John Deere Tractor Compact Utility 4200 4300 4400 TM1677 07420
2019-04-23
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4200, 4300 and 4400
Compact Utility Tractors
TECHNICAL
MANUAL
John Deere
Lawn & Grounds Care Division
TM1677 (Apr01)
Replaces TM1677 (Jul99)
Litho in U.S.A
M91749
4200 Tractor
M91750
4300 Tractor
M91814
4400 Tractor
INTRODUCTION
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support
program.
Safety
Specifications and
Information
The manual is organized so that all the information on a
particular system is kept together. The order of grouping
is as follows:
•
•
•
•
•
•
•
•
•
Note:
Table of Contents
Specifications
Component Location
System Schematic
Theory of Operation
Troubleshooting Chart
Diagnostics
Tests & Adjustments
Repair
Depending on the particular section or system
being covered, not all of the above groups may
be used.
Each section will be identified with a symbol rather than a
number. The groups and pages within a section will be
consecutively numbered.
We appreciate your input on this manual. To help, there
are postage paid post cards included at the back. If you
find any errors or want to comment on the layout of the
manual please fill out one of the cards and mail it back to
us.
Diesel Engine
Electrical
Gear Power Train
Hydrostatic Power Train
SyncReverser™ Power Train
Final Drive Power Train
Steering
Brakes
Hydraulics
All information, illustrations and
specifications in this manual are based on
the latest information available at the time of
publication. The right is reserved to make
changes at any time without notice.
Miscellaneous
COPYRIGHT© 2001
Deere & Co.
John Deere Worldwide Commercial and
Consumer Equipment Division
Horicon, WI
All rights reserved
Previous Versions 1998
4/6/01
1-1
SAFETY
SAFETY
HANDLE FLUIDS SAFELY-AVOID
FIRES
RECOGNIZE SAFETY INFORMATION
Be Prepared For Emergencies
This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe servicing
practices.
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—
is used with the safety-alert symbol. DANGER
identifies the most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention
to safety messages in this manual.
REPLACE SAFETY SIGNS
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
1-2
4/6/01
SAFETY
USE CARE IN HANDLING AND
SERVICING BATTERIES
USE CARE AROUND HIGHPRESSURE FLUID LINES
Avoid High-pressure Fluids
Prevent Battery Explosions
• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
• Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F).
Prevent Acid Burns
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
• Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid injury from escaping fluid under pressure by
stopping the engine and relieving pressure in the
system before disconnecting or connecting hydraulic or
other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically removed
within a few hours or gangrene may result. Doctors
unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is
available from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Avoid Heating Near Pressurized
Fluid Lines
• If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10 – 15 minutes.
4. Get medical attention immediately.
• If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
4/6/01
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines
or other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
1-3
SAFETY
USE SAFE SERVICE PROCEDURES
Park Machine Safely
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause
impairment or loss of hearing. Wear a suitable hearing
protective device such as earmuffs or earplugs to
protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention
of the operator. Do not wear radio or music
headphones while operating machine.
Before working on the machine:
1. Lower all equipment to the ground.
2. Stop the engine and remove the key.
3. Disconnect the battery ground strap.
4. Hang a “DO NOT OPERATE” tag in operator
station.
Support Machine Properly And Use
Proper Lifting Equipment
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For
loosening and tightening hardware, use the correct size
tools. DO NOT use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches. Use only service parts meeting John Deere
specifications.
1-4
If you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely
by a jack. Follow recommended procedures in this
manual.
Lifting heavy components incorrectly can cause severe
injury or machine damage. Follow recommended
procedure for removal and installation of components
in the manual.
Work In Clean Area
Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your
job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
4/6/01
SAFETY
Using High Pressure Washers
Avoid Harmful Asbestos Dust
Directing pressurized water at electronic/electrical
components or connectors, bearings, hydraulic seals,
fuel injection pumps or other sensitive parts and
components may cause product malfunctions. Reduce
pressure and spray at a 45 to 90 degree angle.
Avoid breathing dust that may be generated when
handling components containing asbestos fibers.
Inhaled asbestos fibers may cause lung cancer.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Work In Ventilated Area
Components in products that may contain asbestos
fibers are brake pads, brake band and lining
assemblies, clutch plates, and some gaskets. The
asbestos used in these components is usually found in
a resin or sealed in some way. Normal handling is not
hazardous as long as airborne dust containing
asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material
containing asbestos. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available, apply
a mist of oil or water on the material containing
asbestos. Keep bystanders away from the area.
SERVICE TIRES SAFELY
Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an
exhaust pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
WARNING: California Proposition 65
Warning:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Remove Paint Before Welding Or
Heating
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside
or in a well ventilated area. Dispose of paint and
solvent properly. Remove paint before welding or
heating: If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water
before welding. Remove solvent or paint stripper
containers and other flammable material from area.
Allow fumes to disperse at least 15 minutes before
welding or heating.
4/6/01
Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
1-5
SAFETY
AVOID INJURY FROM ROTATING
BLADES, AUGERS AND PTO
SHAFTS
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. Check the MSDS before you start any job
using a hazardous chemical. That way you will know
exactly what the risks are and how to do the job safely.
Then follow procedures and recommended equipment.
Dispose of Waste Properly
Keep hands and feet away while machine is running.
Shut off power to service, lubricate or remove mower
blades, augers or PTO shafts.
SERVICE COOLING SYSTEM
SAFELY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items as
oil, fuel, coolant, brake fluid, filters, and batteries. Use
leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead
someone into drinking from them. Do not pour waste
onto the ground, down a drain, or into any water
source. Inquire on the proper way to recycle or dispose
of waste from your local environmental or recycling
center, or from your John Deere dealer.
LIVE WITH SAFETY
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off machine. Only remove filler cap when cool
enough to touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
HANDLE CHEMICAL PRODUCTS
SAFELY
1-6
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
4/6/01
CONTENTS
SPECIFICATIONS AND INFORMATION
CONTENTS
Page
GENERAL VEHICLE SPECIFICATIONS – 4200 . . . . . . . . . . . . . . . . . . . 3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PTO (PTO Shaft Speed Measured at 2700 Engine rpm). . . . . . . . . . . . . . . . . . . . . . . 4
3–POINT HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GROUND SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL VEHICLE SPECIFICATIONS – 4300 . . . . . . . . . . . . . . . . . . . 6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PTO (PTO Shaft Speed Measured at 2700 Engine rpm). . . . . . . . . . . . . . . . . . . . . . . 7
3–POINT HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GROUND SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL VEHICLE SPECIFICATIONS – 4400 . . . . . . . . . . . . . . . . . . 10
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PTO (PTO Shaft Speed Measured at 2700 Engine rpm). . . . . . . . . . . . . . . . . . . . . . 11
3–POINT HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
GROUND SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INCH FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . 14
METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . 15
O-RING SEAL SERVICE RECOMMENDATIONS. . . . . . . . . . . . . . . . . . 16
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE . . . . . . . . . . . . . . . . . . 16
FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE . . . . . . . . . . . . . . . . 17
O-RING FACE SEAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
O-RING BOSS FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4/6/01
2-1
CONTENTS
SPECIFICATIONS AND INFORMATION
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIESEL FUEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIESEL FUEL LUBRICITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIESEL FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BREAK–IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION & HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CHASSIS GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
22
22
22
22
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT DRAIN INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRODUCT IDENTIFICATION LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . 23
2-2
4/6/01
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS* – 4200
GENERAL VEHICLE SPECIFICATIONS* – 4200
4200 CST
4200 HST
Make
John Deere/Yanmar
John Deere/Yanmar
Model
3TNE78A
3TNE78A
Type
4-cycle Diesel
4-cycle Diesel
Bore and Stroke
78x84 mm (3.07x3.31 in.)
78x84 mm (3.07x3.31 in.)
Cylinders
3
3
Valves
Overhead Valves
Overhead Valves
Displacement
1204 cm3 (73.5 cu in.)
1204 cm3 (73.5 cu in.)
Compression Ratio
18.0:1
18.0:1
Gross Engine Power
19.6 kW (26.3 hp)
19.6 kW (26.3 hp)
Torque (at rated speed)
63.2 N•m (46.6 lb-ft)
63.2 N•m (46.6 lb-ft)
Torque (max. @ 1600 rpm) 78.5 N•m (57.9 lb-ft)
78.5 N•m (57.9 lb-ft)
Lubrication
Full pressure
Full pressure
Oil filter
Standard Single Element
Standard Single Element
Oil Capacity (w/filter)
3.8 L (4.0 qt)
3.8 L (4.0 qt)
Engine Rated Speed
2700 rpm
2700 rpm
Engine Slow Idle Speed
950 ± 50 rpm
1000 ± 50 rpm
Engine Fast Idle Speed
2920 ± 25 rpm
2920 ± 25 rpm
Cooling system
Liquid w/Pump & Radiator
Liquid w/Pump & Radiator
Air cleaner
Dry-Type w/Safety Element Dry-Type w/Safety Element
ENGINE
ELECTRICAL
Volts
12 VDC
12 VDC
Battery Size - 12V (CCA)
500 Cold Cranking Amps
500 Cold Cranking Amps
Alternator
40 amp
40 amp
Regulator
Internal, Current Limiting
Internal, Current Limiting
Starting Motor
1.2 kW (1.61 hp)
1.2 kW (1.61 hp)
Headlights
37.5 W Halogen Bulb
37.5 W Halogen Bulb
Tail Lights
5 W Bayonet Base
5 W Bayonet Base
Hazard Lights
Type 1156
Type 1156
Instrument Panel Lamps
1.7 W Bayonet Base
1.7 W Bayonet Base
*Specifications and design subject to change without notice.
4/6/01
2-3
FUEL SYSTEM
SPECIFICATIONS & INFORMATION
4200 CST
4200 HST
System Type
Direct Fuel Injection
Direct Fuel Injection
Injection Pump
In-Line w/Solenoid Shutoff In-Line w/Solenoid Shutoff
Fuel type
Diesel
Diesel
Fuel Tank Capacity
37.9 L (10.0 gal)
37.9 L (10.0 gal)
Fuel Filter
Clear Bowl Water
Separator with Disposable
Paper Element,
Water Floating Red Ring
Clear Bowl Water
Separator with Disposable
Paper Element,
Water Floating Red Ring
Type
9 x 3 Collar Shift
HST and Gear
Mechanical Front Wheel
Drive (4-WD)
Yes (Option)
Yes (Option)
Front Axle Fluid Capacity
3.8 L (1.0 gal)
3.8 L (1.0 gal)
Differential Lock
Standard; Foot Operated
Standard; Foot Operated
Number of Speeds
9 Forward, 3 Reverse
Infinite / 3 Range
Final Drive
Spur Gear
Spur Gear
Brakes
Wet Disk
Wet Disk
Steering
Hydraulic Power Assist
Hydraulic Power Assist
Drawbar Tongue Weight
Vertical Capacity Rating
500 kg (1102 lb)
500 kg (1102 lb)
FUEL SYSTEM
DRIVE TRAIN
PTO (PTO Shaft Speed Measured at 2700 Engine rpm)
Type
Independent
Idenpendent
Rotation Direction
Clockwise
Clockwise
Clutch
Multiple Wet Disk
Multiple Wet Disk
Brake
Wet Disk
Wet Disk
Rear Shaft Speed
540 rpm
540 rpm
Mid Shaft Speed
2100 rpm
2100 rpm
2 - Speed Shaft Speeds
540 rpm and 750 rpm
540 rpm and 750 rpm
PTO Output Power
16.0 kW (21.5 hp)
14.9 kW (20.0 hp)
Type
Category One
Category One
Lift Capacity at 61.0 cm
(24 in.) Behind Link Arms
771 kg (1700 lb)
771 kg (1700 lb)
3–POINT HITCH
2-4
4/6/01
CLUTCH
SPECIFICATIONS & INFORMATION
4200 CST
4200 HST
Wet Multiple
None
CLUTCH
Type Disk
HYDRAULIC SYSTEM
(Measurements Taken At
2700 Engine rpm)
(Measurements Taken At
2700 Engine rpm)
Type
Open Center System
Open Center System
Tran/Hydr Fill Capacity
24 L (6.3 gal)
26 L (6.8 gal)
Working Pressure
14652 kPa (2125 psi)
14652 kPa (2125 psi)
Pump
Open Ctr/Gear
Open Ctr/Gear
Front Pump Capacity
19.3 L/min (5.1 gpm)
19.3 L/min (5.1 gpm)
Rear Pump Capacity
27.6 L/min (7.3 gpm)
27.6 L/min (7.3 gpm)
Total Fluid Capacity
46.9 L/min (12.4 gpm)
46.9 L/min (12.4 gpm)
Range A, Gear 1
1.3 km/h (0.8 mph)
6.0 km/h (3.7 mph)
Range A, Gear 2
2.0 km/h (1.3 mph)
Range A, Gear 3
2.7 km/h (1.7 mph)
Range B, Gear 1
3.7 km/h (2.3 mph)
Range B, Gear 2
5.6 km/h (3.5 mph)
Range B, Gear 3
7.5 km/h (4.7 mph)
Range C, Gear 1
10.5 km/h (6.5 mph)
Range C, Gear 2
15.9 km/h (9.9 mph)
Range C, Gear 3
21.2 km/h (13.2 mph)
Range A, Reverse 1
1.3 km/h (0.8 mph)
6.0 km/h (3.7 mph)
Range B, Reverse 1
3.7 km/h (2.3 mph)
10.5 km/h (6.5 mph)
Range C, Reverse 1
10.1 km/h (6.3 mph)
21.1 km/h (13.1 mph)
1213 kg (2675 lbs)
1304 kg (2875 lbs)
Front (Standard)
7.00 - 12 R1
7.00 - 12 R1
Rear (Standard)
12.4 - 16 R1
12.4 - 16 R1
GROUND SPEEDS
10.5 km/h (6.5 mph)
21.1 km/h (13.1 mph)
WEIGHT
w/ROPS, 3PT
TIRES
4/6/01
2-5
GENERAL VEHICLE SPECIFICATIONS* – 4300
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS* – 4300
4300 CST
4300 SRT
4300 HST
Make
John Deere/Yanmar
John Deere/Yanmar
John Deere/Yanmar
Model
3TNE84
3TNE84
3TNE84
Type
4-cycle Diesel
4-cycle Diesel
4-cycle Diesel
Bore and Stroke
84x90 mm (3.31x3.54 in.)
84x90 mm (3.31x3.54 in.)
84x90 mm (3.31x3.54 in.)
Cylinders
3
3
3
Valves
Overhead Valves
Overhead Valves
Overhead Valves
Displacement
1496 cm3 (91.3 cu in.)
1496 cm3 (91.3 cu in.)
1496 cm3 (91.3 cu in.)
Compression Ratio
18.0:1
18.0:1
18.0:1
Gross Engine Power
24.0 kW (32.2 hp)
24.0 kW (32.2 hp)
24.0 kW (32.2 hp)
Torque (at rated speed)
78.5 N•m (57.9 lb-ft)
78.5 N•m (57.9 lb-ft)
78.5 N•m (57.9 lb-ft)
Torque (max. @ 1700 rpm) 99.1 N•m (73.1 lb-ft)
99.1 N•m (73.1 lb-ft)
99.1 N•m (73.1 lb-ft)
Lubrication
Full pressure
Full pressure
Full pressure
Oil filter
Standard Single Element
Standard Single Element
Standard Single Element
Oil Capacity (w/filter)
4.3 L (4.6 qt)
4.3 L (4.6 qt)
4.3 L (4.6 qt)
Engine Rated Speed
2700 rpm
2700 rpm
2700 rpm
Engine Slow Idle Speed
950 ± 50 rpm
950 ± 50 rpm
1000 ± 50 rpm
Engine Fast Idle Speed
2920 ± 25 rpm
2920 ± 25 rpm
2920 ± 25 rpm
Cooling system
Liquid w/Pump & Radiator
Liquid w/Pump & Radiator
Liquid w/Pump & Radiator
Air cleaner
Dry-Type w/Safety Element Dry-Type w/Safety Element Dry-Type w/Safety Element
ENGINE
ELECTRICAL
Volts
12 VDC
12 VDC
12 VDC
Battery Rating
45 amp-hr
45 amp-hr
45 amp-hr
Battery Size - 12V (CCA)
500 Cold Cranking Amps
500 Cold Cranking Amps
500 Cold Cranking Amps
Alternator
40 amp
40 amp
40 amp
Regulator
Internal, Current Limiting
Internal, Current Limiting
Internal, Current Limiting
Starting Motor
1.4 kW (1.88 hp)
1.4 kW (1.88 hp)
1.4 kW (1.88 hp)
Headlights
37.5 W Halogen Bulb
37.5 W Halogen Bulb
37.5 W Halogen Bulb
Tail Lights
5 W Bayonet Base
5 W Bayonet Base
5 W Bayonet Base
Hazard Lights
Type 1156
Type 1156
Type 1156
Instrument Panel Lamps
1.7 W Bayonet Base
1.7 W Bayonet Base
1.7 W Bayonet Base
*Specifications and design subject to change without notice.
2-6
4/6/01
FUEL SYSTEM
SPECIFICATIONS & INFORMATION
4300 CST
4300 SRT
4300 HST
System Type
Direct Fuel Injection
Direct Fuel Injection
Direct Fuel Injection
Injection Pump
In-Line w/Solenoid Shutoff In-Line w/Solenoid Shutoff In-Line w/Solenoid Shutoff
Fuel type
Diesel
Diesel
Diesel
Fuel Tank Capacity
37.9 L (10.0 gal)
37.9 L (10.0 gal)
37.9 L (10.0 gal)
Fuel Filter
Clear Bowl Water
Separator with Disposable
Paper Element,
Water Floating Red Ring
Clear Bowl Water
Separator with Disposable
Paper Element,
Water Floating Red Ring
Clear Bowl Water
Separator with Disposable
Paper Element,
Water Floating Red Ring
Type
Collar Shift
SyncReverser™
Hydrostatic
Mechanical Front Wheel
Drive (4-WD)
Yes (Option)
Yes (Option)
Yes (Option)
Front Axle Fluid Capacity
3.8 L (1.0 gal)
3.8 L (1.0 gal)
3.8 L (1.0 gal)
Differential Lock
Standard; Foot Operated
Standard; Foot Operated
Standard; Foot Operated
Number of Speeds
9 Forward, 3 Reverse
12 Forward-12 Reverse
Infinite / 3 Range
Final Drive
Spur Gear
Spur Gear
Spur Gear
Brakes
Wet Disk
Wet Disk
Wet Disk
Steering
Hydraulic Power Assist
Hydraulic Power Assist
Hydraulic Power Assist
Drawbar Tongue Weight
Vertical Capacity Rating
500 kg (1102 lb)
500 kg (1102 lb)
500 kg (1102 lb)
FUEL SYSTEM
DRIVE TRAIN
PTO (PTO Shaft Speed Measured at 2700 Engine rpm)
Type
Independent
Independent
Independent
Rotation Direction
Clockwise
Clockwise
Clockwise
Clutch
Multiple Wet Disk
Multiple Wet Disk
Multiple Wet Disk
Brake
Wet Disk
Wet Disk
Wet Disk
Rear Shaft Speed
540 rpm
540 rpm
540 rpm
Mid Shaft Speed
2100 rpm
2100 rpm
2100 rpm
2 - Speed Shaft Speeds
540 rpm and 750 rpm
540 rpm and 750 rpm
540 rpm and 750 rpm
PTO Output Power
20.0 kW (26.8 hp)
20.0 kW (26.8 hp)
18.9 kW (25.3 hp)
Type
Category One
Category One
Category One
Lift Capacity at 61.0 cm
(24 in.) Behind Link Arms
999 kg (2200 lb)
999 kg (2200 lb)
999 kg (2200 lb)
3–POINT HITCH
*Specifications and design subject to change without notice.
4/6/01
2-7
CLUTCH
SPECIFICATIONS & INFORMATION
4300 CST
4300 SRT
4300 HST
Wet Multiple
Wet Multiple
None
(Measurements Taken At
2700 Engine rpm)
(Measurements Taken At
2700 Engine rpm)
(Measurements Taken At
2700 Engine rpm)
Type
Open Center System
Open Center System
Open Center System
Tran/Hydr Fill Capacity
24 L (6.3 gal)
24 L (6.3 gal)
26 L (6.8 gal)
Working Pressure
17238 kPa (2500 psi)
17238 kPa (2500 psi)
17238 kPa (2500 psi)
Pump
Open Ctr/Gear
Open Ctr/Gear
Open Ctr/Gear
Front Pump Capacity
19.3 L/min (5.1 gpm)
19.3 L/min (5.1 gpm)
19.3 L/min (5.1 gpm)
Rear Pump Capacity
31.4 L/min (8.3 gpm)
31.4 L/min (8.3 gpm)
31.4 L/min (8.3 gpm)
Total Pump Capacity
50.7 L/min (13.4 gpm)
50.7 L/min (13.4 gpm)
50.7 L/min (13.4 gpm)
Range A, Gear 1
1.6 km/h (1.0 mph)
0.6 km/h (0.4 mph)
7.1 km/h (4.4 mph)
Range A, Gear 2
2.4 km/h (1.5 mph)
1.5 km/h (0.9 mph)
Range A, Gear 3
3.2 km/h (2.0 mph)
1.6 km/h (1.0 mph)
CLUTCH
Type Disk
HYDRAULIC SYSTEM
GROUND SPEEDS
Range A, Gear 4
2.3 km/h (1.4 mph)
Range B, Gear 1
4.4 km/h (2.7 mph)
3.1 km/h (1.9 mph)
Range B, Gear 2
6.6 km/h (4.1 mph)
4.2 km/h (2.6 mph)
Range B, Gear 3
8.9 km/h (5.5 mph)
4.6 km/h (2.8 mph)
Range B, Gear 4
6.4 km/h (4.0 mph)
Range C, Gear 1
12.4 km/h (7.7 mph)
8.6 km/h (5.3 mph)
Range C, Gear 2
18.7 km/h (11.6 mph)
11.9 km/h (7.4 mph)
Range C, Gear 3
21.2 km/h (13.2 mph)
18.1 km/h (11.2 mph)
Range C, Gear 4
Range A, Reverse 1
1.6 km/h (1.0 mph)
0.6 km/h (0.4 mph)
1.5 km/h (0.9 mph)
Range A, Reverse 3
1.6 km/h (1.0 mph)
Range A, Reverse 4
2.3 km/h (1.4 mph)
4.4 km/h (2.7 mph)
3.1 km/h (1.9 mph)
Range B, Reverse 2
4.2 km/h (2.6 mph)
Range B, Reverse 3
4.6 km/h (2.8 mph)
Range B, Reverse 4
6.4 km/h (4.0 mph)
Range C, Reverse 1
2-8
24.9 km/h (15.5 mph)
24.2 km/h (15.0 mph)
Range A, Reverse 2
Range B, Reverse 1
12.4 km/h (7.7 mph)
11.9 km/h (7.4 mph)
8.6 km/h (5.3 mph)
7.1 km/h (4.4 mph)
12.4 km/h (7.7 mph)
24.9 km/h (15.5 mph)
4/6/01
WEIGHT
SPECIFICATIONS & INFORMATION
4300 CST
4300 SRT
Range C, Reverse 2
11.9 km/h (7.4 mph)
Range C, Reverse 3
18.1 km/h (11.2 mph)
Range C, Reverse 4
24.2 km/h (15.0 mph)
4300 HST
WEIGHT
w/ROPS, 3PT
1236 kg (2725 lbs)
1281 kg (2825 lbs)
1315 kg (2900 lbs)
Front (Standard)
7.00-14 R1
7.00-14 R1
7.00-14 R1
Rear (Standard)
11.2-24 R1
11.2-24 R1
11.2-24 R1
TIRES
4/6/01
2-9
GENERAL VEHICLE SPECIFICATIONS* – 4400
SPECIFICATIONS & INFORMATION
GENERAL VEHICLE SPECIFICATIONS* – 4400
4400 SRT
4400 HST
Make
John Deere/Yanmar
John Deere/Yanmar
Model
3TNE88
3TNE88
Type
4-cycle Diesel
4-cycle Diesel
Bore and Stroke
88x90 mm (3.465x3.54 in.) 88x90 mm (3.465x3.54 in.)
Cylinders
3
3
Valves
Overhead Valves
Overhead Valves
Displacement
1642 cm3 (100.2 cu in.)
1642 cm3 (100.2 cu in.)
Compression Ratio
18.0:1
18.0:1
Gross Engine Power
27.6 kW (37.0 hp)
27.6 kW (37.0 hp)
Torque (at rated speed)
87.7 N•m (64.7 lb-ft)
87.7 N•m (64.7 lb-ft)
ENGINE
Torque (max. @ 1700 rpm) 109.8 N•m (81.0 lb-ft)
109.8 N•m (81.0 lb-ft)
Lubrication
Full pressure
Full pressure
Oil filter
Standard Single Element
Standard Single Element
Oil Capacity (w/filter)
4.3 L (4.6 qt)
4.3 L (4.6 qt)
Engine Rated Speed
2700 rpm
2700 rpm
Engine Slow Idle Speed
950 ± 50 rpm
1000 ± 50 rpm
Engine Fast Idle Speed
2920 rpm ± 25 rpm
2920 rpm ± 25 rpm
Cooling system
Liquid w/Pump & Radiator
Liquid w/Pump & Radiator
Air cleaner
Dry-Type w/Safety Element Dry-Type w/Safety Element
ELECTRICAL
Volts
12 VDC
12 VDC
Battery Rating
45 amp-hr
45 amp-hr
Battery Size
500 Cold Cranking Amps
500 Cold Cranking Amps
Alternator
40 amp
40 amp
Regulator
Internal, Current Limiting
Internal, Current Limiting
Starting Motor
1.4 kW (1.88 hp)
1.4 kW (1.88 hp)
Headlights
37.5 W Halogen Bulb
37.5 W Halogen Bulb
Tail Lights
5 W Bayonet Base
5 W Bayonet Base
Hazard Lights
Type 1156
Type 1156
Instrument Panel Lamps
1.7 W Bayonet Base
1.7 W Bayonet Base
*Specifications and design subject to change without notice.
2 - 10
4/6/01
FUEL SYSTEM
SPECIFICATIONS & INFORMATION
4400 SRT
4400 HST
System Type
Direct Fuel Injection
Direct Fuel Injection
Injection Pump
In-Line w/Solenoid Shutoff In-Line w/Solenoid Shutoff
Fuel type
Diesel
Diesel
Fuel Tank Capacity
37.9 L (10.0 gal)
37.9 L (10.0 gal)
Fuel Filter
Glass Bowl
Glass Bowl
Water Separator with
Water Separator with
Disposable Paper Element Disposable Paper Element
FUEL SYSTEM
DRIVE TRAIN
Type
SyncReverser™
Hydrostatic
Mechanical Front Wheel
Drive (4WD)
Standard Equipment
Standard Equipment
Front Axle Fluid Capacity
7.8 L (1.8 gal)
7.8 L (1.8 gal)
Differential Lock
Standard; Foot Operated
Standard; Foot Operated
Number of Speeds
12 Forward, 12 Reverse
Infinite / 3 Range
Final Drive
Spur Gear
Spur Gear
Brakes
Wet Disk
Wet Disk
Steering
Hydraulic Power Assist
Hydraulic Power Assist
Drawbar Tongue Weight
Vertical Capacity Rating
500 kg (1102 lb)
500 kg (1102 lb)
PTO (PTO Shaft Speed Measured at 2700 Engine rpm)
Type
Independent
Independant
Rotation Direction
Clockwise
Clockwise
Clutch
Multiple Wet Disk
Multiple Wet Disk
Brake
Wet Disk
Wet Disk
Rear Shaft Speed
540 rpm
540 rpm
Mid Shaft Speed
2100 rpm
2100 rpm
2 - Speed Shaft Speeds
540 rpm and 750 rpm
540 rpm and 750 rpm
PTO Output Power
22.0 kW (29.5 hp)
21.3 kW (28.6 hp)
Type
Category One
Category One
Lift Capacity at 61.0 cm
(24 in.) Behind Link Arms
999 kg (2200 lb.)
999 kg (2200 lb.)
3–POINT HITCH
4/6/01
2 - 11
CLUTCH
SPECIFICATIONS & INFORMATION
4400 SRT
4400 HST
Wet Multiple
None
CLUTCH
Type Disk
HYDRAULIC SYSTEM
(Measurements Taken At
2700 Engine rpm)
(Measurements Taken At
2700 Engine rpm)
Type
Open Center System
Open Center System
Tran/Hydr Fill Capacity
24 L (6.3 gal)
26 L (6.8 gal)
Working Pressure
17238 kPa (2500 psi)
17238 kPa (2500 psi)
Pump
Open Ctr/Gear
Open Ctr/Gear
Front Pump Capacity
19.3 L/min (5.1 gpm)
19.3 L/min (5.1 gpm)
Rear Pump Capacity
31.4 L/min (8.3 gpm)
31.4 L/min (8.3 gpm)
Total Pump Capacity
50.7 L/min (13.4 gpm)
50.7 L/min (13.4 gpm)
Range A, Gear 1
0.6 km/h (0.4 mph)
7.1 km/h (4.4 mph)
Range A, Gear 2
1.6 km/h (1.0 mph)
Range A, Gear 3
1.7 km/h (1.0 mph)
Range A, Gear 4
2.4 km/h (1.5 mph)
Range B, Gear 1
3.2 km/h (2.0 mph)
Range B, Gear 2
4.4 km/h (2.7 mph)
Range B, Gear 3
4.7 km/h (2.9 mph)
Range B, Gear 4
6.6 km/h (4.1 mph)
Range C, Gear 1
8.9 km/h (5.5 mph)
Range C, Gear 2
12.4 km/h (7.7 mph)
Range C, Gear 3
18.7 km/h (11.6 mph)
Range C, Gear 4
25.1 km/h (15.6 mph)
Range A, Reverse 1
0.6 km/h (0.4 mph)
Range A, Reverse 2
1.6 km/h (1.0 mph)
Range A, Reverse 3
1.7 km/h (1.0 mph)
Range A, Reverse 4
2.4 km/h (1.5 mph)
Range B, Reverse 1
3.2 km/h (2.0 mph)
Range B, Reverse 2
4.4 km/h (2.7 mph)
Range B, Reverse 3
4.7 km/h (2.9 mph)
Range B, Reverse 4
6.6 km/h (4.1 mph)
Range C, Reverse 1
8.9 km/h (5.5 mph)
Range C, Reverse 2
12.4 km/h (7.7 mph)
GROUND SPEEDS
2 - 12
12.4 km/h (7.7 mph)
24.9 km/h (15.5 mph)
7.1 km/h (4.4 mph)
12.4 km/h (7.7 mph)
24.9 km/h (15.5 mph)
4/6/01
WEIGHT
SPECIFICATIONS & INFORMATION
4400 SRT
Range C, Reverse 3
18.7 km/h (11.6 mph)
Range C, Reverse 4
25.1 km/h (15.6 mph)
4400 HST
WEIGHT
w/ROPS, 3PT
1283 kg (2830 lbs)
1326 kg (2925 lbs)
Front (Standard)
7.00 - 14 R1
7.00 - 14 R1
Rear (Standard)
11.2 - 24 R1
11.2 - 24 R1
TIRES
4/6/01
2 - 13
INCH FASTENER TORQUE VALUES
SPECIFICATIONS & INFORMATION
INCH FASTENER TORQUE VALUES
1 or 2b
SAE
Grade
and Head
Markings
5.1
5
8
5.2
8.2
No Marks
5
2
SAE
Grade
and Nut
Markings
8
No Marks
TS1162
Grade 2b
Grade 1
Lubricateda
Drya
SIZE
N•m
lb-ft
N•m
1/4
3.7
2.8
5/16
7.7
3/8
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricateda
Drya
Lubricateda
Drya
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5
10
17
12.5
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270
290
210
360
270
725
540
925
675
1050
750
1300
975
1-1/8
470
300
510
375
470
300
510
375
900
675
1150
850
1450
1075
1850
1350
1-1/4
570
425
725
530
570
425
725
530
1300
950
1650
1200
2050
1500
2600
1950
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2150
1550
2700
2000
3400
2550
1-1/2
1000
725
1250
925
990
725
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for general
use only and include a ±10% variance factor. Check
tightness of fasteners periodically. DO NOT use air
powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of
the bolt head.
2 - 14
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant
such as engine oil, or fasteners with phosphate
and oil coatings. “Dry” means plain or zinc
plated (yellow dichromate - Specification
JDS117) without any lubrication.
b
“Grade 2” applies for hex cap screws (not hex
bolts) up to 152 mm (6-in.) long. “Grade 1”
applies for hex cap screws over 152 mm (6-in.)
long, and for all other types of bolts and screws
of any length.
Reference: JDS—G200.
4/6/01
METRIC FASTENER TORQUE VALUES
SPECIFICATIONS & INFORMATION
METRIC FASTENER TORQUE VALUES
4.8
9.8
10.9
4.8
8.8
9.8
10.9
12.9
4.8
8.8
9.8
10.9
12.9
10
10
5
5
10
10
12.9
12
10
10
5
Property
Class
and
Nut
Markings
12.9
8.8
12
Property
Class
and
Head
Markings
12
TS1163
Class 4.8
Class 8.8 or 9.8
Lubricateda
Drya
SIZE
N•m
lb-ft
N•m
M6
48
3.5
M8
12
M10
Class 10.9
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
6
4.5
9
6.5
8.5
15
11
22
23
17
29
21
M12
40
29
50
M14
63
47
M16
100
M18
Class 12.9
Lubricateda
Drya
Lubricateda
Drya
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
N•m
lb-ft
11
8.5
13
9.5
17
12
15
11.5
19
14.5
16
28
20
32
24
40
30
37
28
47
35
43
32
55
40
63
47
80
60
75
55
95
70
37
75
55
95
70
110
80
140
105
130
95
165
120
80
60
120
88
150
110
175
130
225
165
205
150
260
109
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075
800
M24
330
250
425
310
650
475
825
600
925
675
1150
850
1075
800
1350
1000
M27
490
360
625
450
950
700
1200
875
1350
1000
1700
1250
1600
1150
2000
1500
M30
675
490
850
625
1300
950
1650
1200
1850
1350
2300
1700
2150
1600
2700
2000
M33
900
675
1150
850
1750
1300
2200
1650
2500
1850
3150
2350
2900
2150
3700
2750
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2750
4750
3500
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a
specific application. Torque values listed are for
general use only and include a ±10% variance factor.
Check tightness of fasteners periodically. DO NOT use
air powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same grade.
Make sure fastener threads are clean and that you
properly start thread engagement. This will prevent
them from failing when tightening.
torque values should be applied to the NUT instead of
the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
“Lubricated” means coated with a lubricant
such as engine oil, or fasteners with phosphate
and oil coatings. “Dry” means plain or zinc
plated (yellow dichromate - Specification
JDS117) without any lubrication.
Reference: JDS—G200.
When bolt and nut combination fasteners are used,
4/6/01
2 - 15
O-RING SEAL SERVICE RECOMMENDATIONS
SPECIFICATIONS & INFORMATION
O-RING SEAL SERVICE RECOMMENDATIONS
FACE SEAL FITTINGS WITH INCH STUD ENDS TORQUE
Stud End
Tube Nut
Stud Straight and Tube Nut
Swivel Nut
Locknut
Tube Nut
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut
Nominal Tube O.D./Hose I.D.
Metric
Tube
O.D.
Inch Tube O.D.
Face Seal Tube/Hose End
Thread Size
Tube Nut/
Swivel Nut
Torque
Bulkhead
Locknut
Torque
Dash
Size
in.
mm
-3
0.188
4.76
6
-4
0.250
6.35
8
-5
0.312
7.94
10
-6
0.375
9.52
11/16-16
24
18
24
12
-8
0.500
12.70
13/16-16
50
37
16
-10
0.625
15.88
1-14
69
-12
0.750
19.05
1-3/16-12
22
-14
0.875
22.22
25
-16
1.000
32
-20
38
-24
mm
in.
lb-ft
3/8-24
8
6
7/16-20
12
9
1/2-20
16
12
18
9/16-18
24
18
46
34
3/4-16
46
34
51
62
46
7/8-14
62
46
102
75
102
75
1-1/16-12
102
75
1-3/16-12
102
75
102
75
1-3/16-12
122
90
25.40
1-7/16-12
142
105
142
105
1-5/16-12
142
105
1.25
31.75
1-11/16-12
190
140
190
140
1-5/8-12
190
140
1.50
38.10
2-12
217
160
217
160
1-7/8-12
217
160
12
N•m
12
lb-ft
Straight Fitting or
Locknut Torque
N•m
16
lb-ft
Thread
Size
in.
9/16-18
N•m
O-ring Stud Ends
9
NOTE: Torque tolerance is +15% / –20%.
2 - 16
4/6/01
SPECIFICATIONS & INFORMATIONFACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE
FACE SEAL FITTINGS WITH METRIC STUD ENDS TORQUE
Stud End
Tube Nut
Groove For Metric Identification
Stud Straight and Tube Nut
Swivel Nut
Locknut
Tube Nut
Groove For Metric
Identification
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Bulkhead Union and Bulkhead Locknut
Nominal Tube O.D./Hose
I.D.
Metric
Tube
O.D.
Inch Tube O.D.
O-ring Stud Ends, Straight Fitting or
Locknut
Face Seal Tube/Hose End
Thread
Size
mm
Dash
Size
in.
mm
in.
6
-4
0.250
6.35
9/16-18
8
-5
0.312
7.94
Hex
Size
Tube Nut/
Bulkhead
Swivel
Locknut
Nut
Torque
Torque
mm N•m lb-ft N•m lb-ft
17
16
12
12
9
Thread
Size
Steel or
Hex
Aluminum
Gray Iron
Size
Torque
Torque
mm
mm N•m lb-ft N•m lb-ft
M12X1.5
17
21
15.5
9
6.6
M14X1.5
19
33
24
15
11
10
-6
0.375
9.52
11/16-16
22
24
18
24
18
M16X1.5
22
41
30
18
13
12
-8
0.500 12.70
13/16-16
24
50
37
46
34
M18X1.5
24
50
37
21
15
16
-10
0.625 15.88
1-14
30
69
51
62
46
M22X1.5
27
69
51
28
21
-12
0.750 19.05 1-3/16-12
36
102
75
102
75
M27X2
32
102
75
46
34
22
-14
0.875 22.22 1-3/16-12
36
102
75
102
75
M30X2
36
25
-16
1.000 25.40 1-7/16-12
41
142 105 142 105
M33X2
41
158
116
71
52
M38X2
46
176
130
79
58
28
32
-20
1.25
31.75 1-11/16-12
50
190 140 190 140
M42X2
50
190
140
85
63
38
-24
1.50
38.10
60
217 160 217 160
M48X2
55
217
160
98
72
2-12
NOTE: Torque tolerance is +15% / –20%.
4/6/01
2 - 17
O-RING FACE SEAL FITTINGS
SPECIFICATIONS & INFORMATION
O-RING FACE SEAL FITTINGS
.
A
D
C
E
B
A
1. Inspect the fitting sealing surfaces (A). They must
be free of dirt or defects.
2. Inspect the O-ring (B). It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of
petroleum jelly so O-ring is not displaced during
assembly.
5. Index angle fittings and tighten by hand pressing
joint together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the
chart per dash size stamped on the fitting. Do not
allow hoses to twist when tightening fittings.
O-RING BOSS FITTINGS
1. Inspect boss O-ring boss seat. It must be free of dirt
and defects. If repeated leaks occur, inspect for
defects with a magnifying glass. Some raised
defects can be removed with a slip stone.
B
A
2. Put hydraulic oil or petroleum jelly on the O-ring (A).
Place electrical tape over the threads to protect Oring from nicks. Slide O-ring over the tape and into
the groove (B) of fitting. Remove tape.
2 - 18
3. For angle fittings (C), loosen special nut (D) and
push special washer (E) against threads so Oring can be installed into the groove of fitting.
4. Turn fitting into the boss by hand until special
washer or washer face (straight fitting) contacts
boss face and O-ring is squeezed into its seat.
5. To position angle fittings, turn the fitting counterclockwise a maximum of one turn.
6. Tighten straight fittings to torque value shown on
chart. For angle fittings, tighten the special nut to
value shown in the chart while holding body of
fitting with a wrench.
STRAIGHT FITTING OR SPECIAL NUT TORQUE
Thread
Size
Torquea
Number
of Flatsb
N•m
lb-ft
3/8-24 UNF
8
(6)
2
7/16-20 UNF
12
(9)
2
1/2-20 UNF
16
(12)
2
9/16-18 UNF
24
(18)
2
3/4-16 UNF
46
(34)
2
7/8-14 UNF
62
(46)
1-1/2
1-1/16-12 UN
102
(75)
1
1-3/16-12 UN
122
(90)
1
1-5/16-12 UN
142
(105)
3/4
1-5/8-12 UN
190
(140)
3/4
1-7/8-12 UN
217
(160)
1/2
a. Torque tolerance is ± 10 percent.
b. To be used if a torque wrench cannot be used.
After tightening fitting by hand, put a mark on nut or
boss; then tighten special nut or straight fitting the
number of flats shown.
4/6/01
SPECIFICATIONS & INFORMATION
DIESEL FUEL SPECIFICATIONS
DIESEL FUEL
In general, diesel fuels are blended to satisfy the low air
temperature requirements of the geographical area in
which they are sold.
In North America, diesel fuel is usually specified to
ASTM D975 and sold as either Grade 1 for cold air
temperatures or Grade 2 for warm air temperatures.
If diesel fuels being supplied in your area DO NOT
meet any of the above specifications, use diesel fuels
with the following equivalent properties:
• Cetane Number 40 (minimum)
A cetane number greater than 50 is preferred,
especially for air temperatures below –20 °C (–4 °F) or
elevations above 1500 m (5000 ft).
DIESEL FUEL SPECIFICATIONS
flakes will quickly plug fuel filters and damage
fuel injectors and fuel pumps.
It is recommended that diesel fuel be stored ONLY in a
clean, approved POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter. This will help
prevent any accidental sparks from occurring. Store
fuel in an area that is well ventilated to prevent possible
igniting of fumes by an open flame or spark, this
includes any appliance with a pilot light.
IMPORTANT: Keep all dirt, scale, water or other
foreign material out of fuel.
• Cold Filter Plugging Point (CFPP)
The temperature at which diesel fuel begins to cloud
or jell. Use diesel fuels with a CFPP which is at least 5
°C (9 °F) below the expected low air temperature.
Keep fuel in a safe, protected area and in a clean,
properly marked (“DIESEL FUEL”) container. DO NOT
use deicers to attempt to remove water from fuel. DO
NOT depend on fuel filters to remove water from fuel. It
is recommended that a water separator be installed in
the storage tank outlet. BE SURE to properly discard
unstable or contaminated diesel fuel and/or their
containers when necessary.
• Sulfur Content of 0.05% (maximum)
Diesel fuels for highway use in the United States now
require sulfur content to be less than 0.05%.
ENGINE OIL
If diesel fuel being used has a sulfur content greater
than 0.5%, reduce the service interval for engine oil
and filter by 50%.
Consult your local diesel fuel distributor for properties
of the diesel fuel available in your area.
c
WARNING
California Proposition 65 Warning: Diesel engine
exhaust and some of its elements from this
product are known to the State of California to
cause cancer, birth defects, or other
reproductive harm.
DIESEL FUEL LUBRICITY
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components. Fuel lubricity should pass a minimum of
3300 gram load level as measured by the BOCLE
scuffing test.
