Case IH Tractor Magnum and MX215,MX245,MX275,MX305 Series Service Manual – PDF DOWNLOAD

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Case IH Tractor Magnum and MX215,MX245,MX275,MX305 Series Service Manual

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Case IH Tractor Magnum and MX215,MX245,MX275,MX305 Series Service Manual_87710915
Size : 243 MB
Format : PDF
Language : English
Number of Pages : 2552 pages
Brand: Case IH
Type of machine: Tractor
Type of document: Service Manual
Model: Magnum and MX215,MX245,MX275,MX305 Series
Part Number: 87710915

CASE IH TRACTOR MAGNUM AND MX215,MX245,MX275,MX305 SERIES SERVICE MANUAL – PDF DOWNLOAD:

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TABLE OF CONTENTS:

Case IH Tractor Magnum and MX215,MX245,MX275,MX305 Series Service Manual_87710915
BOOK 1 – General, Electrical, Engine, Steering – 87525613
STANDARD TORQUE SPECIFICATIONS SECTION 1000
TORQUE SPECIFICATIONS – METRIC HARDWARE 1000-4
TORQUE SPECIFICATIONS – STEEL HYDRAULIC FITTINGS 1000-5
TORQUE SPECIFICATIONS – STEEL HYDRAULIC FITTINGS 1000-6
SAFETY, GENERAL INFORMATION, MAINTENANCE SCHEDULE SECTION 1001
SAFETY 1001-3
GENERAL INFORMATION 1001-5
LUBRICATION/MAINTENANCE CHART 1001-6
SYSTEM CAPACITIES 1001-7
COOLING SYSTEM MODULE REMOVAL AND INSTALLATIONSECTION 2001
COOLING SYSTEM MODULE REMOVAL 2001-3
COOLING SYSTEM MODULE INSTALLATION 2001-7
ENGINE REMOVAL AND INSTALLATIONSECTION 2002
SPECIAL TORQUES 2002-3
ENGINE REMOVAL 2002-4
ENGINE INSTALLATION 2002-21
VISCOUS FAN DRIVE TESTSECTION 2003
REQUIRED TOOLS 2003-3
DIAGNOSTIC PROCEDURE 2003-4
FAN SPEED TEST 2003-7
FUEL TANK / FUEL SENDER REMOVAL AND INSTALLATIONSECTION 3001
SPECIAL TORQUES 3001-3
FUEL TANK REMOVAL AND INSTALLATION 3001-3
FUEL LEVEL SENDER REMOVAL AND INSTALLATION 3001-10
ELECTRICAL SCHEMATIC POSTER – Prior to PIN Z6RZ04001 87389708
ELECTRICAL SCHEMATIC POSTER – PIN Z6RZ04001 and After87588600
ELECTRICAL SCHEMATIC POSTER – PIN Z7RZ01521 and After87624272
ELECTRICAL SYSTEM – HOW IT WORKS AND TROUBLESHOOTINGSECTION 4001
SPECIAL TOOLS 4001-4
FUSES AND RELAY IDENTIFICATION 4001-5
Cab Fuses/Relay Location 4001-5
Engine Compartment Fuse/Relay Identification (Power Distribution Box) 4001-5
Fuse Identification 4001-6
Relays 4001-7
INSTRUMENTATION AND CONTROLS 4001-8
CONNECTOR AND COMPONENT LOCATIONS 4001-12
ELECTRICAL CONNECTORS 4001-35
ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS 4001-142
Power Distribution System Circuit Operation 4001-142
Power Distribution Circuit Troubleshooting 4001-142
Power Distribution Schematic 4001-142
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 2
POWER DISTRIBUTION SYMPTOM CHART 4001-143
Diagnostic Tests 4001-144
AUDIO SYSTEM 4001-146
Audio System Circuit Operation 4001-146
Audio System Circuit Troubleshooting 4001-146
Audio System Symptom Chart 4001-146
Audio System Diagnostic Tests 4001-148
CHARGING SYSTEM 4001-152
Charging System Circuit Operation 4001-152
Charging System Circuit Troubleshooting 4001-152
Charging System Symptom Chart 4001-153
Charging System Diagnostic Tests 4001-154
EXTERIOR LIGHTING SYSTEM 4001-158
Exterior Lighting System Circuit Operation 4001-158
Exterior Lighting System Circuit Troubleshooting 4001-158
Exterior Lighting System Symptom Chart 4001-159
Exterior Lighting System Diagnostic Tests 4001-159
INSTRUMENTATION AND WARNING SYSTEM 4001-164
Instrumentation and Warning System Circuit Troubleshooting 4001-164
Instrumentation and Warning System Symptom Chart 4001-164
Instrumentation and Warning System Diagnostic Tests 4001-165
INTERIOR LIGHTING AND HORN SYSTEM 4001-168
Interior Lighting and Horn System Circuit Operation 4001-168
Interior Lighting and Horn System Circuit Troubleshooting 4001-168
Interior Lighting and Horn System Symptom Chart 4001-169
Interior Lighting and Horn System Diagnostic Tests 4001-169
POWER MIRROR SYSTEM 4001-173
Power Mirror Circuit Operation 4001-173
Power Mirror Circuit Troubleshooting 4001-173
Power Mirror System Symptom Chart 4001-174
Power Mirror System Diagnostic Tests 4001-176
