John Deere 6120 to 6420 & 6120L to 6520L Tractors Repair Manual – PDF DOWNLOAD

Description

John Deere 6120 to 6420 & 6120L to 6520L Tractors Repair Manual – PDF DOWNLOAD

DESCRIPTION :

John Deere 6120 to 6420 & 6120L to 6520L Tractors Repair Manual – PDF DOWNLOAD

For complete service information also see:
6120 to 6420
and 6120L to 6520L Tractors
Operation and Tests . . . . . . . . . . . . . . . . . . . TM4646
6120 to 6420
and 6120L to 6520L Tractors
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . TM4733
Front-Wheel Drive Axles – AS and MS
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM4687
Front-Wheel Drive Axles – 700 Series . . . . . CTM4820
POWERTECHä Diesel Engines . . . . . . . . . . CTM104
Mechanical Fuel Injection Systems . . . . . . . CTM207
Electronic Fuel Injection Systems (Level
4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM170
Electronic Fuel Injection Systems (Level
1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM284
Electronic Fuel Injection Systems (Level
11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM220
Electronic Fuel Injection Systems (Level
12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM331
Alternators and Starting Motors. . . . . . . . . . CTM77

Foreword :

This “Repair” manual is valid for the following tractor
types:
6120, 6220, 6320 and 6420
6120L, 6220L, 6320L, 6420L, 6520L

This manual is written for an experienced technician. 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. This is the safety-alert symbol.
• When you see this symbol on your machine or in this manual, be alert to potential for personal injury. Technical Manuals are concise 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.

TABLE OF CONTENTS:

John Deere 6120 to 6420 & 6120L to 6520L Tractors Repair Manual – PDF DOWNLOAD

Contents………………………………………………………………………………………………………………………………… 3
SAFETY………………………………………………………………………………………………………………………………. 7
Safety Measures…………………………………………………………………………………………………………………… 9
Recognize Safety Information……………………………………………………………………………………………………. 9
“Important” Information………………………………………………………………………………………………………… 9
“Note” Information…………………………………………………………………………………………………………….. 9
Prevent Machine Runaway………………………………………………………………………………………………………… 9
Handle Fluids Safely—Avoid Fires………………………………………………………………………………………………… 10
Prevent Battery Explosions……………………………………………………………………………………………………… 10
Prepare for Emergencies………………………………………………………………………………………………………… 10
Prevent Acid Burns…………………………………………………………………………………………………………….. 11
Avoid High-Pressure Fluids……………………………………………………………………………………………………… 12
Service Cooling System Safely…………………………………………………………………………………………………… 12
Remove Paint Before Welding or Heating…………………………………………………………………………………………… 13
Avoid Heating Near Pressurized Fluid Lines……………………………………………………………………………………….. 13
Work In Ventilated Area………………………………………………………………………………………………………… 14
Wear Protective Clothing……………………………………………………………………………………………………….. 14
Practice Safe Maintenance………………………………………………………………………………………………………. 15
Park Machine Safely……………………………………………………………………………………………………………. 15
Use Proper Lifting Equipment……………………………………………………………………………………………………. 16
Construct Dealer-Made Tools Safely………………………………………………………………………………………………. 16
Support Machine Properly……………………………………………………………………………………………………….. 16
Work in Clean Area…………………………………………………………………………………………………………….. 17
Illuminate Work Area Safely…………………………………………………………………………………………………….. 17
Service Machines Safely………………………………………………………………………………………………………… 17
Use Proper Tools………………………………………………………………………………………………………………. 18
Service Tires Safely…………………………………………………………………………………………………………… 18
Service Front-Wheel Drive Tractor Safely…………………………………………………………………………………………. 19
Avoid Eye Contact With Radar……………………………………………………………………………………………………. 19
Keep ROPS Installed Properly……………………………………………………………………………………………………. 19
Replace Safety Signs…………………………………………………………………………………………………………… 20
Dispose of Waste Properly………………………………………………………………………………………………………. 20
Live With Safety………………………………………………………………………………………………………………. 20
Safety Measures on Electronic Control Units………………………………………………………………………………………. 21
GENERAL INFORMATION…………………………………………………………………………………………………………………… 23
Specifications……………………………………………………………………………………………………………………. 25
References, Specifications……………………………………………………………………………………………………… 25
Engine Specifications………………………………………………………………………………………………………….. 26
Cooling System………………………………………………………………………………………………………………… 27
Injection pump (Lucas)…………………………………………………………………………………………………………. 27
Injection pump (Bosch VP44)…………………………………………………………………………………………………….. 28
Electronic Fuel System (Denso Injection Pump; TIER II Engines)……………………………………………………………………… 28
Electronic Fuel System (Stanadyne Injection Pump; TIER II Engines)………………………………………………………………….. 28
Air Intake System……………………………………………………………………………………………………………… 28
Electrical System……………………………………………………………………………………………………………… 29
Hydrostatic Steering System…………………………………………………………………………………………………….. 29
AutoTrac……………………………………………………………………………………………………………………… 29
Clutch……………………………………………………………………………………………………………………….. 29
AutoPowr/IVT transmission………………………………………………………………………………………………………. 30
PowrQuad and PowrQuad Plus Transmissions…………………………………………………………………………………………. 30
AutoQuad Transmission………………………………………………………………………………………………………….. 31
Power Reverser………………………………………………………………………………………………………………… 31
SyncroPlus transmission………………………………………………………………………………………………………… 32
Creeper transmission…………………………………………………………………………………………………………… 32
Rear PTO……………………………………………………………………………………………………………………… 32
Front PTO…………………………………………………………………………………………………………………….. 33
Differential assembly………………………………………………………………………………………………………….. 33
Differential lock……………………………………………………………………………………………………………… 33
Final drives………………………………………………………………………………………………………………….. 33
Front-Wheel Drive……………………………………………………………………………………………………………… 34
FWD Axle with TLS……………………………………………………………………………………………………………… 34
Cab Suspension:……………………………………………………………………………………………………………….. 34
Hydraulic Brakes………………………………………………………………………………………………………………. 34
Parking Lock………………………………………………………………………………………………………………….. 35
Hydraulic System with Axial Piston Pump………………………………………………………………………………………….. 35
Rockshaft…………………………………………………………………………………………………………………….. 35
Front Hitch…………………………………………………………………………………………………………………… 35
Ground Speeds…………………………………………………………………………………………………………………. 36
Front and Rear Wheels………………………………………………………………………………………………………….. 36
Dimensions and Weights…………………………………………………………………………………………………………. 36
Capacities……………………………………………………………………………………………………………………. 37
Handling and Storing Diesel Fuel………………………………………………………………………………………………… 39
Diesel Fuel…………………………………………………………………………………………………………………… 40
Lubricity of Diesel Fuel……………………………………………………………………………………………………….. 40
Diesel Engine Break-In Oil……………………………………………………………………………………………………… 41
Diesel Engine Oil (Engine Serial Number up to 799999)……………………………………………………………………………… 42
Diesel Engine Oil (Engine Serial Number from 800000)………………………………………………………………………………. 43
Transmission and Hydraulic Oil………………………………………………………………………………………………….. 44
Front-Wheel Drive Axle Oil……………………………………………………………………………………………………… 45
Diesel Engine Coolant………………………………………………………………………………………………………….. 46
Supplemental Coolant Additives………………………………………………………………………………………………….. 46
Grease……………………………………………………………………………………………………………………….. 47
Oil Filters…………………………………………………………………………………………………………………… 47
Mixing of Lubricants…………………………………………………………………………………………………………… 47
Lubricant Storage……………………………………………………………………………………………………………… 48
Operating in Warm Temperature Climates…………………………………………………………………………………………… 48
Alternative and Synthetic Lubricants…………………………………………………………………………………………….. 49
Unified Inch Bolt and Screw Torque Values………………………………………………………………………………………… 50
Metric Bolt and Screw Torque Values……………………………………………………………………………………………… 51
Hydraulic system inch fitting torques……………………………………………………………………………………………. 52
Hydraulic system metric fitting torques………………………………………………………………………………………….. 53
Product Identification and Sub-Assembly Serial Numbers…………………………………………………………………………….. 54
Engine serial number…………………………………………………………………………………………………………… 55
Transmission serial number……………………………………………………………………………………………………… 55
Front wheel drive axle serial number…………………………………………………………………………………………….. 55
Operator’s cab serial number……………………………………………………………………………………………………. 55
Operator’s seat serial number…………………………………………………………………………………………………… 56
Sub-assembly serial numbers…………………………………………………………………………………………………….. 56
Tune-Up………………………………………………………………………………………………………………………….. 57
Summary of References (Tune-Up)…………………………………………………………………………………………………. 57
Specifications………………………………………………………………………………………………………………… 57
Using High-Pressure Washers…………………………………………………………………………………………………….. 58
Preliminary Engine Test………………………………………………………………………………………………………… 58
Tractor Tune-Up……………………………………………………………………………………………………………….. 59
Removing and Cleaning the Primary Air Cleaner Element……………………………………………………………………………… 61
Checking the Air Cleaner Safety Element………………………………………………………………………………………….. 61
Installing the Primary Filter Element……………………………………………………………………………………………. 61
Checking the Air Intake System Connections for Leaks………………………………………………………………………………. 62
Checking the Crankcase Vent Hose for Clogging…………………………………………………………………………………….. 62
Cleaning the Radiator Grille Screen……………………………………………………………………………………………… 62
Keeping the Radiator Screen Clean……………………………………………………………………………………………….. 62
Checking the Caps on the Expansion Tank …………………………………………………………………………………………. 63
Checking the Radiator for Leaks…………………………………………………………………………………………………. 63
Checking the Engine Thermostat………………………………………………………………………………………………….. 63
Checking the Operation of the Fuel Transfer Pump………………………………………………………………………………….. 64
Checking the Fuel Filter……………………………………………………………………………………………………….. 65
Checking the Fuel Filter (Denso/Stanadyne Injection Pump; TIER II Engines)…………………………………………………………… 66
Bleeding the Fuel System……………………………………………………………………………………………………….. 66
Bleeding the Fuel System (Stanadyne Injection Pump; TIER II Engines)………………………………………………………………… 66
Bleeding the Fuel System (Denso Injection Pump; TIER II Engines) …………………………………………………………………… 67
Clean the water trap…………………………………………………………………………………………………………… 67
Run the engine until it is warm, and check engine speeds ………………………………………………………………………….. 67
Check setting of fuel injection pump…………………………………………………………………………………………….. 68
Check setting of speed control linkage ………………………………………………………………………………………….. 68
Cleaning the Battery, Cables and Battery Box with a Clean Cloth ……………………………………………………………………. 68
Checking the Neutral Start Circuit………………………………………………………………………………………………. 69
Check operation of starting motor……………………………………………………………………………………………….. 70
Checking the lighting circuit…………………………………………………………………………………………………… 70
Final engine check…………………………………………………………………………………………………………….. 70
Tractor Operation Check………………………………………………………………………………………………………… 71
Predelivery Inspection…………………………………………………………………………………………………………….. 73
Predelivery Inspection…………………………………………………………………………………………………………. 73
ENGINE………………………………………………………………………………………………………………………………. 75
Installing and Removing Components………………………………………………………………………………………………….. 77
Specifications………………………………………………………………………………………………………………… 77
Removing the Engine……………………………………………………………………………………………………………. 77
Installing the Engine………………………………………………………………………………………………………….. 86
FUEL, AIR INTAKE, COOLING AND EXHAUST SYSTEMS……………………………………………………………………………………………. 93
Speed Control…………………………………………………………………………………………………………………….. 95
Summary of References (Speed Control)……………………………………………………………………………………………. 95
General Information……………………………………………………………………………………………………………. 95
Specifications………………………………………………………………………………………………………………… 95
Adjusting the Hand Throttle Lever and Accelerator Pedal……………………………………………………………………………. 96
Adjusting the Speed Control Linkage……………………………………………………………………………………………… 97
Hand Throttle Lever—Exploded View……………………………………………………………………………………………….. 98
Accelerator Pedal on Tractors with Open Operator’s Station…………………………………………………………………………. 99