DIESEL FUEL STORAGE
IMPORTANT:
DO NOT USE GALVANIZED
CONTAINERS—diesel fuel stored in galvanized
containers reacts with zinc coating in the
container to form zinc flakes. If fuel contains
water, a zinc gel will also form. The gel and
4/6/01
Use the appropriate oil viscosity based on the expected
air temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
• PLUS–50®—SAE 15W-40;
• TORQ–GARD SUPREME®—SAE 5W-30.
• TORQ–GARD SUPREME®—SAE 15W-40;
• UNI–GARD™—SAE 15W-40;
• UNI–GARD™—SAE 5W-30.
The following John Deere oils are also recommended,
based on their specified temperature range:
• TURF–GARD®—SAE 10W-30;
• PLUS–4®—SAE 10W-30;
• TORQ–GARD SUPREME®—SAE 30.
• UNI–GARD™—SAE 10W-30;
• UNI–GARD™—SAE 30.
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
• SAE 15W-40—API Service Classification CF–4 or
higher;
• SAE 5W-30—API Service Classification CC or
higher;
• SAE 10W-30—API Service Classification CF or
higher;
• SAE 30—API Service Classification CF or higher.
• CCMC Specification D4 or Mercedes Benz
MB228.1 or higher.
2 - 19
BREAK–IN ENGINE OIL
SPECIFICATIONS & INFORMATION
IMPORTANT: If diesel fuel with sulfur content
greater than 0.5% is used, reduce the service
interval for oil and filter by 50%.
aluminum and cast iron types.
If this preferred John Deere oil is not available, use a
break-in engine oil meeting the following specification
during the first 100 hours of operation:
BREAK-IN OIL
SAE10W-30
SAE 30
SAE 5W-30
SAE 15W-40
• API Service Classification CE or higher.
• CCMC Specification D4 or higher.
PREFERRED
M58275
AIR TEM PERATURE
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ENOIL in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
BREAK–IN ENGINE OIL
IMPORTANT: ONLY use this specified break-in oil
in rebuilt or remanufactured engines for the first
100 hours (maximum) of operation. DO NOT use
PLUS–50®, SAE 15W40 oil, oils meeting
specifications API CG–4, API CF–4, or CCMC
Specifications, these oils will not allow rebuilt or
remanufactured engines to break-in properly.
M58275
A IR TEM PER ATUR E
IMPORTANT: After the break-in period, use the
John Deere oil that is recommended for this
engine.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ENOIL4 in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
The following John Deere oil is PREFERRED:
• BREAK–IN ENGINE OIL.
John Deere BREAK–IN ENGINE OIL is formulated
with special additives for aluminum and cast iron type
engines to allow the power cylinder components
(pistons, rings, and liners as well) to “wear-in” while
protecting other engine components, valve train and
gears, from abnormal wear. Engine rebuild instructions
should be followed closely to determine if special
requirements are necessary.
John Deere BREAK–IN ENGINE OIL is also
recommended for non-John Deere engines, both
2 - 20
4/6/01
TRANSMISSION & HYDRAULIC OIL
SPECIFICATIONS & INFORMATION
TRANSMISSION & HYDRAULIC OIL
CHASSIS GREASE
The same type of oil is recommended for all
transmissions in the 45, 46, 4700 tractors. Use the
appropriate oil viscosity based on these air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature hydrostatic transmission or hydraulic system
failures.
IMPORTANT: ONLY use a quality grease in this
application. DO NOT mix any other greases in
this application. DO NOT use any BIO–GREASE
in this application.
The following John Deere greases are PREFERRED:
IMPORTANT:
Mixing of LOW VISCOSITY HY–
GARD® and HY–GARD® oils is permitted. DO
NOT mix any other oils in this transmission. DO
NOT use engine oil or “Type F” (Red) Automatic
Transmission Fluid in this transmission.
The following John Deere transmission and hydraulic
oil is PREFERRED:
• LOW VISCOSITY HY–GARD®—JDM J20D.
The following John Deere oil is also recommended if
above preferred oil is not available:
• HY–GARD®—JDM J20C.
Other oils may be used if above recommended John
Deere oils are not available, provided they meet one of
the following specifications:
• John Deere Standard JDM J20D;
• John Deere Standard JDM C.
• MOLY HIGH-TEMPERATURE EP GREASE®—
JDM J25C, NLGI Grade 2;
• HIGH-TEMPERATURE EP GREASE®—JDM
J13E4, NLGI Grade 2.
• GREASE–GARD™—JDM J25C, NLGI Grade 2.
Other greases may be used if above preferred John
Deere greases are not available, provided they meet
one of the following specifications:
• John Deere Standard JDM J25C, NLGI Grade 2;
• John Deere Standard JDM J13E4, NLGI Grade 2.
IMPORTANT: If minimum air temperature should
fall below -10 °C (14 °F), the grease must be
heated to at least five degrees above the lower
limit before start-up or components may be
damaged.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper
grease for your customers:
JDM J13E4
NLGI Grade 2
JDM J25C
NLGI Grade 2
JDM J20D
JDM J20C
• Module DX,GREA1 in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• the Lubrication Sales Manual PI7032.
PREFERRED
AIR TEM PERATURE
M58275
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
for your customers:
• Module DX,ANTI in JDS–G135;
• Section 530, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lubrication Sales Manual PI7032.
4/6/01
AIR TEM PERATURE
M58275
2 - 21
ALTERNATIVE LUBRICANTS
SPECIFICATIONS & INFORMATION
ALTERNATIVE LUBRICANTS
OIL FILTERS
Conditions in certain geographical areas outside the
United States and Canada may require different
lubricant recommendations than the ones printed in
this technical manual or the operator's manual. Consult
with your John Deere Dealer, or Sales Branch, to
obtain the alternative lubricant recommendations.
IMPORTANT: Filtration of oils is critical to proper
lubrication performance. Always change filters
regularly.
The following John Deere oil filters are PREFERRED:
IMPORTANT: Use of alternative lubricants could
cause reduced life of the component.
If alternative lubricants are to be used, it is
recommended that the factory fill be thoroughly
removed before switching to any alternative lubricant.
SYNTHETIC LUBRICANTS
Synthetic lubricants may be used in John Deere
equipment if they meet the applicable performance
requirements (industry classification and/or military
specification) as shown in this manual.
The recommended temperature limits and service or
lubricant change intervals should be maintained as
shown in the operator’s manual, unless otherwise
stated on lubricant label.
Avoid mixing different brands, grades, or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
• AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL
FILTERS.
Most John Deere filters contain pressure relief and
anti-drainback valves for better engine protection.
Other oil filters may be used if above recommended
John Deere oil filters are not available, provided they
meet the following specification:
• ASTB Tested In Accordance With SAE J806.
John Deere Dealers: You may want to cross-reference
the following publications to recommend the proper oil
filter for your customers:
• Module DX,FILT in JDS–G135;
• Section 540, Lubricants & Hydraulics, of the John
Deere Merchandise Sales Guide;
• Lawn & Grounds Care Tune-Up Guide PI672.
COOLANT
The engine cooling system when filled with a proper
dilution mixture of antifreeze and deionized or distilled
water provides year-round protection against corrosion,
cylinder or liner pitting, and winter freeze protection
down to –37 °C (–34 °F).
The following John Deere coolant is PREFERRED:
LUBRICANT STORAGE
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected
from dust, moisture, and other contamination. Store
drums on their sides. Make sure all containers are
properly marked as to their contents. Dispose of all old,
used containers and their contents properly.
MIXING OF LUBRICANTS
In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their
lubricants to meet certain specifications and
performance requirements. Mixing different lubricants
can interfere with the proper functioning of these
additives and lubricant properties which will downgrade
their intended specified performance.
• PRE-DILUTED DIESEL ENGINE ANTIFREEZE/
SUMMER COOLANT™ (TY16036).
• COOL–GARD COOLANT CONCENTRATE™.
This coolant satisfies specifications for “Automobile
and Light Duty Engine Service” and is safe for use in
equipment, including aluminum block gasoline engines
and cooling systems.
The above preferred pre-diluted antifreeze provides:
• adequate heat transfer
• corrosion-resistant chemicals for the cooling
system
• compatibility with cooling system hose and seal
material
• protection during extreme cold and extreme hot
weather operations
• chemically pure water for better service life
• compliance with ASTM D4656 (JDM H24C2)
specifications
If above preferred pre-diluted coolant is not available,
the
following
John
Deere
concentrate
is
recommended:
• DIESEL ENGINE ANTIFREEZE/SUMMER
COOLANT CONCENTRATE™ (TY16034).
2 - 22
4/6/01
SPECIFICATIONS & INFORMATION
If either of above recommended engine coolants are
available use any Automobile and Light Duty Engine
Service ethylene glycol base coolant, meeting the
following specification:
• ASTM D3306 (JDM H24C1).
Read container label completely before using and
follow instructions as stated.
IMPORTANT: To prevent engine damage, DO NOT
use pure antifreeze or less than a 50% antifreeze
mixture in the cooling system. DO NOT mix or
add any additives/conditioners to the cooling
system in equipment. Water used to dilute
engine coolant concentrate must be of high
quality—clean, clear, potable water (low in
chloride and hardness–Table 1) is generally
acceptable. DO NOT use salt water. Deionized or
distilled water is ideal to use. Coolant that is not
mixed to these specified levels and water purity
can cause excessive scale, sludge deposits,
and increased corrosion potential.
COOLANT DRAIN INTERVAL
Service coolants are not being used; drain, flush, and
refill the cooling system according to instructions found
on product container or in equipment operator’s manual
or technical manual.
PRODUCT IDENTIFICATION
LOCATIONS
When ordering parts or submitting a warranty claim, it
is IMPORTANT that you include the product
identification number, and the component product
identification numbers.
The location of the product identification numbers and
component product identification numbers are shown.
PRODUCT IDENTIFICATION NUMBER
Located on frame above RH front axle.
Table 1: Water Quality
Property
Requirements
Total Solids, Max
340 ppm (20 grns/gal)
Total Hardness, Max
170 ppm (10 grns/gal)
Chloride (as Cl), Max
40 ppm (2.5 grns/gal)
Sulfate (as SO4), Max
100 ppm (5.8 grns/gal)
Mix 50 percent antifreeze concentrate with 50 percent
distilled or deionized water. This mixture and the prediluted mixture (TY16036) will protect the cooling
system down to -37 °C (-34 °F) and up to 108 °C (226
°F).
Certain geographical areas may require lower air
temperature protection. See the label on your
antifreeze container or consult your John Deere dealer
to obtain the latest information and recommendations.
COOLANT DRAIN INTERVAL
When using John Deere Pre-Diluted (TY16036)
Automobile and Light Duty Engine Service coolants,
drain and flush the cooling system and refill with fresh
coolant mixture every 36 months or 3,000 hours of
operation, whichever comes first.
M91660
4200:
LV4200C120001–3270000 Gear (CST)
LV4200C327001– Sync Shift (SST)
LV4200H120001– Hydro (HST)
LV4200E229001– Export (All models)
4300:
LV4300C130001–335000 Gear (CST)
LV4300C335001– Sync Shift (SST)
LV4300H130001– Hydro (HST)
LV4300S130001– SyncReverser™ (SRT)
LV4300E239001– Export (All models)
4400:
LV4400H140001– Hydro (HST)
LV4400S140001– SyncReverser™ (SRT)
LV4400E249001– Export (All models)
When using John Deere Concentrate (TY16034)
Automobile and Light Duty Engine Service coolants or
John Deere Cool-Gard Coolant Concentrate for
Automobile and Light Duty Engine Service, drain and
flush the cooling system and refill with fresh coolant
mixture every 24 months or 2,000 hours of operation,
whichever comes first.
If above John Deere Automobile and Light Duty Engine
4/6/01
2 - 23
PRODUCT IDENTIFICATION LOCATIONS
SPECIFICATIONS & INFORMATION
ENGINE PRODUCT IDENTIFICATION NUMBER
Located on top center of engine.
M91286
Non-EPA Engines:
4200 (Engine S/N –016705) (All models)
4300 (Engine S/N –011018) (All models)
4400 (Engine S/N –004914) (All models)
EPA Certified Engines:
4200 (Engine S/N 016706–) (All models)
4300 (Engine S/N 011019–) (All models)
4400 (Engine S/N 004915–) (All models)
2 - 24
4/6/01
CONTENTS
DIESEL ENGINE
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TESTS AND ADJUSTMENT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATIONAL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE VALUES, NON-STANDARD FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL AND AIR SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COOLING SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICATION SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SLOW IDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONNECTING ROD SIDE PLAY CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONNECTING ROD BEARING CLEARANCE CHECK . . . . . . . . . . . . . . . . . . . . . . 19
CRANKSHAFT END PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CRANKSHAFT MAIN BEARING CLEARANCE CHECK. . . . . . . . . . . . . . . . . . . . . . 20
VALVE LIFT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CAMSHAFT END PLAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TIMING GEAR BACKLASH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL INJECTION NOZZLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
THERMOSTAT OPENING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INJECTION PUMP STATIC TIMING ADJUSTMENT (NON-EPA ENGINES) . . . . . . 24
INJECTION PUMP TIMING ADJUSTMENT (EPA ENGINES) . . . . . . . . . . . . . . . . . 26
FAN/ALTERNATOR DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RADIATOR BUBBLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL TRANSFER PUMP TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL SYSTEM LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BLEED FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ROCKER COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ROCKER ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION . . . . . . . . . . . . . 34
CYLINDER HEAD AND VALVES DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . 35
4/6/01
3-1
CONTENTS CONTINUED
VALVE SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE RECESSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRIND VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAP VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURE PISTON-TO-CYLINDER HEAD CLEARANCE . . . . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT AND MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL AND COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT FOLLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING GEAR COVER MOUNTING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT AND WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATION - FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP (NON EPA ENGINES). . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP (EPA ENGINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR INSPECTION/TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR GEAR TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
DIESEL ENGINE
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4/6/01
DIESEL ENGINE
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yanmar
Model 4200 (Non-EPA –016705, EPA Certified 016706–). . . . . . . . . . . . . . . . . . . . . . . . . . . .3TNE78A
Model 4300 (Non-EPA –011018, EPA Certified 011019–). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNE84
Model 4400 (Non-EPA –004914, EPA Certified 004915–). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNE88
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Cycle Diesel
Gross Power
4200 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6 kW (26.3 hp)
4300 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 kW (32.2 hp)
4400 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.6 Kw (37.0 hp)
Torque (at rated speed)
4200 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2 N•m (46.6 lb-ft)
4300 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.5 N•m (57.9 lb-ft)
4400 @ 2700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.7 N•m (64.7 lb-ft)
Torque (max)
4200 @ 1600 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.5 N•m (57.9 lb-ft)
4300 @ 1700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.1 N•m (73.1 lb-ft)
4400 @ 1700 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109.8 N•m (81.0 lb-ft)
Number of Cylinders (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bore
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 mm (3.07 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 mm (3.465 in.)
Stroke
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.54 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 mm (3.54 in.)
Displacement
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.204 L (73.5 cu in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.496 L (91.3 cu in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.642 L (100.2 cu in.)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—3—2
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise (viewed from flywheel)
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection Type
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 1
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid
Oil Capacity (w/filter)
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 3.82 L (4.04 qt)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 4.31 L (4.55 qt)
Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Slow Idle
CST, SST and SRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 ± 50 rpm
HST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
High Idle (All - No Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2920 ± 25 rpm
4/6/01
3-3
REPAIR SPECIFICATIONS
DIESEL ENGINE
REPAIR SPECIFICATIONS
Valve Train
Rocker Arm Shaft OD (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.97 - 15.98 mm (0.628 - 0.629 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.628 in.)
Rocker Arm and Shaft Support Bushing ID (All)16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit16.09 mm (0.633 in.)
Oil Clearance (All)0.02 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit 0.15 mm (0.006 in.)
Push Rod Bend (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0 - 0.03 mm (0.0 - 0.001 in.)
Cylinder Head and Valves
Cylinder Head Distortion (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0 - 0.05 mm (0.0 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Intake Valve Seat Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36 - 1.53 mm (0.054 - 0.060 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.07 - 1.24 mm (0.042 - 0.049 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.)
Exhaust Valve Seat Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66 - 1.87 mm (0.066 - 0.074 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24 - 1.45 mm (0.042 - 0.049 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
Intake Valve Stem OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.95 - 6.96 mm (0.274 - 0.274 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 mm (0.272 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.96 - 7.98 mm (0.313 - 0.314 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.311 in.)
Exhaust Valve Stem OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.94 - 6.96 mm (0.273 - 0.274 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 mm (0.272 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.96 - 7.97 mm (0.313 - 0.314 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.311 in.)
Valve Head Thickness (All)
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24 - 1.44 mm (0.049 - 0.057 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35 - 1.55 mm (0.053 - 0.061 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Intake Valve Recession
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.30 - 0.50 mm (0.012 - 0.020 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.31 - 0.51 mm (0.012 - 0.020 in.)
Wear Limit (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Exhaust Valve Recession (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Valve Guide Stem-To-Guide Oil Clearance
Intake (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.07 mm (0.001 - 0.003 in.)
Exhaust (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.08 mm (0.002 - 0.003 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Valve Guide ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.00 - 7.02 mm (0.275 - 0.276 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 (0.315 - 0.316 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
Valve Guide Projection
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm (0.591 in.)
3-4
4/6/01
DIESEL ENGINE
REPAIR SPECIFICATIONS
Valve Spring Free Length
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4 mm (1.748 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 mm (1.654 in.)
Maximum Spring Inclination (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.)
Valve Spring Tension (Measured With Spring Compressed 1.0 mm (0.039 in.)
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61 - 2.71 kg (7.96 - 5.98 lb)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 - 3.10 kg (5.20 - 6.83 lb)
Valve Seat Surface Angle (All)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Timing (All)
Intake Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° - 20° BTDC
Intake Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40° - 50° ABDC
Exhaust Valve Opens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51° - 61° BBDC
Exhaust Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° - 23° ATDC
Piston-to-Cylinder Head Clearance (All). . . . . . . . . . . . . . . . . . . . . . .0.66 - 0.78 mm (0.026 - 0.031 in.)
Connecting Rod
Large End Bearing ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.02 mm (1.811- 1.812 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 - 51.01mm (2.008 - 2.008 in.)
Large End Bearing Thickness (All) . . . . . . . . . . . . . . . . . . . . . . . . . . .1.49 - 1.50 mm (0.059 - 0.059 in.)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.625 mm (0.064 in.)
Oil Clearance
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.09 mm (0.002 - 0.004 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.07 mm (0.002 - 0.003 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Connecting Rod Side Play (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.4 mm (0.008 - 0.016 in.)
Piston Rings
First Compression Piston Ring Groove Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04 - 2.05 mm (0.080 - 0.081 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.07 - 2.08 mm (0.081 - 0.082 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.06 - 2.08 mm (0.081 - 0.082 in.)
First Compression Piston Ring Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94 - 1.96 mm (0.076 - 0.077 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.97 - 1.99 mm (0.078 - 0.078 in.)
First Compression Piston Ring Minimum Side Clearance (All) . . . . .0.08 - 0.11 mm (0.003 - 0.004 in.)
Second Compression Piston Ring Groove Width
4200, 4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04 - 2.05 mm (0.080 - 0.081 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.03 - 2.04 mm (0.080 - 0.080 in.)
Second Compression Piston Ring Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 - 1.99 mm (0.078 - 0.078 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.97 - 1.99 mm (0.078 - 0.078 in.)
Second Compression Piston Ring Minimum Side Clearance
4200, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.08 mm (0.002 - 0.003 in.)
Oil Control Piston Ring Groove Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.02 - 3.03 mm (0.119 - 0.119 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.02 - 4.03 mm (0.158 - 0.159 in.)
Oil Control Piston Ring Width
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.97 - 2.99 mm (0.117 - 0.118 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97 - 3.99 mm (0.156 - 0.157 in.)
Oil Control Piston Ring Minimum Side Clearance (All). . . . . . . . . . . .0.03 - 0.06 mm (0.001 - 0.002 in.)
Piston Ring End Gap (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
4/6/01
3-5
REPAIR SPECIFICATIONS
DIESEL ENGINE
Piston Pin
Piston Pin OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.99 - 23.00 mm (0.905 - 0.906 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.99 - 26.00 mm (1.023 - 1.024 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Piston Pin Bushing ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.02 - 23.04 mm (0.906 - 0.907 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.03 - 26.04 mm (1.025 - 1.025 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.)
Piston Pin-To-Rod Bore Oil Clearance (All) . . . . . . . . . . . . . . . . . . . .0.03 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Piston Pin Bore (In Piston) ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.00 - 23.01 mm (0.906 - 0.906 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.00 - 26.01 mm (1.024 - 1.024 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
Piston Pin-To-Piston Oil Clearance (All). . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.02 mm (0 - 0.001 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Piston
Standard Piston OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.95 - 77.98 mm (3.069 - 3.070 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.90 mm (3.067 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.95 - 83.98 mm (3.305 - 3.306 in.)
4300 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 mm (3.303 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87.95 - 87.98 mm (3.462 - 3.464 in.)
4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.90 mm (3.461 in.)
Oversize Piston OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.20 - 78.23 mm (3.079 - 3.080 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.15 mm (3.077 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.20 - 84.23 mm (3.315 - 3.316 in.)
4300 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.10 mm (3.311 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.20 - 88.23 mm (3.472 - 3.474 in.)
4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.10 mm (3.469 in.)
Cylinder Bore ID
Standard Bore ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.00 - 78.03 mm (3.071 - 3.072 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.00 - 84.03 mm (3.307 - 3.308 in.)
4300 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.00 - 88.03 mm (3.465 - 3.466 in.)
4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.20 mm (3.472 in.)
Oversize Bore ID
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.25 - 78.28 mm (3.081 - 3.082 in.)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.25 - 84.28 mm (3.317 - 3.318 in.)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88.25 - 88.28 mm (3.474 - 3.476 in.)
Piston-to-Cylinder Clearance
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.055 mm (0.002 in.)
Cylinder Roundness (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0 - 0.0004 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Cylinder Taper (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 - 0.01 mm (0 - 0.0004 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Deglazing (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
Reboring (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° crosshatch pattern
3-6
4/6/01
DIESEL ENGINE
REPAIR SPECIFICATIONS
Crankshaft and Main Bearings
Connecting Rod Crankshaft Journal OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.95 - 42.96 mm (1.691 - 1.691 in.)
4200 Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47.95 - 47.96 mm (1.888 - 1.888 in.)
4300, 4400 Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
Main Bearing Journal OD
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46.95 - 46.96 mm (1.848 - 1.849 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.95 - 53.96 mm (2.124 - 2.124 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.91 mm (2.122 in.)
Main Bearing Oil Clearance
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.09 mm (0.002 - 0.004 in.)
4200 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.07 mm (0.002 - 0.003 in.)
4300, 4400 (Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Crankshaft Bend (Maximum- All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Crankshaft End Play (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.09 - 0.27 mm (0.004 - 0.011 in.)
Camshaft
Camshaft End Play (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.25 mm (0.002 - 0.010 in.)
Camshaft Bend (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 0.02 mm (0 - 0.001 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Camshaft Side Gap (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.25 mm (0.002 - 0.010 in.)
Lobe Height- Intake and Exhaust (All) . . . . . . . . . . . . . . . . . . . . . .38.64 - 38.77 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
Bearing Journal OD (All)
Flywheel Side and Gear Side. . . . . . . . . . . . . . . . . . . . . . . . . .44.93 - 44.95 mm (1.769 - 1.770 in.)
Intermediate Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44.91 - 44.94 mm (1.768 - 1.769 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.85 mm (1.766 in.)
Oil Clearance (Gear and Flywheel Ends) . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.13 mm (0.002 - 0.005 in.)
Oil Clearance (Intermediate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.07 - 0.12 mm (0.003 - 0.005 in.)
Camshaft Followers
Stem OD (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.98 - 11.99 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore ID (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.00 - 12.02 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Oil Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.01 - 0.04 mm (0.0004 - 0.0016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Idler Gear
Shaft OD (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45.95 - 45.98 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Bushing ID (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46.00 - 46.03 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.)
Clearance (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Pump
Rotor Shaft OD to Side Cover Hole ID Clearance (All) . . . . . . . . . . .0.01 - 0.04 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Inner Rotor and Outer Rotor-to-Pump Body Side Clearance
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.10 mm (0.002 - 0.004 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.09 mm (0.001 - 0.004 in.)
4/6/01
3-7
TESTS AND ADJUSTMENT SPECIFICATIONS
DIESEL ENGINE
Wear Limit (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Outer Rotor to Pump Body Clearance (All) . . . . . . . . . . . . . . . . . . . .0.10 - 0.16 mm (0.004 - 0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Inner Rotor to Outer Rotor Clearance Wear Limit (All). . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
TESTS AND ADJUSTMENT SPECIFICATIONS
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15 - 0.25 mm (0.006 - 0.010 in.)
Connecting Rod Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.4 mm (0.008 - 0.016 in.)
Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.07 mm (0.002 - 0.003 in.)
Crankshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.09 - 0.27 mm (0.004 - 0.011 in.)
Crankshaft Main Bearing Clearance. . . . . . . . . . . . . . . . . . . . . . . . . .0.04 - 0.07 mm (0.001 - 0.003 in.)
Camshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 - 0.25 mm (0.002 - 0.010 in.)
Timing Gear Backlash
All Except Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.07 - 0.15 mm (0.003 - 0.005 in.)
Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.11 - 0.19 mm (0.004 - 0.008 in.)
Fuel Injection Nozzle
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19600 +1000/–0 kPa (2843 + 145/–0 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . None For A Minimum of 10 Seconds
Chatter and Spray Pattern at 19600 ± 1000 kPa (2843 ± 145 psi):
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chatter Sound
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fine Stream
Fast Hand Lever Movement. . . . . . . . . . . . . . . . . . . . . . .Fine Atomized Spray, 150° Spray Pattern
Alternator Drive Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 15 mm (0.4 - 0.6 in.)
Fuel Injection Pump Static Timing (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ± 1° BTDC
OPERATIONAL TESTS
Cooling System Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ± 15 kPa (12.8 ± 2.2 psi)
Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69.5 - 72.5° C (157 - 163° F)
Minimum Lift Height above 85° C (185° F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm (0.315 in.)
Radiator Cap Opening Pressure (All) . . . . . . . . . . . . . . . 0.9 ± 0.15 kg/cm2, 88 ± 15 kPa, 12.8 ± 2.2 psi
Cylinder Compression Pressure
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3138 ± 98 kPa (455 ± 14 psi)
4200 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2555 ± 98 kPa (370 ± 14 psi)
4300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3236 ± 98 kPa (469 ± 14 psi)
4300 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2550 ± 98 kPa (370 ± 14 psi)
4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3432 ± 98 kPa (498 ± 14 psi)
4400 (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2746 ± 98 kPa (398 ± 14 psi)
Difference Between Cylinders (Maximum- All). . . . . . . . . . . . . . . . . . . . . 245 ± 49 kPa (36 ± 7 psi)
Oil Pressure
4200 (Rated Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 ± 0.05 MPa (42 ± 7.2 psi)
4300, 4400 (Rated Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.34 ± 0.05 MPa (49 ± 7.2 psi)
Slow Idle (All - Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.06 MPa (8.7 psi)
Oil Relief Valve Opening Pressure (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 - 392 kPa (43 - 57 psi)
Oil Pressure Switch Opening Pressure (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - 62 kPa (6 - 9 psi)
3-8
4/6/01
TORQUE VALUES, NON-STANDARD FASTENERS
DIESEL ENGINE
TORQUE VALUES, NON-STANDARD FASTENERS
Cylinder Head Bolts (Lubricating Oil Applied)
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 - 71 N•m (49 - 52 lb-ft)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 - 91 N•m (63 - 67 lb-ft)
Connecting Rod Bolts (Lubricating Oil Applied)
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 - 54 N•m (33 - 40 lb-ft)
Flywheel Mounting Bolts (All - Lubricating Oil Applied) . . . . . . . . . . . . . . . . . 83 - 88 N•m (62 - 65 lb-ft)
Main Bearing Bolts (Lubricating Oil Applied)
4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.5 - 80.4 N•m (56 - 59 lb-ft)
4300, 4400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 - 100 N•m (71 - 74 lb-ft)
Crankshaft Pulley Bolt (All - Lubricating Oil Applied) . . . . . . . . . . . . . . . . . 113 - 122 N•m (83 - 90 lb-ft)
Fuel Injector Nozzle Nut (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8 - 8.8 N•m (5 - 6.5 lb-ft)
Governor Weight Support Nut (All). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 - 49 N•m (33 - 36 lb-ft)
Rocker Arm Mounting Cap Screw and Nut (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (19 lb-ft)
Oil Pump Mounting Cap Screw (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft)
Starting Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N•m (35 lb-ft)
SPECIAL TOOLS
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
Number
Name
Use
JDG991
Fast Idle Adjustment Tool
Use to set fast idle.
D15001NU
Magnetic Follower Holder
Kit
Hold cam followers
installing camshaft.
JDF13
Nozzle Cleaning Kit
Use to clean fuel injection nozzles.
D-20019WI
Valve Guide Knurler
Use to knurl inside diameter of valve guides.
JDE118
Valve Guide Driver
Use to remove and install valve guides in
cylinder head.
D-20021WI
Valve Guide Reamer
Use to ream out valve guides.
when
removing
and
OTHER MATERIALS
Number
Name
Use
TY15130 LOCTITE®
No. 395
John Deere Form-InPlace Gasket
Seals rear oil seal case and flywheel housing to
engine block. Seals oil pan to timing gear
housing and engine block.
TY9370
LOCTITE No. 242
Thread Lock and Sealer
(Medium Strength)
Apply to threads of crankshaft pulley cap screw.
LOCTITE® is a registered trademark of the Loctite Corp.
4/6/01
3-9
THEORY OF OPERATION
DIESEL ENGINE
THEORY OF OPERATION
The injection pump meters fuel as determined by the
governor and delivers it at high pressure to the injection
nozzles.
FUEL AND AIR SYSTEM
OPERATION
The injection nozzle prevents flow until high pressure is
reached, opening the valve and spraying atomized fuel
into the combustion chamber. Injection lines contain
trapped fuel whenever injection is not taking place.
Function:
The air intake system filters and supplies air needed for
combustion.
A small amount of fuel leaks past the nozzle valve to
lubricate the fuel injection nozzle. This leakage
combines with excess fuel from the injection pump and
is returned to tank. Any air in the fuel system is bled out
with return fuel to the fuel tank.
Theory of Operation:
A fuel level sensor mounted in the fuel tank informs the
operator of the fuel level.
Fuel system supplies fuel to injection nozzles.
Air Intake System:
E
D
B
M94772
Engine intake air enters the inlet hose (A) behind the
grille, and flows into the air filter body (B). The air
cleaner also has a rubber, one way, unloading valve
(C), that ejects heavy dirt particles from the air stream
during engine operation before they reach the filters.
The operator can squeeze the valve to remove the
large particles. The air cleaner elements filter the air,
which then flows through hose (D) to the intake
manifold.
An air filter restriction indicator (E) at the rear of the air
cleaner informs the operator when the air filter needs
servicing.
C
A
Fuel System:
A mechanical fuel transfer pump (A) draws fuel from
the tank outlet. The low pressure fuel from the fuel
pump flows through the filter/water separator (B) to the
fuel the injector pump inlet (C). The injection pump
then directs high pressure fuel through the injector
lines (D) for combustion. Excess fuel is returned, along
with fuel from the injectors, through the return line (E)
to the fuel tank.
If the unit runs out of fuel, there are two air bleed lines
that allow air to escape from the top of the filter and the
injection pump. These two lines allow the system to be
self bleeding.
The engine speed is controlled by the throttle lever and
rod. The rod is connected to the injection pump
governor control lever. The fuel shutoff solenoid
controls the injection pump shutoff shaft. When the
solenoid is retracted (key in the START or ON position),
the engine can be started. When the key is turned off,
return springs on the shutoff shaft, extend the solenoid,
moving the shutoff linkage to the shutoff position. The
solenoid also closes if the tractor is operated in an
unsafe condition. (See “ENGINE SHUTOFF CIRCUIT
OPERATION” in the Electrical section.)
3 - 10
4/6/01
COOLING SYSTEM OPERATION
DIESEL ENGINE
COOLING SYSTEM OPERATION
B
C
A
MX1026
Function:
The coolant pump (A) circulates coolant through the
cooling system, drawing hot coolant from the engine
block, circulating it through the radiator for cooling.
Theory of Operation:
The pressurized cooling system includes the radiator,
water pump, fan and thermostat (B).
During the warm-up period, the thermostat remains
closed and the impeller type coolant pump draws
coolant from the bypass tube. Coolant from the pump
flows to the cylinder block water jacket and up through
the cylinder head providing a fast warm-up.
Once the engine has reached operating temperature,
the thermostat opens and coolant is pumped from the
bottom of the radiator via the lower radiator hose into
the cylinder block. Here it circulates through the block
and around the cylinders.
When coolant system pressure exceeds 48 kPa (7
psi), a valve in the radiator cap opens to allow coolant
to discharge into the coolant recovery tank.
When temperature is reduced, a vacuum is produced in
the radiator and coolant is drawn back out of the
coolant recovery tank through a valve in the radiator
cap.
A coolant temperature sensor (C) informs the operator
of the engine coolant temperature and warns of a high
temperature condition by lighting a lamp.
Start To Open . . . . . . . . . 69.5 - 72.5° C (157 - 163° F)
Fully Opened . . . . . . . . . . . . . . . . . . . . 85° C (185° F)
From the block, coolant is then directed through the
cylinder head, and into thermostat housing.
With the thermostat open, warm engine coolant passes
through the housing into the top of the radiator where it
is circulated to dissipate heat.
4/6/01
3 - 11
LUBRICATION SYSTEM OPERATION
DIESEL ENGINE
LUBRICATION SYSTEM OPERATION
A ROCKER ARMS
B
C CRANKSHAFT MAIN
MAIN OIL L
GALLEY
OIL PRESSURE
SENSOR
ROCKER ARM
SHAFT
BEARINGS
K
D CAMSHAFT
OIL FILTER J
BEARINGS
CONNECTING I
ROD JOURNAL
IDLER
E GEAR
BUSHING
H
INJECTION PUMP
RESERVOIR
INTAKE SCREEN G
PUMP PRESSURE OIL
OIL PUMP F
PRESSURE FREE OIL
Function:
A full pressure system lubricates engine parts with
filtered oil.
Theory of Operation:
The pressure lubrication system consists of a positive
displacement gear-driven pump (F), oil strainer (G), full
flow oil filter (J), oil pressure regulating valve and an
electrical pressure warning switch. (K)
A drilled passage from the rear camshaft bearing
through the cylinder block and cylinder head supplies
lubricating oil to the rocker arm shaft (B). The hollow
shaft distributes oil to the rocker arms (A), cam
followers and valves.
Lubrication oil is supplied to the fuel injection pump (H)
from the main oil galley through external oil lines.
An oil pressure sensor (K) activates an indicator light to
alert the operator to shut down the engine if oil
pressure drops below specification.
The pump draws lubrication oil from the oil pan through
a strainer and a suction tube. The oil is then pumped
through an oil passage to the oil filter and through the
engine block main oil galley (L).
From the main oil galley, oil is forwarded under
pressure to the crankshaft main bearing journals (C)
and idler gear bushing (E). Drilled cross-passages in
the crankshaft (I) distribute the oil from the main
bearings to connecting rod bearings.
Lube oil holes in main bearing oil grooves direct oil to
the camshaft bearings (D).
3 - 12
4/6/01
TROUBLESHOOTING CHART—3TNE
DIESEL ENGINE
●
●
●
●
●
●
●
●
●
●
●
●
Piston ring, piston or cylinder worn
●
●
●
●
Crankshaft pin or bearing seized
●
●
●
●
●
●
Piston rings installed incorrectly
●
Crankshaft pin or bearing worn
●
●
●
●
●
●
●
●
●
●
●
● Grind valve seat, regrind valves
●
●
Replace head gasket
●
●
●
●
●
Bore or hone cylinder & replace piston
●
Regrind crank and replace bearings
●
●
Stagger piston ring gaps
●
●
Install piston rings correctly
●
● Replace rings and check cylinder
●
Regrind crank and replace bearings
●
●
Check for damage and re-torque bolts
●
Remove head and inspect for damage
Measure timing gear backlash
●
●
●
●
●
●
●
Check valve guides and stems
●
Repair or replace governor
Adjust valve clearance. Check vlave
timimg
●
●
Engine running too cool
Replace valve and check valve guide
●
●
●
●
Exhaust temperature too high
●
●
●
●
High pressure
●
●
Governor not functioning properly
Solution
● Adjust valve clearance
●
●
●
Intake/exhaust valve guides worn
Low pressure
Low water temperature
Overheating
Low compression
Low oil pressure
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Under Load
During Idling
Excessive engine vribration
●
●
Excessive timing gear backlash
Cooling System
●
●
Connecting rod bolt loose
4/6/01
●
Problem or Symptom
●
●
●
Improper timing between injection
pump, intake & exhaust valves
Uneven combustion sound
Black
White
Black
●
●
Piston ring end gaps not correct
Intake
Coolant manifold
pressure
Lubricating Oil
●
Broken or seized piston ring
Foreign matter in combustion chamber
Engine
surges
●
Leaking cylinder head gasket
Engine System
Under load
●
Compression leakage from valve seat
Seized intake/exhaust valve
Exhaust Color
White
●
Excess
smoke
Improper intake or exhaust valve
clearance
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART
●
●
Check thermostat
Engine running too hot
●
●
● Check thermostat, fan belt tension
Coolant level low
●
●
● Check cooling system for level/leaks
●
Cracked water jacket
●
●
Malfunctioning thermostat
●
●
Water pump/alternator belt loose
●
●
3 - 13
Repair or replace water jacket
●
Check or replace thermostat
● Adjust fan belt tension
TROUBLESHOOTING CHART—3TNE
DIESEL ENGINE
●
●
●
●
●
●
●
●
●
●
●
●
Piston ring, piston or cylinder worn
●
●
●
●
Crankshaft pin or bearing seized
●
●
●
●
●
●
Piston rings installed incorrectly
●
Crankshaft pin or bearing worn
●
●
●
●
●
●
●
●
●
●
●
● Grind valve seat, regrind valves
●
●
Replace head gasket
●
●
●
●
●
Bore or hone cylinder & replace piston
●
Regrind crank and replace bearings
●
●
Stagger piston ring gaps
●
●
Install piston rings correctly
●
● Replace rings and check cylinder
●
Regrind crank and replace bearings
●
●
Check for damage and re-torque bolts
●
Remove head and inspect for damage
Measure timing gear backlash
●
●
●
●
●
●
●
Check valve guides and stems
●
Repair or replace governor
Adjust valve clearance. Check vlave
timimg
●
●
Engine running too cool
Replace valve and check valve guide
●
●
●
●
Exhaust temperature too high
●
●
●
●
High pressure
●
●
Governor not functioning properly
Solution
● Adjust valve clearance
●
●
●
Intake/exhaust valve guides worn
Low pressure
Low water temperature
Overheating
Low compression
Low oil pressure
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Under Load
During Idling
Excessive engine vribration
●
●
Excessive timing gear backlash
Cooling System
●
●
Connecting rod bolt loose
4/6/01
●
Problem or Symptom
●
●
●
Improper timing between injection
pump, intake & exhaust valves
Uneven combustion sound
Black
White
Black
●
●
Piston ring end gaps not correct
Intake
Coolant manifold
pressure
Lubricating Oil
●
Broken or seized piston ring
Foreign matter in combustion chamber
Engine
surges
●
Leaking cylinder head gasket
Engine System
Under load
●
Compression leakage from valve seat
Seized intake/exhaust valve
Exhaust Color
White
●
Excess
smoke
Improper intake or exhaust valve
clearance
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART
●
●
Check thermostat
Engine running too hot
●
●
● Check thermostat, fan belt tension
Coolant level low
●
●
● Check cooling system for level/leaks
●
Cracked water jacket
●
●
Malfunctioning thermostat
●
●
Water pump/alternator belt loose
●
●
3 - 13
Repair or replace water jacket
●
Check or replace thermostat
● Adjust fan belt tension
TROUBLESHOOTING CHART—3TNE
DIESEL ENGINE
●
●
●
●
●
●
●
●
●
●
●
●
Piston ring, piston or cylinder worn
●
●
●
●
Crankshaft pin or bearing seized
●
●
●
●
●
●
Piston rings installed incorrectly
●
Crankshaft pin or bearing worn
●
●
●
●
●
●
●
●
●
●
●
● Grind valve seat, regrind valves
●
●
Replace head gasket
●
●
●
●
●
Bore or hone cylinder & replace piston
●
Regrind crank and replace bearings
●
●
Stagger piston ring gaps
●
●
Install piston rings correctly
●
● Replace rings and check cylinder
●
Regrind crank and replace bearings
●
●
Check for damage and re-torque bolts
●
Remove head and inspect for damage
Measure timing gear backlash
●
●
●
●
●
●
●
Check valve guides and stems
●
Repair or replace governor
Adjust valve clearance. Check vlave
timimg
●
●
Engine running too cool
Replace valve and check valve guide
●
●
●
●
Exhaust temperature too high
●
●
●
●
High pressure
●
●
Governor not functioning properly
Solution
● Adjust valve clearance
●
●
●
Intake/exhaust valve guides worn
Low pressure
Low water temperature
Overheating
Low compression
Low oil pressure
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Under Load
During Idling
Excessive engine vribration
●
●
Excessive timing gear backlash
Cooling System
●
●
Connecting rod bolt loose
4/6/01
●
Problem or Symptom
●
●
●
Improper timing between injection
pump, intake & exhaust valves
Uneven combustion sound
Black
White
Black
●
●
Piston ring end gaps not correct
Intake
Coolant manifold
pressure
Lubricating Oil
●
Broken or seized piston ring
Foreign matter in combustion chamber
Engine
surges
●
Leaking cylinder head gasket
Engine System
Under load
●
Compression leakage from valve seat
Seized intake/exhaust valve
Exhaust Color
White
●
Excess
smoke
Improper intake or exhaust valve
clearance
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART
●
●
Check thermostat
Engine running too hot
●
●
● Check thermostat, fan belt tension
Coolant level low
●
●
● Check cooling system for level/leaks
●
Cracked water jacket
●
●
Malfunctioning thermostat
●
●
Water pump/alternator belt loose
●
●
3 - 13
Repair or replace water jacket
●
Check or replace thermostat
● Adjust fan belt tension
Exhaust temperature too high
High pressure
●
Low pressure
●
Low water temperature
●
Overheating
Low compression
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Excessive engine vribration
Under Load
●
Problem or Symptom
Solution
Replace engine oil and filter
Repair
Check and repair oil pump
Oil filter clogged
●
Oil pressure relief valve worn
●
Clean, adjust or replace relief valve
Oil level low
●
Add oil
●
Wrong type of fuel
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Replace oil filter
●
Check and adjust injection pump timing
●
● Check and adjust injection pump timing
●
●
Drain and replace fuel
Water in fuel
●
Fuel filter clogged
●
●
●
Air entering fuel system
●
●
●
Clogged or cracked fuel lines
●
●
●
Clean or replace fuel lines
Fuel volume to injection pump low
●
●
●
Check or replace fuel transfer pump
●
●
Check and repair
Replace fuel filter
●
●
Uneven volume of fuel injected
●
●
●
●
●
●
●
●
●
●
●
Engine at high altitude/temperature
●
●
Clogged exhaust pipe
●
●
●
Clogged air filter
●
●
● Check fuel injector pump and injectors
●
●
Poor fuel injection pattern
Check and repair fuel supply system
●
●
Excessive volume of fuel injected
Air/Exhaust
●
Oil pump worn
Retarded fuel injection pump timing
Electrical
Black
External/internal oil leak
Advanced fuel injection pump timing
Fuel System
White
Black
●
DIESEL ENGINE
Intake
Coolant manifold
pressure
Lubricating Oil
Low oil pressure
●
During Idling
Under load
Engine
surges
Uneven combustion sound
Exhaust Color
White
●
Excess
smoke
Improper engine oil viscosity/type
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Lubricating Oil System
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART—3TNE
●
●
●
●
●
●
●
● Check fuel injector pump and injectors
Clean or replace fuel injector nozzles
●
●
●
●
Clean or replace air filter
●
Use higher output engine
● Clean exhaust pipe
Starting motor defective
●
Repair or replace starting motor
Alternator defective
●
Repair or replace alternator
Open circuit in wiring
●
Repair wiring
Battery voltage low
●
Recharge battery
3 - 14
4/6/01
Exhaust temperature too high
High pressure
●
Low pressure
●
Low water temperature
●
Overheating
Low compression
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Excessive engine vribration
Under Load
●
Problem or Symptom
Solution
Replace engine oil and filter
Repair
Check and repair oil pump
Oil filter clogged
●
Oil pressure relief valve worn
●
Clean, adjust or replace relief valve
Oil level low
●
Add oil
●
Wrong type of fuel
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Replace oil filter
●
Check and adjust injection pump timing
●
● Check and adjust injection pump timing
●
●
Drain and replace fuel
Water in fuel
●
Fuel filter clogged
●
●
●
Air entering fuel system
●
●
●
Clogged or cracked fuel lines
●
●
●
Clean or replace fuel lines
Fuel volume to injection pump low
●
●
●
Check or replace fuel transfer pump
●
●
Check and repair
Replace fuel filter
●
●
Uneven volume of fuel injected
●
●
●
●
●
●
●
●
●
●
●
Engine at high altitude/temperature
●
●
Clogged exhaust pipe
●
●
●
Clogged air filter
●
●
● Check fuel injector pump and injectors
●
●
Poor fuel injection pattern
Check and repair fuel supply system
●
●
Excessive volume of fuel injected
Air/Exhaust
●
Oil pump worn
Retarded fuel injection pump timing
Electrical
Black
External/internal oil leak
Advanced fuel injection pump timing
Fuel System
White
Black
●
DIESEL ENGINE
Intake
Coolant manifold
pressure
Lubricating Oil
Low oil pressure
●
During Idling
Under load
Engine
surges
Uneven combustion sound
Exhaust Color
White
●
Excess
smoke
Improper engine oil viscosity/type
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Lubricating Oil System
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART—3TNE
●
●
●
●
●
●
●
● Check fuel injector pump and injectors
Clean or replace fuel injector nozzles
●
●
●
●
Clean or replace air filter
●
Use higher output engine
● Clean exhaust pipe
Starting motor defective
●
Repair or replace starting motor
Alternator defective
●
Repair or replace alternator
Open circuit in wiring
●
Repair wiring
Battery voltage low
●
Recharge battery
3 - 14
4/6/01
Exhaust temperature too high
High pressure
●
Low pressure
●
Low water temperature
●
Overheating
Low compression
Water in crankcase
Fuel oil in crankcase
Excessive oil consumption
Excessive fuel comsumption
Poor return to low speed
Excessive engine vribration
Under Load
●
Problem or Symptom
Solution
Replace engine oil and filter
Repair
Check and repair oil pump
Oil filter clogged
●
Oil pressure relief valve worn
●
Clean, adjust or replace relief valve
Oil level low
●
Add oil
●
Wrong type of fuel
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Replace oil filter
●
Check and adjust injection pump timing
●
● Check and adjust injection pump timing
●
●
Drain and replace fuel
Water in fuel
●
Fuel filter clogged
●
●
●
Air entering fuel system
●
●
●
Clogged or cracked fuel lines
●
●
●
Clean or replace fuel lines
Fuel volume to injection pump low
●
●
●
Check or replace fuel transfer pump
●
●
Check and repair
Replace fuel filter
●
●
Uneven volume of fuel injected
●
●
●
●
●
●
●
●
●
●
●
Engine at high altitude/temperature
●
●
Clogged exhaust pipe
●
●
●
Clogged air filter
●
●
● Check fuel injector pump and injectors
●
●
Poor fuel injection pattern
Check and repair fuel supply system
●
●
Excessive volume of fuel injected
Air/Exhaust
●
Oil pump worn
Retarded fuel injection pump timing
Electrical
Black
External/internal oil leak
Advanced fuel injection pump timing
Fuel System
White
Black
●
DIESEL ENGINE
Intake
Coolant manifold
pressure
Lubricating Oil
Low oil pressure
●
During Idling
Under load
Engine
surges
Uneven combustion sound
Exhaust Color
White
●
Excess
smoke
Improper engine oil viscosity/type
Poor
exhaust
color
Exhaust
smoke
No smoke
Cause
Engine will not start
Lubricating Oil System
Engine
starts but
does not
continue
to run
Low engine
output
Misfiring
Engine will not
start
Normal
Problem or Symtom
Loud knocking noise during combustion
TROUBLESHOOTING CHART—3TNE
●
●
●
●
●
●
●
● Check fuel injector pump and injectors
Clean or replace fuel injector nozzles
●
●
●
●
Clean or replace air filter
●
Use higher output engine
● Clean exhaust pipe
Starting motor defective
●
Repair or replace starting motor
Alternator defective
●
Repair or replace alternator
Open circuit in wiring
●
Repair wiring
Battery voltage low
●
Recharge battery
3 - 14
4/6/01
ENGINE SYSTEM DIAGNOSIS
DIESEL ENGINE
ENGINE SYSTEM DIAGNOSIS
Test Conditions:
• Machine parked on level surface.
