (power supply)
F03/16 20-amp, heated rear window
Fuses (fuse box F04) on tractors with AutoPowr/IVT transmission from
serial no. 398656
<- Go to Section TOC
Section 40 page 269
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F04/01 10-amp, ECU controller (power supply)
F04/02 10-amp, ECU controller (battery voltage)
F04/03 10-amp, GreenStar (power supply)
F04/04 15-amp, main (key) switch (battery voltage)
F04/05 30-amp, accessories
<- Go to Section TOC
Section 40 page 270
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
F04/06
F04/07
F04/08
F04/09
F04/10
F04/11
F04/12
F04/13
F04/14
F04/15
F04/16
Group 25: Fuses, Relays and Switches
30-amp, power supply for electronics
30-amp, accessories
20-amp, fuel preheater
10-amp, basic informator BIF, SFA controller (power supply)
10-amp, basic informator BIF (battery voltage)
10-amp, fuel pump
10-amp, performance monitor PRF, JDLink (power supply)
10-amp, CAN BUS terminator
10-amp, UIC controller (power supply)
10-amp, TCU controller (power supply)
Not used
Fuses (fuse box F05) on tractors with AutoPowr/IVT transmission from
serial no. 398656
<- Go to Section TOC
Section 40 page 271
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
10-amp, air-conditioning system, relay for fan, ClimaTrak (power
F05/01
supply)
F05/02 10-amp, 2-pin plug for front loader
F05/03 10-amp, PLC controller (power supply)
F05/04 10-amp, PLC controller (battery voltage)
<- Go to Section TOC
Section 40 page 272
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Section 40 - ELECTRICAL SYSTEM
F05/05
F05/06
F05/07
F05/08
F05/09
F05/10
F05/11
F05/12
F05/13
F05/13
F05/14
F05/14
F05/15
F05/16
Group 25: Fuses, Relays and Switches
10-amp, TCU controller (battery voltage)
Not used
10-amp, accessories
10-amp, windshield wiper and washer
10-amp, rear window wiper and washer
10-amp, electric rear-view mirrors, signal socket
10-amp, GreenStar, TEC controller (power supply)
10-amp, dome light, radio (battery voltage)
20-amp, fan
30-amp, ClimaTrak (fan)
20-amp, fan
10-amp, ClimaTrak (battery voltage)
10-amp, 3-terminal socket, socket strip (power supply)
30-amp, 3-terminal socket, socket strip (battery voltage)
Fuses (fuse box F06) on tractors with AutoPowr/IVT transmission from
serial no. 398656
<- Go to Section TOC
Section 40 page 273
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
DEFINITIONS:
F06/01 10-amp, horn
F06/02 10-amp, cigarette lighter
F06/03 15-amp, operator′s seat
F06/04 10-amp, radio (power supply)
F06/05 10-amp, shift console light and radio lighting
<- Go to Section TOC
Section 40 page 274
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Section 40 - ELECTRICAL SYSTEM
F06/06
F06/07
F06/08
F06/09
F06/10
F06/11
F06/12
F06/13
F06/14
F06/15
F06/16
Group 25: Fuses, Relays and Switches
10-amp, beacon light
10-amp, front corner worklight
10-amp, worklights on fenders (rear-facing)
15-amp, outer worklight on rear of cab roof or Xenon (HID) worklight
on right rear of cab roof
15-amp, inner worklight on rear of cab roof or Xenon (HID) worklight
on left rear of cab roof
10-amp, outer worklight on front of cab roof
10-amp, inner worklight on front of cab roof
Fuse tester
10-amp, AutoTrac (power supply)
10-amp, AutoTrac (battery voltage)
15-amp, light switch (pin B)
Fuses (fuse box F07) on tractors with AutoPowr/IVT transmission from
serial no. 398656
<- Go to Section TOC
Section 40 page 275
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
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
<- Go to Section TOC
Section 40 page 276
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Section 40 - ELECTRICAL SYSTEM
F07/06
F07/07
F07/08
F07/09
F07/10
F07/11
F07/12
F07/13
F07/14
F07/15
F07/16
Group 25: Fuses, Relays and Switches
10-amp, dipped-beam headlight, left
10-amp, dipped-beam headlight, right
15-amp, full-beam headlights
30-amp, lights on cab frame
10-amp, r.h. tail light, l.h. clearance light, license plate light
10-amp, l.h. tail light, r.h. clearance light
10-amp, lighting
10-amp, dipped beam, left (lights on cab frame)
10-amp, dipped beam, right (lights on cab frame)
30-amp, headlights
15-amp, full-beam headlights
Relays (relay box K08) on tractors with AutoPowr/IVT transmission
from serial no. 398656
<- Go to Section TOC
Section 40 page 277
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Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K08/1
K08/2
K08/3
K08/4
K08/5
K08/6
K08/7
Group 25: Fuses, Relays and Switches
Relay for full-beam headlights
Relay for dipped-beam headlights
Relay for lights on cab frame
Relay for headlights and worklights on cab frame
Relay for worklights on front of cab roof
Relay for worklights on rear of cab roof
Relay for front corner/fender worklights (rear-facing)
Relays (relay box K09) on tractors with AutoPowr/IVT transmission
from serial no. 398656
<- Go to Section TOC
Section 40 page 278
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Section 40 - ELECTRICAL SYSTEM
DEFINITIONS:
K09/1
K09/1
K09/2
K09/2
K09/3
K09/4
K09/5
K09/6
K09/7
<- Go to Section TOC
Group 25: Fuses, Relays and Switches
3-amp, lighting diode
1-amp, diode for power supply to electronics
3-amp, CAN BUS diode
1-amp, CAN BUS diode
Relay for fuel preheater
Relay for air-conditioning system
Not used
Not used
Not used
Section 40 page 279
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Relays (relay box K10) on tractors with AutoPowr/IVT transmission
from serial no. 398656
DEFINITIONS:
K10/1
K10/1
K10/2
K10/3
K10/4
Fan relay
ClimaTrak bridging plug
Acoustic alarm for park lock
Relay for 3-terminal socket, power outlet strip
Plug for ”come home” mode
Replacing the Main Fuses
<- Go to Section TOC
Section 40 page 280
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
Group 25: Fuses, Relays and Switches
Fuse covers
Main fuse (F13)
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Open the hood.
Take covers (A) off the two fuses.
Replace fuse (B) or (C).
<- Go to Section TOC
Section 40 page 281
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Put the covers back on the fuses.
<- Go to Section TOC
Section 40 page 282
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Take the cover off the fuse.
<- Go to Section TOC
Section 40 page 283
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Take the cover off the fuse.
Replace fuse (B).
Put the cover back on the fuse.
<- Go to Section TOC
Section 40 page 284
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Fuses of Electrical Starting Aid for Stage I
and II Engines to 97/68/EC (Level 4 or 11 ECUs)
(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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
<- Go to Section TOC
Section 40 page 285
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Take the cover off the fuse.
Replace fuse (B).
Put the cover back on the fuse.
<- Go to Section TOC
Section 40 page 286
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Open the hood.
Take cover (A) off the fuse.
Replace fuse (B).
<- Go to Section TOC
Section 40 page 287
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Put the cover back on the fuse.
<- Go to Section TOC
Section 40 page 288
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Fuse for Fuel Injection Pump (with Stage
I Engines to 97/68/EC (Level 4 ECU) (AutoPowr/IVT
Transmission)
LEGEND:
A
B
Fuse covers
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Open the hood.
Take cover (A) off the fuse.
<- Go to Section TOC
Section 40 page 289
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replace fuse (B).
Put the cover back on the fuse.
<- Go to Section TOC
Section 40 page 290
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the LTC Coolant Pump Fuse
(AutoPowr/IVT Transmission)
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Open the hood.
Take cover (A) off the fuse.
Replace fuse (B).
<- Go to Section TOC
Section 40 page 291
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Put the cover back on the fuse.
<- Go to Section TOC
Section 40 page 292
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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:
To prevent damage to the electrical system, never use a fuse with a rating
higher than the one already installed.
Lift hood.
<- Go to Section TOC
Section 40 page 293
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Take covers (A) off the two fuses.
Replace fuse (B) or (C).
Put the covers back on the fuses.
<- Go to Section TOC
Section 40 page 294
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Starting Motor Relay for Stage I and II
Engines to 97/68/EC (Level 4 or 11 ECUs)
LEGEND:
A
B
C
Starting motor relay cover
Cap screw
Starting motor relay (K01)
The starting motor relay is on the left side of the engine block.
CAUTION:
Disconnect the battery ground cable (-).
Open the hood.
Remove cap screw (B) and cover (A).
<- Go to Section TOC
Section 40 page 295
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
→NOTE:
For identification purposes, mark the wires before disconnecting them.
Disconnect relay (C) and insert a new one.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement
Specification
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
<- Go to Section TOC
Section 40 page 296
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Starting Motor Relay for Stage I and II
Engines to 97/68/EC (Level 4 or 11 ECUs)
(AutoPowr/IVT Transmission)
LEGEND:
A
B
C
Starting motor relay cover
Cap screw
Starting motor relay (K01)
The starting motor relay is on the left side of the engine block.
CAUTION:
Disconnect the battery ground cable (-).
Open the hood.
Remove cap screw (B) and cover (A).
<- Go to Section TOC
Section 40 page 297
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
→NOTE:
For identification purposes, mark the wires before disconnecting them.
Disconnect relay (C) and insert a new one.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement
Specification
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
<- Go to Section TOC
Section 40 page 298
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Relay of Electrical Starting Aid for Stage I
and II Engines to 97/68/EC (Level 4 or 11 ECUs)
LEGEND:
A
B
C
Cover of relay for electrical starting aid
Nut with protective cap
Relay K36, electrical starting aid
The electrical starting aid relay is located at the right-hand side of the engine block.
CAUTION:
Disconnect the battery ground cable (-).
Open the hood.
Take off the protective cap and nut (B).
Remove cover (A).
<- Go to Section TOC
Section 40 page 299
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
→NOTE:
For identification purposes, mark the wires before disconnecting them.
Disconnect relay (C) and insert a new one.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement Specification
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
<- Go to Section TOC
Section 40 page 300
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Relay of Electrical Starting Aid for Stage I
and II Engines to 97/68/EC (Level 4 or 11 ECUs)
(AutoPowr/IVT Transmission)
LEGEND:
A
B
C
Cover of relay for electrical starting aid
Nut with protective cap
Relay K36, electrical starting aid
The electrical starting aid relay is located at the right-hand side of the engine block.
CAUTION:
Disconnect the battery ground cable (-).
Open the hood.
Take off the protective cap and nut (B).
<- Go to Section TOC
Section 40 page 301
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Remove cover (A).
→NOTE:
For identification purposes, mark the wires before disconnecting them.
Disconnect relay (C) and insert a new one.
Assemble in reverse order.
Tightening torques for installation:
Item
Measurement Specification
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
Replacing Relay for Fuel Injection Pump (with Stage
I Engines to 97/68/EC only (Level 4 ECU))
LEGEND:
A
B
C
Attaching screw
Plug
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.
<- Go to Section TOC
Section 40 page 302
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Take out attaching screw (A).
Disconnect plug (B).
Replace relay (C) with a new one.
Assemble in reverse order.
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.
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 303
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Battery Cut-off Switch Relay
Version 1
LEGEND:
A
B
C
D
Nut and washer
Nut and washer
Screw
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:
Disconnect the battery ground cable (-).
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.
Assemble in reverse order.
Tightening torques for installation:
<- Go to Section TOC
Section 40 page 304
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Item
Measurement Specification
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
Version 2
LEGEND:
A
B
C
D
E
F
Latches
Covers
Nuts and washers
Screws and washers
Screws and nuts
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
<- Go to Section TOC
Section 40 page 305
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
CAUTION:
Disconnect the battery ground cable (-).
Open the hood.
Disconnect the battery.
Open latches (A) and remove covers (B).
Remove nuts and washers (C) and battery cable.
→NOTE:
For identification purposes, mark the wires before disconnecting them.
Remove screws and washers (D) and control line.
Take off screws and nuts (E) and replace the battery cut-off relay (version 2) (F).
Assemble in reverse order.
Item
Measurement Specification
Battery cable to battery cut-off relay (version 2), M10 hex. nut
Torque
15 to 20 N˙m
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
<- Go to Section TOC
Section 40 page 306
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Battery Cut-off Switch Relay
Version 1
LEGEND:
A
B
C
Screw
Relay K48 for battery cut-off switch (version 1)
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.
Assemble in reverse order.
Version 2
<- Go to Section TOC
Section 40 page 307
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
Group 25: Fuses, Relays and Switches
Screw
Relay K57 for battery cut-off switch (version 2)
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.
Assemble in reverse order.
Replacing the Main Switch
LEGEND:
A
B
C
Main switch
Plug
Special nut
If necessary: Carry out preliminary work, refer to“Removing Trim Panels from Cowl”.
CAUTION:
Disconnect negative (-) cable from battery.
Take off the special nut (C) on the outside.
<- Go to Section TOC
Section 40 page 308
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Pull out main switch (A).
Pull off plug (B) and install new switch.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 309
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Brake Switches
LEGEND:
A
B
C
Brake switch
Plug
Screws
For preliminary work, refer to“Removing Trim Panels from Cowl”.
Disconnect plug (B).
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 PowerFill”, 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.
For installation, follow removal procedure in reverse order.
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
<- Go to Section TOC
Section 40 page 310
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
Group 25: Fuses, Relays and Switches
Screws
Screws
Console
Sheet-metal nut
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 311
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Worklight Switches
LEGEND:
A
B
C
D
Worklight switches
Plugs
Worklight switch
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
<- Go to Section TOC
Section 40 page 312
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Removing electrical connectors
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 313
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switch for Lights on Cab Frame
LEGEND:
A
B
Switch for lights on cab frame
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Extract the wires of the switch (A; for lights on cab frame) from the plug using a JDG777
Extraction tool
JDG777
Removing electrical connectors
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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 switch for lights on cab frame (A) out to the front of the console and replace it with
a new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Beacon Light Switch
LEGEND:
A
B
Beacon light switch
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Extract the wires of the switch (A; for beacon light) from the plug using a JDG777
Extraction tool
JDG777
Removing electrical connectors
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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 beacon light switch (A) out to the front of the console and replace it with a new one.
For installation, follow removal procedure in reverse order.
Replacing the Hazard Warning Light Switch
LEGEND:
A
B
C
D
Screws
Screws
Console
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.
For installation, follow removal procedure in reverse order.
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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”.
<- Go to Section TOC
Section 40 page 318
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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.
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
H
J
Group 25: Fuses, Relays and Switches
Switch (turn signal/horn/full-beam)
Switch (electrical reverser control)
Screws
Screws
Screws
Screws
Screws
Wiring harness (W18; windshield wiper switch)
Microswitch (roll mode)
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
K
L
M
N
O
P
Group 25: Fuses, Relays and Switches
Lever (roll mode)
Windshield wiper and washer switch
Mounting
Grip for windshield wiper and washer
Cover
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).
Assemble in reverse order.
Tighten the steering wheel nut.
Item
Measurement
Specification
Steering wheel to steering column, hex. nut
Torque
50 N˙m
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
, Accessing the Addresses and Diagnostic Trouble Codes”.
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”.
<- Go to Section TOC
Section 40 page 321
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Tractor with electrical reverser control (PowrQuad Plus and AutoQuad
Plus transmissions) from serial no. 398656 (version 2)
LEGEND:
A
B
C
D
E
Switch (turn signal/horn/full-beam)
Switch (reverser control)
Screws
Cover
Screws
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
F
G
H
J
K
L
M
N
O
P
Group 25: Fuses, Relays and Switches
Screws
Screws
Guide sleeve
Wiring harness (W18; windshield wiper switch)
Intermittent-wipe relay
Microswitch (roll mode)
Lever (roll mode)
Windshield wiper and washer switch
Mounting
Grip for windshield wiper and washer
Remove the steering wheel.
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).
Replace switches (A) or (B) as complete assemblies.
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).
Assemble in reverse order.
Tighten the steering wheel nut.
Item
Measurement
Specification
Steering wheel to steering column, hex. nut
Torque
50 N˙m
35 lb-ft
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace switch (A) or microswitch (L), you must check the basic
control unit (BCU) for diagnostic trouble codes. See ”Reference 245-05-002
, Accessing the Addresses and Diagnostic Trouble Codes”.
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”.
Tractors with reverser control (AutoPowr/IVT transmission)
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
H
J
K
Group 25: Fuses, Relays and Switches
Switch (turn signal/horn/full-beam)
Switch (reverser control)
Screws
Cover
Screws
Screws
Screws
Guide sleeve
Wiring harness (W18; windshield wiper switch)
Intermittent-wipe relay
<- Go to Section TOC
Section 40 page 325
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Section 40 - ELECTRICAL SYSTEM
L
M
N
O
P
Group 25: Fuses, Relays and Switches
Microswitch (roll mode)
Lever (roll mode)
Windshield wiper and washer switch
Mounting
Grip for windshield wiper and washer
Remove the steering wheel.
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).
Replace switches (A) or (B) as complete assemblies.
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).
Assemble in reverse order.
Tighten the steering wheel nut.
Item
Measurement
Specification
Steering wheel to steering column, hex. nut
Torque
50 N˙m
35 lb-ft
IMPORTANT:
If you replace switch (A) or microswitch (L), you must check the basic
control unit (BCU) for diagnostic trouble codes. See ”Reference 245-05-002
, Accessing the Addresses and Diagnostic Trouble Codes”.
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”.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Rear Window Wiper and Washer
Switch
LEGEND:
A
B
C
Knob
Sheet-metal nut
Symbol disk
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
→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.
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Disconnect the plug and replace the rear window wiper and washer switch with a new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Windshield/Rear Window Switch
Replacing the windshield switch
LEGEND:
A
B
C
D
Wiring connector
Screws
Cover
Windshield switch
For preliminary work, refer to“Removing Trim Panels from Cowl”.
Disconnect connector (A).
→NOTE:
For identification purposes, mark the layout of the leads before you extract
them.
Using JDG777
Extraction tool
<- Go to Section TOC
Section 40 page 329
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
JDG777
Removing electrical connectors
tool, extract male terminal body.
Extract terminals from plug (refer to“METRI PACK Connectors with Terminal Lock at the
Rear”in Section 40, Group 05).
→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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the rear window switch
LEGEND:
A
B
Screws
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.
For installation, follow removal procedure in reverse order.
Replacing the Dome Light Door Switch
LEGEND:
<- Go to Section TOC
Section 40 page 331
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Section 40 - ELECTRICAL SYSTEM
A
Group 25: Fuses, Relays and Switches
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Handbrake Switch
LEGEND:
A
B
C
D
E
F
G
Screws
Trims
Screws
Washers
Bracket
Plug
Handbrake switch
Take out screws (A) and remove trims (B).
Remove trim panels from the rear wall of the cab.
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the handbrake 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”.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Front Wheel Drive Switch
LEGEND:
A
B
Front-wheel drive switch
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press the front-wheel drive switch (A) out to the front of the console and replace it with a new
one.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the front-wheel drive 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”.
<- Go to Section TOC
Section 40 page 335
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Headland Management (HMS) Switch
LEGEND:
A
Switch for Headland Management System (HMS)
B
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press out the HMS switch (A) to the front of the console and replace it with a new one.
For installation, follow removal procedure in reverse order.
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”.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Record/Save Switch
LEGEND:
A
B
Record/save switch
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press the record/save switch (A) out to the front of the console and replace it with a new one.
For installation, follow removal procedure in reverse order.
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 ,
Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Program Switch
Tractors with shift console
LEGEND:
A
B
C
Program switch
Plug
SCV control levers
Remove the grips from the SCV control levers (C).
Remove cover from switch console.
Disconnect plug (B).
Press the program switch (A) out to the front of the console and replace it with a new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the program 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”.
Tractors with Command Arm
LEGEND:
A
B
<- Go to Section TOC
Screws
Screws
Section 40 page 339
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
C
D
E
Group 25: Fuses, Relays and Switches
Cover
Program switch
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.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the program 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”.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Rear PTO Preselector Switch
LEGEND:
A
B
Rear PTO preselector switch
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press the rear PTO preselector switch (A) out to the front of the console and replace it with a
new one.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the rear PTO preselector 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”.
<- Go to Section TOC
Section 40 page 341
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switch for AutoQuad Transmission
LEGEND:
A
B
Switch for AutoQuad transmission
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plugs (B).
Press out switch (A; for AutoQuad transmission) to the front of the console and replace it with
a new one.
For installation, follow removal procedure in reverse order.
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”.
<- Go to Section TOC
Section 40 page 342
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replace the Switch for Gear Selector and Automode
Switches on range shift lever
LEGEND:
1
2
A
B
C
Shift lever for PowrQuad Plus and AutoQuad transmissions
Shift lever for AutoQuad Plus transmission
Screws
Grip
Plug
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
D
Group 25: Fuses, Relays and Switches
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.
Assemble in reverse order.
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
B
Gear selector switch
Plug
Cab
Remove panel from control console.
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Disconnect plug (B).
Press gear selector switch (A) out to the top and replace it with a new one.
Assemble in reverse order.
CAUTION:
The symbols on all the gear selector switches must match (i.e. the symbols
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
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 from serial no. 398656
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
Group 25: Fuses, Relays and Switches
Bowden cables
Screws
Screw
Cable binder
Plug
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).
Disconnect plug (E).
Press out gear selector switch (F) to the front of the console and replace it with a new one.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Assemble in reverse order.
CAUTION:
The symbols on all the gear selector switches must match (i.e. the symbols
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
the electronic PowrQuad controller (EPC) for diagnostic trouble codes. See
”Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
Codes”.
<- Go to Section TOC
Section 40 page 347
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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
B
C
D
E
Park lock switch
Stud with nut
Plug
Neutral position of range shift lever
Switch point
Remove floor-mat and take trim elements off the control console.
Disconnect plug (C).
Take the nuts off studs (B).
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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.
Assemble in reverse order.
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
from serial no. 398656
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
PowrQuad controller (EPC) for diagnostic trouble codes. See ”Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
Section 40 page 349
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Fan Switch
<- Go to Section TOC
Section 40 page 350
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
H
Group 25: Fuses, Relays and Switches
Console
Knobs
Phillips-head screws
Panel
Phillips-head screws
Cover
Phillips-head screws
Cover
Carefully pry out consoles (A) using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
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.
For installation, follow removal procedure in reverse order.
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switch of the Air-Conditioning System
Compressor
LEGEND:
A
B
Compressor switch (air conditioning)
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Differential Lock Switch.
LEGEND:
A
B
C
Differential lock switch
Floor plate
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.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the differential lock 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”.
<- Go to Section TOC
Section 40 page 353
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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
B
PTO switch
Plug
Remove panel from control console.
Disconnect plug (B).
Replacing the PTO switch on tractors with shift console
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
H
I
Group 25: Fuses, Relays and Switches
Knob
Knob cap
Snap ring
Washer
Spring
Washer
Collar
Shift console
Switch
Remove knob cap (B) and snap ring (C).
Remove knob (A) and parts (D - G).
Replace parts or switch (I) as necessary.
<- Go to Section TOC
Section 40 page 355
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
For installation, follow removal procedure in reverse order.
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
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
Removing the rear PTO switch and/or front PTO switch from tractors
with Command Arm
<- Go to Section TOC
Section 40 page 356
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
Group 25: Fuses, Relays and Switches
Screws
Screws
Cover
Rear PTO switch
Plug
Front PTO switch
Plug
On the underside of the Command Arm, take out screws (A).
Take out screws (B) and lay the panel on one side.
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).
For installation, follow removal procedure in reverse order.
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
“Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
Codes”.
<- Go to Section TOC
Section 40 page 357
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the External Control Switch for the Rear
PTO
LEGEND:
A
B
C
D
Screws
Cover
Plug
Threaded bushing
Take out screws (A) and remove cover (B).
Disconnect plug (C).
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 358
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the external control switch for the rear PTO, you should
check the basic control unit (BCU) for diagnostic trouble codes. See
“Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
Codes”.
<- Go to Section TOC
Section 40 page 359
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Rockshaft′s Remote Control Switch
LEGEND:
A
B
C
D
Screws
Cover
Plug
Screws
Take out screws (A) and remove cover (B).
Disconnect plug (C).
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.
Assemble in reverse order.
IMPORTANT:
If you replace the rockshaft′s remote control 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”.
<- Go to Section TOC
Section 40 page 360
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switches for the Electrical Rear-View
Mirrors
LEGEND:
A
B
Switch for the electrical rear-view mirrors
Plugs
Carefully pry out the consoles using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
Disconnect plugs (B).
Press out switches (A; for electrical rear-view mirrors) to the front of the console and replace
them with new ones.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 361
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switch for the Heated Rear-View
Mirrors
LEGEND:
A
B
Switch for the heated rear-view mirrors
Plug
Carefully pry out the consoles using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press out switch (A; for heated rear-view mirror) to the front of the console and replace it with
a new one.
For installation, follow removal procedure in reverse order.
Replacing the Switch for the Heated Rear Window
<- Go to Section TOC
Section 40 page 362
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
Group 25: Fuses, Relays and Switches
Switch for the heated rear window
Plug
Carefully pry out the consoles using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
Disconnect plug (B).
Press out switch (A; for heated rear window) to the front of the console and replace it with a
new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 363
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing Switch of Battery Cut-off Switch
Version 1
LEGEND:
A
B
C
D
Console
Lock-nut
Switch of battery cut-off switch (version 1) (S117)
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.
Assemble in reverse order.
Version 2
<- Go to Section TOC
Section 40 page 364
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
Group 25: Fuses, Relays and Switches
Console
Switch of battery cut-off switch (version 2) (S125)
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).
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 365
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replace the AutoTrac Switch
Tractors with shift console
Remove the grips from the selective control valve levers.
Remove cover from switch console.
Disconnect plug.
Press out AutoTrac switch (A) to the front of the console and replace it with a new one.
Assemble in reverse order.
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
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
Tractors with Command Arm
<- Go to Section TOC
Section 40 page 366
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
Group 25: Fuses, Relays and Switches
Screws
Screws
Cover
AutoTrac switch
Plug
On the underside of the Command Arm, take out screws (A).
Take out screws (B) and lay the panel on one side.
Open out cover (C).
<- Go to Section TOC
Section 40 page 367
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Disconnect plug (E).
From the inside, press out AutoTrac switch (D) and replace it with a new one.
Assemble in reverse order.
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
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
Section 40 page 368
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Switch for the Electro-hydraulic Pickup Hitch
LEGEND:
A
B
C
D
E
Screws
Screws
Cover
Switch for the electro-hydraulic pick-up hitch
Plug
Tractors with cab and CommandArm only
<- Go to Section TOC
Section 40 page 369
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
On the underside of the CommandArm, 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 the switch for the electro-hydraulic pick-up hitch (D), and replace it
with a new one.
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 370
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Cruise Control Potentiometer on
Tractors with AutoQuad Transmission
LEGEND:
A
B
C
Knob
Hex. nut
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
Disconnect plug and remove console.
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.
<- Go to Section TOC
Section 40 page 371
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the cruise control potentiometer, you should check the
engine control unit (ECU) for diagnostic trouble codes. See “Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
Section 40 page 372
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the Cruise Control Potentiometer on
Tractors with AutoPowr/IVT Transmission
LEGEND:
A
B
C
Knob
Hex. nut
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
Disconnect plug and remove console.
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.
<- Go to Section TOC
Section 40 page 373
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the cruise control potentiometer, you should check the user
interface controller (UIC) for diagnostic trouble codes. See “Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
Section 40 page 374
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replace the Auto-mode Potentiometer on Tractors
with AutoQuad Plus Transmission
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
→NOTE:
For identification purposes, mark the plugs before you pull them out.
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.
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 375
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the Auto-mode potentiometer, you must check the electronic
PowrQuad controller (EPC) for diagnostic trouble codes. See ”Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
<- Go to Section TOC
Section 40 page 376
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Rockshaft Control
Replacing the sensitivity potentiometer of rockshaft control on
tractors with shift console
LEGEND:
A
B
C
D
E
<- Go to Section TOC
Sensitivity potentiometer of rockshaft control
Shield
Plug
Screw
Hex. nut
Section 40 page 377
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Remove cover from switch console.
Disconnect plug (C).
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.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the sensitivity potentiometer of rockshaft control, you should
check the basic control unit (BCU) for diagnostic trouble codes. See
“Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
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
<- Go to Section TOC
Section 40 page 378
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
Group 25: Fuses, Relays and Switches
Position feedback unit
Plug
Hex. socket screws
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 379
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the position feedback unit, you should check the basic
control unit (BCU) for diagnostic trouble codes. See “Reference 245-05-002
, Accessing the Addresses and Diagnostic Trouble Codes”.
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
<- Go to Section TOC
Section 40 page 380
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
Group 25: Fuses, Relays and Switches
Knobs
Hex. nuts
Depth-setting potentiometer of rockshaft control
Hex. socket screw
Screws
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.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 381
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the position feedback unit′s harness, you should check the
basic control unit (BCU) for diagnostic trouble codes. See “Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
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
<- Go to Section TOC
Section 40 page 382
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
Group 25: Fuses, Relays and Switches
Screws
Screws
Cover
Rockshaft control potentiometers
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).
Pull off the knobs.
Take off the lock nut.
Disconnect plug (E).
Pull out potentiometer (D) and install a new one.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the potentiometers, you should check the basic control unit
(BCU) for diagnostic trouble codes. See “Reference 245-05-002 , Accessing
the Addresses and Diagnostic Trouble Codes”.
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)”.
<- Go to Section TOC
Section 40 page 383
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Replacing the depth-setting potentiometer on tractors with Command
Arm
LEGEND:
A
B
C
D
E
Screws
Screws
Cover
Depth-setting potentiometer of rockshaft control
Plug
On the underside of the Command Arm, take out screws (A).
<- Go to Section TOC
Section 40 page 384
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Take out screws (B) and lay the panel on one side.
Fold out cover (C).
Carefully pry out the depth-setting potentiometer (D) using a screwdriver at the location
indicated (arrow).
Disconnect plug (E).
Replace the depth-setting potentiometer with a new one.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the depth-setting potentiometer of rockshaft control, you
should check the basic control unit (BCU) for diagnostic trouble codes. See
“Reference 245-05-002 , Accessing the Addresses and Diagnostic Trouble
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
<- Go to Section TOC
Section 40 page 385
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
Group 25: Fuses, Relays and Switches
Screws
Screws
Cover
Rockshaft control rapid withdrawal switch
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 rapid withdrawal switch (D) and replace it with a new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 386
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
IMPORTANT:
If you replace the rapid withdrawal 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”.