Accelerator Pedal, with Mechanical Speed Control………………………………………………………………………………….. 100
Accelerator Pedal, With Electronic Speed Control (“Cruise Control”)…………………………………………………………………. 102
Changing the Accelerator Pedal’s Potentiometer……………………………………………………………………………………. 104
Replacing the Accelerator Pedal Assembly (AutoPowr/IVT)……………………………………………………………………………. 104
Removing the Accelerator Pedal’s Potentiometer……………………………………………………………………………………. 105
Removing the Hand Throttle’s Potentiometer……………………………………………………………………………………….. 106
Fuel System………………………………………………………………………………………………………………………. 109
Summary of References (Fuel System)……………………………………………………………………………………………… 109
General Information……………………………………………………………………………………………………………. 109
Special Tool (Dealer-Fabricated)………………………………………………………………………………………………… 110
Removing the Fuel Tank…………………………………………………………………………………………………………. 110
Installing the Fuel Tank……………………………………………………………………………………………………….. 111
Replacing the Fuel Gauge Sending Unit……………………………………………………………………………………………. 112
Changing the Fuel Transfer Pump…………………………………………………………………………………………………. 114
Changing the Fuel Filter……………………………………………………………………………………………………….. 115
Bleeding the Fuel System……………………………………………………………………………………………………….. 115
Bleed the Air from the Fuel System (with Denso/Stanadyne Injection Pump)…………………………………………………………….. 116
Installing Check Valve in Fuel System……………………………………………………………………………………………. 117
Installing Fuel System Check Valve (Denso/Stanadyne Injection Pump; TIER II Engines)………………………………………………….. 118
Air Intake System…………………………………………………………………………………………………………………. 119
Air Intake System (Summary of References)………………………………………………………………………………………… 119
General Information……………………………………………………………………………………………………………. 119
Air filter – Exploded view……………………………………………………………………………………………………… 120
Replacing the Sending Unit for Air Cleaner Restriction (B02)……………………………………………………………………….. 121
Cooling System……………………………………………………………………………………………………………………. 123
Cooling System (Summary of References)…………………………………………………………………………………………… 123
General Information……………………………………………………………………………………………………………. 123
Specifications………………………………………………………………………………………………………………… 124
Removing and Installing the Ring-Shaped Cooler……………………………………………………………………………………. 124
Remove the Radiator……………………………………………………………………………………………………………. 125
Change the Fan or the Viscous Fan Drive………………………………………………………………………………………….. 130
Remove and Install the Intercooler………………………………………………………………………………………………. 131
Remove/Install the Intercooler (with TIER II Engines)……………………………………………………………………………… 132
Removing and Installing the Expansion Tank……………………………………………………………………………………….. 133
Removing and Installing the Thermostat Valve……………………………………………………………………………………… 134
Installing the Radiator………………………………………………………………………………………………………… 135
Filling the Cooling System with Coolant………………………………………………………………………………………….. 136
Relieving Tension on the Drive Belt……………………………………………………………………………………………… 138
Change the Drive Belt………………………………………………………………………………………………………….. 138
Replacing the Drive Belt Tensioner………………………………………………………………………………………………. 140
Repairing the Fan Console………………………………………………………………………………………………………. 141
Remove and Install Fan Console (with Mechanical Coolant Pump)………………………………………………………………………. 143
Cold-Weather Starting Aid………………………………………………………………………………………………………….. 145
Summary of References (Cold-Weather Starting Aids)………………………………………………………………………………… 145
Fuel Preheater………………………………………………………………………………………………………………… 145
Electrical Starting Aid………………………………………………………………………………………………………… 146
Coolant Heater………………………………………………………………………………………………………………… 146
Exhaust System……………………………………………………………………………………………………………………. 147
Summary of References (Exhaust System)…………………………………………………………………………………………… 147
General Information……………………………………………………………………………………………………………. 147
Specifications………………………………………………………………………………………………………………… 147
Exhaust to Top Right…………………………………………………………………………………………………………… 148
Exhaust to Bottom Right………………………………………………………………………………………………………… 153
ELECTRICAL SYSTEM…………………………………………………………………………………………………………………….. 155
Connectors……………………………………………………………………………………………………………………….. 161
Connectors – Summary of References………………………………………………………………………………………………. 161
Special Tools…………………………………………………………………………………………………………………. 161
General………………………………………………………………………………………………………………………. 165
Using high-pressure washers…………………………………………………………………………………………………….. 165
Disconnecting electrical circuits……………………………………………………………………………………………….. 166
Stripping Wire Ends……………………………………………………………………………………………………………. 167
Installing a Terminal………………………………………………………………………………………………………….. 168
WEATHER PACK Connectors………………………………………………………………………………………………………… 169
METRI PACK Connector With Terminal Lock at the Rear……………………………………………………………………………….. 172
METRI PACK Connectors with Terminal Lock at the Front……………………………………………………………………………… 175
METRI PACK Connectors………………………………………………………………………………………………………….. 177
Connector at CAN Bus Terminating Resistor………………………………………………………………………………………… 180
Connectors for Electronic Control Units………………………………………………………………………………………….. 182
Connectors……………………………………………………………………………………………………………………. 188
CRIMP SNAP IN connectors……………………………………………………………………………………………………….. 192
KOSTAL Connectors……………………………………………………………………………………………………………… 194
DEUTSCH Connectors…………………………………………………………………………………………………………….. 196
Individual Terminals…………………………………………………………………………………………………………… 198
Fuse and Relay Boxes…………………………………………………………………………………………………………… 199
Fuse and Relay Box on Tractors with Open Operator’s Station………………………………………………………………………… 202
Wiring Harnesses………………………………………………………………………………………………………………….. 205
Wiring Harnesses for Tractors with SyncroPlus or PowrQuad Transmissions and TIER I Engine — Recondition (Summary of References)……………. 205
Wiring Harnesses for Tractors with SyncroPlus or PowrQuad Transmissions and TIER II Engine — Recondition (Summary of References)…………… 207
Wiring Harnesses for Tractors with SyncroPlus or PowrQuad Transmission from Serial No. 398656 — Recondition (Summary of References)………… 209
Wiring Harnesses for Tractors with PowrQuad Plus Transmission and TIER I Engine — Recondition (Summary of References)…………………….. 211
Wiring Harnesses for Tractors with AutoQuad Transmission and TIER I Engine — Recondition (Summary of References)…………………………. 213
Wiring Harnesses for Tractors with PowrQuad Plus or AutoQuad Transmission and TIER II Engine — Recondition (Summary of References)…………. 215
Wiring Harnesses for Tractors with PowrQuad Plus or AutoQuad Plus Transmission from Serial No. 398656 — Recondition (Summary of References)…. 216
Wiring Harnesses for Tractors with AutoPowr/IVT Transmission and TIER II Engine — Recondition (Summary of References)…………………….. 218
Wiring Harnesses for Tractors with AutoPowr/IVT transmission from Serial No. 398656 — Recondition (Summary of References)…………………. 220
Wiring Harnesses for Tractors with Open Operator’s Station and TIER I Engine — Repair (Summary of References)……………………………. 222
Wiring Harnesses for Tractors with Open Operator’s Station and TIER II Engine — Repair (Summary of References)…………………………… 223
Disconnecting electrical circuits……………………………………………………………………………………………….. 223
Ground Point Locations…………………………………………………………………………………………………………. 224
Removing and Installing Harness W01 — Power Supply………………………………………………………………………………… 226
Remove and Install Harness W01 — Power Supply (Open Operator’s Station)……………………………………………………………… 227
Removing and Installing Harness W02 — Tier I Engine Wiring Harness (without Engine Control or with Level 1 ECU)………………………….. 228
Removing and Installing Harness W02 — Tier II Engine Wiring Harness (with Level 12 ECU)……………………………………………….. 230
Remove and Install Harness W02 — Engine (Level 12 ECU) from Serial No. 398656………………………………………………………… 232
Removing and Installing Harness W02 — Tier II Engine Wiring Harness (with Level 11 ECU) (AutoPowr/IVT Transmission)………………………. 234
Remove and Install Harness W02 — Engine (Level 11 ECU) (AutoPowr/IVT Transmission) from Serial No. 398656……………………………….. 236
Removing and Installing Harness W02 — TIER I Engine Wiring Harness (Open Operator’s Station)…………………………………………… 238
Removing and Installing Harness W02 — Tier II Engine Wiring Harness (with Level 12 ECU) (Open Operator’s Station)………………………… 240
Removing and Installing Harness W03 — Starting Aid for TIER I and TIER II Engines (without Engine Control or with Level 1 or 12 ECUs)………. 242
Remove and Install Harness W03 — Starting Aid (Level 12 ECU) from Serial No. 398656…………………………………………………… 243
Removing and Installing Harness W03 — Starting Aid, for TIER II Engines (with Level 11 ECU) (AutoPowr/IVT Transmission)…………………… 244
Removing and Installing Harness W03 — Starting Aid (Level 11 ECU) (AutoPowr/IVT transmission) from Serial No. 398656……………………… 245
Removing and Installing Harness W04 — Headlights………………………………………………………………………………….. 246
Removing and Installing Harness W06 — Front-Wheel Drive Axle with TLS……………………………………………………………….. 247
Removing and Installing Harness W07 — Front PTO…………………………………………………………………………………… 248
Removing and Installing Harness W08 — Cab Harness, for TIER I Engine………………………………………………………………… 250
Removing and Installing Harness W08 — Cab Harness, for TIER II Engine……………………………………………………………….. 252
Remove and Install Harness W08 — Cab from Serial No. 398656………………………………………………………………………… 254
Removing and Installing Harness W08 — Cab Wiring Harness, for TIER II Engine (AutoPowr/IVT Transmission)………………………………… 256
Remove and Install Harness W08 — Cab (AutoPowr/IVT Transmission) from Serial No. 398656……………………………………………….. 258
Removing and Installing Harness W08 — Open Operator’s Station, for TIER I Engine……………………………………………………… 260
Removing and Installing Harness W08 — Open Operator’s Station, for TIER II Engine…………………………………………………….. 262
Removing and Installing Harness W09 — Cab – Cowl, TIER I Engine…………………………………………………………………….. 264
Removing and Installing Harness W09 — Cab – Cowl, TIER II Engine……………………………………………………………………. 266
Remove and Install Harness W09 — Cowl from Serial No. 398656……………………………………………………………………….. 268
Removing and Installing Harness W09 — Cowl, for TIER II Engine (AutoPowr/IVT Transmission)…………………………………………….. 270
Remove and Install Harness W09 — Cowl (AutoPowr/IVT Transmission) from Serial No. 398656………………………………………………. 272
Removing and Installing Harness W09 — Cab – Cowl, TIER I Engine (Open Operator’s Station)”…………………………………………….. 274
Removing and Installing Harness W09 — Cab – Cowl, TIER II Engine (Open Operator’s Station)…………………………………………….. 276
Removing and Installing Harness W10 — Shift Console……………………………………………………………………………….. 278
Removing and Installing Harness W11 — Transmission Shift and Hand Throttle…………………………………………………………… 279
Removing and Installing Harness W11 — Speed Control Lever and Hand Throttle (AutoPowr/IVT transmission)…………………………………. 280
Removing and Installing Harness W12 — Command Arm (AutoPowr/IVT transmission)………………………………………………………… 281
Removing and Installing Harness W13 — Clutch Sending Unit………………………………………………………………………….. 282
Removing and Installing Harness W14 — 3-Terminal Power Outlet Socket………………………………………………………………… 283
Removing and Installing Harness W14 — 3-Terminal Power Outlet Socket (Open Operator’s Station)…………………………………………. 284
Removing and Installing Harness W15 — ECU, for TIER I Engine (without Engine Control)…………………………………………………. 285
Removing and Installing Harness W15 — ECU, for TIER I Engine (ECU Level 1)…………………………………………………………… 286
Removing and Installing Harness W15 — ECU, for TIER II Engine (ECU Level 12)…………………………………………………………. 287
Remove and Install Harness W15 — Engine Control Unit (Level 12 ECU) from Serial No. 398656…………………………………………….. 288
Removing and Installing Harness W15 — ECU, for TIER II Engine (ECU Level 11) (AutoPowr/IVT Transmission)………………………………… 289
Remove and Install Harness W15 — ECU (Level 11 ECU) (AutoPowr/IVT Transmission) from Serial No. 398656………………………………….. 290
Removing and Installing Harness W16 — E-SCV / E-ICV Controller (SIC)………………………………………………………………… 292
Removing and Installing Harness W17 — Multi-function Unit………………………………………………………………………….. 294