POWER SEAT SYSTEM 4001-185
Power Seat System Circuit Operation 4001-185
Power Seat System Circuit Troubleshooting 4001-185
Power Seat System Symptom Chart 4001-186
Power Seat System Diagnostic Tests 4001-187
STARTING SYSTEM 4001-191
Starting System Circuit Operation 4001-191
Starter Motor Circuit Troubleshooting 4001-191
Starting System Symptom Chart 4001-191
Starting System Diagnostic Tests 4001-193
WIPER/WASHER SYSTEM 4001-198
Wiper/Washer System Circuit Operation 4001-198
Wiper/Washer System Circuit Troubleshooting 4001-198
Wiper/Washer System Symptom Chart 4001-199
Wiper/Washer System Diagnostic Tests 4001-200
STEERING COLUMN AND STEERING HAND PUMPSECTION 5001
SPECIAL TOOLS 5001-2
SPECIAL TORQUES 5001-3
STEERING COLUMN AND STEERING HAND PUMP 5001-3
REMOVAL 5001-3
STEERING HAND PUMP SERVICE 5001-7
STEERING COLUMN ASSEMBLY 5001-9
INSTALLATION 5001-10
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 3
BOOK 1A – Electrical (continued) – 87611218
ELECTRICAL SYSTEM – HOW IT WORKS AND TROUBLESHOOTING, PIN Z6RZ04001 AND AFTER
SPECIAL TOOLS 4002-4
FUSES AND RELAY IDENTIFICATION 4002-5
Cab Fuses/Relay Location 4002-5
Engine Compartment Fuse/Relay Identification (Power Distribution Box) 4002-5
Fuse Identification 4002-6
Relays 4002-7
INSTRUMENTATION AND CONTROLS 4002-8
CONNECTOR AND COMPONENT LOCATIONS 4002-12
ELECTRICAL CONNECTORS 4002-34
ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS 4002-141
Power Distribution System Circuit Operation 4002-141
Power Distribution Circuit Troubleshooting 4002-141
Power Distribution Schematic 4002-141
POWER DISTRIBUTION SYMPTOM CHART 4002-142
Diagnostic Tests 4002-143
AUDIO SYSTEM 4002-145
Audio System Circuit Operation 4002-145
Audio System Circuit Troubleshooting 4002-145
Audio System Symptom Chart 4002-145
Audio System Diagnostic Tests 4002-147
CHARGING SYSTEM 4002-151
Charging System Circuit Operation 4002-151
Charging System Circuit Troubleshooting 4002-151
Charging System Symptom Chart 4002-152
Charging System Diagnostic Tests 4002-153
EXTERIOR LIGHTING SYSTEM 4002-157
Exterior Lighting System Circuit Operation 4002-157
Exterior Lighting System Circuit Troubleshooting 4002-157
Exterior Lighting System Symptom Chart 4002-158
Exterior Lighting System Diagnostic Tests 4002-158
INSTRUMENTATION AND WARNING SYSTEM 4002-163
Instrumentation and Warning System Circuit Troubleshooting 4002-163
Instrumentation and Warning System Symptom Chart 4002-163
Instrumentation and Warning System Diagnostic Tests 4002-164
INTERIOR LIGHTING AND HORN SYSTEM 4002-167
Interior Lighting and Horn System Circuit Operation 4002-167
Interior Lighting and Horn System Circuit Troubleshooting 4002-167
Interior Lighting and Horn System Symptom Chart 4002-168
Interior Lighting and Horn System Diagnostic Tests 4002-168
POWER MIRROR SYSTEM 4002-172
Power Mirror Circuit Operation 4002-172
Power Mirror Circuit Troubleshooting 4002-172
Power Mirror System Symptom Chart 4002-173
Power Mirror System Diagnostic Tests 4002-175
POWER SEAT SYSTEM 4002-184
Power Seat System Circuit Operation 4002-184
Power Seat System Circuit Troubleshooting 4002-184
Power Seat System Symptom Chart 4002-185
Power Seat System Diagnostic Tests 4002-186
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 4
STARTING SYSTEM 4002-190
Starting System Circuit Operation 4002-190
Starter Motor Circuit Troubleshooting 4002-190
Starting System Symptom Chart 4002-190
Starting System Diagnostic Tests 4002-192
WIPER/WASHER SYSTEM 4002-197
Wiper/Washer System Circuit Operation 4002-197
Wiper/Washer System Circuit Troubleshooting 4002-197
Wiper/Washer System Symptom Chart 4002-198
Wiper/Washer System Diagnostic Tests 4002-199
BOOK 1B – Electrical (Continued) – 87678524
ELECTRICAL SCHEMATIC POSTER – PIN Z7RZ01521 and After87624272
ELECTRICAL SYSTEM – HOW IT WORKS AND TROUBLESHOOTING,
PIN Z7RZ01521 AND AFTER SECTION 4003
SPECIAL TOOLS 4003-4
FUSES AND RELAY IDENTIFICATION 4003-5
Cab Fuses/Relay Location 4003-5
Engine Compartment Fuse/Relay Identification (Power Distribution Box) 4003-5