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).
<- Go to Section TOC
Section 40 page 387
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Electrical Activators for Selective Control Valves (ESCV)
Replacing the control lever
LEGEND:
A
B
C
D
E
Screws
Screws
Cover
Electrical activators of the selective control valves
Plugs
<- Go to Section TOC
Section 40 page 388
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Section 40 - ELECTRICAL SYSTEM
F
Group 25: Fuses, Relays and Switches
Screws
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 the relevant plug (E).
Take out the relevant screw (F).
Take out the relevant electrical SCV activator (D), and install a new one.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace any of the SCVs′ electrical activators, you should check the ESCV/E-ICV controller (SIC) for diagnostic trouble codes. See “Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
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
<- Go to Section TOC
Section 40 page 389
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
Group 25: Fuses, Relays and Switches
Function adjustment wheel
Grub screws
Control knob
Nut
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
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.
For installation, follow removal procedure in reverse order.
Replacing the transport lock switch
<- Go to Section TOC
Section 40 page 390
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
Group 25: Fuses, Relays and Switches
Transport lock switch
Plug
Carefully pry out the console using a screwdriver at the locations indicated (arrows).
Disconnect plug (B).
Press out transport lock switch (A) to the front of the console and replace it with a new one.
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 391
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
Electrical Activators for Independent Control Valves
(E-ICV)
Removing the multi-function lever console
LEGEND:
A
B
C
D
Hex. socket screw
Multi-function lever console
Bracket
Armrest of operator′s seat
Disconnect the plug behind the operator′s seat.
<- Go to Section TOC
Section 40 page 392
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Section 40 - ELECTRICAL SYSTEM
Group 25: Fuses, Relays and Switches
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.
For installation, follow removal procedure in reverse order.
IMPORTANT:
If you replace the multi-function lever console, you should check the ESCV/E-ICV controller (SIC) for diagnostic trouble codes. See “Reference
245-05-002 , Accessing the Addresses and Diagnostic Trouble Codes”.
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
<- Go to Section TOC
Section 40 page 393
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
G
H
J
K
L
M
Group 25: Fuses, Relays and Switches
Phillips-head screw
Cover
Plug
Transport lock switch
Screw
Clamp
Screw
Pin
Actuator of interlock switch
Hex. socket screw
Multi-function lever
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).
<- Go to Section TOC
Section 40 page 394
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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.
For installation, follow removal procedure in reverse order.
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 ,
Accessing the Addresses and Diagnostic Trouble Codes”.
IMPORTANT:
If you replace the multi-function lever, you should recalibrate the E-SCV / EICV controller (SIC). See 245-SIC-001 , Calibration and Input Addresses (ESCV and E-ICV)”.
<- Go to Section TOC
Section 40 page 395
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Section 40 - ELECTRICAL SYSTEM
Group 30: Monitoring Systems
Group 30 - Monitoring Systems
Monitoring Systems - Recondition (Summary of
References)
”General information”
”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)”
”Disconnecting electrical circuits”
”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”.
<- Go to Section TOC
Section 40 page 396
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Section 40 - ELECTRICAL SYSTEM
Group 30: Monitoring Systems
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.
Disconnecting electrical circuits
Before working on the electrical system, always disconnect battery ground strap (-).
<- Go to Section TOC
Section 40 page 397
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Section 40 - ELECTRICAL SYSTEM
Group 30: Monitoring Systems
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
Disconnect plugs (B).
Replace the coolant temperature sender (A).
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Section 40 - ELECTRICAL SYSTEM
Group 30: Monitoring Systems
Assemble in reverse order.
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
B
Latches
Acoustic alarm
The acoustic alarm is located in the fuse and relay boxes behind the operator′s seat just
below the rear window.
Press down latches (A) and lift off the trim panel.
Pull out acoustic alarm (B) and replace it with a new one.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 30: Monitoring Systems
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 40 page 400
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
Replace the Acoustic Alarm (Park Lock) on Tractors
with AutoPowr/IVT Transmission
LEGEND:
A
B
Latches
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.
Press down latches (A) and lift off the trim panel.
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.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
<- Go to Section TOC
Group 40: Electrical Components
Section 40 page 402
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
Group 40 - Electrical Components
Electrical Components - Recondition (Summary of
References)
”General information”
”Special tools”
”Specifications”
”Disconnecting electrical circuits”
”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.
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
JDG359
<- Go to Section TOC
Section 40 page 403
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
Repairing DEUTSCH connectors
Specifications
Item
Measurement Specification
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
Disconnecting electrical circuits
Before working on the electrical system, always disconnect battery ground strap (-).
<- Go to Section TOC
Section 40 page 404
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
Assemble in reverse order.
Check the power supply to the seven terminals in the socket.
Terminal 3 (A) is the ground connection.
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
Section 40 page 406
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
Replacing the 3-Terminal Power Outlet Socket
CAUTION:
Disconnect negative (-) cable from battery.
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:
For identification purposes, mark the wires before disconnecting them.
<- Go to Section TOC
Section 40 page 407
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
For installation, follow removal procedure in reverse order.
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.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
Replacing the Multiple Power-Outlet Socket Strip
CAUTION:
Disconnect the battery ground cable (-).
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:
For identification purposes, mark the wires before disconnecting them.
Disconnect wires and replace socket strip.
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Section 40 page 409
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
CAUTION:
Make sure wires are connected correctly.
Connect wires to new socket strip.
Item
Measurement Specification
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.
Item
Measurement Specification
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.
Item
Measurement Specification
Bracket of multiple power-outlet socket strip, M6 cap screw
Torque
11 N˙m
8.5 lb-ft
Replace trim and floor mat.
<- Go to Section TOC
Section 40 page 410
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
Open the cover on the fuse box.
Remove the trim panel.
Disconnect the socket from the wiring harness.
Take out the screws that hold the socket on.
Replace socket and harness.
For installation, follow removal procedure in reverse order.
Operator′s cab (tractors with Stage II engine to 97/68/EC)
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Section 40 page 411
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
CAUTION:
Disconnect negative (-) cable from battery.
The service socket is located in the rear wall of the operator′s cab, just below the fuse box on
the l.h. side.
Open the cover on the fuse box.
Remove the trim panel.
Take out the screws that hold the socket on.
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.
Wiring harness repair kit
JDG359
Repairing DEUTSCH connectors
For extracting service socket terminals refer to “"DEUTSCH Connectors"” in Section 40, Group
05.
<- Go to Section TOC
Section 40 page 412
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
For installation, follow removal procedure in reverse order.
Removing the Wiper Motor
<- Go to Section TOC
Section 40 page 413
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
F
Group 40: Electrical Components
Nut
Wiper arm
Motor cover
Plug
Screw
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).
<- Go to Section TOC
Section 40 page 414
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 415
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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
<- Go to Section TOC
Section 40 page 416
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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).
<- Go to Section TOC
Section 40 page 417
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
Section 40 page 418
TM4756-REPAIR MANUAL
Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
Section 40 page 419
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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).
<- Go to Section TOC
Section 40 page 420
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
Section 40 page 421
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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).
<- Go to Section TOC
Section 40 page 423
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
<- Go to Section TOC
Section 40 page 424
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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
<- Go to Section TOC
Section 40 page 425
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Section 40 - ELECTRICAL SYSTEM
LEGEND:
A
B
C
D
E
1
2
3
Group 40: Electrical Components
Plug
Lead
Grommet
Nut and washer
Strap
Green lead
White lead
Brown lead
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!
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.
<- Go to Section TOC
Section 40 page 426
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Section 40 - ELECTRICAL SYSTEM
Group 40: Electrical Components
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.
Assemble in reverse order.
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
B
C
<- Go to Section TOC
Plug
Plug
Rivets
Section 40 page 427
TM4756-REPAIR MANUAL
AUTOPOWR/IVT TRANSMISSION
(g) by Belgreen
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!
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.
Assemble in reverse order.
<- Go to Section TOC
Section 40 page 428
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TM4756-REPAIR MANUAL
(g) by Belgreen
Section 53 - AUTOPOWR/IVT TRANSMISSION
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00 - Removal and Installation of
AutoPowr/IVT Transmission
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or in the European Microfiche Tool Catalog (MTC).
Lifting eye
JDG19
Installing and removing tractor components
Load-positioning sling
D01042AA
Installing and removing tractor components
[ This tool permits the adjustment of the angle of the load being handled. ]
<- Go to Section TOC
Section 53 page 1
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Dealer-Fabricated Special Tools
Unlocking Device
dealer fabricated
LEGEND:
A
B
C
D
E
F
Threaded rod M6, 170 mm (6.7 in.)
Nut M6 (14M7272)
Washer 20 mm x 2.5 mm (3/4” x 0.1 in.)
Nut M6 (14M7272)
Yoke (L80051)
Pin (AL79051)
For unlocking the park lock.
Suspension Device
dealer fabricated
<- Go to Section TOC
Section 53 page 2
TM4756-REPAIR MANUAL
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
I
145 mm (5.7 in.)
15 mm (0.6 in.)
15 mm (0.6 in.)
Bore, 13 mm (1/2”)
Bore, 11 mm (7/16”)
90 mm (3.54 in.)
15 mm (0.6 in.)
15 mm (0.6 in.)
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
Item
Measurement Specification
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.)
<- Go to Section TOC
Section 53 page 3
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Item
Measurement Specification
Cap Screws, Front Cab Mountings to Main Frame
Torque
240 N˙m
175 lb.-ft.
<- Go to Section TOC
Section 53 page 4
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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
Section 56, Group 00.
[3] -
LEGEND:
A
B
Drain Plug, AutoPowr/IVT Transmission
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.
<- Go to Section TOC
Section 53 page 5
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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.
<- Go to Section TOC
Section 53 page 6
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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.
<- Go to Section TOC
Section 53 page 7
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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 counterbracket (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
B
C
1
2
Yoke
Counter-Bracket
Special Tool (Dealer-Fabricated)
Park Lock Engaged
Park Lock Disengaged
Unlocking Device
dealer fabricated
<- Go to Section TOC
Section 53 page 8
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
LEGEND:
A
B
C
D
E
F
Threaded rod M6, 170 mm (6.7 in.)
Nut M6 (14M7272)
Washer 20 mm x 2.5 mm (3/4” x 0.1 in.)
Nut M6 (14M7272)
Yoke (L80051)
Pin (AL79051)
For unlocking the park lock.
CAUTION:
The disengaging lever is subject to great tension. Improper handling may
result in personal injury.
[11] -
<- Go to Section TOC
Section 53 page 9
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
LEGEND:
A
B
C
D
Special Tool (Dealer-Fabricated)
JDG19 Lifting Eye
JDG19 Lifting Eye
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
Installing and removing tractor components
Suspension Device
dealer fabricated
<- Go to Section TOC
Section 53 page 10
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
LEGEND:
A
B
C
D
E
F
G
H
I
145 mm (5.7 in.)
15 mm (0.6 in.)
15 mm (0.6 in.)
Bore, 13 mm (1/2”)
Bore, 11 mm (7/16”)
90 mm (3.54 in.)
15 mm (0.6 in.)
15 mm (0.6 in.)
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).
Load-positioning sling
D01042AA
<- Go to Section TOC
Section 53 page 11
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Installing and removing tractor components
[ This tool permits the adjustment of the angle of the load being handled. ]
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.
<- Go to Section TOC
Section 53 page 12
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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.
<- Go to Section TOC
Section 53 page 13
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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
1
2
Special Tool (Dealer-Fabricated)
Park Lock Engaged
Park Lock Disengaged
Unlocking Device
dealer fabricated
LEGEND:
A
B
C
Threaded rod M6, 170 mm (6.7 in.)
Nut M6 (14M7272)
Washer 20 mm x 2.5 mm (3/4” x 0.1 in.)
<- Go to Section TOC
Section 53 page 14
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
D
E
F
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
Nut M6 (14M7272)
Yoke (L80051)
Pin (AL79051)
For unlocking the park lock.
CAUTION:
The disengaging lever is subject to great tension. Improper handling may
result in personal injury.
[3] -
Install shaft (A).
[4] -
<- Go to Section TOC
Section 53 page 15
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
LEGEND:
A
B
C
D
Special Tool (Dealer-Fabricated)
JDG19 Lifting Eye
JDG19 Lifting Eye
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
Installing and removing tractor components
Suspension Device
dealer fabricated
<- Go to Section TOC
Section 53 page 16
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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). ]
Load-positioning sling
D01042AA
Installing and removing tractor components
[ This tool permits the adjustment of the angle of the load being handled. ]
<- Go to Section TOC
Section 53 page 17
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
Transmission
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:
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.
Item
Measurement Specification
Cap Screws, Output Housing to Differential Housing
Torque
135 N˙m
(100 lb.-ft.)
<- Go to Section TOC
Section 53 page 18
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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:
The disengaging lever is subject to great tension. Improper handling may
result in personal injury.
[8] - For further installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 53 page 19
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 00: Removal and Installation of AutoPowr/IVT
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
<- Go to Section TOC
Section 53 page 20
TM4756-REPAIR MANUAL
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.
Item
Measurement Specification
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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 53 page 21
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
Group 05 - Transmission Shift Controls
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”
<- Go to Section TOC
Section 53 page 22
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
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
<- Go to Section TOC
Section 53 page 23
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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).
<- Go to Section TOC
Section 53 page 24
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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.
<- Go to Section TOC
Section 53 page 25
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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).
Item
Measurement
Specification
Support
Torque
1.2 N˙m
0.89 lb-ft
Exploded view showing the grip on the speed control lever
<- Go to Section TOC
Section 53 page 26
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
K
Group 05: Transmission Shift Controls
Cover
Bearing
Support
Speed wheel
Left half of grip
Potentiometer
Right half of grip
Bottom left half of grip
Bottom right half of grip
Removing and installing the operation unit
<- Go to Section TOC
Section 53 page 27
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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).
<- Go to Section TOC
Section 53 page 28
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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] -
Take out attaching screws (A).
<- Go to Section TOC
Section 53 page 29
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[2] -
On the underside, take out attaching screws (A).
[3] -
Disconnect the operation unit (A) from its electrical connectors.
→NOTE:
Before pulling out the connectors, mark them so as to avoid installing them
in the wrong positions.
[4] -
Remove attaching screws (A).
<- Go to Section TOC
Section 53 page 30
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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).
<- Go to Section TOC
Section 53 page 31
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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
<- Go to Section TOC
Section 53 page 32
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
I
J
<- Go to Section TOC
Group 05: Transmission Shift Controls
Right half of grip
Grip assembly
Gate (with Command Arm)
Gate
Strap
Potentiometer
Wiring harness assembly and switchboard
Operation unit
Spring
Toothed segment
Section 53 page 33
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
Reverser control, reconditioning
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 (-).
<- Go to Section TOC
Section 53 page 34
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[1] -
Remove steering wheel (A).
[2] - Remove multi-function unit (B).
[3] -
Remove attaching screws (A).
[4] - Fold back trim panel (A).
<- Go to Section TOC
Section 53 page 35
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[5] -
Remove attaching screws (A).
[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.
<- Go to Section TOC
Section 53 page 36
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
Reconditioning the Clutch Actuation Mechanism
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 (-).
Replacing the potentiometer
<- Go to Section TOC
Section 53 page 37
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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] -
Take out attaching screws (A).
[5] - Pull off connector (B) and take off the potentiometer.
Assembly: Re-install the parts in reverse order, referring to the exploded view (drawing).
<- Go to Section TOC
Section 53 page 38
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
Reconditioning the clutch pedal
[1] -
Disengage ball joint (A) at the potentiometer.
[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).
<- Go to Section TOC
Section 53 page 39
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[5] - Recondition the clutch actuation as required.
Assembly: Re-install the parts in reverse order, referring to the exploded view (drawing).
[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.
Item
Measurement Specification
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
<- Go to Section TOC
Section 53 page 40
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
<- Go to Section TOC
Group 05: Transmission Shift Controls
Console
Belleville spring
Back-up ring
Friction washer
Hex. nut
Bearing
Ball socket
Clutch pedal
Bushing
Washer
Self-locking fillister screw
Stop
Potentiometer (B65)
Cover
Ball end
Section 53 page 41
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
P
Q
R
S
T
U
V
<- Go to Section TOC
Group 05: Transmission Shift Controls
Ball joint assembly
Leaf spring
Adapter
Spring
Adapter
Retaining screw
Wiring harness, with clutch pedal switch (S72)
Section 53 page 42
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
Reconditioning the Manual Park Lock Release
Mechanism
[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] -
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
<- Go to Section TOC
Section 53 page 43
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
<- Go to Section TOC
Group 05: Transmission Shift Controls
Threaded pin
Knurled nut
Bowden cable
Clamp
Plug
Clamp
Spring clip
Pin
Section 53 page 44
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
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.
<- Go to Section TOC
Section 53 page 45
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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] -
Take plug (A) out of the threaded bore.
[4] -
Disconnect bowden cable (A) from the clamp.
<- Go to Section TOC
Section 53 page 46
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 05: Transmission Shift Controls
[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.
<- Go to Section TOC
Section 53 page 47
TM4756-REPAIR MANUAL
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.
<- Go to Section TOC
Section 53 page 48
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Group 10 - Input Housing
AutoPowr/IVT Transmission Input Housing Reconditioning (Summary of References)
”Special tools”
”Specifications”
”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)”
<- Go to Section TOC
Section 53 page 49
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
”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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Seal installer
KJD10235
Installation of transmission oil pump seal (repair level 1 and 2)
<- Go to Section TOC
Section 53 page 50
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Specifications
Item
Measurement Specification
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
Front plate, M18x1.5 screw plug
Torque
50 N˙m
37 lb-ft
Front plate, M20x1.5 screw plug
Torque
55 N˙m
40 lb-ft
Front plate attaching screws
<- Go to Section TOC
Torque
Section 53 page 51
23 N˙m
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Item
Group 10: Input Housing
Measurement Specification
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
<- Go to Section TOC
Section 53 page 52
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 53
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Remove the fitting.
[4] -
Remove the line.
[5] -
Remove fitting with filter.
Vibration damper installation
<- Go to Section TOC
Section 53 page 54
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 55
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] - Install fitting (B).
Tighten the fittings (A) and (B).
Item
Measurement
Specification
Fitting, vibration damper
Torque
80 N˙m
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).
Item
Measurement
Specification
Fitting, vibration damper
Torque
80 N˙m
59 lb-ft
<- Go to Section TOC
Section 53 page 56
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 57
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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
<- Go to Section TOC
Section 53 page 58
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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
B
C
<- Go to Section TOC
Solenoid valve, BG disk brake
Solenoid valve, C1 clutch
Solenoid valve, C2 clutch
Section 53 page 59
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
D
E
F
G
H
I
J
Group 10: Input Housing
Solenoid valve, C4 clutch
Solenoid valve, C3 clutch
CF proportional valve
Damper piston CF
Damper piston CR
CR proportional valve
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.
<- Go to Section TOC
Section 53 page 60
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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
<- Go to Section TOC
Section 53 page 61
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement Specification
Solenoid valves to control block, attaching screws
Torque
6 N˙m
4 lb-ft
<- Go to Section TOC
Section 53 page 62
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 53 page 63
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 64
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[7] -
Place passage plate on control block.
[8] -
Insert attaching screws (A) and tighten them.
Item
Measurement
Specification
Passage plate to control block, attaching screws
Torque
10 N˙m
7 lb-ft
Final assembly:
Refer to “Installing the clutch control block” .
<- Go to Section TOC
Section 53 page 65
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 66
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement Specification
Clutch control block to input housing, attaching screws
Torque
10 N˙m
7 lb-ft
<- Go to Section TOC
Section 53 page 67
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 68
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[8] -
Install screw plug with O-ring on cover and tighten.
Item
Measurement
Specification
Screw plug on cover, clutch control block
Torque
25 N˙m
18 lb-ft
[9] -
Install the gasket.
<- Go to Section TOC
Section 53 page 69
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement Specification
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)” .
<- Go to Section TOC
Section 53 page 70
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Installing and Removing the Transmission Oil Filter
(Repair Level 1 and 2)
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
<- Go to Section TOC
Section 53 page 71
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement Specification
Filter housing to system pressure control block
Torque
50—60 N˙m
37—44 lb-ft
<- Go to Section TOC
Section 53 page 72
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Removing the System Pressure Control Block
(Repair Level 1 and 2)
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
B
C
Sending unit, cold-weather starting valve (B87):
Sending unit, oil filter restriction indicator light (S73)
Sending unit, system pressure indicator light (S74)
Remove sending units (A), (B) and (C).
<- Go to Section TOC
Section 53 page 73
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Take the attaching screws out of the control block.
[4] -
Lift off filter plate and gasket.
<- Go to Section TOC
Section 53 page 74
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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 (coldweather 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” .
<- Go to Section TOC
Section 53 page 75
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Installing System Pressure Control Block (Repair
Level 1 and 2)
[1] -
LEGEND:
A
B
C
D
Gasket
Valve plate
Gasket
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.
<- Go to Section TOC
Section 53 page 76
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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] -
<- Go to Section TOC
Section 53 page 77
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Tighten attaching screws now to their final torque in ascending order of the position numbers
indicated in the drawing.
Item
Measurement Specification
System pressure control block to transmission housing, attaching screws
Torque
10 N˙m
7 lb-ft
<- Go to Section TOC
Section 53 page 78
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[6] -
Check the O-ring (A) at the pressure sending unit and replace if necessary.
[7] -
LEGEND:
A
B
C
Sending unit for filter by-pass valve (B87; cold-weather starting)
Sending unit, oil filter restriction indicator light (S73)
Sending unit, system pressure indicator light (S74)
Secure pressure sending units (A), (B) and (C).
Item
Measurement
Specification
Pressure sending unit on filter housing
Torque
12 N˙m
9 lb-ft
<- Go to Section TOC
Section 53 page 79
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[8] -
Secure cable from sending unit for system pressure indicator light using the cable holder.
Item
Measurement
Specification
Cable holder to filter housing, attaching screw
Torque
9 N˙m
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" .
<- Go to Section TOC
Section 53 page 80
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Replacing Thermostat Valve (Repair Level 1 and 2)
[1] -
Take out screw plug (A).
[2] -
Thermostat valve - exploded view
LEGEND:
A
B
C
D
E
Spring
Thermal element
Disk
O-ring
Screw plug
Disassemble thermostat valve.
[3] - After installation of new valve tighten screw plug to the specified torque.
Item
Measurement
Specification
Thermostat valve, M36 x 1.5 screw plug
Torque
130 N˙m
95 lb-ft
<- Go to Section TOC
Section 53 page 81
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Replacing Filter By-Pass Valve (Cold-Weather
Starting) (Repair Level 1 and 2)
[1] -
Take out screw plug (A).
[2] -
Filter by-pass valve (cold-weather starting) - exploded view
LEGEND:
A
B
C
D
E
Thermal element
Piston
Spring
O-ring
Screw plug
Disassemble filter by-pass valve (cold-weather starting).
[3] - After installation of new valve tighten screw plug to the specified torque.
Item
Measurement Specification
Filter by-pass valve (cold-weather starting), M22 x 1.5 screw plug
Torque
30 N˙m
22 lb-ft
<- Go to Section TOC
Section 53 page 82
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 83
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 84
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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).
<- Go to Section TOC
Section 53 page 85
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Remove the snap ring.
[4] -
Remove the ball bearing.
Assembling the transmission oil pump
[1] -
Install the ball bearing.
<- Go to Section TOC
Section 53 page 86
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 87
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[5] -
Install O-ring (A).
Final assembly:
Refer to “Installing the transmission oil pump” .
<- Go to Section TOC
Section 53 page 88
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 89
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Tighten the attaching screws on the transmission oil pump.
Item
Measurement
Specification
Transmission oil pump attaching screws
Torque
23 N˙m
17 lb-ft
<- Go to Section TOC
Section 53 page 90
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[4] -
Install the snap ring.
→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.
<- Go to Section TOC
Section 53 page 91
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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" .
<- Go to Section TOC
Section 53 page 92
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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).
<- Go to Section TOC
Section 53 page 93
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 94
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 95
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Install screw plugs in front plate and tighten them.
Item
Measurement Specification
Front plate, M14x1.5 screw plug Torque
35 N˙m
26 lb-ft
Front plate, M18x1.5 screw plug Torque
50 N˙m
37 lb-ft
Front plate, M20x1.5 screw plug Torque
55 N˙m
40 lb-ft
[4] -
Move front plate to correct position.
<- Go to Section TOC
Section 53 page 96
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement
Specification
Front plate attaching screws
Torque
23 N˙m
17 lb-ft
<- Go to Section TOC
Section 53 page 97
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[6] -
Install screw union to front plate and tighten.
Item
Measurement
Specification
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” .
<- Go to Section TOC
Section 53 page 98
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Separating Transmission Halves, Input/Output
Housing (Repair Level 2)
Preliminary work:
Refer to “Removing the AutoPowr/IVT transmission” .
[1] -
LEGEND:
A
B
Input housing
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.
<- Go to Section TOC
Section 53 page 99
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 100
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 101
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Remove cable holder.
[4] -
Disconnect both connections to hydrostatic unit.
→NOTE:
Before pulling out the connectors, mark them so as to avoid installing them
in the wrong positions.
[5] -
Remove BG disk brake attaching screws.
<- Go to Section TOC
Section 53 page 102
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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”.
<- Go to Section TOC
Section 53 page 103
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 104
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Drive in both dowel pins until they are flush with the surface.
[4] -
Install BG disk brake attaching screws and tighten them.
Item
Measurement
Specification
BG disk brake, attaching screws
Torque
115 N˙m
85 lb-ft
<- Go to Section TOC
Section 53 page 105
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[5] -
Place wiring harness in cover notch and fix it by means of cable holders.
Item
Measurement
Specification
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”.
<- Go to Section TOC
Section 53 page 106
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input 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.
<- Go to Section TOC
Section 53 page 107
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Remove ring gear (P4/BG) from P4 planetary drive.
[4] -
Remove spacer.
<- Go to Section TOC
Section 53 page 108
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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).
<- Go to Section TOC
Section 53 page 109
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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”.
<- Go to Section TOC
Section 53 page 110
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 111
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Final assembly:
See reference”Installing the BG Disk Brake”.
<- Go to Section TOC
Section 53 page 112
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
<- Go to Section TOC
Section 53 page 113
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 114
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
<- Go to Section TOC
Section 53 page 115
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.).
<- Go to Section TOC
Section 53 page 116
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[11] -
Install P4/BG ring gear.
[12] -
Install five seal rings (A) and close them.
→NOTE:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
Final assembly:
See reference”Installing Shift Turret”.
<- Go to Section TOC
Section 53 page 117
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Repairing P4 Planet Pinion Carrier and C3/C4 Clutch
(Repair Level 2)
Preliminary work:
See reference”Removing Shift Turret”.
Removing P4 planet pinion carrier and C3/C4 clutch
[1] -
Remove shim (shift turret end play).
[2] -
Remove ring gear (P4/BG) from P4 planetary drive.
<- Go to Section TOC
Section 53 page 118
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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
<- Go to Section TOC
Section 53 page 119
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[1] -
Before installing the planet pinion carrier, check the three seal rings (A). Install the seal rings
and close them.
→NOTE:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
[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.).
<- Go to Section TOC
Section 53 page 120
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 121
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 122
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[7] -
Install shim.
Final assembly:
See reference”Installing Shift Turret”.
<- Go to Section TOC
Section 53 page 123
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Repairing P4/BG Ring Gear (Repair Level 2)
Preliminary work:
See reference”Removing Shift Turret”.
Removal and disassembly of ring gear (P4/BG)
[1] -
Remove shim (shift turret end play).
[2] -
Remove ring gear (P4/BG) from P4 planetary drive.
<- Go to Section TOC
Section 53 page 124
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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)
<- Go to Section TOC
Section 53 page 125
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[1] -
Install ring gear carrier in BG ring gear as shown.
[2] -
Install the snap ring.
[3] -
Insert ball bearing.
<- Go to Section TOC
Section 53 page 126
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[4] -
Install the snap ring.
[5] -
Install the ring gear (P4/BG).
[6] -
Install shim (shift turret end play).
<- Go to Section TOC
Section 53 page 127
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Final assembly:
See reference”Installing Shift Turret”.
<- Go to Section TOC
Section 53 page 128
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Removing Hydrostatic Unit (Repair Level 2)
Preliminary work:
See reference”Removing Shift Turret”.
[1] -
Remove pressure hoses (A) and (B) to hydrostatic unit.
[2] -
Remove the hydrostatic unit attaching screws.
<- Go to Section TOC
Section 53 page 129
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Carefully lift hydrostatic unit out of the transmission housing.
[4] -
Remove pressure hose.
[5] -
Remove the fitting, if necessary.
<- Go to Section TOC
Section 53 page 130
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 131
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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”.
<- Go to Section TOC
Section 53 page 132
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
Item
Measurement
Specification
Hydrostatic unit, end play
End play
0.2 - 0.5 mm
0.008 - 0.020 in.
<- Go to Section TOC
Section 53 page 133
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
Item
Measurement
Specification
Hydrostatic unit pressure hose, fitting
Torque
50 N˙m
37 lb-ft
[7] - Coat O-ring (A) with oil and install it in the ring-shaped groove.
<- Go to Section TOC
Section 53 page 134
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[8] -
Install pressure hose in the position shown and tighten it.
Item
Measurement
Specification
Pressure hose to fitting
Torque
40 N˙m
30 lb-ft
[9] -
Install O-ring (A) in the ring-shaped groove.
<- Go to Section TOC
Section 53 page 135
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[10] -
Install O-ring on hollow screw, and install pressure hose in the position shown to damper.
[11] - Tighten the hollow screw.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 53 page 136
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[13] -
Insert hydrostatic unit attaching screws and tighten them.
Item
Measurement
Specification
Hydrostatic unit, attaching cap screws
Torque
115 N˙m
85 lb-ft
[14] -
Connect pressure hose (A) to housing and tighten.
Item
Measurement
Specification
Pressure hose to fitting
Torque
40 N˙m
30 lb-ft
[15] - Connect pressure hose (B) to housing and tighten.
Item
Measurement
Specification
Pressure hose to elbow
Torque
80 N˙m
59 lb-ft
Final assembly:
<- Go to Section TOC
Section 53 page 137
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
If necessary, see reference”Preparations for installation of individual components in
transmission housing”.
See reference”Installing Shift Turret”.
<- Go to Section TOC
Section 53 page 138
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input 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.