Removing and Installing Harness W18 — Windshield Wiper Switch (Without Intermittent Wipe)……………………………………………… 295
Removing and Installing Harness W18 — Windshield Wiper Switch (With Intermittent Wipe)………………………………………………… 296
Removing and Installing Harness W19 — Cab Roof, for TIER I Engine…………………………………………………………………… 298
Removing and Installing Harness W19 — Cab Roof, for TIER II Engine………………………………………………………………….. 300
Removing and Installing Harness W20 — Headlights on Cab Frame………………………………………………………………………. 303
Removing and Installing Harness W21 — Worklights on Front of Cab Roof……………………………………………………………….. 307
Removing and Installing Harness W22 — Worklights on Rear of Cab Roof………………………………………………………………… 308
Removing and Installing Harness W22 — Xenon (HID) Worklights on Rear of Cab Roof……………………………………………………… 309
Removing and Installing Harness W23 — Windshield Wiper…………………………………………………………………………….. 310
Removing and Installing Harness W24 — Rear Window Wiper……………………………………………………………………………. 312
Removing and Installing Harness W25 — Rear Window Wiper Switch……………………………………………………………………… 313
Removing and Installing Harness W26 — Fan and Air-Conditioner………………………………………………………………………. 314
Removing and Installing Harness W26 — Fan and Air-conditioner from Serial No. 398656………………………………………………….. 315
Removing and Installing Harness W26 — ClimaTrak (Cab)……………………………………………………………………………… 316
Removing and Installing Harness W27 — Turn Signal Lights…………………………………………………………………………… 318
Removing and Installing Harness W28 — Front End of Transmission (SyncroPlus and PowrQuad Transmissions)…………………………………. 320
Removing and Installing Harness W28 — Front End of Transmission (PowrQuad Plus and AutoQuad Transmissions)………………………………. 322
Removing and Installing Harness W28 — Front End of Transmission (AutoPowr/IVT transmission)……………………………………………. 324
Remove and Install Harness W28 — Front End of Transmission (Open Operator’s Station)………………………………………………….. 326
Removing and Installing Harness W29 — Valve Block (AutoPowr/IVT Transmission)………………………………………………………… 327
Remove and Install Harness W30 — Rear End of Transmission………………………………………………………………………….. 329
Removing and Installing Harness W30 — Rear End of Transmission (Open Operator’s Station)………………………………………………. 332
Removing and Installing Harness W31 — 7-Terminal Power Outlet Socket………………………………………………………………… 333
Removing and Installing Harness W32 — Stepper Motors………………………………………………………………………………. 334
Removing and Installing Harness W33 — Service…………………………………………………………………………………….. 337
Removing and Installing Harness W34 — Electric Rear-View Mirrors……………………………………………………………………. 338
Removing and Installing Harness W35 — Access Step Lighting and Battery Cut-off Switch (Version 1)………………………………………. 340
Removing and Installing Harness W35 — Access Step Lighting and Battery Cut-off Switch (Version 2)………………………………………. 342
Removing and Installing Harness W36 — GreenStar 60-amp Socket, for TIER I Engine……………………………………………………… 344
Removing and Installing Harness W36 — 60-amp GreenStar Implement Socket……………………………………………………………… 346
Removing and Installing Harness W37 — GreenStar Connection, for TIER I Engine………………………………………………………… 348
Removing and Installing Harness W39 — GreenStar (Cab), for TIER I Engine…………………………………………………………….. 350
Removing and Installing Harness W39 — GreenStar (Cab)……………………………………………………………………………… 352
Removing and Installing Harness W39 — GreenStar with TEC Control Unit (Cab), for TIER I Engine…………………………………………. 354
Removing and Installing Harness W39 — GreenStar with Tractor Equipment interface Controller (Cab)………………………………………. 356
Removing and Installing Harness W40 — GreenStar (Cab Roof), for TIER I Engine………………………………………………………… 358
Removing and Installing Harness W40 — GreenStar (Cab Roof)…………………………………………………………………………. 359
Removing and Installing Harness W41 — JDLink……………………………………………………………………………………… 360
Removing and Installing Harness W42 — Battery Cut-Off Switch, Version 1……………………………………………………………… 362
Removing and Installing Harness W42 — Battery Cut-Off Switch, Version 2……………………………………………………………… 364
Removing and Installing Harness W43 — Back-Up Alarm……………………………………………………………………………….. 366
Removing and Installing Harness W43 — Back-Up Alarm (AutoPowr/IVT Transmission)………………………………………………………. 368
Removing and Installing Harness W44 — Back-Up Alarm / Switch for Power Reverser or PowrQuad Transmission………………………………… 370
Removing and Installing Harness W45 — Back-Up Alarm / Switch for SyncroPlus Transmission………………………………………………. 372
Removing and Installing Harness W47 — ClimaTrak (Cab Roof)…………………………………………………………………………. 373
Removing and Installing Harness W48 — ClimaTrak (Cowl)…………………………………………………………………………….. 375
Removing and Installing Harness W49 — ClimaTrak (Evaporator Housing)………………………………………………………………… 377
Removing and Installing Harness W50 — GreenStar (CAN BUS Terminator)………………………………………………………………… 379
Removing and Installing Harness W51 — AutoTrac (Cab)………………………………………………………………………………. 380
Removing and Installing Harness W52 — AutoTrac (Steering Angle Sensor)………………………………………………………………. 382
Removing and Installing Harness W53 — AutoTrac (Command Arm)……………………………………………………………………….. 384
Charging Circuit………………………………………………………………………………………………………………….. 385
Special Tools…………………………………………………………………………………………………………………. 385
Specifications………………………………………………………………………………………………………………… 385
Repairing the Alternator……………………………………………………………………………………………………….. 385
Disconnecting Electrical Circuits……………………………………………………………………………………………….. 386
Relieve Drive Belt Tension……………………………………………………………………………………………………… 386
Remove/Install the Alternator…………………………………………………………………………………………………… 387
Pulley Removal and Installation…………………………………………………………………………………………………. 388
Starter Motor Circuit……………………………………………………………………………………………………………… 389
Repairing the Starter Motor…………………………………………………………………………………………………….. 389
Specifications………………………………………………………………………………………………………………… 389
Disconnecting Electrical Circuits……………………………………………………………………………………………….. 389
Removing and Installing the Starting Motor……………………………………………………………………………………….. 390
Fuses, Relays and Switches…………………………………………………………………………………………………………. 391
Fuses, Relays and Switches – Recondition (Summary of References)……………………………………………………………………. 391
General Information……………………………………………………………………………………………………………. 392
Special or Essential Tools……………………………………………………………………………………………………… 392
Specifications………………………………………………………………………………………………………………… 393
Disconnecting electrical circuits……………………………………………………………………………………………….. 393
Removing Trim Panels from Cowl………………………………………………………………………………………………….. 394
Fuse and Relay Boxes on Tractors with Operator’s Cab up to Serial No. 398655…………………………………………………………. 397
Fuse and Relay Boxes on Tractors with Operator’s Cab from Serial No. 398656………………………………………………………….. 408
Fuse and Relay Boxes on Tractors with Operator’s Cab and AutoPowr/IVT Transmission up to Serial No. 398655………………………………. 419
Fuse and Relay Boxes on Tractors with Operator’s Cab and AutoPowr/IVT Transmission from Serial No. 398656……………………………….. 430
Fuse and Relay Box on Tractors with Open Operator’s Station………………………………………………………………………… 441
Replacing the Main Fuses……………………………………………………………………………………………………….. 444
Replacing Fuses of Electrical Starting Aid, TIER I and TIER II Engine (without engine control or with Level 1 or 12 ECU)………………….. 445
Replacing Fuses of Electrical Starting Aid, TIER II Engine (Level 11 ECU) (AutoPowr/IVT Transmission)…………………………………… 446
Replacing the LTC Coolant Pump Fuse (AutoPowr/IVT Transmission)…………………………………………………………………….. 447
Replace the Fuses for Power Supply to the Implement BUS (60-amp Implement Socket)…………………………………………………….. 448
Replacing Starting Motor Relay, TIER I and TIER II Engine (without engine control or with Level 1 or 12 ECU)…………………………….. 449
Replacing Starting Motor Relay, TIER II Engine (Level 11 ECU) (AutoPowr/IVT Transmission)……………………………………………… 450
Replacing Relay of Electrical Starting Aid, TIER I and TIER II Engine (without engine control or with Level 1 or 12 ECU)………………….. 451
Replacing Relay of Electrical Starting Aid, TIER II Engine (Level 11 ECU) (AutoPowr/IVT Transmission)…………………………………… 452
Replace the Power Supply Relays for the Implement BUS……………………………………………………………………………… 453
Replacing the Main Switch………………………………………………………………………………………………………. 454
Replacing the Brake Switches……………………………………………………………………………………………………. 455
Replacing the Light Switch……………………………………………………………………………………………………… 456
Replacing Full/Dipped-Beam Switch……………………………………………………………………………………………….. 457
Replacing the Worklight Switches………………………………………………………………………………………………… 457
Replace the Switch for Lights on Cab Frame……………………………………………………………………………………….. 458
Replacing the Beacon Light Switch……………………………………………………………………………………………….. 459
Replacing the Hazard Warning Light Switch………………………………………………………………………………………… 460
Replacing the Turn Signal Switch………………………………………………………………………………………………… 461
Replacing the Horn Switch………………………………………………………………………………………………………. 461
Replacing Switches on Multi-Function Unit………………………………………………………………………………………… 462
Replacing the Rear Window Wiper and Washer Switch…………………………………………………………………………………. 469
Replacing the Rear Window Switch………………………………………………………………………………………………… 470
Replace the Dome Light Door Switch………………………………………………………………………………………………. 470
Replacing the Front-Wheel Drive Switch…………………………………………………………………………………………… 471
Replacing the Headland Management (HMS) Switch……………………………………………………………………………………. 472
Replacing the Record/Save Switch………………………………………………………………………………………………… 473
Replace the Program Switch……………………………………………………………………………………………………… 474
Replacing the Switch for AutoQuad Transmission……………………………………………………………………………………. 476
Replace the Switch for Gear Selector and Auto-mode………………………………………………………………………………… 477
Replacing the Park Lock Switch on Tractors with PowrQuad Plus, AutoQuad or AutoQuad Plus Transmissions………………………………….. 480
Replacing the Back-Up Alarm Switch………………………………………………………………………………………………. 481
Replacing the Fan Switch……………………………………………………………………………………………………….. 482
Replacing the Switch of the Air-Conditioning System Compressor……………………………………………………………………… 483
Replacing the Differential Lock Switch…………………………………………………………………………………………… 484
Replace the PTO Switches……………………………………………………………………………………………………….. 486
Replacing the Rockshaft Remote Control Switch…………………………………………………………………………………….. 489
Replace the Switches for the Electrical Rear-View Mirrors………………………………………………………………………….. 490
Replace the Switch for the Heated Rear-View Mirrors……………………………………………………………………………….. 490
Replace the Switch for the Heated Rear Window…………………………………………………………………………………….. 491
Replace the AutoTrac Switch…………………………………………………………………………………………………….. 491
Replacing the Cruise Control Potentiometer on Tractors with AutoQuad Transmission…………………………………………………….. 493
Replace the Cruise Control Potentiometer on Tractors with AutoPowr/IVT Transmission…………………………………………………… 494
Replace the Auto-mode Potentiometer on Tractors with AutoQuad Plus Transmission………………………………………………………. 495
Rockshaft Control……………………………………………………………………………………………………………… 496
Electrical Activators for Selective Control Valves (E-SCV)…………………………………………………………………………. 502
Electrical Activators for Independent Control Valves (E-ICV)……………………………………………………………………….. 505
Monitoring Systems………………………………………………………………………………………………………………… 509
Monitoring Systems – Recondition (Summary of References)…………………………………………………………………………… 509
General Information……………………………………………………………………………………………………………. 509
Note…………………………………………………………………………………………………………………………. 509
Note…………………………………………………………………………………………………………………………. 510
Note…………………………………………………………………………………………………………………………. 510
Disconnecting electrical circuits……………………………………………………………………………………………….. 510
Replacing the Engine Speed Sending Unit (B01)…………………………………………………………………………………….. 511
Replacing the Engine Oil Pressure Sending Unit (B04)………………………………………………………………………………. 512
Replacing the Sending Unit for the Coolant Temperature Gauge (B08)………………………………………………………………….. 513
Replacing the Acoustic Alarm……………………………………………………………………………………………………. 514
Replacing the Acoustic Alarm (Park Lock) on Tractors with AutoPowr/IVT Transmission…………………………………………………… 515