Fuse Identification 4003-6
Relays 4003-7
INSTRUMENTATION AND CONTROLS 4003-8
CONNECTOR AND COMPONENT LOCATIONS 4003-12
Cab Exterior 4003-12
Cab Interior 4003-15
Engine/Engine Compartment 4003-20
Transmission 4003-27
Hitch System 4003-31
ELECTRICAL CONNECTORS 4003-33
ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS 4003-141
Power Distribution System Circuit Operation 4003-141
Power Distribution Circuit Troubleshooting 4003-141
Power Distribution Schematic 4003-141
POWER DISTRIBUTION SYMPTOM CHART 4003-142
Diagnostic Tests 4003-143
AUDIO SYSTEM 4003-147
Audio System Circuit Operation 4003-147
Audio System Circuit Troubleshooting 4003-147
Audio System Symptom Chart 4003-147
Audio System Diagnostic Tests 4003-149
CHARGING SYSTEM 4003-153
Charging System Circuit Operation 4003-153
Charging System Circuit Troubleshooting 4003-153
Charging System Symptom Chart 4003-154
Charging System Diagnostic Tests 4003-155
EXTERIOR LIGHTING SYSTEM 4003-159
Exterior Lighting System Circuit Operation 4003-159
Exterior Lighting System Circuit Troubleshooting 4003-159
Exterior Lighting System Symptom Chart 4003-160
Exterior Lighting System Diagnostic Tests 4003-160
INSTRUMENTATION AND WARNING SYSTEM 4003-165
Instrumentation and Warning System Circuit Troubleshooting 4003-165
Instrumentation and Warning System Symptom Chart 4003-165
Instrumentation and Warning System Diagnostic Tests 4003-166
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 5
INTERIOR LIGHTING AND HORN SYSTEM 4003-169
Interior Lighting and Horn System Circuit Operation 4003-169
Interior Lighting and Horn System Circuit Troubleshooting 4003-169
Interior Lighting and Horn System Symptom Chart 4003-170
Interior Lighting and Horn System Diagnostic Tests 4003-170
POWER MIRROR SYSTEM 4003-174
Power Mirror Circuit Operation 4003-174
Power Mirror Circuit Troubleshooting 4003-174
Power Mirror System Symptom Chart 4003-175
Power Mirror System Diagnostic Tests 4003-177
POWER SEAT SYSTEM 4003-186
Power Seat System Circuit Operation 4003-186
Power Seat System Circuit Troubleshooting 4003-186
Power Seat System Symptom Chart 4003-187
Power Seat System Diagnostic Tests 4003-188
STARTING SYSTEM 4003-192
Starting System Circuit Operation 4003-192
Starter Motor Circuit Troubleshooting 4003-192
Starting System Symptom Chart 4003-192
Starting System Diagnostic Tests 4003-194
WIPER/WASHER SYSTEM 4003-199
Wiper/Washer System Circuit Operation 4003-199
Wiper/Washer System Circuit Troubleshooting 4003-199
Wiper/Washer System Symptom Chart 4003-200
Wiper/Washer System Diagnostic Tests 4003-201
BOOK 2 – Power Train – 87678525
POWERSHIFT TRANSMISSION SYSTEM – HOW IT WORKS AND TROUBLESHOOTINGSECTION 6000
TRANSMISSION SYSTEM INTRODUCTION 6000-3
TRANSMISSION SYSTEM CONTROLS 6000-5
TRANSMISSION SYSTEM COMPONENTS 6000-6
TRANSMISSION LUBE AND DISTRIBUTION TUBES 6000-8
POWERSHIFT TRANSMISSION CLUTCH LAYOUT 6000-10
POWERSHIFT VALVE CLUTCH ENGAGEMENTS 6000-11
POWER FLOW (REVERSE SPEEDS) 6000-30
POWER FLOW (REVERSE SPEEDS) 6000-32
POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) 6000-34
POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) 6000-40
INCHING VALVE OPERATION 6000-42
INSTRUMENTATION CLUSTER – TRANSMISSION LEAKAGE CHECK 6000-46
MASTER CLUTCH PRESSURE CHECK 6000-49
TRANSMISSION INPUT SHAFT AND DRIVE PLATESECTION 6001
SPECIAL TORQUES 6001-3
TRANSMISSION INPUT SHAFT AND DRIVE PLATE REMOVAL 6001-4
TRANSMISSION INPUT SHAFT AND DRIVE PLATE INSTALLATION 6001-8
INPUT DROP BOXSECTION 6002
SPECIAL TOOLS 6002-3
SPECIAL TORQUES 6002-3
INPUT DROP BOX 6002-4
DISASSEMBLY 6002-6
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 6
ENGINE FRAME AND DROP BOX SPLITSECTION 6003
SPECIAL TORQUES 6003-3
SPECIAL TOOLS 6003-3
ENGINE FRAME AND DROP BOX SPLIT 6003-4
REMOVAL 6003-4
INSTALLATION 6003-6
SPEED TO RANGE TRANSMISSION SPLIT SECTION 6005
SPECIAL TOOLS 6005-3
SPECIAL TORQUES 6005-3
SPEED TO RANGE TRANSMISSION SPLIT 6005-4
REMOVAL 6005-4
INSTALLATION 6005-7
SPEED TRANSMISSIONSECTION 6006