• Park brake engaged.
• Key switch in OFF position unless indicated otherwise.
Test Location
Normal
If Not Normal
1. Engine dipstick and
exterior engine surface.
Oil level is between “L” and “H” marks.
Oil filter clean.
Fill oil to correct level.
Change oil and filter.
Oil is not burnt, or contaminated with
metal particles, fuel, or coolant.
Change oil and filter. Inspect for source
of contamination.
No external leakage.
Check gaskets, seals, plugs, cylinder
head, block, intake manifold and
breather.
Coolant level is between marks on tank
when engine is warm.
Coolant in radiator is full to top.
Add proper coolant.
Coolant is not contaminated with oil, fuel
or discolored brown.
Drain and flush system. Check for
source of contamination.
Radiator screen free of debris.
Clean or replace.
Water pump not leaking.
Inspect water pump.
Hoses not cracked or leaking.
Pressure test radiator and cap.
Clamps and radiator cap tight.
Tighten cap and clamps.
Fan belt tight, not glazed or cracked.
Replace belt and adjust tension.
Fan blades not damaged or warped.
Replace fan.
Fuel level correct, not contaminated.
Correct grade of fuel, no water in fuel.
Drain and clean fuel tank. Add fresh fuel.
Fuel pump in-line filter free of debris.
Replace filters.
Fuel shutoff valve in “ON” position.
Move to “ON” position.
Fuel hoses not cracked or leaking.
Replace.
Fuel hose clamps tight.
Replace or tighten.
Air filter hose not cracked, clamps tight.
Replace and tighten clamps.
2. Coolant tank and
radiator.
3. Fuel tank, pump,
lines, filter shutoff valve.
4. Air filter and air intake.
Element not plugged. Air filter housing
sealed, no dirt tracking inside filter
element.
5. Fuel shutoff solenoid.
(Key in RUN position.)
4/6/01
Fuel shutoff solenoid must pull in and
stay in. Solenoid must bottom out.
Shutoff shaft must still move slightly.
Replace element or housing.
Clean any dirt from under solenoid boot.
If solenoid will not pull in and hold in,
See “Fuel Shutoff Solenoid Circuit
Diagnosis” in ELECTRICAL section.
3 - 15
TESTS AND ADJUSTMENTS
DIESEL ENGINE
TESTS AND ADJUSTMENTS
Difference Between Cylinders
(max- All). . . . . . . . . . . . . 245 ± 49 kPa (36 ± 7 psi)
CYLINDER COMPRESSION TEST
Reason:
To determine the condition of the pistons, rings,
cylinder walls and valves.
Equipment:
• JT01682 Compression Gauge Assembly
• JDG560 Adapter
Results:
• If the pressure reading is below specification, squirt
clean engine oil into the cylinders through the
injector ports and repeat the test.
• If the pressure increases significantly, check piston,
rings, and cylinder walls for wear or damage.
• If the pressure does not increase significantly,
check for leaking valves, valve seats or cylinder
head gasket.
SLOW IDLE ADJUSTMENT
Procedure:
1. Remove the injection nozzles.
IMPORTANT: The slow idle adjustment is the only
adjustment that can be made on this engine.
The fast idle and torque capsule adjustments
are pre-set by the engine manufacturer to
comply with strict EPA/CARB emissions
requirements, and are adjustable ONLY by
authorized diesel service facilities.
Reason:
To achieve proper slow idle rpm setting. Provides
adequate rpm to keep the engine running smoothly
without stalling.
A
B
T6333EU
Equipment:
• JT05719 Hand Held Digital Tachometer
2. Install the heat protector from end of injector and
install JDG560 adapter (A).
3. Install JT01682 Compression Gauge Assembly (B)
and JDG560 Adapter.
4. Disconnect the fuel control solenoid connector.
NOTE: Make sure the air cleaner is clean and not
restricted. Replace the air cleaner element as
necessary.
Procedure:
IMPORTANT: DO NOT overheat starting motor
during test.
5. Crank the engine for five seconds with the starting
motor. Minimum cranking speed is 250 rpm.
6. Record the pressure reading for each cylinder.
Specifications:
Cylinder Compression Pressure
4200 . . . . . . . . . . . . . . 3138 ± 98 kPa (455 ± 14 psi)
4200 (Minimum) . . . . 2555 ± 98 kPa (370 ± 14 psi)
4300 . . . . . . . . . . . . . . 3236 ± 98 kPa (469 ± 14 psi)
4300 (Minimum) . . . . 2550 ± 98 kPa (370 ± 14 psi)
4400 . . . . . . . . . . . . . . 3432 ± 98 kPa (498 ± 14 psi)
4400 (Minimum) . . . . 2746 ± 98 kPa (398 ± 14 psi)
3 - 16
1. Place a small piece of reflective tape on the
crankshaft pulley.
2. Start the engine and run for 5 minutes to attain
operating temperature.
3. Move the throttle lever to slow idle position.
4. Use JT05719 Hand Held Digital Tachometer to
check engine speed at the crankshaft pulley.
5. Visually check that the injection pump throttle lever
is against slow idle stop screw. Slow idle speed is
set to specification.
Specification:
CST and SRT Tractors . . . . . . . . . . . . . 950 ± 50 rpm
HST Tractors . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
4/6/01
VALVE CLEARANCE ADJUSTMENT
DIESEL ENGINE
14°
BTDC
12°
BTDC
A
Direction
of Engine
Rotation
1
Center Line
A
B
Flywheel Timing Marks
M91893
5. Locate the inspection hole in right side of the
transmission tunnel. The flywheel can be seen
inside the inspection hole.
Results:
• If the slow idle rpm is not according to
specifications, loosen the nut (A) and turn the slow
idle stop screw (B) clockwise to increase the
engine speed, or counterclockwise to decrease the
engine speed until the slow idle speed is correct.
After adjustment, tighten the nut.
VALVE CLEARANCE ADJUSTMENT
Reason:
To be sure the valves are fully opening and closing at
the correct time, and not wearing the valve train
unnecessarily.
Equipment:
• Feeler Gauge
• 10 mm End Wrench
• Flat Blade Screwdriver
• 17 mm Wrench
Procedure:
1. The engine must be cool (room temperature)
before the valve clearance is checked.
2. Be sure ignition key is OFF before attempting to
turn engine by hand.
3. Open the hood and remove the engine side covers.
4. Remove the rocker arm cover. (See “ROCKER
ARM COVER REMOVAL AND INSTALLATION”).
4/6/01
NOTE: “Top Dead Center (TDC)” is when the piston is
at it’s highest point of travel in the cylinder on
the compression stroke.
Number one cylinder is located at rear of
engine (flywheel side).
6. Turn the crankshaft pulley while watching the
flywheel inside the inspection hole. Align the
number one TDC mark (A) on the flywheel with the
pointer on the tunnel.
NOTE: When top dead center is reached, the rocker
arms for that cylinder will be motionless as the
crankshaft is rotated. If rocker arms are still
moving when TDC is approached, rotate
crankshaft one full revolution and try again.
7. Try to move rocker arms and/or push rods for No. 1
cylinder:
• If the rocker arms and push rods are loose, the
piston is at TDC on the compression stroke. Go to
step 8.
• If the rocker arms and/or push rods are not loose,
rotate the flywheel one revolution (360°), and
recheck the rocker arms and push rods.
3 - 17
CONNECTING ROD SIDE PLAY CHECK
DIESEL ENGINE
13. Check that the rocker arms and push rods for
cylinder number three are loose.
14. Repeat steps 7 – 13 for number three cylinder.
15. Repeat steps 7 – 11 for number two cylinder.
16. Replace the rocker arm cover, air cleaner bracket
and housing, and the muffler.
17. Replace the engine side covers and hood.
C
B
A
MX1194
8. Slide a feeler gauge between the valve cap (A) and
rocker arm to measure the clearance.
CONNECTING ROD SIDE PLAY
CHECK
Reason:
To determine proper side clearance between the
crankshaft and the connecting rod.
Equipment:
• Feeler Gauge
NOTE: The engine must be removed from the tractor
to perform this test.
Procedure:
T6105BF
9. To adjust the valves, loosen the lock nut (B) and
turn the adjusting screw (C) until the blade of the
feeler gauge can be inserted between the rocker
arm and valve cap. Hold the adjusting screw while
tightening the lock nut.
10. Recheck the valve clearance after tightening the
lock nut.
1. Remove the oil pan, crankcase extension, oil pickup, and balancer assembly.
2. Insert a feeler gauge, according to specifications,
between the connecting rod cap and the crankshaft.
Specification:
Valve Clearance . 0.15 – 0.25 mm (0.006 – 0.010 in.)
M82116A
Normal
Not Normal
11. Check that the valve cap on the valve stem
remained seated on the valve and inside the valve
spring retainer.
12. Turn the crankshaft pulley counter clockwise (as
viewed from operator’s seat or flywheel end)
approximately 2/3 of a revolution (240°) while
watching the observation hole for the number three
timing mark.
3 - 18
3. Connecting rod side play is 0.2 - 0.4 mm (0.008 0.016 in.).
Results:
• If the side play exceeds specification, replace the
bearing inserts or the connecting rod.
4/6/01
DIESEL ENGINE
CONNECTING ROD BEARING CLEARANCE CHECK
CONNECTING ROD BEARING
CLEARANCE CHECK
7. Remove the rod bolts and the connecting rod cap.
NOTE: The flattened PLASTIGAGE (B) will be found
on either the bearing insert or crankshaft
journal.
Reason:
To measure oil clearance between connecting rod
bearing and crankshaft journal.
Equipment:
• PLASTIGAGE®
8. Use the graduation marks on the envelope (C) to
compare the width of the flattened PLASTIGAGE at
its widest point. The number within the graduation
marks indicates the bearing clearance in inches or
millimeters depending on which side of the envelope
is used.
NOTE: The engine must be removed from the tractor
to perform this procedure.
Procedure:
C
1. Remove the oil pan, and oil pickup.
IMPORTANT: The connecting rod caps must be
installed on the same connecting rod and in the
same direction to prevent crankshaft and
connecting rod damage.
B
M82117A
2. Remove the connecting rod cap.
3. Wipe oil from the bearing insert and the crankshaft
journal.
4. Put a piece of PLASTIGAGE® (A), or an
equivalent, along the full length of the bearing insert
approximately 6 mm (0.25 in.) off center.
9. Measure the connecting rod bearing oil clearance.
Specification:
Connecting Rod Bearing Oil Clearance
4200 . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Result:
• If the clearance exceeds the wear limit
specification, replace the bearing inserts.
10. Remove the PLASTIGAGE®.
A
M35351
PLASTIGAGE® is a registered trademark of the
DANA Corporation.
5. Turn the crankshaft approximately 30° from bottom
dead center.
6. Install the connecting rod end cap and original rod
bolts. Tighten the rod bolts to specification.
Specification:
Connecting Rod Bolt Torque
4200 . . . . . . . . . . . . . . . . .37 - 41 N•m (27 - 30 lb-ft)
4300, 4400 . . . . . . . . . . . .44 - 54 N•m (33 - 40 lb-ft)
4/6/01
3 - 19
CRANKSHAFT END PLAY CHECK
DIESEL ENGINE
CRANKSHAFT END PLAY CHECK
CRANKSHAFT MAIN BEARING
CLEARANCE CHECK
Reason:
To determine proper side clearance between the
crankshaft and the engine block.
Reason:
To measure oil clearance between main bearing and
crankshaft journal.
Equipment:
Equipment:
• Dial Indicator
• PLASTIGAGE®
Procedure:
NOTE: Crankshaft end play can be measured at front
end or rear end of crankshaft. Procedure is
performed from the rear end. The flywheel is
removed to show detail.
NOTE: The engine must be removed from the tractor
to perform this test.
Procedure:
1. Remove the oil pan, and oil pickup.
IMPORTANT: Main bearing caps must be installed
on the same main bearing and in the same
direction to prevent crankshaft and main
bearing damage.
2. Remove the main bearing cap.
3. Wipe oil from the bearing insert and the crankshaft
journal.
4. Put a piece of PLASTIGAGE® (A), or an
equivalent, along the full length of the bearing insert
approximately 6 mm (0.25 in.) off center.
A
B
A
M82118A
1. Fasten the dial indicator (B) to engine and position
indicator tip on end of crankshaft (A).
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging bearings.
2. Push the crankshaft toward rear as far as possible.
3. Zero the dial indicator.
4. Using a bar, gently pry the crankshaft as far
forward as possible.
5. Crank shaft end play is 0.09 - 0.27 mm (0.004 0.011 in.).
M35382
5. Install the main bearing cap and bolts. Tighten the
bolts to specification.
Specification:
Main Bearing Bolt Torque
4200 . . . . . . . . . . . . . .76.5 - 80.4 N•m (56 - 59 lb-ft)
4300, 4400 . . . . . . . . . . .96 - 100 N•m (71 - 74 lb-ft)
Results:
• If the end play exceeds 0.27 mm (0.011 in,),
replace the thrust bearings.
3 - 20
6. Remove the bolts and main bearing caps.
4/6/01
VALVE LIFT CHECK
DIESEL ENGINE
NOTE: The flattened PLASTIGAGE® (B) will be found
on either the bearing insert or crankshaft
journal.
C
T6333DT
B
M82119A
7. Use the graduation marks (C) on the envelope to
compare the width of the flattened PLASTIGAGE®
at its widest point. The number within the graduation
marks indicates the bearing clearance in inches or
millimeters, depending on which side of the
envelope is used.
Specification:
Main Bearing Oil Clearance
4200 . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Result:
• If the clearance exceeds the wear limit
specification, replace the bearing inserts.
8. Remove PLASTIGAGE®.
®PLASTIGAGE is a registered trademark of the
DANA Corporation.
VALVE LIFT CHECK
3. Fasten the dial indicator to the engine and position
the indicator tip on the valve retainer. The valve
must be fully closed and the rocker arm must move
freely.
4. Zero the dial indicator.
5. Manually turn the crankshaft pulley clockwise (from
the fan end).
6. Observe the dial indicator as the valve is moved to
the full open position. Repeat for each valve.
Results:
• The valve lift should be the same for all valves. If
one or more valves have less travel than the
others, remove and inspect the camshaft, followers
and push rods. (See “CAMSHAFT”) in this section.
If the camshaft, followers and push rods are within
specification remove and inspect the cylinder
head. (See “CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION”).
CAMSHAFT END PLAY CHECK
Reason:
To determine proper side clearance between camshaft
gear end journal and thrust plate.
Equipment:
• Dial Indicator
Reason:
Check wear on cam lobes, followers, and/or push rods.
Equipment:
• Dial Indicator
Procedure:
1. Remove the rocker arm cover. (See “ROCKER
COVER REMOVAL AND INSTALLATION”).
2. Adjust the valve clearance.
4/6/01
Procedure:
1. Remove the timing gear cover. (See “TIMING
GEAR COVER”).
2. Fasten the dial indicator to the engine and position
indicator tip on end of camshaft.
3. Push the camshaft toward the rear as far as
possible.
4. Zero the dial indicator.
5. Pull the camshaft forward as far as possible.
3 - 21
TIMING GEAR BACKLASH CHECK
DIESEL ENGINE
FUEL INJECTION NOZZLE TEST
c CAUTION
M37512
6. Standard end play is 0.05 - 0.25 mm (0.002 - 0.010
in.).
Results:
• If the end play exceeds 0.25 mm (0.010 in.),
remove the camshaft and replace the thrust plate.
(See “CAMSHAFT”).
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body from
high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
Reason:
TIMING GEAR BACKLASH CHECK
To determine opening pressure, leakage, chatter and
spray pattern of the fuel injection nozzle.
Reason:
Equipment:
To check for wear between meshing gears, resulting in
excessive noise and poor engine performance.
Equipment:
• D01109AA Diesel Fuel Injection Nozzle Tester
• D01110AA Adapter Set
• 23622 Straight Adapter
• Container
• Dial Indicator
Procedure:
1. Measure the backlash between meshing gears.
2. The backlash for all gears EXCEPT the oil pump
gear is 0.07 - 0.15 mm (0.003 - 0.006 in.).
3. The backlash for the oil pump gear is 0.11 - 0.19
mm (0.004 - 0.008 in.).
Results:
• If the backlash exceeds specifications, replace
meshing gears as a set:
Idler Gear, Camshaft Gear, Crankshaft Gear, Oil Pump
Gear AND/OR Idler Gear, Fuel Injection Pump Gear.
3 - 22
4/6/01
FUEL INJECTION NOZZLE TEST
DIESEL ENGINE
Connections:
• If the injection nozzle leaks fuel, disassemble and
inspect the nozzle assembly for contamination.
Inspect the valve seating surface. Replace the
nozzle assembly if necessary.
B
C
D
A
E
F
Procedure 3:
1. Test the fuel injection nozzle chatter and spray
pattern following the nozzle tester manufacturer's
instructions.
2. Pressurize nozzle to 19600 kPa (2843 psi).
3. With slow hand lever movement there should be a
“chatter” sound.
4. With fast hand lever movement the nozzle should
exhibit an even, fine atomized spray pattern (G).
5. Place a sheet of white paper 30 cm (12 in.) below
the nozzle. The injection spray should form a
perfect circle on the paper.
M35913
1. Connect the fuel injection nozzle (F) to D01109AA
Diesel Fuel Injection Nozzle Tester (A) using parts
36352 (B), 23617 (C), 23621 (D) from D01110AA
Adapter Set, and 23622 straight adapter.
G
IMPORTANT: Use clean filtered diesel fuel when
testing injection nozzles to get best test results.
Procedure 1:
Test the fuel injection nozzle opening pressure
following the Nozzle Tester manufacturer's instructions.
The opening pressure is 19600 +1000/–0 kPa (2843
+145/–0 psi).
H
Results:
• If the pressure reading does not meet specification,
disassemble the injection nozzle and inspect for
contamination or a stuck valve. If necessary, add
or remove shims to change opening pressure.
Procedure 2:
Test fuel injection nozzle leakage following the nozzle
tester manufacturer's instructions.
1. Dry the nozzle completely using a lint-free cloth.
2. Pressurize the nozzle to 19600 kPa (2843 psi).
3. Watch for leakage from nozzle spray orifice.
M82121A
Results:
• If nozzle chatter or the spray pattern does not meet
specifications, disassemble the injection nozzle
and
inspect
the
nozzle
assembly
for
contamination. Inspect the valve seating surface.
Replace the nozzle assembly if necessary.
• If there is excessive difference in the spray angle or
injection angle, incomplete atomizing or sluggish
starting/stopping of injection (H), disassemble the
injection nozzle and inspect the nozzle assembly
for contamination. Replace the nozzle assembly if
necessary.
Results:
• Fuel should not leak from the nozzle when the
nozzle is pressurized.
4/6/01
3 - 23
THERMOSTAT OPENING TEST
DIESEL ENGINE
THERMOSTAT OPENING TEST
INJECTION PUMP STATIC TIMING
ADJUSTMENT (NON-EPA ENGINES)
Reason:
To determine opening temperature of thermostat.
4200 (-016705)
4300 (-011018)
4400 (-004914)
Equipment:
Reason:
• Thermometer
• Glass Container
• Heating Unit
To make sure that the injection pump timing is set to
manufacturers specification.
Equipment:
• Timing Tool (Made from high pressure pipe, nut and
a clear plastic straw**)
** straw from WD40, carburetor cleaner, brake
parts cleaner, etc.
• External fuel supply
Procedure:
c CAUTION
DO NOT allow thermostat or thermometer to rest
against the side or bottom of glass container
when heating water. Either may rupture if
overheated.
1. Suspend the thermostat and a thermometer in a
container of water.
2. Heat and stir the water. Observe the opening
action of the thermostat as the water heats up.
3. Remove the thermostat and observe the closing
action as it cools.
Procedure:
IMPORTANT: The injection pump timing should be
correct. The timing is set at the factory, and will
not normally change during the life of the
engine. Check and adjust the timing only as the
last option, or if there is reason to believe the
timing has been altered.
Check the fuel, fuel supply system, injectors, air
intake system and cylinder compression before
continuing.
NOTE: If the injection pump has been removed from
engine without disturbing engine crankshaft
and pump gear, perform step 1 to obtain a
close starting point, then perform the entire
timing procedure.
1. Align the arrow or line on the injection pump flange
on the mark noted during pump removal.
M82122A
Results:
• The thermostat should begin opening at 69.5 72.5° C (157 - 163° F) and be fully open at 85° C
(185° F).
• Replace the thermostat if the fully open lift height is
less than 8 mm (0.31 in.), or if the closing action is
not smooth and slow.
M57132
NOTE: Normal rotation, as viewed from the flywheel
end, is counterclockwise. The number one fuel
injection line is toward the flywheel.
2. Remove the number one fuel injection line.
3 - 24
4/6/01
INJECTION PUMP STATIC TIMING ADJUSTMENT (NON-EPA ENGINES)
DIESEL ENGINE
10. Slowly turn the flywheel counterclockwise (as
viewed from the flywheel end) until the fuel in the
straw just starts to move. Stop rotating the flywheel
the instant the fuel begins to move.
B
NOTE: If there is no fuel movement, engine may be on
exhaust stroke. Rotate flywheel 360° and
repeat test.
Drill Out
(#45 drill bit)
A
Direction
of Engine
Rotation
30-50 mm
(1.2-2.0 in.)
14°
BTDC
12°
BTDC
C
1
Injection
Pump
3. Install the timing tool (A) and clear straw (B).
4. Remove the access panel from the flywheel
housing.
5. Prime the pump to fill it with fuel.
6. Disconnect battery negative (–) terminal and
remove fuel shutoff solenoid.
7. Turn the flywheel counterclockwise (as viewed
from the flywheel end) until the timing tool straw
has fuel showing.
14°
BTDC
B
12°
BTDC
Direction
of Engine
Rotation
1
C
Flywheel Timing Marks
11. Check the injection pump timing marks on the
flywheel. The 14° mark on the flywheel must line
up with the center of the timing hole (C) in the
flywheel housing.
Results:
• If the timing is not within specifications, loosen the
pump mounting bolts and turn the pump toward
the engine block to retard the timing or away from
the block to advance the timing. Recheck the
timing.
If the timing did not change, remove pump and
have tested by an authorized diesel injection
service shop.
• If the timing is correct, remove timing tool, install
number one injection line, install the access cover
to the flywheel housing.
A
Flywheel Timing Marks
8. Turn the crankshaft pulley clockwise (back) until
the No. 1 cylinder top dead center (TDC) mark (A)
and pump timing marks (B) have gone past the
center of the timing hole in the flywheel housing
(C) by at least 50 mm (2 in.).
9. Snap the straw with your finger until the level of the
fuel, or a bubble, is set part way up the straw. This
will be the point to watch for fuel movement.
4/6/01
3 - 25
INJECTION PUMP TIMING ADJUSTMENT (EPA ENGINES)
INJECTION PUMP TIMING
ADJUSTMENT (EPA ENGINES)
DIESEL ENGINE
FAN/ALTERNATOR DRIVE BELT
ADJUSTMENT
Reason:
To keep proper tension on the belt to drive the water
pump and the alternator.To prevent shortened belt and
bearing life.
Equipment:
• JDG529 or JDST28 BeltTension Gauge
• Straight Edge
Procedure:
MX1339A
1. Check the belt tension between the fan and
alternator using a belt tension gauge and a straight
edge.
EPA engines have EPA compliance sticker on rocker
arm cover as shown above.
ATTENTION!
DO NOT attempt to adjust the fuel injection
pump timing. For most engine problems, the
fuel injection pump timing will not have to be
adjusted. If the engine performed well at one
time, then performance dropped, the fuel
injection timing is NOT the problem. Fuel
injection timing, once set by the engine
manufacturer, should NOT change during the
life of the engine.
M54014
2. With applied force of 98 N (22 lb-force) the belt
deflection is 10 - 15 mm (0.4 - 0.6 in.).
Results:
IMPORTANT: Fuel injection pump timing should
NOT change during the life of the engine unless
the pump has been altered illegally, or there is
excessive wear to the camshaft injection pump
cam lobes and lifters.
• If deflection is not within specifications, loosen both
alternator mounting cap screws/nuts. Apply force
to FRONT alternator housing only (near the belt)
until tension is correct. Tighten cap screws/nuts.
First check the fuel quality, fuel supply, fuel
injectors, air intake system, and engine
compression in all cylinders before considering
fuel injection timing problems.
If all other possibilities have been ruled out and
it is determined that the fuel injection pump and
governor assembly are in need of repair, they
must be replaced ONLY as complete
assemblies.
Only an authorized factory trained technician is
allowed to remove and install these assemblies.
3 - 26
4/6/01
RADIATOR BUBBLE TEST
DIESEL ENGINE
RADIATOR BUBBLE TEST
COOLING SYSTEM PRESSURE
TEST
Reason:
To determine if compression pressure is leaking from
cylinder.
Reason:
Equipment:
Equipment:
• JDG560 Adapter
Inspect the cooling system for leaks.
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
Procedure:
1. With the coolant at the proper level and the radiator
cap tight, run the engine for 5 minutes to bring it to
operating temperature.
2. Remove the cap from the recovery tank.
3. Check for bubbles coming from the overflow hose
at the bottom of the tank.
• If bubbles are present, isolate the source of the
compression leak.
4. Remove the injection nozzles.
5. Install JDG560 Adapter in the injection port of the
cylinder to be tested.
6. Move the piston to the bottom of the stroke with
intake and exhaust valves closed.
7. Connect the hose from a compressed air source to
the adapter.
8. Apply shop air pressure into the cylinder.
9. Check for bubbles in the recovery tank or air
escaping from the muffler, air cleaner or oil fill
opening.
10. Repeat for each cylinder.
Results:
• If bubbles are present in the recovery tank, check
for cracks in the cylinder head and block. Check for
a damaged head gasket.
• If air escapes from the muffler, check for a worn
exhaust valve.
• If air escapes from the air cleaner, check for a worn
intake valve.
• If air escapes from the engine oil fill, check for worn
piston rings.
Procedure:
1. Remove the cap and attach the pressure pump to
radiator.
2. Apply pressure according to specifications, not to
exceed 97 kPa (14 psi).
3. Check for leaks throughout the cooling system.
After 15 seconds the minimum pressure is 88 kPa
(12.8 psi).
T6333AW
Results:
• Pressure should hold to 88 ± 15 kPa (12.8 ± 2.2
psi). If pressure decreases, check for leaks.
Repair leaks or replace parts as necessary.
• If the pressure test still indicates leakage after all
external leaks have been stopped, a defective
head gasket, cracked block, or cylinder head may
be the cause. (See “RADIATOR BUBBLE TEST”).
RADIATOR CAP PRESSURE TEST
Reason:
Test the radiator cap for operating in the correct
pressure range.
Equipment:
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
4/6/01
3 - 27
ENGINE OIL PRESSURE TEST
DIESEL ENGINE
Procedure:
1. Install the radiator cap (A) on the pressure pump.
2. Apply pressure. Pressure valve in the cap should
open at 88 kPa (12.8 psi).
A
T6333AX
Results:
• If the cap leaks, retighten and test again. Replace
the cap if pressure is not within specification.
ENGINE OIL PRESSURE TEST
T6471FB
Reason:
To determine if the engine bearings or the lubrication
system components are worn.
Equipment:
• JT03017 Hose Assembly
• JT05577 Pressure Gauge (100 psi)
• JT03349 Connector
Results:
• If the oil pressure is not within specifications,
inspect the oil pump.
• If the oil pump is within specifications, the engine
may have parts worn beyond specifications. See
the TROUBLESHOOTING CHART for more
information.
Procedure:
1. Remove the oil pressure sender.
2. Install JTO3349 Connector.
3. Connect JTO3017 Hose Assembly and JTO5577
Pressure Gauge.
IMPORTANT: DO NOT run the engine if there is
insufficient oil pressure!
4. Start the engine. If the pressure reading is below
0.06 MPa (8.7 psi) at slow idle rpm, STOP THE
ENGINE.
5. If the oil pressure is at least 0.06 MPa (8.7 psi) run
the engine approximately five minutes to heat the
oil. Check the oil pressure at 2700 rpm.
Specification:
Oil Pressure
4200 . . . . . . . . . . . . . 0.29 ± 0.05 MPa (42 ± 7.2 psi)
4300, 4400 . . . . . . . . 0.34 ± 0.05 MPa (49 ± 7.2 psi)
3 - 28
4/6/01
FUEL TRANSFER PUMP TESTS
DIESEL ENGINE
FUEL TRANSFER PUMP TESTS
D
PRESSURE TEST
Reason:
To determine supply pump operating pressure.
Equipment:
• JDG356 Fuel Pump Pressure Test Kit
E
MX1156
C
B
A
2. Disconnect fuel transfer pump outlet hose from fuel
injection pump (D). Collect fuel in graduated
container (E) as key switch is turned to “START”
position to crank engine 15 seconds. Compare fuel
amount to specification.
Specification:
Fuel flow 15 sec.. . . . . . . . . . . . . 50 mL (1.5 oz. min.)
MX1155
Procedure:
1. Disconnect the transfer pump to injector pump
hose (A).
2. Install the hose and gauge to outlet side of transfer
pump (B).
3. Crank or start engine, or operate transfer pump
with hand primer lever (C) if equipped.
4. Record fuel pressure reading on gauge.
Results:
If the pressure is below specification, replace the fuel
supply pump.
Specification:
Fuel pressure . . . . . . . . . . . . . . 29 kPa (4.2 psi) min.
FLOW TEST
Conditions:
Fuel temperature for tests. . . . . . . 15-25°C (59-77°F)
1. Disconnect fuel shutoff solenoid wire.
4/6/01
FUEL SYSTEM LEAKAGE TEST
Reason:
Tests the fuel system plumbing for external leakage.
This test also determines if air is entering the fuel
system at connections, allowing fuel to siphon back to
tank.
Procedure:
1. Disconnect the fuel supply line and return line at
the fuel tank.
2. Place the fuel return line into a suitable container
to catch drained fuel.
c CAUTION
DO NOT apply more than 103 kPa (15 psi) air
pressure to the fuel system. Damage to the
injection pump or personal injury may result.
3. Apply 34 - 69 kPa (5 - 10 psi) air pressure to fuel
supply hose until all fuel is drained from the system.
4. Plug the end of the fuel return hose.
5. Apply 34 - 69 kPa (5 - 10 psi) air pressure to the
fuel system at the fuel supply line. DO NOT exceed
a maximum pressure of 103 kPa (15 psi).
3 - 29
BLEED FUEL SYSTEM
DIESEL ENGINE
6. Apply liquid soap and water solution to all joints
and connections in the fuel system, and inspect for
leaks.
C
Results:
• Find leaks and repair or replace parts as
necessary.
Fuel Filter
BLEED FUEL SYSTEM
All engines are equipped with an automatic air venting
system which makes the fuel system self-bleeding.
• Assure that all fuel line connections are securely
tightened.
• Add fuel to the fuel tank.
• Crank the engine to allow fuel system to bleed
itself.
ENGINE REPAIR
ENGINE REMOVAL
1. Split the tractor between the flywheel housing and
the tunnel. (See “TRACTOR SPLITTING FRONT”)
in the Hydrostatic Power Train section for HST
tractors; (“TRACTOR SPLITTING FRONT”) in the
Gear Power Train section for CST tractors; or
(“TRACTOR
SPLITTING
FRONT”)
in
the
SyncReverser Power Train section for SRT tractors.)
2. Remove the hood.
3. Drain the coolant from the radiator and the engine
block.
4. Drain the lubrication oil, and the fuel tank.
5. Remove the battery.
6. Remove the muffler.
7. Remove the coolant overflow tank.
8. Remove the air cleaner.
9. Remove the radiator coolant hoses.
10. Disconnect the hydraulic cooler lines.
11. Remove the radiator.
12. Remove the dipstick and tube.
13. Remove the starting motor wires.
14. Disconnect the intake manifold air heater.
A
B
M94772a
15. Disconnect the throttle rod (A).
16. Label and disconnect the fuel hoses (B).
17. Remove the fuel filter shield and fuel filter (C) from
the engine.
18. Disconnect the fuel solenoid.
19. Disconnect the oil pressure sending unit.
20. Remove the hood support.
21. Disconnect the fuel tank sending unit.
22. Remove the flasher, if equipped.
23. Remove the steering wheel.
24. Remove the control panel.
25. Remove the left side shield.
26. Disconnect the wiring harness, oil pressure switch,
and ground wires from the engine.
27. Remove the return springs, and the left side brake
pedals.
28. Remove the bushing from the brake pedal shaft.
29. Remove the return spring, cotter pin, and washer
from the brake pedal shaft, and remove the right
side pedal with the pedal shaft from the tractor.
30. Label and remove the fuel hoses from the fuel
tank.
31. Loosen the dash board support, and pull the
support toward the rear of the tractor.
32. Lift out the fuel tank.
33. Remove the pedal support.
34. Install lifting brackets to the cylinder head.
35. Install the engine hoist to the lift brackets. Lift the
engine slightly and safely support the tractor frame.
NOTE:
Use more than one support to support the
frame. The frame will pivot on the front axle,
and could slip off of a single support.
36. Disconnect the front wiring harness.
3 - 30
4/6/01
ROCKER COVER REMOVAL/INSTALLATION
DIESEL ENGINE
ROCKER COVER REMOVAL/
INSTALLATION
D
E
G
E
B
A
D
F
J
I
M94981
C
H
37. Label the hydraulic lines (D) and hoses from the
steering control unit (E) and disconnect.
38. Remove the flywheel from the engine. (See
“FLYWHEEL”).
39. Remove the flywheel housing from the engine.
NOTE:
The flywheel housing is heavy. Use an
assistant, and proper tools to remove and lift
the flywheel housing.
The starting motor may be removed with the
flywheel housing.
40. With the frame supported, and the engine attached
to the engine hoist, remove the cap screws that
fasten the engine oil pan to the frame (eight on each
side). Lift and slide the engine out of the back of the
frame. Place the engine on a bench or suitable
engine stand.
NOTE: The engine is heavy and is a tight fit to the
frame. Use an engine hoist and an assistant to
remove the engine from the frame.
4/6/01
M91950
1. Remove the air cleaner and muffler.
2. Remove three rocker cover nuts (A).
3. Remove the breather hose (B).
4. Remove the rocker cover (C) from the cylinder
head.
5. Remove the breather cap (D), plate (E), and baffle
(F).
6. Wash the baffle in a safe solvent and blow dry with
air. Replace the baffle if it comes apart or is
deteriorated.
7. Install the baffle.
8. Install the breather plate and a new O-ring (G)
before replacing breather cover.
9. Inspect the rocker cover gasket (H), and O-rings (I)
and (J) for before reinstalling the rocker arm cover.
Replace if damaged.
10. Clean the cylinder head surface and install the
rocker cover to the cylinder head. Install the rocker
cover nuts.
3 - 31
ROCKER ARM ASSEMBLY
DIESEL ENGINE
ROCKER ARM ASSEMBLY
Removal/Installation and Disassembly/Assembly:
1. Remove the rocker cover. (See “ROCKER COVER
REMOVAL/ INSTALLATION”).
2. Remove the rocker arm end support and rocker
arm center support mounting cap screws.
3. Lift the rocker arm assembly from the cylinder head
and set the assembly on a bench.
NOTE:
If the rocker arm shaft assembly is to be
disassembled, replace components in same
location on the rocker arm shaft they were
removed from.
4. Note the positions of the rocker arm assembly
components. Slide the components off the rocker
arm shaft.
A
5. Lift the push rods from the cylinder head and note
the order of removal for reassembly.
6. Inspect the rocker arm components and push rods.
7. Reinstall the push rods to their original location in
the cylinder head, with the ball shaped end down in
head.
8. Lubricate all parts with clean oil during assembly.
9. Assemble the rocker arm assembly components in
the reverse order of removal.
10. Place the rocker arm assembly on the cylinder
head.
• Align the rocker arms with the valves and push
rods.
• Align the rocker arm end supports and center
supports with the corresponding holes in the head.
11. Install the rocker arm support cap screws. Tighten
the cap screws to 26 N•m (19 lb-ft).
12. Adjust the valve clearance.
B
C
D
E
F
G
H
M
I
L
K
J
M91949B
A. Shaft End Support (2)
E. Spring (3)
I. Stud
B. Cap Screw M8X50 (6)
F. Rocker Arm
J. Push Rod (6)
C. Jam Nut (6)
G. Rocker Arm Shaft
K. Valve Caps (6)
D. Adjuster Screw (6)
H. Plug (2)
L. Center Support (2)
3 - 32
M. Cap Screw M8X25
4/6/01
ROCKER ARM ASSEMBLY
DIESEL ENGINE
Inspection:
Length
Measure bending of push rod:
M82023A
M35262
1. Measure the outer diameter of the rocker arm
shaft.
• Rocker arm shaft OD is 15.97 - 15.98 mm (0.628 0.629 in.).
• Replace the rocker arm shaft if the OD is less than
15.95 mm (0.628 in.).
1. Place the push rod on a flat surface. Use a feeler
gauge to measure any gaps between the push rod
and flat surface.
• Replace any push rod with more than (0.03 mm
(0.001 in.) bend.
Inspect Rocker Arm Contact Surfaces:
B
C
A
M76398
M82022A
2. Measure the inner diameters of the rocker arms
and supports.
• Standard ID is 16.00 - 16.02 mm (0.630 - 0.631
in.).
• Replace the rocker arms or supports if the ID is
more than 16.09 mm (0.633 in.).
3. Measure the rocker arm shaft to rocker arm
bushing oil clearance. Oil clearance is the difference
between the OD of the rocker arm shaft and the ID
of the rocker arms.
• Standard oil clearance is 0.02 - 0.05 mm (0.001 0.002 in.).
• If the clearance exceeds 0.14 mm (0.006 in.)
replace the rocker arm shaft and rocker arms.
4/6/01
1. Check the surface of the adjusting screw that
contacts the push rod (A) for wear. Replace the
adjusting screw (B) if it is worn or damaged.
2. Check the surface (C) of the rocker arm that comes
in contact with the valve cap for wear. Replace
rocker arm if necessary.
3. Check the socket portion of the push rod where the
valve clearance adjusting screw contacts the push
rod. Replace the push rod if it is worn or damaged.