Electrical Components……………………………………………………………………………………………………………… 517
Electrical Components – Recondition (Summary of References)………………………………………………………………………… 517
General Information……………………………………………………………………………………………………………. 517
Special Tools…………………………………………………………………………………………………………………. 517
Specifications………………………………………………………………………………………………………………… 518
Disconnecting electrical circuits……………………………………………………………………………………………….. 518
Replacing the 7-Terminal Power Outlet Socket……………………………………………………………………………………… 519
Replacing the 3-Terminal Power Outlet Socket……………………………………………………………………………………… 520
Replacing the Multiple Power-Outlet Socket Strip………………………………………………………………………………….. 522
Replacing the Service Socket……………………………………………………………………………………………………. 523
Removing the Wiper Motor……………………………………………………………………………………………………….. 526
Adjusting the Headlights……………………………………………………………………………………………………….. 527
Adjusting the Lights on the Cab Frame……………………………………………………………………………………………. 529
Safety Instructions for Replacing a Halogen Bulb………………………………………………………………………………….. 530
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units……………………………………………………………….. 531
Replacing Xenon (HID) Worklights and Ballast Units……………………………………………………………………………….. 532
SYNCROPLUS TRANSMISSION……………………………………………………………………………………………………………….. 535
Installing and Removing Components………………………………………………………………………………………………….. 537
Special or Essential Tools……………………………………………………………………………………………………… 537
Dealer-Manufactured Special Tools……………………………………………………………………………………………….. 538
Specifications………………………………………………………………………………………………………………… 539
Removing the Clutch Housing…………………………………………………………………………………………………….. 540
Installing the Clutch Housing…………………………………………………………………………………………………… 544
Removing the Gear Transmission………………………………………………………………………………………………….. 545
Installing the Gear Transmission………………………………………………………………………………………………… 546
Transmission Shift Controls………………………………………………………………………………………………………… 549
SyncroPlus Transmission Shift Units – Reconditioning (Summary of References)…………………………………………………………. 549
Specifications………………………………………………………………………………………………………………… 549
Reconditioning the Gear Shift Mechanism………………………………………………………………………………………….. 550
Reconditioning the Range Shift Mechanism…………………………………………………………………………………………. 553
Checking and Adjusting the Shift Units…………………………………………………………………………………………… 556
Adjusting the Clutch Pedal……………………………………………………………………………………………………… 560
Perma Clutch II Module…………………………………………………………………………………………………………….. 561
SyncroPlus Transmission, Perma Clutch II Module – Reconditioning (Summary of References)………………………………………………. 561
Special or Essential Tools……………………………………………………………………………………………………… 561
Specifications………………………………………………………………………………………………………………… 563
Removing the Clutch……………………………………………………………………………………………………………. 564
Reconditioning the Clutch………………………………………………………………………………………………………. 565
Installing the Clutch………………………………………………………………………………………………………….. 572
Removing the Transmission Oil Pump………………………………………………………………………………………………. 572
Reconditioning the Transmission Oil Pump…………………………………………………………………………………………. 574
Installing the Transmission Oil Pump…………………………………………………………………………………………….. 578
Valves and Other Hydraulic Components……………………………………………………………………………………………. 581
Reconditioning the Engagement Override Valve……………………………………………………………………………………… 582
Reconditioning the Clutch Cooling Valve………………………………………………………………………………………….. 582
Reconditioning the Cooling Pilot Valve…………………………………………………………………………………………… 583
Reconditioning the Filter Relief Valve…………………………………………………………………………………………… 583
Reconditioning the Pressure-Regulating Valve……………………………………………………………………………………… 584
Reconditioning the Lube Relief Valve…………………………………………………………………………………………….. 584
Reconditioning the Cooler Relief Valve…………………………………………………………………………………………… 585
Reconditioning the Clutch Pedal Valve……………………………………………………………………………………………. 585
Replacing the Temperature and Pressure Sending Units………………………………………………………………………………. 591
Gear Transmission…………………………………………………………………………………………………………………. 593
SyncroPlus Transmission, Gear Transmission – Reconditioning (Summary of References)…………………………………………………… 593
Special or Essential Tools……………………………………………………………………………………………………… 593
Specifications………………………………………………………………………………………………………………… 594
Gear Transmission – Sectional View………………………………………………………………………………………………. 595
Disassembling the Gear Transmission……………………………………………………………………………………………… 596
Reconditioning the Gear Transmission…………………………………………………………………………………………….. 598
Preparation for Installing the Gear Transmission………………………………………………………………………………….. 613
Reconditioning the Shift Cover………………………………………………………………………………………………….. 617
Adjusting the Gear Transmission Shift Mechanism…………………………………………………………………………………… 618
Adjusting the Neutral Start Switch………………………………………………………………………………………………. 618
POWER REVERSER TRANSMISSION……………………………………………………………………………………………………………. 621
Installing and Removing Components………………………………………………………………………………………………….. 623
Special or Essential Tools……………………………………………………………………………………………………… 623
Dealer-Manufactured Special Tools……………………………………………………………………………………………….. 624
Specifications………………………………………………………………………………………………………………… 625
Removing the Power Reverser Module………………………………………………………………………………………………. 625
Installing the Power Reverser Module…………………………………………………………………………………………….. 629
Removing and Installing the Gear Transmission…………………………………………………………………………………….. 630
Transmission Shift Controls………………………………………………………………………………………………………… 631
Power Reverser Shift Units – Reconditioning (Summary of References)…………………………………………………………………. 631
Specifications………………………………………………………………………………………………………………… 631
Reconditioning the Gear Shift Mechanism………………………………………………………………………………………….. 632
Reconditioning the Range Shift Mechanism…………………………………………………………………………………………. 635
Reconditioning the Forward/Reverse Control……………………………………………………………………………………….. 638
Checking and Adjusting the Shift Units…………………………………………………………………………………………… 640
Adjusting the Reverse Drive Lever……………………………………………………………………………………………….. 644
Adjusting the Reverse Drive Linkage……………………………………………………………………………………………… 645
Adjusting the Clutch Pedal……………………………………………………………………………………………………… 646
Power Reverser Module……………………………………………………………………………………………………………… 649
Power Reverser Transmission, Power Reverser Module – Reconditioning (Summary of References)……………………………………………. 649
Special or Essential Tools……………………………………………………………………………………………………… 649
Specifications………………………………………………………………………………………………………………… 651
Power Reverser Module – Sectional View…………………………………………………………………………………………… 654
Components of Power Train………………………………………………………………………………………………………. 655
Removing the Disk Brake………………………………………………………………………………………………………… 655
Reconditioning the Disk Brake…………………………………………………………………………………………………… 658
Installing the Disk Brake………………………………………………………………………………………………………. 660
Removing the Clutch and Planetary Carrier………………………………………………………………………………………… 663
Reconditioning the Clutch and Planetary Carrier…………………………………………………………………………………… 664
Installing the Clutch and Planetary Carrier………………………………………………………………………………………. 672
Removing the Transmission Oil Pump………………………………………………………………………………………………. 672
Reconditioning the Transmission Oil Pump…………………………………………………………………………………………. 674
Installing the Transmission Oil Pump…………………………………………………………………………………………….. 678
Valves and Other Hydraulic Components……………………………………………………………………………………………. 680
Reconditioning the Pressure-Regulating Valve……………………………………………………………………………………… 682
Reconditioning the Cooling Pilot Valve…………………………………………………………………………………………… 683
Reconditioning the Clutch Cooling Valve………………………………………………………………………………………….. 684
Reconditioning the Engagement Override Valve……………………………………………………………………………………… 684
Reconditioning the Filter Relief Valve…………………………………………………………………………………………… 685
Reconditioning the Cooler Relief Valve…………………………………………………………………………………………… 685
Reconditioning the Lube Relief Valve…………………………………………………………………………………………….. 686
Reconditioning the Sump Valve…………………………………………………………………………………………………… 686
Reconditioning the Accumulator Piston……………………………………………………………………………………………. 687
Reconditioning the Forward/Reverse Valve…………………………………………………………………………………………. 688
Reconditioning the Fwd/Rev Cooling Control Valve………………………………………………………………………………….. 692
Reconditioning the Modulator Valve………………………………………………………………………………………………. 693
Reconditioning the Connecting Valve……………………………………………………………………………………………… 693
Reconditioning the Clutch Pedal Valve……………………………………………………………………………………………. 694
Replacing the Temperature and Pressure Sending Units………………………………………………………………………………. 702
Replacing the Oil Filter……………………………………………………………………………………………………….. 703
Replacing the Neutral Start Switch………………………………………………………………………………………………. 703
Gear Transmission…………………………………………………………………………………………………………………. 705
Power Reverser Transmission, Gear Transmission – Reconditioning (Summary of References)……………………………………………….. 705
Special or Essential Tools……………………………………………………………………………………………………… 705
Specifications………………………………………………………………………………………………………………… 706
Gear Transmission – Sectional View………………………………………………………………………………………………. 707
Disassembling the Gear Transmission……………………………………………………………………………………………… 708
Reconditioning the Gear Transmission…………………………………………………………………………………………….. 710
Preparation for Installing the Gear Transmission………………………………………………………………………………….. 721
Reconditioning the Shift Cover………………………………………………………………………………………………….. 725
Adjusting the Shift Mechanism on the Gear Transmission…………………………………………………………………………….. 726
AUTOPOWR/IVT TRANSMISSION……………………………………………………………………………………………………………… 729
Installing and Removing Components………………………………………………………………………………………………….. 731
Specifications………………………………………………………………………………………………………………… 731
Removing the AutoPowr/IVT Transmission…………………………………………………………………………………………… 731
Installing the AutoPowr/IVT Transmission…………………………………………………………………………………………. 735
Transmission Shift Controls………………………………………………………………………………………………………… 739
AutoPowr/IVT Transmission Shift Units – Reconditioning (Summary of References)……………………………………………………….. 739
Reconditioning the Speed Control Lever…………………………………………………………………………………………… 739
Reverser control, reconditioning………………………………………………………………………………………………… 748
Reconditioning the Clutch Actuation Mechanism…………………………………………………………………………………….. 749
Reconditioning the Manual Park Lock Release Mechanism……………………………………………………………………………… 754
Releasing the Park Lock Manually………………………………………………………………………………………………… 756
Input Housing…………………………………………………………………………………………………………………….. 759
AutoPowr/IVT Transmission, Input Housing — Reconditioning (Summary of References)…………………………………………………….. 759
Special Tools…………………………………………………………………………………………………………………. 760
Specifications………………………………………………………………………………………………………………… 761
Replace Hydrostatic Unit Speed Sending Unit (B62) (Repair Level 1 and 2)…………………………………………………………….. 764
Replacing Pressure Sending Unit B87, S73, S74 (Repair Level 1 and 2)………………………………………………………………… 765
Replacing Thermostat Valve (Repair Level 1 and 2)…………………………………………………………………………………. 766
Replacing Filter By-Pass Valve (Cold-Weather Starting) (Repair Level 1 and 2)………………………………………………………… 766
Replacing the Oil Filter (Repair Level 1 and 2)…………………………………………………………………………………… 767
Removing the System Pressure Control Block (Repair Level 1 and 2)…………………………………………………………………… 768
Installing System Pressure Control Block (Repair Level 1 and 2)…………………………………………………………………….. 769
Removing the Transmission Oil Pump (Repair Level 1 and 2)………………………………………………………………………….. 773
Reconditioning the Transmission Oil Pump (Repair Level 1 and 2)…………………………………………………………………….. 774
Installing the Transmission Oil Pump (Repair Level 1 and 2)………………………………………………………………………… 776
Removing the Vibration Damper (Repair Level 1 and 2)………………………………………………………………………………. 778
Reconditioning the Vibration Damper (Repair Level 1 and 2)…………………………………………………………………………. 778
Installing the Vibration Damper (Repair Level 1 and 2)…………………………………………………………………………….. 780
Removing the Front Plate (Repair Level 1 and 2)…………………………………………………………………………………… 780
Installing the Front Plate (Repair Level 1 and 2)…………………………………………………………………………………. 782