PICTORIAL INDEX – SPEED TRANSMISSION 6006-3
SPECIFICATIONS 6006-4
SPECIAL TORQUES 6006-4
TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR 6006-4
SPECIAL TOOLS 6006-5
SPEED TRANSMISSION WITH CREEP OPTION 6006-6
ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH 6006-14
TRANSMISSION ASSEMBLY WITH CREEP OPTION 6006-78
TRANSMISSION ASSEMBLY WITHOUT CREEP OPTION 6006-80
RANGE TRANSMISSION TO REAR FRAME SPLITSECTION 6007
SPECIAL TOOLS 6007-3
SPECIAL TORQUES 6007-3
RANGE TRANSMISSION TO REAR FRAME SPLIT 6007-4
DISASSEMBLY 6007-4
ASSEMBLY 6007-7
RANGE TRANSMISSION SECTION 6008
SPECIFICATIONS 6008-3
TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR 6008-3
SPECIAL TORQUES 6008-3
SPECIAL TOOLS 6008-4
RANGE TRANSMISSION 6008-5
Removing the Shaft Master Clutch 6008-5
Removing the Input Shaft, Countershaft and Mechanical Front Drive (MFD) / Park Brake Assembly 6008-7
Disassembly of the Master Clutch 6008-12
Exploded View of the Master Clutch 6008-14
Assembly of the Master Clutch 6008-15
Disassembly of the Range Transmission Input Shaft 6008-16
Exploded View of the Range Transmission Input Shaft 6008-22
Assembly of the Range Transmission Input Shaft 6008-23
Cross-Section of Input Shaft 6008-32
Disassembly of the Range Transmission Countershaft 6008-33
Exploded View of the Range Transmission Countershaft 6008-37
Assembly of the Range Transmission Countershaft 6008-38
Mechanical Front Drive (MFD) – Emergency Brake Disassembly 6008-45
Exploded View of MFD and Emergency Brake 6008-51
Assembly of the MFD / Emergency Brake 6008-52
Exploded View of the Range Transmission Countershaft, Input Shaft, and MFD Input Shaft 6008-66
Installing the Range Transmission Countershaft, Input Shaft,
and MFD Input Shaft into the Range Transmission Housing 6008-67
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 7
SETTING THE END PLAY OF THE RANGE TRANSMISSION
COUNTERSHAFT AND INPUT SHAFT 6008-73
Installing the Range Input Master Clutch 6008-75
TRANSMISSION CONTROL VALVES AND INCHING VALVE SECTION 6009
SPECIAL TORQUES 6009-3
POWERSHIFT TRANSMISSION CONTROL VALVES 6009-3
TRANSMISSION CONTROL VALVE CONFIGURATION 6009-4
INCHING VALVE 6009-15
REAR FRAMESECTION 6011
(NOTE: Book 2A contains updated information in Section 6011 Use Section 6011 in Book 2A in place of this original
section)
HYDRAULIC PUMP DRIVE SECTION 6012
SPECIAL TORQUES 6012-3
SPECIFICATIONS 6012-3
PUMP DRIVE 6012-3
Removal 6012-3
Disassembly 6012-4
Assembly 6012-7
Installation 6012-12
MECHANICAL FRONT DRIVE (MFD) CONTROL SYSTEM – HOW IT WORKS SECTION 6013
MECHANICAL FRONT DRIVE (MFD) 6013-3
ELECTRONIC MFD CONTROL 6013-5
MFD CONTROL MODES 6013-7
MFD FUNCTIONAL TESTS 6013-8
MFD Valve 6013-9
Solenoid Cartridge Valve 6013-9
TROUBLESHOOTING 6013-10
DIFFERENTIAL LOCK CONTROL SYSTEM – HOW IT WORKSSECTION 6014
ELECTRONIC DIFFERENTIAL LOCK CONTROL 6014-5
DIFFERENTIAL LOCK CONTROL MODES 6014-7
DIFFERENTIAL LOCK CONTROL 6014-8
DIFFERENTIAL LOCK FUNCTIONAL TESTS 6014-9
TROUBLESHOOTING 6014-12
PTO/DIFFERENTIAL LOCK VALVE CIRCUIT 6014-15
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 8
BOOK 2A – Power Train (Continued) – 87710918
REAR FRAMESECTION 6011
SPECIFICATIONS 6011-3
SPECIAL TORQUES 6011-3
SPECIAL TOOLS 6011-3
DIFFERENTIAL 6011-4
Removal 6011-4
Disassembly 6011-10
PINION SHAFT 6011-14
Removal and Disassembly 6011-14
Assembly and Installation 6011-16
HEAVY DUTY PINION SHAFT 6011-23
Removal and Disassembly 6011-23
Assembly and Installation 6011-25
DIFFERENTIAL ASSEMBLY 6011-31
DIFFERENTIAL INSTALLATION 6011-36
ADJUSTING THE DIFFERENTIAL PRELOAD 6011-43
ADJUSTING THE RING AND PINION BACKLASH 6011-45
BEVEL PINION AND GEAR TOOTH CONTACT CHECK 6011-46
BOOK 3 – Power Train (Continued), Brakes – 87689443
MFD OUTPUT SHAFT SECTION 6015
SPECIAL TORQUES 6015-3
MFD OUTPUT SHAFT 6015-4
MFD DRIVE SHAFTSECTION 6016
SPECIAL TORQUES 6016-3
MFD DRIVE SHAFT REMOVAL 6016-4
MFD DRIVE SHAFT INSTALLATION 6016-6
LIMITED SLIP MFD DIFFERENTIAL SECTION 6017
SPECIFICATIONS 6017-2
SPECIAL TORQUES 6017-2
SPECIAL TOOLS 6017-2