<- Go to Section TOC
Section 53 page 139
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[3] -
Remove snap ring.
[4] -
Remove snap ring and closure disk from the shaft.
[5] -
Remove snap ring.
<- Go to Section TOC
Section 53 page 140
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 141
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input 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.
<- Go to Section TOC
Section 53 page 142
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 143
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 144
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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”.
<- Go to Section TOC
Section 53 page 145
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.
Item
Measurement
Specification
Transmission housing, M14x1.5 screw plugs
Torque
35 N˙m
26 lb-ft
Item
Measurement
Specification
Transmission housing, M38x2 screw plugs
Torque
140 N˙m
103 lb-ft
<- Go to Section TOC
Section 53 page 146
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 147
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[6] -
Tighten the elbow fitting.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Hydrostatic unit pressure hose, fitting
Torque
50 N˙m
37 lb-ft
<- Go to Section TOC
Section 53 page 148
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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.)
<- Go to Section TOC
Section 53 page 149
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.).
The result is the thickness of the shim to be used.
Item
Measurement Specification
End play between shift turret and direction turret
End play
0.20 - 0.40 mm
0.008 - 0.016 in.
Example:
As an example, dimension (A) is 13.60 mm (0.535 in.)
As an example, dimension (B) is 11.40 mm (0.448 in.)
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.
Shim thickness in the example is 1.90 mm (0.075 in.).
<- Go to Section TOC
Section 53 page 150
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
As an example, dimension (A) is 4.24 mm (0.167 in.)
<- Go to Section TOC
Section 53 page 151
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.).
The result is the thickness of the shim to be used.
Item
Measurement
Specification
Direction turret taper roller bearing
End play
0 - 0.08 mm
0 - 0.003 in.
Example:
As an example, dimension (A) is 4.24 mm (0.167 in.)
As an example, dimension (B) is 2.45 mm (0.096 in.)
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.
Shim thickness in the example is 1.75 mm (0.069 in.).
<- Go to Section TOC
Section 53 page 152
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[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.
<- Go to Section TOC
Section 53 page 153
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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”.
<- Go to Section TOC
Section 53 page 154
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input 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.
<- Go to Section TOC
Section 53 page 155
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
[5] -
Install and tighten attaching screws.
Item
Measurement
Specification
Output to input housing, attaching screws
Torque
46 N˙m
34 lb-ft
Final assembly:
Refer to "Installing the AutoPowr/IVT transmission" .
<- Go to Section TOC
Section 53 page 156
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
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”
<- Go to Section TOC
Section 53 page 157
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
“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)”
<- Go to Section TOC
Section 53 page 158
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Replacing Pressure Sending Units B87, S73, S74 of
System Pressure Control Block (Repair Level 1 and
2)
[1] -
LEGEND:
A
B
C
Sending unit for filter by-pass valve (B87; cold-weather starting)
Sending unit, oil filter restriction indicator light (S73)
Sending unit, system pressure indicator light (S74)
<- Go to Section TOC
Section 53 page 159
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 10: Input Housing
Disconnect pressure sending unit plugs from transmission wiring harness.
→NOTE:
Before pulling out the connectors, mark them so as to avoid installing them
in the wrong positions.
[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.
Item
Measurement Specification
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.
Item
Measurement
Specification
Cable holder to filter housing, attaching screw
Torque
9 N˙m
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.
<- Go to Section TOC
Section 53 page 160
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Replace Hydrostatic Unit Speed Sending Unit (B62)
(Repair Level 1 and 2)
[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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 53 page 161
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Group 15 - Output Housing
AutoPowr/IVT Transmission Output Housing Reconditioning (Summary of References)
”Special tools”
”Specifications”
”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”
<- Go to Section TOC
Section 53 page 162
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Installation tool
dealer-fabricated
Removing and installing the park lock control block and the check valve (repair level 1 and 2)
Tube
<- Go to Section TOC
Section 53 page 163
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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)
<- Go to Section TOC
Section 53 page 164
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Specifications
Item
Measurement
Specification
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
Transmission housing, M18x1.5 screw plug
Torque
50 N˙m
37 lb-ft
Transmission housing, M20x1.5 screw plug
Torque
55 N˙m
41 lb-ft
Transmission housing, M38x2 screw plug
Torque
140 N˙m
104 lb-ft
Threaded pins, through-drive shaft
Torque
15 N˙m
11 lb-ft
Transmission speed sending unit
<- Go to Section TOC
Torque
Section 53 page 165
10 N˙m
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Item
Group 15: Output Housing
Measurement
Specification
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
<- Go to Section TOC
Section 53 page 166
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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).
<- Go to Section TOC
Section 53 page 167
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[3] -
Remove attaching screws (A).
[4] - Remove control block (B).
<- Go to Section TOC
Section 53 page 168
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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
B
C
D
E
F
G
H
I
J
K
L
M
N
O
<- Go to Section TOC
Lever
Lever arm
Pressure sending unit
Screw plug
Check valve
Solenoid valve
Housing
Screw plug
Tappet
Cylinder
Piston
Washer
Spring
Spring
Rod
Section 53 page 169
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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).
<- Go to Section TOC
Section 53 page 170
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Remove plate (C) and solenoid valves (B). Remove pressure sending unit (A) and connecting
fitting (D).
[5] -
Take out screw plug (A).
<- Go to Section TOC
Section 53 page 171
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 172
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[8] -
Take out screw plug (A).
[9] -
Remove snap ring (A).
<- Go to Section TOC
Section 53 page 173
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
<- Go to Section TOC
Section 53 page 174
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
<- Go to Section TOC
Section 53 page 175
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
<- Go to Section TOC
Section 53 page 176
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[3] -
Install check valves (A), (B) and (C).
Item
Measurement
Specification
Check valve (A), park lock control block
Torque
18 N˙m
13 lb-ft
Item
Measurement
Specification
Check valve (B), park lock control block
Torque
15 N˙m
11 lb-ft
[4] -
Install check valve (A).
Item
Measurement
Specification
Check valve (A), park lock control block
Torque
18 N˙m
13 lb-ft
<- Go to Section TOC
Section 53 page 177
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[5] -
Install check valve (A).
Item
Measurement
Specification
Check valve, park lock control block
Torque
18 N˙m
13 lb-ft
[6] -
Install O-ring (A) in the cylinder.
[7] -
Carefully compress back-up ring (A), and install.
<- Go to Section TOC
Section 53 page 178
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[8] -
Make sure that the seal ring is making proper contact.
[9] -
Install O-ring (A).
[10] -
Install O-ring (A) on the piston.
<- Go to Section TOC
Section 53 page 179
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[11] -
Install back-up ring (A).
[12] -
Place washer (A) in the housing bore.
[13] -
Install the outer and inner springs.
<- Go to Section TOC
Section 53 page 180
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
<- Go to Section TOC
Section 53 page 181
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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
Removing and installing the park lock control block, cylinder and piston.
<- Go to Section TOC
Section 53 page 182
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
Item
Measurement
Specification
M40 x 2 screw plug, park lock control block
Torque
70 N˙m
52 lb-ft
<- Go to Section TOC
Section 53 page 183
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[24] -
Install check valve (A).
[25] -
Use an installation tool (A; dealer-fabricated) to tighten the check valve.
Item
Measurement
Specification
Check valve, park lock control block
Torque
10 N˙m
7 lb-ft
<- Go to Section TOC
Section 53 page 184
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[26] -
Install screw plug (A).
Item
Measurement
Specification
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).
Item
Measurement
Specification
Pressure sending unit, park lock control block
Torque
10 N˙m
7 lb-ft
<- Go to Section TOC
Section 53 page 185
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[28] -
Install solenoid valves (A).
[29] - Install plate (C) by means of retaining screws (B), and tighten.
Item
Measurement
Specification
Attaching screws, solenoid valve
Torque
10 N˙m
7 lb-ft
[30] -
Install coils (A) on the solenoid valves.
<- Go to Section TOC
Section 53 page 186
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[31] -
Screw in test port (A) and tighten it.
Item
Measurement
Specification
Test port, park lock control block
Torque
15 N˙m
11 lb-ft
Final assembly:
Refer to “Installing the park lock control block” .
<- Go to Section TOC
Section 53 page 187
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Installing Park Lock Control Block (Repair Level 1
and 2)
[1] -
Align control block (B) and gasket at housing.
[2] - Tighten attaching screws (A).
Item
Measurement
Specification
Attaching screws, park lock control block
Torque
11 N˙m
8 lb-ft
[3] -
Install pin (A).
<- Go to Section TOC
Section 53 page 188
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Install cover (B) and gasket. Tighten attaching screws (A).
Item
Measurement
Specification
Attaching screws, park lock control block
Torque
11 N˙m
8 lb-ft
Final assembly:
Refer to "Removing and Installing the main frame (summary of references)" .
Refer to "Installing the AutoPowr/IVT transmission" .
<- Go to Section TOC
Section 53 page 189
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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
B
C
D
E
F
G
H
I
J
K
L
M
N
<- Go to Section TOC
Locking pawl
Cotter pin
Pin
Washer
Roller
Lock cam
Thrust bearing
Axial needle bearing
Bushing
Shaft
Compression spring
O-ring
Screw plug
Lever
Section 53 page 190
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
O
Group 15: Output Housing
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).
<- Go to Section TOC
Section 53 page 191
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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
<- Go to Section TOC
Section 53 page 192
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[1] -
Install lock cam (A) and axial bearing (B).
[2] -
Install bushing (A).
[3] -
Install locking pawl (B) and shaft (A).
<- Go to Section TOC
Section 53 page 193
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Align lever (A) as shown and drive in spring pin.
[5] -
Install compression spring (B). Tighten screw plug (A).
Item
Measurement
Specification
M18 x 1.5 screw plug
Torque
50 N˙m
37 lb-ft
Final assembly:
Refer to “Installing the park lock control block” .
<- Go to Section TOC
Section 53 page 194
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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).
<- Go to Section TOC
Section 53 page 195
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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] -
<- Go to Section TOC
Section 53 page 196
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
<- Go to Section TOC
Section 53 page 197
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output 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.
<- Go to Section TOC
Section 53 page 198
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: 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”.
<- Go to Section TOC
Section 53 page 199
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
<- Go to Section TOC
Section 53 page 200
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[3] -
Remove the snap ring.
[4] -
Pull drive shaft with ball bearing out of the housing.
[5] -
Press ball bearing from drive shaft.
<- Go to Section TOC
Section 53 page 201
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[6] -
Remove both snap rings (A).
[7] -
Press second ball bearing from drive shaft.
Final assembly:
See reference”Installing hydrostatic unit drive shaft”.
<- Go to Section TOC
Section 53 page 202
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Removing Through-Drive Shaft (Repair Level 2)
Preliminary work:
See reference”Removing the Direction Turret and Reverse Intermediate Shaft”.
[1] -
Remove the seven seal rings.
[2] -
Remove the snap ring.
<- Go to Section TOC
Section 53 page 203
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[3] -
Turn housing through 180° and remove the second snap ring.
[4] -
Remove through-drive shaft using a suitable puller.
[5] -
Remove the snap ring.
[6] - Pull off ball bearing (A).
[7] - Remove seal rings (B) from through-drive shaft.
Final assembly:
<- Go to Section TOC
Section 53 page 204
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
See reference”Installing through-drive shaft”.
<- Go to Section TOC
Section 53 page 205
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Removing Pneumatic Pump and Idler Gear (Repair
Level 2)
Preliminary work:
See reference”Removing the Direction Turret and Reverse Intermediate Shaft”.
Removing idler gear
[1] -
Remove snap ring (shaft, pneumatic pump).
[2] -
Remove shaft using a slide hammer.
<- Go to Section TOC
Section 53 page 206
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 207
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 208
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output 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
<- Go to Section TOC
Section 53 page 209
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[1] -
Remove the pneumatic pump′s tappet (A).
[2] -
Take out the screw plug.
[3] -
Remove the snap ring.
<- Go to Section TOC
Section 53 page 210
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Remove the valve with its O-ring, washer and spring.
[5] -
Pull out the piston.
[6] -
Remove ball and retaining ring from piston.
<- Go to Section TOC
Section 53 page 211
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[7] -
Take out the screw plug.
[8] -
Remove piston and spring from the housing.
Final assembly:
See reference”Installing pneumatic pump and idler gear”.
<- Go to Section TOC
Section 53 page 212
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
<- Go to Section TOC
Section 53 page 213
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 214
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 215
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[7] -
Align pump gear and install shaft.
→NOTE:
Align shaft so that the cylindrical pin is located in the housing recess.
[8] -
Install the snap ring.
<- Go to Section TOC
Section 53 page 216
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[9] -
LEGEND:
A
B
C
D
E
F
G
H
I
Snap ring
Valve
O-ring
Washer
Spring
Retaining ring
Ball
Piston
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).
<- Go to Section TOC
Section 53 page 217
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[11] -
Install piston with ball and retaining ring.
[12] -
Install the spring.
[13] -
Install the O-ring and washer on the valve.
<- Go to Section TOC
Section 53 page 218
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[14] -
Install the valve.
[15] -
Install the snap ring.
[16] -
Install screw plug with O-ring.
[17] - Tighten screw plug.
Item
Measurement
Specification
Pneumatic pump, screw plug
Torque
140 N˙m
104 lb-ft
<- Go to Section TOC
Section 53 page 219
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[18] -
Install the spring and piston in the housing.
[19] -
Install screw plug with O-ring.
[20] - Tighten screw plug.
Item
Measurement
Specification
M18 x 1.5 screw plug
Torque
50 N˙m
37 lb-ft
Installing idler gear
<- Go to Section TOC
Section 53 page 220
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
As an example, dimension (A) is 178.30 mm (7.02 in.)
→NOTE:
The snap ring must be in contact with upper groove face.
[3] - Remove snap ring again afterwards.
<- Go to Section TOC
Section 53 page 221
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Install both bearing cups (A) as far as they will go.
[5] -
Install both bearing cones.
[6] -
Align idler gear for shaft installation.
<- Go to Section TOC
Section 53 page 222
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
<- Go to Section TOC
Section 53 page 223
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[10] -
Measure dimension (B) from housing flange to shaft face.
As an example, dimension (B) is 180.30 mm (7.02 in.)
Thedifference of the two dimensions is the thickness of the shim to be used.
Example
As an example, dimension (A) is 178.30 mm (7.02 in.)
As an example, dimension (B) is 180.30 mm (7.10 in.)
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.)
Shim thickness in the example is 2.00 mm (0.08 in.).
[11] -
Insert a shim of the calculated thickness.
<- Go to Section TOC
Section 53 page 224
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
Item
Measurement
Specification
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:
See reference”Installing the Direction Turret and Reverse Intermediate Shaft”.
<- Go to Section TOC
Section 53 page 225
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
<- Go to Section TOC
Section 53 page 226
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[3] -
Install snap ring for second ball bearing.
[4] -
Press ball bearing on shaft until it contacts the snap ring.
[5] -
Install drive shaft.
<- Go to Section TOC
Section 53 page 227
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[6] -
Secure drive shaft with snap ring.
[7] -
Install snap ring in hollow shaft.
[8] -
Install hollow shaft until it contacts the drive shaft.
<- Go to Section TOC
Section 53 page 228
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Final assembly:
See reference”Installing the Direction Turret and Reverse Intermediate Shaft”.
<- Go to Section TOC
Section 53 page 229
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
Item
Measurement
Specification
Threaded pins, through-drive shaft
Torque
15 N˙m
11 lb-ft
<- Go to Section TOC
Section 53 page 230
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[4] -
Heat up ball bearing.
[5] - Install hot ball bearing on through-drive shaft as far as it will go.
[6] -
Install the snap ring.
<- Go to Section TOC
Section 53 page 231
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[7] -
Install four seal rings (A) and close them.
IMPORTANT:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
[8] -
Insert through-drive shaft in housing or in gear (hydrostatic unit drive gear) which had been
inserted beforehand.
<- Go to Section TOC
Section 53 page 232
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[9] -
Secure through-drive shaft with snap ring.
[10] -
Turn housing through 180° and install second snap ring.
<- Go to Section TOC
Section 53 page 233
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[11] -
Install the seven seal rings and close them.
IMPORTANT:
Apply some petroleum jelly to the seal rings and position them in the
middle of the shaft.
Final assembly:
See reference”Installing the Direction Turret and Reverse Intermediate Shaft”.
<- Go to Section TOC
Section 53 page 234
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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.
<- Go to Section TOC
Section 53 page 235
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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).
<- Go to Section TOC
Section 53 page 236
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
Item
Measurement
Specification
Transmission housing, M14x1.5 screw plug
Torque
35 N˙m
26 lb-ft
→NOTE:
The screw plug secures the direction turret.
<- Go to Section TOC
Section 53 page 237
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[7] -
Remembering to include O-rings, screw in all plugs and tighten.
Item
Measurement Specification
Transmission housing, M10x1 screw plug
Torque
25 N˙m
18 lb-ft
Transmission housing, M14x1.5 screw plug Torque
35 N˙m
26 lb-ft
Transmission housing, M18x1.5 screw plug Torque
50 N˙m
37 lb-ft
Transmission housing, M20x1.5 screw plug Torque
55 N˙m
41 lb-ft
Transmission housing, M38x2 screw plug
Torque
140 N˙m
104 lb-ft
[8] -
Coat O-rings (A) with oil and install them on connecting tube.
<- Go to Section TOC
Section 53 page 238
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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”.
<- Go to Section TOC
Section 53 page 239
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
See reference ”Installing the AutoPowr/IVT Transmission” .
<- Go to Section TOC
Section 53 page 240
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
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”
<- Go to Section TOC
Section 53 page 241
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
“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)”
<- Go to Section TOC
Section 53 page 242
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Replacing Transmission Speed Sending Unit (B63)
(Repair Level 1 and 2)
[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.
Item
Measurement
Specification
Transmission 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.
<- Go to Section TOC
Section 53 page 243
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
Replacing Transmission Input Speed Sending Unit
(B61) (Repair Level 1 and 2)
[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.
Item
Measurement
Specification
Transmission input speed sending unit
Torque
30 N˙m
22 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.
Replace the Transmission Output Speed Sending
Unit (B84) (Repair Level 1 and 2)
<- Go to Section TOC
Section 53 page 244
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 15: Output Housing
[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.
Item
Measurement
Specification
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)
<- Go to Section TOC
Section 53 page 245
TM4756-REPAIR MANUAL
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.
Item
Measurement
Specification
Pressure sending unit, park lock control block
Torque
10 N˙m
7 lb-ft
<- Go to Section TOC
Section 53 page 246
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
Group 20 - Differential Drive Shaft Assembly
AutoPowr/IVT Transmission - Differential Drive
Shaft, Summary of References
AutoPowr/IVT Transmission - Differential Drive Shaft, Summary of References
Repair Specifications
Differential Drive Shaft, Sectional View
Remove the Differential Drive Shaft
Disassemble the Differential Drive Shaft
Cone Point Adjustment
Assemble the Differential Drive Shaft
Specifications
Item
Measurement Specification
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
<- Go to Section TOC
Section 53 page 247
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Group 20: Differential Drive Shaft Assembly
O-ring
Seal ring
Ring
Housing
Shim (quantity and thickness as required)
Cap screw (6 used)
Cover
Differential drive shaft
Special nut
Shim (quantity and thickness as required)
Front-wheel drive gear
Snap-ring
Section 53 page 248
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
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.
<- Go to Section TOC
Section 53 page 249
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
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).
<- Go to Section TOC
Section 53 page 250
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[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.
<- Go to Section TOC
Section 53 page 251
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[8] -
Separate the cover and housing.
[9] -
Remove the front-wheel drive gear (A).
[10] -
Remove the tapered roller bearing cup.
<- Go to Section TOC
Section 53 page 252
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
Cone Point Adjustment
[1] -
<- Go to Section TOC
Section 53 page 253
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
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).
<- Go to Section TOC
Section 53 page 254
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[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.
<- Go to Section TOC
Section 53 page 255
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
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.
<- Go to Section TOC
Section 53 page 256
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[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.
<- Go to Section TOC
Section 53 page 257
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[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.
<- Go to Section TOC
Section 53 page 258
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[10] -
Install spacer.
[11] -
Install shims (to adjust end play of differential drive shaft).
[12] -
Heat up tapered roller bearing cone and install.
<- Go to Section TOC
Section 53 page 259
TM4756-REPAIR MANUAL
Section 53 - AUTOPOWR/IVT TRANSMISSION
Group 20: Differential Drive Shaft Assembly
[13] -
Reseat bearing.
[14] -
Install special nut (A) and tighten.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 53 page 260
TM4756-REPAIR MANUAL
POWRQUAD PLUS, AUTOQUAD AND AUTOQUAD PLUS
TRANSMISSIONS
(g) by Belgreen
[16] - Measure axial play of differential drive shaft.
Item
Measurement
Specification
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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 53 page 261
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Table of contents
Group 00 - Removal and Installation of Components .......................................................... 1
Special Tools .......................................................................................................................... 1
Dealer-Fabricated Special Tools ............................................................................................. 1
Repair Specifications .............................................................................................................. 2
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Reconditioning the B1 Brake .............................................................................................. 113
Installing the B1 Brake Housing ......................................................................................... 115
Removing the B2-B3 Brake Housing .................................................................................. 115
Reconditioning the B2 Brake .............................................................................................. 117
Reconditioning the B3 Brake .............................................................................................. 119
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
Repair specifications .......................................................................................................... 189
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Group 00 - Removal and Installation of Components
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Lifting eye
JD-244-1
Removing and installing tractor components
Lifting eye
JDG19
Removing and installing tractor components
Dealer-Fabricated Special Tools
See also Section 99, Group 05.
<- Go to Section TOC
Section 55 page 1
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Device for suspending the PowrQuad module during removal and installation
Repair Specifications
Item
Measurement
Specificatio
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 .
<- Go to Section TOC
Section 55 page 2
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Remove and Install the AutoQuad Transmission
See Remove PowrQuad Transmission .
See Install PowrQuad Transmission .
<- Go to Section TOC
Section 55 page 3
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 55 page 4
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
[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:
Trap any oil as it emerges. Seal the open ends so that no dust can
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.
<- Go to Section TOC
Section 55 page 5
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
[7] -
Take out screws (A) and pull suction line (B) out of the differential housing.
→NOTE:
Trap any oil as it emerges. Seal the open ends so that no dust can
penetrate.
[8] -
Remove cable clamp (A) and move the wiring harness to the rear after disconnecting all
connectors.
[9] -
<- Go to Section TOC
Section 55 page 6
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Install dealer-fabricated suspension device (A) on the PowrQuad module and attach lifting
tackle.
Suspension Device
dealer fabricated
Device for suspending the PowrQuad module during removal and installation
Take all screws (B) out of the flange, move the PowrQuad module to the front, and lift it out.
<- Go to Section TOC
Section 55 page 7
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 55 page 8
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Device for suspending the PowrQuad module during removal and installation
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.
Item
Measurement Specification
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).
<- Go to Section TOC
Section 55 page 9
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
[2] -
Check all seals, install suction line (B) and tighten screws (A) to the specified torque.
Item
Measurement Specification
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:
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.
For further assembly, follow disassembly procedure in reverse order.
<- Go to Section TOC
Section 55 page 10
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 55 page 11
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Removing and installing tractor components
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.
<- Go to Section TOC
Section 55 page 12
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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
Removing and installing tractor components
Applying even pressure, locate the creeper transmission on the range transmission.
<- Go to Section TOC
Section 55 page 13
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
Install cap screws (A) and tighten them to the specified torque.
Item
Measurement Specification
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.
For further assembly, follow disassembly procedure in reverse order.
<- Go to Section TOC
Section 55 page 14
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 55 page 15
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
[4] -
Screw the JDG19 lifting eyes (A) onto the housing and attach the hoist.
Lifting eye
JDG19
Removing and installing tractor components
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.
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.
<- Go to Section TOC
Section 55 page 16
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 00: Removal and Installation of Components
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
Removing and installing tractor components
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.
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.
Item
Measurement Specification
Cap Screws, Range Transmission to Differential Housing
Torque
90 N˙m
65 lb.-ft.
<- Go to Section TOC
Section 55 page 17
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
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 .
<- Go to Section TOC
Section 55 page 18
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
Group 05 - Transmission Shift Controls
PowrQuad Transmission Shift Units - Reconditioning
(Summary of References)
”Specifications”
”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
Item
Measurement
Specification
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.
Self-locking retaining screw, clutch pedal to console
Torque
10 N˙m
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
<- Go to Section TOC
Section 55 page 19
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
Repairing the Range Shift Linkage (PowrQuad Plus
and AutoQuad Transmissions)
LEGEND:
1
2
3
4
5
6
7
8
9
10
<- Go to Section TOC
Gear selector
Handle
Shifting gate
Park lock switch
Cap screw
Washer
Bearing bushing
Shift quadrant, park lock
Support pin
Support pin
Section 55 page 20
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Group 05: Transmission Shift Controls
Belleville spring
Shift quadrant, ranges A and B
Support
Self-locking hex. nut
Shift lever with harness
Shift quadrant, ranges C and D
Shift quadrant, range E
Rubber bearing
Washer
Shim (thickness as required)
Bracket
Bowden cable, park lock
Bowden cable, ranges A and B
Bowden cable, ranges C and D
Bowden cable, range E
Rubber sleeve
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).
Item
Measurement
Specification
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.
Item
Measurement
Specification
Support pin attaching screw
Torque
25 N˙m
19 lb-ft
Adjusting preload at quadrants
<- Go to Section TOC
Section 55 page 21
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 55 page 22
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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.
<- Go to Section TOC
Section 55 page 23
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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
B
C
D
<- Go to Section TOC
Bowden cable, park lock
Bowden cable, range E
Bowden cable, ranges A and B
Bowden cable, ranges C and D
Section 55 page 24
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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.
<- Go to Section TOC
Section 55 page 25
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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
B
C
Circuit board with gear-shift switches
Attaching screws
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
<- Go to Section TOC
Section 55 page 26
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[1] - Take off the trim panels.
LEGEND:
A
B
C
Electrical plug connection
Electrical plug connection
Electrical plug connection
[2] - Disconnect the shifter unit from electrical plug connections (A), (B) and (C).
<- Go to Section TOC
Section 55 page 27
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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).
<- Go to Section TOC
Section 55 page 28
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[5] -
LEGEND:
A
B
Attaching screw
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.
<- Go to Section TOC
Section 55 page 29
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
→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
B
Spring
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).
<- Go to Section TOC
Section 55 page 30
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
A
B
Group 05: Transmission Shift Controls
Wiring harness
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.
<- Go to Section TOC
Section 55 page 31
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
1
2
3
4
5
6
Group 05: Transmission Shift Controls
Handle assembly, AutoQuad Plus transmission
Handle assembly, PowrQuad Plus transmission
O-ring
Screw
Locking washer
Console
<- Go to Section TOC
Section 55 page 32
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
1
2
3
4
5
6
7
8
9
10
<- Go to Section TOC
Group 05: Transmission Shift Controls
Shift lever assembly with harness
Bushing
Pin assembly
Spring pin
Carriage bolt
Console
Screw
Clamp
Support
Hex. nut
Section 55 page 33
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
11
12
13
14
15
16
17
18
19
20
21
22
<- Go to Section TOC
Group 05: Transmission Shift Controls
Support
Screw
Washer
Washer
Screw
Spring
Console
Flanged nut
Clamp
Carriage bolt
Bracket
Screw
Section 55 page 34
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
Exploded view, range shift A-E
LEGEND:
1
2
3
4
5
6
7
<- Go to Section TOC
Cams
Side frame
Bushing
Retaining clip
Screw
Washer
Lever
Section 55 page 35
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
8
9
10
11
12
13
14
15
16
17
18
19
20
21
<- Go to Section TOC
Group 05: Transmission Shift Controls
Pin
End panel
Belleville spring
Quadrant, E
Lever
Quadrant, C-D
Quadrant, A-B
Quadrant, park lock
Retaining washer
Spacer
Shaft
Pin
Park lock switch
Spring
Section 55 page 36
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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] -
<- Go to Section TOC
Section 55 page 37
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
LEGEND:
A
B
C
D
E
Shift lever
Bowden cable, range E
Bowden cable, ranges C and D
Bowden cable, ranges A and B
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.
• The shift lever must not bump, jam or catch against the shift gate.
[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
<- Go to Section TOC
Section 55 page 38
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
Item
Measurement
Specification
Attaching screws
Torque
25 N˙m
19 lb-ft
[3] -
<- Go to Section TOC
Section 55 page 39
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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.
<- Go to Section TOC
Section 55 page 40
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 55 page 41
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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:
Slacken off the yoke′s locknut before disengaging the bowden cable.
[12] IMPORTANT:
Make sure that the park lock is disengaged properly.
Do this by pressing the bowden cable (J) down (use force).
<- Go to Section TOC
Section 55 page 42
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
[15] - Engage the bowden cable and lock it with the locknut.
[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.
<- Go to Section TOC
Section 55 page 43
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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.
• The shift lever must not bump, jam or catch against the shift gate.
<- Go to Section TOC
Section 55 page 44
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
• It must be possible to move the shift lever to its park position without any difficulty
whatsoever.
[3] -
LEGEND:
A
B
C
D
Bowden cable, range E
Bowden cable, ranges C and D
Bowden cable, ranges A and B
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.
[6] - Re-check the adjustment once again.
<- Go to Section TOC
Section 55 page 45
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
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:
Slacken off the yoke′s locknut before disengaging the bowden cable.
<- Go to Section TOC
Section 55 page 46
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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).
[5] - Engage the bowden cable and lock it with the locknut.
[6] - Re-check the adjustment once again.
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.
<- Go to Section TOC
Section 55 page 47
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
Repairing the Clutch Actuation (PowrQuad Plus,
AutoQuad and AutoQuad Plus Transmissions)
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 (-).
Replacing the potentiometer
<- Go to Section TOC
Section 55 page 48
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
<- Go to Section TOC
Section 55 page 49
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[4] -
Remove attaching screws (A).
[5] - Pull off connector (B) and take off the potentiometer.
Assembly: Re-install the parts in reverse order, referring to the exploded view (drawing).
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.
<- Go to Section TOC
Section 55 page 50
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
Assembly: Re-install the parts in reverse order, referring to the exploded view (drawing).
[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.
<- Go to Section TOC
Section 55 page 51
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
[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.
Item
Measurement Specification
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) between adapter and clutch pedal is 7.5 mm (0.3
in.).