3 - 33
CYLINDER HEAD AND VALVES REMOVAL AND INSTALLATION
CYLINDER HEAD AND VALVES
REMOVAL AND INSTALLATION
DIESEL ENGINE
Installation:
1. Reassemble the cylinder head and valves. (See
“CYLINDER HEAD AND VALVES DISASSEMBLY
AND ASSEMBLY”).
Removal:
1. Remove the rocker arm cover. (See “ROCKER
COVER REMOVAL/ INSTALLATION”).
2. Remove the rocker arm assembly, push rods and
valve caps. (“See ROCKER ARM ASSEMBLY”).
3. Remove the exhaust and intake manifolds. (See
“EXHAUST
MANIFOLD”
and
“INTAKE
MANIFOLD”.)
4. Remove the water pump. (See “THERMOSTAT
AND WATER PUMP”).
5. Remove the fuel injection nozzles. (See FUEL
INJECTION NOZZLES”).
IMPORTANT: The oil passage in the gasket must
be located over the oil passage in cylinder
block.
2. Place a new cylinder head gasket on the engine
block. Dowels in the engine block will assist in
aligning the gasket.
3. Place the cylinder head on the engine block.
Dowels in the engine block will again assist in
alignment.
Exhaust Manifold Side
7
1
13
3
11
5
9
10
6
12
14
4
2
8
Timing Gear End
Flywheel End
A
Intake Manifold Side
Cylinder Head Bolt- Tightening Order
4. Dip the head bolts in clean engine oil, install and
tighten in the sequence shown, in three stages of
gradually-increasing torque. Tighten the head bolts
to specification.
M91949A
Specification:
8
14
12
2
4
9
10
6
5
3
1
11
13
7
6. Remove the cylinder head bolts (A) in the order
shown.
7. Remove the cylinder head from the engine block.
The edge opposite the water pump hangs over the
engine block. Use this edge to aid in removing the
cylinder head. Before using force to remove head,
verify that all the bolts are removed from the cylinder
head.
8. Disassemble and inspect the cylinder head and
valves. (See “CYLINDER HEAD AND VALVES
DISASSEMBLY AND ASSEMBLY”).
3 - 34
Cylinder Head Bolt Torque
4200 . . . . . . . . . . . . . . . . .67 - 71 N•m (49 - 52 lb-ft)
4300, 4400 . . . . . . . . . . . .85 - 91 N•m (63 - 67 lb-ft)
IMPORTANT: Cylinder head bolts must be checked
for proper torque after 50 hours of engine
operation.
5. Install the fuel injection nozzles. (See FUEL
INJECTION NOZZLES”).
6. Install the water pump. (See “THERMOSTAT AND
WATER PUMP”).
7. Install the exhaust and intake manifolds. (See
“EXHAUST
MANIFOLD”
and
“INTAKE
MANIFOLD”.)
8. Install the rocker arm assembly, push rods and
valve caps. (See “ROCKER COVER REMOVAL/
INSTALLATION” and “ROCKER ARM ASSEMBLY”).
4/6/01
DIESEL ENGINE
CYLINDER HEAD AND VALVES DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD AND VALVES
DISASSEMBLY AND ASSEMBLY
Cylinder Head:
1. Remove the valve caps from the valves. The valve
caps should be installed on the valves they were
removed from.
2. Compress the valve spring using a valve spring
compressor and remove the collet halves, retainer,
valve spring and valve stem seal for each valve.
3. The intake and exhaust valve guides are press fit.
Replace the guides only if necessary. (See VALVE
GUIDES”).
4. The valve seats are not replaceable. If inspection
of the cylinder head reveals valve seats that are
damaged or worn beyond repair, the cylinder head
must be replaced. (See “CYLINDER HEAD AND
VALVES DISASSEMBLY AND ASSEMBLY”).
5. Inspect all remaining parts for wear or damage.
(See
“CYLINDER
HEAD
AND
VALVES
DISASSEMBLY AND ASSEMBLY”).
IMPORTANT: Do not reuse stem seals if removed.
Used seals will leak.
6. Install new valve stem seals over the valve guides.
7. Apply clean engine oil on intake and exhaust valve
stems during assembly.
8. Install the valve springs with smaller pitch end or
paint mark toward cylinder head.
9. Compress the valve springs and retainer until the
collet halves are able to be installed in the grooves
of the valve stem.
10. Carefully release the tension on the spring
compressor.
11. Tap on the end of the valve with a plastic hammer
to ensure the collet halves have seated properly on
the valve stem.
12. Repeat for the remaining valves.
13. Measure valve recession if new valves were
installed. (See “VALVE RECESSION”).
M82028A
1. To measure the cylinder head flatness, place a
straightedge along each of the four sides and each
diagonal. Measure clearance between straight edge
and combustion surface with a feeler gauge.
• Standard distortion is 0.05 mm (0.002 in.) or less.
• If the distortion exceeds 0.05 mm (0.002 in.), but is
less than 0.15 mm (0.006 in.) resurface the
cylinder head.
• If the distortion is 0.15 mm (0.006 in.) or more,
replace the cylinder head.
2. If the cylinder head was resurfaced:
• Measure piston-to-cylinder head clearance. (See
“MEASURE CYLINDER HEAD TO PISTON
CLEARANCE”).
• Measure valve recession. (See “CYLINDER HEAD
AND VALVES DISASSEMBLY AND ASSEMBLY”).
• Measure valve seat width. (See “VALVE SEATS”).
NOTE: After each valve has been assembled, tap on
top of valve stem with a plastic hammer to seat
retainer.
Inspection/Replacement:
Before inspection, thoroughly clean all components of
carbon or dirt.
4/6/01
3 - 35
VALVE SEATS
DIESEL ENGINE
VALVE SEATS
A
2. If the valve faces are worn, burned or pitted, grind
valves to proper face angle.
• If the valve head thickness (A) is less than 0.50 mm
(0.020 in.) after grinding, replace the valve.
M82029A
1. Measure the valve seat widths.
SpecificationSpecificationIntake Valve Seat Width
42001.36 - 1.53 mm (0.054 - 0.060 in.)
Wear Limit1.98 mm (0.078 in.)
4300, 44001.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit1.74 mm (0.069 in.)
43 mm
(1.7 in.)
60 mm
(2.4 in.)
Exhaust Valve Seat Width
4200 . . . . . . . . . . 1.66 - 1.87 mm (0.066 - 0.074 in.)
Wear Limit . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
4300, 4400 . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.)
Wear limit . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
2. If necessary, grind the valve seats to meet
specifications. (See “GRIND VALVE SEATS”).
Intake and Exhaust Valves:
M82031A
3. Measure the valve stem diameter at two locations,
as shown.
Specification:
M35307
1. Check the valves for out-of-round, bent or warped
condition using a valve inspection center. Replace
valve if necessary.
3 - 36
Intake Valve Stem OD
4200 . . . . . . . . . . 6.95 - 6.96 mm (0.274 - 0.274 in.)
Wear Limit . . . . . . . . . . . . . . . . 6.90 mm (0.272 in.)
4300, 4400 . . . . . 7.96 - 7.98 mm (0.313 - 0.314 in.).
Wear Limit . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Exhaust Valve Stem OD
4200 . . . . . . . . . . 6.94 - 6.96 mm (0.273 - 0.274 in.)
Wear Limit . . . . . . . . . . . . . . . . 6.90 mm (0.272 in.)
4300, 4400 . . . . . 7.96 - 7.97mm (0.313 - 0.314 in.).
Wear Limit . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
• If the valve stem diameter is less than the wear
limit, replace the valve.
4/6/01
VALVE RECESSION
DIESEL ENGINE
VALVE RECESSION
3. Subtract the valve stem OD from the valve guide ID
to obtain the oil clearance.
A
Specification:
Valve Stem-To-Guide Oil Clearance
Intake Valve
All. . . . . . . . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
Wear Limit- 4200. . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit- 4300, 4400. . . . . . 0.20 mm (0.008 in.)
Exhaust Valve
All . . . . . . . . . . . 0.05 - 0.08 mm (0.002 - 0.003 in.)
Wear Limit- 4200. . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit- 4300, 4400. . . . . . 0.20 mm (0.008 in.)
• If the ID of the valve guide is less than the wear
limit, determine the guide-to-stem oil clearance
(guide diameter minus stem diameter).
• If the oil clearance exceeds 0.15 mm (0.006 in.) but
is less than 0.20 mm (0.008 in.), knurl the valve
guides using D-20019WI Valve Guide Knurler
• If clearance exceeds 0.20 mm (0.008 in.), replace
valve guides using JDE118 Valve Guide Driver.
M82032A
A
1. Measure valve recession (A) using a depth gauge.
Specification:
Intake Valve Recession
4200 . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
4300, 4400 . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Exhaust Valve Recession
All. . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
VALVE GUIDES
1. Clean the valve guides using a valve guide brush.
2. Measure the valve guide inside diameter.
• New valve guides must be cooled in a container of
liquid nitrogen or equivalent before driving into
cylinder head.
• The intake and exhaust valve guides are different.
The exhaust valve guide has one groove and the
intake valve guide has none.
• Install the valve guides with the tapered ends down.
Push the valve guides into the cylinder head until
the valve guide projection (A) is within
specification.
Specification:
Intake Valve ID
4200 . . . . . . . . . 7.00 - 7.015 mm (0.275 - 0.276 in.)
Wear Limit . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
4300, 4400 . . . . . 8.01 - 8.03 mm (0.315 - 0.316 in.).
Wear Limit . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
Exhaust Valve Recession
All. . . . . . . . . . . . . . 0.3 - 0.5 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
4/6/01
Specification:
Valve Guide Projection
4200 . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . 15 mm (0.591 in.)
• Ream the inside diameter of valve guides using D20021WI Valve Guide Reamer.
3 - 37
VALVE SPRINGS
DIESEL ENGINE
VALVE SPRINGS
EXHAUST MANIFOLD
M8 x 22
M8 x 60
M8
B
C
A
M94810
M82034A
1. Measure the valve spring free length.
Specification:
Valve Spring Free Length
4200 . . . . . . . . . . . . . . . . . . . . . . 44.4 mm (1.75 in.)
4300, 4400 . . . . . . . . . . . . . . . . . . 42 mm (1.654 in.)
1. Remove the muffler and gasket (A).
2. Remove the exhaust manifold (B) and gasket (C).
3. Clean the mating surfaces, and replace the
exhaust manifold gasket.
4. Install the exhaust manifold. Tighten all fasteners.
INTAKE MANIFOLD
M8 x 35
A
D
A
C
B
M8 x 25
M82035A
2. Measure the spring inclination (A).
• Replace the spring if the measurement exceeds
1.10 mm (0.044 in.)
3 - 38
M94811
1. Remove the fuel filter bracket (not shown).
2. Remove the intake air heater (A).
3. Remove the fuel injection lines (not shown).
4. Remove the intake manifold (B).
5. Clean the mating surfaces, and replace the intake
manifold gasket (C).
6. Install the intake manifold.
7. Replace the intake air heater gasket (D), and install
the intake air heater.
8. Install the fuel injection lines.
9. Tighten all fasteners to specification.
4/6/01
GRIND VALVE SEATS
DIESEL ENGINE
GRIND VALVE SEATS
If the valve recession exceeds the maximum
specifications or the seats cannot be reconditioned,
replace the valves or the cylinder head.
NOTE: LIGHTLY grind the valve seats for only a few
seconds to avoid excessive valve seat width.
1. Grind the intake valve seat using a 30° seat grinder
and the exhaust valve seat using a 45° seat grinder.
Follow the tool manufacturers instructions.
M82039A
B
C
15°
A
Cylinder
Head
3. If the seat width (A) is too wide after grinding, grind
the lower seat surface (B) using a 70° seat grinder
until the seat width is close to specifications.
4. Grind the upper seat surface (C) using a 15° seat
grinder until the seat width is narrowed to
specifications.
5. If the valve seats (D) are ground, measure valve
recession. (See “CYLINDER HEAD AND VALVES
DISASSEMBLY AND ASSEMBLY”) Check the
contact pattern between the seat and valve with
bluing dye.
6. Lap the valves. (See “LAP VALVES”).
4/6/01
NOTE:
Use a rubber type lapping tool for valves
without a lapping tool groove slit.
M82041A
If the seat does not make proper contact, lap the valve
into the seat:
2. Measure the valve seat width after grinding.
D
LAP VALVES
1. Apply a small amount of fine lapping compound to
the face of the valve.
2. Turn the valve to lap the valve to the seat.
3. Lift the valve from the seat every 8 to 10 strokes.
Lap until a uniform ring appears around the surface
of the valve face.
4. Wash all parts in solvent to remove lapping
compound. Dry all parts.
5. Check the position of the lap mark on the valve
face. Lap marks must be on or near the center of the
valve face.
MEASURE PISTON-TO-CYLINDER
HEAD CLEARANCE
1. Place three 10 mm (0.4 in.) long pieces of 1.5 mm
(0.06 in.) diameter soft wire in three positions on the
flat part of the piston head.
2. Install the cylinder head and old gasket. Install
cylinder head bolts and tighten in proper sequence.
(See “CYLINDER HEAD AND VALVES REMOVAL
AND INSTALLATION”).
3. Slowly turn the crankshaft one complete revolution.
4. Remove the cylinder head and gasket.
3 - 39
PISTON AND CONNECTING ROD
DIESEL ENGINE
M82042A
5. Measure the thickness of the flattened section of
each piece of wire. Calculate the average thickness
of the wires to obtain the piston-to-cylinder head
clearance specification.
• If the clearance is less than 0.64 - 0.82 mm (0.025 0.032 in.), replace cylinder head. (See
“CYLINDER HEAD AND VALVES REMOVAL AND
INSTALLATION”).
C
B
PISTON AND CONNECTING ROD
A
NOTE: The engine must be removed from the tractor
to perform this procedure.
Removal:
1. Remove the oil pan, and oil pickup tube.
2. Remove the cylinder head. (See “CYLINDER
HEAD
AND
VALVES
REMOVAL
AND
INSTALLATION”).
3. Check the cylinder bore for ridges. These ridges
can cause damage to piston if ridge is not removed.
4. If necessary, remove any ridge from the top of the
cylinder bore using a ridge reamer.
5. Measure the connecting rod side play. (See
“CONNECTING ROD SIDE PLAY CHECK”).
6. Measure the crankshaft end play. (See
“CRANKSHAFT END PLAY”).
7. Measure the connecting rod bearing clearance.
(See
“CONNECTING
ROD
BEARING
CLEARANCE CHECK”).
IMPORTANT: Keep the connecting rods and rod
caps together. Rods and caps are a matched
set. Note the alignment marks on each part.
M82196AB
8. Remove the rod bolts (A), connecting rod cap (B)
and bearing inserts (C).
IMPORTANT:
The pistons and cylinders are
matched. Pistons must be installed in the
cylinders from which they are removed.
9. Note the connecting rod alignment mark in relation
to the cylinders. Starting at the flywheel end with
cylinder number one, then two, etc.
10. Push the piston and connecting rod out of the
cylinder bore using a wooden dowel.
11. Disassemble and inspect all parts for wear or
damage. (See ”PISTON CLEARANCE CHECK”).
12. Inspect the cylinder bore. (See “CYLINDER
BORE”).
Installation:
• Apply clean engine oil to all parts during
installation.
• Always replace the connecting rod bolts. DO NOT
reuse the bolts.
3 - 40
4/6/01
PISTON AND CONNECTING ROD
DIESEL ENGINE
IMPORTANT: Pistons must be installed in the
cylinders from which they were removed and in
the same direction. Be careful not to damage
the crankshaft rod journals while installing
pistons.
1. Assemble the piston and connecting rod. (See
“Disassembly” below.)
4. Match the connecting rods to caps using alignment
marks (H). Install the rod caps.
5. Dip the entire connecting rod bolt in clean engine
oil. Install new bolts and tighten to specification.
Specification:
Connecting Rod Bolt Torque
4200 . . . . . . . . . . . . . . . . .37 - 41 N•m (27 - 30 lb-ft)
4300, 4400 . . . . . . . . . . . .44 - 54 N•m (33 - 40 lb-ft)
E
6. If a new piston and connecting rod were installed,
stamp a number corresponding to the cylinder
number on the connecting rod and rod cap.
7. Install the cylinder head. (See “CYLINDER HEAD
AND VALVES REMOVAL AND INSTALLATION”).
8. Install the oil pan, and oil pickup tube.
Disassembly:
D
IMPORTANT: Pistons must be installed on the
same connecting rod they were removed from.
G
F
L
H
M
G
A
M82196AB
J
2. Install the piston and connecting rod into the
cylinder from which it was removed. The alignment
mark on the connecting rod (D) and/or the piston
size mark (E) on top of piston should point toward
the fuel injection pump.
IMPORTANT: Do not touch bearing insert surfaces.
Oil and acid from your finger will corrode the
bearing surface.
3. Install the bearing inserts to the connecting rod
and rod cap, aligning tangs (F) with grooves (G).
IMPORTANT:
Connecting rod caps must be
installed on the same connecting rods they
were removed from.
4/6/01
I
I
K
M82197AB
• Put a mark on each piston and connecting rod to
aid in assembly.
3 - 41
PISTON AND CONNECTING ROD
DIESEL ENGINE
• Remove snap rings (I) from piston pin (J) and
remove pin.
• The piston pin bushing (K) is a press fit in the
connecting rod. Remove the bushing only if
replacement is necessary.
• Inspect all parts for wear or damage. Replace as
necessary.
• Remove the 1st and 2nd compression rings (L) and
oil ring with expander (M).
P
N
O
Assembly:
• Apply clean engine oil to all parts during assembly.
IMPORTANT: The pistons must be installed on the
same connecting rod they were removed from.
E
M82046A
4. Install the oil ring over the expander with the ring
gap (N) opposite (180°) of the expander ends (O).
5. Install the second compression ring, with the small
diameter of taper toward top of piston, in the middle
groove. Turn the ring until the gap (P) is 120° away
from the oil ring gap (N).
J
I
P
120°
N
120°
D
G
Q
M82198AB
1. Assemble the piston to the connecting rod with
piston mark (E) on the same side as the connecting
rod stamped mark (D). If a new connecting rod is
used, assemble the piston to the connecting rod
with piston mark opposite the connecting rod
bearing insert groove (G). Be sure the oil hole in the
piston pin bushing is aligned with the hole in the
connecting rod.
2. Install the piston pin (J) and retaining/snap rings.
3. Install an oil ring expander (M) in the bottom ring
groove of the piston, with the ends above either end
of the piston pin.
3 - 42
120°
M82199A
6. Install the first compression ring (chrome plated),
with the manufacturer's mark “R”, “T” or “RN” (near
the ring gap) toward the top of the piston, in the top
groove. Turn the ring until the gap (Q) is 120° away
from the second ring gap.
4/6/01
PISTON INSPECTION
DIESEL ENGINE
PISTON INSPECTION
Result:
Connecting Rod Bearing
1. Install the connecting rod cap and bearing inserts
on the connecting rod. Install the old connecting rod
bolts and tighten to specification.
• If the bearing oil clearance exceeds the wear limit
grind the crankshaft connecting rod journals and
install undersized bearing inserts, or replace the
bearing inserts and the crankshaft.
Piston Ring Groove
Specification:
Connecting Rod Bolt Torque
4200 . . . . . . . . . . . . . . . . .37 - 41 N•m (27 - 30 lb-ft)
4300, 4400 . . . . . . . . . . . .44 - 54 N•m (33 - 40 lb-ft)
M35360
1. With the rings installed on the piston, measure the
piston ring groove side clearance. Measure at
several places around each piston.
2. Replace the rings or the piston if the clearances
exceed specification.
M82048A
Specification:
2. Measure the connecting rod bearing diameter.
Specification:
Connecting Rod Bearing ID
4200 . . . . . . . . 46.00 - 46.02 mm (1.811 - 1.812 in.)
4300, 4400 . . . 51.00 - 51.01 mm (2.008 - 2.008 in.)
First compression ring groove- side clearance
All . . . . . . . . . . . 0.08 - 0.11 mm (0.003 - 0.004 in.)
Second compression ring groove- side clearance
4200, 4400 . . . . . 0.04 - 0.07 mm (0.001 - 0.003 in.)
4300 . . . . . . . . . . 0.05 - 0.08 mm (0.002 - 0.003 in.)
Oil control ring groove- side clearance
All . . . . . . . . . . . 0.03 - 0.06 mm (0.001 - 0.002 in.)
Result
• Replace the bearing inserts if the bearing diameter
is not within specification.
3. Measure the oil clearance between the bearing
inserts and the crankshaft, and verify that the
clearance is within specification.
Specification:
Connecting Rod Bearing Oil Clearance
4200 . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . . 0.04 - 0.07mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
4/6/01
3 - 43
PISTON INSPECTION
DIESEL ENGINE
Piston Ring End Gap
1. Measure the piston pin diameter. Measure the
diameter at six places. Replace any pin that is not
within specification.
B
Specification:
Piston Pin OD
4200 . . . . . . . . 22.99 - 23.00 mm (0.905 - 0.906 in.)
Wear Limit . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
4300, 4400 . . . 25.99 - 26.00 mm (1.023 - 1.024 in.)
Wear Limit . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Piston Pin Bore:
A
M37683
30 mm
(1.18 in.)
B
M82049A
1. Measure the pin bore diameter in the piston.
1. Use a piston to push the ring (A) approximately 30
mm (1.18 in.) from the bottom of the cylinder bore.
Measure the piston ring end gap (B).
Specification:
Piston Ring End Gap
All . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . 1.50 mm (0.059in.)
Specification:
Piston Pin Bore ID
4200 . . . . . . . . 23.00 - 23.01 mm (0.906 - 0.906 in.)
Wear Limit . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
4300, 4400 . . . 26.00 - 26.01 mm (1.024 - 1.024 in.)
Wear Limit . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
2. Piston pin-to-piston oil clearance is the bore ID
minus the pin OD.
Specification:
Piston Pin-to-Piston Oil Clearance
(All) . . . . . . . . . . . 0.00 - 0.02 mm (0.00 - 0.001 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
• If the piston pin bore exceeds the wear limit,
replace the piston.
• If the piston pin is less than the wear limit, replace
the piston pin.
• If the bore clearance exceeds the wear limit replace
the piston, piston pin or both.
M82050A
3 - 44
4/6/01
PISTON INSPECTION
DIESEL ENGINE
Piston Pin Bushing
23 mm (0.905 in.)
M82200A
M82051A
1. Measure the piston pin bushing diameter in the
connecting rod.
Specification:
Piston Pin Bushing ID
4200 . . . . . . . . 23.02 - 23.04 mm (0.906 - 0.907 in.)
Wear Limit . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
4300, 4400 . . . 26.03 - 26.04 mm (1.025 - 1.025 in.)
Wear Limit . . . . . . . . . . . . . . . 26.10 mm (1.028 in.)
• If the bushing diameter exceeds the wear limit,
replace bushing.
2. Piston pin-to-rod bore oil clearance is the bore ID
minus the pin OD.
• If the bushing clearance (bushing ID minus pin OD)
exceeds specification replace the bushing or the
piston pin.
Specification:
Piston Pin-to-Rod Bore Oil Clearance
All . . . . . . . . . . . 0.03 - 0.05 mm (0.001 - 0.002 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
NOTE: The piston pin bushing is a press fit. Replace
the bushing using a driver set. When installing
the bushing, make sure to align the oil hole in
the bushing with the hole in the connecting rod.
Piston Diameter:
NOTE:
4/6/01
M82052A
1. Measure the piston diameter perpendicular to the
piston pin bore 23 mm (0.905 in.) from the bottom
of the piston skirt.
Specification:
Standard Piston OD
4200 . . . . . . . . 77.95 - 77.98 mm (3.069 - 3.070 in.)
Wear Limit . . . . . . . . . . . . . . . 77.90 mm (3.067 in.)
4300 . . . . . . . . 83.95 - 83.98 mm (3.305 - 3.306 in.)
Wear Limit . . . . . . . . . . . . . . . 83.90 mm (3.303 in.)
4400 . . . . . . . . 87.95 - 87.98 mm (3.462 - 3.464 in.)
Wear Limit . . . . . . . . . . . . . . . 87.90 mm (3.461 in.)
Oversize Piston OD
4200 . . . . . . . . 78.20 - 78.23 mm (3.079 - 3.080 in.)
Wear Limit . . . . . . . . . . . . . . . 78.15 mm (3.077 in.)
4300 . . . . . . . . 84.20 - 84.23 mm (3.315 - 3.316 in.)
Wear Limit . . . . . . . . . . . . . . . 84.10 mm (3.311 in.)
4400 . . . . . . . . 88.20 - 88.23 mm (3.472 - 3.474 in.)
Wear Limit . . . . . . . . . . . . . . . 88.10 mm (3.469 in.)
• If the piston diameter is less than the wear limit,
install a new piston.
If the engine has had a previous major
overhaul, oversize pistons and rings may have
been installed. Pistons and rings are available
in 0.25 mm (0.010 in.) oversize.
3 - 45
CYLINDER BORE
DIESEL ENGINE
CYLINDER BORE
NOTE:
If the engine has had a previous major
overhaul, the cylinders may have been bored
oversize. Pistons and rings are available in
0.25 mm (0.010 in.) oversize.
• If the cylinder bore standard ID exceeds the wear
limit, have the cylinder rebored.
• If the cylinder is rebored, oversize pistons and rings
must be installed.
• If the cylinder bore exceeds the oversize bore ID,
replace the cylinder block.
• If the piston-to-cylinder bore clearance (cylinder
bore ID minus piston OD) exceeds specification,
replace the cylinder block, piston or both; or rebore
cylinder and install oversize piston and rings.
• Slight uneven wear, flaws, or minor damage may be
corrected by deglazing. (See “CYLINDER BORE”).
Deglazing:
IMPORTANT: If the cylinder bores are to be
deglazed with crankshaft installed in engine, put
clean shop towels over crankshaft to protect
journal and bearing surfaces from any
abrasives.
1. Deglaze the cylinder bores using a flex-hone with
180 grit stones.
2. Use the flex-hone as instructed by the
manufacturer to obtain a 30 - 40° crosshatch
pattern as shown.
M82053A
1. Measure the cylinder bore diameter at three
positions; top, middle and bottom. At these three
positions, measure in both directions; along the
crankshaft center line and the direction of the
crankshaft rotation.
Specification:
Standard Cylinder Bore ID
4200 . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.)
Wear Limit . . . . . . . . . . . . . . . 78.20 mm (3.079 in.)
4300 . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.)
Wear Limit . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
4400 . . . . . . . . 88.00 - 88.03 mm (3.465 - 3.466 in.)
Wear Limit . . . . . . . . . . . . . . . 88.20 mm (3.472 in.)
Oversize Cylinder Bore ID
4200 . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.)
4300 . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.)
4400 . . . . . . . . 88.25 - 88.28 mm (3.474 - 3.476 in.)
Piston-to-Cylinder Clearance
4200 . . . . . . . . . . . . . . . . . . . . 0.050 mm (0.002 in.)
4300, 4400 . . . . . . . . . . . . . . . 0.055 mm (0.002 in.)
Cylinder Roundness
All. . . . . . . . . . . . 0.00 - 0.01 mm (0.00 - 0.000 4in.)
Wear Limit . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Cylinder Taper
All. . . . . . . . . . . . 0.00 - 0.01 mm (0.00 - 0.0004 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
3 - 46
IMPORTANT: Do not use gasoline, kerosene or
commercial solvents to clean cylinder bores.
Solvents will not remove all abrasives from
cylinder walls.
3. Remove excess abrasive residue from the cylinder
walls using a clean dry rag. Clean the cylinder walls
using clean white rags and warm soapy water.
Continue to clean the cylinder until white rags show
no discoloration.
M82054A
Reboring:
NOTE:
The cylinder block can be rebored to use
4/6/01
CRANKSHAFT REAR OIL SEAL
DIESEL ENGINE
oversize pistons and rings. Pistons and rings
are available in 0.25 mm (0.010 in.) oversize.
10. Clean the cylinder thoroughly using warm soapy
water until clean white rags show no discoloration.
11. Dry the cylinder and apply engine oil.
1. Align the center of bore to the drill press center.
CRANKSHAFT REAR OIL SEAL
IMPORTANT: Check stone for wear or damage. Use
a rigid hone with 300 grit stones.
2. Adjust the hone so the lower end is even with the
lower end of cylinder bore.
3. Adjust the rigid hone stones until they contact the
narrowest point of the cylinder.
4. Coat the cylinder with honing oil. The hone should
turn by hand. Adjust the hone if it is too tight.
5. Run the drill press at about 250 rpm. Move the
hone up and down in order to obtain a 30 - 40°
crosshatch pattern.
Replacement:
1. Split the tractor between the flywheel housing and
the tunnel. (See “TRACTOR SPLITTING FRONT”)
in the Hydrostatic Power Train section for HST
tractors; (“TRACTOR SPLITTING FRONT”) in the
Gear Power Train section for CST tractors; or
(“TRACTOR
SPLITTING
FRONT”)
in
the
SyncReverser Power Train section for SRT tractors.)
2. Remove the drive coupling.
3. Remove flywheel. (See “FLYWHEEL”).
A
30 - 40°
B
C
M82349A
M52959
NOTE: Measure the bore when the cylinder is cool.
6. Stop the press and check the cylinder diameter.
NOTE: Finish should not be smooth. It should have a
30 - 40° crosshatch pattern.
4. Remove the rear oil seal (A), case-to-crankcase
extension cap screws and the oil seal case-tocrankcase cap screws (B).
5. Remove the rear oil seal case (C).
6. Replace the oil seal. Install the seal, with the lip
toward the cylinder block, flush with the surface of
the oil seal case.
NOTE:
7. Remove the rigid hone when the cylinder is within
0.03 mm (0.001 in.) of desired size.
8. Use a flex hone with 180 grit stones for honing to
final size.
9. Check the bore for size, taper and out-of-round.
(See Inspection procedures.)
If the crankshaft is grooved at the oil seal
contact point, the seal can be installed 3 mm
(0.12 in.) farther into the oil seal case.
7. Install the oil seal case to the crankcase and
crankcase extension.
IMPORTANT: Do not use solvents to clean the
cylinder bores. Solvents will not remove all the
metal particles and abrasives produced during
honing.
4/6/01
3 - 47
CRANKSHAFT FRONT OIL SEAL
DIESEL ENGINE
CRANKSHAFT FRONT OIL SEAL
7. Remove the connecting rod bolts and rod caps.
Discard the connecting rod bolts.
8. Push the pistons and connecting rods away from
crankshaft.
A
D
B
M82203A
C
E
1. Remove the timing gear cover (A). (See “TIMING
GEAR COVER”).
2. Replace the oil seal (B). Install new seal with the lip
toward inside of gear housing cover, flush with the
surface of the cover.
CRANKSHAFT AND MAIN
BEARINGS
B
A
M91948c
Removal:
1. Check the crankshaft end play. (See
“CRANKSHAFT END PLAY CHECK”).
2. Remove the cylinder head. (See “CYLINDER
HEAD
AND
VALVES
REMOVAL
AND
INSTALLATION”).
3. Remove the rear oil seal. (See “CRANKSHAFT
REAR OIL SEAL”).
4. Remove the timing gear cover mounting plate.
(See “TIMING GEAR COVER”).
5. Check the crankshaft rod bearing clearance. (See
“CONNECTING ROD BEARING CLEARANCE
CHECK”).
IMPORTANT:
Connecting rod caps must be
installed on the same connecting rods from
which they were removed. Note the alignment
marks on the caps and rods.
6. Check the crankshaft main bearing clearance.
(See
“CRANKSHAFT
MAIN
BEARING
CLEARANCE CHECK”).
IMPORTANT: Main bearing caps must be installed
on the same main bearings from which they
were removed.
9. Remove the main bearing bolts (A), caps (B) and
cap thrust bearings (C).
10. Remove the crankshaft (D).
11. Remove the block thrust bearings and main
bearing inserts (E).
12. Inspect all parts for wear or damage.
Installation:
• Apply clean engine oil to all parts during
installation.
IMPORTANT: Do not touch bearing insert surfaces.
Oil and acid from your finger will corrode the
bearing surface.
1. Install the grooved bearing inserts in the crankshaft
bearing bores, aligning the tangs with the slots in
the bores.
2. Install the block thrust bearings with the oil grooves
facing away from the engine block.
3. Install the crankshaft.
4. Install the bearing inserts in the main bearing caps,
aligning the tangs with the slots in the caps.
NOTE: The main bearing caps have “raised arrows”
that are stamped with numbers. Both
correspond to their location on the engine
3 - 48
4/6/01
DIESEL ENGINE
block. Install all bearing caps with the “arrow”
toward the flywheel end of the engine. Install
the bearing caps beginning with the thrust
bearing cap (no number), number 1, then 2,
etc. The main bearing cap at the gear train end
does not have a number.
5. Install the thrust bearings, with the oil grooves
facing away from the cap, in the number “1” main
bearing cap.
6. Install the main bearing caps in their original
locations with arrows pointing toward the flywheel
side of the engine.
IMPORTANT: DO NOT use high speed power tools
or air wrenches to tighten main bearing bolts.
CRANKSHAFT AND MAIN BEARINGS
13. Install the rear oil seal. (See “CRANKSHAFT
REAR OIL SEAL
14. Install the flywheel. (See “FLYWHEEL”).
15. Install the timing gear cover. (See “TIMING GEAR
COVER”).
16. Install the front oil seal. (See “CRANKSHAFT
FRONT OIL SEAL”.)
17. Install the oil pan.
Inspection/Replacement:
• Inspect the crankshaft gear for chipped or broken
teeth. Replace if necessary.
To Replace Gear:
1. Remove the gear from crankshaft using a knifeedge puller and a press.
7. Dip each main bearing bolt entirely in clean engine
oil. Install the bolts and tighten. DO NOT tighten to
specifications.
8. Using a soft-faced hammer, tap the front end of the
crankshaft then the rear end of the crankshaft to
align the thrust bearings.
9. Tighten the main bearing bolts to specification.
When tightening, start at the center main bearing
cap and work your way out, alternating to the ends.
Turn the crankshaft by hand. If it does not turn
easily, disassemble the parts and find the cause.
Specification:
Main Bearing Bolt Torque
4200 . . . . . . . . . . . . . .76.5 - 80.4 N•m (56 - 59 lb-ft)
4300, 4400 . . . . . . . . . . .96 - 100 N•m (71 - 74 lb-ft)
IMPORTANT: The connecting rod caps must be
installed on the same connecting rods they
were removed from.
Never reuse connecting rod bolts, replace with
new.
10. Match the connecting rod caps to the rods using
alignment marks. Install the caps to the rods.
11. Dip entire connecting rod bolt in clean engine oil.
Install new bolts to the rods, and tighten to
specification.
Specification:
B
A
M82060A
2. Heat new gear to approximately 150°C (302°F).
Install gear with timing mark (A) toward press table.
Align slot in gear with key (B) in shaft. Press
crankshaft into gear until gear is tight against
crankshaft shoulder.
c CAUTION
DO NOT heat oil over 182° C (360° F). Oil fumes
or oil can ignite above 193° C (380° F). Use a
thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
Connecting Rod Bolt Torque
4200 . . . . . . . . . . . . . . . . .37 - 41 N•m (27 - 30 lb-ft)
4300, 4400 . . . . . . . . . . . .44 - 54 N•m (33 - 40 lb-ft)
12. Install the timing gear cover mounting plate. (See
“TIMING GEAR COVER MOUNTING PLATE”).
M82061A
4/6/01
3 - 49
CRANKSHAFT AND MAIN BEARINGS
DIESEL ENGINE
3. Inspect the crankshaft for bend using V-blocks and
a dial indicator. Turn the crankshaft slowly and read
variations on the indicator. If the variation is greater
than 0.02 mm (0.001 in.), replace the crankshaft.
4. Measure the crankshaft connecting rod journal and
main bearing journal diameters at several places
around each journal.
M82063
D
C
M82062A
Specification:
Connecting Rod Journal OD (C):
4200 . . . . . . . . 42.95 - 42.96 mm (1.691 - 1.691 in.)
Wear Limit . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
4300, 4400 . . . 47.95 - 47.96 mm (1.888 - 1.888 in.)
Wear Limit . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
Main Bearing Journal OD (D):
4200 . . . . . . . . 46.95 - 46.96 mm (1.848 - 1.849 in.)
Wear Limit . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
4300, 4400 . . . 53.95 - 53.96 mm (2.124 - 2.124 in.)
Wear Limit . . . . . . . . . . . . . . . 53.91 mm (2.122 in.)
• If the journal diameter (C) is less than the
specification, but greater than the wear limit, have
the journals ground undersize by a qualified
machine shop.
• If journals are ground, undersize bearing inserts
must be installed. Bearing inserts are available in
0.25 mm (0.010 in.) undersize.
• If the journal diameter is less than the wear limit,
replace the crankshaft.
5. Install the bearing inserts and main bearing caps
on the main bearings. Tighten the main bearing
bolts to specification.
6. Measure the main bearing inner diameter.
• Subtract the main bearing journal OD of the
crankshaft from the main bearing ID to obtain the
main bearing oil clearance.
Specification:
Main Bearing Oil Clearance
4200 . . . . . . . . . . 0.04 - 0.09 mm (0.002 - 0.004 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
4300, 4400 . . . . . 0.04 - 0.07 mm (0.002 - 0.003 in.)
Wear Limit . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
• If the crankshaft is within specification, but the main
bearing oil clearance exceeds the wear limit,
replace the bearing inserts.
• If the crankshaft is not within specification, have
crankshaft journals ground undersize by a qualified
machine shop and install undersized bearing
inserts.
• If the crankshaft is worn past the wear limit, replace
the crankshaft.
7. Clean and inspect the oil passages in the main
bearing journals, connecting rod journals and main
bearing bores in cylinder block.
8. Inspect the crankshaft for cracks or damage.
Replace if necessary.
Specification:
Main Bearing Bolt Torque
4200 . . . . . . . . . . . . . .76.5 - 80.4 N•m (56 - 59 lb-ft)
4300, 4400 . . . . . . . . . . .96 - 100 N•m (71 - 74 lb-ft)
3 - 50
4/6/01
FLYWHEEL AND COUPLING
DIESEL ENGINE
FLYWHEEL AND COUPLING
Removal/Installation:
IMPORTANT:
Always
mounting bolts.
install
new
C
flywheel
1. Split the tractor between the flywheel housing and
the tunnel. (See “TRACTOR SPLITTING FRONT”)
in the Hydrostatic Power Train section for HST
tractors; (“TRACTOR SPLITTING FRONT”) in the
Gear Power Train section for CST tractors; or
(“TRACTOR
SPLITTING
FRONT”)
in
the
SyncReverser Power Train section for SRT tractors.)
E
D
MX1414
4. Remove the flywheel mounting cap screws (C) and
remove the flywheel (D) from crankshaft.
5. Dowel pin (E) in the crankshaft correctly locates
the flywheel on the crankshaft.
6. Install the flywheel. Apply lubrication oil to the
flywheel bolts and tighten to specification.
A
Torque Specification:
Flywheel Bolts . . . . . . . . . 83 - 88 N•m (62 - 65 lb-ft).
7. Installation of the flex-plate, clutch or coupling, is
the reverse of removal.
B
MX1413
2. Mark coupling as to which side faces flywheel for
proper reassembly.
3. Remove four coupling cap screws (A) and remove
coupling (B) from the flywheel.
CAMSHAFT
Removal:
1. Remove the rocker arm assembly and push rods.
(See “ROCKER ARM ASSEMBLY”).
2. Remove the timing gear cover. (See “TIMING
GEAR COVER”).
3. Check the camshaft end play. (See “CAMSHAFT
END PLAY CHECK”).
4. Check the backlash of the timing gears. (See
“TIMING GEAR BACKLASH CHECK”).
NOTE: If a magnetic follower holder kit is not available,
turn engine until oil pan is upward, to hold cam
followers away from camshaft.
5. Hold the cam followers away from the camshaft
using a magnetic follower holder kit such as
D15001NU.
6. Rotate the crankshaft and align the timing marks.
4/6/01
3 - 51
CAMSHAFT
DIESEL ENGINE
IMPORTANT: DO NOT allow the camshaft lobes to
hit any bearing surfaces while removing the
camshaft. Machined surfaces can be damaged.
7. Remove two thrust plate mounting cap screws, the
thrust plate, and the camshaft.
8. Inspect all parts for wear or damage.
5. Install the push rods and rocker arm assembly.
(See
“ROCKER
COVER
REMOVAL/
INSTALLATION”).
Inspection/Replacement:
B
Installation:
C
• Apply clean engine oil on all parts during
installation.
IMPORTANT: DO NOT allow camshaft lobes to hit
bearing surfaces while installing camshaft.
Machined surfaces and bearings can be
damaged.
A
B
A
2
2
3
D
1. Check the camshaft side gap using a feeler gauge.
• If the side gap (A) exceeds 0.05 - 0.25 mm (0.002 0.010in.), remove the camshaft gear (B) and
replace thrust plate (C).
2. Remove the gear (if required) from camshaft using
a knife-edge puller and a press.
• Inspect the gear for chipped or broken teeth.
Replace the gear if necessary.
3
1
1
E
E
Gear Removal/Installation:
C
(Viewed From Gear Case)
1. Rotate the crankshaft to align the timing marks (1,
2 and 3).
NOTE: The fuel injection drive gear (A), the camshaft
gear (B) and the crankshaft gear (C) all must
be correctly timed to the idler gear (D). It is not
necessary to time the oil pump gear (E).
Due to the odd number of teeth on the idler
gear, timing marks will only align periodically.
2. Install the camshaft.
3. Install the thrust plate and cap screws.
4. Install the timing gear cover. (See “TIMING GEAR
COVER”).
3 - 52
c CAUTION
DO NOT heat oil over 182° C (360° F). Oil fumes
or oil can ignite above 193° C (380° F). Use a
thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
1. Heat the gear in oil to approximately 150oC
(300oF).
IMPORTANT: Be sure thrust plate is not between
camshaft gear and camshaft shoulder while
installing gear.
4/6/01
CAMSHAFT
DIESEL ENGINE
G
D
H
C
F
B
M82068A
M82071A
2. Install the thrust plate (C) if removed. Install the
gear (B) with timing mark “C” side toward press
table. Align the slot in the gear with key (D) in shaft.
Press the camshaft into gear until gear is tight
against camshaft shoulder.
• Thrust plate must spin freely on camshaft.
5. Measure the camshaft journal diameters.
• Gear housing (F) and flywheel (G) end camshaft
journal OD is 44.93 - 44.95 mm (1.769 - 1.770 in.)
• Intermediate (H) camshaft journal OD is 44.91 44.94 mm (1.768 - 1.769 in.).
• If the journal diameters are less than 44.85 mm
(1.766 in.), replace the camshaft.
I
M82069A
J
M82072
3. Inspect the camshaft for bend using V-blocks and a
dial indicator. Turn the camshaft slowly and read
variations on the indicator.
• If the variation is greater than 0.02 mm (0.001 in.),
replace the camshaft.
E
M82070A
6. Measure the camshaft bushing (I) diameter at the
gear housing end.
• Standard camshaft bushing ID is 44.99 - 45.06 mm
(1.771 - 1.774 in.)
• Replace the bushing If the diameter exceeds
45.10 mm (1.776 in.).
• If the bushing clearance (bushing ID minus
camshaft journal OD) exceeds 0.20 mm
(0.008 in.), replace the bushing, camshaft or both.
7. Replace the camshaft bushing using a chisel. Be
careful not to push the bushing inside the engine.
8. Align the oil holes (J) in new bushing and cylinder
block. Install bushing using a driver set.