DIFFERENTIAL CARRIER ASSEMBLY REMOVAL 6017-3
DIFFERENTIAL DISASSEMBLY 6017-4
Pinion Disassembly 6017-8
DIFFERENTIAL ASSEMBLY 6017-11
DIFFERENTIAL CARRIER ASSEMBLY 6017-15
Pinion Position and Assembly 6017-15
Shim Pack Thickness Chart 6017-16
Setting The Pinion Depth 6017-17
Adjusting Bearing Preload 6017-20
DIFFERENTIAL INSTALLATION 6017-22
Checking Backlash 6017-23
Ring Gear and Pinion Tooth Pattern Interpretation 6017-25
Installation of Carrier Assembly to Axle Housing 6017-27
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 9
LOCKING MFD DIFFERENTIAL SECTION 6018
SPECIFICATIONS 6018-3
SPECIAL TORQUES 6018-3
SPECIAL TOOLS 6018-3
REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY 6018-4
REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING 6018-5
DISASSEMBLY OF THE DIFFERENTIAL 6018-7
PINION DISASSEMBLY 6018-9
ASSEMBLY OF THE DIFFERENTIAL 6018-12
DIFFERENTIAL CARRIER ASSEMBLY 6018-16
SETTING THE PINION DEPTH 6018-18
ADJUSTING BEARING PRELOAD 6018-21
DIFFERENTIAL INSTALLATION 6018-23
REAR AXLE AND PLANETARIESSECTION 6019
SPECIAL TOOLS 6019-3
SPECIAL TORQUES 6019-5
SPECIFICATIONS 6019-5
GENERAL INFORMATION 6019-5
REAR AXLE 6019-6
AXLE HOUSING DISASSEMBLY 6019-9
PLANETARY DISASSEMBLY 6019-11
DIFFERENTIAL CARRIER SEAL REPLACEMENT 6019-13
PLANETARY ASSEMBLY – THREE PIN 6019-14
PLANETARY ASSEMBLY – FOUR PIN 6019-15
AXLE HOUSING ASSEMBLY 6019-18
HOW TO DETERMINE RAM PRESSURE 6019-23
AXLE INSTALLATION 6019-26
AXLE SEAL WEAR SLEEVE INSTALLATION (4-Inch Axle Only) 6019-30
POWER TAKE OFF CONTROL SYSTEM – HOW IT WORKS SECTION 6020
POWER TAKE OFF 6020-3
ELECTRONIC PTO CONTROL 6020-4
PTO SYSTEM CONTROL 6020-7
PTO CONTROL MODES 6020-8
PTO VALVE OIL SUPPLY 6020-10
PTO/DIFFERENTIAL LOCK VALVE 6020-11
TROUBLESHOOTING 6020-12
PTO CLUTCH ENGAGED 6020-13
TROUBLESHOOTING 6020-14
MFD PLANETARY HUB, STEERING KNUCKLE AND DRIVE SHAFTSECTION 6022
SPECIFICATIONS 6022-3
SPECIAL TORQUES 6022-3
SPECIAL TOOLS 6022-3
PLANETARY HUB DISASSEMBLY 6022-4
STEERING KNUCKLE AND KINGPIN DISASSEMBLY 6022-9
AXLE DRIVE SHAFT DISASSEMBLY 6022-13
AXLE SHAFT ASSEMBLY 6022-14
KINGPIN ASSEMBLY 6022-16
STEERING KNUCKLE ASSEMBLY 6022-20
PLANETARY HUB ASSEMBLY 6022-24
Ten Bolt Axle Only 6022-29
Twelve Bolt Axle Only 6022-33
All Axles 6022-38
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 10
SUSPENSION MFD AXLESECTION 6023
SPECIAL TORQUES 6023-2
SUSPENSION MFD AXLE 6023-3
Disassembly 6023-3
Assembly 6023-13
Position Sensor Adjustment 6023-25
SUSPENSION MFD AXLE SYSTEM – HOW IT WORKS AND TROUBLESHOOTINGSECTION 6024
SUSPENDED MFD AXLE OPERATION 6024-3
SUSPENDED MFD AXLE- CALIBRATION MODE 6024-9
ERROR TABLE 6024-11
SUSPENDED MFD AXLE- MANUAL OPERATION MODE (TEST MODE) 6024-13
SUSPENDED MFD AXLE- DEMONSTRATION MODE 6024-16
PTO CLUTCH ASSEMBLY SINGLE, REVERSIBLE AND DUAL SPEEDSECTION 6025
(NOTE: Book 3A contains updated information in Section 6025 Use Section 6025 in Book 3A in place of this original
section)
BRAKE VALVESECTION 7001
SPECIAL TORQUES 7001-2
BRAKE VALVE 7001-3
Removal 7001-3
Disassembly 7001-4
Assembly 7001-6
Installation 7001-8
BRAKE CYLINDERSSECTION 7002
SPECIAL TORQUES 7002-3
SPECIFICATIONS 7002-3
BRAKE CYLINDERS 7002-3
Disassembly 7002-3
Assembly 7002-5
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 11
BOOK 3A – Power Train (Continued), Brakes – 87710919
PTO CLUTCH ASSEMBLY SINGLE, REVERSIBLE AND DUAL SPEEDSECTION 6025
SPECIAL TOOLS 6025-3
SPECIAL TORQUES 6025-3
PTO CLUTCH ASSEMBLY 6025-4
General 6025-4
PTO CLUTCH SERVICE 6025-4
Removal 6025-4
Disassembly 6025-6
Assembly 6025-16
Exploded View of PTO Clutch 6025-16
Cross Section of PTO Clutch and Output Shaft Assembly 6025-33
SINGLE SPEED REVERSIBLE SHAFT PTO 6025-34
Disassembly 6025-34
Assembly 6025-37
Exploded View of PTO Output Shaft and Driven Gear Assembly 6025-37
SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR 6025-41
Removal 6025-41
Assembly 6025-43
Reversible PTO Output Shaft Bearing Adjustment 6025-45
SINGLE SPEED REVERSIBLE SHAFT PTO 6025-47
Cross Section of PTO Output Shaft Assembly 6025-47