<- Go to Section TOC
Section 55 page 52
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 05: Transmission Shift Controls
Exploded view of clutch actuation mechanism
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
<- Go to Section TOC
Console
Belleville spring
Back-up ring
Friction washer
Hex. nut
Bearing
Ball socket
Clutch pedal
Bushing
Washer
Self-locking fillister head screw
Limit stop
Potentiometer (B65)
Section 55 page 53
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
N
O
P
Q
R
S
T
U
V
<- Go to Section TOC
Group 10: PowrQuad Module
Cover
Ball end
Ball joint assembly
Leaf spring
Adapter
Spring
Adapter
Attaching screw
Wiring harness, with clutch pedal switch (S72)
Section 55 page 54
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Group 10 - PowrQuad Module
PowrQuad, PowrQuad Plus and AutoQuad
Transmissions - Summary of References
Before reconditioning the PowrQuad module, refer to the following:
”Special tools”
”Specifications”
”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”
”Recondition the B2 brake”
”Recondition the B3 brake”
”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”
<- Go to Section TOC
Section 55 page 55
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
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
<- Go to Section TOC
Section 55 page 56
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
D01045AA
Driving in bushings, bearings and seals
Hydraulic puller set
D01048AA
Removal of bearings
Mechanical puller set
D01173AA
Removal of bearings
<- Go to Section TOC
Section 55 page 57
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Specifications
Item
Measurement
Specificatio
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)
<- Go to Section TOC
Torque
Section 55 page 58
45 N˙m
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Item
Group 10: PowrQuad Module
Measurement
Specificatio
n
33 lb-ft
K2 solenoid valve (Y39)
Torque
45 N˙m
33 lb-ft
K3 solenoid valve (Y32)
Torque
45 N˙m
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
<- Go to Section TOC
Section 55 page 59
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Electrically actuated PowrQuad module
LEGEND:
A
B
C
D
E
F
G
H
Disk brake housing (reverse brake)
Planet gear housing with forward clutch and C4 clutch
B2-B3 brake housing
B1 brake housing
Front transmission cover
Front valve housing
Transmission oil filter housing
Shift valve housing
<- Go to Section TOC
Section 55 page 60
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
Item
Measurement
Specification
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.
Item
Measurement
Specification
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.
Item
Measurement Specification
Pressure switch, restriction indicator of the transmission oil filter
Torque
4 to 7 N˙m
3 to 5 lb-ft
<- Go to Section TOC
Section 55 page 61
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
→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.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 55 page 62
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
screws at least 3 minutes to settle.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Transmission oil filter to filter housing
Torque
30 N˙m
22 lb-ft
<- Go to Section TOC
Section 55 page 63
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 64
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 55 page 65
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Removing and Installing the Valves in the Front
Valve Housing
Exploded view of valves and front valve housing
LEGEND:
A
B
C
D
E
F
Transmission oil filter by-pass valve
Cooler relief valve
Lube oil relief valve
Reverse solenoid (Y36) and shift valve (reverse)
Forward solenoid (Y33) and shift valve (forward)
Enable proportional solenoid (Y38)
Reconditioning the by-pass valve of the transmission oil filter
<- Go to Section TOC
Section 55 page 66
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Item
Measurement
Specification
Transmission oil filter by-pass valve, plug
Torque
20 N˙m
15 lb-ft
Reconditioning the pressure-relief valve of the cooler
[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.
<- Go to Section TOC
Section 55 page 67
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Install valve (C), spring (B) and plug (A). Tighten the plug.
Item
Measurement
Specification
Cooler relief valve, plug
Torque
30 N˙m
22 lb-ft
Reconditioning the lube oil relief valve
[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.
Item
Measurement
Specification
Lube oil relief valve, plug
Torque
20 N˙m
15 lb-ft
Reconditioning the reverse solenoid (Y36) and the shift valve
<- Go to Section TOC
Section 55 page 68
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
Remove solenoid valve (A), spring (B) and shift valve (C).
[2] - Check components for wear. Replace, if necessary.
[3] →NOTE:
Before installing the valve, check that its bore is clean.
Install shift valve (C), spring (B) and solenoid valve (A). Tighten solenoid valve (A).
Item
Measurement
Specification
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).
[2] - Check components for wear. Replace, if necessary.
[3] →NOTE:
Before installing the valve, check that its bore is clean.
<- Go to Section TOC
Section 55 page 69
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Install shift valve (C), spring (B) and solenoid valve (A). Tighten solenoid valve (A).
Item
Measurement
Specification
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:
Before installing the valve, check that its bore is clean.
Install the enable proportional solenoid valve (A) and tighten it to its proper torque.
Item
Measurement
Specification
Enable proportional solenoid (Y38), screw
Torque
25 N˙m
18 lb-ft
<- Go to Section TOC
Section 55 page 70
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 71
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Item
Measurement
Specification
Front transmission cover, screw
Torque
60 N˙m
44 lb-ft
Final assembly:
Refer to “Removing and Installing the Front Valve Housing” .
<- Go to Section TOC
Section 55 page 72
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
<- Go to Section TOC
Section 55 page 73
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
Remove cover (A).
[2] -
Remove return valve (A) and spring (B).
[3] - Check components for wear. Replace, if necessary.
[4] →NOTE:
Before installing the valve, check that its bores are clean and allow a
through-passage.
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
Reinstall the return valve and put the cover back on. Tighten cap screws.
Item
Measurement Specification
Cover for return valve and gear-to-gear modulation valve, screw
Torque
12 N˙m
9 lb-ft
Reconditioning the gear-to-gear modulator valve and pressure
accumulator
<- Go to Section TOC
Section 55 page 74
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
Remove cover (A).
[2] -
Remove accumulator (A), pin (B), the two springs (C) and modulator valve (D).
[3] - Check components for wear. Replace, if necessary.
[4] →NOTE:
Before installing the valve, check that its bores are clean and allow a
through-passage.
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
Reinstall the valves and put the cover back on. Tighten cap screws.
Item
Measurement Specification
Cover for return valve and gear-to-gear modulation valve, screw
Torque
12 N˙m
9 lb-ft
Reconditioning the pressure-regulating valve
<- Go to Section TOC
Section 55 page 75
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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:
Before installing the valve, check that its bore is clean.
Install the pressure-regulating valve and tighten the plug.
Item
Measurement
Specification
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).
[2] - Check components for wear. Replace, if necessary.
<- Go to Section TOC
Section 55 page 76
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] →NOTE:
Before installing the valves, check that the bore is clean and allows a
through-passage.
Install the valves and tighten the plug.
Item
Measurement Specification
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.
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
Install the shift valve housing, tightening all the screws evenly.
Item
Measurement
Specification
Shift valve housing, screw
Torque
11 N˙m
8 lb-ft
<- Go to Section TOC
Section 55 page 77
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
<- Go to Section TOC
Section 55 page 78
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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 B3C4.
Solenoid valve K2 is now designated as solenoid valve 1 (Y62); it shifts B1B2.
Solenoid valve and B1-B2 shift valve
[1] -
Remove the K1 solenoid valve (A; Y40), shift valve (B) and spring (C).
[2] - Check components for wear. Replace, if necessary.
[3] →NOTE:
Before installing the valve, check that its bore is clean.
Install the valve, tightening it to its proper torque.
Item
Measurement
Specification
K1 solenoid valve (Y40)
Torque
45 N˙m
33 lb-ft
Solenoid valve and B2-B3 shift valve
<- Go to Section TOC
Section 55 page 79
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
Remove the K2 solenoid valve (A; Y39), shift valve (B) and spring (C).
[2] - Check components for wear. Replace, if necessary.
[3] →NOTE:
Before installing the valve, check that its bore is clean.
Install the valve, tightening it to its proper torque.
Item
Measurement
Specification
K2 solenoid valve (Y39)
Torque
45 N˙m
33 lb-ft
Solenoid valve and B3-C4 shift valve
[1] -
Remove the K3 solenoid valve (A; Y32), shift valve (B) and spring (C).
[2] - Check components for wear. Replace, if necessary.
[3] →NOTE:
Before installing the valve, check that its bore is clean.
<- Go to Section TOC
Section 55 page 80
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Install the valve, tightening it to its proper torque.
Item
Measurement
Specification
K3 solenoid valve (Y32)
Torque
45 N˙m
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.
<- Go to Section TOC
Section 55 page 81
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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] -
Remove snap ring (A).
[2] -
Take screws (A) out of the transmission oil pump.
<- Go to Section TOC
Section 55 page 82
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 83
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
B
C
D
E
F
G
H
I
J
K
L
M
N
O
<- Go to Section TOC
Bushing
Input shaft
Bearing
Screw (6 used
Pump housing
Dowel pin (2 used)
Drive gear
Idler gear
Air pump operating pin
Pump piston
Rubber ball
Lower spring retainer
Spring
Upper spring retainer with O-ring
Snap ring
Section 55 page 84
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
P
Q
R
S
T
U
V
W
X
Y
Group 10: PowrQuad Module
Front transmission cover
Bearing
Snap ring
Seal ring
O-ring
Input flange
Plastic binder
Bellows
Input flange
Input shaft
Disassembling the transmission oil pump
[1] -
LEGEND:
A
B
C
Pump housing
Pump gears
Input shaft
Remove input shaft (C).
[2] - Take the pump gears (B) out of the pump housing.
<- Go to Section TOC
Section 55 page 85
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] - Check the input shaft for wear.
LEGEND:
A
B
Input shaft on tractor 6820
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
<- Go to Section TOC
Section 55 page 86
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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
Driving in bushings, bearings and seals
[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.
Bushing, bearing and seal driver sets
D01045AA
Driving in bushings, bearings and seals
Hydraulic puller set
<- Go to Section TOC
Section 55 page 87
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
D01048AA
Removal of bearings
Mechanical puller set
D01173AA
Removal of bearings
Repairing the pneumatic pump
<- Go to Section TOC
Section 55 page 88
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
LEGEND:
A
B
C
D
E
F
G
Pneumatic pump operating pin
Piston
Rubber ball
Lower spring retainer
Spring
Upper spring retainer with O-ring
Snap ring
Remove the air pump operating pin (A) from the pump housing.
<- Go to Section TOC
Section 55 page 89
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.).
<- Go to Section TOC
Section 55 page 90
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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).
<- Go to Section TOC
Section 55 page 91
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 92
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 55 page 93
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Removing the Gear-Shift Planetary Drive
Preliminary work:
See reference ”Removing and Installing the Front Transmission Cover” in this Group.
[1] -
LEGEND:
A
B
Cover
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.
<- Go to Section TOC
Section 55 page 94
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[2] -
LEGEND:
A
B
C
D
Planetary carrier
3rd gear sun gear
2nd gear sun gear
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.
<- Go to Section TOC
Section 55 page 95
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
B
C
D
E
F
G
H
I
J
B1 brake housing
Screw
Bushing
1st gear sun gear
Thrust washer
2nd gear sun gear
[ A bearing bushing is integrated into the sun gear only from tractor serial no. 392759. ]
K
Thrust washer
3rd gear sun gear with thrust washer
Planetary carrier
Thrust washer
Spiral ring
L
Spiral ring
M
N
O
P
Ring gear with thrust washer
Planet gear shaft
Retaining pin
Thrust washer
[ The spiral rings are omitted from tractor serial number 343455. ]
[ The spiral rings are omitted from tractor serial number 343455. ]
<- Go to Section TOC
Section 55 page 96
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Q
R
S
T
U
Bearing
Spacer
Planet gear
Thrust washer
Cover
V
Screw
Group 10: PowrQuad Module
[ From tractor serial no. 424468, partial uncovering no longer suffices; it must be uncovered fully. ]
[1] -
LEGEND:
A
B
Thrust washer
Ring gear
Inspect thrust washer (A) and ring gear (B). Replace, if necessary.
<- Go to Section TOC
Section 55 page 97
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[2] -
LEGEND:
A
B
Spiral ring
Spiral ring
Inspect spiral rings (A) and (B). Replace, if necessary.
[ The spiral rings are omitted from tractor serial number 343455. ]
CAUTION:
Take care when disassembling. The spiral rings are under pressure.
<- Go to Section TOC
Section 55 page 98
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] -
LEGEND:
A
B
C
3rd gear sun gear with thrust washer
Thrust washer
2nd gear sun gear
D
E
F
Thrust washer
1st gear sun gear
Thrust washer
[ A bearing bushing is integrated into the sun gear only from tractor serial no. 392759. ]
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.
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Section 55 page 99
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
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Group 10: PowrQuad Module
[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.
Bushing, bearing and seal driver sets
D01045AA
Driving in bushings, bearings and seals
<- Go to Section TOC
Section 55 page 100
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 101
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] -
LEGEND:
A
B
C
D
E
F
G
Planetary carrier
Planet gear
Planet gear shaft
Retaining pin
Thrust washers
Needle bearing
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
B
Needle bearing
Spacer
Insert needle bearings (A) and spacer (B) into the planet gear.
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Section 55 page 102
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[2] IMPORTANT:
Before assembling, make sure that the oil passages in the planet gear
shafts and planetary carrier are not blocked.
LEGEND:
A
B
Thrust washer
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.
<- Go to Section TOC
Section 55 page 103
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Install Gear-Shift Planetary Drive
[1] -
LEGEND:
A
B
Thrust washer
Spiral ring
Check thrust washer (A). The thrust washer must not be worn or damaged.
[2] - Install the bottom spiral ring (B)
[ The spiral rings are omitted from tractor serial number 343455. ]
.
<- Go to Section TOC
Section 55 page 104
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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
[ The spiral rings are omitted from tractor serial number 343455. ]
is put on.
<- Go to Section TOC
Section 55 page 105
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[4] -
LEGEND:
A
Spiral ring
Install the top spiral ring (A)
[ The spiral rings are omitted from tractor serial number 343455. ]
in such a way that the ends (A) of the top and bottom spiral rings are at opposite sides.
<- Go to Section TOC
Section 55 page 106
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[5] -
LEGEND:
A
B
Timing mark on ring gear
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.
<- Go to Section TOC
Section 55 page 107
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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).
<- Go to Section TOC
Section 55 page 108
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[10] -
LEGEND:
A
B
C
D
E
F
G
1st gear sun gear
2nd gear sun gear
3rd gear sun gear
Thrust washer
Thrust washer
Thrust washer
Thrust washer on 3rd gear sun gear
Refer to the cross-sectional view before installing the sun gears and thrust washers.
[11] -
LEGEND:
A
B
C
1st gear sun gear
2nd gear sun gear
3rd gear sun gear with thrust washer
Install sun gears (A), (B) and (C), remembering to include thrust washers.
<- Go to Section TOC
Section 55 page 109
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 110
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[13] -
LEGEND:
A
Cover
Put on cover (A). Coat the screws with Thread Lock and Sealer LOCTITE ™ 243 (L41475), and
tighten.
Item
Measurement
Specification
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:
<- Go to Section TOC
Section 55 page 111
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
See reference “Removing the Gear-Shift Planetary Drive” in this Group.
Take out screws (A).
<- Go to Section TOC
Section 55 page 112
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Reconditioning the B1 Brake
Preliminary work:
See reference ”Removing the B1 Brake Housing” in this Group.
[1] -
LEGEND:
A
B
Spring (4 used)
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] -
<- Go to Section TOC
Section 55 page 113
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
LEGEND:
A
B
C
D
E
F
B2-B3 brake housing
Sealing ring
B2 piston
B2 piston plate
B2 disk
B1-B2 separator plate
G
H
I
J
K
L
M
Spring
B1 disk
B1 plate
B1 piston plate
B1 piston
B1 brake housing
Attaching screw
[ From tractor ser. no. 411806, the separator plate is replaced by two thinner plates ]
Refer to the exploded view before assembling the B1-B2 brake.
Final assembly:
See reference ”Installing the B1 Brake Housing” in this Group.
<- Go to Section TOC
Section 55 page 114
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 55 page 115
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Remove the B2-B3 brake housing (A).
<- Go to Section TOC
Section 55 page 116
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Reconditioning the B2 Brake
Preliminary work:
See reference ”Removing the B2-B3 Brake Housing” in this Group.
[1] -
LEGEND:
A
B
Springs (4 used)
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.
<- Go to Section TOC
Section 55 page 117
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] -
LEGEND:
A
B
C
D
E
F
B2-B3 brake housing
Seal ring
B2 brake piston
B2 piston plate
B2 disk
B1-B2 separator plate
G
H
I
J
K
L
Spring
B1 disk
B1 plate
B1 piston plate
B1 brake piston
B1 brake housing
[ From tractor ser. no. 411806, the separator plate is replaced by two thinner plates ]
Refer to the exploded view before assembling the B2 brake.
Final assembly:
See reference ”Installing the B2-B3 Brake Housing” in this Group.
<- Go to Section TOC
Section 55 page 118
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Reconditioning the B3 Brake
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] -
Take out screws (A).
[3] - Take out the various components of the B3 brake and check them. Replace, if
necessary.
[4] -
<- Go to Section TOC
Section 55 page 119
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
LEGEND:
A
B
C
D
E
F
G
H
I
J
Planet gear housing
Seal
B3 plate
B3 disk
B3 piston plate
Spring
B3 brake piston
B2-B3 brake housing
Dowel pin
Screw
Refer to the exploded view before assembling the B3 brake.
[5] →NOTE:
Keep all the screws and bores clean and dry (i.e. free of oil and grease).
<- Go to Section TOC
Section 55 page 120
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Tighten attaching screws (A) evenly.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 55 page 121
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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).
<- Go to Section TOC
Section 55 page 122
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
<- Go to Section TOC
Section 55 page 123
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
S
T
U
V
W
X
Group 10: PowrQuad Module
Dowel pin
Thrust washer
Bushing
[ 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. ]
Retainer
Anti-cavitation check valve
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
<- Go to Section TOC
Section 55 page 124
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
LEGEND:
A
Anti-cavitation check valves
Inspect clutch piston and anti-cavitation check valves (A).
→NOTE:
LEGEND:
A
B
Retainer
Ball
The anti-cavitation check valve consists of retainer (A) and ball (B). The
valve ball must not be jammed; it must move freely.
<- Go to Section TOC
Section 55 page 125
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 126
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 127
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 128
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[7] -
LEGEND:
A
B
Bushing
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.
Bushing, bearing and seal driver sets
D01045AA
Driving in bushings, bearings and seals
→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.
<- Go to Section TOC
Section 55 page 129
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[9] -
LEGEND:
A
Seal ring
Coat seal ring (A) with grease and install it in the groove at the clutch drum.
→NOTE:
Position the seal ring in the ring groove so that it is not damaged when the
piston is installed.
[10] -
LEGEND:
A
B
Piston
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.
<- Go to Section TOC
Section 55 page 130
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 131
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
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Group 10: PowrQuad Module
[14] -
LEGEND:
A
Clutch hub
Insert the clutch hub (A).
[15] -
LEGEND:
A
B
Disk with liner
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.
<- Go to Section TOC
Section 55 page 132
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
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Group 10: PowrQuad Module
[17] -
LEGEND:
A
Guide pin
Install the spring guide pins (A).
[18] -
LEGEND:
A
Spring
Insert the springs (A).
<- Go to Section TOC
Section 55 page 133
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
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Group 10: PowrQuad Module
[19] -
Apply sealing compound LOCTITE ™ 243 (medium strength) to the threaded bores.
[20] -
LEGEND:
A
B
Hole
Dowel pin
Install the clutch cover. Position the clutch cover so that the bores (A) for the dowel pins (B)
are aligned.
<- Go to Section TOC
Section 55 page 134
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 55 page 135
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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” .
<- Go to Section TOC
Section 55 page 136
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] -
Take out screws (A) and remove the reverse brake housing.
[2] - Repair the reverse brake. See “Repairing the reverse brake” in this group.
<- Go to Section TOC
Section 55 page 137
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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).
<- Go to Section TOC
Section 55 page 138
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[4] -
LEGEND:
A
B
C
D
E
F
G
H
Dowel pin
Bearing bushing
Seal ring
Mounting screw
Reverse brake housing
Gasket
Reverse brake piston
Piston plate
Reverse brake disk (4
[ Tractors 6820 ]
I
or 5
[ Tractors 6920 ]
J
<- Go to Section TOC
used)
Spring (8 used)
Section 55 page 139
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Reverse brake plate (3
[ Tractors 6820 ]
K
or 4
[ Tractors 6920 ]
L
M
used)
Ring gear
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.
Bushing, bearing, and seal driver sets
D01045AA
Driving in bushings, bearings and seals
Final assembly: Refer to “Installing the reverse brake” .
Installing the reverse brake
[1] - Clean the sealing surfaces and install the gasket.
<- Go to Section TOC
Section 55 page 140
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
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Group 10: PowrQuad Module
[2] -
Install the reverse brake housing and tighten screws (A).
Item
Measurement
Specification
Reverse brake housing, screw
Torque
50 N˙m
37 lb-ft
Final assembly: See “Installing PowrQuad transmission” .
<- Go to Section TOC
Section 55 page 141
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 142
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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
B
C
<- Go to Section TOC
Piston plate
Disk
Clutch plate
Section 55 page 143
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Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
<- Go to Section TOC
Group 10: PowrQuad Module
Planetary carrier
Retaining pin
Thrust washer
Planet gear
Planet gear shaft
Clutch hub
Thrust washer
Needle bearing
Bushing
Spring
Guide pin
Seal ring
Clutch piston
Seal ring
Bushing
Drive shaft
Snap-ring
Thrust washer
Clutch drum
Overspeed relief valve
Section 55 page 144
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
1
2
3
4
5
6
7
8
<- Go to Section TOC
Group 10: PowrQuad Module
Planet gear housing
Thrust washer
Seal ring
Drive shaft
Snap-ring
Clutch hub
Snap-ring
Bushing
Section 55 page 145
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Group 10: PowrQuad Module
Clutch piston
Seal ring
Seal ring
Thrust washer
Clutch drum
Attaching screw
Bushing
Ball
Spring
Retainer
Spring
Guide pin
Piston plate
Disk with liner
Disk without liner
Retaining pin
Thrust washer
Planet gear
Needle bearing
Planet gear shaft
Planetary carrier
Thrust washer
Recondition or assemble the forward clutch and planetary drive as required, using the crosssection and exploded views as guidelines.
[1] →NOTE:
It is not necessary to remove drive shaft (A) unless it is damaged.
<- Go to Section TOC
Section 55 page 146
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
LEGEND:
A
B
Drive shaft
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).
<- Go to Section TOC
Section 55 page 147
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Bushing, bearing and seal driver sets
D01045AA
Driving in bushings, bearings and seals
<- Go to Section TOC
Section 55 page 148
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[5] -
LEGEND:
A
B
Bushing
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.
Bushing, bearing and seal driver sets
D01045AA
Driving in bushings, bearings and seals
[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.
<- Go to Section TOC
Section 55 page 149
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[8] -
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.
[9] -
At the clutch drum, apply a light coat of grease to the mounting surfaces of the clutch piston.
<- Go to Section TOC
Section 55 page 150
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[10] -
LEGEND:
A
Seal ring
Coat seal ring (A) with grease and install it in the groove at the clutch drum.
→NOTE:
Position the seal ring in the ring groove so that it is not damaged when the
piston is installed.
[11] -
LEGEND:
A
B
Piston
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.
<- Go to Section TOC
Section 55 page 151
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[13] -
LEGEND:
A
B
C
Piston plate
Guide pin
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.
<- Go to Section TOC
Section 55 page 152
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[15] -
LEGEND:
A
Clutch hub
Insert the clutch hub (A).
[16] -
LEGEND:
A
B
Disk with liner
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.
<- Go to Section TOC
Section 55 page 153
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 154
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
<- Go to Section TOC
Section 55 page 155
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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.
Item
Measurement
Specification
Forward clutch drum, screw
Torque
50 N˙m
37 lb-ft
<- Go to Section TOC
Section 55 page 156
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[23] -
LEGEND:
A
B
Drive shaft
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
<- Go to Section TOC
Section 55 page 157
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[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
B
C
Planet gear shaft
Planet gear
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).
<- Go to Section TOC
Section 55 page 158
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[4] -
LEGEND:
A
B
C
D
E
Thrust washers
Needle bearing
Planet gear
Planet gear shaft
Retaining pin
Check the components. Replace, if necessary.
[5] -
LEGEND:
A
B
C
Thrust washers
Needle bearing
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.
<- Go to Section TOC
Section 55 page 159
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 160
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
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.
<- Go to Section TOC
Section 55 page 161
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[3] -
Install pressure plate (A) and ring gear (B).
Final assembly:
See reference “Installing the Reverse Brake” in this Group.
<- Go to Section TOC
Section 55 page 162
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
Replacing the output shaft
Preliminary work: See “Removing the PowrQuad transmission” .
Exploded view of output shaft
LEGEND:
A
B
C
D
E
F
G
Seal ring
Transmission output shaft
Bearing bushing
O-ring
Snap ring
Sleeve
Rear PTO drive shaft
Repair or assemble the components of the drive shaft as required, using the exploded view
illustration as a guide.
<- Go to Section TOC
Section 55 page 163
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 10: PowrQuad Module
[1] - Check the transmission output shaft, the rear PTO drive shaft, the sleeve and all
components for wear. Replace, if necessary.
LEGEND:
A
B
C
Sleeve
Rear PTO drive shaft
Transmission output shaft
[2] -
LEGEND:
A
B
C
D
Seal ring
O-rings
Bushing
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.
Bushing, bearing, and seal driver sets
D01045AA
Driving in bushings, bearings and seals
[3] - Make sure the oil passages (D) of the transmission output shaft are open.
<- Go to Section TOC
Section 55 page 164
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
Final assembly: See “Installing PowrQuad transmission” .
<- Go to Section TOC
Section 55 page 165
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper 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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
Repair specifications
Item
Measurement Specification
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
<- Go to Section TOC
Section 55 page 166
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
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.
<- Go to Section TOC
Section 55 page 167
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
Repairing the creeper transmission
Preliminary work:
See “Removing the creeper transmission” .
Creeper transmission — Sectional view
<- Go to Section TOC
Section 55 page 168
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
<- Go to Section TOC
Section 55 page 169
Group 15: Creeper Transmission
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Group 15: Creeper Transmission
Roller bearing
Snap ring
Snap ring
Wear sleeve
Ball bearing
Snap ring
Snap ring
Lube passage seal
Input shaft with gear
Drive sleeve
Housing
Shift collar
Output gear
Thrust washer
Snap ring
Output drive gear/friction brake
Snap ring
Bushing
Spring (friction brake)
Brake disks (3 used)
Externally splined disk (3 used)
Backing plate
Cap screw (3 used)
Thrust washer
Needle bearing
Snap ring
Transmission lube oil seal
Countershaft
Needle bearing
Countershaft drive gear
Intermediate plate
Exploded view of the input/output drive shaft and shifter assembly
<- Go to Section TOC
Section 55 page 170
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
<- Go to Section TOC
Group 15: Creeper Transmission
Output sleeve
Input shaft
Shift collar
Dowel pin
Spring pin
Shift fork
Ball bearing
Snap ring
Snap ring
O-ring
Shifter shaft
Lever
Detent pin
Spring
Section 55 page 171
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Group 15: Creeper Transmission
Washer
Plug
Shifter fork detent
Sealing sleeve
Snap ring
Thrust washer
Needle bearing
Snap ring
Snap ring
Thrust washer
Drive gear
Input shaft
Bushing
Spring washer
Externally splined disk (3 used)
Brake disks (3 used)
Backing plate
Hex. socket screw (3 used)
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
B
C
<- Go to Section TOC
Shifter shaft
O-ring
Spring pin
Section 55 page 172
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
D
E
F
G
H
I
J
Group 15: Creeper Transmission
Shift fork
Dowel pin
Distance 6.75 to 7.25 mm (0.266 to 0.285 in.)
Spring
Detent pin
Washer
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.
Item
Measurement Specification
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
<- Go to Section TOC
Section 55 page 173
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[3] -
LEGEND:
A
B
C
D
E
Shifter fork
Spring pins
Lever, shifter shaft
Shift collar
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
B
C
D
Snap ring
Shaft
Bearing
Snap ring
Remove snap ring (A).
[7] - Remove input/output shaft (B) rearward through bearing (C).
<- Go to Section TOC
Section 55 page 174
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[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.).
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[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.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[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).
<- Go to Section TOC
Section 55 page 175
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[17] - Remove drive sleeve (C) from shaft.
[18] -
Take out cap screws (A).
[19] -
LEGEND:
A
B
C
D
Backing plate
Brake disks (3 used)
Externally splined disk (3 used)
Spring washer
Remove parts (A—D).
Item
Measurement Specification
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.
<- Go to Section TOC
Section 55 page 176
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[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.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
→NOTE:
Insert the bearing at a depth of up to 1 mm (0.039 in.) beneath the surface
of the hub.
[22] -
LEGEND:
A
B
C
D
Backing plate
Brake disks
Externally splined disks
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.
<- Go to Section TOC
Section 55 page 177
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[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).
Item
Measurement
Specification
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).
<- Go to Section TOC
Section 55 page 178
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[36] -
LEGEND:
A
B
C
D
Snap ring
Shaft
Bearing
Snap ring
Push the input/output shaft (B) through bearing (C).
[37] - Install snap ring (A).
[38] -
Position the shift collar (A) at the dowel pins (C) of the shifter fork (B) and push onto the
output drive shaft.
<- Go to Section TOC
Section 55 page 179
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[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
B
C
D
<- Go to Section TOC
Cap screw (8 used)
Dowel pin (2 used)
Intermediate plate
Countershaft drive gear
Section 55 page 180
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
Group 15: Creeper Transmission
Dowel pin (2 used)
Cap screw (2 used)
Housing
Roller bearing
Snap ring
Snap ring
Wear sleeve
Cover
Cap screw (5 used)
Oil seal
Countershaft
Needle bearing
Cap screw (3 used)
Plug
O-ring
Repair or assemble the countershaft as required, using the illustration as a guide.
Repairing the countershaft
[1] -
LEGEND:
A
B
C
D
E
Shaft snap ring
Shaft
Countershaft drive gear
Bearing snap ring
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.
<- Go to Section TOC
Section 55 page 181
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[4] - Remove bearing from the rear using a 60 mm (2-3/8 in.) driver.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[5] -
Remove needle bearing (A) from housing, if necessary, using a 50 mm (2 in.) driver.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[6] - Install a new bearing in the housing. Use a 64 mm (2-1/2 in.) driver disk with a 43 mm
(1-11/16 in.) pilot disk.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[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.
<- Go to Section TOC
Section 55 page 182
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[10] -
Remove wear sleeve (A) from front of countershaft, if necessary.