4. Measure the camshaft lobe height (E).
• Camshaft lobe height is 38.64 - 38.77 mm (1.521 1.526 in.).
• If the lobe height is less than 38.40 mm (1.512 in.),
replace the camshaft.
4/6/01
3 - 53
CAMSHAFT FOLLOWERS
DIESEL ENGINE
Inspection:
K
B
A
L
M82074A
M82073
9. Measure the intermediate (K) and flywheel end (L)
camshaft bore diameters.
• Standard camshaft bore ID is 45.00 - 45.025 mm
(1.772 - 1.773 in.)
• If the bore diameter exceeds 45.10 mm (1.776 in.),
replace cylinder block.
• If the bore clearance (bore ID minus camshaft
journal OD) exceeds 0.20 mm (0.008 in.), replace
camshaft, cylinder block or both.
• Apply John Deere Form-In-Place Gasket, or an
equivalent, on the outer edge of the plug. Install
the plug until it bottoms in the bore.
7. Inspect the cam follower contact surface for normal
contact (A) or abnormal wear (B). Replace if
necessary.
M82075A
CAMSHAFT FOLLOWERS
Removal/Installation:
1. Remove the camshaft. (See “CAMSHAFT”).
2. Remove the oil pan and strainer.
IMPORTANT: Cam followers must be installed in
the same bores from which they were removed.
3. Put a mark on each cam follower and the cylinder
block bore to aid in installation.
4. Remove the cam followers.
5. Inspect all parts for wear or damage.
6. Apply clean engine oil to all parts during
installation.
• Installation is done in the reverse order of removal.
3 - 54
8. Measure the cam follower stem diameter.
• Standard cam follower stem OD is 11.98 - 11.99
mm (0.471 - 0.472 in.)
• If the stem diameter is less than 11.93 mm (0.470
in.), replace cam follower.
9. Measure the cam follower bore diameter in the
cylinder block.
• Standard cam follower bore ID is 12.00 - 12.02 mm
(0.472 - 0.473 in.)
• If the cam follower bore diameter exceeds 12.05
mm (0.474 in.), replace the cylinder block.
• Standard cam follower bore clearance is 0.01 - 0.04
mm (0.0004 - 0.002 in.).
• If the bore clearance (bore ID minus follower stem
OD) exceeds 0.12 mm (0.005 in.), replace the
cam follower, cylinder block or both.
4/6/01
TIMING GEAR COVER
DIESEL ENGINE
TIMING GEAR COVER
2
3
4
5
1
8
6
8
27
7
9
10
11
5
4
26
25
24
23
12
13
22
14
21
16
20
15
17
5
4
19
M91955
18
1. Cap Screw M8x30
8. Form-In-Place Gasket
15. Cap Screw M8x12
22. Oil Fill Cap
2. Cap Screw M8x20
9. Cap Screw M8x55
16. Seal Washer M8
23. Dowel
3. Seal Washer
10. Timing Gear Cover
17. Oil Seal
24. O-Ring
4. Cover
11. Stud M10
18. Cap Screw M8x16
25. Stud M8x22
5. Gasket (3 used)
12. Cap Screw
19. Cap Screw M8x85
26. Nut
6. Mounting Plate
13. Cover (3 used)
20. Cap Screw M8x45
27. O-Ring
7. Bolt M8x16
14. O-Ring
21. O-Ring
4/6/01
3 - 55
IDLER GEAR
DIESEL ENGINE
IDLER GEAR
Removal/Installation:
1. Remove the alternator and belt.
Removal/Installation:
1. Remove the timing gear cover. (See “TIMING
GEAR COVER”).
2. Check the backlash of timing gears. (See “TIMING
GEAR BACKLASH CHECK”).
C
B
A
M57125
2. Remove the fan (A), spacer (B) and pulley (C).
3. Remove the crankshaft pulley cap screw and
washer.
4. Remove the crankshaft pulley using a two-jaw
puller.
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align periodically.
When all timing marks on gears align, the
piston closest to the water pump is at TDC on
compression stroke. Number one cylinder is
closest to the flywheel.
3. Rotate the crankshaft and align the timing marks.
C
NOTE: It is not necessary to remove end cover and Oring or fuel injection pump gear cover to
remove timing gear cover.
B
5. Remove the mounting cap screws and timing gear
cover.
6. Inspect the crankshaft oil seal for wear or damage.
Replace if necessary.
• Replace the oil seal using a driver set. Install the
seal with lip toward inside of gear housing cover.
Install the seal flush with surface of cover.
A
4. Remove two cap screws (A), shaft (B) and 43T
gear (C).
5. Inspect all parts for wear or damage.
Installation is done in the reverse order of removal.
E
D
M35295
7. Installation is done in the reverse order of removal.
• Replace the seal washer.
• Align the pin (D) in crankshaft pulley with the hole
(E) in the crankshaft gear. Install the crankshaft
pulley.
• Adjust the fan/alternator drive belt tension.
3 - 56
M82209A
6. Inspect the gear for chipped or broken teeth.
Replace if necessary.
• Measure the idler gear shaft diameter.
• Standard idler gear shaft OD is 45.95 - 45.98 mm
(1.809 - 1.810 in.)
• If the shaft diameter is less than 45.93 mm (1.808
in.), replace idler gear shaft.
7. Measure the idler gear bushing diameter.
• Standard idler gear bushing ID is 46.00 - 46.03 mm
(1.811 - 1.812 in.).
• Replace the bushing if diameter exceeds 46.03 mm
(1.812 in.).
• If the bore clearance (bushing ID minus shaft OD)
exceeds 0.15 mm (0.006 in.), replace the bushing,
shaft, or both.
4/6/01
TIMING GEAR COVER MOUNTING PLATE
DIESEL ENGINE
2. Check the oil pump gear backlash. Replace the oil
pump assembly if backlash is more than 0.12 mm
(0.005 in.).
To Replace The Bushing:
C
D
B
C
B
M82210A
1. Replace the bushing using a driver set.
2. Align the oil holes in bushing (D) and idler gear (C).
3. Install the bushing flush with surface of idler gear.
A
M82215A
TIMING GEAR COVER MOUNTING
PLATE
Removal/Installation:
1. Remove the camshaft. (See “CAMSHAFT”).
2. Remove the idler gear. (See “IDLER GEAR”).
3. Remove the fuel injection pump.
4. Remove the oil pump. (See “OIL PUMP”).
5. Remove the mounting cap screws and plate.
6. Replace the O-rings.
7. Installation is the reverse of removal.
OIL PAN AND STRAINER
3. Remove the mounting cap screws (A), the oil pump
(B) and gasket (C).
4. Inspect all parts for wear or damage.
Oil Pump Disassembly/Assembly:
E
F
D
G
Removal/Installation:
NOTE: The engine must be removed from the tractor
to remove the oil pan.
1. Remove the oil pan.
2. Remove the oil pick up strainer.
3. Clean and inspect all parts.
4. Install the oil pick up strainer.
5. Install the oil pan.
6. Fill the engine with correct engine oil.
OIL PUMP
Removal/Installation:
M82216A
1. The gear (D) is press fit on rotor shaft (E). Remove
gear using a knife edge puller and a press.
2. Inspect all parts for wear or damage.
3. Coat all parts with clean engine oil.
4. Install the outer rotor (F) with identification mark
(G) facing toward rotor shaft assembly.
5. Measure the rotor shaft outer diameter and the
shaft hole diameter in cover.
• Standard clearance is 0.01 - 0.04 mm (0.001 0.002 in.).
• Replace the pump if the clearance is greater than
0.2 mm (0.008 in.).
1. Remove the timing gear cover. (See “TIMING
GEAR COVER”).
4/6/01
3 - 57
OIL PUMP
DIESEL ENGINE
H
I
M51571
M76428
6. Check the rotor recess.
• Standard rotor recess is 0.03 - 0.09 mm (0.001 0.004 in.).
• Replace the pump if the recess exceeds 0.15 mm
(0.006 in.).
9. Check the oil pressure relief valve. If the relief valve
piston (H) is sticking in the pump body, clean parts
to allow free movement of the piston in pump body.
10. Inspect the spring (I) for cracks. The spring is not
serviceable. If damage is identified, replace the oil
pump assembly.
M51572
7. Measure outer rotor-to-pump body clearance.
• Standard clearance is 0.10 - 0.16 mm
(0.004 - 0.006 in.).
• Replace the pump if the clearance is more than
0.25 mm (0.010 in.).
M51573
8. Check inner-to-outer rotor clearance.
• Replace the pump if clearance is more than 0.15
mm (0.006 in.).
3 - 58
4/6/01
THERMOSTAT AND WATER PUMP
DIESEL ENGINE
THERMOSTAT AND WATER PUMP
• If coolant is leaking between the cylinder head and
the pump housing:
The gasket between the head and the pump is
defective. Remove the water pump and replace the
gasket.
2. Inspect the water pump for a worn bearing shaft by
removing the fan belt and checking for excessive
movement of the fan. Replace the water pump if
excessive movement is noticed.
• If the bearing shaft is making noise when operating:
Check the fan belt tension. If adjustment does not
relieve the noise, the bearing shaft is defective.
Replace the water pump.
Inspection:
1. Inspect the water pump for coolant leakage. If the
origin of the leak cannot be determined, test the
cooling system. (See “COOLING SYSTEM
PRESSURE TEST”).
• If coolant is leaking at the pulley flange:
The shaft seal is defective. Replace the water
pump.
1
2
3
4
19
5
6
7
8
9
10
18
11
13
12
17
16
15
20
14
M91821
1. Cap Screw M8x20
6. Plug
11. Pulley
16. Cap Screw m8x55
2. Cover
7. Gasket
12. Spacer
17. Gasket
3. Gasket
8. Temperature Switch
13. Fan
18. Plug
4. Thermostat
9. Water Pump
14. Cap Screw w/Washer
M6x25
19. Gasket
5. Gasket
10. Cap Screw M8x60
15. Fan Belt
20. Drain Valve
4/6/01
3 - 59
FUEL FILTER ASSEMBLY
Replacement:
1. Open the engine drain valve to drain coolant.
2. Disconnect the coolant temperature sensor lead.
3. Disconnect the upper and lower radiator hoses.
4. Remove the fan/alternator drive belt.
5. Remove the cap screws, fan, spacer and pulley.
6. Remove the mounting cap screws, pump and
gasket.
7. Inspect the pump for wear or damage.
8. Test the thermostat for proper operation. (See
“THERMOSTAT OPENING TEST”).
9. Installation is done in the reverse order of removal.
10. Adjust the fan/alternator drive belt tension.
DIESEL ENGINE
FUEL FILTER ASSEMBLY
B
D
E
F
D
C
A
M82370B
1. Remove the retaining ring (A) from the mounting
base (B) while holding on to the filter cover (C).
2. Remove the filter cover from the mounting base.
3. Remove and replace the O-rings (D) and filter
element (E).
4. Be sure the spring (F) is in the filter cover and
place the filter element in the filter cover.
5. Before installing the filter cover and element in the
mounting base, verify the O-ring is in the groove
inside the mounting base.
6. Install the filter cover and the element in the
mounting base.
7. Place the retaining ring over filter cover and screw
on the mounting base to retain filter cover to
mounting base.
IMPORTANT: Tighten only enough to keep the filter
assembly from leaking. Overtightening the
retaining nut may damage the filter cover or
retaining ring.
3 - 60
4/6/01
COMPONENT LOCATION - FUEL SUPPLY
DIESEL ENGINE
COMPONENT LOCATION - FUEL
SUPPLY
1
2
11
3
4
10
9
8
5
6
7
1. Fuel Tank
4. Nozzle Leak-Off Hose
(Short)
7. Transfer Pump
10. Fuel Tank-to-Transfer
Pump Hose
2. Return Fuel Hose
5. Nozzle Leak-Off Hose
(Long)
8. Transfer Pump-to-Filter
Hose
11. Drain Valve
3. Fuel Filter-to-Injection
Pump Hose
6. Air Vent Check Valve
9. Fuel Filter
4/6/01
3 - 61
COMPONENT LOCATION - FUEL SUPPLY
DIESEL ENGINE
1
2
21
20
3
19
4
5
18
6
7
17
8
9
16
15
14
13
10
11
12
M82370A
11
1. Fuel Return To Tank
7. Filter Bowl
13. Banjo Bolt & Fitting
19. O-Ring
2. Filter Mounting Base
8. Cap
14. Hose, Filter to F.I.P
20. Spring
3. O-Ring
9. Injector Fuel Return
15. Hose
21. Shutoff Valve
4. Filter
10. Return Fuel Lines
16. Retaining Ring
22.
5. Spring
11. Copper Washers
17. Cap screw
23.
6. O-Ring
12. Check Valve
18. Shut Off Lever
24.
3 - 62
4/6/01
FUEL INJECTION PUMP (NON EPA ENGINES)
DIESEL ENGINE
FUEL INJECTION PUMP (NON EPA
ENGINES)
8. Remove three mounting nuts (B).
Removal:
c CAUTION
A
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
B
M82231
9. Remove four cap screws, washers, the cover and
gasket.
10. Use chalk or paint to mark the injection pump gear
to the idler gear (A).
11. Remove the nut and lock washer (B).
IMPORTANT: Never steam clean or pour cold water
on an injection pump while the pump is running
or warm. Doing so can damage the pump.
1. Clean the injection pump lines and area around the
pump using parts cleaning solvent or steam cleaner.
2. Loosen the fuel injection line connectors slightly to
release pressure in the fuel system. When
loosening the connectors, use another wrench to
keep the delivery valves from loosening.
3. Loosen the line clamps, and remove the fuel
injection lines.
4. Disconnect the fuel filter hoses.
5. Remove the external lube line.
6. Disconnect the fuel shutoff solenoid link.
M37794
12. Use a puller to remove the gear from the injection
pump shaft.
13. Remove the injection pump and O-ring.
DO NOT attempt to service the injection pump or
governor. If the unit is in need of repair, it must be
serviced by a qualified fuel injection repair shop.
Installation:
A
B
M82230
1. Install a new O-ring to the injection pump.
2. Put the injection pump onto the back of the gear
cover mounting plate. Align the key on the shaft with
the keyway in the gear. Be sure to align the marks
on gears made during removal.
3. Install lock washer and nut. Tighten to
specification.
4. Install a new gasket, cover, four washers and cap
screws.
5. Install three mounting nuts. Do not tighten.
7. Note the position of the timing marks (A) on the
injection pump and the gear cover mounting plate.
4/6/01
3 - 63
FUEL INJECTION PUMP (EPA ENGINES)
6. Align the timing marks on the mounting plate and
injection pump to the same place as when removed.
Tighten the mounting nuts to specifications.
7. Connect the fuel shutoff solenoid link.
8. Connect the fuel filter hoses.
9. Install fuel injection lines and tighten line clamp cap
screws.
IMPORTANT: If the oil has been drained out of the
fuel injection pump housing, add oil as
necessary. The fuel injection pump can be
damaged if operated without the proper amount
of oil.
10. Remove the fill plug and add clean engine oil to the
housing. Add until the oil begins to drip out of
external lube line inlet.
11. Install the external lube line. When installing the
line, put one copper washer between the mounting
bolt head and lube line and the other between the
lube line and housing.
If a new injection pump is being installed, check and
adjust injection pump static timing. (See “INJECTION
PUMP STATIC TIMING ADJUSTMENT PRE-EPA
ENGINES”).
DIESEL ENGINE
FUEL INJECTION PUMP (EPA
ENGINES)
Removal:
c CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
IMPORTANT: Never steam clean or pour cold water
on an injection pump while the pump is running
or warm. Doing so can damage the pump.
1. Clean the injection pump lines and area around the
pump using parts cleaning solvent or steam cleaner.
2. Loosen the fuel injection line nuts. When loosening
the nuts on the injector pump, use another wrench
to keep the delivery valves from loosening.
3. Loosen the line clamps, and remove the fuel
injection lines.
4. Disconnect the fuel filter hoses.
5. Remove the external lube line.
6. Disconnect the fuel shutoff solenoid.
A
B
M82230
7. Note the position of the timing marks (A) on the
injection pump and the gear cover mounting plate.
8. Remove three mounting nuts (B).
3 - 64
4/6/01
FUEL INJECTION PUMP (EPA ENGINES)
DIESEL ENGINE
A
B
M37794
M82231
9. Remove four cap screws, washers, the cover and
gasket.
10. Use chalk or paint to mark the injection pump gear
to the idler gear (A).
C
D
12. Use a puller to remove the gear from the injection
pump shaft.
13. Remove the injection pump and O-ring.
IMPORTANT: If it is determined that either the fuel
injection pump and governor assembly are in
need of repair, they must be replaced ONLY as
complete assemblies. Only an authorized
factory trained technician is allowed to remove
and install these assemblies. If replacement is
necessary, remove and install the fuel injection
pump/governor assembly as a complete,
assembly.
Installation:
MX2355
NOTE:
Timing gear cover removed for photo only.
Timing gear cover does not need to be
removed for injector pump removal.
1. Install a new O-ring to the injection pump.
2. Put the injection pump onto the back of the gear
cover mounting plate. Install three mounting nuts.
Do not tighten. Align the key on the shaft with the
keyway in the gear. Be sure to align the marks on
gears made during removal.
3. Install nut. Tighten to specification.
4. Install a new gasket on the cover, and install the
cover with four washers and cap screws.
IMPORTANT: DO NOT loosen four cap screws (C)
attaching gear to hub! This gear/hub assembly
times the injector pump camshaft in relation the
crankshaft for precise timing of EPA engines.
This procedure is done at the pump
manufacturing plant and cannot be duplicated
in the field!
E
11. Remove nut (D).
MX1399
4/6/01
3 - 65
FUEL INJECTION NOZZLES
5. Align the timing mark on the pump flange to the
fifth mark (E) from the top of the mounting plate.
Tighten the mounting nuts.
6. Connect the fuel shutoff solenoid.
7. Connect the fuel filter hoses.
8. Install fuel injection lines and tighten to
specification. Install line clamps.
Specification:
Injector line nuts . . . . . . . . . . . 30-35Nm (22-25 lb ft)
IMPORTANT: If the oil has been drained out of the
fuel injection pump housing, add oil as
necessary. The fuel injection pump can be
damaged if operated without the proper amount
of oil.
9. Remove the fill plug and add clean engine oil to the
housing. Add until the oil begins to drip out of
external lube line inlet.
10. Install the external lube line. When installing the
line, put one copper washer between the mounting
bolt head and lube line and the other between the
lube line and housing.
If a new injection pump is being installed, check and
adjust injection pump static timing. (See “INJECTION
PUMP STATIC TIMING ADJUSTMENT PRE-EPA
ENGINES”).
DIESEL ENGINE
FUEL INJECTION NOZZLES
Removal/Installation:
IMPORTANT: Never steam clean or pour cold water
on injection pump while the pump is running or
warm. Doing so can damage the pump.
1. Clean the injection pump lines and area around the
pump using a parts cleaning solvent or steam
cleaner.
c CAUTION
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard by
relieving
pressure
before
disconnecting
hydraulic or other lines. Tighten all connections
before applying pressure. Search for leaks with
a piece of cardboard. Protect hands and body
from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable source. Such information is
available from the Deere & Company Medical
Department in Moline, Illinois, U.S.A.
NOTE:
Nozzles are matched to the cylinders. If
removing more than one nozzle, tag nozzles,
according to the cylinder from which it was
removed.
2. Loosen fuel injection line connectors-to-nozzles
slightly to relieve pressure in the fuel system.
3. Loosen line clamp(s) and remove fuel injection
lines.
3 - 66
4/6/01
FUEL INJECTION NOZZLES
DIESEL ENGINE
Installation:
A
Installation is done in reverse order of removal.
• Install a new ring and heat protector when installing
injection nozzles.
B
C
Disassembly/Assembly:
NOTE: If servicing more than one nozzle, keep parts
for each nozzle separate from one another.
D
1. Remove retaining nut (S) and disassemble internal
parts of injection nozzle. Keep parts organized for
ease of assembly.
2. Clean and inspect nozzle assembly. (See
“CLEANING/INSPECTION”).
E
F
K
L
4. Remove clamps (B) and leakoff hoses (C).
5. Remove nuts and retaining plates (A).
6. Remove injection nozzle (D), ring (E) and Teflon
heat protector (F). If ring and protector stay in
cylinder head, thread a cap screw into protector
and pull from cylinder head.
G
M
N
O
H
P
I
T
Q
J
R
D
S
M82126
If nozzles are stuck in cylinder head:
• Grind the head of a cap screw (I) so it fits inside a
nut from an old injection line (J).
• Use two nuts (H) to attach a large flat washer (G) to
the cap screw.
• Install assembly onto nozzle (D) and use a puller
and slide hammer to pull nozzle from cylinder
head.
7. Test injection nozzles. (See “FUEL INJECTION
NOZZLE TEST”).
4/6/01
M82093A
3. Carefully clamp injector body (L) in a soft-jaw vice.
NOTE: Insert the same number of shims (M) that were
removed from injector. Number of shims will
affect the opening pressure of the fuel nozzle
and will be tested after assembly.
4. Reassemble fuel nozzle in the order shown above.
5. Tighten retaining nut to 6.8 - 8.8 N•m (60 - 78 lbin.).
6. After assembly is complete, test injection nozzle.
(See “FUEL INJECTION NOZZLE TEST”).
3 - 67
FUEL INJECTION NOZZLES
DIESEL ENGINE
Cross Section
Cleaning/Inspection:
NOTE:
L
To clean nozzles properly, JDF13 Nozzle
Cleaning Kit is recommended. The Cleaning
Kit is available through the John Deere
SERVICEGARD™ Catalog.
1. Remove anti-corrosive grease from new or
reconditioned nozzles by washing them thoroughly
in diesel fuel.
K
IMPORTANT: Never use a steel brush to clean
nozzles as this will distort the spray hole.
2. Remove carbon from used nozzles, and clean by
washing in diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary
to use a brass wire brush (supplied in Nozzle
Cleaning Kit).
M
T
N
P
R
O
T
P
M82094A
S
Q
R
M37684
K. Return Pipe
P. Separator Plate
L. Injector Body
Q. Nozzle Valve
M. Shim(s)
R. Nozzle Body
N. Spring
S. Retaining Nut
O. Spring Seat
T. Index Pin
3 - 68
3. After removing carbon or lacquer from the exterior
of nozzle, inspect sealing surfaces between
separator plate (P) and nozzle body (R) for nicks
or scratches.
4. Contact area of separator plate (both parts) must
not be scored or pitted. Use an inspection
magnifier (No. 16487 or equivalent) to aid in
making the inspection.
5. Check nozzle contact surface on separator plate
for wear. If contact surface is more than 0.10 mm
(0.004 in.), replace nozzle assembly.
4/6/01
STARTING MOTOR REMOVAL AND INSTALLATION
DIESEL ENGINE
P
C
R
B
M82095A
6. Inspect the piston (large) part of nozzle valve (P) to
see that it is not scratched or scored and that lower
(tip) end of valve is not broken. If any of these
conditions are present, replace the nozzle
assembly.
7. Further inspect the nozzle assembly by performing
a slide test. Use the following procedure:
• Dip the nozzle valve (P) in clean diesel fuel. Insert
valve in nozzle body (Q).
• Hold nozzle vertical, and pull valve out about 1/3 of
its engaged length.
• Release valve. Valve should slide down to its seat
by its own weight.
Replace nozzle assembly if the valve does not slide
freely to its seat.
STARTING MOTOR REMOVAL AND
INSTALLATION
A
M91668
1. Remove the alternator. (See “ALTERNATOR
REMOVAL AND INSTALLATION”).
2. Remove the nut securing the battery cable and
wires on the starting motor (A).
3. Disconnect the starting motor solenoid wire (B).
4. Remove the cap screws securing the starting
motor to the bell housing. Remove the starting
motor.
Installation:
Installation is done in the reverse order of removal.
• DO NOT overtighten the starting motor cap
screws! Tighten the starting motor cap screws
to 88 N•m (65 lb-ft).
Removal:
IMPORTANT:
Always disconnect the negative
cable from the battery before working on any
electrical components.
4/6/01
3 - 69
STARTING MOTOR DISASSEMBLY AND ASSEMBLY
DIESEL ENGINE
STARTING MOTOR DISASSEMBLY AND ASSEMBLY
D
C
B
E
A
K
J
F
I
G
H
M94643
A. Motor
D. Brush Spring
G. Solenoid
J. Idler Gear
B. Field Coil
E. Brush
H. Overrunning Clutch
K. Drive Gear
C. Armature
F. Plunger
I. Pinion
3. Remove the cap screws (C) that secure the motor
to the clutch housing.
Disassembly:
A
D
E
C
M91666
B
M82233A
4. Separate the cover (D) from the motor (E).
1. Disconnect the field lead (A).
2. Remove the cover screws (B).
3 - 70
4/6/01
STARTING MOTOR DISASSEMBLY AND ASSEMBLY
DIESEL ENGINE
M
H
L
M36759
E
F
G
M91667
5. Remove motor (E), armature (F), and brush holder
(G) as a unit from the clutch housing (H).
NOTE: Brushes are not serviceable separately. If the
brushes require replacement, the entire brush
holder, with brushes attached, must be
replaced.
8. Remove the armature (L) from the field coil
housing (M).
9. Inspect and test the brushes, holder, field coil and
armature. (See “STARTING MOTOR INSPECTION/
TEST”).
Assembly:
Assembly is done in the reverse order of disassembly.
NOTE:
Apply multipurpose grease to bearing cup
inside rear cover.
J
N
I
K
K
M36754
M36754
6. Pry the brush springs (I) away and pull the
negative brushes (J) up enough to allow the springs
to hold the brushes in place.
7. Remove the brush holder (K).
4/6/01
IMPORTANT: When installing the rear cover, be
sure the field coil brush wires (N) do not touch
the cover. Turn the brush holder (K) slightly to
take up slack in the brush wires. Press the wires
inward to clear the rear cover.
3 - 71
STARTING MOTOR INSPECTION/TEST
DIESEL ENGINE
STARTING MOTOR INSPECTION/
TEST
IMPORTANT: Do not clean armature with solvent.
Solvent can damage insulation on windings.
Use only mineral spirits and a soft bristle brush.
O
P
I
A
K
M82234
1. Measure brush lengths (A). Minimum brush length
is 8.5 mm (0.335 in.). Replace brush if length is
below minimum.
4. Test for grounded field winding:
• Touch one probe of tester to field coil brush (Q) and
other probe to field coil housing (R).
• Be sure the brush lead is not touching the frame. If
there is continuity, the coil is grounded and the field
coil housing assembly must be replaced.
5. Test for open field coil:
• Touch one probe of tester to each field coil brush.
• If there is no continuity, the field coil is open and the
field coil housing assembly must be replaced.
6. Inspect armature. Look for signs of dragging
against pole shoes.
7. Inspect commutator. Look for roughness, burned
bars, or any material which might cause short
circuits between bars. If necessary, clean and touch
up with 400 sandpaper. NEVER use emery cloth.
Clean all dust from armature when finished.
NOTE: Test armature windings using an ohmmeter or
test light.
NOTE: Test brush holder using an ohmmeter or test
light.
2. Test brush holder (K):
• Touch one probe of tester to negative brush holder
(O) and other probe to field brush holder (P).
• If there is continuity, replace the brush holder.
3. Inspect springs (I) for wear or damage. Replace if
necessary.
S
Q
T
R
M82235
M82236
8. Test for grounded windings:
• Touch probes on one commutator bar (S) and
armature shaft (T). Armature windings are
connected in series, so only one commutator bar
needs to be checked.
• If test shows continuity, a winding is grounded and
the armature must be replaced.
9. Test for open circuit windings:
• Touch probes on two different commutator bars.
• If test shows no continuity, there is an open circuit
and the armature must be replaced.
NOTE: Test field coil using an ohmmeter or test light.
3 - 72
4/6/01
STARTING MOTOR GEAR TRAIN
DIESEL ENGINE
2. Install a new housing bearing (U) tight against the
shoulder of the shaft using an appropriate size
socket that only presses on the inner race of the
bearing.
3. Install a new cover bearing (U) tight against the
shoulder of the shaft using a driver set.
-
STARTING MOTOR GEAR TRAIN
Disassembly/Inspection:
M82125A
10. Test for short circuit windings using a growler.
• Put armature in a growler and hold a hacksaw
blade above each slot while slowly rotating
armature.
• If coil is shorted, the blade will vibrate on the slot.
D
A
NOTE: A short circuit most often occurs because of
copper dust or filings between two commutator
segments.
11. If test indicates short circuit windings, clean the
commutator of dust and filings. Check the armature
again. If the test still indicates a short circuit, replace
the armature.
12. Inspect armature cover and housing bearings for
wear or damage. Replace if necessary.
B
C
M82233
1. Remove the field wire (A) and two motor-to-clutch
housing cap screws (B).
2. Remove the motor (C) from the clutch housing (D).
To Replace Bearings:
V
U
E
M82237
M82238
1. Remove the bearings using a knife-edge puller set.
NOTE: The bearings are press fit.
3. Remove two clutch housing-to-solenoid housing
screws (E) to separate the clutch housing from the
solenoid/motor assembly.
IMPORTANT: Install both bearings with the sealed
side toward armature.
4/6/01
3 - 73
STARTING MOTOR GEAR TRAIN
DIESEL ENGINE
7. Put the clutch housing assembly into a soft-jawed
vice, as shown.
8. Tighten the vise slowly, until the drive gear
compresses.
9. Remove the circlip (K) and retainer (L).
F
c CAUTION
The shaft could be propelled from the clutch unit
with considerable force if the spring is not
allowed to extend fully while in the vise!.
10. While holding the clutch assembly, slowly open the
vise until all spring compression is relieved.
M82239
C
D
4. Remove the plunger spring (F).
J
A
I
B
M82242
11. Remove the drive gear (A), spring (B), and clutch
(C) assembly from the housing (D).
H
M82240
G
G
5. Remove the retainer (G), five rollers (H), and pinion
gear (I).
6. Remove the steel ball (J).
F
L
K
B
E
M82243a
12. Remove the toothed washer (E), spring (F), and
clutch shaft (G).
13. Inspect all parts for wear or damage.
M82241
Assembly:
Assembly is done in the reverse order of disassembly.
3 - 74
4/6/01
STARTING MOTOR SOLENOID
DIESEL ENGINE
• Apply multipurpose grease to bearings, clutch
shaft, springs, pinion gears, retainer, rollers and
steel ball.
• Install the large washer with the flat side toward the
clutch assembly.
• Install the retainer with the cupped side away from
the clutch assembly.
G
STARTING MOTOR SOLENOID
Disassembly/Inspection:
A
C
M36771
5. Inspect the contact plates (G) for excessive
burning or pitting. Contacts and plunger come as a
kit. If contacts or plunger are defective, replace all
the parts with the kit.
B
Assembly:
M82233A
1. Disconnect the field lead (A).
2. Remove three screws (B), the cover and gasket
(C).
Assembly is done in the reverse order of disassembly.
H
I
F
D
M36771
E
M82245
3. Remove the plunger (D).
4. Inspect the copper washer (E) and spring (F).
4/6/01
NOTE: The assembly sequence of the left and right
terminals is similar. Be sure solenoid terminal
lead (H) is installed between terminal bolt and
contact plate. Also, be sure smaller contact
plate (I) is on the left side.
3 - 75
ALTERNATOR REMOVAL AND INSTALLATION
ALTERNATOR REMOVAL AND
INSTALLATION
DIESEL ENGINE
• Sandpaper (No. 00 or 400-grit silicon carbide
paper).
Specification:
Removal:
IMPORTANT:
Always disconnect the negative
cable from the battery before working on any
electrical components.
1. Remove the negative cable from the battery.
2. Remove the left side panels as required to access
the alternator.
Exposed Brush Length
Minimum . . . . . . . . . . . . . . . . . . . 4.5 mm (0.17 in.)
Maximum. . . . . . . . . . . . . . . . . . 10.5 mm (0.41 in.)
Rotor Slip Ring Diameter (Min.) . . . 14 mm (0.55 in.)
Pulley Nut Torque. . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Belt Deflection at 98 N (22 lb-force):
. . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.4 - 0.6 in.)
Disassembly:
NOTE: Clamp the pulley in a soft jaw vise and use an
air impact wrench to remove the pulley nut.
C
A
E
D
B
M91672
M52469
3. Lift the plastic protective cover (A) from the positive
(red) lead. Remove the nut and washer, and remove
the lead from the alternator stud.
4. Remove the wire harness connector (B) from the
alternator and move the wiring harness to the side
5. Remove the mounting bolts (C). Remove the
alternator.
1. Remove the pulley nut (D) and pulley (E).
G
F
Installation:
Installation is done in the reverse order of removal.
H
• Tighten the drive belt. (See “FAN/ALTERNATOR
DRIVE BELT ADJUSTMENT”).
M52470
ALTERNATOR DISASSEMBLY
Equipment:
• Volt-Ohm-Amp Meter
• 13 Ton Bearing Puller Set
• Soldering Gun (120 Watt Capacity)
• Solder (Only 60-40 Resin Core)
3 - 76
2. Remove the nut, washer and insulator from the
battery terminal post (F).
3. Remove three screws (G) securing the cover (H) to
the body. Remove the cover.
4/6/01
ALTERNATOR DISASSEMBLY
DIESEL ENGINE
8. Remove cap screws and nuts (O) and slide off the
rear case assembly (P).
K
I
J
R
L
Q
M52472
4. Remove two screws securing the brush holder and
cover to the body. Remove the brush holder and
cover.
NOTE: Remember the location of the short screw (J)
on the regulator tab, and the long screw (L) on
the brush holder.
5. Remove the three screws securing the voltage
regulator (K) to body. Remove the voltage regulator.
M52475
9. Slide the rotor out of the front frame.
10. Remove the bearing retainer plate (Q).
11. Press bearing (R) from the case.
Inspection:
S
T
N
U
M
M52474
M52471
6. Remove four screws (M) and straighten the wire
leads.
7. Remove the rectifier (N).
P
O
1. Inspect bearing (S) for smooth rotation. Replace if
necessary.
2. Inspect slip rings (T) for dirt or rough spots. If
necessary, use No. 00 sandpaper or 400-grit silicon
carbide paper to polish the rings.
3. Measure the outer diameter of the slip rings.
Replace the rotor if less than 14 mm (0.55 in.).
4. Check for continuity between slip rings using an
ohmmeter or continuity tester. Replace the rotor
assembly if there is no continuity.
5. Check for continuity between the slip rings and the
rotor core (U). Replace the rotor assembly if there is
continuity.
NOTE:
A
Use an ohmmeter that is sensitive to 0—1
ohm.
M52473
4/6/01
3 - 77
ALTERNATOR DISASSEMBLY
DIESEL ENGINE
6. Inspect the stator for defective insulation,
discoloration, or burned odor.
7. Check for continuity between each of the four
stator leads and the body. Replace the frame
assembly if there is continuity.
10. Check for continuity between the brush and
terminal (W). Check for continuity between the
brush and terminal (X). There should be continuity
only at these points.
Assembly:
NOTE: The stator is not serviced separately. If the
stator is bad it must be replaced as part of the
frame assembly.
Assembly procedure is the reverse of disassembly.
NOTE: Check that the rotor fan does not contact the
case, and that the rotor assembly turns
smoothly in the bearing.
V
U
Y
Z
M52477
NOTE: Set the ohmmeter to the K ohm range.
M91674
8. Check for continuity between the main lead (U) and
each diode lead (V). Reverse the ohmmeter leads
and recheck. If there is continuity in one direction,
but not the other, the diode is working correctly.
Replace any diode or rectifier plate that is not
working correctly.
IMPORTANT: The short screw is installed in the
regulator tab (Y). If the longer screw (Z) is
installed in the brush holder. If installed in the
wrong position it will contact the frame and will
cause damage to the charging system.
• Clamp the pulley in a soft jaw vise. Install the pulley
nut. Tighten the nut to 69 N•m (51 lb-ft).
4.5 mm
(0.17 in.)
M52478
9. Measure the length of the brush protruding from
the holder. The minimum dimension is 4.5 mm (0.17
in.). Replace the brushes if worn below the
minimum. Maximum exposed new brush length is
10.5 mm (0.41 in.).
W
X
M52479
3 - 78
4/6/01
ALTERNATOR COMPONENTS
DIESEL ENGINE
ALTERNATOR COMPONENTS
13
12
11
10
9
8
7
6
5
4
14
3
2
1
25
26
15
24
16
17
18
20
19
21
22
M91878
23
1. Nut
2. Pulley
3. Spacer (40 amp only)
4. Front Frame
5. Stator
6. Stud
7. Bearing
8. Cover
9. Screw
10. Rotor
11. Bearing
12. Cover
13. Thrust Washer (40 A)
14. Cap Screw
15. Cover
16. Screw
17. Brush Assembly
18. Screw
19. Screw
20. Regulator
21. Diode Assembly
22. Cap Screw
23. Rear Frame
24. Nut
25. Nut
26. Insulator Bushing
4/6/01
3 - 79
ALTERNATOR COMPONENTS
3 - 80
DIESEL ENGINE
4/6/01
CONTENTS
ELECTRICAL
CONTENTS
Page
READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . 5
THEORY AND DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . 6
THEORY OF OPERATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSTIC INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONDUCTORS FOR 12 VOLT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS (NORTH AMERICAN AND EUROPEAN) . . . . . . . . . 8
NORTH AMERICAN ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . 9
COMPONENT LOCATION – CONTROLS & LOAD CENTER. . . . . . . . . . . . . . . . . . 11
COMPONENT LOCATION – TRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SCHEMATICS AND WIRING HARNESSES. . . . . . . . . . . . . . . . . . . . . . 14
WIRE COLOR CODES (OLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . 16
W3 NEUTRAL START WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W4 CRUISE CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
W5 CRUISE CONTROL MAGNET WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . 16
MAIN ELECTRICAL SCHEMATIC-NORTH AMERICAN . . . . . . . . . . . . . . . . . . . . . . 17
W1 MAIN WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAIN ELECTRICAL SCHEMATIC-NORTH AMERICAN (NEW) . . . . . . . . . . . . . . . . 19
W1 MAIN WIRING HARNESS (NEW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WIRE COLOR CODES (NEW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
THEORY AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
POWER CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MANIFOLD HEATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CRANKING CIRCUIT ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MANIFOLD HEATER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL SUPPLY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE SHUTOFF CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . 47
ENGINE SHUTOFF CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TACHOMETER CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
HOUR METER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CHARGING CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . 53
4/6/01
4-1
CONTENTS CONTINUED
ELECTRICAL
Page
CHARGING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . .
CONTROL PANEL GAUGES DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARK BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLD START LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL INDICATOR LIGHTS SCHEMATIC . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL INDICATOR LIGHTS DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . .
LIGHTS OPERATION (OLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS OPERATION (NEW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
56
56
56
57
58
60
60
60
60
61
62
64
65
66
70
71
72
76
77
78
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
GROUND CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD TEST BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNREGULATED AMPERAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REGULATED AMPERAGE AND VOLTAGE TESTS . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING MOTOR AMPERAGE DRAW TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO-LOAD AMPERAGE DRAW AND RPM TESTS . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD HEATER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE BLOCK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V2 DIODE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL LIGHT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION NEUTRAL SWITCH TEST – CST . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION NEUTRAL SWITCH TEST – HST & SRT . . . . . . . . . . . . . . . . . .
TURN SIGNAL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
80
81
82
82
83
83
84
85
86
87
87
88
88
89
89
90
91
91
92
92
93
93
94
4/6/01
ELECTRICAL
CONTENTS CONTINUED
Page
HAZARD SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REAR & MID PTO SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2-SPEED PTO SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
FRONT PTO SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
FRONT PTO SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CRUISE CONTROL SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CRUISE CONTROL MAGNET TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
BRAKE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
PARK BRAKE SWITCH TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
FUEL GAUGE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FUEL SHUTOFF SOLENOID TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
EUROPEAN ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . 101
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . 101
COMPONENT LOCATION – TRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
COMPONENT LOCATION – CONTROLS & LOAD CENTER. . . . . . . . . . . . . . . . . 106
WIRE COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
MAIN ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
W1 MAIN WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
WIRE COLOR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
MAIN ELECTRICAL SCHEMATIC (NEW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
W1 MAIN WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . 115
W3 HST NEUTRAL START WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . 115
W4 CRUISE CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
W5 CRUISE CONTROL MAGNET WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . 116
W6 TRAILER CONNECTOR WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 117
W7 2–SPEED PTO WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
W8 FRONT PTO WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
THEORY AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
POWER CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
POWER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
MANIFOLD HEATER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CRANKING CIRCUIT ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 133
CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
MANIFOLD HEATER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
FUEL SUPPLY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
FUEL SUPPLY ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ENGINE SHUTOFF CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . 145
ENGINE SHUTOFF CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4/6/01
4-3
CONTENTS CONTINUED
ELECTRICAL
Page
CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TACHOMETER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOURMETER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING CIRCUIT ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL PRESSURE LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . .
CONTROL PANEL GAUGES DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR PTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR PTO ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR PTO ELECTRICAL CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . .
2-SPEED PTO DIAGNOSIS (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-SPEED PTO DIAGNOSIS (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MID & FRONT PTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MID & FRONT PTO ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . .
MID AND FRONT PTO DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHT SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE LIGHTS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHT SWITCH ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL SWITCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HAZARD SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN/HAZARD LIGHTS ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . .
LIGHTS DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . .
CRUISE CONTROL DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
150
150
150
151
152
154
154
154
155
156
158
159
160
162
164
166
167
168
170
170
171
172
172
173
174
182
183
184
EUROPEAN CAB ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . 186
COMPONENT LOCATION – CAB ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . .
CAB SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . . . . . .
CAB ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W10 CAB LEFT TURN SIGNAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . .
W11 CAB RIGHT TURN SIGNAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . .
187
188
189
190
191
191
CAB ELECTRICAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . 192
THEORY AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
CAB POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB POWER CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB WIPER DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB WASHER PUMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
193
194
196
198
4/6/01
READING ELECTRICAL SCHEMATICS
ELECTRICAL - NORTH AMERICAN
READING ELECTRICAL
SCHEMATICS
The identifying letter is always the same for a specific
component, but the identifying numbers are numbered
consecutively from upper left to lower right. The
terminal designation (J) is placed directly outside the
symbol next to the connecting wire path. Switch
positions (K) are also placed directly outside the
symbol. The solid line (L) shows the position the switch
is currently in and dash lines (M) represent other switch
positions.
The schematic is made up of individual circuits laid out
in a sequence of related functions. It is formatted with
all power wires (A) across the top and all ground wires
(B) across the bottom. Current flow is generally from
top to bottom through each circuit and component. All
components are shown in the OFF position. The
diagram does not list connector (C) information unless
needed to avoid confusion. If the connector is shown,
the number next to it is the terminal pin location (D) in
the connector.
Each circuit is identified at the bottom of the drawing by
a section number (N) and section name (O).
The circuit number (P) and wire color (Q) of the wires
are shown directly next to the wire path.
Each component is shown by a symbol (E), its name
(F), and an identification code (G). The identification
code contains a device identifying letter (H) and
number (I).
The same component name and identification code are
used consistently on all diagrams in this section.
Components can be easily cross-referenced.