BOOK 4 – Hydraulics, Chassis – 87710920
HYDRAULIC SCHEMATIC – NORTH AMERICAN87518874
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC SECTION 8000
SIMPLE SCHEMATIC 8000-13
COMMON SYMBOLS 8000-15
HYDRAULIC SYSTEM – HOW IT WORKS AND TROUBLESHOOTING SECTION 8001
GENERAL INTRODUCTION 8001-3
REAR CHARGE/LUBE PUMP PRESSURE TEST 8001-19
REAR CHARGE/LUBE PUMP FLOW TEST 8001-21
REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE 8001-22
FRONT/REGULATED SYSTEM PUMP FLOW TEST 8001-26
STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE 8001-28
STEERING SYSTEM PROBLEMS 8001-30
PRIORITY AND REGULATOR VALVE 8001-32
PFC AXIAL PISTON PUMP 8001-35
PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE 8001-45
PFC PISTON PUMP FLOW CHECK AT REMOTE COUPLERS 8001-46
PFC PISTON PUMP FLOW TEST 8001-48
TWINFLOW PFC PISTON PUMP FLOW TEST 8001-50
PFC PISTON PUMP FLOW COMPENSATOR SETTING 8001-52
PUMP COMPENSATOR VALVE INSPECTION 8001-54
POWER BEYOND SYSTEM 8001-55
FLOW CHECK AT POWER BEYOND COUPLERS 8001-57
PFC PUMP OPERATIONAL PROBLEMS 8001-59
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 12
PTO AND DIFFERENTIAL LOCK VALVESECTION 8002
SPECIAL TORQUES 8002-2
SPECIFICATIONS 8002-2
PTO AND DIFFERENTIAL LOCK VALVE 8002-3
REMOTE VALVE AND COUPLER SERVICESECTION 8003
SPECIAL TORQUES 8003-2
REMOTE VALVE AND COUPLER SERVICE 8003-3
REMOTE VALVE REMOVAL AND SERVICE 8003-5
REMOTE COUPLERS 8003-13
REMOTE HYDRAULIC SYSTEM – HOW IT WORKS AND TROUBLESHOOTINGSECTION 8004
REMOTE HYDRAULIC SYSTEM INTRODUCTION 8004-3
REMOTE VALVE SYSTEM COMPONENTS 8004-5
REMOTE VALVE SYSTEM CONTROLS 8004-11
REMOTE VALVE OPERATION 8004-15
REMOTE VALVE PROBLEMS AND WHERE TO LOOK 8004-24
REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION 8004-26
PFC PISTON PUMP FLOW CHECK AT REMOTE COUPLERS 8004-27
REMOTE VALVE SYSTEM TESTING 8004-29
PFC VALVE HIGH PRESSURE TEST 8004-30
PFC HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE 8004-31
STANDARD PUMP COMPENSATOR VALVE INSPECTION 8004-32
REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK 8004-33
REMOTE VALVE COUPLER TEST 8004-34
LOAD CHECK INSPECTION 8004-35
OPERATIONAL PROBLEMS 8004-36
PRIORITY AND REGULATOR VALVESECTION 8005
SPECIAL TORQUES 8005-3
PRIORITY VALVE AND REGULATOR 8005-4
Removal 8005-4
Disassembly 8005-6
Assembly 8005-9
Installation 8005-12
CROSS SECTION OF PRIORITY AND REGULATOR VALVE 8005-14
CHARGE PUMPSECTION 8006
CHARGE PUMP 8006-3
Removal 8006-3
Installation 8006-4
PFC PISTON PUMP AND HYDRAULIC FILTERSECTION 8007
SPECIAL TORQUES 8007-3
PFC PISTON PUMP 8007-3
Removal 8007-3
Installation 8007-5
HITCH SYSTEM – HOW IT WORKSSECTION 8008
THREE POINT HITCH 8008-3
ELECTRONIC HITCH CONTROL 8008-4
HITCH CONTROL VALVE 8008-14
General 8008-14
Raise and Lower Solenoids 8008-14
Raise and Lower Pilot Spools 8008-14
Raise Spool 8008-14
Lower Poppet 8008-14
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 13
Load Check Poppet 8008-14
Manual Raise or Lower Control Pins 8008-14
Overload Relief Valve 8008-14
Neutral Function and Troubleshooting 8008-16
Raise Function and Troubleshooting 8008-18
Lower Function and Troubleshooting 8008-20
Troubleshooting Hitch Leaks Down Over Time 8008-22
Hitch Leak Down Inspection Points 8008-23
SETUP / ADJUSTMENT SEQUENCE 8008-24
HITCH CONTROL VALVE SECTION 8009
Removal 8009-3
Disassembly 8009-5
Assembly 8009-7
Installation 8009-9
HITCH CONTROL VALVE CROSS SECTION 8009-11
TRACTOR HITCH SECTION 8010
SPECIAL TORQUES 8010-3
TRACTOR HITCH 8010-3
EDC PIN ASSEMBLY 8010-20
POTENTIOMETER (HITCH POSITION SENSOR) 8010-21
CAM SWAY LIMITER 8010-23
CAM BUMPERS FOR DRAFT ARM 8010-25
DRAWBAR, HIGH VERTICAL CAPACITY 8010-26
TRAILER BRAKE SYSTEMS – HOW IT WORKS SECTION 8011
HYDRAULIC BRAKE SYSTEMS 8011-4
European / NAO Hydraulic Trailer Brakes 8011-4
Italian Hydraulic Trailer Brakes 8011-8
PNEUMATIC BRAKE SYSTEMS 8011-11
Pneumatic Trailer Brakes 8011-11
European Pneumatic Trailer Brakes 8011-11
Italian Pneumatic Trailer Brakes 8011-14
ROW (Rest of World) Pneumatic Trailer Brakes (NAR, ANZ, CIS, LAR, EEAA) 8011-17