[11] - Install new sleeve using a 32 mm (1-1/4 in.) driver.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[12] -
LEGEND:
A
B
C
D
E
Shaft snap ring
Shaft
Countershaft drive gear
Bearing snap ring
Shaft bearing
If required, install a new bearing (E) using a 60 mm (2-3/8-in.) driver disk and a 28.5 mm
(1-1/8 in.) pilot disk.
Bushing, bearing, and seal driver set
D01045AA
Install bushings, bearings, and seals
[13] - Install snap ring (D).
[14] - Install countershaft drive gear (C) into the housing with widest flange toward front of
housing.
<- Go to Section TOC
Section 55 page 183
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: Creeper Transmission
[15] - Install countershaft (B) into the housing through rear needle bearing, drive gear, and
front roller bearing (E).
[16] - Install snap ring (A).
Final assembly:
See “Installing the creeper transmission” .
<- Go to Section TOC
Section 55 page 184
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 15: 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).
Item
Measurement Specification
Intermediate plate to range transmission, cap screw
Torque
70 N˙m
50 lb-ft
<- Go to Section TOC
Section 55 page 185
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[7] -
Install the creeper transmission. See “Installing the creeper or option transmission” .
Final assembly:
See “Installing PowrQuad transmission” .
<- Go to Section TOC
Section 55 page 186
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Group 20 - Range Transmission
Range Transmission - Reconditioning (Summary of
References)
”Special tools”
”Specifications”
”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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
2-1/2 in. heavy duty socket
JDT44
Removing and tightening intermediate shaft nut
Bushing, bearing, and seal driver set
D01045AA
Removal and installation of bearings and bushings
Puller set
D01047AA
Removal of bearings and bushings
<- Go to Section TOC
Section 55 page 187
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Bracket
Dealer-fabricated
A-Flat steel bar 25x10x145 mm; (1x0.4x5.7 in.)
Holding the shift rod detent when adjusting the shifting mechanism
<- Go to Section TOC
Section 55 page 188
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Repair specifications
Item
Measurement Specification
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” .
<- Go to Section TOC
Section 55 page 189
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: 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:
<- Go to Section TOC
Section 55 page 190
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
A
B
C
D
E
F
G
H
I
J
K
L
M
N
<- Go to Section TOC
Group 20: Range Transmission
Drive shaft
Gear, range C
Synchronizer unit
Gear, range D
Synchronizer unit
Gear, range E
Differential drive shaft
Gear
Gear
Front-wheel drive gear
Gear
Gear, range B
Synchronizer unit
Gear, range A
Section 55 page 191
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
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
B
C
D
E
F
Shifter fork, ranges C and D
Shift rod, range E
Shift rod, ranges C and D
Shift rod, ranges A and B
Balls
Locking pin
Repair (remove and install) the shifter assembly parts using the sectional view illustration as
a guide.
<- Go to Section TOC
Section 55 page 192
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
→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
<- Go to Section TOC
Section 55 page 193
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
<- Go to Section TOC
Section 55 page 194
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
<- Go to Section TOC
Section 55 page 195
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[9] -
Carefully pull out differential drive shaft and remove parts from shaft.
Removing the drive shaft
[1] -
LEGEND:
A
B
C
D
Shift rod, range E
Shift fork, range E
Shift rod, ranges C and D
Shift fork, ranges C and D
Remove shift rods and forks.
<- Go to Section TOC
Section 55 page 196
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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
<- Go to Section TOC
Section 55 page 197
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
40 km/h (25 mph) drive shaft - Exploded view
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
<- Go to Section TOC
Snap ring
Taper roller bearing cup
Cap screw
Housing
Plug
Retaining plate
Cap screw
Taper roller bearing cup
Adjusting ring
Sealing sleeve
Taper roller bearing cone
Drive shaft
Gear, range E
Synchronizer unit
Thrust washer
Sleeve
Gear (range D)
Section 55 page 198
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
18
19
20
21
22
23
Group 20: Range Transmission
Synchronizer unit
Sleeve
Gear, range C
Thrust washer
Taper roller bearing cone
Snap ring (thickness as required)
50 km/h (31 mph) drive shaft - Exploded view
LEGEND:
1
2
3
4
5
<- Go to Section TOC
Snap ring
Taper roller bearing cup
Cap screw
Housing
Plug
Section 55 page 199
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Group 20: Range Transmission
Retaining plate
Cap screw
Taper roller bearing cup
Adjusting ring
Sealing sleeve
Taper roller bearing cone
Thrust washer
Needle bearing
Gear, range A
Sleeve
Drive shaft
Thrust washer
Gear, range E
Synchronizer unit
Thrust washer
Sleeve
Gear, range D
Synchronizer unit
Gear, range C
Thrust washer
Taper roller bearing cone
Snap ring (thickness as required)
Check the drive shaft and repair or assemble it as required, using the exploded view
illustration as a guide.
Exploded view of differential drive shaft
<- Go to Section TOC
Section 55 page 200
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Group 20: Range Transmission
Differential drive shaft
Taper roller bearing assy.
Spacer washer (quantity and thickness as required)
Spacer
Spacer washer (quantity and thickness as required)
Taper roller bearing assy.
Adjusting ring
Wear sleeve
Gear, range A
Synchronizer unit
Sleeve
Gear, range B
Gear, range E
Front-wheel drive gear
Gear, range D
Gear, range C
Check the differential drive shaft and repair or assemble it as required, using the exploded
view illustration as a guide.
<- Go to Section TOC
Section 55 page 201
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Shifting mechanism - Exploded view
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
Ball
Locking pin
Spring
Shift rod, range E
Shift rod, ranges C and D
Shift rod, ranges A and B
Shift fork, ranges C and D
Shift fork, range E
Shifter fork, ranges A and B
Wear lining
Threaded pin
Check the shifting mechanism and repair or assemble it as required, using the exploded view
illustration as a guide.
<- Go to Section TOC
Section 55 page 202
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
→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
2
3
4
<- Go to Section TOC
Pin
Bushing
Washer
Locking pawl
Section 55 page 203
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Group 20: Range Transmission
Bushing
Shaft
Snap ring
Spring
O-ring
Plug
Cotter pin
Locking cam
Thrust washer
Needle bearing
Washer
Lever arm
Spring pin
O-ring
Dowel pin
Spring
Square plate
Washer
Bushing
Cotter pin
Retaining clip
Lever arm
Support bushing
Washer
Screw
Rod
Hex. nut
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] -
Remove snap ring (A).
<- Go to Section TOC
Section 55 page 204
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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).
<- Go to Section TOC
Section 55 page 205
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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).
<- Go to Section TOC
Section 55 page 206
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[7] CAUTION:
Heat bearing in a bearing heater. Do not exceed 150°C (300°F). Proceed
with care to avoid burns.
Install bearing cone (A).
[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
<- Go to Section TOC
Section 55 page 207
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
<- Go to Section TOC
Section 55 page 208
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[4] -
Screw in adjustment ring (A).
Adjusting end play of drive shaft
[1] -
Tighten adjusting ring until specified end play is obtained.
Item
Measurement
Specification
Drive shaft adjustment
End play
0.013 to 0.080 mm
0.0005 to 0.0030 in.
<- Go to Section TOC
Section 55 page 209
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
Item
Measurement
Specification
Adjusting ring - locking plate, cap screw
Torque
25 N˙m
18 lb-ft
[4] -
LEGEND:
A
B
C
D
Shift rod, range E
Shift fork, range E
Shift rod, ranges C and 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.
<- Go to Section TOC
Section 55 page 210
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
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.
<- Go to Section TOC
Section 55 page 211
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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).
<- Go to Section TOC
Section 55 page 212
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[7] CAUTION:
Heat bearing in a bearing heater. Do not exceed 150°C (300°F). Proceed
with care to avoid burns.
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.
<- Go to Section TOC
Section 55 page 213
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
<- Go to Section TOC
Section 55 page 214
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[12] -
Install parking lock pawl and snap ring (C).
[13] - Install spring (B) and plug (A).
Item
Measurement
Specification
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
<- Go to Section TOC
Section 55 page 215
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
2-1/2 in. Heavy Duty Socket
JDT44
Remove and install differential drive shaft nut
Item
Measurement
Specification
Differential drive shaft nut
Torque
550 N˙m
405 lb-ft
[4] - Determine end play.
[5] - Remove shims until specified end play is obtained.
Item
Measurement
Specification
Differential drive shaft adjustment
End play
0.013 to 0.080 mm
0.0005 to 0.0030 in.
<- Go to Section TOC
Section 55 page 216
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[6] - Tighten differential drive shaft nut again using special tool JDT44 or a commercial
socket and secure it in two places.
2-1/2 in. Heavy Duty Socket
JDT44
Remove and install differential drive shaft nut
Item
Measurement
Specification
Differential drive shaft nut
Torque
550 N˙m
405 lb-ft
[7] -
Install balls and springs (A) of shift rod detent.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 55 page 217
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
<- Go to Section TOC
Section 55 page 218
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[6] - Tighten threaded pins of shift forks.
Item
Measurement
Specification
Threaded pins of shift forks
Torque
40 N˙m
30 lb-ft
[7] - Check the shift mechanism again.
Final assembly: “Installing the range transmission” .
<- Go to Section TOC
Section 55 page 219
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: 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.
[4] - Tighten cap screws (B).
Item
Measurement
Specification
Shift cover to range transmission, cap screws
Torque
70 N˙m
50 lb-ft
[5] -
Install the range transmission.
Final assembly: Before installing the range transmission, see “Installing the range
transmission” .
<- Go to Section TOC
Section 55 page 220
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Repairing the shift cover
[1] -
Remove shift cover (A).
<- Go to Section TOC
Section 55 page 221
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[2] -
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
Lever
Spring pin
Gasket
Dowel pin
Shift cover
Locking cam
Thrust washer
Needle bearing
Cap screw
O-ring
Washer
Lever arm
O-ring
Lever, ranges A and B
Lever, range E
Spring pin
Lever, ranges C and D
Repair or assemble the shift cover as required, using the exploded view illustration as a
guide.
<- Go to Section TOC
Section 55 page 222
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
[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.
[5] - Tighten cap screws (B).
Item
Measurement
Specification
Shift cover to range transmission, cap screws
Torque
70 N˙m
50 lb-ft
<- Go to Section TOC
Section 55 page 223
TM4756-REPAIR MANUAL
Section 55 - POWRQUAD PLUS, AUTOQUAD AND
AUTOQUAD PLUS TRANSMISSIONS
Group 20: Range Transmission
Replacing the speed sender
[1] -
LEGEND:
A
Sender for ground speed (B35)
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] -
<- Go to Section TOC
Section 55 page 224
TM4756-REPAIR MANUAL
DRIVE SYSTEMS
(g) by Belgreen
LEGEND:
A
B
Ground speed sender (B35)
Ground speed sender (B09)
C
D
E
F
G
Transmission speed sender (B104/1)
O-ring
Protective cap
Terminal
Mounting screw
[ For tractors with creeper ]
Install new sender in housing with O-ring.
[5] - Tighten mounting screws (C).
Item
Measurement
Specification
Mounting screw, speed sender
Torque
20 N˙m
15 lb-ft
<- Go to Section TOC
Section 55 page 225
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Section 56 - DRIVE SYSTEMS
Table of contents
Group 00 - Removal and Installation of Components .......................................................... 1
Special Tools .......................................................................................................................... 1
Dealer-Fabricated Special Tools ............................................................................................. 4
Repair Specifications .............................................................................................................. 8
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
General Information ........................................................................................................... 266
Special Tools ...................................................................................................................... 266
Repair Specifications .......................................................................................................... 267
Summary of Torques .......................................................................................................... 267
Preliminary Work ................................................................................................................ 268
Installing and Removing Drive Shaft .................................................................................. 270
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Group 00 - Removal and Installation of Components
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
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
<- Go to Section TOC
Section 56 page 1
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 56 page 2
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 56 page 3
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Dealer-Fabricated Special Tools
Adapter Strut
dealer fabricated
LEGEND:
A
B
C
D
E
F
G
H
80 mm (3.2 in.)
45 mm (1.8 in.)
400 mm (16 in.)
360 mm (14.17 in.)
140 mm (5.51 in.)
13 mm (1/2 in.) dia. bore
19 mm (3/4 in.) dia. bore
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
<- Go to Section TOC
Section 56 page 4
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
a
b
c
d
e
f
A
Group 00: Removal and Installation of Components
250 mm (10 in.)
50 mm (2 in.)
15 mm (0.6 in.)
205 mm (8.1 in.)
16 mm (0.6 in.)
18 mm (45/64 in.) dia. hole
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
<- Go to Section TOC
Section 56 page 5
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 56 page 6
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Removal and installation of final drive housings and other tractor components. Used in
conjunction with support stand D05007ST.
<- Go to Section TOC
Section 56 page 7
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Repair Specifications
Item
Measurement
Specificatio
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.
<- Go to Section TOC
Section 56 page 8
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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)
in Section 56, Group 05.
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.
<- Go to Section TOC
Section 56 page 9
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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).
<- Go to Section TOC
Section 56 page 10
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
Item
Measurement Specification
Cap Screws, Front-Wheel Drive Clutch Housing to Range Transmission
Torque
50 N˙m
37 lb.-ft.
For further assembly, follow disassembly procedure in reverse order.
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.
<- Go to Section TOC
Section 56 page 11
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
IMPORTANT:
On tractors equipped with air brakes, it is vitally important to check that
the trailer brake valve is set correctly.
<- Go to Section TOC
Section 56 page 12
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Remove the Differential Housing
[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] - 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 (FrontWheel Drive Axle) in Section 56, Group 05.
[5] - If equipped, disengage the clutch cable.
<- Go to Section TOC
Section 56 page 13
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[6] -
Remove drain screw (A) and allow the transmission oil to drain out.
→NOTE:
Trap the oil in a container with a capacity of at least 60 liters (15 U.S.gal.).
[7] -
LEGEND:
A
B
C
D
JT05724 Universal Support Stand
JT05723 Universal Support Stand
Front Support of JT05723
L78499 Bracket
<- Go to Section TOC
Section 56 page 14
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
E
F
Group 00: Removal and Installation of Components
Wooden Block
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
<- Go to Section TOC
Section 56 page 15
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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
B
C
D
E
F
G
H
80 mm (3.2 in.)
45 mm (1.8 in.)
400 mm (16 in.)
360 mm (14.17 in.)
140 mm (5.51 in.)
13 mm (1/2 in.) dia. bore
19 mm (3/4 in.) dia. bore
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.
<- Go to Section TOC
Section 56 page 16
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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
Removal and installation of the operator′s cab
Lifting eyes (2 used)
dealer fabricated
<- Go to Section TOC
Section 56 page 17
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
Commercial M16, DIN 582 Lifting Eye Nut
M16 Nut
Threaded Rod M16 x 100 mm (4 in.), Grade 8.8
Coat threaded rod (C) with LOCTITE ™ 271 (TY43513), and screw it into eye nut (A) until it
bottoms. Lock with nut (B).
[9] -
Loosen the front cab mounting screws (A), but do NOT take them out.
<- Go to Section TOC
Section 56 page 18
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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).
<- Go to Section TOC
Section 56 page 19
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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] -
<- Go to Section TOC
Section 56 page 20
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
Steering Pressure Line
Steering LS Line
SCV Bowden Cables
Connector
Height-Adjustable Trailer Hitch Rails
Connector
Bowden Cable
Center Link
Connector
Connector
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.
<- Go to Section TOC
Section 56 page 21
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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:
Trap any oil as it emerges. Seal the open ends so that no dust can
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).
<- Go to Section TOC
Section 56 page 22
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[18] -
Take out screw (A).
[19] -
Disconnect return hose (A) and hose (B). Take out the screw that holds on the hose bracket.
<- Go to Section TOC
Section 56 page 23
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[20] -
Disconnect the oil cooler hoses (A).
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.
[21] -
Remove cap screws (A) using the special tools (B) and (C).
Support stand
D05007ST
<- Go to Section TOC
Section 56 page 24
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Removal and installation of differential housing.
Extension
JDG749
Removal and installation of differential housing.
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.
<- Go to Section TOC
Section 56 page 25
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 56 page 26
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 56 page 27
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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.
Flywheel turning tool
JDG820
Turning flywheel on 6-cylinder engines
<- Go to Section TOC
Section 56 page 28
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[5] -
Remove cap screws (A) using the special tools (B) and (C).
Support stand
D05007ST
Removal and installation of differential housing.
Extension
JDG749
Removal and installation of differential housing.
[6] - Reverse removal procedure to install the bowden cables, brake lines and hydraulic
hoses back in place.
<- Go to Section TOC
Section 56 page 29
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[7] - Lower and mount the operator′s cab.
Tighten the front cab mounting screws (A) to the torques prescribed.
Item
Measurement
Specification
Front Cab Mounting, Cap Screw
Torque
220 N˙m
160 lb.-ft.
Tighten the rear cab mounting screws (A) to the specified torque.
Item
Measurement
Specification
Cab to Final Drive Housing, Cap Screw
Torque
220 N˙m
160 lb.-ft.
<- Go to Section TOC
Section 56 page 30
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[8] -
Install oil cooler hoses (A).
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.
[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
The cable must
The cable must
The cable must
operated.
be free of tension.
not come into contact with moving parts.
not be bent or crushed.
not chafe against other components when the clutch is
[10] - For further assembly, follow disassembly procedure in reverse order.
<- Go to Section TOC
Section 56 page 31
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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)
in Section 55, Group 05.
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).
<- Go to Section TOC
Section 56 page 32
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Remove Final Drives
[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] -
Remove drain screw (A) and allow the transmission oil to drain out.
→NOTE:
Trap the oil in a container with a capacity of at least 60 liters (15 U.S.gal.).
<- Go to Section TOC
Section 56 page 33
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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
<- Go to Section TOC
Section 56 page 34
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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).
<- Go to Section TOC
Section 56 page 35
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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
Removal and installation of the operator′s cab
Lifting eyes (2 used)
dealer fabricated
<- Go to Section TOC
Section 56 page 36
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
LEGEND:
A
B
C
Commercial M16, DIN 582 Lifting Eye Nut
M16 Nut
Threaded Rod M16 x 100 mm (4 in.), Grade 8.8
Coat threaded rod (C) with LOCTITE ™ 271 (TY43513), and screw it into eye nut (A) until it
bottoms. Lock with nut (B).
[9] -
Loosen the front cab mounting screws (A), but do NOT take them out.
<- Go to Section TOC
Section 56 page 37
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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
<- Go to Section TOC
Section 56 page 38
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Removal and installation of final drive housings. Also required: dealer-fabricated holding
devices, see Special Tools (Dealer-Fabricated).
Holding fixture
dealer fabricated
LEGEND:
a
b
c
d
e
f
A
250 mm (10 in.)
50 mm (2 in.)
15 mm (0.6 in.)
205 mm (8.1 in.)
16 mm (0.6 in.)
18 mm (45/64 in.) dia. hole
M12x30 mm screw
Removal and installation of final drive housings and other tractor components. Used in
conjunction with support stand D05007ST.
Holding fixture
dealer fabricated
<- Go to Section TOC
Section 56 page 39
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Removal and installation of final drive housings and other tractor components. Used in
conjunction with support stand D05007ST.
→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.
<- Go to Section TOC
Section 56 page 40
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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).
<- Go to Section TOC
Section 56 page 41
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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
<- Go to Section TOC
Section 56 page 42
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Removal and installation of final drive housings. Also required: dealer-fabricated holding
devices, see Special Tools (Dealer-Fabricated).
Holding fixture
dealer fabricated
LEGEND:
a
b
c
d
e
f
A
250 mm (10 in.)
50 mm (2 in.)
15 mm (0.6 in.)
205 mm (8.1 in.)
16 mm (0.6 in.)
18 mm (45/64 in.) dia. hole
M12x30 mm screw
Removal and installation of final drive housings and other tractor components. Used in
conjunction with support stand D05007ST.
Holding fixture
dealer fabricated
<- Go to Section TOC
Section 56 page 43
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
Item
Measurement Specification
Cap Screws, Final Drive Housing to Differential Housing
Torque
230 N˙m
170 lb.-ft.
<- Go to Section TOC
Section 56 page 44
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Lower the cab and tighten cap screws (A) to the specified torque.
Item
Measurement
Specification
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.
Item
Measurement Specification
Hex. Socket Screw, Bracket of Stabilizer Bar to Final Drive Housing
Torque
710 N˙m
525 lb.-ft.
<- Go to Section TOC
Section 56 page 45
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 56 page 46
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Remove Rear PTO
[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] -
Remove drain screw (A) and allow the transmission oil to drain out.
→NOTE:
Trap the oil in a container with a capacity of at least 60 liters (15 U.S.gal.).
<- Go to Section TOC
Section 56 page 47
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 56 page 48
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 56 page 49
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
Item
Measurement Specification
Cap Screws, Rear PTO Housing to Differential Housing
Torque
240 N˙m
175 lb.-ft.
Item
Measurement Specification
Attaching Screws, Center Link Bracket to PTO Housing / Differential Housing
Torque
340 N˙m
250 lb.-ft.
For further assembly, follow disassembly procedure in reverse order.
When finished, add transmission oil and check the oil level.
<- Go to Section TOC
Section 56 page 50
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
Remove Front PTO
[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] -
Remove grille screen.
Disconnect hoses (A) from front PTO oil cooler and seal open ends.
<- Go to Section TOC
Section 56 page 51
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
[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.
<- Go to Section TOC
Section 56 page 52
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 00: Removal and Installation of Components
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.
<- Go to Section TOC
Section 56 page 53
TM4756-REPAIR MANUAL
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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 54
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Group 05 - U-Jointed Shafts and Torsion Damper
Summary of References (U-Jointed Shafts and
Torsion Damper)
”Special tools”
”Use of special tool KJD10426”
”Specifications”
”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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Flywheel turning tool
JDG820
Turning flywheel on 6-cylinder engines
Adapter
KJD10426
<- Go to Section TOC
Section 56 page 55
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Tighten the screws of the engine u.j. shaft. Also refer to“Use of Special Tool KJD10426”.
<- Go to Section TOC
Section 56 page 56
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Use of Special Tool KJD10426
LEGEND:
A
B
C
D
Torque wrench
Socket wrench insert
Adapter KJD10426
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.
2.
3.
4.
Adjust torque wrench (A) to 135 N˙m (100 lb-ft).
InstallKJD10426adapter (C) on a second torque wrench.
Connect both torque wrenches by using a standard 17 mm hex. socket insert (B).
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.
<- Go to Section TOC
Section 56 page 57
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Repair specifications
Item
Measurement
Specificatio
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
B
C
D
<- Go to Section TOC
M12 corrugated-head screw
M12 corrugated-head screw
M10 cap screw
M8 cap screw
Section 56 page 58
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Remove Front-Wheel Drive U.j. Shaft
[1] -
LEGEND:
A
B
Anti-wrap guard
Anti-wrap guard
Remove anti-wrap guards (A) and (B).
<- Go to Section TOC
Section 56 page 59
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[2] -
Tractor without TLS axle
Tractors with TLS axle (not available for all models)
LEGEND:
A
B
U.j. shaft
Screw
Remove screws (B) from the flange.
[3] - Disconnect u.j. shaft (A) from the flange and pull it off the clutch shaft.
<- Go to Section TOC
Section 56 page 60
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
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
B
Bearing cup
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.
<- Go to Section TOC
Section 56 page 61
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[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.
<- Go to Section TOC
Section 56 page 62
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[3] -
LEGEND:
A
B
Universal joint
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
B
Bearing cup
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.
<- Go to Section TOC
Section 56 page 63
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[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.
<- Go to Section TOC
Section 56 page 64
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
Install Front-Wheel Drive U.j. Shaft
[1] -
LEGEND:
A
B
Back-up ring
Plastic bushing
Slide back-up ring (A) and plastic bushing (B) onto clutch shaft.
<- Go to Section TOC
Section 56 page 65
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[2] -
Tractor without TLS axle
Tractors with TLS axle (not available for all models)
LEGEND:
A
B
U.j. shaft
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.
Item
Measurement
Specification
U.j. shaft to u.j. shaft flange, screws
Torque
180 N˙m
133 lb-ft
<- Go to Section TOC
Section 56 page 66
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[4] -
LEGEND:
A
B
Anti-wrap guard
Anti-wrap guard
Install anti-wrap guards (A) and (B) and tighten screws to the specified torque.
Item
Measurement
Specification
Anti-wrap guard to bracket, cap screw
Torque
35 N˙m
26 lb-ft
Item
Measurement Specification
Anti-wrap guard to front-wheel drive housing, cap screw
Torque
25 N˙m
18 lb-ft
<- Go to Section TOC
Section 56 page 67
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
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.
<- Go to Section TOC
Section 56 page 68
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
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.
<- Go to Section TOC
Section 56 page 69
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[4] - For installation, follow removal procedure in reverse order.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 70
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and Torsion Damper
[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
B
Torsion damper
Bearing housing
Install torsion damper (A) on bearing housing (B).
[4] - Install torsion damper.
<- Go to Section TOC
Section 56 page 71
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 05: U-Jointed Shafts and 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).
Item
Measurement
Specification
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.
Item
Measurement
Specification
Torsion damper to flywheel, cap screw
Torque
35 N˙m
26 lb-ft
[4] - Ensure seal (A) is seated correctly.
<- Go to Section TOC
Section 56 page 72
TM4756-REPAIR MANUAL
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).
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 73
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Group 10 - Front-Wheel Drive Clutch
Drive Systems - Front-Wheel Drive Clutch, Summary
of References
Special Tools
Repair Specifications
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
<- Go to Section TOC
Section 56 page 74
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Puller
JDG811
Removing the taper roller bearing cup from housing
Bushing
Dealer-fabricated
Removing and installing Belleville spring
Bushing, bearing, and seal driver set
D01045AA
Removing and installing bearings and bushings.
<- Go to Section TOC
Section 56 page 75
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Other material
Number
Name
• L41475 (us)
Adhesive
• 243 LOCTITE ™ (loctite)
Use
Cementing the oil transfer plate in the clutch
drum
• L64500 (us)
Liquid sealant Clutch housing to transmission housing
• 574 LOCTITE ™ (loctite)
<- Go to Section TOC
Section 56 page 76
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Repair Specifications
Item
Measurement
Specification
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
[ on earlier solenoid valves only ]
Torque
3 to 4 N˙m
2.5 to 3.0 lb-ft
Housing, dowel pins
Amount of protrusion
12 mm
0.47 in.
Front-Wheel Drive Clutch - Sectional View
<- Go to Section TOC
Section 56 page 77
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
Group 10: Front-Wheel Drive Clutch
L
Clutch Shaft
Belleville Spring
Piston Housing
Handbrake Band
Piston
Front-Wheel Drive Gear
Disk Pack
Check Valve
Housing
Solenoid Valve
Hub
Speed Sensor
M
Impulse Disk
<- Go to Section TOC
[ AutoPowr/IVT transmission only ]
[ AutoPowr/IVT transmission only ]
Section 56 page 78
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Front-Wheel Drive Clutch — Exploded View
<- Go to Section TOC
Section 56 page 79
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
<- Go to Section TOC
Group 10: Front-Wheel Drive Clutch
Section 56 page 80
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
LEGEND:
1
Gear
2
Clutch drum
3
4
5
6
7
8
9
10
11
12
13
Spring
Check valve (3 used)
Lock washer (3 used)
Taper roller bearing
Thrust washer
Thrust plate
Oil transfer plate
Bearing bushing (2 used)
Clutch drum and gear
Thrust washer
Hub
Externally splined disk (7 used
[ 50 km/h version only ]
[ 50 km/h version only ]
[ at 6820 ]
14
; 9 used
[ 6920 and 6920S ]
)
Internally splined disk (6 used
[ 6820 ]
15
; 8 used
[ 6920 and 6920S ]
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
)
Bearing bushing
Piston (thickness varies with no. of disks)
O-ring
Belleville spring
Ring
Snap ring
Plug (8 mm; 0.32 in. dia.)
Seal ring (2 used)
Clutch shaft
Seal ring
Taper roller bearing
Shim (quantity as required)
Speed sending unit
[ AutoPowr/IVT transmission only ]
O-ring
Bearing quill
Seal ring
Protective panel
[ AutoPowr/IVT transmission only ]
34
Housing
Speed sensor
35
36
37
Solenoid valve
Dowel pin (2 used)
LOCTITE ™ 574 (L64500) liquid sealant
<- Go to Section TOC
[ AutoPowr/IVT transmission only ]
Section 56 page 81
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
Front-Wheel Drive Clutch - Replace Front-Wheel
Drive Axle Speed Sensor (B89)
LEGEND:
A
B
Protective panel
Sensor B89
[1] - Remove protective panel
[ AutoPowr/IVT transmission only ]
(A).
[2] - Pull out plug on wiring harness and remove sensor B89
[ AutoPowr/IVT transmission only ]
(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.
Item
Measurement Specification
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).
<- Go to Section TOC
Section 56 page 82
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
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.
<- Go to Section TOC
Section 56 page 83
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Solenoid valve coil, nut
Torque
3 to 4 N˙m
2.5 to 3.0 lb-ft
[8] - Connect wiring harness plug (A).
<- Go to Section TOC
Section 56 page 84
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
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).
<- Go to Section TOC
Section 56 page 85
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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.
<- Go to Section TOC
Section 56 page 86
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[10] -
Remove the clutch and handbrake band from the housing.
[11] -
Remove handbrake band from clutch.
<- Go to Section TOC
Section 56 page 87
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[12] -
Remove the taper roller bearing cup using JDG811 puller.
Bearing cup removal tool
JDG811
Remove taper roller bearing cup from housing
<- Go to Section TOC
Section 56 page 88
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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.
<- Go to Section TOC
Section 56 page 89
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[15] -
Take off ring (A) and belleville spring (B).
[16] -
Remove piston (A).
[17] -
Remove hub (A).
<- Go to Section TOC
Section 56 page 90
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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
<- Go to Section TOC
Section 56 page 91
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive 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.
<- Go to Section TOC
Section 56 page 92
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
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] -
Install thrust washer (A).
<- Go to Section TOC
Section 56 page 93
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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.
<- Go to Section TOC
Section 56 page 94
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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).
<- Go to Section TOC
Section 56 page 95
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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
<- Go to Section TOC
Section 56 page 96
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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
Section 60, Group 20.
[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.
<- Go to Section TOC
Section 56 page 97
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
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.
<- Go to Section TOC
Section 56 page 98
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[27] -
Install speed sender
[ AutoPowr/IVT transmission only ]
(A).