S1 Key
Switch
Wht
Wht
Red
B
F2
15 Amp
Fuse
On Off
Seat Seat
S2
A
Seat
Switch
414
Yel/
Blk
Red
X1
S1
X2
X3
M
210
Red
D
D
6
C
Start
800
Pink
X3
30
K2
Ignition
Relay
87
86
85
Run
Off
L
K
J
F3
15 Amp
Fuse
K1
Start
Relay
F1
Fusible
Link
X3
H
1
215
Org
X2
721
Pur/
Wht
Red
S
G
E
I
X3
G1
Battery
M1
Starting
Motor
M
W1
Shielded
Ground
H
W2
Engine
X5
Wiring
Yel/
Harness
T1
Wht
Ignition
X6
Yel/Wht
Yel/Wht
Coil
E
X3
T2
Ignition
Coil
P
E1
Spark
Plug
B
F
SE1-Power and Starting Circuit
4/6/01
F
805 Pnk/Blk
B
Blk
710
Pur
O
E2
Spark
Plug
Yel/
Wht
Wht
C
SE2-Ignition and Interlock Circuit
Blk/Yel
N
Q
105 Blk
SE3-PTO and Interlock
4-5
THEORY AND DIAGNOSTIC INFORMATION
THEORY AND DIAGNOSTIC
INFORMATION
ELECTRICAL - NORTH AMERICAN
WIRE COLOR ABBREVIATION
CHART
Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black
THEORY OF OPERATION
INFORMATION
Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
The theory of operation stories divide the electrical
system into individual circuits by function. Each circuit
is isolated from the main wiring schematic and only
shows the components that are used in it. The story
contains information on function, operating conditions,
and theory of operation. The circuit schematics are
drawn with the components in the operating position,
with the power, or battery positive, into them across the
top and the ground, or battery negative, across the
bottom.
Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green
Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown
Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange
Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink
Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple
Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red
Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan
Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
DIAGNOSTIC INFORMATION
Yel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow
The diagnostic procedures is used to test the complete
circuit regardless of the problem or complaint. Select a
symptom or system from the quick check or
troubleshooting chart and follow the test procedures
under that heading.
Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Black/White
The diagnostic procedure lists:
Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . .Brown/Yellow
• Test conditions
• Test sequence
• Test location
• Normal reading
• Check or test to perform if reading is not normal
When performing the test or check, be sure to set your
machine up to the test conditions listed and follow the
sequence carefully. The middle “NORMAL” column
gives the reading or condition that should be obtained
when performing the test or check. If the results of the
test or check are not normal, perform the test, check, or
adjustment listed in the third “IF NOT NORMAL”
column to repair the malfunction. The detailed tests or
adjustments referred to in the “IF NOT NORMAL”
column are located at the end of that group. The
system diagram that accompanies each test procedure
is drawn to resemble machine components. The key
number on the art matches the number in the “TEST
LOCATION” column and the leader line points to the
exact point the test is to be made.
Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue
Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White
Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White
Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green
Dk Brn/Red . . . . . . . . . . . . . . . . . Dark Brown/Red
Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow
Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green
Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue
Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green
Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White
Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black
Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White
Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black
Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White
Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . White/Black
Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red
Yel/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black
Yel/Red . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red
Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White
4-6
4/6/01
COMMON CIRCUIT TESTS
ELECTRICAL - NORTH AMERICAN
COMMON CIRCUIT TESTS
for high resistance and open circuits:
1. Check all terminals and grounds of the circuit for
corrosion.
2. If terminals are not corroded or loose, the problem
is in the component or wiring.
Shorted Circuit:
A shorted circuit may result in the wrong component
operating (i.e. improper wire-to-wire contact). To test for
a shorted or improperly wired circuit:
1. Turn component switch ON.
2. Start at the controlling switch of the component that
should not be operating.
3. Follow the circuit and disconnect wires at
connectors until component stops operating.
4. Shorted or improper connections will be the last two
wires disconnected.
M85601
Grounded Circuit:
Grounded circuits usually result in no component
operation or a blown fuse.
M85600
High Resistance or Open Circuit:
High resistance or open circuits usually result in slow,
dim or no component operation (i.e. poor, corroded, or
disconnected connections). Voltage at the component
will be low when the component is in operation. To test
M85602
CONDUCTORS FOR 12 VOLT CIRCUITS
STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS
SAE WIRE SIZE (GAUGE)
20
18
16
14
12
10
METRIC WIRE SIZE (MM)
0.5
0.8
1.0
2.0
3.0
5.0
TYPICAL STRANDING
7 X 28
16 X 30
19 X 29
19 X 27
19 X 25
19 X 23
MINIMUM CONDUCTOR AREA
IN CIRCULAR MILS
1072
1537
2336
3702
5833
9343
4/6/01
4-7
SPECIFICATIONS (NORTH AMERICAN AND EUROPEAN)
ELECTRICAL - NORTH AMERICAN
SPECIFICATIONS (NORTH AMERICAN AND EUROPEAN)
Battery:
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 VDC
BCI Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1
CCA Rating (Amps at –18° C (0° F)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Amps
Reserve Capacity (minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specific Gravity at full charge (26.7°C (80°F)) . . . . . . . . . . . . . . . . . . . . .1.265 or above
Electrolyte Required Fill (Approx.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)
Load test (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 amp for 15 seconds
Starting Motor:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 kW (2.68 hp)
Amp Draw (on vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 amps (max.)
No-load Amp Draw (free running) . . . . . . . . . . . . . . . . . . . . . . 325 amps for 15 seconds
Alternator:
North American / European
Rating (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 amps
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amps (min.)
European
Rating (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 amps
Unregulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amps (min.)
Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 – 13.2 VDC
Unregulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 VAC
Fuel Shutoff Solenoid (Dual Coil):
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Pull-in voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8 VDC
Hold voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 VDC
Sensors:
Fuel Gauge Resistance (variable). . . . . . . . . . . . . . . . . . . . approximately 5 – 110 ohms
Fuel Gauge Voltage Drop Across Gauge (full – empty) . . . . . . . . . . . . 5.72 – 0.87 VDC
Engine Coolant Temperature (variable). . . . . . . . . . . . . . . approximately 40 – 700 ohms
Engine Oil Pressure Switch. . . . . . . . Closes (Light from ON to OFF) at 49 kPa (7.1 psi)
Manifold Heater:
Resistance (through element) . . . . . . . . . . . . . . . . . . . . . . approximately 0.3 – 0.5 ohms
Lighting:
Headlights (halogen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5 Watts
Tail Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Watts–Bayonet Base
Hazard Lights . . . . . . . . . . . . . . . . . . . . . .32 Candle Power, Single Element, Type 1156
Instrument Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Watts–Bayonet Base
4-8
4/6/01
ELECTRICAL - NORTH AMERICAN
NORTH AMERICAN ELECTRICAL
SECTION
NORTH AMERICAN ELECTRICAL SECTION
K9—Rear PTO Relay (SE2, W1)
M1—Starting Motor (SE1, W1)
P1—Engine Tachometer (SE5, W1)
ELECTRICAL SCHEMATIC AND
WIRING HARNESS LEGEND
P3—Fuel Gauge (SE5, W1)
B1—Fuel Gauge Sensor (SE5, W1)
P4—Engine Coolant Temperature Gauge (SE5, W1)
B2—Engine Oil Pressure Switch (SE5, W1)
R1—Manifold Heater (SE2, W1)
B3—Engine Coolant Temperature Sensor (SE6, W1)
R2—Variable Thermistor (SE2, W1)
E1—LH Tail Light (SE4, W1)
S1—Key Switch (SE1, W1)
E2—LH Hazard Light (SE4, W1)
S2—Seat Switch (SE2, W1)
E3—RH Tail Light (SE4, W1)
S3—Transmission Neutral Switch (Hydrostatic - HST,
and SyncReverser™ - SRT) (SE2, W1)
E4—RH Hazard Light (SE5, W1)
P2—Hour Meter (SE5, W1)
E5—LH Headlight (SE6, W1)
S4—Transmission Neutral
Only)(SE2, W1)
Switch
(Gear
E6—RH Headlight (SE6, W1)
S5—Rear PTO Switch (SE2, W1)
E7—LH Work Light (Option)(SE6, W1)
S6—Mid PTO Switch (Option)(SE2, W1)
E8—RH Work Light (Option)(SE6, W1)
S7—Park Brake Switch (SE2, W1)
F1—Fuse - 30 amp (SE1, W1)
S8—Turn Signal Switch (SE5, W1)
F2—Fuse - 30 amp (Option)(SE4, W1)
S9—Light Switch (SE5, W1)
F3—Fuse - 30 amp (SE4, W1)
S10—Cruise Control Switch (Option)(SE5, W1)
F4—Not Used
S11—Brake Switch (SE5, W1)
F5—Fuse - 10 amp (SE2, W1)
V1—Diode Block (SE2, W1)
F6—Fuse - 20 amp (SE5, W1)
V2—Diode (SE2,W1)
F7—Fuse - 20 amp (SE5, W1)
W1—Battery Frame Ground (SE1, W1)
F8—Fuse - 20 amp (Option)(SE5, W1)
Y1—Starting Motor Solenoid (SE1, W1)
G1—Battery (SE1, W1)
Y2—Fuel Shutoff Solenoid (SE2, W1)
G2—Alternator (SE3, W1)
Y3—Cruise Control Magnet (Option)(SE5, W1)
-
CST
H1—RH Turn Light (SE5, W1)
H2—LH Turn Light (SE5, W1)
H3—PTO Light (SE5, W1)
H4—Discharge Light (SE5, W1)
H5—Cold Start Light (SE5, W1)
H6—Park Brake Light (SE5, W1)
H7—Engine Oil Pressure Light (SE5, W1)
H8—Cruise Control Indicator Light (Option)(SE5, W1)
H9—Backup Alarm (SE2, W1)
K1—Manifold Heater Relay (SE2, W1)
K2—Start Relay (SE1, W1)
K3—Fuel Shutoff Relay (SE2, W1)
K4—Engine Run Relay (SE2, W3)
K5—Safety Relay (SE2, W1)
K6—Safety Relay (SE2, W1)
K7—Accessory Relay (SE4, W1)
K8—Cruise Control Relay (Option)(SE5, W1)
4/6/01
4-9
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND
ELECTRICAL - NORTH
AMERICAN
CONNECTORS:
E4 RH Hazard Light (SE4, W1)
X1—W1 Main Wiring Harness to Fusible Link (SE1,
W1)
X24—W1 Main Wiring Harness to H9 Backup Alarm
(SE2, W1)
NOTE: X2 supplied with cap and jumper wire if X3 is
connected to transmission neutral switch on
gear (CST) tractors.
X3 supplied with cap and jumper wire if X2 is
connected to transmission neutral switch on
hydrostatic (HST) or SyncReverser™ - (SRT)
tractors.
WIRING HARNESSES:
W1—Main Wiring Harness
W2—Fuel Shutoff Solenoid Wiring Harness
W3—Neutral Start Wiring Harness (HST & SRT)
(included in the W4 Wiring Harness protective
wrap)
W4—Cruise Control Wiring Harness
X2—W1 Main Wiring Harness to W3 Neutral Start
Wiring Harness (HST and SRT) (SE2, W1)
W5—Cruise Control Magnet Wiring Harness
X3—W1 Main Wiring Harness to S4 Transmission
Neutral Switch Wiring Harness (CST Only) (SE2,
W1)
X4—W1 Main Wiring Harness to W2 Fuel Shutoff
Solenoid Wiring Harness (SE2, W1)
X5—W1 Main Wiring Harness to S6 Mid PTO Switch
(Option) (SE2, W1)
X6—W1 Main Wiring Harness to Control Panel Circuit
Board (SE5, W1)
X7—W1 Main Wiring Harness to Control Panel Circuit
Board (SE5, W1)
X8—W1 Main Wiring Harness to Control Panel Circuit
Board (SE5, W1)
X9—W1 Main Wiring Harness to W4 Cruise Control
Wiring Harness (SE4, W1)
X10—W4 Cruise Control Wiring Harness to S10 Cruise
Control Switch (SE5, W4)
X11—W4 Cruise Control Wiring Harness to S11 Brake
Switch (SE5, W4)
X12—W4 Cruise Control Wiring Harness to W5 Cruise
Control Magnet Wiring Harness (SE5, W4)
X13—W1 Main Wiring Harness to W8 Trailer
Connector Wiring Harness (SE4/SE5/SE6, W1)
X16—W1 Main Wiring Harness to E8 RH Work Light
(Option) (SE6, W1)
X17—W1 Main Wiring Harness to E7 LH Work Light
(Option) (SE6, W1)
X18—W1 Main Wiring Harness to E1 LHTail Light
(SE4, W1)
X19—W1 Main Wiring Harness to E2 LH Hazard Light
(SE4, W1)
X20—W1 Main Wiring Harness to E1 LH Tail Light and
E2 LH Hazard Light (SE4, W1)
X21—W1 Main Wiring Harness to E3 RH Tail Light
(SE4, W1)
X22—W1 Main Wiring Harness to E4 RH Hazard Light
(SE4, W1)
X23—W1 Main Wiring Harness to E3 RH Tail Light and
4 - 10
4/6/01
ELECTRICAL - NORTH AMERICAN
COMPONENT LOCATION – CONTROLS & LOAD CENTER
COMPONENT LOCATION – CONTROLS & LOAD CENTER
P1 Engine Tachometer
P4 Engine Coolant
Temperature Gauge
P3 Fuel Gauge
H4 Discharge Light
H6 Park Brake Light
H7 Engine Oil Pressure
Light
H3 PTO Light
H8 Cruise Control Light
H5 Cold Start Light
P2 Hour Meter
S8 Turn Signal Switch
M89699
S9 Light Switch
S10 Cruise Control Switch
Control Panel
F9-F12
Fuse
11
K4
K4 Engine
Run
Relay
1
10
K3
K3 Fuel
Shutoff
Relay
9
K2
Start
Relay
A
B
A
K1
Manifold
Relay
K2
2
B
3
K7
Access.
Relay
K1
K6
Safety
Relay
K7
4
K11
Spare
K5
Safety
Relay
K6
K10
Spare
V1
Diode
Block
K5
K9
K9 Rear
PTO
Relay
DB1
K8
K8 Cruise
Control
Relay
F1-F8
Fuse
5
6
7
12
Spare Fuses
8
F10 - 10 Amp
F11 - 20 Amp
F12 - 30 Amp
Relay / Diode Block / Fuse
Load Center
4/6/01
4 - 11
COMPONENT LOCATION – TRACTOR
ELECTRICAL - NORTH AMERICAN
COMPONENT LOCATION – TRACTOR
S9 Light Switch
Control Panel
S11 Brake Switch
X6 and X7
S1 Key Switch
B1 Fuel Gauge Sensor
S8 Turn
Signal
Switch
Y3 Cruise Control Magnet
R1 Manifold Heater
Y2 Fuel Shutoff
Solenoid
Load Center
B3 Engine Coolant
Temperature Sensor
W1 Battery
Frame
Ground
(RH Side)
M1 Starting
Motor
X1
Fusible
Link
G2 Alternator
G1 Battery
M91890A
4 - 12
4/6/01
COMPONENT LOCATION – TRACTOR
ELECTRICAL - NORTH AMERICAN
E3 RH Tail Light
E4 RH Hazard Light
E1 LH Tail Light
X18, X19 and X20
E2 LH
Hazard Light
S2 Seat Switch
S3 HST or SRT Transmission
Neutral Switch
X21, X22 and X23
S7 Park Brake Switch
X2
S4 CST Transmission
Neutral Switch
4/6/01
M91891
4 - 13
SCHEMATICS AND WIRING HARNESSES
SCHEMATICS AND WIRING
HARNESSES
WIRE COLOR CODES (OLD)
Circuit
Number
Wire
Size
Color
002A
5.0
Red
M1, G2
002B
5.0
Red
X1 (Fusible Link),
K1(30)
002C
5.0
Red
X1 (Fusible Link),
Splice 002
Termination
Points
ELECTRICAL - NORTH AMERICAN
Circuit
Number
Wire
Size
Color
Termination
Points
050K
1.0
Blk
Splice 050, X6
050L
0.5
Blk
B1, Splice 050
072A
1.0
Red
X6, Splice 072
072B
1.0
Red
S1, Splice 072
072C
0.8
Red
Splice 072, F5
072D
0.8
Red
Splice 072, G2
103A
1.0
Org
S9, Splice 103
103B
1.0
Org
Splice 103, S8
002D
5.0
Red
Splice 002, F2
103C
1.0
Org
Splice 103, F8
002E
1.0
Red
Splice 002, K4(30)
115A
1.0
Dk Grn
S8, Splice 115
010A
1.0
Blk
E6, Splice 010
115B
0.8
Dk Grn
X7, Splice 115
010B
1.0
Blk
E5, Splice 010
115C
0.8
Dk Grn
Splice 115, X22
010C
5.0
Blk
W1, Splice 010
115D
0.8
Dk Grn
Splice 115, X21
010D
0.8
Blk
DB1-7, Splice 010
115E
1.0
Dk Grn
Splice 115, X13
010E
0.5
Blk
DB1-7, K2(85)
118
1.0
Gry
F8, X13
010F
0.5
Blk
K2(85), K3(85)
119A
1.0
Wht
E6, Splice 119
010G
0.8
Blk
Splice 010, X20
119B
1.0
Wht
E5, Splice 119
010H
0.8
Blk
Splice 010, X17
119C
2.0
Wht
Splice 119, F7
010J
2.0
Blk
Splice 010, X13
119D
0.8
Wht
Splice 119, X6
010K
0.8
Blk
Splice 010, X16
122A
1.0
Red
S8, Splice 122
010L
0.8
Blk
Splice 010, X23
122B
3.0
Red
S9, Splice 122
010N
1.0
Blk
X4, W1
122C
3.0
Red
F3, Splice 122
010T
(–)
Therm.
K3(85), R2
125A
1.0
Dk Grn
S8, Splice 125
012
5.0
Red
S1, F1
125B
0.8
Dk Grn
X7, Splice 125
050A
2.0
Blk
W1, Splice 050
125C
0.8
Dk Grn
Splice 125, X19
050B
0.5
Blk
K1(85), Splice 050
125D
0.8
Dk Grn
Splice 125, X18
050C
0.5
Blk
K1(85), K4(85)
125E
1.0
Dk Grn
Splice 125, X13
050D
0.5
Blk
K4(85), K5(85)
138
2.0
Gry
S9, F7
050E
0.5
Blk
K5(85), K6(85)
143
2.0
Org
S9, F6
050F
0.5
Blk
K6(85), K7(85)
147A
2.0
Pur
F6, Splice 147
050G
0.5
Blk
K7(85), K8(85)
147B
0.8
Pur
Splice 147, X17
050H
0.5
Blk
K8(85), K9(85)
147C
2.0
Pur
Splice 147, X13
050J
0.8
Blk
Splice 050, X9
4 - 14
4/6/01
WIRE COLOR CODES (OLD)
ELECTRICAL - NORTH AMERICAN
Circuit
Number
Wire
Size
Color
Termination
Points
Circuit
Number
Wire
Size
Color
Termination
Points
147D
0.8
Pur
Splice 147, X16
546
0.5
Lt Blu
K5(30), S7
209
0.8
Wht
X9, S1
556
0.5
Lt Blu
K6(86), DB1- 2
212
0.5
Red
K7(86), S1
562A
0.8
Red
F5, Splice 562
222
2.0
Red
K7(87), X13
562B
0.5
Red
K9(30), Splice 562
238
0.8
Gry
X9, K8(86)
562C
0.5
Red
Splice 562, S7
247
0.8
Pur
X9, K8(87)
562D
0.5
Red
S5, Splice 562
252
2.0
Red
K7(30), F2
562E
0.5
Red
Splice 562, S2
264A
0.8
Yel
K8(30), X9
562F
0.5
Red
Splice 562, X5
264B
0.8
Yel
K8(30), X6
572A
1.0
Red
S1, K2(30)
302A
1.0
Red
DB1- 8, Splice 302
572B
0.8
Red
K2(30), DB1- 3
302B
1.0
Red
K4(87), Splice 302
573A
0.5
Org
Splice 573, S5
302C
1.0
Red
Splice 302, X4
573B
0.5
Org
V2, Splice 573
309
1.0
Wht
K2(87), M1
573C
0.5
Org
K9(86), Splice 573
319
(+)
Therm.
K3(87a), R2
574
0.5
Yel
K9(87a), X7
325
0.8
Dk Grn
X6, G2
586
0.5
Lt Blu
S7, X6
329A
1.0
Wht
X4, K3(30)
587A
0.5
Pur
X2, Splice 587
329B
1.0
Wht
K3(30), K3(86)
587B
0.5
Pur
V2, Splice 587
334
0.8
Yel
X7, G2
587C
0.5
Pur
K5(86), Splice 587
347
0.5
Pur
X6, B2
587D
0.5
Pur
K6(30), Splice 587
353
0.5
Org
X6, B1
594
0.5
Yel
S7, X5
359
0.5
Wht
X6, B3
383
3.0
Org
K1(87), R1
385A
0.8
Dk Grn
X7, Splice 385
385B
0.8
Dk Grn
Splice 385, S1
385C
0.5
Dk Grn
Splice 385, K1(86)
505
0.5
Dk Grn
X2, X3
518A
0.5
Gry
DB1- 6, K2(86)
518B
0.5
Gry
K2(86), X2
521
0.5
Brn
K4(86), DB1- 5
533
0.5
Org
K5(87), K6(87a)
539A
0.5
Wht
DB1- 1, DB1- 4
539B
0.5
Wht
DB1- 4, S2
4/6/01
4 - 15
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS
ELECTRICAL - NORTH AMERICAN
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS
Blk
Wht
Wht
X4 To W1 Main Wiring Harness
M76875
Y2 Fuel Shutoff Solenoid
W3 NEUTRAL START WIRING HARNESS
(In W4 Cruise Control Wiring Harness protective wrap)
Dk Grn
Gry
Dk Grn
Gry
To S3 Neutral
Start Switch (HST & SRT)
X2 To W1 Main
Wiring Harness
W4 CRUISE CONTROL WIRING HARNESS
Dk Grn
Wht
To S3 HST & SRT
Neutral Start Switch
X2 To W1 Main
Wiring Harness
W3 Neutral Start Wiring Harness
Gry
X9 To W1 Main
Wiring Harness
Blk
Dk Grn
Gry
Yel
Gry
Yel
Gry
Yel
Gry
Blk
Gry
Pur
Yel
Yel
X11 TO S11
Brake Switch
X12 To Y3 Cruise
Control Magnet
Wht
Pur
Gry
X10 To S10 Cruise
Cruise Control Switch
Gry
Yel
W5 CRUISE CONTROL MAGNET WIRING HARNESS
Wht
Wht
X12 To W4 Cruise
Control Wiring Harness
Y3 Cruise Control
Magnet
4 - 16
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
002E Red
002E Red
209 Wht
072C
Red
7 385B Dk Grn
Aid
Off
002C
Red
A
S1 Key
Switch
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
562E Red
572A Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
1
K9 Rear
PTO
Relay
87 87A
A
B
V2
Diode
050H
Blk
X3
X2
G2
Alternator
M
E3 RH
Tail
Light
X18 X19
87 87A
222
Red
334
Yel
125D
Dk Grn
X13 Trailer
Connector
050G
Blk
7
4
521
Brn
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
86
30
85
87 87A
325 Dk Grn
586 Lt Blu
010D
010F Blk
Blk
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
329A
Wht
K3 Fuel
Shutoff
Relay
050B
Blk
G1
Battery
R1 Manifold
Heater
Blk
W1 Battery
Frame
Ground
050A Blk
010N Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
329B
30
87A 87
319
Wht
010T
Blk
4
A
147C Pur
147A Pur
S8 Turn
Signal Switch
X7
X7
D
X6
X13 Trailer
Connector
E8 RH Work
Light (Option)
X16
E7 LH Work
Light (Option)
X6
A
H3 PTO
Light
H2 LH
Turn
Light
X17
010K Blk
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
1
6
X16
119D
Wht
072A
Red
115B
Dk Grn
E
2
147D
Pur
X17
2
010J Blk
147C Pur
B
P
385A Dk Grn
X4
562C
Red
594
Yel
86
85
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
Switched Power
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 17
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Unswitched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
010C Blk
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
F6 Fuse
B
302B Red
K5
Safety
Relay
86
119C Wht
A
118 Gry
B
S9 Light
Switch
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
A
F7 Fuse
143 Org
103B
Org
F8 Fuse
103C Org
F
K
050C Blk
Blk
Wht
010A Blk
010B Blk
115A Dk Grn 4
125B
Dk Grn
3
138 Gry
3
122A
Red
X6
325
Dk Grn
002E
Red
587D Org
Wht
X4
115D 115C
Dk Grn Dk Grn
115E
Dk Grn
2
B
(0) Right
(1) Off
(2) Left
1
Flasher
125A Dk Grn 3
125E Dk Grn
103B
Org
103A Org
122B Red
E6 RH
Headlight
E5 LH
Headlight
1
X13 Trailer
Connector
X21 X22
125C
Dk Grn
302C Red
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
(2) Road
(3) Field
+
302B Red
302A Red
8
85
E4 RH
Hazard
Light
5
K7
Accessory
Relay
594
Yel
587A Org
S3 Transmission
Neutral Switch
(HST and SRT)
S4 Transmission
Neutral Switch
(CST)
385A Dk Grn
30
P
050F
Blk
587B
Org
X2
X3
86
X5
In Neutral Pedal Released
Pedal Depressed
In Gear
V1
Diode
Block
7
L
574
Yel
505 Dk Grn
A
B
IG
572B Red 3
010E
Blk
309
Wht
G
30
E1 LH
Tail
Light
119B Wht
(0) Off
(1) Hazard
556 Lt Blu
2
K2
Start
Relay
85
86
573B
Org
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
W2 Front
Frame
Ground
X23
E2 LH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
002A
Red
562B
Red
85
V1 Diode
Block
539B Wht 4
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
562F Red
B
002B Red
1/31/01
Off
On
562B
Red
F5 Fuse
Start
Run
Off
Acc.
B
X20
072A Red
A
3 212 Red
A
002A Red
010L
Blk
072D Red
5 072B Red
F1
Fuse
87A 87
119A Wht
010G
Blk
072A Red
2
30
122C Red
002D
Red
212 Red
6 572A Red
012 Red 1
122C Red
B
A
4 209 Wht
B
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
002E Red
002E Red
209 Wht
072C
Red
7 385B Dk Grn
Aid
Off
002C
Red
A
S1 Key
Switch
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
562E Red
572A Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
1
K9 Rear
PTO
Relay
87 87A
A
B
V2
Diode
050H
Blk
X3
X2
G2
Alternator
M
E3 RH
Tail
Light
X18 X19
87 87A
222
Red
334
Yel
125D
Dk Grn
X13 Trailer
Connector
050G
Blk
7
4
521
Brn
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
86
30
85
87 87A
325 Dk Grn
586 Lt Blu
010D
010F Blk
Blk
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
329A
Wht
K3 Fuel
Shutoff
Relay
050B
Blk
G1
Battery
R1 Manifold
Heater
Blk
W1 Battery
Frame
Ground
050A Blk
010N Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
329B
30
87A 87
319
Wht
010T
Blk
4
A
147C Pur
147A Pur
S8 Turn
Signal Switch
X7
X7
D
X6
X13 Trailer
Connector
E8 RH Work
Light (Option)
X16
E7 LH Work
Light (Option)
X6
A
H3 PTO
Light
H2 LH
Turn
Light
X17
010K Blk
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
1
6
X16
119D
Wht
072A
Red
115B
Dk Grn
E
2
147D
Pur
X17
2
010J Blk
147C Pur
B
P
385A Dk Grn
X4
562C
Red
594
Yel
86
85
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
Switched Power
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 17
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Unswitched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
010C Blk
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
F6 Fuse
B
302B Red
K5
Safety
Relay
86
119C Wht
A
118 Gry
B
S9 Light
Switch
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
A
F7 Fuse
143 Org
103B
Org
F8 Fuse
103C Org
F
K
050C Blk
Blk
Wht
010A Blk
010B Blk
115A Dk Grn 4
125B
Dk Grn
3
138 Gry
3
122A
Red
X6
325
Dk Grn
002E
Red
587D Org
Wht
X4
115D 115C
Dk Grn Dk Grn
115E
Dk Grn
2
B
(0) Right
(1) Off
(2) Left
1
Flasher
125A Dk Grn 3
125E Dk Grn
103B
Org
103A Org
122B Red
E6 RH
Headlight
E5 LH
Headlight
1
X13 Trailer
Connector
X21 X22
125C
Dk Grn
302C Red
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
(2) Road
(3) Field
+
302B Red
302A Red
8
85
E4 RH
Hazard
Light
5
K7
Accessory
Relay
594
Yel
587A Org
S3 Transmission
Neutral Switch
(HST and SRT)
S4 Transmission
Neutral Switch
(CST)
385A Dk Grn
30
P
050F
Blk
587B
Org
X2
X3
86
X5
In Neutral Pedal Released
Pedal Depressed
In Gear
V1
Diode
Block
7
L
574
Yel
505 Dk Grn
A
B
IG
572B Red 3
010E
Blk
309
Wht
G
30
E1 LH
Tail
Light
119B Wht
(0) Off
(1) Hazard
556 Lt Blu
2
K2
Start
Relay
85
86
573B
Org
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
W2 Front
Frame
Ground
X23
E2 LH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
002A
Red
562B
Red
85
V1 Diode
Block
539B Wht 4
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
562F Red
B
002B Red
1/31/01
Off
On
562B
Red
F5 Fuse
Start
Run
Off
Acc.
B
X20
072A Red
A
3 212 Red
A
002A Red
010L
Blk
072D Red
5 072B Red
F1
Fuse
87A 87
119A Wht
010G
Blk
072A Red
2
30
122C Red
002D
Red
212 Red
6 572A Red
012 Red 1
122C Red
B
A
4 209 Wht
B
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
002E Red
002E Red
209 Wht
072C
Red
7 385B Dk Grn
Aid
Off
002C
Red
A
S1 Key
Switch
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
562E Red
572A Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
1
K9 Rear
PTO
Relay
87 87A
A
B
V2
Diode
050H
Blk
X3
X2
G2
Alternator
M
E3 RH
Tail
Light
X18 X19
87 87A
222
Red
334
Yel
125D
Dk Grn
X13 Trailer
Connector
050G
Blk
7
4
521
Brn
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
86
30
85
87 87A
325 Dk Grn
586 Lt Blu
010D
010F Blk
Blk
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
329A
Wht
K3 Fuel
Shutoff
Relay
050B
Blk
G1
Battery
R1 Manifold
Heater
Blk
W1 Battery
Frame
Ground
050A Blk
010N Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
329B
30
87A 87
319
Wht
010T
Blk
4
A
147C Pur
147A Pur
S8 Turn
Signal Switch
X7
X7
D
X6
X13 Trailer
Connector
E8 RH Work
Light (Option)
X16
E7 LH Work
Light (Option)
X6
A
H3 PTO
Light
H2 LH
Turn
Light
X17
010K Blk
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
1
6
X16
119D
Wht
072A
Red
115B
Dk Grn
E
2
147D
Pur
X17
2
010J Blk
147C Pur
B
P
385A Dk Grn
X4
562C
Red
594
Yel
86
85
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
Switched Power
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 17
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Unswitched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
010C Blk
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
F6 Fuse
B
302B Red
K5
Safety
Relay
86
119C Wht
A
118 Gry
B
S9 Light
Switch
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
A
F7 Fuse
143 Org
103B
Org
F8 Fuse
103C Org
F
K
050C Blk
Blk
Wht
010A Blk
010B Blk
115A Dk Grn 4
125B
Dk Grn
3
138 Gry
3
122A
Red
X6
325
Dk Grn
002E
Red
587D Org
Wht
X4
115D 115C
Dk Grn Dk Grn
115E
Dk Grn
2
B
(0) Right
(1) Off
(2) Left
1
Flasher
125A Dk Grn 3
125E Dk Grn
103B
Org
103A Org
122B Red
E6 RH
Headlight
E5 LH
Headlight
1
X13 Trailer
Connector
X21 X22
125C
Dk Grn
302C Red
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
(2) Road
(3) Field
+
302B Red
302A Red
8
85
E4 RH
Hazard
Light
5
K7
Accessory
Relay
594
Yel
587A Org
S3 Transmission
Neutral Switch
(HST and SRT)
S4 Transmission
Neutral Switch
(CST)
385A Dk Grn
30
P
050F
Blk
587B
Org
X2
X3
86
X5
In Neutral Pedal Released
Pedal Depressed
In Gear
V1
Diode
Block
7
L
574
Yel
505 Dk Grn
A
B
IG
572B Red 3
010E
Blk
309
Wht
G
30
E1 LH
Tail
Light
119B Wht
(0) Off
(1) Hazard
556 Lt Blu
2
K2
Start
Relay
85
86
573B
Org
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
W2 Front
Frame
Ground
X23
E2 LH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
002A
Red
562B
Red
85
V1 Diode
Block
539B Wht 4
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
562F Red
B
002B Red
1/31/01
Off
On
562B
Red
F5 Fuse
Start
Run
Off
Acc.
B
X20
072A Red
A
3 212 Red
A
002A Red
010L
Blk
072D Red
5 072B Red
F1
Fuse
87A 87
119A Wht
010G
Blk
072A Red
2
30
122C Red
002D
Red
212 Red
6 572A Red
012 Red 1
122C Red
B
A
4 209 Wht
B
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (OLD)
002E Red
002E Red
209 Wht
072C
Red
7 385B Dk Grn
Aid
Off
002C
Red
A
S1 Key
Switch
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
562E Red
572A Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
1
K9 Rear
PTO
Relay
87 87A
A
B
V2
Diode
050H
Blk
X3
X2
G2
Alternator
M
E3 RH
Tail
Light
X18 X19
87 87A
222
Red
334
Yel
125D
Dk Grn
X13 Trailer
Connector
050G
Blk
7
4
521
Brn
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
86
30
85
87 87A
325 Dk Grn
586 Lt Blu
010D
010F Blk
Blk
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
329A
Wht
K3 Fuel
Shutoff
Relay
050B
Blk
G1
Battery
R1 Manifold
Heater
Blk
W1 Battery
Frame
Ground
050A Blk
010N Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
329B
30
87A 87
319
Wht
010T
Blk
4
A
147C Pur
147A Pur
S8 Turn
Signal Switch
X7
X7
D
X6
X13 Trailer
Connector
E8 RH Work
Light (Option)
X16
E7 LH Work
Light (Option)
X6
A
H3 PTO
Light
H2 LH
Turn
Light
X17
010K Blk
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
1
6
X16
119D
Wht
072A
Red
115B
Dk Grn
E
2
147D
Pur
X17
2
010J Blk
147C Pur
B
P
385A Dk Grn
X4
562C
Red
594
Yel
86
85
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
Switched Power
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 17
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Unswitched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
010C Blk
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
F6 Fuse
B
302B Red
K5
Safety
Relay
86
119C Wht
A
118 Gry
B
S9 Light
Switch
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
A
F7 Fuse
143 Org
103B
Org
F8 Fuse
103C Org
F
K
050C Blk
Blk
Wht
010A Blk
010B Blk
115A Dk Grn 4
125B
Dk Grn
3
138 Gry
3
122A
Red
X6
325
Dk Grn
002E
Red
587D Org
Wht
X4
115D 115C
Dk Grn Dk Grn
115E
Dk Grn
2
B
(0) Right
(1) Off
(2) Left
1
Flasher
125A Dk Grn 3
125E Dk Grn
103B
Org
103A Org
122B Red
E6 RH
Headlight
E5 LH
Headlight
1
X13 Trailer
Connector
X21 X22
125C
Dk Grn
302C Red
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
(2) Road
(3) Field
+
302B Red
302A Red
8
85
E4 RH
Hazard
Light
5
K7
Accessory
Relay
594
Yel
587A Org
S3 Transmission
Neutral Switch
(HST and SRT)
S4 Transmission
Neutral Switch
(CST)
385A Dk Grn
30
P
050F
Blk
587B
Org
X2
X3
86
X5
In Neutral Pedal Released
Pedal Depressed
In Gear
V1
Diode
Block
7
L
574
Yel
505 Dk Grn
A
B
IG
572B Red 3
010E
Blk
309
Wht
G
30
E1 LH
Tail
Light
119B Wht
(0) Off
(1) Hazard
556 Lt Blu
2
K2
Start
Relay
85
86
573B
Org
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
W2 Front
Frame
Ground
X23
E2 LH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
002A
Red
562B
Red
85
V1 Diode
Block
539B Wht 4
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
562F Red
B
002B Red
1/31/01
Off
On
562B
Red
F5 Fuse
Start
Run
Off
Acc.