Removing Clutch Control Block (Repair Level 1 and 2)………………………………………………………………………………. 783
Reconditioning Clutch Control Block (Repair Level 1 and 2)…………………………………………………………………………. 785
Installing the Clutch Control Block (Repair Level 1 and 2)…………………………………………………………………………. 790
Separating the Input and Output Housings (Repair Level 2)………………………………………………………………………….. 793
Joining the Input and Output Housings (Repair Level 2)…………………………………………………………………………….. 794
Removing BG Disk Brake (Repair Level 2)………………………………………………………………………………………….. 795
Installing BG Disk Brake (Repair Level 2)………………………………………………………………………………………… 797
Removing Shift Turret (Repair Level 2)…………………………………………………………………………………………… 798
Reconditioning the Shift Turret (Repair Level 2)………………………………………………………………………………….. 799
Installing the Shift Turret (Repair Level 2)……………………………………………………………………………………… 805
Removing the Hydrostatic Unit (Repair Level 2)……………………………………………………………………………………. 806
Installing the Hydrostatic Unit (Repair Level 2)………………………………………………………………………………….. 809
Reconditioning the Hydrostatic Unit Output Shaft (Repair Level 2)…………………………………………………………………… 814
Measuring the Gaps Between Transmission Shafts (Repair Level 2)…………………………………………………………………….. 818
Replacing the Wiring Harness / Replacing the Fittings on the Housing (Repair Level 2)…………………………………………………. 824
Output Housing……………………………………………………………………………………………………………………. 827
AutoPowr/IVT Transmission, Output Housing — Reconditioning (Summary of References)……………………………………………………. 827
Special or Essential Tools……………………………………………………………………………………………………… 828
Specifications………………………………………………………………………………………………………………… 829
Replacing Transmission Input Speed Sending Unit (B61) (Repair Level 1 and 2)…………………………………………………………. 831
Replacing Transmission Output Speed Sending Unit (B63) (Repair Level 1 and 2)………………………………………………………… 832
Replace Pressure Sending Unit (B90) for Park Lock Control Block (Repair Level 1 and2)………………………………………………… 832
Replacing the Bleed Valve (Repair Level 2)……………………………………………………………………………………….. 833
Removing the Park Lock Control Block (Repair Level 1 and 2)………………………………………………………………………… 834
Reconditioning the Park Lock Control Block (Repair Level 1 and 2)…………………………………………………………………… 835
Reconditioning the Park Lock Cam (Repair Level 1 and 2)……………………………………………………………………………. 846
Installing the Park Lock Control Block (Repair Level 1 and 2)………………………………………………………………………. 849
Removing the Pneumatic Pump (Repair Level 1 and 2)………………………………………………………………………………… 850
Installing the Vibration Damper (Repair Level 1 and 2)…………………………………………………………………………….. 851
Removing the Direction Turret and Reverse Intermediate Shaft (Repair Level 2)………………………………………………………… 853
Installing Direction Turret and Reverse Intermediate Shaft (Repair Level 2)………………………………………………………….. 855
Removing the Drive Shaft for the Hydrostatic Unit (Repair Level 2)………………………………………………………………….. 858
Removing the Through-Drive Shaft (Repair Level 2)…………………………………………………………………………………. 859
Installing the Through-Drive Shaft (Repair Level 2)……………………………………………………………………………….. 862
Removing the Drive Gear for the Hydrostatic Unit (Repair Level 2)…………………………………………………………………… 865
Removing the Idler Gear with Pneumatic Pump Drive (Repair Level 2)………………………………………………………………….. 867
Installing the Idler Gear with Pneumatic Pump Drive (Repair Level 2)………………………………………………………………… 868
Replacing the Screw Plugs (Repair Level 1 and 2) …………………………………………………………………………………. 870
Differential Drive Shaft Assembly…………………………………………………………………………………………………… 871
AutoPowr/IVT Transmission, Differential Drive Shaft — Reconditioning (Summary of References)…………………………………………… 871
Specifications………………………………………………………………………………………………………………… 871
Differential Drive Shaft — Sectional View………………………………………………………………………………………… 872
Disassembling the Differential Drive Shaft (without Bearings)………………………………………………………………………. 873
Reconditioning the Cover with the Park Lock Pawl………………………………………………………………………………….. 876
Assembling the Differential Drive Shaft (without Bearings)…………………………………………………………………………. 877
Replacing the Differential Drive Shaft / Reconditioning the Bearings………………………………………………………………… 882
POWRQUAD, POWRQUAD PLUS AND AUTOQUAD TRANSMISSIONS……………………………………………………………………………………….. 887
Installing and Removing Components………………………………………………………………………………………………….. 889
Specifications………………………………………………………………………………………………………………… 889
PowrQuad Plus Transmission, Removal and Installation………………………………………………………………………………. 889
AutoQuad Transmission, Removal and Installation…………………………………………………………………………………… 890
Removing the PowrQuad Transmission………………………………………………………………………………………………. 890
Installing the PowrQuad Transmission…………………………………………………………………………………………….. 894
Removing Creeper or Option Transmissions…………………………………………………………………………………………. 895
Installing Creeper or Option Transmissions……………………………………………………………………………………….. 897
Removing the Range Transmission…………………………………………………………………………………………………. 899
Installing the Range Transmission……………………………………………………………………………………………….. 901
Transmission Shift Controls………………………………………………………………………………………………………… 903
PowrQuad Transmission Shift Units – Reconditioning (Summary of References)…………………………………………………………… 903
Specifications………………………………………………………………………………………………………………… 904
Gear Shift Linkage, Reconditioning (Reverser Control on Steering Column)…………………………………………………………….. 905
Range Shift Linkage, Reconditioning (Reverser Control on Steering Column)……………………………………………………………. 908
Reconditioning the Reverser Control (on Steering Column)…………………………………………………………………………… 912
Adjusting the Reverse Drive Lever (Reverser Control on Steering Column)……………………………………………………………… 914
Adjusting the Reverse Drive Linkage……………………………………………………………………………………………… 915
Checking and Adjusting the Shift Mechanisms/Linkages (Reverser Control on Steering Column)…………………………………………….. 916
Repairing the Range Shift Linkage (PowrQuad Plus and AutoQuad Transmissions)…………………………………………………………. 922
Check and Adjust the Shift Controls/Linkages (PowrQuad Plus and AutoQuad transmissions)……………………………………………….. 926
Adjust the Clutch Pedal (PowrQuad Transmission)…………………………………………………………………………………… 932
Reconditioning the Clutch Actuation (PowrQuad Plus & AutoQuad Transm.)………………………………………………………………. 933
PowrQuad Module…………………………………………………………………………………………………………………… 937
PowrQuad, PowrQuad Plus and AutoQuad Transmissions – Summary of References…………………………………………………………… 937
Special or Essential Tools……………………………………………………………………………………………………… 937
Specifications………………………………………………………………………………………………………………… 939
Transmission Components………………………………………………………………………………………………………… 942
Replacing the Neutral Start Circuit (with Mech. Actuated PowrQuad Module)……………………………………………………………. 943
Replace Temperature Sensor and Pressure Switches………………………………………………………………………………….. 943
Removing and Installing the Oil Filter Housing……………………………………………………………………………………. 946
Replacing the Oil Filter……………………………………………………………………………………………………….. 947
Removing and Installing the Front Valve Housing…………………………………………………………………………………… 948
Removing and Installing the Valves in the Front Valve Housing………………………………………………………………………. 951
Removing and Installing the Valves in the Front Valve Housing (with Mech. Actuated PowrQuad Module)…………………………………….. 955
Remove and Install the Front Transmission Cover…………………………………………………………………………………… 965
Removing and Installing the Valves in the Front Transmission Cover………………………………………………………………….. 968
Removing and Installing the Valves in the Front Transmission Cover (with Mech. Actuated PowrQuad Module)………………………………… 972
Replacing the Clutch Pedal Valve (with Mech. Actuated PowrQuad Module)………………………………………………………………. 976
Removing and Installing the Shift Valve Housing…………………………………………………………………………………… 981
Remove and Install the Valves in the Shift Valve Housing…………………………………………………………………………… 981
Removing and Installing the Shift Valve Housing (with Mech. Actuated PowrQuad Module)…………………………………………………. 984
Removing and Installing the Valves in the Shift Valve Housing (with Mech. Actuated PowrQuad Module)…………………………………….. 986
Removing the Transmission Oil Pump………………………………………………………………………………………………. 989
Reconditioning the Transmission Oil Pump…………………………………………………………………………………………. 990
Installing the Transmission Oil Pump…………………………………………………………………………………………….. 994
Removing the Gear-Shift Planetary Drive………………………………………………………………………………………….. 995
Repairing the Gear-Shift Planetary Drive…………………………………………………………………………………………. 996
Install Gear-Shift Planetary Drive……………………………………………………………………………………………….1002
Removing the B1 Brake Housing……………………………………………………………………………………………………1007
Reconditioning the B1 Brake……………………………………………………………………………………………………..1007
Installing the B1 Brake Housing………………………………………………………………………………………………….1009
Removing the B2-B3 Brake Housing…………………………………………………………………………………………………1010
Reconditioning the B2 Brake……………………………………………………………………………………………………..1010
Reconditioning the B3 Brake……………………………………………………………………………………………………..1012
Installing the B2-B3 Brake Housing……………………………………………………………………………………………….1014
Removing the C4 Clutch………………………………………………………………………………………………………….1015
Recondition the C4 Clutch……………………………………………………………………………………………………….1015
Installing the C4 Clutch………………………………………………………………………………………………………..1023
Removing the Reverse Brake………………………………………………………………………………………………………1025
Reconditioning the Reverse Brake…………………………………………………………………………………………………1025
Installing the Reverse Brake…………………………………………………………………………………………………….1028
Removing the Forward Clutch with Planetary Drive (Forward/Reverse)…………………………………………………………………..1029
Recondition Forward Clutch with Planetary Drive (Forward/Reverse)……………………………………………………………………1029
Installing the Forward Clutch with Planetary Drive (Forward/Reverse)…………………………………………………………………1040
Replacing the Output Shaft………………………………………………………………………………………………………1042
Creeper Transmission……………………………………………………………………………………………………………….1045
Creeper Transmission – Reconditioning (Summary of References)……………………………………………………………………….1045
Specifications…………………………………………………………………………………………………………………1045
Removing the Creeper Transmission………………………………………………………………………………………………..1046
Reconditioning the Creeper Transmission…………………………………………………………………………………………..1047
Installing the Creeper Transmission………………………………………………………………………………………………1062
Reconditioning the Shift Cover…………………………………………………………………………………………………..1066
Option Transmission………………………………………………………………………………………………………………..1067
Option Transmission – Reconditioning (Summary of References)………………………………………………………………………..1067
Specifications…………………………………………………………………………………………………………………1067
Removing the Option Transmission…………………………………………………………………………………………………1067
Reconditioning the Option Transmission……………………………………………………………………………………………1069
Installing the Option Transmission……………………………………………………………………………………………….1076
Range Transmission…………………………………………………………………………………………………………………1079
Range Transmission- Reconditioning (Summary of References)………………………………………………………………………….1079
Specifications…………………………………………………………………………………………………………………1080
Range Transmission – Sectional View………………………………………………………………………………………………1082
Removing the Range Transmission………………………………………………………………………………………………….1084
Reconditioning the Range Transmission…………………………………………………………………………………………….1085
Installing the Range Transmission………………………………………………………………………………………………..1107
Reconditioning the Shift Cover…………………………………………………………………………………………………..1114
Replacing the Transmission Speed Sensor (B104)…………………………………………………………………………………….1115
DRIVE SYSTEMS…………………………………………………………………………………………………………………………1117
Installing and Removing Components…………………………………………………………………………………………………..1119
Special or Essential Tools………………………………………………………………………………………………………1119
Dealer-Manufactured Special Tools………………………………………………………………………………………………..1121
Specifications…………………………………………………………………………………………………………………1123
Removing the FWD Clutch…………………………………………………………………………………………………………1124
Installing the FWD Clutch……………………………………………………………………………………………………….1125
Removing the Differential Housing………………………………………………………………………………………………..1126
Installing the Differential Housing………………………………………………………………………………………………1134