[28] -
Install clutch shaft (A).
[29] - Install taper roller bearing cup.
[30] -
Install thrust washer (A).
<- Go to Section TOC
Section 56 page 99
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[31] -
Install thrust washer (A).
[32] -
Install bearing cone (A).
[33] -
Install shaft (A).
<- Go to Section TOC
Section 56 page 100
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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).
<- Go to Section TOC
Section 56 page 101
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[40] -
Install bearing quill (B) temporarily without shims.
[41] - Tighten cap screws (A).
Item
Measurement
Specification
Bearing quill to housing, cap screw
Torque
25 N˙m
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.
Item
Measurement
Specification
Clutch shaft
End play
0.025 to 0.100 mm
0.001 to 0.004 in.
[4] - Tighten bearing quill cap screws.
Item
Measurement
Specification
Bearing quill to housing, cap screw
Torque
25 N˙m
18 lb-ft
<- Go to Section TOC
Section 56 page 102
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 10: Front-Wheel Drive Clutch
[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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 103
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[6] -
Ensure the dowel pins (A) are inserted at the correct depth.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 104
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
Seal installation tool
JDG236
Installing seal rings and bearing cups
17-1/2 ton puller set
D01173AA
Removing and installing bearings
Bushing, bearing, and seal driver set
D01045AA
<- Go to Section TOC
Section 56 page 105
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
Removing and installing bushings, bearings, bearing cups, and oil seal rings
Differential removal tool
JT07131
Removing and installing the differential
Differential - Specifications
Item
Measurement
Specification
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.
Differential
Backlash
Value etched on outer circumference of gear, ±
0.11 mm (0.004 in.)
Differential - Sectional View
<- Go to Section TOC
Section 56 page 106
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
A
B
C
D
E
F
G
<- Go to Section TOC
Group 15: Differential
Left bearing quill
Bearing cone
Bearing cup
Thrust washer
Drive bevel gear
Support
Thrust washer
Section 56 page 107
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Group 15: Differential
Drive bevel gear
Disks
Disk
Ring gear
Piston
Differential cover
Bearing cup
Bearing cone
Right bearing quill
Seal rings
Thrust washer
Shaft
Needle bearing thrust washers
Needle bearing
Thrust washers (with tang)
Snap rings
Differential - Exploded View
LEGEND:
<- Go to Section TOC
Section 56 page 108
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
<- Go to Section TOC
Group 15: Differential
Bearing quill, l.h. side
Shims (quantity as required)
Tapered roller bearing cone
Oil line
Seal rings
Tapered roller bearing cone
Bearing quill, r.h. side
Differential ring gear
Shaft
Cap screw
Tapered roller bearing cup
Housing
Thrust washer
Bevel gear
Thrust washer
Bevel gear
Bevel gear
Internally splined disk
Externally splined disk
Piston
Housing cover
Tapered roller bearing cup
Section 56 page 109
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
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] -
<- Go to Section TOC
Section 56 page 110
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
LEGEND:
A
B
C
D
E
F
G
Nut
Bracket
Threaded rod
Bracket
Handle
Nut
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.
<- Go to Section TOC
Section 56 page 111
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[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.
<- Go to Section TOC
Section 56 page 112
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
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
with care to avoid burns.
Install ring gear.
<- Go to Section TOC
Section 56 page 113
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[4] -
LEGEND:
A
Piston inlet
Remove the differential lock piston from the cover by applying air to piston inlet (A).
[5] -
LEGEND:
A
B
C
Bevel gear
Internally splined disks
Externally splined disks
Remove bevel gear (A) from housing.
[6] - Remove disk pack (B) and (C).
Item
Measurement
Specification
Clutch disks
Thickness (when new)
3.3 mm
0.129 in.
[7] -
Remove bearing cup from cover or housing.
<- Go to Section TOC
Section 56 page 114
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[8] - Remove screw (A).
[9] -
Remove the shaft.
[10] - Take off the bevel gears and thrust washers.
[11] -
LEGEND:
A
B
Differential pinion
Thrust washer
Remove the differential pinion (A) and thrust washer (B).
Assemble the differential
[1] -
LEGEND:
A
B
Tapered roller bearing cup
Tapered roller bearing cup
Install tapered roller bearing cup (A) in the housing.
<- Go to Section TOC
Section 56 page 115
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[2] - Install tapered roller bearing cup (B) on the housing cover using installation toolJDG236.
[3] -
LEGEND:
A
B
Bevel gear
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.
<- Go to Section TOC
Section 56 page 116
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[6] -
LEGEND:
A
Screw
Install screw (A) on the bevel gear shaft and tighten to specified torque.
Item
Measurement
Specification
Bevel gear shaft, retaining screw
Torque
150 N˙m
110 lb-ft
[7] -
LEGEND:
A
B
Bevel gear
Thrust washer
Install thrust washer (B) on bevel gear (A).
<- Go to Section TOC
Section 56 page 117
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[8] -
LEGEND:
A
B
C
Bevel gear
Internally splined disks
Externally 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.
<- Go to Section TOC
Section 56 page 118
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[11] -
LEGEND:
A
Screw
Put the cover on the housing and tighten the screws to specified torque.
Item
Measurement
Specification
Cover to housing, screw
Torque
150 N˙m
110 lb-ft
[12] CAUTION:
LEGEND:
A
B
C
Bearing quill
Bearing quill
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.
<- Go to Section TOC
Section 56 page 119
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
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.
Item
Measurement
Specification
Differential bearing quill, screw
Torque
90 N˙m
66 lb-ft
<- Go to Section TOC
Section 56 page 120
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[4] -
LEGEND:
A
B
C
D
E
F
G
Nut
Bracket
Threaded rod
Bracket
Handle
Nut
Extension
RemoveJT07131removal tool.
Next step:
SeeDifferential - Adjust Preloadin Section 56.
<- Go to Section TOC
Section 56 page 121
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
Differential - Adjust Preload
Preliminary work:
See Remove the Rear PTO in Section 56.
See Remove the Final Drives 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.
Item
Measurement
Specification
Differential bearing
Bearing preload
0.05 - 0.13 mm
0.002 - 0.005 in.
<- Go to Section TOC
Section 56 page 122
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
[3] - Install screws on right-hand and left-hand differential bearing quills and tighten to
specified torque.
Item
Measurement
Specification
Differential bearing quill, screws
Torque
90 N˙m
66 lb-ft
Next step:
SeeDifferential - Adjust Backlashin Section 56.
<- Go to Section TOC
Section 56 page 123
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 15: Differential
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.
Item
Measurement Specification
Differential Backlash
<- Go to Section TOC
Value etched on outer circumference of gear ± 0.11 mm (0.004 in.)
Section 56 page 124
TM4756-REPAIR MANUAL
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.
<- Go to Section TOC
Section 56 page 125
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
Group 20 - Hydraulic Pump Drive
Hydraulic Pump Drive — Summary of References
Before reconditioning the pump drive, refer to the following:
”Special tools”
”Specifications”
”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”
<- Go to Section TOC
Section 56 page 126
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or in the European Microfiche Tool Catalog (MTC).
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
<- Go to Section TOC
Section 56 page 127
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
Repair Specifications
Item
Measurement Specification
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.)
<- Go to Section TOC
Section 56 page 128
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
Remove and Disassemble Pump Drive Pinion Gear
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
<- Go to Section TOC
Pump Drive Pinion Gear
Snap Ring
Pinion Gear Bearing Cone (2 used)
Pinion Gear Bearing Cup (2 used)
Sleeve
Bearing Spacer Ring (Inner)
Bearing Snap Ring (Outer)
Sleeve Locking Dowel Pin
Bearing Snap Ring (Outer)
Drive Gear Bearing Cup (2 used)
Drive Gear Bearing Cone (2 used)
Snap Ring
Bearing Spacer Ring (Inner)
Section 56 page 129
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
N
O
Group 20: Hydraulic Pump Drive
Pump Drive Gear
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
<- Go to Section TOC
Section 56 page 130
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[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).
<- Go to Section TOC
Section 56 page 131
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
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.
<- Go to Section TOC
Section 56 page 132
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[8] →NOTE:
The bearing cups are a loose fit.
Remove the bearing cups and the outer bearing snap ring (A) from the differential housing.
<- Go to Section TOC
Section 56 page 133
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
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.
<- Go to Section TOC
Section 56 page 134
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[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
individually for accurate measurement.
[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
<- Go to Section TOC
Section 56 page 135
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 136
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
Assembling and installing the pump drive pinion
[1] -
<- Go to Section TOC
Section 56 page 137
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
IMPORTANT:
LEGEND:
A
B
C
D
E
F
G
H
I
Pump drive pinion
Clamping ring
Top bearing cone
Bearing cup
Bearing spacer ring
Cup clamping ring
Sleeve
Bearing cup
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.
<- Go to Section TOC
Section 56 page 138
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[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.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 139
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 20: Hydraulic Pump Drive
[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.
<- Go to Section TOC
Section 56 page 140
TM4756-REPAIR MANUAL
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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 141
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or in the European Microfiche Tool Catalog (MTC).
JDG778A- Adjusting Tool
DFLX42- Turning Device
DFRW30- Lifting Tool
JT01673- Installation Tool
D01045AA- Bushing, Bearing, and Seal Driver Set
<- Go to Section TOC
Section 56 page 142
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Final Drives - Repair Specifications
Item
Measurement
Specification
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
<- Go to Section TOC
Section 56 page 143
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
<- Go to Section TOC
Group 25: Final Drives
Retaining washer
Screw
Tapered roller bearing
Planetary gear
Outer tapered roller bearing
Seal cup
Outer seal
Special twelve-point screw
O-ring
Retaining washer
Locking plate
Planetary carrier
Ring gear
Bronze thrust washer
Inner tapered roller bearing
Inner oil seal
Housing
Axle shaft
Additional lubrication
Brake piston
Brake disk
Retraction pin
Brake plate
Section 56 page 144
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Remove Planetary Carrier
Preliminary work:
See Remove the Final Drives in Section 56.
[1] -
LEGEND:
A
B
C
D
Ring gear
Planet gear screw
Special twelve-point screw
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.
<- Go to Section TOC
Section 56 page 145
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[5] -
Check the condition of the locking plate.
[6] - Replace plate, if distorted.
<- Go to Section TOC
Section 56 page 146
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
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.
<- Go to Section TOC
Section 56 page 147
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[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.
<- Go to Section TOC
Section 56 page 148
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Assemble Planetary Carrier
LEGEND:
A
B
C
D
E
F
G
H
I
Planetary carrier
Inner pinion bearing cone
Inner pinion bearing cup
Planet pinion
Outer pinion bearing cup
Outer pinion bearing cone
Pinion retaining washer
Pinion retaining cap screw
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.
<- Go to Section TOC
Section 56 page 149
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[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:
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 150
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[12] - Install the planetary carrier assembly and check the rolling drag torque. See “Install
Planetary Carrier and Check Rolling Drag Torque” in this group.
<- Go to Section TOC
Section 56 page 151
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
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.
<- Go to Section TOC
Section 56 page 152
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
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.
<- Go to Section TOC
Section 56 page 153
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[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.
<- Go to Section TOC
Section 56 page 154
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Disassemble and Assemble Axle Shaft
[1] IMPORTANT:
LEGEND:
A
B
C
D
E
F
Strap
Puller
Puller legs
Puller cross bar
76 mm (3 in.) disk
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.
Item
Measurement
Specification
Axle diameter at outer bearing
New diameter
81.050 to 81.083 mm
3.191 to 3.192 in.
<- Go to Section TOC
Section 56 page 155
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[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.
<- Go to Section TOC
Section 56 page 156
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
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.
<- Go to Section TOC
Section 56 page 157
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Final Drives - Install Planetary Carrier and Check
Rolling Drag Torque
Install planetary carrier
[1] -
LEGEND:
A
B
Special Twelve-Point Screw
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.
<- Go to Section TOC
Section 56 page 158
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
LEGEND:
A
Special Twelve-Point Screw
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:
A
Special Twelve-Point Screw
To press the bearings into the correct position, tighten special twelve-point screw (A) to the
specified torque.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 159
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[6] - Tighten special twelve-point screw (A) once again to specified torque.
Item
Measurement Specification
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
B
DFLX42 - Turning Device
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.
<- Go to Section TOC
Section 56 page 160
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[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
B
Lead Ball
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).
<- Go to Section TOC
Section 56 page 161
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[5] -
LEGEND:
A
B
DFLX42 - Turning Device
Torque Wrench without Ratchet
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:
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 162
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[7] -
LEGEND:
A
B
C
Lead Ball
Shim Pack
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.
<- Go to Section TOC
Section 56 page 163
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
Install the planetary carrier and tighten the special twelve-point screw to 200 Nm (148 lb-ft).
[11] -
LEGEND:
A
B
DFLX42 - Turning Device
Torque Wrench without Ratchet
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.
<- Go to Section TOC
Section 56 page 164
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 25: Final Drives
[13] -
LEGEND:
A
Torque Multiplier
Tighten the special twelve-point screw using a torque multiplier (A) to the final torque as
specified.
Item
Measurement Specification
Planetary carrier to axle shaft, special twelve-point screw
Torque
908 N·m
670 lb-ft
[14] -
LEGEND:
A
B
C
Locking Plate
Lock Lugs
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).
<- Go to Section TOC
Section 56 page 165
TM4756-REPAIR MANUAL
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.
<- Go to Section TOC
Section 56 page 166
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
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
<- Go to Section TOC
Section 56 page 167
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Special tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
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
<- Go to Section TOC
Section 56 page 168
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
D01173AA
Removing and installing bearings
Bushing, bearing, and seal driver set
D01045AA
Removing and installing bearing cups, bearing cones, and bushings
<- Go to Section TOC
Section 56 page 169
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Specifications
Item
Measurement Specification
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.
Test length
44 mm at 117 N
1.7 in. at 26 lb force
PTO modulating valve, inner spring
Free length
approx. 111 mm
approx. 4.4 in.
Test length
89 mm at 33 N
3.5 in. at 7 lb force
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,
<- Go to Section TOC
Section 56 page 170
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
soak them for 15 minutes in hydraulic oil.
Never heat bearing cones to temperatures higher than 150°C (300°F).
<- Go to Section TOC
Section 56 page 171
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
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
[ AutoPowr/IVT transmission only ]
.
[5] -
Remove the bearing support (A).
<- Go to Section TOC
Section 56 page 172
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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
<- Go to Section TOC
Section 56 page 173
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
PTO clutch—sectional view
LEGEND:
A
B
<- Go to Section TOC
Bearing cone
Bearing cup
Section 56 page 174
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
<- Go to Section TOC
Group 30: Rear PTO
Snap ring
Backing plate with gear
Clutch hub with thrust washers
Disk (4 used)
Externally splined disk (3 used)
Clutch return plate
Clutch piston
Clutch drum
Brake plate
Brake piston
Seal ring (2 used)
Bearing cup
Bearing cone
Snap ring
Lube cut-off valve
PTO housing
Piston seal (2 used)
Bushing
Piston return spring (7 used)
Snap ring
Bearing support
Section 56 page 175
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
<- Go to Section TOC
Group 30: Rear PTO
Bearing cup
Bearing cone
Snap ring
Lube cut-off valve
Brake piston
Brake plate
Clutch drum
Inner piston seal ring
Outer piston seal ring
Clutch piston
Piston return spring (7 used)
Snap ring
Seal ring (2 used)
Bushing
Thrust washer (2 used)
PTO clutch hub with thrust washer (2 used)
Return plate
Disk (4 used)
Section 56 page 176
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
S
T
U
V
Group 30: Rear PTO
Externally splined disk (3 used)
Backing plate with gear
Bearing cone
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.
<- Go to Section TOC
Section 56 page 177
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[6] - Remove the front bearing cone using a press, a knife-edge puller and a 55.5 mm
(2-3/16 in.) disk.
Bushing, Bearing, and Seal Driver Set
D01045AA
Remove and install bearing cups, bearing cones, and bushings.
[7] -
LEGEND:
A
B
C
D
PTO clutch hub
Washers
Externally splined disks
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).
<- Go to Section TOC
Section 56 page 178
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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
<- Go to Section TOC
Section 56 page 179
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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.
<- Go to Section TOC
Section 56 page 180
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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
<- Go to Section TOC
Section 56 page 181
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[9] -
LEGEND:
A
B
C
D
PTO clutch hub
Disks (4 used)
Externally splined disk (3 used)
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.
Item
Measurement
Specification
Clutch backing plate, cap screw
Torque
35 N˙m
26 lb-ft
<- Go to Section TOC
Section 56 page 182
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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).
<- Go to Section TOC
Section 56 page 183
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[18] - Tighten cap screws.
Item
Measurement
Specification
Bearing support to PTO housing, cap screw
Torque
90 N˙m
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:
Snap rings are available in various sizes (see Parts Catalog).
[24] - Select a snap ring that will provide specified end play.
Item
Measurement
Specification
Clutch assembly
End play
0.015 to 0.15 mm
0.001 to 0.006 in.
[25] - Install
[ AutoPowr/IVT transmission only ]
oil deflector plate.
[26] - Install the rear PTO. See “Installing the Rear PTO” in Group 00 of this Section.
<- Go to Section TOC
Section 56 page 184
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Remove and Disassemble Countershaft
[1] -
Remove oil deflector plate
[ AutoPowr/IVT transmission only ]
.
[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.
<- Go to Section TOC
Section 56 page 185
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
PTO countershaft — sectional view
LEGEND:
A
B
C
D
E
F
G
H
I
J
<- Go to Section TOC
Snap ring
Countershaft drive gear
Bearing cone
Bearing cup
Bearing quill
Shim pack
PTO housing
Bearing cup
Bearing cone
Countershaft
Section 56 page 186
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
PTO countershaft — exploded view
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Bearing cup
Bearing cone
Snap ring
Output gear (540E rpm)
Countershaft
Bearing cone
Bearing cup
Shim pack
Bearing quill
Cap screw (4 used)
Countershaft drive gear
Snap ring
Section 56 page 187
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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.
Bushing, Bearing, and Seal Driver Set
D01045AA
Remove and install bearing cups, bearing cones, and bushings.
[8] - Install a new bearing cup using a 66.7 mm (2-5/8 in.) driver disk and a press.
<- Go to Section TOC
Section 56 page 188
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
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.
Bushing, Bearing, and Seal Driver Set
D01045AA
Remove and install bearing cups, bearing cones, and bushings.
[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.
<- Go to Section TOC
Section 56 page 189
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[4] -
Install the countershaft into the housing.
[5] - Install the same shim pack that was removed.
[6] - Install the bearing quill. Tighten cap screws.
Item
Measurement
Specification
Countershaft bearing quill, cap screw
Torque
50 N˙m
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
individually for accurate measurement.
[10] - Remove the quill and add or subtract shims to provide correct end play.
Item
Measurement
Specification
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).
<- Go to Section TOC
Section 56 page 190
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[12] →NOTE:
The front output drive gear bearing is a loose fit.
Install the output shaft drive gear, thrust washer between gear and front bearing and front
bearing.
[13] - Install the bearing support.
[14] - Install
[ AutoPowr/IVT transmission only ]
oil deflector plate.
[15] - Tighten cap screws.
Item
Measurement
Specification
Bearing support to PTO housing, cap screw
Torque
90 N˙m
66 lb-ft
<- Go to Section TOC
Section 56 page 191
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Remove and Disassemble Output Shaft
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Bearing support
Snap ring
Bearing cup
Bearing cone
Thrust washer
Output gear (1000 rpm)
Snap ring
Sleeve
Collar
Output gear (540 rpm)
Output shaft
Magnetic speed pickup disk
Section 56 page 192
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
M
N
O
P
Q
R
S
T
Bearing cone
Bearing cup
PTO housing
Oil seal
Snap ring
Thrust washer
Needle bearing (2 used)
Needle bearing spacer
LEGEND:
A
B
Shift collar (2 used)
Output gear (540E rpm)
<- Go to Section TOC
Section 56 page 193
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
C
D
E
F
G
H
I
E
K
L
M
N
O
P
Q
R
S
Group 30: Rear PTO
Snap ring (4 used)
Thrust washer
Output gear (540E rpm)
Shift collar support
Thrust washer
Needle bearing (2 used)
Needle bearing spacer
Output gear (1000 rpm)
Thrust washer
Bearing cone
Output shaft
Speed pick-up disk
Bearing cone
Bearing cup
Seal ring
Output shaft
Snap ring
[1] -
Remove oil deflector plate
[ AutoPowr/IVT transmission only ]
.
[2] - Remove bearing support (A).
<- Go to Section TOC
Section 56 page 194
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[3] →NOTE:
The front output drive gear bearing is a loose fit.
Remove the front bearing, bearing-to-gear thrust washer and output shaft drive gear from
the shaft.
[4] -
LEGEND:
A
B
C
D
E
F
Spring pin
Shifting gate
Shift yoke and collar
Countershaft snap ring
Countershaft drive gear
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.
<- Go to Section TOC
Section 56 page 195
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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).
<- Go to Section TOC
Section 56 page 196
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[16] -
Remove the magnetic speed pickup disk and rear bearing using a press and a knife-edge
puller.
<- Go to Section TOC
Section 56 page 197
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
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.
<- Go to Section TOC
Section 56 page 198
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[7] -
LEGEND:
A
B
C
D
E
F
Spring pin
Shifting gate
Shift yoke and collar
Countershaft snap ring
Countershaft drive gear
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.
Item
Measurement
Specification
Countershaft bearing quill, cap screw
Torque
50 N˙m
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.
<- Go to Section TOC
Section 56 page 199
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[15] -
Install the output gear, two bearings with a spacer between them and the thrust washer
between output gear and front bearing.
→NOTE:
The front output drive gear bearing is a loose fit.
[16] - Install the front bearing cone on the shaft.
[17] -
Install the bearing support.
[18] - Tighten cap screws.
Item
Measurement
Specification
Bearing support to PTO housing, cap screw
Torque
90 N˙m
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.
<- Go to Section TOC
Section 56 page 200
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[23] - Remove the front bearing retaining snap ring and measure the thickness.
→NOTE:
Snap rings are available in various sizes (see Parts Catalog).
[24] - Select a snap ring that will provide specified end play.
Item
Measurement
Specification
Output shaft
End play
0.015 to 0.15 mm
0.001 to 0.006 in.
[25] - Install oil deflector plate
[ AutoPowr/IVT transmission only ]
.
<- Go to Section TOC
Section 56 page 201
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Remove PTO Shifter
PTO shifter components
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
O-ring
Selector shaft
Cap screw
Bracket
Shifting gate
Bearing bushing (4 used)
Spring pin (2 used)
Bushing (2 used)
Selector shaft bearing
Cap screw (2 used)
Shifter yoke
Shifter yoke
Cap screw
Locking tab
Detent spring
[1] - Remove oil deflector plate
[ AutoPowr/IVT transmission only ]
.
<- Go to Section TOC
Section 56 page 202
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[2] -
Remove the bearing support (A).
[3] →NOTE:
The front output drive gear bearing is a loose fit.
Remove output drive gear front bearing, thrust washer and gear with two bearings and
bearing spacer.
<- Go to Section TOC
Section 56 page 203
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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.
Item
Measurement
Specification
Detent spring
Free length
approx. 20 mm
approx. 0.8 in.
Test length
12 mm at 65 N
0.5 in. at 15 lb
[9] - Remove the shifter rails (C) with E-Clips from the housing.
<- Go to Section TOC
Section 56 page 204
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
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.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 56 page 205
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[9] - Install the spring pin.
[10] →NOTE:
The front output drive gear bearing is a loose fit.
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
[ AutoPowr/IVT transmission only ]
oil deflector plate.
[13] - Tighten cap screws.
Item
Measurement
Specification
Bearing support to PTO housing, cap screw
Torque
90 N˙m
66 lb-ft
<- Go to Section TOC
Section 56 page 206
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[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.
<- Go to Section TOC
Section 56 page 207
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[2] -
Remove housing-to-mounting plate cap screws (A) and remove the plate and gasket.
<- Go to Section TOC
Section 56 page 208
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Disassemble and Assemble Modulating Valve
[1] -
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
Snap Ring
Plug with O-Ring
Accumulator Piston
Outer Spring
Inner Spring
Pin
Modulating Valve
Test Port Plug with O-Ring (2 used)
Valve Housing
Valve Housing-to-Mounting Plate Plate Gasket
Mounting Plate
Mounting Plate-to-PTO Housing Gasket
Inspect parts and replace as necessary.
Item
Measurement Specification
PTO modulating valve, outer spring
Free length
approx. 70 mm
approx. 2.75 in.
Test length
44 mm at 117 N
1.7 in. at 26 lb force
PTO modulating valve, inner spring
Free length
approx. 111 mm
approx. 4.4 in.
Test length
89 mm at 33 N
3.5 in. at 7 lb force
<- Go to Section TOC
Section 56 page 209
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
[2] - Tighten test port plugs with O-rings (H).
Item
Measurement
Specification
PTO modulating valve, test plug
Torque
12 N˙m
9 lb-ft
<- Go to Section TOC
Section 56 page 210
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Install Modulating Valve
[1] -
Install valve housing-to-mounting plate gasket and cap screws (A). Tighten screws.
Item
Measurement Specification
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.
Item
Measurement
Specification
PTO modulating valve to PTO housing, cap screw
Torque
16 N˙m
11 lb-ft
<- Go to Section TOC
Section 56 page 211
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Changing and adjusting the bowden cable
Actuating components of PTO shift with Command Arm
LEGEND:
A
B
C
<- Go to Section TOC
Shifter shaft
Yoke
Lock nut
Section 56 page 212
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
D
E
F
G
H
I
J
K
L
M
N
O
Group 30: Rear PTO
Bowden cable
Rubber sleeve
Retainer
Retainer
PTO speed selector lever
Handle
Washer
Hex. nut
Washer
Washer
Spring washer
Self-locking hex. nut
[1] -
<- Go to Section TOC
Section 56 page 213
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 30: Rear PTO
Actuating components of PTO shift without Command Arm
LEGEND:
A
B
C
D
E
F
G
<- Go to Section TOC
Shifter shaft
Retainer
Retainer
Bowden cable
Rubber sleeve
Retainer
Retainer
Section 56 page 214
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
H
I
J
K
L
M
N
O
Group 35: Front PTO
P
PTO speed selector lever
Handle
Washer
Hex. nut
Cover
Washer
Spring washer
Bushing
Creeper selector lever
Q
R
S
Bushing
Washer
Self-locking hex. nut
[ If equipped ]
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.
<- Go to Section TOC
Section 56 page 215
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Group 35 - Front PTO
Front PTO - Reconditioning (Summary of
References)
Before reconditioning the front PTO, refer to the following:
”Other material”
”Specifications”
”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
<- Go to Section TOC
Section 56 page 216
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Specifications
Item
Measurement
Specification
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
Cooler relief valve, plug
Torque
20 N˙m
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.
Bearing quill to housing cover, screw
Torque
10 N˙m
7.5 lb-ft
<- Go to Section TOC
Section 56 page 217
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Item
Measurement
Specification
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.
Bearing quill to housing cover, screw
Torque
10 N˙m
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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
Apply LOCTITE ™ 243 (L41475) thread lock and sealer to screws.
Number
Name
Use
• L41475 (loctite)
Thread lock
Cementing screws at the front PTO
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
<- Go to Section TOC
Section 56 page 218
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: 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.
Item
Measurement Specification
Y01 - Solenoid valve for front PTO to housing, screws
Torque
8 - 10 N˙m
6 - 7.5 lb-ft
[4] - Connect the connectors.
<- Go to Section TOC
Section 56 page 219
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Reconditioning the Modulator Valve
[1] -
Take out cap screws.
[2] - Lift off modulator valve (A) together with its gasket.
[3] -
LEGEND:
A
B
C
D
E
F
G
H
Spool
Spring
Spring
Spring pin
Sleeve
O-ring
Plug
Snap ring
Check the valve for damage, clean, oil and re-assemble.
<- Go to Section TOC
Section 56 page 220
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[4] -
LEGEND:
A
B
Outer spring
Inner spring
Check spring forces.
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 221
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[6] - Tighten the cap screws evenly.
Item
Measurement
Specification
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.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 56 page 222
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
LEGEND:
A
B
C
D
Group 35: Front PTO
Plug
O-ring
Filter element
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.
<- Go to Section TOC
Section 56 page 223
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Reconditioning the Pressure-Regulating Valve
LEGEND:
A
B
C
D
E
Plug
O-ring
Shim (quantity as required)
Spring
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).
Item
Measurement
Specification
Pressure-regulating valve
Pressure
1200 kPa
12 bar
174 psi
[4] - Install valve. Tighten the plug.
<- Go to Section TOC
Section 56 page 224
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Checking the Cooler Relief and Filter By-Pass Valves
LEGEND:
A
B
Cooler relief valve
Filter by-pass valve
Apply Thread Lock and Sealer L41475 ( LOCTITE ™ 243) to the threads and contact surfaces
of both plugs.
Number
Name
Use
• L41475 (loctite)
Thread lock
Cementing screws at the front PTO
Tighten the cooler relief valve plug.
Item
Measurement
Specification
Cooler relief valve, plug
Torque
20 N˙m
15 lb-ft
Removing and Installing the Valve Plate
<- Go to Section TOC
Section 56 page 225
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
[4] - Tighten the hex. socket screws evenly.
Item
Measurement
Specification
Valve plate to front PTO, cap screws
Torque
10 N˙m
7.5 lb-ft
<- Go to Section TOC
Section 56 page 226
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Front PTO — Sectional View
Clockwise-rotating front PTO (viewed in direction of travel)
LEGEND:
<- Go to Section TOC
Section 56 page 227
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
<- Go to Section TOC
Group 35: Front PTO
Cover
Special sealing ring
Shift collar
Drive gear
Special sealing ring
Drive shaft
Ring gear
Disk clutch
Cover
PTO stub shaft
PTO brake
Oil distribution baffle
Spring
Housing cover
Pressure-regulating valve
Housing
Section 56 page 228
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Counterclockwise-rotating front PTO (viewed in direction of travel)
LEGEND:
A
B
<- Go to Section TOC
Cover
Special sealing ring
Section 56 page 229
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
<- Go to Section TOC
Group 35: Front PTO
Shift collar
Drive gear
Special sealing ring
Drive shaft
Idler gear shaft
Ring gear
Disk clutch
Cover
PTO stub shaft
PTO brake
Spacer bushing
Oil distribution baffle
Spring
Housing cover
Housing
Section 56 page 230
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
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.