B
X20
072A Red
A
3 212 Red
A
002A Red
010L
Blk
072D Red
5 072B Red
F1
Fuse
87A 87
119A Wht
010G
Blk
072A Red
2
30
122C Red
002D
Red
212 Red
6 572A Red
012 Red 1
122C Red
B
A
4 209 Wht
B
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
30A
30A
–––
10A
20A
20A
20A
A
002
002D
002
–––
072C
0143
138
103C
RELAYS
DIODE BLOCK
B
012
252
122C
–––
562A
147A
119C
118
#
1
DB1
2
539A
3
556
4
572B
5
539A/539B
521
7
518A
2
2
1
4
5
8
3
1
010D/010E
6
4
9
7
7
1
3
4
6
7
5
5
2
9
A
1
9
X7 To Control
Panel Circuit Board
D
E
F
C
B
A
050J
X9 To W5 Cruise
264
Control Wiring
Harness (Option) 247A
238
E
F
C
B
A
209
W2 Ground
383
302A
302B
302C
505
587A
X2 To W3
Neutral Start
Wiring Harness
119A
119B 119C
119D
E5 LH Headlight
G2
Alternator
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
002C
002D
334
072D
325
359
G
H
E
D
C
359
J
K
072A
119D
353
050K
122B
B
002A
5
6
11
10
7
103A
002E
072A
072B
072C
072D
309
M1 Starting
Motor
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
87
8
12
86
30
85
87 87A
Relay
Schematic
K2
K3
K4
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K5
K6
K7
X13 Trailer Connector
(Option) (from rear of connector)
3
4
S9 Light
Switch
1
572A
385B
5 6
010J Blk
K8
K9
SPARE
SPARE
2 1
125E Dk Grn
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
012
S1 Key
Switch
X3 To S4
Transmission
Neutral Switch
Relay/Fuse
Block Harness
122C
505
S7
Park Brake
Switch
586
562C
594
518B
573A
573B
573C
V2 Diode
(Soldered
In-Line)
573B
010A
010H
010B
010J
010C
010K
010D
010L
010G
562F
To X13 Trailer
Connector
(Option)
010L
115C
010K
147D
546
125A
147A
125B
147C
147B
125C
147D
125D
125E
Y1
Starting
Motor
Solenoid
573A
S5 Rear
PTO Switch
4 - 18
222 Red
X21 To E3
RH Tail Light
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
125D
010G
Fusible Link
562D
115E Dk Grn
4
Red
125C
309
5
115D
010J 125E
118
147C
115E 222
115A 115D
115B 115E
115C
562A 562D
562B 562E
562C 562F
594
118 Gry
7
3
8
122A
122B
6
2
7
3
1
147C Pur
Relay/Fuse
Load Center
050A
050B 050J
050K
050L
587A
587B
587C
587D
587B
002B
X1 To Fusible Link
002C
Relay #
138
2 B
072B
209 4
85
B
DB1
002A
119A
4
87A
A
103A
103B
103C
S8 Turn
Signal Switch
R1 Manifold Heater
3
86
Diode Block
347
586
212
050A
010B
F
385A
385B
385C
122A
115A
103B
125A
010N
010C
347
9
K1
143
329A
302C
Y2 Fuel
Shutoff
Solenoid
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
B2 Engine Oil
Pressure
Switch (NC)
2
Relays
125B
115B
010N
010A
–––
8
Diode Block
Schematic
Diode Block
Socket Layout
050L
E6 RH Headlight
302A
Fuse Block
A
6
8
Relay Socket
Layout
9
3
353
119B
8
B
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
6
30
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
30A
30A
–––
10A
20A
20A
20A
A
002
002D
002
–––
072C
0143
138
103C
RELAYS
DIODE BLOCK
B
012
252
122C
–––
562A
147A
119C
118
#
1
DB1
2
539A
3
556
4
572B
5
539A/539B
521
7
518A
2
2
1
4
5
8
3
1
010D/010E
6
4
9
7
7
1
3
4
6
7
5
5
2
9
A
1
9
X7 To Control
Panel Circuit Board
D
E
F
C
B
A
050J
X9 To W5 Cruise
264
Control Wiring
Harness (Option) 247A
238
E
F
C
B
A
209
W2 Ground
383
302A
302B
302C
505
587A
X2 To W3
Neutral Start
Wiring Harness
119A
119B 119C
119D
E5 LH Headlight
G2
Alternator
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
002C
002D
334
072D
325
359
G
H
E
D
C
359
J
K
072A
119D
353
050K
122B
B
002A
5
6
11
10
7
103A
002E
072A
072B
072C
072D
309
M1 Starting
Motor
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
87
8
12
86
30
85
87 87A
Relay
Schematic
K2
K3
K4
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K5
K6
K7
X13 Trailer Connector
(Option) (from rear of connector)
3
4
S9 Light
Switch
1
572A
385B
5 6
010J Blk
K8
K9
SPARE
SPARE
2 1
125E Dk Grn
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
012
S1 Key
Switch
X3 To S4
Transmission
Neutral Switch
Relay/Fuse
Block Harness
122C
505
S7
Park Brake
Switch
586
562C
594
518B
573A
573B
573C
V2 Diode
(Soldered
In-Line)
573B
010A
010H
010B
010J
010C
010K
010D
010L
010G
562F
To X13 Trailer
Connector
(Option)
010L
115C
010K
147D
546
125A
147A
125B
147C
147B
125C
147D
125D
125E
Y1
Starting
Motor
Solenoid
573A
S5 Rear
PTO Switch
4 - 18
222 Red
X21 To E3
RH Tail Light
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
125D
010G
Fusible Link
562D
115E Dk Grn
4
Red
125C
309
5
115D
010J 125E
118
147C
115E 222
115A 115D
115B 115E
115C
562A 562D
562B 562E
562C 562F
594
118 Gry
7
3
8
122A
122B
6
2
7
3
1
147C Pur
Relay/Fuse
Load Center
050A
050B 050J
050K
050L
587A
587B
587C
587D
587B
002B
X1 To Fusible Link
002C
Relay #
138
2 B
072B
209 4
85
B
DB1
002A
119A
4
87A
A
103A
103B
103C
S8 Turn
Signal Switch
R1 Manifold Heater
3
86
Diode Block
347
586
212
050A
010B
F
385A
385B
385C
122A
115A
103B
125A
010N
010C
347
9
K1
143
329A
302C
Y2 Fuel
Shutoff
Solenoid
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
B2 Engine Oil
Pressure
Switch (NC)
2
Relays
125B
115B
010N
010A
–––
8
Diode Block
Schematic
Diode Block
Socket Layout
050L
E6 RH Headlight
302A
Fuse Block
A
6
8
Relay Socket
Layout
9
3
353
119B
8
B
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
6
30
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
30A
30A
–––
10A
20A
20A
20A
A
002
002D
002
–––
072C
0143
138
103C
RELAYS
DIODE BLOCK
B
012
252
122C
–––
562A
147A
119C
118
#
1
DB1
2
539A
3
556
4
572B
5
539A/539B
521
7
518A
2
2
1
4
5
8
3
1
010D/010E
6
4
9
7
7
1
3
4
6
7
5
5
2
9
A
1
9
X7 To Control
Panel Circuit Board
D
E
F
C
B
A
050J
X9 To W5 Cruise
264
Control Wiring
Harness (Option) 247A
238
E
F
C
B
A
209
W2 Ground
383
302A
302B
302C
505
587A
X2 To W3
Neutral Start
Wiring Harness
119A
119B 119C
119D
E5 LH Headlight
G2
Alternator
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
002C
002D
334
072D
325
359
G
H
E
D
C
359
J
K
072A
119D
353
050K
122B
B
002A
5
6
11
10
7
103A
002E
072A
072B
072C
072D
309
M1 Starting
Motor
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
87
8
12
86
30
85
87 87A
Relay
Schematic
K2
K3
K4
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K5
K6
K7
X13 Trailer Connector
(Option) (from rear of connector)
3
4
S9 Light
Switch
1
572A
385B
5 6
010J Blk
K8
K9
SPARE
SPARE
2 1
125E Dk Grn
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
012
S1 Key
Switch
X3 To S4
Transmission
Neutral Switch
Relay/Fuse
Block Harness
122C
505
S7
Park Brake
Switch
586
562C
594
518B
573A
573B
573C
V2 Diode
(Soldered
In-Line)
573B
010A
010H
010B
010J
010C
010K
010D
010L
010G
562F
To X13 Trailer
Connector
(Option)
010L
115C
010K
147D
546
125A
147A
125B
147C
147B
125C
147D
125D
125E
Y1
Starting
Motor
Solenoid
573A
S5 Rear
PTO Switch
4 - 18
222 Red
X21 To E3
RH Tail Light
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
125D
010G
Fusible Link
562D
115E Dk Grn
4
Red
125C
309
5
115D
010J 125E
118
147C
115E 222
115A 115D
115B 115E
115C
562A 562D
562B 562E
562C 562F
594
118 Gry
7
3
8
122A
122B
6
2
7
3
1
147C Pur
Relay/Fuse
Load Center
050A
050B 050J
050K
050L
587A
587B
587C
587D
587B
002B
X1 To Fusible Link
002C
Relay #
138
2 B
072B
209 4
85
B
DB1
002A
119A
4
87A
A
103A
103B
103C
S8 Turn
Signal Switch
R1 Manifold Heater
3
86
Diode Block
347
586
212
050A
010B
F
385A
385B
385C
122A
115A
103B
125A
010N
010C
347
9
K1
143
329A
302C
Y2 Fuel
Shutoff
Solenoid
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
B2 Engine Oil
Pressure
Switch (NC)
2
Relays
125B
115B
010N
010A
–––
8
Diode Block
Schematic
Diode Block
Socket Layout
050L
E6 RH Headlight
302A
Fuse Block
A
6
8
Relay Socket
Layout
9
3
353
119B
8
B
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
6
30
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (OLD)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
30A
30A
–––
10A
20A
20A
20A
A
002
002D
002
–––
072C
0143
138
103C
RELAYS
DIODE BLOCK
B
012
252
122C
–––
562A
147A
119C
118
#
1
DB1
2
539A
3
556
4
572B
5
539A/539B
521
7
518A
2
2
1
4
5
8
3
1
010D/010E
6
4
9
7
7
1
3
4
6
7
5
5
2
9
A
1
9
X7 To Control
Panel Circuit Board
D
E
F
C
B
A
050J
X9 To W5 Cruise
264
Control Wiring
Harness (Option) 247A
238
E
F
C
B
A
209
W2 Ground
383
302A
302B
302C
505
587A
X2 To W3
Neutral Start
Wiring Harness
119A
119B 119C
119D
E5 LH Headlight
G2
Alternator
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
002C
002D
334
072D
325
359
G
H
E
D
C
359
J
K
072A
119D
353
050K
122B
B
002A
5
6
11
10
7
103A
002E
072A
072B
072C
072D
309
M1 Starting
Motor
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
87
8
12
86
30
85
87 87A
Relay
Schematic
K2
K3
K4
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K5
K6
K7
X13 Trailer Connector
(Option) (from rear of connector)
3
4
S9 Light
Switch
1
572A
385B
5 6
010J Blk
K8
K9
SPARE
SPARE
2 1
125E Dk Grn
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
012
S1 Key
Switch
X3 To S4
Transmission
Neutral Switch
Relay/Fuse
Block Harness
122C
505
S7
Park Brake
Switch
586
562C
594
518B
573A
573B
573C
V2 Diode
(Soldered
In-Line)
573B
010A
010H
010B
010J
010C
010K
010D
010L
010G
562F
To X13 Trailer
Connector
(Option)
010L
115C
010K
147D
546
125A
147A
125B
147C
147B
125C
147D
125D
125E
Y1
Starting
Motor
Solenoid
573A
S5 Rear
PTO Switch
4 - 18
222 Red
X21 To E3
RH Tail Light
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
125D
010G
Fusible Link
562D
115E Dk Grn
4
Red
125C
309
5
115D
010J 125E
118
147C
115E 222
115A 115D
115B 115E
115C
562A 562D
562B 562E
562C 562F
594
118 Gry
7
3
8
122A
122B
6
2
7
3
1
147C Pur
Relay/Fuse
Load Center
050A
050B 050J
050K
050L
587A
587B
587C
587D
587B
002B
X1 To Fusible Link
002C
Relay #
138
2 B
072B
209 4
85
B
DB1
002A
119A
4
87A
A
103A
103B
103C
S8 Turn
Signal Switch
R1 Manifold Heater
3
86
Diode Block
347
586
212
050A
010B
F
385A
385B
385C
122A
115A
103B
125A
010N
010C
347
9
K1
143
329A
302C
Y2 Fuel
Shutoff
Solenoid
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
B2 Engine Oil
Pressure
Switch (NC)
2
Relays
125B
115B
010N
010A
–––
8
Diode Block
Schematic
Diode Block
Socket Layout
050L
E6 RH Headlight
302A
Fuse Block
A
6
8
Relay Socket
Layout
9
3
353
119B
8
B
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
6
30
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
002D Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
072C
Red F5
Fuse
A
S1 Key
Switch
A
Off
On
562B
Red
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
87A 87
573B
Org
1
B
309
Wht
B
X2
87 87A
222
Red
334
Yel
050G
Blk
125B
Dk Grn
3
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
521
Brn
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
86
30
85
87 87A
587D Org
325 Dk Grn
586 Lt Blu
329A
Wht
K3 Fuel
Shutoff
Relay
Blk
W1 Battery
010D Blk
Frame
050B Blk
Ground
050A Blk
010P Blk
010C Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
30
K5
Safety
Relay
87A 87
319
Wht
562C
Red
594
Yel
86
85
F6 Fuse
A
147C Pur
147A Pur
B
X18
E1 LH
Tail
Light
115B
Dk Grn
S8 Turn
Signal Switch
X7
X7
D
E
X6
2
147B
Pur
X21
E3 RH
Tail
Light
H3 PTO
Light
H2 LH
Turn
Light
1
X13 Trailer
Connector
E8 RH Work
Light
X16 010K Blk
119D
Wht
E7 LH Work
Light
X6
A
6
X16
X17
X17
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
010J Blk
147C Pur
118B Gry
072A
Red
010P
Blk
118D Gry
118A Gry
A
B
Fuse 119C Wht
B
P
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 19
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Switched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
Unswitched Power
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
010T
Blk
X4
86
138B F7
A
F8 Fuse
010A
Blk
010B Blk
302B Red
Blk
329B
138C Gry
103 Org
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
1
103 Org
2
138A Gry
3
143 Org
4
F
K
050C Blk
Wht
Wht
050B
Blk
R1 Manifold
Heater
(2) Road
118C Gry
X6
325
Dk Grn
002D
Red
385A Dk Grn
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
122A
Red
2
125A Dk Grn 3
125D Dk Grn
7
4
B
+
302B Red
302A Red
010D
010F Blk
Blk
E6 RH
Headlight
E5 LH
Headlight
115A Dk Grn 4
125C
Dk Grn
X13 Trailer
Connector
122B Red
(0) Right
(1) Off
(2) Left
1
Flasher
115C
Dk Grn
115D
Dk Grn
X19
K7
Accessory
Relay
302C Red
G1
Battery
1/31/01
85
385A Dk Grn
X4
W2 Front
Frame
Ground
G2
Alternator
050F
Blk
587A Org
S3 Transmission
Neutral Switch
(All Transmissions)
8
30
P
574
Yel
587B
Org
X2
M
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
050H
Blk
86
5
X22
594
Yel
Transmission Engaged
V1
Diode
Block
7
V2
Diode
L
572B Red 3
010E
Blk
A
87 87A
B
IG
X5
Transmission Disengaged
002A Red
K9 Rear
PTO
Relay
E2 LH
Hazard
Light
X13 Trailer
Connector
556 Lt Blu
2
K2
Start
Relay
G
30
A
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
85
86
E4 RH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
562B
Red
85
V1 Diode
Block
539B Wht 4
002B Red
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
002A
Red
562F Red
B
562E Red
572A Red
(0) Off
(1) Hazard
(3) Field
H9
Backup Alarm
7 385B Dk Grn
30
X23
X20
072A Red
X24 562H Red
3 212 Red
A
S9 Light
Switch
072D Red
5 072B Red
F1
Fuse
119A Wht
119B Wht
010L
Blk
010G
Blk
072A Red
2
B
212 Red
6 572A Red
012 Red 1
122C Red
Fuse Block
Internal Link
209 Wht
4 209 Wht
122C Red
B
A
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
002D Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
072C
Red F5
Fuse
A
S1 Key
Switch
A
Off
On
562B
Red
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
87A 87
573B
Org
1
B
309
Wht
B
X2
87 87A
222
Red
334
Yel
050G
Blk
125B
Dk Grn
3
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
521
Brn
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
86
30
85
87 87A
587D Org
325 Dk Grn
586 Lt Blu
329A
Wht
K3 Fuel
Shutoff
Relay
Blk
W1 Battery
010D Blk
Frame
050B Blk
Ground
050A Blk
010P Blk
010C Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
30
K5
Safety
Relay
87A 87
319
Wht
562C
Red
594
Yel
86
85
F6 Fuse
A
147C Pur
147A Pur
B
X18
E1 LH
Tail
Light
115B
Dk Grn
S8 Turn
Signal Switch
X7
X7
D
E
X6
2
147B
Pur
X21
E3 RH
Tail
Light
H3 PTO
Light
H2 LH
Turn
Light
1
X13 Trailer
Connector
E8 RH Work
Light
X16 010K Blk
119D
Wht
E7 LH Work
Light
X6
A
6
X16
X17
X17
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
010J Blk
147C Pur
118B Gry
072A
Red
010P
Blk
118D Gry
118A Gry
A
B
Fuse 119C Wht
B
P
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 19
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Switched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
Unswitched Power
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
010T
Blk
X4
86
138B F7
A
F8 Fuse
010A
Blk
010B Blk
302B Red
Blk
329B
138C Gry
103 Org
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
1
103 Org
2
138A Gry
3
143 Org
4
F
K
050C Blk
Wht
Wht
050B
Blk
R1 Manifold
Heater
(2) Road
118C Gry
X6
325
Dk Grn
002D
Red
385A Dk Grn
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
122A
Red
2
125A Dk Grn 3
125D Dk Grn
7
4
B
+
302B Red
302A Red
010D
010F Blk
Blk
E6 RH
Headlight
E5 LH
Headlight
115A Dk Grn 4
125C
Dk Grn
X13 Trailer
Connector
122B Red
(0) Right
(1) Off
(2) Left
1
Flasher
115C
Dk Grn
115D
Dk Grn
X19
K7
Accessory
Relay
302C Red
G1
Battery
1/31/01
85
385A Dk Grn
X4
W2 Front
Frame
Ground
G2
Alternator
050F
Blk
587A Org
S3 Transmission
Neutral Switch
(All Transmissions)
8
30
P
574
Yel
587B
Org
X2
M
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
050H
Blk
86
5
X22
594
Yel
Transmission Engaged
V1
Diode
Block
7
V2
Diode
L
572B Red 3
010E
Blk
A
87 87A
B
IG
X5
Transmission Disengaged
002A Red
K9 Rear
PTO
Relay
E2 LH
Hazard
Light
X13 Trailer
Connector
556 Lt Blu
2
K2
Start
Relay
G
30
A
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
85
86
E4 RH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
562B
Red
85
V1 Diode
Block
539B Wht 4
002B Red
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
002A
Red
562F Red
B
562E Red
572A Red
(0) Off
(1) Hazard
(3) Field
H9
Backup Alarm
7 385B Dk Grn
30
X23
X20
072A Red
X24 562H Red
3 212 Red
A
S9 Light
Switch
072D Red
5 072B Red
F1
Fuse
119A Wht
119B Wht
010L
Blk
010G
Blk
072A Red
2
B
212 Red
6 572A Red
012 Red 1
122C Red
Fuse Block
Internal Link
209 Wht
4 209 Wht
122C Red
B
A
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
002D Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
072C
Red F5
Fuse
A
S1 Key
Switch
A
Off
On
562B
Red
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
87A 87
573B
Org
1
B
309
Wht
B
X2
87 87A
222
Red
334
Yel
050G
Blk
125B
Dk Grn
3
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
521
Brn
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
86
30
85
87 87A
587D Org
325 Dk Grn
586 Lt Blu
329A
Wht
K3 Fuel
Shutoff
Relay
Blk
W1 Battery
010D Blk
Frame
050B Blk
Ground
050A Blk
010P Blk
010C Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
30
K5
Safety
Relay
87A 87
319
Wht
562C
Red
594
Yel
86
85
F6 Fuse
A
147C Pur
147A Pur
B
X18
E1 LH
Tail
Light
115B
Dk Grn
S8 Turn
Signal Switch
X7
X7
D
E
X6
2
147B
Pur
X21
E3 RH
Tail
Light
H3 PTO
Light
H2 LH
Turn
Light
1
X13 Trailer
Connector
E8 RH Work
Light
X16 010K Blk
119D
Wht
E7 LH Work
Light
X6
A
6
X16
X17
X17
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
010J Blk
147C Pur
118B Gry
072A
Red
010P
Blk
118D Gry
118A Gry
A
B
Fuse 119C Wht
B
P
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 19
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Switched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
Unswitched Power
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
010T
Blk
X4
86
138B F7
A
F8 Fuse
010A
Blk
010B Blk
302B Red
Blk
329B
138C Gry
103 Org
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
1
103 Org
2
138A Gry
3
143 Org
4
F
K
050C Blk
Wht
Wht
050B
Blk
R1 Manifold
Heater
(2) Road
118C Gry
X6
325
Dk Grn
002D
Red
385A Dk Grn
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
122A
Red
2
125A Dk Grn 3
125D Dk Grn
7
4
B
+
302B Red
302A Red
010D
010F Blk
Blk
E6 RH
Headlight
E5 LH
Headlight
115A Dk Grn 4
125C
Dk Grn
X13 Trailer
Connector
122B Red
(0) Right
(1) Off
(2) Left
1
Flasher
115C
Dk Grn
115D
Dk Grn
X19
K7
Accessory
Relay
302C Red
G1
Battery
1/31/01
85
385A Dk Grn
X4
W2 Front
Frame
Ground
G2
Alternator
050F
Blk
587A Org
S3 Transmission
Neutral Switch
(All Transmissions)
8
30
P
574
Yel
587B
Org
X2
M
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
050H
Blk
86
5
X22
594
Yel
Transmission Engaged
V1
Diode
Block
7
V2
Diode
L
572B Red 3
010E
Blk
A
87 87A
B
IG
X5
Transmission Disengaged
002A Red
K9 Rear
PTO
Relay
E2 LH
Hazard
Light
X13 Trailer
Connector
556 Lt Blu
2
K2
Start
Relay
G
30
A
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
85
86
E4 RH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
562B
Red
85
V1 Diode
Block
539B Wht 4
002B Red
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
002A
Red
562F Red
B
562E Red
572A Red
(0) Off
(1) Hazard
(3) Field
H9
Backup Alarm
7 385B Dk Grn
30
X23
X20
072A Red
X24 562H Red
3 212 Red
A
S9 Light
Switch
072D Red
5 072B Red
F1
Fuse
119A Wht
119B Wht
010L
Blk
010G
Blk
072A Red
2
B
212 Red
6 572A Red
012 Red 1
122C Red
Fuse Block
Internal Link
209 Wht
4 209 Wht
122C Red
B
A
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 NA (NEW)
F3 Fuse
Fuse Block Internal Link
Fuse Block Internal Link
002D Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
072C
Red F5
Fuse
A
S1 Key
Switch
A
Off
On
562B
Red
562D Red
562A Red
S5 Rear
PTO Switch
562C Red
539A Wht
S2 Seat
Switch
518A Gry
X5
521
Brn
518B Gry
87A 87
573B
Org
1
B
309
Wht
B
X2
87 87A
222
Red
334
Yel
050G
Blk
125B
Dk Grn
3
X7
574 Yel
B
385A Dk Grn
334 Yel
C
A
521
Brn
86
85
30
87 87A
K1
Manifold
Heater
Relay
383
Org
86
30
85
87 87A
587D Org
325 Dk Grn
586 Lt Blu
329A
Wht
K3 Fuel
Shutoff
Relay
Blk
W1 Battery
010D Blk
Frame
050B Blk
Ground
050A Blk
010P Blk
010C Blk
SE1 - STARTING
R2 Variable
Thermistor
010F Blk
30
K5
Safety
Relay
87A 87
319
Wht
562C
Red
594
Yel
86
85
F6 Fuse
A
147C Pur
147A Pur
B
X18
E1 LH
Tail
Light
115B
Dk Grn
S8 Turn
Signal Switch
X7
X7
D
E
X6
2
147B
Pur
X21
E3 RH
Tail
Light
H3 PTO
Light
H2 LH
Turn
Light
1
X13 Trailer
Connector
E8 RH Work
Light
X16 010K Blk
119D
Wht
E7 LH Work
Light
X6
A
6
X16
X17
X17
010H Blk
B
_
H4
Discharge
Light
H5 Cold
Start
Light
Q
H1 RH
Turn
Light
010J Blk
147C Pur
118B Gry
072A
Red
010P
Blk
118D Gry
118A Gry
A
B
Fuse 119C Wht
B
P
556
Lt Blu
86
30
87 87A
85
H8 Cruise
Indicator
Light (Opt.)
587D
Org
30
87 87A
K6
Safety
Relay
G
P2 Hour
Meter
(Opt.)
n/min
P1 Engine
Tachometer
t0
P3
Fuel
Gauge
H7 Oil
Pressure
Light
H6 Park
Brake
Light
209 Wht
A
Off
On
Engage
Blk
Wht
X10
Wht
X10
S11 Brake
Switch
P4 Engine
Coolant
Temperature
Gauge
On
Gry
050E Blk
050F Blk
050F Blk
264B
Yel
S7 Park
Brake Switch
050G Blk
050C Blk
050J Blk
050K Blk
050L Blk
K8
Cruise
Control
Relay
86
85
B
C
D
050J Blk
E
Blk
Gry
X11
Blu
Yel
87 87A
X12
W5 Cruise Control
Wiring Harness (Option)
Wht
Wht
X12
SE2 - IGNITION
Secondary Switched Power
SE3 - CHARGING
4 - 19
Q
B1 Fuel
Gauge
Sensor
Yel
X6
t0
347
Pur
050L
Blk
P
Y3 Cruise
Control Magnet
050K Blk
050L Blk
B3 Engine
Coolant
Temperature
Switch
B2 Engine Oil
Pressure
Switch (NC)
010C Blk
010C Blk
Switched Power
E
359
Wht
353
Org
Blu
050J Blk
050K Blk
050L Blk
Unswitched Power
X11
30
050H Blk
050C Blk
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
X6
Off
X10
Gry
X6
050K
Blk
Pur
J
C
X6
On
586 Lt Blu
010N
Blk
D
S10 Cruise
Control
Switch
X9
X6
209 Wht
533 Org
Off
546 Lt Blu
85
010F
Blk
010T
Blk
X4
86
138B F7
A
F8 Fuse
010A
Blk
010B Blk
302B Red
Blk
329B
138C Gry
103 Org
K4
Engine
Run
Relay
050D Blk
587C 546 Lt Blu
Org
X4
1
103 Org
2
138A Gry
3
143 Org
4
F
K
050C Blk
Wht
Wht
050B
Blk
R1 Manifold
Heater
(2) Road
118C Gry
X6
325
Dk Grn
002D
Red
385A Dk Grn
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
122A
Red
2
125A Dk Grn 3
125D Dk Grn
7
4
B
+
302B Red
302A Red
010D
010F Blk
Blk
E6 RH
Headlight
E5 LH
Headlight
115A Dk Grn 4
125C
Dk Grn
X13 Trailer
Connector
122B Red
(0) Right
(1) Off
(2) Left
1
Flasher
115C
Dk Grn
115D
Dk Grn
X19
K7
Accessory
Relay
302C Red
G1
Battery
1/31/01
85
385A Dk Grn
X4
W2 Front
Frame
Ground
G2
Alternator
050F
Blk
587A Org
S3 Transmission
Neutral Switch
(All Transmissions)
8
30
P
574
Yel
587B
Org
X2
M
M1
Starting
Motor
Y1
Starting
Motor
Red
Solenoid
050H
Blk
86
5
X22
594
Yel
Transmission Engaged
V1
Diode
Block
7
V2
Diode
L
572B Red 3
010E
Blk
A
87 87A
B
IG
X5
Transmission Disengaged
002A Red
K9 Rear
PTO
Relay
E2 LH
Hazard
Light
X13 Trailer
Connector
556 Lt Blu
2
K2
Start
Relay
G
30
A
Off
On
S6 Mid
PTO Switch
(Option)
572B Red
85
86
E4 RH
Hazard
Light
212 252
Red Red
5
518A Gry 6
539A Wht
562B
Red
85
V1 Diode
Block
539B Wht 4
002B Red
86
573C Org
(Operator Off)
(Operator On)
Fusible
Link
573A Org
F2
Fuse
B
072D
Red
002A
Red
562F Red
B
562E Red
572A Red
(0) Off
(1) Hazard
(3) Field
H9
Backup Alarm
7 385B Dk Grn
30
X23
X20
072A Red
X24 562H Red
3 212 Red
A
S9 Light
Switch
072D Red
5 072B Red
F1
Fuse
119A Wht
119B Wht
010L
Blk
010G
Blk
072A Red
2
B
212 Red
6 572A Red
012 Red 1
122C Red
Fuse Block
Internal Link
209 Wht
4 209 Wht
122C Red
B
A
010G Blk
010L Blk
010G Blk
010L Blk
002A Red
002A Red
Control Panel
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
010C
Blk
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
–––
30A
–––
10A
20A
20A
20A
A
002
002C
002D
–––
072C
143
138B
138C
B
012
252
122C
–––
562A
147A
119C
118A
#
1
DB1
2
539A
4
5
8
7
556
3
1
6
4
9
7
4
572B
2
2
1
3
1
5
539A/539B
3
4
6
521
7
6
7
518A
8
010D/010E
302A
9
–––
9
3
5
6
8
5
2
9
8
Diode Block
Schematic
Diode Block
Socket Layout
125B
115B
D
E
F
C
B
A
050J
X9 To W5 Cruise
Control Wiring 264A
Harness (Option) 247
238
353
B2 Engine Oil
Pressure
Switch (NC)
050L
F
C
B
A
209
F
G
H
E
D
C
359
J
347
586
K
010C
050A
050B
347
S8 Turn
Signal Switch
W2 Ground
383
R1 Manifold Heater
A
1
B
2
9
A
4
5
119A
119B 119C
119D
119B
E6 RH Headlight
010A
G2
Alternator
010B
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
K2
334
072D
325
359
002A
K5
K6
212
M1 Starting
Motor
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
86
30
85
87 87A
K4
K7
Relay
Schematic
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K9
SPARE
SPARE
3
2 B
4
1
572A
385B
5 6
Relay/Fuse
Load Center
2 1
125D Dk Grn
S9 Light
Switch
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
8
562F
Relay/Fuse
Block Harness
587A
To X13 Trailer
Connector
(Option) 010J
309
115D Dk Grn
4
518B
010L
115C
010C
010J 010G
010K 010H
010L
573A
573B
573C
115A 115C
115B 115D
562A 562D
562B 562E
562C 562F
562C 562H
125A
147A
125B
147C
147B
125C
147D
125D
010K
147D
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
118C
010G
Fusible Link
562D
573A
S5 Rear
PTO Switch
4 - 20
222 Red
X21 To E3
RH Tail Light
125C
Y1
Starting
Motor
Solenoid
5
118B
125D
118D 147C
115D 222
R2
573B
594
118D Gry
7
Red
143
X3 To S4
Transmission
Neutral Switch
V2 Diode
(Soldered
In-Line)
6
3
7
3
1
147C Pur
2
138A
122C 138C
309
87
010J Blk
587A
587B
587C
587D
002B
X1 To Fusible Link
002C
30
Relay Socket
Layout
012
S1 Key
Switch
X24 To H9
Backup Alarm
587B
85
X13 Trailer Connector
(Option) (from rear of connector)
002A
119A
86
546
072B
209 4
072A
072B
072C
072D
Relay #
87
8
12
K3
85
S7
Park Brake
Switch
586
594
122A 138A
122B 138B
010N
010A 010P
010B
7
B
562H
E5 LH Headlight
6
11
10
K8
385A
385B
385C
302A
302B
302C
3
A
103
050A
050J
050K
050L
87A
DB1
072A
119D
353
050K
562C
B
122A
115A
103
125A
010P
010D
302C
Y2 Fuel
Shutoff
Solenoid
E
86
30
Diode Block
122B
010N
329A
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
RELAYS
K1
X7 To Control
Panel Circuit Board
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
Serial Numbers for Wiring Harness Use:
LV4200C327136–
LV4200H320279–
Fuse Block
LV4300C335215–
LV4300S336172–
LV4300H330219–
LV4400S334080–
Relays
LV4700H340245–
DIODE BLOCK
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
–––
30A
–––
10A
20A
20A
20A
A
002
002C
002D
–––
072C
143
138B
138C
B
012
252
122C
–––
562A
147A
119C
118A
#
1
DB1
2
539A
4
5
8
7
556
3
1
6
4
9
7
4
572B
2
2
1
3
1
5
539A/539B
3
4
6
521
7
6
7
518A
8
010D/010E
302A
9
–––
9
3
5
6
8
5
2
9
8
Diode Block
Schematic
Diode Block
Socket Layout
125B
115B
D
E
F
C
B
A
050J
X9 To W5 Cruise
Control Wiring 264A
Harness (Option) 247
238
353
B2 Engine Oil
Pressure
Switch (NC)
050L
F
C
B
A
209
F
G
H
E
D
C
359
J
347
586
K
010C
050A
050B
347
S8 Turn
Signal Switch
W2 Ground
383
R1 Manifold Heater
A
1
B
2
9
A
4
5
119A
119B 119C
119D
119B
E6 RH Headlight
010A
G2
Alternator
010B
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
K2
334
072D
325
359
002A
K5
K6
212
M1 Starting
Motor
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
86
30
85
87 87A
K4
K7
Relay
Schematic
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K9
SPARE
SPARE
3
2 B
4
1
572A
385B
5 6
Relay/Fuse
Load Center
2 1
125D Dk Grn
S9 Light
Switch
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
8
562F
Relay/Fuse
Block Harness
587A
To X13 Trailer
Connector
(Option) 010J
309
115D Dk Grn
4
518B
010L
115C
010C
010J 010G
010K 010H
010L
573A
573B
573C
115A 115C
115B 115D
562A 562D
562B 562E
562C 562F
562C 562H
125A
147A
125B
147C
147B
125C
147D
125D
010K
147D
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
118C
010G
Fusible Link
562D
573A
S5 Rear
PTO Switch
4 - 20
222 Red
X21 To E3
RH Tail Light
125C
Y1
Starting
Motor
Solenoid
5
118B
125D
118D 147C
115D 222
R2
573B
594
118D Gry
7
Red
143
X3 To S4
Transmission
Neutral Switch
V2 Diode
(Soldered
In-Line)
6
3
7
3
1
147C Pur
2
138A
122C 138C
309
87
010J Blk
587A
587B
587C
587D
002B
X1 To Fusible Link
002C
30
Relay Socket
Layout
012
S1 Key
Switch
X24 To H9
Backup Alarm
587B
85
X13 Trailer Connector
(Option) (from rear of connector)
002A
119A
86
546
072B
209 4
072A
072B
072C
072D
Relay #
87
8
12
K3
85
S7
Park Brake
Switch
586
594
122A 138A
122B 138B
010N
010A 010P
010B
7
B
562H
E5 LH Headlight
6
11
10
K8
385A
385B
385C
302A
302B
302C
3
A
103
050A
050J
050K
050L
87A
DB1
072A
119D
353
050K
562C
B
122A
115A
103
125A
010P
010D
302C
Y2 Fuel
Shutoff
Solenoid
E
86
30
Diode Block
122B
010N
329A
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
RELAYS
K1
X7 To Control
Panel Circuit Board
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
Serial Numbers for Wiring Harness Use:
LV4200C327136–
LV4200H320279–
Fuse Block
LV4300C335215–
LV4300S336172–
LV4300H330219–
LV4400S334080–
Relays
LV4700H340245–
DIODE BLOCK
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
–––
30A
–––
10A
20A
20A
20A
A
002
002C
002D
–––
072C
143
138B
138C
B
012
252
122C
–––
562A
147A
119C
118A
#
1
DB1
2
539A
4
5
8
7
556
3
1
6
4
9
7
4
572B
2
2
1
3
1
5
539A/539B
3
4
6
521
7
6
7
518A
8
010D/010E
302A
9
–––
9
3
5
6
8
5
2
9
8
Diode Block
Schematic
Diode Block
Socket Layout
125B
115B
D
E
F
C
B
A
050J
X9 To W5 Cruise
Control Wiring 264A
Harness (Option) 247
238
353
B2 Engine Oil
Pressure
Switch (NC)
050L
F
C
B
A
209
F
G
H
E
D
C
359
J
347
586
K
010C
050A
050B
347
S8 Turn
Signal Switch
W2 Ground
383
R1 Manifold Heater
A
1
B
2
9
A
4
5
119A
119B 119C
119D
119B
E6 RH Headlight
010A
G2
Alternator
010B
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
K2
334
072D
325
359
002A
K5
K6
212
M1 Starting
Motor
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
86
30
85
87 87A
K4
K7
Relay
Schematic
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K9
SPARE
SPARE
3
2 B
4
1
572A
385B
5 6
Relay/Fuse
Load Center
2 1
125D Dk Grn
S9 Light
Switch
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
8
562F
Relay/Fuse
Block Harness
587A
To X13 Trailer
Connector
(Option) 010J
309
115D Dk Grn
4
518B
010L
115C
010C
010J 010G
010K 010H
010L
573A
573B
573C
115A 115C
115B 115D
562A 562D
562B 562E
562C 562F
562C 562H
125A
147A
125B
147C
147B
125C
147D
125D
010K
147D
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
118C
010G
Fusible Link
562D
573A
S5 Rear
PTO Switch
4 - 20
222 Red
X21 To E3
RH Tail Light
125C
Y1
Starting
Motor
Solenoid
5
118B
125D
118D 147C
115D 222
R2
573B
594
118D Gry
7
Red
143
X3 To S4
Transmission
Neutral Switch
V2 Diode
(Soldered
In-Line)
6
3
7
3
1
147C Pur
2
138A
122C 138C
309
87
010J Blk
587A
587B
587C
587D
002B
X1 To Fusible Link
002C
30
Relay Socket
Layout
012
S1 Key
Switch
X24 To H9
Backup Alarm
587B
85
X13 Trailer Connector
(Option) (from rear of connector)
002A
119A
86
546
072B
209 4
072A
072B
072C
072D
Relay #
87
8
12
K3
85
S7
Park Brake
Switch
586
594
122A 138A
122B 138B
010N
010A 010P
010B
7
B
562H
E5 LH Headlight
6
11
10
K8
385A
385B
385C
302A
302B
302C
3
A
103
050A
050J
050K
050L
87A
DB1
072A
119D
353
050K
562C
B
122A
115A
103
125A
010P
010D
302C
Y2 Fuel
Shutoff
Solenoid
E
86
30
Diode Block
122B
010N
329A
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
RELAYS
K1
X7 To Control
Panel Circuit Board
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
Serial Numbers for Wiring Harness Use:
LV4200C327136–
LV4200H320279–
Fuse Block
LV4300C335215–
LV4300S336172–
LV4300H330219–
LV4400S334080–
Relays
LV4700H340245–
DIODE BLOCK
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
ELECTRICAL
MAIN WIRING HARNESS–4200/4300/4400 NA (NEW)
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
SIZE
30A
–––
30A
–––
10A
20A
20A
20A
A
002
002C
002D
–––
072C
143
138B
138C
B
012
252
122C
–––
562A
147A
119C
118A
#
1
DB1
2
539A
4
5
8
7
556
3
1
6
4
9
7
4
572B
2
2
1
3
1
5
539A/539B
3
4
6
521
7
6
7
518A
8
010D/010E
302A
9
–––
9
3
5
6
8
5
2
9
8
Diode Block
Schematic
Diode Block
Socket Layout
125B
115B
D
E
F
C
B
A
050J
X9 To W5 Cruise
Control Wiring 264A
Harness (Option) 247
238
353
B2 Engine Oil
Pressure
Switch (NC)
050L
F
C
B
A
209
F
G
H
E
D
C
359
J
347
586
K
010C
050A
050B
347
S8 Turn
Signal Switch
W2 Ground
383
R1 Manifold Heater
A
1
B
2
9
A
4
5
119A
119B 119C
119D
119B
E6 RH Headlight
010A
G2
Alternator
010B
B3 Engine
Coolant
Temperature
Switch
G2
Alternator
K2
334
072D
325
359
002A
K5
K6
212
M1 Starting
Motor
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
385C
518A/518B
329B
521
587C
556
212
238
573C
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050H
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
383
309
–––
302B
533
–––
222
247
–––
–––
–––
319
–––
–––
533
–––
–––
574
86
30
85
87 87A
K4
K7
Relay
Schematic
NOTE: K7 Accessory relay is used with trailer connection option, K8 cruise control
relay is used with cruise control option.
K9
SPARE
SPARE
3
2 B
4
1
572A
385B
5 6
Relay/Fuse
Load Center
2 1
125D Dk Grn
S9 Light
Switch
X5 To S6 Mid
PTO Switch
(Supplied with
Cap and Jumper)
8
562F
Relay/Fuse
Block Harness
587A
To X13 Trailer
Connector
(Option) 010J
309
115D Dk Grn
4
518B
010L
115C
010C
010J 010G
010K 010H
010L
573A
573B
573C
115A 115C
115B 115D
562A 562D
562B 562E
562C 562F
562C 562H
125A
147A
125B
147C
147B
125C
147D
125D
010K
147D
X23 To E3 RH Tail Light
and E4 RH Hazard Light
X22 To E4
RH Hazard Light
X16 To E8
RH Work Light
S2 Seat Switch
562E
539B
118C
010G
Fusible Link
562D
573A
S5 Rear
PTO Switch
4 - 20
222 Red
X21 To E3
RH Tail Light
125C
Y1
Starting
Motor
Solenoid
5
118B
125D
118D 147C
115D 222
R2
573B
594
118D Gry
7
Red
143
X3 To S4
Transmission
Neutral Switch
V2 Diode
(Soldered
In-Line)
6
3
7
3
1
147C Pur
2
138A
122C 138C
309
87
010J Blk
587A
587B
587C
587D
002B
X1 To Fusible Link
002C
30
Relay Socket
Layout
012
S1 Key
Switch
X24 To H9
Backup Alarm
587B
85
X13 Trailer Connector
(Option) (from rear of connector)
002A
119A
86
546
072B
209 4
072A
072B
072C
072D
Relay #
87
8
12
K3
85
S7
Park Brake
Switch
586
594
122A 138A
122B 138B
010N
010A 010P
010B
7
B
562H
E5 LH Headlight
6
11
10
K8
385A
385B
385C
302A
302B
302C
3
A
103
050A
050J
050K
050L
87A
DB1
072A
119D
353
050K
562C
B
122A
115A
103
125A
010P
010D
302C
Y2 Fuel
Shutoff
Solenoid
E
86
30
Diode Block
122B
010N
329A
334
D
X6 To Control
Panel Circuit Board
264B
325
385A
574
RELAYS
K1
X7 To Control
Panel Circuit Board
NOTE: Fuses F2 and F4 are used with trailer
connection option, Fuse F6 is used with work
light option.
B1
Fuel Gauge
Sensor
Serial Numbers for Wiring Harness Use:
LV4200C327136–
LV4200H320279–
Fuse Block
LV4300C335215–
LV4300S336172–
LV4300H330219–
LV4400S334080–
Relays
LV4700H340245–
DIODE BLOCK
X18 To E1
LH Tail Light
X20 To E1 LH Tail Light
and E2 RH Hazard Light
X19 To E2
LH Hazard Light
010H
147B
X17 To E7
LH Work Light
1/31/01
WIRE COLOR CODES (NEW)
ELECTRICAL - NORTH AMERICAN
WIRE COLOR CODES (NEW)
Circuit
Number
Wire
Size
Color
Termination
Points
Circuit
Number
Wire
Size
Color
Termination
Points
072A
1.0
Red
X6, Splice 072
002A
5.0
Red
M1, G2
072B
1.0
Red
S1, Splice 072
002B
5.0
Red
X1 (Fusible Link),
K1(30)
072C
0.8
Red
Splice 072, F5
072D
0.8
Red
Splice 072, G2
103
0.8
Org
S8, S9
115A
1.0
Dk Grn
S8, Splice 115
115B
0.8
Dk Grn
X7, Splice 115
115C
0.8
Dk Grn
Splice 115, X22
115D
1.0
Dk Grn
Splice 115, X13
118A
1.0
Gry
F8, Splice 118
118B
0.8
Gry
Splice 118, X13
118C
0.8
Gry
Splice 118, X18
118D
1.0
Gry
Splice 118, X21
119A
1.0
Wht
E6, Splice 119
119B
1.0
Wht
E5, Splice 119
119C
2.0
Wht
Splice 119, F7
119D
0.8
Wht
Splice 119, X6
122A
1.0
Red
S8, Splice 122
122B
3.0
Red
S9, Splice 122
122C
3.0
Red
F3, Splice 122
125A
1.0
Dk Grn
S8, Splice 125
125B
0.8
Dk Grn
X7, Splice 125
125C
0.8
Dk Grn
Splice 125, X19
125D
1.0
Dk Grn
Splice 125, X13
138A
2.0
Gry
S9, Splice 138
138B
2.0
Gry
Splice 138, F7
138C
1.0
Gry
Splice 138, F8
143
2.0
Org
S9, F6
147A
2.0
Pur
F6, Splice 147
147B
0.8
Pur
Splice 147, X17
147C
2.0
Pur
Splice 147, X13
147D
0.8
Pur
Splice 147, X16
002C
5.0
Red
X1 (Fusible Link),
Splice 002
002D
5.0
Red
Splice 002, F2
010A
1.0
Blk
E6, Splice 010
010B
1.0
Blk
E5, Splice 010
010C
5.0
Blk
W2, Splice 010
010D
0.8
Blk
DB1-7, W2
010E
0.5
Blk
DB1-7, K2(85)
010F
0.5
Blk
K2(85), K3(85)
010G
0.8
Blk
Splice 010, X20
010H
0.8
Blk
Splice 010, X17
010J
2.0
Blk
Splice 010, X13
010K
0.8
Blk
Splice 010, X16
010L
0.8
Blk
Splice 010, X23
010N
1.0
Blk
X4, Splice 010
010P
1.0
Blk
Splice 010, W2
010T
(–)
Therm.
K3(85), R2
012
5.0
Red
S1, F1
050A
2.0
Blk
W2, Splice 050
050B
0.5
Blk
K1(85), W2
050C
0.5
Blk
K1(85), K4(85)
050D
0.5
Blk
K4(85), K5(85)
050E
0.5
Blk
K5(85), K6(85)
050F
0.5
Blk
K6(85), K7(85)
050G
0.5
Blk
K7(85), K8(85)
050H
0.5
Blk
K8(85), K9(85)
050J
0.8
Blk
Splice 050, X9
050K
1.0
Blk
Splice 050, X6
050L
0.5
Blk
B1, Splice 050
4/6/01
4 - 21
WIRE COLOR CODES (NEW)
ELECTRICAL - NORTH AMERICAN
Circuit
Number
Wire
Size
Color
Termination
Points
Circuit
Number
Wire
Size
Color
Termination
Points
209
0.8
Wht
X9, S1
556
0.5
Lt Blu
K6(86), DB1- 2
212
0.5
Red
K7(86), S1
562A
0.8
Red
F5, Splice 562
222
2.0
Red
K7(87), X13
562B
0.5
Red
K9(30), Splice 562
238
0.8
Gry
X9, K8(86)
562C
0.5
Red
Splice 562, S7
247
0.8
Pur
X9, K8(87)
562D
0.5
Red
S5, Splice 562
252
2.0
Red
K7(30), F2
562E
0.5
Red
Splice 562, S2
264A
0.8
Yel
K8(30), X9
562F
0.5
Red
Splice 562, X5
264B
0.8
Yel
K8(30), X6
562H
0.5
Red
Splice 562, X24
302A
1.0
Red
DB1- 8, Splice 302
572A
1.0
Red
S1, K2(30)
302B
1.0
Red
K4(87), Splice 302
572B
0.8
Red
K2(30), DB1- 3
302C
1.0
Red
Splice 302, X4
573A
0.5
Org
Splice 573, S5
309
1.0
Wht
K2(87), M1
573B
0.5
Org
V2, Splice 573
319
(+)
Therm.
K3(87a), R2
573C
0.5
Org
K9(86), Splice 573
325
0.8
Dk Grn
X6, G2
574
0.5
Yel
K9(87a), X7
329A
1.0
Wht
X4, K3(30)
586
0.5
Lt Blu
S7, X6
329B
1.0
Wht
K3(30), K3(86)
587A
0.5
Pur
X2, Splice 587
334
0.8
Yel
X7, G2
587B
0.5
Pur
V2, Splice 587
347
0.5
Pur
X6, B2
587C
0.5
Pur
K5(86), Splice 587
353
0.5
Org
X6, B1
587D
0.5
Pur
K6(30), Splice 587
359
0.5
Wht
X6, B3
594
0.5
Yel
S7, X5
383
3.0
Org
K1(87), R1
385A
0.8
Dk Grn
X7, Splice 385
385B
0.8
Dk Grn
Splice 385, S1
385C
0.5
Dk Grn
Splice 385, K1(86)
505
0.5
Dk Grn
X2, X3
518A
0.5
Gry
DB1- 6, K2(86)
518B
0.5
Gry
K2(86), X2
521
0.5
Brn
K4(86), DB1- 5
533
0.5
Org
K5(87), K6(87a)
539A
0.5
Wht
DB1- 1, DB1- 4
539B
0.5
Wht
DB1- 4, S2
546
0.5
Lt Blu
K5(30), S7
4 - 22
4/6/01
TROUBLESHOOTING
ELECTRICAL - NORTH AMERICAN
Check ground circuit
●
Test battery and battery
connections
●
●
●
●
●
See Manifold Heater Circuit
Diagnosis
●
See Fuel Supply Circuit
Diagnosis
●
●
See Charging Circuit
Diagnosis
●
See Control Panel Indicator
Diagnosis
●
4/6/01
●
●
●
●
●
●
See Lights Circuit Diagnosis
Check for shorted circuit
Fuel gauge does not work properly
●
Headlight problem
See Cranking Circuit
Diagnosis
Instrument lights problems
●
Engine will not run when operator
leaves seat
●
Engine coolant temperature light
problem
See Engine Shutoff Circuit
Diagnosis
Discharge light problem
●
Battery goes dead, discharges or
overcharges
●
Engine oil light problem
Engine cranks but will not start
See Power Circuit Diagnosis
Check or
Solution
Improper component operating with
switch
Starter cranking problems
Problem or
Symptom
Engine will not shut off
TROUBLESHOOTING
●
●
●
4 - 23
THEORY AND DIAGNOSIS
THEORY AND DIAGNOSIS
POWER CIRCUIT OPERATION
Function:
Provides unswitched and switched power to the
primary components whenever the battery is
connected.