Removing the Final Drives……………………………………………………………………………………………………….1138
Installing the Final Drives……………………………………………………………………………………………………..1143
Removing the Rear PTO…………………………………………………………………………………………………………..1146
Installing the Rear PTO…………………………………………………………………………………………………………1149
Removing the Front PTO………………………………………………………………………………………………………….1151
Installing the Front PTO………………………………………………………………………………………………………..1152
U-Jointed Shafts and Torsion Damper………………………………………………………………………………………………….1155
Summary of References (U-Jointed Shafts and Torsion Damper)…………………………………………………………………………1155
Special Tools………………………………………………………………………………………………………………….1155
Use of Special Tool KJD10426…………………………………………………………………………………………………….1156
Specifications…………………………………………………………………………………………………………………1157
Remove U.J. Shaft (Front-Wheel Drive)…………………………………………………………………………………………….1158
Reconditioning the U.j. Shaft (FWD)………………………………………………………………………………………………1158
Installing the U.j. Shaft (FWD)………………………………………………………………………………………………….1161
Removing the U.j. Shaft (Engine)…………………………………………………………………………………………………1162
Removing and Installing the Ring-Shaped Cooler…………………………………………………………………………………….1163
Removing the Torsion Damper……………………………………………………………………………………………………..1164
Changing the Torsion Damper Bearings……………………………………………………………………………………………..1165
Installing the Torsion Damper……………………………………………………………………………………………………1165
Installing Engine U.J. Shaft…………………………………………………………………………………………………….1166
Front-Wheel Drive Clutch……………………………………………………………………………………………………………1167
Front-Wheel Drive Clutch – Reconditioning (Summary of References)……………………………………………………………………1167
Special Tools………………………………………………………………………………………………………………….1167
Other Material…………………………………………………………………………………………………………………1168
Specifications…………………………………………………………………………………………………………………1168
Replacing the Sending Unit for Front-Wheel Drive Axle Speed (B89)……………………………………………………………………1169
Disassembling the Front Wheel Drive Clutch………………………………………………………………………………………..1170
Front-Wheel Drive Clutch — Exploded View………………………………………………………………………………………….1174
Assembling the Front-Wheel Drive Clutch…………………………………………………………………………………………..1175
Differential………………………………………………………………………………………………………………………1183
Differential – Reconditioning (Summary of References)………………………………………………………………………………1183
Specifications…………………………………………………………………………………………………………………1183
Replacing the Sending Unit (B09 or B35 or B84)…………………………………………………………………………………….1184
Removing the Differential……………………………………………………………………………………………………….1185
Disassembling the Differential…………………………………………………………………………………………………..1186
Differential — Exploded View…………………………………………………………………………………………………….1190
Assembling the Differential……………………………………………………………………………………………………..1191
Installing the Differential……………………………………………………………………………………………………..1194
Hydraulic Pump Drive……………………………………………………………………………………………………………….1197
Specifications…………………………………………………………………………………………………………………1197
Reconditioning the Hydraulic Pump Drive…………………………………………………………………………………………..1197
Adjusting the Hydraulic Pump Drive……………………………………………………………………………………………….1205
Final Drives………………………………………………………………………………………………………………………1207
Special or Essential Tools………………………………………………………………………………………………………1207
Specifications…………………………………………………………………………………………………………………1208
Reconditioning the Final Drives………………………………………………………………………………………………….1208
Rear PTO………………………………………………………………………………………………………………………….1221
Rear PTO Options — Summary of References………………………………………………………………………………………….1221
Special Tools………………………………………………………………………………………………………………….1222
Dealer-Fabricated Special Tools………………………………………………………………………………………………….1223
Other Material…………………………………………………………………………………………………………………1224
Specifications…………………………………………………………………………………………………………………1225
Replacing the Output Shaft Seal Ring……………………………………………………………………………………………..1227
Changing the O-Ring on Reversible PTO…………………………………………………………………………………………….1228
Removing the PTO Clutch…………………………………………………………………………………………………………1229
Reconditioning the PTO Clutch……………………………………………………………………………………………………1230
Installing the PTO Clutch……………………………………………………………………………………………………….1236
Reconditioning the PTO Brake…………………………………………………………………………………………………….1237
Disassembling the PTO Drive Train………………………………………………………………………………………………..1238
Reconditioning the Output Shaft (540/1000 rpm Reversible)…………………………………………………………………………..1241
Reconditioning the Countershaft (540/1000 rpm)…………………………………………………………………………………….1243
Assembling the PTO Drive Train…………………………………………………………………………………………………..1244
Adjusting Taper Roller Bearing at Output Shaft…………………………………………………………………………………….1245
Adjusting the Taper Roller Bearing of the Countershaft……………………………………………………………………………..1246
Installing the Support and Adjusting the Taper Roller Bearings………………………………………………………………………1248
Installing the PTO Housing………………………………………………………………………………………………………1248
Removing the PTO Modulating Valve………………………………………………………………………………………………..1249
Reconditioning the PTO Modulating Valve…………………………………………………………………………………………..1249
Installing the PTO Modulating Valve………………………………………………………………………………………………1250
Repairing the Solenoid Valve…………………………………………………………………………………………………….1251
Replacing the PTO Speed Sending Unit……………………………………………………………………………………………..1252
Front PTO…………………………………………………………………………………………………………………………1253
Front PTO – Reconditioning (Summary of References)…………………………………………………………………………………1253
Other Material…………………………………………………………………………………………………………………1254
Specifications…………………………………………………………………………………………………………………1255
General Repair Procedures……………………………………………………………………………………………………….1257
Replacing the Solenoid Valve…………………………………………………………………………………………………….1257
Reconditioning the Modulator Valve……………………………………………………………………………………………….1258
Replacing the Front PTO Speed Sending Unit (B58)…………………………………………………………………………………..1259
Cleaning and Replacing the Filter………………………………………………………………………………………………..1260
Reconditioning the Pressure-Regulating Valve………………………………………………………………………………………1261
Checking the Cooler Relief and Filter By-Pass Valves……………………………………………………………………………….1262
Removing and Installing the Valve Plate…………………………………………………………………………………………..1262
Front PTO — Sectional View………………………………………………………………………………………………………1263
Disassembling the Front PTO……………………………………………………………………………………………………..1265
Reconditioning the Oil Pump……………………………………………………………………………………………………..1267
Reconditioning the PTO Clutch……………………………………………………………………………………………………1270
Reconditioning the PTO Brake…………………………………………………………………………………………………….1275
Reconditioning the Intermediate Gear Shaft (PTO Rotating Counterclockwise)……………………………………………………………1278
Reconditioning the Drive Shaft…………………………………………………………………………………………………..1279
Assembling the Front PTO………………………………………………………………………………………………………..1283
Front Implement Drive………………………………………………………………………………………………………………1289
Front Implement Drive (Summary of References)……………………………………………………………………………………..1289
General Information…………………………………………………………………………………………………………….1289
Special Tools………………………………………………………………………………………………………………….1289
Specifications…………………………………………………………………………………………………………………1290
Summary of Torques……………………………………………………………………………………………………………..1290
Preliminary work……………………………………………………………………………………………………………….1291
Removing and Installing the Drive Shaft Adapter……………………………………………………………………………………1292
Removing and Installing the Drive Shaft…………………………………………………………………………………………..1294
STEERING AND BRAKES……………………………………………………………………………………………………………………1299
Hydrostatic Steering……………………………………………………………………………………………………………….1301
Hydrostatic Steering (Summary of References)………………………………………………………………………………………1301
Special Tools………………………………………………………………………………………………………………….1301
Specifications…………………………………………………………………………………………………………………1303
Preliminary Work……………………………………………………………………………………………………………….1303
Disconnect/Connect Steering or Brake Hoses………………………………………………………………………………………..1304
Steering Valve – Removal (Tractors with Cab)………………………………………………………………………………………1304
Steering Valve – Removal (Tractors without Cab)……………………………………………………………………………………1309
Disassembling the Steering Valve…………………………………………………………………………………………………1312
Exploded View of Steering Valve………………………………………………………………………………………………….1315
Assembling the Steering Valve……………………………………………………………………………………………………1316
Adjusting the Shock Valves………………………………………………………………………………………………………1323
Steering Wheel and Steering Column (With Cab)……………………………………………………………………………………..1324
Steering Wheel and Steering Column (Tractors without Cab)…………………………………………………………………………..1326
Recondition the Steering Column………………………………………………………………………………………………….1327
Steering Valve – Installation (Tractors with Cab)………………………………………………………………………………….1328
Steering Valve – Installation (Tractors without Cab)……………………………………………………………………………….1333
Steering Cylinder………………………………………………………………………………………………………………….1337
Steering Cylinder (Summary of References)…………………………………………………………………………………………1337
General Information…………………………………………………………………………………………………………….1337
Special or Essential Tools………………………………………………………………………………………………………1337
Specifications…………………………………………………………………………………………………………………1338
Removing the Steering Cylinder…………………………………………………………………………………………………..1338
Disassembling the Steering Cylinder………………………………………………………………………………………………1339
Assembling the Steering Cylinder…………………………………………………………………………………………………1340
Installing the Steering Cylinder…………………………………………………………………………………………………1340
Brake Valve……………………………………………………………………………………………………………………….1343
Summary of References (Brake Valve)………………………………………………………………………………………………1343
Special Tools………………………………………………………………………………………………………………….1343
Specifications…………………………………………………………………………………………………………………1343
Accumulators – Remove and Install from Tractor Serial Number 440694………………………………………………………………….1344
Brake Valve (With Power Fill)……………………………………………………………………………………………………1346
Power-Fill Brake Valve with MFWD and Disk Brake …………………………………………………………………………………..1362
Rear Brakes……………………………………………………………………………………………………………………….1383
Summary of References (Rear Brakes)………………………………………………………………………………………………1383
Special or Essential Tools………………………………………………………………………………………………………1383
Specifications…………………………………………………………………………………………………………………1385
Removing the Rear Brakes………………………………………………………………………………………………………..1385
Installing the Rear Brake……………………………………………………………………………………………………….1388
Checking Brake Pistons for Return Movement and Leakage……………………………………………………………………………..1389
Final assembly…………………………………………………………………………………………………………………1390
Bleeding the Brakes (Brake Valve, Power-Fill Brakes/MFWD and Disk Brake)……………………………………………………………..1390
AutoTrac………………………………………………………………………………………………………………………….1393
Summary of References (AutoTrac)…………………………………………………………………………………………………1393
Removal and Installation of Steering Control Valve (Y49)……………………………………………………………………………1393
Removal and Installation of Steering Input Device (B138)……………………………………………………………………………1395
Hydraulic System………………………………………………………………………………………………………………………1397
Controls………………………………………………………………………………………………………………………….1399
Hydraulic System — Controls (Summary of References) ……………………………………………………………………………….1399
Specifications…………………………………………………………………………………………………………………1399
Selective Control Valves — Removing and Installing the Actuating Elements…………………………………………………………….1400
Selective Control Valves — Adjusting the Bowden Cable………………………………………………………………………………1403
Removing and Installing the Multifunction Lever……………………………………………………………………………………1404
Adjusting the Multi-Function Lever……………………………………………………………………………………………….1406
Hydraulic Pump and Charge Oil Pump…………………………………………………………………………………………………..1407
Other Material…………………………………………………………………………………………………………………1407
Specifications…………………………………………………………………………………………………………………1407
Removing and Installing the Charge Pump…………………………………………………………………………………………..1409
Reconditioning the Charge Pump…………………………………………………………………………………………………..1410
Charge Pump – Checking the Lube Oil Valve…………………………………………………………………………………………1412
Hydraulic Oil Reservoir — Restrictor……………………………………………………………………………………………..1412
Hydraulic Pump — Removing and Installing the Pressure-and-Flow Controller…………………………………………………………….1413