<- Go to Section TOC
Section 56 page 231
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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.
<- Go to Section TOC
Section 56 page 232
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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).
<- Go to Section TOC
Section 56 page 233
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
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).
<- Go to Section TOC
Section 56 page 234
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[3] -
Take out key (A).
[4] - Take out cap screws (B).
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
<- Go to Section TOC
Snap ring
Gear
Key
Pin (4 used)
Cover
Bushing (4 used)
Gear
Gear
Housing
Cap screws (4 used)
Cover
Section 56 page 235
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
L
M
Group 35: Front PTO
Oil manifold
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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
[3] - Tighten hex. socket screws (A) evenly.
Item
Measurement
Specification
Oil manifold, hex. socket screw
Torque
10 N˙m
7.5 lb-ft
Installing the oil pump
<- Go to Section TOC
Section 56 page 236
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[1] -
When assembling the oil pump, coat cover-to-housing sealing surfaces with LOCTITE ™ 574
flexible sealant.
Number
Name
Use
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
[3] - Tighten cap screws (B) evenly.
Item
Measurement
Specification
Oil pump installation, cap screws
Torque
10 N˙m
7.5 lb-ft
[4] - Install key (A).
<- Go to Section TOC
Section 56 page 237
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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”.
<- Go to Section TOC
Section 56 page 238
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Reconditioning the PTO Clutch
Preliminary work: Before removing the output shaft, see reference“Disassembling the Front
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.
<- Go to Section TOC
Section 56 page 239
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Mechanical puller set
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!
Remove snap ring (A).
[10] →NOTE:
Puller is in a slightly inclined position.
Remove bearing; to do so, position a puller below the first spring coil.
Mechanical puller set
<- Go to Section TOC
Section 56 page 240
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
D01173AA
Pulling off the taper roller bearings
Exploded view of PTO clutch
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Clutch cage
Seal ring
Seal ring
Back-up ring
Piston
Disk with teeth on outside
Disk with teeth on inside
Pressure plate
Snap ring
Spring
Spring support
Pressure ring
Section 56 page 241
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
M
N
O
P
Q
R
S
T
U
V
W
X
Group 35: Front PTO
Roller bearing
Snap ring
Hub
Gear
Snap ring
Thrust washer
Roller bearing
Hex. socket screw (18 used)
Pressure ring
Taper roller bearing
PTO stub shaft
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.
<- Go to Section TOC
Section 56 page 242
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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:
Before installing the disks, dip them in oil.
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.
[11] - Install snap ring (A).
[12] - Coat gear contact surface on hub with LOCTITE ™ 574 flexible sealant.
Number
Name
Use
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
<- Go to Section TOC
Section 56 page 243
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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.
Item
Measurement
Specification
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
• L41475 (loctite)
Thread lock
Cementing screws at the front PTO
Item
Measurement Specification
PTO stub shaft, hex. nut (65 mm across flats)
Torque
50 N˙m
36.5 lb-ft
Next step: Before installing the output shaft, see reference“Assembling the Front PTO”.
<- Go to Section TOC
Section 56 page 244
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Reconditioning the PTO Brake
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
<- Go to Section TOC
Clutch cage
Thrust pin (6 used)
Pressure plate
Disk with teeth on inside
Disk with teeth on outside
Spring (6 used)
Cover
Taper roller bearing
Cap screw (4 used)
Stop (4 used)
Gear with stop
Section 56 page 245
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Preliminary work: Before removing the output shaft, see reference“Disassembling the Front
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.
Mechanical puller set
D01173AA
Pulling off the taper roller bearings
[4] -
Install pressure plate (A) with the blind holes facing upward (see arrow).
<- Go to Section TOC
Section 56 page 246
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[5] →NOTE:
Before installing the disks, dip them in oil.
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.
Item
Measurement
Specification
Lid on clutch cage, cap screw
Torque
10 N˙m
7.5 lb-ft
<- Go to Section TOC
Section 56 page 247
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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.
<- Go to Section TOC
Section 56 page 248
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[13] -
Replace ring gear (A).
[14] - Install stops (B).
[15] - Tighten cap screws (C).
Item
Measurement
Specification
Ring gear at PTO brake
Torque
10 N˙m
7.5 lb-ft
[16] - Make sure that springs are properly positioned.
Next step: Before installing the output shaft, see reference“Assembling the Front PTO”.
Reconditioning the Intermediate Gear Shaft (PTO
Rotating Counterclockwise)
LEGEND:
A
B
<- Go to Section TOC
Taper roller bearing assembly
Intermediate gear shaft
Section 56 page 249
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
C
D
E
F
F
Group 35: Front PTO
Taper roller bearing assembly
Shim (quantity as required)
Spacer bushing
Cover
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.
<- Go to Section TOC
Section 56 page 250
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Reconditioning the Drive Shaft
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Seal ring
Taper roller bearing assy.
Special sealing ring
Snap ring
Washer
Ball bearing
Spacer
Snap ring
Gear
Drive shaft
Spring (5 used)
Ball (5 used)
Section 56 page 251
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
M
N
O
P
Q
R
S
T
U
V
W
X
Group 35: Front PTO
Shift collar
Special sealing ring
Taper roller bearing assy.
Key
Snap ring
Shift pawl
Plastic tip (2 used)
Shifter shaft
O-ring
Shift lever
Shim (thickness as required)
Cover
[1] -
LEGEND:
A
B
C
D
E
F
Taper roller bearing cone
Special seal
Gear
Shift collar
Special seal
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).
<- Go to Section TOC
Section 56 page 252
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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).
<- Go to Section TOC
Section 56 page 253
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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).
<- Go to Section TOC
Section 56 page 254
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[13] - Install snap ring (A).
[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).
<- Go to Section TOC
Section 56 page 255
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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.
<- Go to Section TOC
Section 56 page 256
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
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).
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 257
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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).
<- Go to Section TOC
Section 56 page 258
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[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.
<- Go to Section TOC
Section 56 page 259
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[9] -
Coat housing sealing surfaces with sealant.
Number
Name
Use
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
[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.
Item
Measurement
Specification
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).
Item
Measurement Specification
Bearing quill and housing cover, taper roller bearings
Capacity
40 ml
1.4 fl oz
Number
Name
Use
• L154115 (us)
Special grease
Lubricating the taper roller bearings
[13] - Make sure that the special seal does not get damaged!
<- Go to Section TOC
Section 56 page 260
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[14] - Install taper roller bearing cups (A) and (B).
[15] -
Install seal ring (A).
Adjusting the taper roller bearing at the output shaft
<- Go to Section TOC
Section 56 page 261
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[1] -
Install bearing quill (A) without shims to obtain a measurable axial play. Tighten the hex.
socket screws evenly.
Item
Measurement Specification
Bearing quill to housing cover, hex. socket screw
Torque
10 N˙m
7.5 lb-ft
[2] - Measure end play.
[3] - Remove bearing quill.
[4] - Place shims under bearing quill until a bearing preload is obtained.
Item
Measurement
Specification
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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
Item
Measurement Specification
Bearing quill to housing cover, hex. socket screw
Torque
10 N˙m
7.5 lb-ft
<- Go to Section TOC
Section 56 page 262
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
Adjusting end play of drive shaft
[1] -
Install bearing quill (A). Tighten the hex. socket screws evenly.
Item
Measurement Specification
Bearing quill to housing cover, hex. socket screws
Torque
10 N˙m
7.5 lb-ft
[2] - Measure end play.
<- Go to Section TOC
Section 56 page 263
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 35: Front PTO
[3] - Remove bearing quill.
[4] - Keep adding shims until the prescribed end play is reached.
Item
Measurement
Specification
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
• L154115 (us)
Special grease
Lubricating the taper roller bearings
[6] - Apply LOCTITE ™ 574 (L64500) flexible sealant to the sealing surface of the bearing
quill. Install the bearing quill.
Number
Name
Use
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
[7] - Tighten the hex. socket screws.
Item
Measurement Specification
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.
Item
Measurement
Specification
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
• L64500 (loctite)
Flexible sealant
Sealing the surfaces on the front PTO
Item
Measurement Specification
Bearing quill to housing cover, hex. socket screw
Torque
10 N˙m
7.5 lb-ft
Final assembly
<- Go to Section TOC
Section 56 page 264
TM4756-REPAIR MANUAL
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.
<- Go to Section TOC
Section 56 page 265
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
Group 40 - Front Implement Drive
Front Implement Drive (Summary of References)
”General information”
”Special tools”
”Specifications”
”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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or in the European Microfiche Tool Catalog (MTC).
Flywheel turning tool
JDG820
Turning flywheel on 6-cylinder engines
<- Go to Section TOC
Section 56 page 266
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
Repair Specifications
Item
Measurement
Specification
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)
2
M8 screw; 8 used/34±3 N˙m (25±2 lb-ft)
3
M10 screw; 4 used/46±3 N˙m (34±2 lb-ft)
<- Go to Section TOC
Section 56 page 267
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
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)
<- Go to Section TOC
Section 56 page 268
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
Take off front plate (A) or basic weight.
<- Go to Section TOC
Section 56 page 269
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
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.
Item
Measurement
Specification
Damper to drive shaft, hex. socket screws
Torque
34±3 N˙m
25±2 lb-ft
<- Go to Section TOC
Section 56 page 270
TM4756-REPAIR MANUAL
Section 56 - DRIVE SYSTEMS
Group 40: Front Implement Drive
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:
<- Go to Section TOC
Section 56 page 271
TM4756-REPAIR MANUAL
STEERING AND BRAKES
A
B
C
D
E
F
(g) by Belgreen
Coupler
Drive shaft
M8 cap screw
M10 cap screw
Torsion damper
Washer
Secure coupler (A) to the drive shaft (B). Tighten the eight cap screws (C) in cross-wise
fashion.
Item
Measurement
Specification
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).
Item
Measurement Specification
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.
<- Go to Section TOC
Section 56 page 272
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
Section 60 - STEERING AND BRAKES
Table of contents
Group 05 - Hydrostatic Steering ............................................................................................. 1
Hydrostatic Steering (Summary of References) ..................................................................... 1
Special Tools .......................................................................................................................... 2
Repair Specifications .............................................................................................................. 4
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
Repair specifications .......................................................................................................... 174
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
Repair Specifications .......................................................................................................... 199
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
TM4756-REPAIR MANUAL
(g) by Belgreen
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
<- Go to Global Table of contents
TM4756-REPAIR MANUAL
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”
<- Go to Section TOC
Section 60 page 1
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Special Tools
→NOTE:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or in the European Microfiche Tool Catalog (MTC).
Disconnecting tool
KJD10293
Disconnecting/connecting steering or brake hoses
Assembly tool set
KML10018A
LEGEND:
A
B
C
D
E
F
G
<- Go to Section TOC
Base (KML10018-1)
Spring installer (KML10018-3)
Shaft holder (KML10018-4)
Seal installer (KML10018-2)
Piston (KML10018-5)
Seal installer (KML10018-6)
Piston (KML10018-7)
Section 60 page 2
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Repair of steering units
Special tools required for repair
Steering valve type
[ see type plate on steering valve ]
A
B
C
D
E
X
X
OSPF 160 LS (Danfoss)
X
X
OSPQ 125/200 LS (Danfoss)
X
X
F
G
X
X
Hydraulic hand-operated pump
D01019AA
Adjusting the shock valves
Adapter
JT03248
Adjusting the shock valves
<- Go to Section TOC
Section 60 page 3
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Repair Specifications
Item
Measurement
Specification
Steering wheel to spindle, cap screw (up to tractor serial no.
359011)
Torque
50 N˙m (35 lb-ft)
Steering wheel to spindle, cap screw (from tractor serial no.
359012)
Torque
30 N˙m (22 lb-ft)
Adjusting ring on spindle, self-locking hex. nut
Torque
20 N˙m (15 lb-ft)
Shock valves
Adjustment pressure
23500 to 25500 kPa (235 to 255 bar;
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)
Torque
55 N˙m (40 lb-ft)
Connector (elbow) to steering valve (connection for LS-line)
Torque
35 N˙m (25 lb-ft)
Steering wheel and column
Steering valve
Preliminary Work
Disconnect battery ground strap (—).
<- Go to Section TOC
Section 60 page 4
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 5
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 6
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 7
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 8
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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).
<- Go to Section TOC
Section 60 page 9
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Remove adjusting ring (B) and washer.
Remove hex. nut (A) and pull off the steering wheel.
Remove snap ring (A).
Remove washer (B).
Pull off knob (A).
Take out screws (B) and remove cover (C).
<- Go to Section TOC
Section 60 page 10
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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).
<- Go to Section TOC
Section 60 page 11
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Disconnect all multi-function unit (A) connectors from below. Remove multi-function unit.
Remove housing (A) and pull off handle (B).
Remove cover (A).
<- Go to Section TOC
Section 60 page 12
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Remove screws (A).
Remove steering column (B).
Remove trim (A).
Disconnect hydraulic lines at steering valve (B).
Remove screws (A) and steering valve.
<- Go to Section TOC
Section 60 page 13
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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
B
C
D
Stator
Rotor
Rotor shaft
Distributor plate
Take off rotor (B) and stator (A).
Take off rotor shaft (C) and distributor plate (D).
<- Go to Section TOC
Section 60 page 14
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 15
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 16
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
E
F
Group 05: Hydrostatic Steering
Thrust bearing assy.
Retaining ring
Leaf springs
Valve sleeve
Valve spool
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.
<- Go to Section TOC
Section 60 page 17
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Exploded View of Steering Valve
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
<- Go to Section TOC
Shock valve (2 used)
Threaded plug (2 used)
Seal ring (2 used)
Adjusting screw (2 used)
Spring (2 used)
Spring guide (2 used)
Ball (2 used)
Suction valve assembly (2 used)
Seal ring assembly
Thrust washer
Thrust bearing
Thrust washer
Retaining ring
Valve spool
Section 60 page 18
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
15
16
Group 05: Hydrostatic Steering
17
Cross-pin
Valve sleeve
Control valve assembly
18
Threaded plug with O-ring
19
Spring
20
Control piston assembly
21
Control piston
22
Pin
23
Spring
24
Ball
25
Plug
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Seal ring
Housing
Ball
Threaded bushing
Leaf springs
Rotor shaft
O-ring
Distributor plate
Rotor
O-ring
Stator
Cover
Seal washers (7 used)
Cap screw (6 used)
Cap screw with spring pin
Type plate
Impact screws
<- Go to Section TOC
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
[ Steering valve OSPQ 125/200 LS only ]
Section 60 page 19
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 20
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 21
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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
<- Go to Section TOC
Section 60 page 22
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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).
<- Go to Section TOC
Section 60 page 23
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 24
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 25
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 26
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
[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
B
C
D
Stator
Rotor
Cross-pin
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.
<- Go to Section TOC
Section 60 page 27
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 28
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 29
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Tighten threaded plug (A) to 30 N˙m (23 lb-ft).
<- Go to Section TOC
Section 60 page 30
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Adjusting the Shock Valves
LEGEND:
A
B
C
D
E
F
G
H
D01019AA hand-pump with gauge and hydraulic hose
Hydraulic hose
Adapter L38860
Coupler JT03248
Fitting
Valve spool
Shock valve (right-hand lock)
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).
<- Go to Section TOC
Section 60 page 31
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
[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
B
C
<- Go to Section TOC
Cover
O-ring
Self-locking hex. nut
Section 60 page 32
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
D
E
F
G
H
I
J
K
L
M
N
Group 05: Hydrostatic Steering
Washer
Adjusting ring
Hex. nut
Retaining plate
Steering wheel
Snap ring
Washer
Steering column assembly
Top collar
Collar insulator
Bottom collar
Recondition the Steering Column
LEGEND:
A
B
C
D
E
F
<- Go to Section TOC
Cap
Pin
Lever
Spring
Pin
Gas compression cylinder
Section 60 page 33
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
G
H
I
J
K
L
M
<- Go to Section TOC
Group 05: Hydrostatic Steering
Bushing
Hex. socket screws
Snap-ring
Washer
Steering column
Pin
Shaft (replace as complete assembly)
Section 60 page 34
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 35
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 36
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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.
<- Go to Section TOC
Section 60 page 37
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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).
<- Go to Section TOC
Section 60 page 38
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
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).
<- Go to Section TOC
Section 60 page 39
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 05: Hydrostatic Steering
Put on the steering wheel. Install the retaining plate and hex. nut (A).
Tighten hex. nut (A) to specified torque.
Item
Measurement Specification
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).
<- Go to Section TOC
Section 60 page 40
TM4756-REPAIR MANUAL
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 (—).
<- Go to Section TOC
Section 60 page 41
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or European Microfiche Tool Catalog (MTC).
DFLX41- Socket Wrench Insert
<- Go to Section TOC
Section 60 page 42
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Brake Valve - Repair Specifications
Item
Measurement Specification
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.
<- Go to Section TOC
Section 60 page 43
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Item
Measurement Specification
Filter in Brake Valve
Torque
5 N·m
4 lb.-ft.
<- Go to Section TOC
Section 60 page 44
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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.
<- Go to Section TOC
Section 60 page 45
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
→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.
Item
Measurement Specification
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” .
<- Go to Section TOC
Section 60 page 46
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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
B
O-ring
Snap ring
Install O-ring (A) and snap ring (B) on the piston.
<- Go to Section TOC
Section 60 page 47
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[2] -
LEGEND:
A
B
Seal ring
Seal ring
Install seal rings (A) and (B).
[3] -
LEGEND:
A
O-ring
Install O-ring (A) on annular piston.
<- Go to Section TOC
Section 60 page 48
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[4] -
LEGEND:
A
Seal ring
Install seal ring (A).
[5] -
LEGEND:
A
Snap ring
Install the annular piston on the piston.
[6] - Install snap ring (A).
<- Go to Section TOC
Section 60 page 49
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[7] -
LEGEND:
A
B
Wiper seal
O-ring
Install O-ring (B) and wiper seal (A) on the guide piece.
[8] -
LEGEND:
A
B
Spring
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.
<- Go to Section TOC
Section 60 page 50
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Brake Valve - Exploded View
Exploded view of power fill brake valve
Exploded view of power fill brake valve
LEGEND:
1
2
3
4
5
6
<- Go to Section TOC
Cover
Intermediate Cover
Gasket
Stop Screw
Restrictor
O-Ring
Section 60 page 51
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Group 10: Brake Valve
Valve
O-Ring
O-Ring
Valve
O-Ring
Plug
LS Check Valve Assembly
Piston
Snap Ring
Seal Ring and O-Ring
Annular Piston
Seal Ring and O-Ring
Seal Ring
Spring
Cover
O-Ring
O-Ring
Valve Assembly
Spring
Spool
Spring
O-Ring
Plug
Wiper Seal
O-Ring
Guide Piece
O-Ring
Inlet Check Valve Assembly
O-Ring
Valve Assembly
O-Ring
Fitting
O-Ring
Fitting
Orifice
Spring
O-Ring
Fitting
Outlet Valve Assembly
Exploded view - Power-fill brake valve with MFWD and disk brake (up
to tractor serial number 444807)
<- Go to Section TOC
Section 60 page 52
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
4
5
6
7
8
9
10
11
12
13
<- Go to Section TOC
Group 10: Brake Valve
Cap Screw (8 used)
Cover
Intermediate Cover
Gasket
Plug
O-Ring
Valve
O-Ring
O-Ring
LS Check Valve Assembly
Plugs (2 used)
Section 60 page 53
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
<- Go to Section TOC
Group 10: Brake Valve
O-Ring (2 used)
Spring (2 used)
Spool (2 used)
Expansion Plug
Spring (2 used)
Valve Assembly (2 used)
O-Ring (2 used)
O-Ring (2 used)
Cover (2 used)
Plug
O-Ring
Spool
O-Ring
O-Ring
Expansion Plug (4 used)
Expansion Plug (2 used)
Orifice (2 used)
Spring (2 used)
O-Ring (2 used)
Fitting (2 used)
Outlet Valve Assembly (2 used)
O-Ring
Fitting
O-Ring
Valve Assembly
O-Ring
Fitting
Inlet Check Valve Assembly
Wiper Seal (2 used)
O-Ring (2 used)
Guide Piece (2 used)
O-Ring (2 used)
Piston (2 used)
Snap Ring (4 used)
Seal Ring and O-Ring (2 used)
Annular Piston (2 used)
Seal Ring and O-Ring (2 used)
Seal Ring (2 used)
Spring
Cap Screw (2 used)
Hex. Nut (2 used)
Threaded Pin with Filter Insert
Valve (2 used)
O-Ring
Fitting
O-Ring
Spring
[ Valve Spool Parts must not be interchanged ]
[ Seal Ring Parts must not be interchanged ]
Section 60 page 54
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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
2
3
4
5
6
7
8
9
<- Go to Section TOC
Brake Valve Assembly
Cover Assembly
Intermediate Cover
Gasket
O-Ring
O-Ring
Spring
Valve
Back-Up Ring
Section 60 page 55
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Group 10: Brake Valve
25
LS Check Valve Assembly
O-Ring
O-Ring
Plug
Expansion Plug
Spool
Spring
O-Ring
Plug
Spring
Valve Assembly
O-Ring
O-Ring
Cover
Expansion Plug
Spool Assembly
26
Back-Up Ring
27
Back-Up Ring
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
O-Ring
Plug
Fitting
O-Ring
Spring
Orifice
Expansion Plug
Fitting
Fitting assembly
O-Ring
Fitting
Valve Assembly
O-Ring
Piston
O-Ring
Guide Piece
O-Ring
Wiper Seal
Snap Ring
Seal Ring and O-Ring
Annular Piston
Seal Ring and O-Ring
O-Ring
Spring
Brake Housing
Cap Screw
Hex. Nut
Threaded Pin with Filter Insert
Valve
O-Ring
Cap Screws
<- Go to Section TOC
[ Parts must not be interchanged ]
[ Parts must not be interchanged ]
[ Parts must not be interchanged ]
Section 60 page 56
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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
B
C
Screws
Grip
Trim Panel
Take out screws (A) and remove grip (B).
[2] - Fold trim panel (C) up.
<- Go to Section TOC
Section 60 page 57
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[3] -
LEGEND:
A
Pin
Take out pin (A) and lift off the brake pedals.
[4] -
LEGEND:
A
B
C
D
E
Hydraulic Hose
Hydraulic Hose
Screw
Screw
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.
<- Go to Section TOC
Section 60 page 58
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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).
<- Go to Section TOC
Section 60 page 59
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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 reinstallation.
<- Go to Section TOC
Section 60 page 60
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
LEGEND:
A
B
Spool
Spring
Remove spring (B) and spool (A).
[6] -
LEGEND:
A
B
C
D
E
F
Cover
O-Ring
O-Ring
Valve Assembly
Spring
Spool
Disassemble the spool, check individual parts for wear and replace if necessary. Clean and
assemble the parts.
<- Go to Section TOC
Section 60 page 61
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[7] -
LEGEND:
A
Socket Wrench
Unscrew the guide piece using socket wrenchDFLX41(A).
[8] -
Remove the guide piece and piston.
<- Go to Section TOC
Section 60 page 62
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 63
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[12] -
LEGEND:
A
Plug
Remove plug (A).
[13] -
Drive out the LS check valve.
<- Go to Section TOC
Section 60 page 64
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake 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.
<- Go to Section TOC
Section 60 page 65
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[1] -
LEGEND:
A
B
C
Orifice
Spring
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.
<- Go to Section TOC
Section 60 page 66
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[4] -
Install the inlet check valve and tighten to the specified torque.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Fitting to brake valve
Torque
45 N˙m
33 lb-ft
<- Go to Section TOC
Section 60 page 67
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[6] -
LEGEND:
A
B
O-Ring
O-Ring
Install O-rings (A) and (B) on the LS check valve and coat them with oil.
[7] -
Install the LS check valve.
<- Go to Section TOC
Section 60 page 68
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[8] -
LEGEND:
A
Plug
Install plug (A) and tighten to the specified torque.
Item
Measurement
Specification
Plug to brake valve
Torque
45 N˙m
33 lb-ft
[9] -
LEGEND:
A
B
Spring
Guide Piece
Disassemble the piston with spring (A) and guide piece (B), check for wear and replace parts
as necessary.
SeeRecondition Guide Piece and Pistonin Section 60.
<- Go to Section TOC
Section 60 page 69
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[10] -
Position the piston and guide piece.
[11] -
Using socket wrenchDFLX41(A), tighten the guide piece to the specified torque.
Item
Measurement
Specification
Guide piece to brake valve
Torque
100 N˙m
75 lb-ft
[12] IMPORTANT:
Note correct side, correct direction and relation of the parts for reinstallation.
<- Go to Section TOC
Section 60 page 70
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
LEGEND:
A
B
Spool
Spring
Install spool (A) and spring (B).
[13] →NOTE:
When installing the plug, remember the spring force.
LEGEND:
A
Plug
Install plug (A) and tighten to the specified torque.
Item
Measurement
Specification
Plug to brake valve
Torque
100 N˙m
75 lb-ft
<- Go to Section TOC
Section 60 page 71
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[14] -
LEGEND:
A
Filter
Install filter (A) and tighten to the specified torque.
Item
Measurement
Specification
Filter in brake valve
Torque
5 N˙m
4 lb-ft
[15] -
LEGEND:
A
Valves
Install valves (A) and tighten to the specified torque.
Item
Measurement
Specification
Valve to brake valve, plug
Torque
15 N˙m
11 lb-ft
<- Go to Section TOC
Section 60 page 72
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 73
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Brake Valve - Tightening Sequence for Screws
LEGEND:
A
B
Cover
Screws
Install cover (A) and tighten screws (B) to the specified torque in the sequence shown.
Item
Measurement
Specification
Cover to brake valve, screws
Torque
12 N˙m
9 lb-ft
Next step:
SeeInstall Brake Valve (Power Fill Brakes)in Section 60.
<- Go to Section TOC
Section 60 page 74
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Brake Switch to Bracket
Torque
12 N˙m
9 lb-ft
<- Go to Section TOC
Section 60 page 75
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 76
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Power-Fill Brake Valve with MFWD and Disk Brake
(up to Tractor Serial Number 444807)
Preliminary work
Disconnect battery ground cable (—).
Remove the Brake Valve
Take out screws (A) and (B). Remove trim panel (C).
<- Go to Section TOC
Section 60 page 77
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Take out pin (A) and lift off the brake pedals.
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 off hydraulic hose (A).
<- Go to Section TOC
Section 60 page 78
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Take out the lower hex. socket screw (A) and lift off the brake valve.
Disassemble the brake valve
LEGEND:
A
Cover
→NOTE:
Depending on tractor version, the brake switch may have to be taken off
first.
Remove cover (A).
<- Go to Section TOC
Section 60 page 79
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Remove valves (A).
Remove filter (A).
Use socket wrench
Socket Wrench Insert
dealer fabricated
<- Go to Section TOC
Section 60 page 80
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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.
<- Go to Section TOC
Section 60 page 81
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Remove plug (A).
Take out spring (B) and spool (A).
Disassemble the spool.
Remove plug (A).
<- Go to Section TOC
Section 60 page 82
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Remove valve (A).
Remove fitting (A).
Unscrew the inlet check valve.
<- Go to Section TOC
Section 60 page 83
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Remove plug (A).
Drive out the LS check valve.
Exploded view
<- Go to Section TOC
Section 60 page 84
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
4
5
6
7
8
9
10
11
12
13
<- Go to Section TOC
Group 10: Brake Valve
Cap Screw (8 used)
Cover
Intermediate Cover
Gasket
Plug
O-Ring
Valve
O-Ring
O-Ring
LS Check Valve Assembly
Plugs (2 used)
Section 60 page 85
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
<- Go to Section TOC
Group 10: Brake Valve
O-Ring (2 used)
Spring (2 used)
Spool (2 used)
Expansion Plug
Spring (2 used)
Valve Assembly (2 used)
O-Ring (2 used)
O-Ring (2 used)
Cover (2 used)
Plug
O-Ring
Spool
O-Ring
O-Ring
Expansion Plug (4 used)
Expansion Plug (2 used)
Orifice (2 used)
Spring (2 used)
O-Ring (2 used)
Fitting (2 used)
Outlet Valve Assembly (2 used)
O-Ring
Fitting
O-Ring
Valve Assembly
O-Ring
Fitting
Inlet Check Valve Assembly
Wiper Seal (2 used)
O-Ring (2 used)
Guide Piece (2 used)
O-Ring (2 used)
Piston (2 used)
Snap Ring (4 used)
Seal Ring and O-Ring (2 used)
Annular Piston (2 used)
Seal Ring and O-Ring (2 used)
Seal Ring (2 used)
Spring
Cap Screw (2 used)
Hex. Nut (2 used)
Threaded Pin with Filter Insert
Valve (2 used)
O-Ring
Fitting
O-Ring
Spring
[ Valve Spool Parts must not be interchanged ]
[ Seal Ring Parts must not be interchanged ]
Section 60 page 86
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Assemble the brake valve
LEGEND:
A
B
C
Orifice
Spring
Fitting
Install the outlet valves.
Put O-ring (A) onto the inlet check valve.
<- Go to Section TOC
Section 60 page 87
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Screw in the inlet check valve.
Screw in fitting (A).
Screw in the valve and tighten to specified torque.
Item
Measurement
Specification
Valve
Torque
10 N˙m
7.4 lb.-ft.
Tighten plug (A).
<- Go to Section TOC
Section 60 page 88
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Put O-rings (A) and (B) onto the LS check valve.
Install the LS check valve (A).
<- Go to Section TOC
Section 60 page 89
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Screw in plug (A).
Install snap ring (B) on piston. Install O-ring (A).
Install seal ring (B). Install seal ring (A).
<- Go to Section TOC
Section 60 page 90
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Install O-ring (A) on annular piston.
Install seal ring (A).
Install the annular piston on the piston. Install snap ring (A).
<- Go to Section TOC
Section 60 page 91
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Install O-ring (B) and wiper seal (A) on the guide piece.
Install guide piece (B) on the piston. Install spring (A).
LEGEND:
A
B
C
D
E
F
<- Go to Section TOC
Cover
O-Ring
O-Ring
Valve Assembly
Spring
Spool
Section 60 page 92
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Assemble the spool.
Install spool (A) and spring (B).
Screw in plug (A).
<- Go to Section TOC
Section 60 page 93
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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.
Item
Measurement
Specification
Torque
5 N˙m
4 lb.-ft.
<- Go to Section TOC
Section 60 page 94
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Install valves (A).
Install gasket (A).
Install intermediate cover (A) on the cover.