Italian Hydraulic Trailer Brake Schematic 8011-19
Italian Pneumatic Trailer Brake Schematic 8011-21
PEDAL AND PEDAL SWITCH ADJUSTMENTSSECTION 9001
INCHING PEDAL SWITCH ADJUSTMENT 9001-3
BRAKE PEDAL ADJUSTMENTS 9001-4
CAB RAISE / REMOVAL AND INSTALLATIONSECTION 9005
SPECIAL TORQUES 9005-3
SPECIAL TOOLS 9005-3
CAB RAISE PROCEDURE 9005-4
CAB LOWERING PROCEDURE 9005-7
CAB REMOVAL 9005-10
CAB INSTALLATION 9005-17
HOOD REMOVAL SECTION 9008
Hood Removal 9008-3
Hood Installation 9008-4
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 14
BOOK 5 – Air Conditioning – 87525617
AIR CONDITIONING SYSTEM – TROUBLESHOOTING AND FAULT CODESSECTION 9010
SAFETY PROCEDURES 9010-5
SPECIAL TOOLS 9010-6
A/C THERMAL OPERATION 9010-7
A/C SYSTEM COMPONENTS 9010-9
Cab HVAC Box Components – Automatic Temperature Control 9010-9
Chassis Components 9010-11
AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION 9010-12
Operation Modes 9010-15
Automatic Mode 9010-15
Defog Mode 9010-15
Automatic Operation Summary 9010-16
Defog/Dehumidify Operation Summary 9010-17
ATC FAULT CODES 9010-18
ATC Fault Code 111 9010-18
ATC Fault Code 112 9010-19
ATC Fault Code 115 9010-19
ATC Fault Code 116 9010-20
ATC Fault Code 120 9010-20
ATC Fault Code 121 9010-21
ATC Fault Code 122 9010-21
ATC Fault Code 125 9010-22
ATC Fault Code 126 9010-22
ATC Fault Code 127 9010-23
ATC Fault Code 128 9010-23
ATC Fault Code 129 9010-24
ATC Fault Code 130 9010-24
ATC Fault Code 131 9010-25
ATC Fault Code 132 9010-25
ATC Fault Code 133 9010-26
ATC Fault Code 134 9010-26
LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES 9010-27
Controller-Based Resistance Tests 9010-27
ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) 9010-29
ATC Field Reported Symptoms/Causes 9010-32
COMPRESSOR AND CLUTCH 9010-33
Operational Check 9010-33
Electrical Test 9010-36
Compressor Clutch Control Circuit Test Procedure 9010-36
Service Note: Adjusting Clutch Air Gap 9010-38
HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT 9010-39
Background 9010-39
Possible Failure Modes – Fault Codes 129 and 134 9010-40
Electrical Test 9010-41
High Pressure Switch and Circuit Test 9010-41
Low Pressure Switch and Circuit Test 9010-42
HEATER CONTROL VALVE 9010-43
Operational Check 9010-43
Electrical Test 9010-44
Heater Control Valve Power, Signal and Ground Test 9010-44
BLOWER SPEED AND TEMPERATURE CONTROL POTENTIOMETERS 9010-45
Background 9010-45
Possible Failure Modes – Fault Codes 120, 121 9010-45
Electrical Test 9010-46
Common Control Potentiometer and Circuit Test Procedure 9010-46
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 15
BLOWER AND BLOWER SPEED DRIVER 9010-47
Background 9010-47
Power, Signal and Ground Circuit 9010-47
Possible Failure Modes 9010-47
Blower Motor/Blower Driver Power, Signal and Ground Test 9010-48
CAB AND EVAPORATOR TEMPERATURE SENSORS 9010-49
Background 9010-49
Electrical Test 9010-51
Power Circuit 9010-51
Possible Failure Modes – Fault Codes 111, 115 and 116 9010-52
Cab Temperature Sensor and Circuit Test 9010-53
Evaporator Temperature Sensor and Circuit Test 9010-54
CONTROLLER POWER, GROUND, AND ATC SWITCH 9010-56
Background 9010-56
Power and Ground Circuit 9010-56
Possible Failure Modes 9010-56
Controller Power Supply and Ground Test 9010-56
ATC Switch and Circuit Test 9010-57
Defog/Defrost Switch and Circuit Test 9010-57
CAB PRESSURIZER BLOWER 9010-58
Background 9010-58
Power and Ground 9010-58
Cab Pressurizer Blower & Relay Power Supply and Ground Test 9010-58
ACCESSING THE HVAC BOX 9010-59
STANDARD AIR CONDITIONING (STD) TROUBLESHOOTING 9010-60
Standard A/C Operation 9010-61
Smart Pressure Switch Cycling System 9010-61
Standard A/C Controls and Their Function 9010-62
Symptom-Based Standard A/C Troubleshooting 9010-63
Controller Power, Ground And A/C Switch 9010-65
Background 9010-65
Power and Ground Circuit 9010-65
Possible Failure Modes 9010-65
Controller Power Supply and Ground Test 9010-65
A/C Switch and Circuit Test 9010-66
Compressor And Clutch 9010-67