Hydraulic Pump — Reconditioning the Pressure-and-Flow Controller…………………………………………………………………….1414
Removing and Installing the Hydraulic Pump………………………………………………………………………………………..1416
Reconditioning the Hydraulic Pump………………………………………………………………………………………………..1418
Valves……………………………………………………………………………………………………………………………1425
Reconditioning the Hydraulic System Valves — Summary of References…………………………………………………………………..1425
Special Tools………………………………………………………………………………………………………………….1425
Special Tools (Dealer Fabricated)………………………………………………………………………………………………..1426
Specifications…………………………………………………………………………………………………………………1427
Hydraulic System — General Instructions on Safety and Repair………………………………………………………………………..1429
Direct Control of Rockshaft……………………………………………………………………………………………………..1430
Rockshaft Valve (Narrow Version) — Removal and Installation of Spacer Housing…………………………………………………………1431
Removing the Rockshaft Valve…………………………………………………………………………………………………….1433
Recondition the Rockshaft Valve………………………………………………………………………………………………….1434
Rockshaft Valve — Depth to Which Raising and Lowering Valves are Screwed In…………………………………………………………..1441
Rockshaft Valve — Removing and Installing the Stepper Motor…………………………………………………………………………1441
Rockshaft Valve — Centering the Stepper Motor……………………………………………………………………………………..1443
Installing the Rockshaft Valve…………………………………………………………………………………………………..1444
Removing the Main Block…………………………………………………………………………………………………………1446
Reconditioning the Main Block……………………………………………………………………………………………………1448
Installing the Main Block……………………………………………………………………………………………………….1452
Reconditioning the Hydraulic Oil Filter…………………………………………………………………………………………..1453
Rockshaft…………………………………………………………………………………………………………………………1455
Special or Essential Tools………………………………………………………………………………………………………1455
Other Material…………………………………………………………………………………………………………………1455
Specifications…………………………………………………………………………………………………………………1456
Rockshaft — Removing and Installing the Electronic Control Unit……………………………………………………………………..1456
Rockshaft — Removing and Installing the Position Sensor and Toothed Segment…………………………………………………………..1457
Rockshaft — Removing and Installing the Rockshaft………………………………………………………………………………….1460
Rockshaft — Removing the Rockshaft Cylinders………………………………………………………………………………………1463
Rockshaft — Reconditioning the Rockshaft Cylinders…………………………………………………………………………………1463
Rockshaft — Installing the Rockshaft Cylinders…………………………………………………………………………………….1465
Rockshaft — Removing and Installing the Draft Sensors and Draft Link Bearing Pins……………………………………………………..1466
Selective Control Valves and Couplers………………………………………………………………………………………………..1471
Reconditioning the Selective Control Valves and Couplers — Summary of References………………………………………………………1471
Special Tools………………………………………………………………………………………………………………….1472
Special Tools (Dealer Fabricated)………………………………………………………………………………………………..1472
Other Material…………………………………………………………………………………………………………………1472
Specifications…………………………………………………………………………………………………………………1473
Reconditioning the Selective Control Valves and Couplers — General Instructions on Safety and Reconditioning……………………………..1476
SCV Identification……………………………………………………………………………………………………………..1477
Arrangement of the Shuttle Valves………………………………………………………………………………………………..1478
Removing the Selective Control Valves…………………………………………………………………………………………….1480
Series 200/300 Selective Control Valves — Replacing the Control Knobs………………………………………………………………..1482
Series 200/300 Selective Control Valves — Inspecting the Check Valves………………………………………………………………..1483
Series 200/300 Selective Control Valves — Inspecting the Inlet Check Valve and Metering Valve…………………………………………..1484
Series 200 Selective Control Valves — Reconditioning……………………………………………………………………………….1486
Series 300 Selective Control Valves — Inspecting the Pressure Compensator Valve……………………………………………………….1492
Series 300 Selective Control Valves — Reconditioning……………………………………………………………………………….1494
Installing the Selective Control Valves…………………………………………………………………………………………..1502
Selective Control Valves — Installing the Endplate…………………………………………………………………………………1504
Selective Control Valves — Reconditioning the Couplers……………………………………………………………………………..1508
Independent Control Valve (ICV)……………………………………………………………………………………………………..1513
Reconditioning Independent Control Valves — Summary of References……………………………………………………………………1513
Other Material…………………………………………………………………………………………………………………1513
Specifications…………………………………………………………………………………………………………………1514
Removing the Independent Control Valve (M-ICV)…………………………………………………………………………………….1518
Recondition the Independent Control Valve (M-ICV)………………………………………………………………………………….1520
Independent Control Valves — Reconditioning the Inlet Plate…………………………………………………………………………1532
Assemble the Independent Control Valve (M-ICV)…………………………………………………………………………………….1533
Installing the Independent Control Valve (M-ICV)…………………………………………………………………………………..1535
Independent Control Valve (E-ICV) — Removing and Installing the Stepper Motors………………………………………………………..1536
Removing the Independent Control Valve (E-ICV)…………………………………………………………………………………….1539
Recondition the Independent Control Valve (E-ICV)………………………………………………………………………………….1540
Assembling the Independent Control Valves (E-ICV)………………………………………………………………………………….1546
Installing the Independent Control Valve (E-ICV)…………………………………………………………………………………..1548
MISCELLANEOUS…………………………………………………………………………………………………………………………1549
Installing and Removing Components…………………………………………………………………………………………………..1551
Specifications…………………………………………………………………………………………………………………1551
Removing and Installing the Main Frame (Summary of References)………………………………………………………………………1551
Removing the Main Frame…………………………………………………………………………………………………………1552
Installing the Main Frame……………………………………………………………………………………………………….1558
Removing and Installing the Front Axle or Front-Wheel Drive Axle (Summary of References)……………………………………………….1559
Removing the Front Axle…………………………………………………………………………………………………………1560
Installing the Front Axle……………………………………………………………………………………………………….1561
Removing the Front-Wheel Drive Axle………………………………………………………………………………………………1562
Installing the Front-Wheel Drive Axle…………………………………………………………………………………………….1564
Removing the Front-Wheel Drive Axle With TLS………………………………………………………………………………………1565
Installing the Front-Wheel Drive Axle With TLS…………………………………………………………………………………….1569
Removing and Installing the Front Axle Support (Summary of References)……………………………………………………………….1571
Removing the Front Axle Support………………………………………………………………………………………………….1571
Installing the Front Axle Support………………………………………………………………………………………………..1577
Main Frame………………………………………………………………………………………………………………………..1579
Specifications…………………………………………………………………………………………………………………1579
Recondition the Main Frame (with or without TLS front-wheel drive axle)………………………………………………………………1579
Front Axle………………………………………………………………………………………………………………………..1585
Special or Essential Tools………………………………………………………………………………………………………1585
Specifications…………………………………………………………………………………………………………………1586
Front Axle – Reconditioning (Summary of References)………………………………………………………………………………..1586
Removing the Front Axle…………………………………………………………………………………………………………1587
Reconditioning the Front Axle……………………………………………………………………………………………………1587
Installing the Front Axle……………………………………………………………………………………………………….1597
Checking and Adjusting Toe-In……………………………………………………………………………………………………1599
Front Wheels, Rear Wheels and Fenders………………………………………………………………………………………………..1601
Front Wheels, Rear Wheels and Fenders – Reconditioning (Summary of References)………………………………………………………..1601
Special or Essential Tools………………………………………………………………………………………………………1601
Specifications…………………………………………………………………………………………………………………1602
Pivoting Front Fender…………………………………………………………………………………………………………..1604
Removing the Front and Rear Wheels……………………………………………………………………………………………….1606
Reconditioning the Front and Rear Wheels………………………………………………………………………………………….1608
Installing the Front and Rear Wheels……………………………………………………………………………………………..1612
Trailer Mounting and Swinging Drawbar………………………………………………………………………………………………..1617
Tightening Torque On Center Link Bracket………………………………………………………………………………………….1617
Tightening Torques On Swinging Drawbar……………………………………………………………………………………………1617
Tightening Torques On High-Clearance Drawbar………………………………………………………………………………………1618
Adjusting the High-Clearance Drawbar……………………………………………………………………………………………..1619
Adjusting the Retaining Strap……………………………………………………………………………………………………1619
Triple Link Suspension (TLS) of Front-Wheel Drive Axle…………………………………………………………………………………1621
Triple Link Suspension (TLS) of FWD Axle (Summary of References)…………………………………………………………………….1621
Special or Essential Tools………………………………………………………………………………………………………1622
Other Material…………………………………………………………………………………………………………………1625
Specifications…………………………………………………………………………………………………………………1626
Relieving Pressure in the Hydraulic System………………………………………………………………………………………..1628
Removing/Installing the Oscillation Limiter……………………………………………………………………………………….1629
Removing the Panhard Link……………………………………………………………………………………………………….1630
Installing the Panhard Link……………………………………………………………………………………………………..1631
Removing and Installing the Sensor Rod……………………………………………………………………………………………1632
Removing the Position Sensor…………………………………………………………………………………………………….1633
Reconditioning the Position Sensor……………………………………………………………………………………………….1635
Installing the Position Sensor…………………………………………………………………………………………………..1636
Removing the Hydraulic Cylinder………………………………………………………………………………………………….1637
Repairing the Hydraulic Cylinder…………………………………………………………………………………………………1644
Installing the Hydraulic Cylinder………………………………………………………………………………………………..1656
Removing the Control Valve Block…………………………………………………………………………………………………1661
Repairing the Valves in the Control Valve Block……………………………………………………………………………………1663
Installing the Control Valve Block……………………………………………………………………………………………….1670
Removing the Accumulator………………………………………………………………………………………………………..1672
Reconditioning the Accumulator…………………………………………………………………………………………………..1673
Installing the Accumulator………………………………………………………………………………………………………1674
Removing and Reconditioning the Bearing Support……………………………………………………………………………………1675
Installing the bearing support…………………………………………………………………………………………………..1683
OPERATOR’S CAB………………………………………………………………………………………………………………………..1689
Installing and Removing Components…………………………………………………………………………………………………..1691
Special Tools………………………………………………………………………………………………………………….1691
Dealer-Fabricated Special Tools………………………………………………………………………………………………….1693
Specifications…………………………………………………………………………………………………………………1695
Operator’s Cab / Open Station, Tilting or Removing and Installing……………………………………………………………………1696
Tilting the Operator’s Cab Upward………………………………………………………………………………………………..1696
Tilting the Operator’s Cab Downward………………………………………………………………………………………………1705
Removing the Operator’s Cab……………………………………………………………………………………………………..1711
Installing the Operator’s Cab……………………………………………………………………………………………………1721
Removing the Open Operator’s Station……………………………………………………………………………………………..1726
Installing the Open Operator’s Station……………………………………………………………………………………………1732
Checking and Adjusting the Shift Mechanisms/Linkages……………………………………………………………………………….1735
Controls and Instruments……………………………………………………………………………………………………………1737
Controls and Instruments (Summary of References)…………………………………………………………………………………..1737
Replacing Bulbs on the Instrument Unit……………………………………………………………………………………………1737
Removing Control Unit…………………………………………………………………………………………………………..1738
Removing Control Unit for the Lighting System……………………………………………………………………………………..1738
Instructions when Replacing a Control Unit………………………………………………………………………………………..1739
Replacing the UIM Control Unit…………………………………………………………………………………………………..1739
Replacing a VTI Display…………………………………………………………………………………………………………1740
Replacing a BCU Control Unit…………………………………………………………………………………………………….1740
Replacing a BCU Control Unit (Tractors without Cab)………………………………………………………………………………..1741
Replacing a TCU Control Unit…………………………………………………………………………………………………….1742