<- Go to Section TOC
Section 60 page 95
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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).
<- Go to Section TOC
Section 60 page 96
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
Group 10: Brake Valve
Hydraulic Hose
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.
<- Go to Section TOC
Section 60 page 97
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Tighten hex. socket screws (C) and (D).
Item
Measurement
Specification
Brake Valve Attaching Screws
Torque
100 N˙m
75 lb.-ft.
Secure the brake pedals with pin (A).
Adjusting the brake pedals
[1] - Lock the brake pedals together.
<- Go to Section TOC
Section 60 page 98
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[2] - Measure pedal play at both pistons.
Pedal play must be within the following range.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Brake Switch
Clearance
6 mm
0.24 in.
Adjusting the brake switches (with AutoPowr/IVT)
<- Go to Section TOC
Section 60 page 99
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[1] - Make sure that the brake pedals are adjusted correctly.
[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
<- Go to Section TOC
Section 60 page 100
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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.
<- Go to Section TOC
Section 60 page 101
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Remove Power-Fill Brake Valve with MFWD and Disk
Brake
Preliminary work:
Disconnect battery ground cable (—).
Relieve pressure at accumulator.
SeeAccumulators - Removal and Installationin Section 60.
Remove the brake valve
<- Go to Section TOC
Section 60 page 102
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[1] -
LEGEND:
A
B
C
Screws
Grip
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.
<- Go to Section TOC
Section 60 page 103
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[4] -
LEGEND:
A
B
C
D
E
F
Hydraulic Hose
Connector
Screw
Screw
Hydraulic Line
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
Take off hydraulic hose (A).
<- Go to Section TOC
Section 60 page 104
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[10] -
LEGEND:
A
Screw
Remove screw (A) and brake valve.
Next step:
SeeRecondition Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.
<- Go to Section TOC
Section 60 page 105
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Recondition Power-Fill Brake Valve with MFWD and
Disk Brake
Preliminary work:
SeeRemove Power-Fill Brake Valve with MFWD and Disk Brakein Section 60.
Disassemble the brake valve
[1] →NOTE:
Depending on tractor version, the brake switch may have to be taken off
first.
LEGEND:
A
Cover
Remove cover (A).
<- Go to Section TOC
Section 60 page 106
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 107
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
LEGEND:
A
Plug
Remove plug (A).
[5] IMPORTANT:
Note correct side, correct direction and relation of the parts for reinstallation.
LEGEND:
A
B
Spool
Spring
Remove spring (B) and spool (A).
<- Go to Section TOC
Section 60 page 108
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[6] -
LEGEND:
A
B
C
D
E
F
Cover
O-Ring
O-Ring
Valve Assembly
Spring
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).
<- Go to Section TOC
Section 60 page 109
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 110
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[10] -
LEGEND:
A
Plug
Remove plug (A).
[11] -
LEGEND:
A
B
Valve
Spring
Remove valve (A) and spring (B).
<- Go to Section TOC
Section 60 page 111
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[12] -
LEGEND:
A
Fitting
Remove fitting (A).
[13] -
Remove the inlet check valve.
<- Go to Section TOC
Section 60 page 112
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[14] -
LEGEND:
A
Plug
Remove plug (A).
[15] -
Drive out the LS check valve.
<- Go to Section TOC
Section 60 page 113
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[16] -
LEGEND:
A
B
C
Orifice
Spring
Fitting
Remove orifices (A), springs (B) and fittings (C).
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.
<- Go to Section TOC
Section 60 page 114
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[1] -
LEGEND:
A
B
C
Orifice
Spring
Fitting
Install orifices (A), springs (B) and fittings (C).
[2] - Tighten the outlet valves to the specified torque.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 60 page 115
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[4] -
Install the inlet check valve and tighten to the specified torque.
Item
Measurement
Specification
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.
Item
Measurement
Specification
Fitting to brake valve
Torque
45 N˙m
33 lb-ft
<- Go to Section TOC
Section 60 page 116
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[6] -
LEGEND:
A
B
O-Ring
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).
<- Go to Section TOC
Section 60 page 117
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[8] -
LEGEND:
A
Plug
Install plug (A) and tighten to the specified torque.
Item
Measurement
Specification
Plug to brake valve
Torque
45 N˙m
33 lb-ft
[9] -
LEGEND:
A
B
Valve
Compression Spring
Install valve and compression spring.
<- Go to Section TOC
Section 60 page 118
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[10] -
LEGEND:
A
Plug
Install plug (A) and tighten to the specified torque.
Item
Measurement
Specification
Plug to brake valve
Torque
45 N˙m
33 lb-ft
[11] -
LEGEND:
A
B
Spring
Guide Piece
Disassemble the piston with spring (A) and guide piece (B), check for wear and replace parts
as necessary.
SeeRecondition Guide Piece and Pistonin Section 60.
<- Go to Section TOC
Section 60 page 119
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
Item
Measurement
Specification
Guide piece to brake valve
Torque
100 N˙m
75 lb-ft
[14] IMPORTANT:
Note correct side, correct direction and relation of the parts for reinstallation.
<- Go to Section TOC
Section 60 page 120
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
LEGEND:
A
B
Spool
Spring
Install spool (A) and spring (B).
[15] →NOTE:
When installing the plug, remember the spring force.
LEGEND:
A
Plug
Install plug (A) and tighten to the specified torque.
Item
Measurement
Specification
Plug to brake valve
Torque
100 N˙m
75 lb-ft
<- Go to Section TOC
Section 60 page 121
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[16] -
LEGEND:
A
Filter
Install filter (A) and tighten to the specified torque.
Item
Measurement
Specification
Filter in brake valve
Torque
5 N˙m
4 lb-ft
[17] -
LEGEND:
A
Valves
Install valves (A) and tighten to the specified torque.
Item
Measurement
Specification
Valve to brake valve, plug
Torque
15 N˙m
11 lb-ft
<- Go to Section TOC
Section 60 page 122
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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.
<- Go to Section TOC
Section 60 page 123
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
Brake Valve - Tightening Sequence for Screws
LEGEND:
A
B
Cover
Screws
Install cover (A) and tighten screws (B) to the specified torque in the sequence shown.
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 60 page 124
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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).
<- Go to Section TOC
Section 60 page 125
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[2] -
LEGEND:
A
B
Hydraulic Hose
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.
<- Go to Section TOC
Section 60 page 126
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[6] - Install screws (C) and (D) and tighten to the specified torque.
Item
Measurement
Specification
Brake Valve Attaching Screws
Torque
100 N·m
75 lb.-ft.
[7] -
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.
<- Go to Section TOC
Section 60 page 127
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
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
B
C
Adjusting Screw
Roller
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
<- Go to Section TOC
Section 60 page 128
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
AutoPowr/IVT).
Adjust the brake switches (without AutoPowr/IVT)
LEGEND:
A
Adjusting Screws
[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.
Item
Measurement
Specification
Brake Switch
Clearance
6 mm
0.24 in.
[3] -
LEGEND:
A
B
C
Screws
Grip
Trim Panel
Attach trim panel (C) using screws (A) and re-install handle (B).
<- Go to Section TOC
Section 60 page 129
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 10: Brake Valve
[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
B
Adjusting Screw
Adjusting Screw
[1] - Make sure that the brake pedals are adjusted correctly.
[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).
<- Go to Section TOC
Section 60 page 130
TM4756-REPAIR MANUAL
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
B
C
Screws
Grip
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.
<- Go to Section TOC
Section 60 page 131
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
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
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 60 page 132
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
[1] -
LEGEND:
A
B
C
Brake plate
Final drive shaft
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
<- Go to Section TOC
Section 60 page 133
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
E
F
G
H
<- Go to Section TOC
Group 15: Rear Wheel Brakes
Ball
O-ring
Bleed screw
Seal ring
Seal ring
Brake piston
Brake disk
Backing plate
Section 60 page 134
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
Recondition the Rear Wheel Brakes
Preliminary work:
SeeRemove the Rear Wheel Brakesin Section 60.
[1] -
LEGEND:
A
B
Brake piston
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.
Item
Measurement
Specification
Brake disk
Thickness (Minimum)
5.5 mm (0.216 in.)
<- Go to Section TOC
Section 60 page 135
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
[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.
<- Go to Section TOC
Section 60 page 136
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
Install the Rear Brakes
[1] -
LEGEND:
A
B
Brake piston
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
B
C
Brake plate
Final drive shaft
Brake disk
Install brake plate (A), brake disk (C) and final drive shaft (B) as shown.
<- Go to Section TOC
Section 60 page 137
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
Next step:
SeeInstall the Final Drivesin Section 56.
Final Assembly
See “Installing the Final Drives” , Section 56, Group 00.
<- Go to Section TOC
Section 60 page 138
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
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.
2.
3.
4.
Left front brake
Right front brake
Trailer control valve, bleed screw
Left rear brake
With hydraulic trailer brake and MFWD with disk brake:
<- Go to Section TOC
Section 60 page 139
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
1.
2.
3.
4.
Group 15: Rear Wheel Brakes
Left front brake
Right front brake
Left rear brake
Trailer brake valve
Bleeding procedure
[1] -
Without trailer brake
LEGEND:
A
B
Hex. nut
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
<- Go to Section TOC
Section 60 page 140
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 15: Rear Wheel Brakes
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
<- Go to Section TOC
Section 60 page 141
TM4756-REPAIR MANUAL
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
B
C
Hex. nut
Bleed screw
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.
<- Go to Section TOC
Section 60 page 142
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
Group 20 - Handbrake
Summary of References (Handbrake)
”Specifications”
”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
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 60 page 143
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
Remove Handbrake
Preliminary work:
SeeRemove the Front-Wheel Drive Clutchin Section 56.
[1] -
LEGEND:
A
B
Screws
Bearing quill
Take out screws (A) and remove bearing quill (B).
[2] -
LEGEND:
A
B
C
Spring pin
Lever shaft
Plug
Remove plug (C).
[3] - Remove spring pin (A) and pull out lever shaft (B).
<- Go to Section TOC
Section 60 page 144
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
[4] -
LEGEND:
A
Plug
Remove plug (A).
[5] -
LEGEND:
A
Shaft
Use a screw to remove shaft (A).
<- Go to Section TOC
Section 60 page 145
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
[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.
<- Go to Section TOC
Section 60 page 146
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
Exploded view of handbrake - Tractor 6820
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
<- Go to Section TOC
Lever
Strap
Lever
Brake band
Strap
Lever shaft
Strap
Lever
Arm
Strap
Seal ring
Shaft
Section 60 page 147
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
Exploded view of handbrake - Tractors 6920 and
6920S
LEGEND:
A
B
C
D
E
F
G
H
I
J
<- Go to Section TOC
Lever
Strap
Lever
Brake band
Brake band
Strap
Strap
Lever shaft
Strap
Lever
Section 60 page 148
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
K
L
M
N
<- Go to Section TOC
Group 20: Handbrake
Arm
Strap
Seal ring
Shaft
Section 60 page 149
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
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
<- Go to Section TOC
Section 60 page 150
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
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.
<- Go to Section TOC
Section 60 page 151
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
Install shaft (A).
Screw in plug (A).
Screw in plug (C).
Install lever shaft (B) and drive in spring pin (A).
<- Go to Section TOC
Section 60 page 152
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
→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).
Item
Measurement
Specification
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.
<- Go to Section TOC
Section 60 page 153
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
LEGEND:
A
Adjusting screw
Adjust the brake band at adjusting screw (A).
[2] - Tighten locknut on adjusting screw to specified torque.
Item
Measurement
Specification
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
<- Go to Section TOC
Section 60 page 154
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
<- Go to Section TOC
Group 20: Handbrake
Spring
Unlocking rod
Handle
Handbrake lever
Locking pawl
Toothed segment
Bracket
Sender for handbrake indicator light
Console
Trim panel
Rubber sleeve
Handbrake cable (top part)
Handbrake cable (bottom part)
Terminal
Bracket
Bracket (AutoPowr/IVT transmission only)
Section 60 page 155
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
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
B
Screws
Trim panel
Take out screws (A) and remove trim panel (B).
<- Go to Section TOC
Section 60 page 156
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 20: Handbrake
4.
LEGEND:
A
B
Pin
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
B
C
D
Snap ring
Sleeve
Locknut
Handbrake cable (top part)
Remove snap ring (A).
[2] - Unfasten locknut (C) and unscrew the sleeve (B).
<- Go to Section TOC
Section 60 page 157
TM4756-REPAIR MANUAL
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).
[4] - Install snap ring (A).
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.
<- Go to Section TOC
Section 60 page 158
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
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:
Order tools according to information given in the U.S. SERVICEGARD ™
Catalog or from the European Microfiche Tool Catalog (MTC).
FKM10002 / JT05470- Universal pressure test kit
AR52361- Coupler socket
Specifications
Item
Measurement Specification
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.
<- Go to Section TOC
Section 60 page 159
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
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.
<- Go to Section TOC
Section 60 page 160
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
Hydraulic Trailer Brake Valve up to Serial No.
466428
Changing the trailer brake valve
LEGEND:
A
B
Cap screws
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.
<- Go to Section TOC
Section 60 page 161
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
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
B
C
Valve spool
Disk
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
B
C
Valve body
Spring
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.
<- Go to Section TOC
Section 60 page 162
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
Group 25: Hydraulic Trailer Brake
Restriction valve
Cover
O-ring L53976
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
<- Go to Section TOC
Section 60 page 163
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
Group 25: Hydraulic Trailer Brake
Hydraulic line
Fitting
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
B
<- Go to Section TOC
Check valve
Trailer brake valve
Section 60 page 164
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
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.
<- Go to Section TOC
Section 60 page 165
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
[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 ]
(pilot and brake pressure)
1:6
1:9
Pilot pressure
1700 kPa
17 bar
247 psi
1100 kPa
11 bar
160 psi
Brake pressure
(at coupler)
9400—11000 kPa 9500—10800 kPa
94—110 bar
95—108 bar
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.
<- Go to Section TOC
Section 60 page 166
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
Hydraulic Trailer Brake Valve from Serial No.
466429
Changing the trailer brake valve
LEGEND:
A
B
Cap screws
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
<- Go to Section TOC
Section 60 page 167
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
Group 25: Hydraulic Trailer Brake
Hydraulic line
Fitting
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
<- Go to Section TOC
Section 60 page 168
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
LEGEND:
A
B
Group 25: Hydraulic Trailer Brake
Check valve
Trailer brake valve
O-ring
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.
<- Go to Section TOC
Section 60 page 169
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 25: Hydraulic Trailer Brake
Check Hydraulic Trailer Brake Valve
LEGEND:
A
Pressure Gauge FKM10207
B
Connector FKM10302
C
Pressure Hose FKM10209
D
Connector FKM10303
E
Connector FKM10305
F
Quick Coupler Socket
G
H
Coupler Plug
Pressure Gauge FKM10205
I
Connector FKM10303
J
Fitting KJD10128
<- Go to Section TOC
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
[ Available as spare part ]
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
[ Included in pressure gauge set FKM10002 ]
Section 60 page 170
TM4756-REPAIR MANUAL
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)
Brake pressure at coupler: 12000 - 14000 kPa (120 - 140 bar; 1740 - 2031 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.
Brake pressure at coupler: 9500 - 10800 kPa (95 - 108 bar; 1378 - 1566 psi)
Perform the maximum pressure test at the following pressure.
Pilot pressure at brake valve: 1400 kPa (14 bar; 203 psi)
Brake pressure at coupler: 12000 - 14000 kPa (120 - 140 bar; 1740 - 2031 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.
<- Go to Section TOC
Section 60 page 171
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Group 30 - Air Brakes up to Serial No. 398655
Air Brakes up to Serial No. 398655 (Summary of
References)
”Special tools”
”Specifications”
”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
<- Go to Section TOC
Section 60 page 172
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Checking the air brake system
<- Go to Section TOC
Section 60 page 173
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Repair specifications
Item
Measurement
Specification
Operating pressure (downstream of pressureregulating valve)
Pressure
790 to 830 kPa (7.9 to 8.3 bar; 115 to
120 psi)
Leak test
Pressure drop within a period
of 10 min
max. 16 kPa (0.16 bar; 2.3 psi)
Dual-line brake check
Pressure with foot brake or
hand brake engaged
700 to 740 kPa (7.0 to 7.4 bar; 102 to
107 psi)
Single-line brake check
Pressure with foot brake and
hand brake disengaged
500 to 540 kPa (5.0 to 5.4 bar; 73 to 78
psi)
—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)
Cylinder head screws
Torque
20 N˙m (15 lb-ft), then turn an
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)
Screws on connecting rod bearing
Torque
6 N˙m (4.5 lb-ft), then turn an additional
70°
Screws, bearing flange to crankcase
Torque
12 N˙m (9 lb-ft)
Time required to fill compressed air tank
Air compressor
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.
<- Go to Section TOC
Section 60 page 174
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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.
<- Go to Section TOC
Section 60 page 175
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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.
<- Go to Section TOC
Section 60 page 176
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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
B
C
D
E
Pressure Oil Line
Return Oil Line
Air Intake Line
Compressed Air Line
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.
<- Go to Section TOC
Section 60 page 177
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Gaskets for the Compressor
<- Go to Section TOC
Section 60 page 178
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
<- Go to Section TOC
Group 30: Air Brakes up to Serial No. 398655
Section 60 page 179
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Group 30: Air Brakes up to Serial No. 398655
Aluminium ring
Plug
Cylinder head screw (4 used)
Cylinder head
Gasket
Valve plate
Gasket
Crankcase (compressor)
O-ring
Bearing quill
Seal ring
Nut
Hex. socket screw (4 used)
Aluminium ring
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 lbft).
<- Go to Section TOC
Section 60 page 180
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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:
Item
Measurement
Specification
Compressed air hose
Torque
14 N˙m
(10 lb-ft)
<- Go to Section TOC
Section 60 page 181
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
2
3
4
5
6
7
8
9
10
Group 30: Air Brakes up to Serial No. 398655
Test and filler connection
Fitting
Lock nut
Thrust ring
O-ring
Compressed air tank
Bracket
Drain valve
Elbow fitting
Fitting
Changing the preload valve
Support the tractor properly and remove the right rear wheel.
Disconnect cable (A) on preload valve (D).
Remove cap screws (B).
Loosen collar nuts (C and E) and pull out hoses.
<- Go to Section TOC
Section 60 page 182
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Remove preload valve (D).
For installation, reverse the removal procedure.
Item
Measurement
Specification
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).
For installation, follow removal procedure in reverse order.
Item
Measurement
Specification
Preload valve, cap screw (M8x75)
Torque
28 N˙m
(20 lb-ft)
Changing the pressure-regulating valve
<- Go to Section TOC
Section 60 page 183
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
IMPORTANT:
Before carrying out any work, be sure to observe all safety instructions.
Support the tractor properly and remove the right rear wheel.
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.
For installation, reverse the removal procedure.
Changing the trailer control valve (dual-line +
single-line brake)
<- Go to Section TOC
Section 60 page 184
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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).
For installation, reverse the removal procedure.
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).
<- Go to Section TOC
Section 60 page 185
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Changing the trailer control valve (single-line
brake)
LEGEND:
A
B
C
D
E
Hose to coupling end “black, single-line brake”
Hose to trailer control valve (dual-line brake)
Hose from trailer control valve (dual-line brake)
Hose to trailer control valve (dual-line brake)
M20x60 cap screw
Support the tractor properly and remove the left rear wheel.
Disconnect hoses (A), (B), (C) and (D).
Remove screw (E).
For installation, reverse the removal procedure.
→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
<- Go to Section TOC
Section 60 page 186
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Group 30: Air Brakes up to Serial No. 398655
Bracket
O-ring
Thrust ring
Lock nut
Elbow fitting
Cutting ring
Backup sleeve
Collar nut
Hose (from trailer control valve; dual-line brake)
Hose (to trailer control valve; dual-line brake)
Hose (to trailer control valve; dual-line brake)
Lock nut
Thrust ring
O-ring
Trailer control valve (single-line brake)
Single-line brake
<- Go to Section TOC
Section 60 page 187
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Changing the Coupling Ends
<- Go to Section TOC
Section 60 page 188
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Group 30: Air Brakes up to Serial No. 398655
Plug (M22x1)
Quick-release valve
O-ring
Pressure ring
Hex. nut
Elbow fitting
Elbow fitting
Hex. nut
Fitting
Pressure ring
O-ring
Coupling end (red, supply)
Bracket
Coupling end (black, single-line brake)
Fitting
Coupling end (yellow, dual-line brake)
Hex. nut
Hose
Hose clamp
Elbow fitting
Cap screw
Disconnect the appropriate line (A).
Disconnect the appropriate coupling end (B) and take out the screw-in element.
For installation, follow removal procedure in reverse order.
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.
<- Go to Section TOC
Section 60 page 189
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Tighten line (B) to 14 N˙m (10 lb-ft).
Install toothed disks (D) between bracket (E) and the pressure gauge housing.
<- Go to Section TOC
Section 60 page 190
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
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 for any damage:
Check that components function
correctly:
Test drive the tractor, operate
the components:
•Do the lines and hoses rub?
•Compressor drive
•Leaks in the system
•Loose or defective attachments?
•Air cleaner
•Reaction time
•Coupling ends, function and condition
•Lube supply
•Variability of trailer control
valve
•Is there corrosion or dirt in the system?
•Pressure control valve
•Handbrake
•Linkage, cables and joints must move freely.
Any sign of damage?
•Trailer control valves
•Any build-up of burnt-oil deposits?
•Pressure gauge
•Drain valve
•Pressure limiting valve (if equipped)
•Time taken for filling
<- Go to Section TOC
Section 60 page 191
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Checking the system for leaks
[1] -
LEGEND:
A
B
KJD10194-1 pressure gauge
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
<- Go to Section TOC
Section 60 page 192
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
Group 30: Air Brakes up to Serial No. 398655
KJD10194-1 Pressure Gauge
KJD10194-2 Hose
KJD10194-5 Coupling End (Red)
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).
<- Go to Section TOC
Section 60 page 193
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Check the Dual-Line Brakes
LEGEND:
A
B
C
D
KJD10194-1 pressure gauge
KJD10194-2 hose
KJD10194-4 coupler (yellow)
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).
<- Go to Section TOC
Section 60 page 194
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
[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).
<- Go to Section TOC
Section 60 page 195
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 30: Air Brakes up to Serial No. 398655
Checking the Single-Line Brakes
LEGEND:
A
B
C
D
KJD10194-1 pressure gauge
KJD10194-2 hose
KJD10194-3 coupler (black)
KJD10194-6 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] - Connect pressure test kit KJD10194 to single-line air brake coupler (black).
[3] - Run engine until the air brake system reaches its operating pressure.
[4] - Read pressure with handbrake and foot brakes not applied.
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
<- Go to Section TOC
Section 60 page 196
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
If necessary, adjust linkage (A) until the prescribed pressure is reached.
Item
Measurement
Specification
Dual-line brake check
Pressure with foot brake or hand brake engaged
700 to 740 kPa (7.0 to 7.4 bar; 102 to 107
psi)
Single-line brake check
Pressure with foot brake and hand brake
disengaged
500 to 540 kPa (5.0 to 5.4 bar; 73 to 78 psi)
Pressure test
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.
<- Go to Section TOC
Section 60 page 197
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Group 31 - Air Brakes from Serial No. 398656
Air Brakes from Serial No. 398656 (Summary of
References)
”Special tools”
”Specifications”
”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
<- Go to Section TOC
Section 60 page 198
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Repair Specifications
Item
Measurement
Specification
Operating Pressure (Downstream of
Pressure Control Valve)
Pressure
790 to 830 kPa (7.9 to 8.3 bar; 115 to 120
psi)
Leak Test
Pressure drop within 10 minutes max. 16 kPa (0.16 bar; 2.3 psi)
Dual-Line Brake
Pressure with Brake Pedal
Depressed or Handbrake
Applied
700 to 740 kPa (7.0 to 7.4 bar; 102 to 107
psi)
Single-Line Brake
Pressure with Brake Pedal and
Handbrake Released
500 to 540 kPa (5.0 to 5.4 bar; 73 to 78 psi)
—15 L (3.96 US.gal.)
Time
approx. 2.25 minutes at rated engine
speed
Compressed-Air Line for Pressure Gauge
Torque
14 N˙m (10 lb.-ft.)
Cheese-Head Screws
Torque
20 N˙m (15 lb.-ft.), then turn through a
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.)
Screws, Connecting Rod Bearing
Torque
6 N˙m (4.5 lb.-ft.), then turn through a
further 70°
Screws, Bearing Flange to Crankcase
Torque
12 N˙m (9 lb.-ft.)
Compressed Air Tank Fill Time
Air Compressor
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.
<- Go to Section TOC
Section 60 page 199
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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.
<- Go to Section TOC
Section 60 page 200
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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.
<- Go to Section TOC
Section 60 page 201
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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
B
C
D
E
Pressure Oil Line
Return Oil Line
Air Intake Line
Compressed Air Line
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.
<- Go to Section TOC
Section 60 page 202
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Gaskets for the Compressor
<- Go to Section TOC
Section 60 page 203
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
<- Go to Section TOC
Group 31: Air Brakes from Serial No. 398656
Section 60 page 204
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
Group 31: Air Brakes from Serial No. 398656
Aluminium ring
Plug
Cylinder head screw (4 used)
Cylinder head
Gasket
Valve plate
Gasket
Crankcase (compressor)
O-ring
Bearing quill
Seal ring
Nut
Hex. socket screw (4 used)
Aluminium ring
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 lbft).
<- Go to Section TOC
Section 60 page 205
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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.
Item
Measurement
Specification
Compressed-air hose
Torque
14 N˙m
(10 lb-ft)
<- Go to Section TOC
Section 60 page 206
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
2
3
4
5
6
7
8
9
10
11
Group 31: Air Brakes from Serial No. 398656
Test and filler connection
Sealing washer
Fitting
Lock nut
Thrust ring
O-ring
Compressed air tank
Bracket
Water drain valve
Elbow fitting
Fitting
Changing the Pressure-Regulating Valve
Support the tractor safely and remove the right rear wheel.
Remove compressed air tank. Remove pressure-regulating valve (A).
For installation, follow removal procedure in reverse order.
<- Go to Section TOC
Section 60 page 207
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
1
2
3
4
5
6
Group 31: Air Brakes from Serial No. 398656
Compressed air tank
Lock nut
Thrust ring
O-ring
Pressure-regulating valve
Fitting
Changing the Precharge Valve
<- Go to Section TOC
Section 60 page 208
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Support the tractor safely and remove the right rear wheel.
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.
Item
Measurement
Specification
Compressed-air hose
Torque
14 N˙m
(10 lb-ft)
Changing the Trailer Control Valve (Dual-Line
Brake)
<- Go to Section TOC
Section 60 page 209
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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).
For installation, follow removal procedure in reverse order.
→NOTE:
Bleed the hydraulic brakes, see "Bleeding the Brakes" , Section 60, Group
15).
Changing the Trailer Control Valve (Single-Line
Brake)
Support the tractor safely and remove the left rear wheel.
<- Go to Section TOC
Section 60 page 210
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Disconnect lines (A), (B) and (C).
Remove the two screws (D).
For installation, follow removal procedure in reverse order.
→NOTE:
Bleed the hydraulic brakes, see"Bleeding the Brakes", Section 60, Group
15).
<- Go to Section TOC
Section 60 page 211
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Change the Coupling Ends
Disconnect the appropriate line.
Disconnect the appropriate coupling end (A) and take out the screw-in element.
For installation, follow removal procedure in reverse order.
LEGEND:
1
<- Go to Section TOC
Coupling End (Yellow, Dual-Line Brake)
Section 60 page 212
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
2
3
4
5
6
7
8
9
10
11
12
13
14
Group 31: Air Brakes from Serial No. 398656
O-Ring
Thrust Ring
Hex. Nut
Elbow Fitting
Coupling End (Black, Single-Line Brake)
O-Ring
Thrust Ring
Fitting
Hex. Nut
Coupling End (Red, Supply)
Cap Screw
[ Coupling End (Supply) For Great Britain only ]
[ 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).
For installation, follow removal procedure in reverse order.
Tighten line (B) to 14 N˙m (10 lb.-ft.).
Install the toothed disks between bracket and the pressure gauge (C) housing.
<- Go to Section TOC
Section 60 page 213
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
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 for any damage:
Check that components function
correctly:
Test drive the tractor, operate
the components:
•Do the lines and hoses rub?
•Compressor drive
•Leaks in the system
•Loose or defective attachments?
•Air cleaner
•Reaction time
•Coupling ends, function and condition
•Lube supply
•Variability of trailer control
valve
•Is there corrosion or dirt in the system?
•Pressure control valve
•Handbrake
•Linkage, cables and joints must move freely.
Any sign of damage?
•Trailer control valves
•Any build-up of burnt-oil deposits?
•Pressure gauge
•Drain valve
•Pressure limiting valve (if equipped)
•Time taken for filling
<- Go to Section TOC
Section 60 page 214
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Check the System for Leaks
[1] -
LEGEND:
A
B
KJD10194-1 Pressure Gauge
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
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Section 60 page 215
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
LEGEND:
A
B
C
D
Group 31: Air Brakes from Serial No. 398656
KJD10194-1 Pressure Gauge
KJD10194-2 Hose
KJD10194-5 Coupling End (Red)
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).
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Section 60 page 216
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Check Dual-Line Brake
LEGEND:
A
B
C
D
KJD10194-1 Pressure Gauge
KJD10194-2 Hose
KJD10194-4 Coupling End (Yellow)
KJD10194-7 Test Fitting
→NOTE:
Before bleeding the brakes, see Bleeding the Brakes (Power-Fill Brakes and
MFWD and Disk Brake) orBleeding the Brakes (Brake Valve without PowerFill)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).
[3] - Run engine until the air brake system reaches its operating pressure.
[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.
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Section 60 page 217
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
[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).
<- Go to Section TOC
Section 60 page 218
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 31: Air Brakes from Serial No. 398656
Checking the Single-Line Brakes
LEGEND:
A
B
C
D
KJD10194-1 pressure gauge
KJD10194-2 hose
KJD10194-3 coupler (black)
KJD10194-6 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] - Connect pressure test kit KJD10194 to single-line air brake coupler (black).
[3] - Run engine until the air brake system reaches its operating pressure.
[4] - Read pressure with handbrake and foot brakes not applied.
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)
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Section 60 page 219
TM4756-REPAIR MANUAL
Section 60 - STEERING AND BRAKES
Group 40: AutoTrac
Support the tractor safely and remove the left rear wheel.
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 cer