Operational Check 9010-67
Electrical Test – Compressor Clutch 9010-70
Clutch Relay Power Supply and Ground Test 9010-71
Service Note: Adjusting Clutch Air Gap 9010-72
High And Low Pressure Switch Clutch Latching Circuit 9010-73
Background 9010-73
Possible Failure Modes – Flashing Pressure Warning Lamp 9010-74
Electrical Test – Pressure Switches 9010-75
High Pressure Switch and Circuit Test 9010-75
Low Pressure Switch and Circuit Test 9010-76
Heater Control Valve 9010-77
Operational Check 9010-77
Electrical Test 9010-78
Temperature Control Potentiometer 9010-79
Background 9010-79
Electrical Test 9010-79
Blower Speed Switch And Blower Motor 9010-80
Background 9010-80
Power and Ground Circuit 9010-80
Possible Failure Modes 9010-80
Blower Speed Switch and Power Circuit Test 9010-81
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 16
Blower Motor Power, and Control Circuit Test 9010-81
Evaporator Temperature Sensor 9010-83
Background 9010-83
Electrical Test – Sensor 9010-83
Power Circuit 9010-84
Service Note: Too Little Cooling/Too Much Heating without Symptoms 9010-84
Evaporator Temperature Sensor and Circuit Test 9010-84
Controller Power, Ground And A/C Switch 9010-86
Background 9010-86
Power and Ground Circuit 9010-86
Possible Failure Modes 9010-86
Controller Power Supply and Ground Test 9010-86
A/C Switch and Circuit Test 9010-87
Cab Pressurizer Blower 9010-88
Background 9010-88
Power and Ground 9010-88
Cab Pressurizer Blower & Relay Power Supply and Ground Test 9010-89
AIR CONDITIONER SYSTEM SERVICESECTION 9020
SPECIFICATIONS 9020-4
SPECIAL TORQUES 9020-4
SPECIAL TOOLS 9020-4
SAFETY PROCEDURES 9020-9
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY 9020-10
RECOVERING PURE 134A REFRIGERANT 9020-12
RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 9020-16
Preparing the Tank 9020-16
Recovery Process 9020-20
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING 9020-26
AIR CONDITIONING TEMPERATURE/PRESSURE CHART 9020-33
LEAK DETECTION 9020-34
Electronic Testing with OEM1437 9020-35
Florescent Leak Detection 9020-36
Fluorescent Dye Injection 9020-36
Fluorescent Leak Testing 9020-42
A/C SYSTEM FLUSHING PROCEDURE 9020-43
Required Tools 9020-44
Precautions 9020-45
Component Flushing Procedure with Power Flush 17550 9020-46
Complete Circuit Flushing Procedure with Power Flush 17550 9020-50
Back Flushing the Thermal Expansion Valve or Refrigerant Line 9020-55
Post Flushing Procedures 9020-57
Flushing Solvent Disposal 9020-59
A/C SYSTEM COMPONENTS 9020-60
Cab HVAC Box Components – Automatic Temperature Control 9020-60
Cab HVAC Components – Standard Systems 9020-62
Chassis Components 9020-64
A/C COMPRESSOR CLUTCH 9020-65
Clutch Removal 9020-65
Exploded View of Clutch 9020-71
Compressor Clutch Replacement 9020-71
A/C COMPRESSOR 9020-79
Oil Level Check or Adjustment 9020-79
Compressor Removal 9020-82
Compressor Installation 9020-85
MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS – 87710915
87710917 – TOC – 17
CONDENSER AND RECEIVER-DRIER 9020-87
Condenser 9020-87
Receiver-Drier 9020-89
ACCESSING THE HVAC BOX 9020-90
THERMAL EXPANSION VALVE TESTING 9020-92
THERMAL EXPANSION VALVE REPLACEMENT 9020-93
EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION 9020-95
BLOWER MOTOR REPLACEMENT 9020-96
HEATER CONTROL VALVE REPLACEMENT 9020-97
EVAPORATOR/HEATER ASSEMBLY 9020-98
Evaporator/Heater Assembly Removal 9020-98
Evaporator/Heater Assembly Installation 9020-101
Post Replacement Procedures 9020-104
EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING 9020-105
BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION 9020-106
CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT 9020-107
ATC Controller 9020-107
Standard A/C Controller 9020-107
Blower Speed Driver (ATC Units Only) 9020-108
CAB AIR FILTER SERVICE 9020-109
CAB RECIRCULATION AIR FILTER SERVICE 9020-110
CAB PRESSURIZATION TEST 9020-111
CAB PRESSURIZER MOTOR REPLACEMENT 9020-113
VISCOUS FAN DRIVE 9020-116

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]