Replacing an SFA Control Unit……………………………………………………………………………………………………1743
Replacing an SIC Control Unit……………………………………………………………………………………………………1744
Replacing an ECU Control Unit……………………………………………………………………………………………………1744
Replacing an ECU Control Unit (Tractors without Cab)……………………………………………………………………………….1745
Replacing an UIC/PLC Control Unit………………………………………………………………………………………………..1745
Replacing the Terminating Resistors………………………………………………………………………………………………1746
Replacing the Performance Monitor (PRF)…………………………………………………………………………………………..1751
Replace the Basic Informator (BIF)……………………………………………………………………………………………….1751
Replacing Instrument Unit (Tractors without Cab)…………………………………………………………………………………..1752
Replace Operation Unit………………………………………………………………………………………………………….1754
Air Conditioning System…………………………………………………………………………………………………………….1755
Air-Conditioning System (Summary of References)……………………………………………………………………………………1755
Special or Essential Tools………………………………………………………………………………………………………1755
Specifications…………………………………………………………………………………………………………………1757
Torques for Tightening Refrigerant Hoses………………………………………………………………………………………….1758
Safety At Work…………………………………………………………………………………………………………………1758
Handling Refrigerant……………………………………………………………………………………………………………1759
In an Emergency………………………………………………………………………………………………………………..1759
Safety Equipment……………………………………………………………………………………………………………….1760
Storage of Refrigerant Containers………………………………………………………………………………………………..1760
R134A Refrigerant………………………………………………………………………………………………………………1761
Important Note…………………………………………………………………………………………………………………1762
Other Materials Specifications…………………………………………………………………………………………………..1762
Lay-Out of Refrigerant Hoses…………………………………………………………………………………………………….1762
Discharging the Air-Conditioning System…………………………………………………………………………………………..1763
Evacuating the Air-Conditioning System……………………………………………………………………………………………1764
Filling with Refrigerant Oil…………………………………………………………………………………………………….1765
Instructions for Starting Up the DENSO Air-Conditioning Compressor…………………………………………………………………..1766
Charging the Air-Conditioning System……………………………………………………………………………………………..1767
Leak Test……………………………………………………………………………………………………………………..1768
Removing the Compressor…………………………………………………………………………………………………………1768
Checking Level in the Compressor…………………………………………………………………………………………………1769
Disassembling the Compressor Clutch………………………………………………………………………………………………1769
Checking Clutch Hub Clearance……………………………………………………………………………………………………1771
Checking the Compressor Manifold…………………………………………………………………………………………………1771
Installing the Compressor……………………………………………………………………………………………………….1772
Removing and Installing the Condenser…………………………………………………………………………………………….1773
Removing and Installing the Receiver-Drier………………………………………………………………………………………..1774
Removing and Installing the Evaporator and Expansion Valve………………………………………………………………………….1775
Replacing the Expansion Valve……………………………………………………………………………………………………1775
Installing Condensation Water Drain Hoses…………………………………………………………………………………………1776
Removing and Installing the Thermostat Switch……………………………………………………………………………………..1776
Adjusting Thermostat Switch Bowden Cables…………………………………………………………………………………………1777
Removing and Installing the High/Low Pressure Switch……………………………………………………………………………….1777
ClimaTrak…………………………………………………………………………………………………………………………1779
ClimaTrak – Summary of References………………………………………………………………………………………………..1779
Removing and Installing the ATC Controller (ClimaTrak)……………………………………………………………………………..1779
Removing and Installing the Driver Unit for Fan Motor (A59)…………………………………………………………………………1780
Removing and Installing the Sending Unit for Ambient Temperature (Front) (B125)……………………………………………………….1780
Removing and Installing the Sending Unit for Ambient Temperature (Rear) (B126)………………………………………………………..1781
Removing and Installing the Sending Unit for Inside Air Temperature (B127)……………………………………………………………1782
Removing and Installing the Sending Unit for Actual Outlet Air Temperature (B128)……………………………………………………..1783
Removing and Installing the Sending Unit for Evaporator Core Temperature (B129)……………………………………………………….1783
Removing and Installing Sending Unit for Refrigerant Pressure (B130)…………………………………………………………………1784
Water Valve (B131) Removal and Installation……………………………………………………………………………………….1784
Mode Control for Position of Air Distribution Flaps (B132), Removal and Installation…………………………………………………..1785
Remove and Install the Defog sensor (B143)………………………………………………………………………………………..1786
Heating System…………………………………………………………………………………………………………………….1789
Heating System (Summary of References)……………………………………………………………………………………………1789
Removal and Installation of Components……………………………………………………………………………………………1789
Adjusting Air Flow Bowden Cables…………………………………………………………………………………………………1791
Seats…………………………………………………………………………………………………………………………….1793
Seats (Summary of References)……………………………………………………………………………………………………1793
Specifications…………………………………………………………………………………………………………………1793
Exploded View of Comfort Seat MSG44-A1……………………………………………………………………………………………1794
Super Comfort Seat MSG83………………………………………………………………………………………………………..1795
Comfort Seat MSG85……………………………………………………………………………………………………………..1807
Air comfort seat MSG95, lower section…………………………………………………………………………………………….1820
Exploded View of the Instructional Seat…………………………………………………………………………………………..1825
Operator’s Cab…………………………………………………………………………………………………………………….1827
Operator’s Cab (Summary of References)……………………………………………………………………………………………1827
Removing Cab Frame……………………………………………………………………………………………………………..1827
Torques for Hardware on Platform Mounting (2-Post ROPS, Standard Version)…………………………………………………………….1828
Cab Mounting Torques……………………………………………………………………………………………………………1829
Removing the Outer Roof…………………………………………………………………………………………………………1831
Removing and Installing the Windshield …………………………………………………………………………………………..1831
Removing and Installing the Rear Window…………………………………………………………………………………………..1832
Removal and Installation of Panoramic Windshield…………………………………………………………………………………..1833
Installing Door Lock……………………………………………………………………………………………………………1839
Adjusting Windshield and Rear Window Contact Pressure………………………………………………………………………………1840
Operator’s Cab Door Removal and Installation………………………………………………………………………………………1840
Roller Sun-Visor Removal and Installation…………………………………………………………………………………………1841
Removing Inner Roof Trim………………………………………………………………………………………………………..1842
Low-Clearance Cab………………………………………………………………………………………………………………….1843
Low-Clearance Cab (Summary of References)…………………………………………………………………………………………1843
Special Tools………………………………………………………………………………………………………………….1843
Specifications…………………………………………………………………………………………………………………1844
Removing the Cab Frame………………………………………………………………………………………………………….1845
Removal and installation of Cab Mountings…………………………………………………………………………………………1846
Removing Outer Roof…………………………………………………………………………………………………………….1847
Remove Windshield………………………………………………………………………………………………………………1847
Install Windshield……………………………………………………………………………………………………………..1848
Removing the Rear Window………………………………………………………………………………………………………..1848
Installing the Rear Window………………………………………………………………………………………………………1849
Installing the Outer Roof……………………………………………………………………………………………………….1850
Removing Cab Frame Trim Panel and Speaker Panel……………………………………………………………………………………1850
Removing the Cab Door…………………………………………………………………………………………………………..1851
Installing the Cab Door…………………………………………………………………………………………………………1851
Replacing the Rear-View Mirror…………………………………………………………………………………………………..1851
Installing and Adjusting the Door Lock……………………………………………………………………………………………1852
Removing the Upper and Lower Side Panels From the Cab Door………………………………………………………………………….1853
Installing the Upper and Lower Side Panels In the Cab Door………………………………………………………………………….1854
Cab Suspension…………………………………………………………………………………………………………………….1857
Cab Suspension — Summary of References……………………………………………………………………………………………1857
Important Instructions………………………………………………………………………………………………………….1857
Specifications…………………………………………………………………………………………………………………1858
Relieving Hydraulic System Pressure………………………………………………………………………………………………1859
Installing and Removing the Cab Suspension Shields…………………………………………………………………………………1859
Removing and Installing the Sensor Rod……………………………………………………………………………………………1860
Adjusting the Sensor Rod………………………………………………………………………………………………………..1860
Removing the Position Sensor…………………………………………………………………………………………………….1861
Reconditioning the Position Sensor……………………………………………………………………………………………….1862
Installing the Position Sensor…………………………………………………………………………………………………..1862
Removing the Accumulator………………………………………………………………………………………………………..1863
Reconditioning the Accumulator…………………………………………………………………………………………………..1864
Installing the Accumulator………………………………………………………………………………………………………1865
Removing Hydraulic Cylinder……………………………………………………………………………………………………..1865
Installing Hydraulic Cylinder……………………………………………………………………………………………………1865
Removing the Control Valve Block…………………………………………………………………………………………………1866
Reconditioning the Valves in the Control Valve Block……………………………………………………………………………….1867
Installing the Control Valve Block……………………………………………………………………………………………….1870
Panhard Link Removal and Installation…………………………………………………………………………………………….1870
Bleeding Cab Suspension Hydraulic Cylinders……………………………………………………………………………………….1871
Special Tools (Dealer-Fabricated)……………………………………………………………………………………………………….1873
Special Tools (Dealer-Fabricated)……………………………………………………………………………………………………1875
DFLX2 – Suspension Device……………………………………………………………………………………………………….1875
DFLX3 ł Suspension Device for PowrQuad Module……………………………………………………………………………………..1876
Lifting Device for Low Clearance Cab……………………………………………………………………………………………..1877
DFLX13 – Holding Device…………………………………………………………………………………………………………1878
Suspension Eyes for Operator’s Cab……………………………………………………………………………………………….1878
Holding Device…………………………………………………………………………………………………………………1879
Holding Tool…………………………………………………………………………………………………………………..1879
DFLX16 – Wooden Block…………………………………………………………………………………………………………..1880
DFRW79 ł Piston Holding Tool…………………………………………………………………………………………………….1880
DFLX22 ł Socket Wrench Insert……………………………………………………………………………………………………1880
DFLX24 – Seal Installer…………………………………………………………………………………………………………1880
DFLX25 ł Driver………………………………………………………………………………………………………………..1881
DFLX17 – Assembly and Guide Mandrels……………………………………………………………………………………………..1881
Turning Device…………………………………………………………………………………………………………………1881
Bushing……………………………………………………………………………………………………………………….1882
DFLX27 ł Driver………………………………………………………………………………………………………………..1882
DFLX23 ł Socket Wrench Insert……………………………………………………………………………………………………1883
DFLX21 – Special Wrench…………………………………………………………………………………………………………1883
Special Tools (available from the dealer)…………………………………………………………………………………………….1885
D01042AA ł Load-Positioning Sling………………………………………………………………………………………………..1885
D05007ST ł Tractor Splitting Stand……………………………………………………………………………………………….1885
JDE83 ł Flywheel Turning Tool……………………………………………………………………………………………………1885
JDG19 ł Special Mounting Brackets………………………………………………………………………………………………..1885
JDG18 – Snap Ring Tool………………………………………………………………………………………………………….1885
JDG23 ł Lifting Sling…………………………………………………………………………………………………………..1886
JDG749 – 1.30 m (52 in.) Torque Extension…………………………………………………………………………………………1886
JDG750 ł Swivel Socket………………………………………………………………………………………………………….1886
JDG820 ł Flywheel Turning Tool…………………………………………………………………………………………………..1886
JT05723 ł Medium-Duty Rear Tractor Splitting Stand…………………………………………………………………………………1886
JT05724 ł Medium-Duty Front Tractor Splitting Stand………………………………………………………………………………..1887
JT05725 ł Universal Support Stand………………………………………………………………………………………………..1887
JT02044 ł Support Stand…………………………………………………………………………………………………………1887
KJD10173 ł Shaft Puller…………………………………………………………………………………………………………1887
KJD10178B ł Cab Tilting Device (NA)………………………………………………………………………………………………1888
KJD10169 – Special Puller……………………………………………………………………………………………………….1889
KJD10293 ł Disconnecting Tool……………………………………………………………………………………………………1889

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