The power circuits are divided among the unswitched
power circuit, switched power circuits (key switch in
RUN, START, or AID positions), and secondary power
circuits. The secondary power circuits become
energized when switched power circuits energize
relays, providing current paths to the secondary
circuits. The secondary power circuits will not be
energized if the relays controlling the current path(s)
fail.
Detailed Theory of Operation, Schematics, and
Troubleshooting of circuits are provided throughout the
electrical section.
Unswitched Power:
Voltage must be present at the following components
with the key switch in the OFF position:
• Battery Positive Terminal
• Starting Motor Terminal B
• F1 Fuse
• Key Switch Terminal 1
• Alternator Terminal B
• Manifold Heater Relay Terminal 30
• Engine Run Relay Terminal 30
• F3 Fuse
• Light Switch Terminal B
• Turn Signal Switch Terminal 2
• F2 Fuse
• Accessory Relay Terminal 30
The positive battery cable connects the battery to the
starting motor. The starting motor bolt is used as the 12
Volt DC tie point for the rest of the electrical system.
The battery cables and the starting motor tie point
connections must be good for the vehicle electrical
system to work properly. The ground cable and positive
cable connections are equally important. Proper
starting motor operation depends on these cables and
connections to carry high current.
With the exception of the B terminal of the alternator,
the electrical circuit is protected by the fusible link
beyond the starting motor tie point. The fusible link is a
short piece of wire that is designed to fail if current load
is too high or a short occurs.
ELECTRICAL - NORTH AMERICAN
RUN ("ON") position, transmission in NEUTRAL,
PTO(s) in NEUTRAL, park brake ENGAGED, and
operator NOT ON seat:
• Key Switch Terminals 3, 4, and 5
• Alternator Terminal IG
• F5 Fuse
• Rear PTO Switch
• K9 Rear PTO Relay Terminals 86 and 30
• X5 Connector (562F Red wire)
NOTE: X5 connector has jumper wire installed unless
Mid PTO option is installed.
• Park Brake Switch Terminals A, B, C and D
• K5 Safety Relay Terminals 86 and 30
• K6 Safety Relay Terminal 30
• Seat Switch
• X9 Connector Terminal A
• Cruise Control Switch
• X6 Connector Terminals A and K
• X7 Connector Terminal A
• Accessory Relay Terminal 86
• X2 Connector (573A Org wire); or, X3 Connector
(505 Dk Grn wire)
NOTE:
The S4 Transmission Neutral Switch is
installed in collar shift gear drive (CST)
tractors; a jumper wire is installed in the X2
connector, and the S3 Transmission Neutral
Switch is not used.
In hydrostatic drive (HST) and SyncReverser™
(SRT) tractors the S3 Transmission Neutral
Switch is used, and a jumper wire is installed in
the X3 connector - eliminating the S4 switch.
• Start Relay Terminal 86
• Diode Block Terminal 6
• Engine Run Relay Terminal 86
Secondary Switched Power - Run:
Voltage must be present at the following components
with the key switch in the RUN ("ON") position,
transmission in NEUTRAL, PTO(s) in NEUTRAL, park
brake ENGAGED, and operator NOT ON seat:
• K5 Safety Relay Terminal 87
• K6 Safety Relay Terminal 87a
• Engine Run Relay Terminal 87
• X4 Connector (302C Red wire)
Switched Power - Run:
Switched Power - Aid:
In addition to the voltage present at the locations of the
unswitched power circuits, voltage must be present at
the following components with the key switch in the
Voltage must be present at the following components
with the key switch in the AID position (key pushed in
4 - 24
4/6/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
209 Wht
4 209 Wht
072A Red
F1
Fuse
072A Red
3 212 Red
A
7
072C
Red
385B
Dk Grn
Start
Run
Off
Acc.
562B
Red
562D Red
F5 Fuse
385A Dk Grn
A
562A Red
385C
Dk Grn
C
(Operator On)
S1 Key
Switch
X5
518A Gry
6
X1
85
K4
Engine
Run
Relay
S17 Mid PTO
Switch (Option)
On Off
86
30
85
87 87A
85
518B Gry
30
87A 87
X3
X3
Org
85
K2 Start
Relay
Pedal Depressed
587A Org
Dk Grn
X2
S3 Transmission
Neutral Switch (HST & SRT)
X2
86
S4 Transmission
Neutral Switch (CST Only)
302B
Red
7
R1 Manifold
Heater
M
M1
Starting
Motor
Red
86
8 302A Red
85
302C
Red
1/31/01
87 87A
A
X7
X6
2
3
S8 Turn
Signal Switch
4
S9 Light
Switch
K7
Accessory
Relay
222
Red
A
X14 Trailer
Connector
+
_
H4
Discharge
Light
587D Org
t0
Q
P3
Fuel
Gauge
H7 Oil
Pressure
Light
P4 Engine
Coolant
Temperature
Gauge
C
J
E
587C
Org
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
X6
K6
Safety
Relay
353
Org
Q
On
Wht
X6
X6
347
Pur
359
Wht
546 Lt Blu
A
562C Red
B
D
586 Lt Blu
586 Lt Blu
SE2 - IGNITION
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
P
H6 Park
Brake
Light
Control Panel Circuit Board
SE3 - CHARGING
4 - 25
t0
C
S7 Park
Brake Switch
Secondary Switched Power
P
B1 Fuel
Gauge
Sensor
Off
594 Yel
Switched Power
122B Red
B
533 Org
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
85
X4
Y1
Starting
Motor
Solenoid
Unswitched Power
A
587B
Org
B
V1
Diode
Block
Off
On
Engage
S10 Cruise
Control
Switch
594
Yel
505 Dk Grn
30
072A
Red
X10
122A Red
Wht
In Neutral
In Gear
383
Org
86
334
Yel
Wht
K9 Rear
PTO Relay
Pedal Released
87 87A
X9
87 87A
2
3
212 252
Red Red
G2
Alternator
30
1
4
V2
Diode
002E
Red
521 Brn
5
V1 Diode
Block
30
K1 Manifold
Heater
Relay
Fusible
Link
X5
S2 Seat
Switch
002E Red
002C
Red
002B Red
86
L
A
H5 Cold
Start
Light
(2) Road
(3) Field
IG
B
573C 562B
Org Red
573B
Org
(Operator Off)
X7
86
S5 Rear
PTO Switch
562C Red
F2
Fuse
B
573A Org
G
562E Red
A
072D
Red
002A
Red
562F Red
B
Aid
Off
002A
Red
Off
On
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
5 072B Red
2
B
002D
Red
212 Red
6
012 Red 1
122C Red
B
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
209 Wht
4 209 Wht
072A Red
F1
Fuse
072A Red
3 212 Red
A
7
072C
Red
385B
Dk Grn
Start
Run
Off
Acc.
562B
Red
562D Red
F5 Fuse
385A Dk Grn
A
562A Red
385C
Dk Grn
C
(Operator On)
S1 Key
Switch
X5
518A Gry
6
X1
85
K4
Engine
Run
Relay
S17 Mid PTO
Switch (Option)
On Off
86
30
85
87 87A
85
518B Gry
30
87A 87
X3
X3
Org
85
K2 Start
Relay
Pedal Depressed
587A Org
Dk Grn
X2
S3 Transmission
Neutral Switch (HST & SRT)
X2
86
S4 Transmission
Neutral Switch (CST Only)
302B
Red
7
R1 Manifold
Heater
M
M1
Starting
Motor
Red
86
8 302A Red
85
302C
Red
1/31/01
87 87A
A
X7
X6
2
3
S8 Turn
Signal Switch
4
S9 Light
Switch
K7
Accessory
Relay
222
Red
A
X14 Trailer
Connector
+
_
H4
Discharge
Light
587D Org
t0
Q
P3
Fuel
Gauge
H7 Oil
Pressure
Light
P4 Engine
Coolant
Temperature
Gauge
C
J
E
587C
Org
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
X6
K6
Safety
Relay
353
Org
Q
On
Wht
X6
X6
347
Pur
359
Wht
546 Lt Blu
A
562C Red
B
D
586 Lt Blu
586 Lt Blu
SE2 - IGNITION
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
P
H6 Park
Brake
Light
Control Panel Circuit Board
SE3 - CHARGING
4 - 25
t0
C
S7 Park
Brake Switch
Secondary Switched Power
P
B1 Fuel
Gauge
Sensor
Off
594 Yel
Switched Power
122B Red
B
533 Org
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
85
X4
Y1
Starting
Motor
Solenoid
Unswitched Power
A
587B
Org
B
V1
Diode
Block
Off
On
Engage
S10 Cruise
Control
Switch
594
Yel
505 Dk Grn
30
072A
Red
X10
122A Red
Wht
In Neutral
In Gear
383
Org
86
334
Yel
Wht
K9 Rear
PTO Relay
Pedal Released
87 87A
X9
87 87A
2
3
212 252
Red Red
G2
Alternator
30
1
4
V2
Diode
002E
Red
521 Brn
5
V1 Diode
Block
30
K1 Manifold
Heater
Relay
Fusible
Link
X5
S2 Seat
Switch
002E Red
002C
Red
002B Red
86
L
A
H5 Cold
Start
Light
(2) Road
(3) Field
IG
B
573C 562B
Org Red
573B
Org
(Operator Off)
X7
86
S5 Rear
PTO Switch
562C Red
F2
Fuse
B
573A Org
G
562E Red
A
072D
Red
002A
Red
562F Red
B
Aid
Off
002A
Red
Off
On
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
5 072B Red
2
B
002D
Red
212 Red
6
012 Red 1
122C Red
B
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
209 Wht
4 209 Wht
072A Red
F1
Fuse
072A Red
3 212 Red
A
7
072C
Red
385B
Dk Grn
Start
Run
Off
Acc.
562B
Red
562D Red
F5 Fuse
385A Dk Grn
A
562A Red
385C
Dk Grn
C
(Operator On)
S1 Key
Switch
X5
518A Gry
6
X1
85
K4
Engine
Run
Relay
S17 Mid PTO
Switch (Option)
On Off
86
30
85
87 87A
85
518B Gry
30
87A 87
X3
X3
Org
85
K2 Start
Relay
Pedal Depressed
587A Org
Dk Grn
X2
S3 Transmission
Neutral Switch (HST & SRT)
X2
86
S4 Transmission
Neutral Switch (CST Only)
302B
Red
7
R1 Manifold
Heater
M
M1
Starting
Motor
Red
86
8 302A Red
85
302C
Red
1/31/01
87 87A
A
X7
X6
2
3
S8 Turn
Signal Switch
4
S9 Light
Switch
K7
Accessory
Relay
222
Red
A
X14 Trailer
Connector
+
_
H4
Discharge
Light
587D Org
t0
Q
P3
Fuel
Gauge
H7 Oil
Pressure
Light
P4 Engine
Coolant
Temperature
Gauge
C
J
E
587C
Org
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
X6
K6
Safety
Relay
353
Org
Q
On
Wht
X6
X6
347
Pur
359
Wht
546 Lt Blu
A
562C Red
B
D
586 Lt Blu
586 Lt Blu
SE2 - IGNITION
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
P
H6 Park
Brake
Light
Control Panel Circuit Board
SE3 - CHARGING
4 - 25
t0
C
S7 Park
Brake Switch
Secondary Switched Power
P
B1 Fuel
Gauge
Sensor
Off
594 Yel
Switched Power
122B Red
B
533 Org
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
85
X4
Y1
Starting
Motor
Solenoid
Unswitched Power
A
587B
Org
B
V1
Diode
Block
Off
On
Engage
S10 Cruise
Control
Switch
594
Yel
505 Dk Grn
30
072A
Red
X10
122A Red
Wht
In Neutral
In Gear
383
Org
86
334
Yel
Wht
K9 Rear
PTO Relay
Pedal Released
87 87A
X9
87 87A
2
3
212 252
Red Red
G2
Alternator
30
1
4
V2
Diode
002E
Red
521 Brn
5
V1 Diode
Block
30
K1 Manifold
Heater
Relay
Fusible
Link
X5
S2 Seat
Switch
002E Red
002C
Red
002B Red
86
L
A
H5 Cold
Start
Light
(2) Road
(3) Field
IG
B
573C 562B
Org Red
573B
Org
(Operator Off)
X7
86
S5 Rear
PTO Switch
562C Red
F2
Fuse
B
573A Org
G
562E Red
A
072D
Red
002A
Red
562F Red
B
Aid
Off
002A
Red
Off
On
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
5 072B Red
2
B
002D
Red
212 Red
6
012 Red 1
122C Red
B
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
122C Red
B
4
012 Red 1
6
2
5
B
002D
Red
072A Red
F1
Fuse
072A Red
3
A
7
072C
Red
Start
Run
Off
Acc.
572A
Red
F5 Fuse
A
On
573A Org
562D Red
562A Red
G
S5 Rear
PTO Switch
562C Red
562E Red
Aid
Off
X5
(Operator On)
86
S1 Key
Switch
002E Red
002A
Red
002C
Red
002B Red
572B Red 3
2
518A Gry 6
5
X5
87 87A
85
K1 Manifold
Heater
Relay
518B Gry
30
Dk Grn
K4
Engine
Run
Relay
In Neutral
In Gear
Org
X3
30
85
87 87A
309 Wht
K2 Start
Relay
Org
505 Dk Grn
A
A
X7
X6
_
X2
S3 Transmission
Neutral Switch (HST & SRT)
86
8 302A Red
85
302C
Red
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
K6
Safety
Relay
J
E
353
Org
X6
X6
347
Pur
359
Wht
546 Lt Blu
562C Red
D
A
P
B1 Fuel
Gauge
Sensor
Off
586 Lt Blu
586 Lt Blu
t0
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
C
B
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
C
Q
594 Yel
Switched Power
P4 Engine
Coolant
Temperature
Gauge
X6
On
Unswitched Power
H7 Oil
Pressure
Light
533 Org
Wht
Y1
Starting
Motor
Solenoid
P3
Fuel
Gauge
587C
Org
X4
M1
Starting
Motor
t0
Q
H4
Discharge
Light
587D Org
A
M
Red
Pedal Depressed
587A Org
Dk Grn
302B
Red
V1
Diode
Block
K7
Accessory
Relay
072A
Red
+
X2
7
87 87A
587B
Org
Pedal Released
85
85
4
S9 Light
Switch
594
Yel
86
86
87A 87
S6 Mid PTO
Switch (Option)
30
S8 Turn
Signal Switch
V2
Diode
S4 Transmission
Neutral Switch (CST Only)
Fusible
Link
B
X3
87 87A
K9 Rear
PTO Relay
002E
Red
521 Brn
V1 Diode
Block
30
On
86
2
B
334
Yel
556 Lt Blu
X1
86
Off
122B Red
3
252
Red
30
85
S2 Seat
Switch
3
L
G2
Alternator
(Operator Off)
1
2 122A Red
IG
B
573C 562B
Org Red
573B
Org
(2) Road
(3) Field
4
F2
Fuse
B
562F Red
B
A
072D
Red
002A
Red
Off
562B
Red
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
072B Red
S7 Park
Brake Switch
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 26
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
1/31/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
122C Red
B
4
012 Red 1
6
2
5
B
002D
Red
072A Red
F1
Fuse
072A Red
3
A
7
072C
Red
Start
Run
Off
Acc.
572A
Red
F5 Fuse
A
On
573A Org
562D Red
562A Red
G
S5 Rear
PTO Switch
562C Red
562E Red
Aid
Off
X5
(Operator On)
86
S1 Key
Switch
002E Red
002A
Red
002C
Red
002B Red
572B Red 3
2
518A Gry 6
5
X5
87 87A
85
K1 Manifold
Heater
Relay
518B Gry
30
Dk Grn
K4
Engine
Run
Relay
In Neutral
In Gear
Org
X3
30
85
87 87A
309 Wht
K2 Start
Relay
Org
505 Dk Grn
A
A
X7
X6
_
X2
S3 Transmission
Neutral Switch (HST & SRT)
86
8 302A Red
85
302C
Red
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
K6
Safety
Relay
J
E
353
Org
X6
X6
347
Pur
359
Wht
546 Lt Blu
562C Red
D
A
P
B1 Fuel
Gauge
Sensor
Off
586 Lt Blu
586 Lt Blu
t0
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
C
B
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
C
Q
594 Yel
Switched Power
P4 Engine
Coolant
Temperature
Gauge
X6
On
Unswitched Power
H7 Oil
Pressure
Light
533 Org
Wht
Y1
Starting
Motor
Solenoid
P3
Fuel
Gauge
587C
Org
X4
M1
Starting
Motor
t0
Q
H4
Discharge
Light
587D Org
A
M
Red
Pedal Depressed
587A Org
Dk Grn
302B
Red
V1
Diode
Block
K7
Accessory
Relay
072A
Red
+
X2
7
87 87A
587B
Org
Pedal Released
85
85
4
S9 Light
Switch
594
Yel
86
86
87A 87
S6 Mid PTO
Switch (Option)
30
S8 Turn
Signal Switch
V2
Diode
S4 Transmission
Neutral Switch (CST Only)
Fusible
Link
B
X3
87 87A
K9 Rear
PTO Relay
002E
Red
521 Brn
V1 Diode
Block
30
On
86
2
B
334
Yel
556 Lt Blu
X1
86
Off
122B Red
3
252
Red
30
85
S2 Seat
Switch
3
L
G2
Alternator
(Operator Off)
1
2 122A Red
IG
B
573C 562B
Org Red
573B
Org
(2) Road
(3) Field
4
F2
Fuse
B
562F Red
B
A
072D
Red
002A
Red
Off
562B
Red
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
072B Red
S7 Park
Brake Switch
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 26
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
1/31/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
F3 Fuse
002 Fuse Block Internal Link
002 Fuse Block Internal Link
A
122C Red
B
4
012 Red 1
6
2
5
B
002D
Red
072A Red
F1
Fuse
072A Red
3
A
7
072C
Red
Start
Run
Off
Acc.
572A
Red
F5 Fuse
A
On
573A Org
562D Red
562A Red
G
S5 Rear
PTO Switch
562C Red
562E Red
Aid
Off
X5
(Operator On)
86
S1 Key
Switch
002E Red
002A
Red
002C
Red
002B Red
572B Red 3
2
518A Gry 6
5
X5
87 87A
85
K1 Manifold
Heater
Relay
518B Gry
30
Dk Grn
K4
Engine
Run
Relay
In Neutral
In Gear
Org
X3
30
85
87 87A
309 Wht
K2 Start
Relay
Org
505 Dk Grn
A
A
X7
X6
_
X2
S3 Transmission
Neutral Switch (HST & SRT)
86
8 302A Red
85
302C
Red
546 Lt Blu
30
87 87A
587D
Org
K5
Safety
Relay
86
85
30
87 87A
K6
Safety
Relay
J
E
353
Org
X6
X6
347
Pur
359
Wht
546 Lt Blu
562C Red
D
A
P
B1 Fuel
Gauge
Sensor
Off
586 Lt Blu
586 Lt Blu
t0
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
X6 K
C
B
Y2 Fuel
Shutoff
Solenoid
SE1 - STARTING
C
Q
594 Yel
Switched Power
P4 Engine
Coolant
Temperature
Gauge
X6
On
Unswitched Power
H7 Oil
Pressure
Light
533 Org
Wht
Y1
Starting
Motor
Solenoid
P3
Fuel
Gauge
587C
Org
X4
M1
Starting
Motor
t0
Q
H4
Discharge
Light
587D Org
A
M
Red
Pedal Depressed
587A Org
Dk Grn
302B
Red
V1
Diode
Block
K7
Accessory
Relay
072A
Red
+
X2
7
87 87A
587B
Org
Pedal Released
85
85
4
S9 Light
Switch
594
Yel
86
86
87A 87
S6 Mid PTO
Switch (Option)
30
S8 Turn
Signal Switch
V2
Diode
S4 Transmission
Neutral Switch (CST Only)
Fusible
Link
B
X3
87 87A
K9 Rear
PTO Relay
002E
Red
521 Brn
V1 Diode
Block
30
On
86
2
B
334
Yel
556 Lt Blu
X1
86
Off
122B Red
3
252
Red
30
85
S2 Seat
Switch
3
L
G2
Alternator
(Operator Off)
1
2 122A Red
IG
B
573C 562B
Org Red
573B
Org
(2) Road
(3) Field
4
F2
Fuse
B
562F Red
B
A
072D
Red
002A
Red
Off
562B
Red
(0) Off
(1) Hazard
(0) Right
(1) Off
(2) Left
1
Flasher
072D Red
072B Red
S7 Park
Brake Switch
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 26
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
1/31/01
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT ELECTRICAL SCHEMATIC
when placed in the RUN or START position),
transmission in NEUTRAL, PTO(s) in NEUTRAL, park
brake ENGAGED, and operator NOT ON seat:
• Key Switch Terminal 7
• Manifold Heater Relay Terminal 86
These circuits are controlled by the key switch and are
protected by the fusible link and the F1 fuse.
Secondary Switched Power - Aid:
Voltage must be present at the following components
with the key switch in the AID position (key pushed in
when placed in the RUN or START position):
• Manifold Heater Relay Terminal 87
• Manifold Heater
(See "MANIFOLD HEATER OPERATION").
Switched Power - Start:
Voltage must be present at the following components
with the key switch in the START position, transmission
in NEUTRAL, PTO(s) in NEUTRAL, park brake
ENGAGED, and operator NOT ON seat:
• Key Switch Terminals 5 and 6
• Start Relay Terminal 30
• Diode Block Terminal 3
• K6 Safety Relay Terminal 86
• Start Relay Coil (If start criteria are met)
NOTE:
These components are in addition to the
components that would have power with the
key switch in the RUN position. However,
voltage would not be present at the cruise
control switch, or at the accessory relay
(terminal 86) with the key switch in the START
position.
Secondary Switched Power - Start:
Voltage must be present at the following components
with the key switch in the START position, transmission
in NEUTRAL, PTO(s) in NEUTRAL, park brake
ENGAGED, and operator NOT ON seat:
• Start Relay Terminal 87
• Starting Motor Terminal A
See "CRANKING CIRCUIT OPERATION".
4/6/01
4 - 27
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
POWER CIRCUIT DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
If Not Normal
1. Starting motor battery (B)
terminal
Battery voltage
Check cable to battery. Test battery.
2. Alternator (B terminal)
Battery voltage
Check 002A Red cable and
connections.
3. Fuse block (F1 fuse)
Battery voltage
Check fusible link, 002C Red wire and
connections.
4. Fuse block (F3 fuse)
Battery voltage
Check internal fuse connection in load
center (tie to F1 fuse).
5. Fuse block (F2 fuse)
Battery voltage
Check 002D Red wire and connections.
6. Accessory relay socket
Battery voltage
Check F2 fuse, 252 Red wire and
connections.
7. Turn signal switch
Battery voltage
Check F3 fuse, 122C and 122A Red
wires and connections.
8. Light switch
Battery voltage
Check F3 fuse, 122C and 122B Red
wires and connections.
9. Key switch
Battery voltage
Check F1 fuse, 012 Red wire and
connections.
10. Manifold heater relay socket
(terminal 30)
Battery voltage
Check fusible link, 002B Red wire and
connections.
11. Engine run relay socket
(terminal 30)
Battery voltage
Check fusible link, 002E Red wire and
connections.
Test Conditions:
• Key switch in RUN position
• Engine OFF
• Park brake ENGAGED
• Transmission in NEUTRAL
• K2, K5, K6, and K9 relays removed from load center
• PTO DISENGAGED, Rear PTO switch disconnected
12. Key switch
Battery voltage
Test key switch (See "KEY SWITCH
TEST"). Replace switch as necessary.
13. Key switch
Battery voltage
Test key switch (See "KEY SWITCH
TEST"). Replace switch as necessary.
14. Key switch
Battery voltage
Test key switch (See "KEY SWITCH
TEST"). Replace switch as necessary.
15. Fuseblock (F5 fuse)
Battery voltage
Check 072A and 072B Red wires and
connections.
16. Seat switch
Battery voltage
Check F5 fuse, 562A and 562E Red
wires and connections.
17. Park brake switch
Battery voltage
Check 562C Red wire and connections.
4 - 28
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
002A Red
2
002C Red
002B Red
Fusible Link
G2 Alternator
1
M1 Starting Motor
072B Red
G1 Battery
072C Red
3
5
4
1
2
3
15
A
86
30
87A
87
002B Red
B
9
A
85
11
4
10
5
11
6
8
7
12
B
Fuseblock
K1 Manifold Heater Relay
(Socket terminal 30)
6
86
30
87A
87
85
10
252
Red 122C
Red
86
30
87A
87
002E Red
85
K4 Engine Run Relay
(Socket terminal 30)
072B Red
K7 Accessory Relay
(Socket terminal 30)
12
209 Wht
13
212 Red
7
122A Red
14 012 Red
S1 Key Switch
S8 Turn Signal Switch
9
122B Red
8
4/6/01
S9 Light Switch
4 - 29
POWER CIRCUIT DIAGNOSIS
Test/Check Point
ELECTRICAL - NORTH AMERICAN
Normal
If Not Normal
18. X5 to S6 Mid PTO switch
(Option)
Battery voltage
Check 562F Red wire and connections.
19. Park brake switch
Battery voltage
Ensure Mid PTO is DISENGAGED. Test
switch - if installed (See "REAR AND
MID PTO SWITCH TEST"). Check 594
Yel wire and connections.
20. Park brake switch
Battery voltage
Ensure park brake is ENGAGED.Test
park brake switch. (See PARK BRAKE
SWITCH TEST").
21. K5 Safety relay socket
(terminal 30)
Battery voltage
Check 546 Lt Blu wire and connections.
22. K9 Rear PTO relay socket
(terminal 30)
Battery voltage
Check 562B Red wire and connections.
23. Rear PTO switch
Battery voltage
Check 562D Red wire and connections.
Test Conditions:
• S5 rear PTO switch connected to wiring harness
24. Rear PTO switch
Battery voltage
Ensure PTO is DISENGAGED. Test rear
PTO switch. (See "REAR AND MID
PTO SWITCH TEST").
25. K9 Rear PTO relay socket
(terminal 86)
Battery voltage
Check 573A and 573C Org wires and
connections.
NOTE: The following three steps are for Hydrostatic (HST) and SyncReverser (SRT) tractors. The X3 connector
is fitted with a plug and jumper wire. For Collar Shift tractors (CST) tractors see steps 31 and 32.
26. S3 transmission neutral switch
Battery voltage
Check X2 connector. Check 573B Org
wire, V2 diode (See "V2 DIODE TEST"),
587B and 587A Org wires and
connections.
27. S3 transmission neutral switch
Battery voltage
Ensure forward pedal linkage is
depressing switch, adjust switch
position if needed. Test switch. (See
"TRANSMISSION NEUTRAL SWITCH
TEST - HST AND SRT").
28. Start relay socket (terminal 86)
Battery voltage
Check 505 Dk Grn wire, X3 connector
and jumper wire, 518B Gry wire and
connections.
29. K5 safety relay socket
(terminal 86)
Battery voltage
Check 587C Org wire and connections.
30. K6 safety relay socket
(terminal 30)
Battery voltage
Check 587D Org wire and connections.
NOTE: The following two steps are for Gear Collar Shift (CST) tractors. The X2 connector is fitted with a plug
and jumper wire. For Hydrostatic (HST) and SyncReverser (SRT) tractors see step 26.
4 - 30
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
A
1
B
3
2
9
A
6
5
4
10
11
7
S2 Seat Switch
8
12
B
Fuseblock
562E Red
562A
Red
562E Red
16
562C Red
S5 Rear
PTO Switch
562D Red
562F
Red
562B
Red
24 573A
Org
23
19
594 Yel
573C Org
25
18
22
S7 Park Brake Switch
86
85
546
Lt Blu
K9 Rear PTO Relay
(Socket terminal 30 & 86)
V2
Diode
17
30
87A
87
573B
Org
20
587B
Org
X5 to S6 Mid PTO
Switch (Option)
HST and SRT
Power Circuit
X3
505 Dk Grn
587A Org
587D Org
Plug and
Jumper Wire
X2
587C
Org
546
Lt Blu
518B
Gry
86
29
30
86
85
S3 Transmission Neutral
Switch (HST & SRT)
87A
26
87
85
K6 Safety Relay
(Socket terminal 30)
30
85
30
87A
87
30
27
K5 Safety Relay
(Socket terminal 30 & 86)
4/6/01
87A
86
87
21
28
K2 Start Relay
(Socket terminal 86)
4 - 31
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
Test/Check Point
Normal
If Not Normal
31. S3 Transmission neutral switch
Battery voltage
Check 587A Org wire, X2 connector
and jumper wire, 505 Dk Grn wire, and
X3 connector and connections.
32. Start relay socket (terminal 86)
Battery voltage
Check 505 Dk Grn wire, X2 connector
and jumper wire, 518B Gry wire and
connections.
Test Conditions:
• V1 diode block removed from load center
33. Diode block socket (terminal 6)
Battery voltage
Check 518A Gry wire and connections.
Test Conditions:
• V1 diode block installed in load center
34. Engine run relay socket
(terminal 86)
Battery voltage
Ensure diode block is fully seated.Test
diode block (See "DIODE BLOCK
TEST"). Check 521 Brn wire and
connections.
35. X6 connector to control panel
Battery voltage
Check 072B and 072A Red wires and
connections.
36. Park brake switch
Battery voltage
Ensure park brake is ENGAGED.Test
switch (See "PARK BRAKE SWITCH
TEST"). Check 562C Red wire and
connections.
37. X6 connector to control panel
Battery voltage
Check 586 Lt Blu wire and connections.
38. Alternator IG Terminal
Battery voltage
Check 072B and 072D Red wires and
connections.
39. Key switch
Battery voltage
Test key switch. (See "KEY SWITCH
TEST").
40. X9 connector
Battery voltage
Check 209 Wht wire and connections.
Test Conditions: Secondary Power
NOTE: The following test is the fuel shutoff solenoid that receives power after the K4 relay is activated when
voltage is provided to the relay coil. The circuit needs to have the K4 relay in place to perform this test.
For further detail see "FUEL SUPPLY OPERATION".
• Key switch in RUN position
• Engine OFF
• Park brake ENGAGED
• Transmission in NEUTRAL
• PTO DISENGAGED
41. X4 connector to fuel shutoff
solenoid
Battery voltage
Battery voltage cannot be
tested at the diode block
socket. The diode block needs
to be installed to energize the
engine run relay coil.
4 - 32
Ensure K4 engine run relay coil is
powered. See step 34. Check relay.
(See "RELAY TEST") Check 302B and
302C Red wires and connections.
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
V1 Diode Block
(Socket terminal 6)
X2
1
4
7
587A Org
Plug and
Jumper Wire
5
302A Red
Gear (CST) Power Circuit
2
8
3
6
9
505
Dk Grn
518A Gry
S3 Transmission Neutral
Switch Connector (CST)
X3
33
518B Gry
34
521
Brn
86
31
32
30
87A
86
87A
87
K2 Start Relay
(Socket terminal 86)
85
K4 Engine Run Relay
(Socket terminal 86)
30
85
302C
Red
87
302B Red
586 Lt Blu
41
562C Red
S7 Park Brake Switch
X4 To W2 Fuel Shutoff
Solenoid Wiring Harness
35
36
072A
Red
37
072B
Red
S1 Key Switch
39
X6-W1 Main Wiring Harness
To Control Panel
072D Red
209 Wht
G2 Alternator
Connector
072C
Red
38
A
1
B
A
2
9
3
10
4
5
11
6
7
G2 Alternator
8
12
40
B
209 Wht
Fuseblock
X9 To W4 Cruise
Control Wiring Harness
562A Red
4/6/01
562C Red
4 - 33
CRANKING CIRCUIT OPERATION
ELECTRICAL - NORTH AMERICAN
CRANKING CIRCUIT OPERATION
MANIFOLD HEATER OPERATION
Function:
Function:
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
To provide an added source of heat for combustion.
Operating Conditions:
Operating Conditions:
• Key switch in START position
• Transmission in NEUTRAL
• Rear PTO DISENGAGED (disengages mid PTO)
Theory of Operation:
The power circuit (fusible link, 002C Red wire, F1 fuse,
and 012 Red wire) provides voltage to the key switch.
When placed in the START position, the key switch
provides current to the start relay contact (572A Red to
terminal 30 of start relay).
The start relay coil is energized through a circuit
consisting of: the key switch (terminal 5), 072B and
072C Red wires, F5 fuse, 562A and 562D Red wires,
PTO switch (OFF position), 573A and 573B Org wires,
V2 diode, 587B and 587A Org wires, X2 (with jumper
wire), 505 Dk Grn wire, S4 transmission neutral switch,
and 518B Gry wire on CST tractors; or, 587A Org wire
to S3 transmission neutral switch, 505 Dk Grn wire, X3
(with jumper wire), and 518B Gry wire on HST and
SRT tractors.
NOTE:
The S4 Transmission Neutral Switch is
installed in collar shift gear drive (CST)
tractors; a jumper wire is installed in the X2
connector, and the S3 Transmission Neutral
Switch is not used.
In hydrostatic (HST) and SyncReverser (SRT)
tractors the S3 Transmission Neutral Switch is
used, and a jumper wire is installed in the X3
connector - eliminating the S4 switch.
When the start relay coil is energized, the K2 relay
contacts close and current flows to the starting motor
solenoid (309 Wht).
• Key switch must be in the START or RUN position
and pushed in to the AID position.
Theory of Operation:
The ignition system is designed to inject diesel fuel into
the piston cylinder where heat from compression
ignites the fuel and air mixture.
When starting a cold engine, compression may not
provide enough heat to ignite the fuel. The manifold
heater is installed to provide added heat to the
incoming combustion air.
The manifold heater is energized (heated) when the
key switch is placed in the AID position (key pushed
into switch). The key can be pushed into the AID
position with the key in either the START or RUN
position. The manifold may be preheated by pushing in
the key, with the switch in the RUN position, for up to 3
seconds before turning the key to the START position.
When the key switch is in the AID position, current is
provided to the K1 manifold heater relay coil (terminal
86) through the 385B and 385C Dk Grn wires. When
the relay coil is energized, the relay contacts close and
unswitched power (002B Red wire - terminal 30) flows
through the contacts and 383 Org wire to the manifold
heater.
The H5 cold start indicator light in the control panel
provides a visual indication that the key is in the AID
position and the manifold heater relay is being
energized. The indicator lamp is powered through the
385B and 385A Dk Grn wires, X7 connector (terminal
C), and control panel circuit board. (See "CONTROL
PANEL INDICATOR LIGHTS").
With the starting motor solenoid energized, the starting
motor solenoid contacts close and high current from
the battery passes through the battery cable and
solenoid contacts to the starting motor. The starting
motor cranks the engine.
c
CAUTION
To avoid injury, ALWAYS engage park brake
when starting the engine.
4 - 34
4/6/01
CRANKING CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
CRANKING CIRCUIT ELECTRICAL SCHEMATIC
S1 Key
Switch
4
012 Red
1
B
Off
6 572A Red
5 072B Red
2
F1
Fuse
A
3
On
F5 Fuse
072C Red
562A Red
B
V2
Diode
Start
Run
Off
Acc.
002C
Red
HST or SRT Tractor Circuit
Pedal Released
Pedal Depressed
Aid
Off
587B
Org
505 Dk Grn
002B Red
S3 Transmission
Neutral Switch
Jumper
Wire
572A Red
86
87A 87
85
587A
Org
X3
587A Org
518B
Gry
518B Gry
30
X2
X3
X3
Fusible
Link
573B
Org
S5 Rear
PTO Switch
7 385B Dk Grn
A
573A Org
562D Red
587A
Org
X2
518B
Gry
K2
Start
Relay
Jumper
Wire
In Neutral
X2
In Gear
505 Dk Grn
309
Wht
B
010E
Blk
X3
X3
S4 Transmission
Neutral Switch
A
V1
Diode
Block
CST Tractor Circuit
7
M
385A Dk Grn
M1
Starting
Motor
Y1
Starting
Motor
Solenoid
385C
002B
Dk Grn Red
010D
Blk
X7
C
K1
Manifold
Heater
Relay
Red
383
Org
R1 Manifold
Heater
G1
Battery
H5 Cold
Start
Light
Blk
010C Blk
050A Blk
050B Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE2 - IGNITION
4 - 35
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
CRANKING CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Key switch in OFF position
Test/Check Point
1. Key switch
Test Conditions:
• Park brake ENGAGED
• Transmission in NEUTRAL
• K1 start relay unplugged
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
Battery voltage
If Not Normal
Check 200 Red wire and F1 fusible link. (See
"POWER CIRCUIT DIAGNOSIS")
• S5 rear PTO switch disconnected from main wiring harness
• PTO DISENGAGED
• Key switch in START position
2. Key switch
Battery voltage
Test switch. (See "KEY SWITCH TEST")
Replace key switch as necessary.
3. F5 fuse
Battery voltage
Check 072B and 072C Red wires and
connections.
4. Rear PTO switch connector
Battery voltage
Check F5 fuse and 562A and 562D Red wires
and connections.
Test Conditions:
• S5 rear PTO switch connected to wiring harness
5. Transmission neutral switch
Battery voltage
Ensure PTO is DISENGAGED. Check 573A and
573B Org wires, V2 diode (See "V2 DIODE
TEST"), 587B and 587A Org wires, and X2
connector. (X2 connector/jumper wire and 505
Dk Grn wire for CST tractors)
6. Transmission neutral switch
Battery voltage
Check switch. (See "TRANSMISSION
NEUTRAL SWITCH TEST - HST AND SRT");
or, (See TRANSMISSION NEUTRAL SWITCH
TEST - CST AND SST"). Adjust or replace
switch as needed.
7. K2 start relay socket (terminal
86)
Battery voltage
Check 505 Dk Grn wire, X3 connector (jumper
wire), and 518B Gry wire and connections.
8. K2 start relay socket (terminal
30)
Battery voltage
Check 572A Red wire and connections.
Test Conditions:
• Park brake ENGAGED
• Transmission in NEUTRAL
• X4 to fuel solenoid wiring harness disconnected
• K1 start relay installed in load center
• PTO DISENGAGED
• Key switch in START position
cCAUTION: Engine may start during this procedure. Disconnect fuel shutoff solenoid.
9. Starting motor
4 - 36
Battery voltage
Check 309 Wht wire and connections. Check K2
start relay. (See "RELAY TEST")
4/6/01
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
002C Red
2
572A Red
3
072B Red
072C Red
F5 Fuse
A
1
1
012 Red
2
3
B
10
6
5
4
7
8
B
S1 Key Switch
A
S3 Transmission
Neutral Switch
(HST & SRT)
HST & SRT Circuit Shown
9
11
12
Fuseblock
5
562A
Red
562D Red
4
6
X2
S5 Rear
PTO Switch
5
587A Org
587B Org
573B Org 573A Org
X3
505 Dk Grn
518B Gry
Plug and
Jumper Wire
V2 Diode
6
572A Red
518B Gry
7
86
30
87A
87
85
M1 Starting Motor
8
K2 Start Relay
002C Red
Fusible Link
9
309 Wht
G1 Battery
W1 Battery Frame Ground
4/6/01
4 - 37
MANIFOLD HEATER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
MANIFOLD HEATER CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Key switch in OFF position
• K1 manifold heater relay removed
Test/Check Point
Normal
If Not Normal
1. Key switch
Battery voltage
(See "POWER CIRCUIT
DIAGNOSIS")
2. Manifold heater relay socket
Battery voltage
Check 002B Red wire and
connections. (See "POWER CIRCUIT
DIAGNOSIS")
Test Conditions:
• Park brake ENGAGED
• K2 start relay removed from load center
• K1 manifold heater relay removed from load center
• Key switch in RUN position; key in AID position (pushed in)
3. Key switch
Battery voltage
Check key switch. (See "KEY
SWITCH TEST"). Replace switch as
needed.
4. Manifold heater relay socket
Battery voltage while key switch
is in AID position
Check 385B and 385C Dk Grn wires
and connections.
Test Conditions:
• Park brake ENGAGED
• K1 manifold heater relay installed in load center
• Key switch in RUN position; key in AID position (pushed in)
5. Manifold heater
Battery voltage
Check 383 Org wire and connections.
Check K1 relay. (See "RELAY TEST").
Replace relay as needed.
Test Conditions:
• Park brake ENGAGED
• Meter set to ohm scale
• Meter negative lead connected to frame ground
• Key switch in OFF position
6. Manifold heater module
4 - 38
Maximum 0.1 ohm resistance
Check manifold heater element.
Replace manifold heater as needed.
4/6/01
MANIFOLD HEATER CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S1 Key Switch
3
385B Dk Grn
1
012 Red
385B
Dk Grn
4
R1 Manifold Heater
385C
Dk Grn
5 6
86
2
30
87
87A
002B Red
383 Org
85
K1 Manifold Heater
Relay Socket
383 Org
B
F1
Fuse
A
002C Red
002B Red
Fusible Link
M1 Starting Motor
G1 Battery
W1 Battery Frame Ground
4/6/01
4 - 39
FUEL SUPPLY OPERATION
FUEL SUPPLY OPERATION
Function:
To start or stop the supply of fuel to the engine.
Operating Conditions (Starting Tractor):
• Key switch must be in the START position.
• Operator ON seat
• PTO DISENGAGED
• Transmission in NEUTRAL
Operating Conditions (Running Tractor):
• Key switch must be in the RUN position.
• Operator ON seat
• PTO ENGAGED
• Transmission in any GEAR
Operating Conditions (Running Tractor):
• Key switch must be in the RUN position.
• Operator ON seat
• PTO DISENGAGED
• Park brake ENGAGED
Operator can leave seat. (See "ENGINE SHUTOFF
CIRCUIT OPERATION")
• PTO can be ENGAGED
Fuel Supply Theory of Operation
The fuel system is designed to inject fuel into the piston
cylinder where heat from compression ignites the fuel
and air mixture.
Fuel is provided to the engine when the fuel shutoff
solenoid is energized. The fuel shutoff solenoid
contains two coils to open the fuel valve. The pull-in
coil, in conjunction with the hold-in coil, overcomes the
spring loaded fuel valve. The hold-in coil keeps the fuel
valve open after the pull-in coil current is reduced
through the R2 thermistor.
The fuel shutoff solenoid is initially energized and
pulled in when the engine run relay contacts close.
Voltage is provided to both of the fuel shutoff solenoid
coils (pull-in and hold-in), which provide enough pull on
the solenoid plunger to overcome the shutoff solenoid
spring.
The fuel shutoff solenoid pull-in coil needs a high
current pulse through it to overcome the solenoid
spring. After the solenoid opens (overcomes the
spring) a lower current will hold the solenoid open. The
combination of the K3 fuel shutoff relay and R2 variable
thermistor provide a means to reduce the current flow
through the fuel shutoff solenoid pull-in coil after the
solenoid opens.
4 - 40
ELECTRICAL - NORTH AMERICAN
The initial high current flows through the 329A Wht wire
to the K3 fuel pull-in relay (terminal 30), through the
contacts, and through the 319 Wht wire to the R2
variable thermistor. The thermistor has a low
resistance to the current initially (lower than the
resistance through the K3 fuel shutoff relay coil). As the
current flows through the thermistor, it heats up and the
resistance through it increases (higher than the
resistance through the K3 fuel shutoff relay coil).
While the current flow through the thermistor is
reduced, the voltage difference across the thermistor is
increased. When the voltage difference is increased
enough to activate the coil of the K3 fuel shutoff relay
(329B Wht), the coil opens the relay contacts and the
variable thermistor is removed from the circuit.
NOTE: The variable thermistor will heat to a maximum
temperature of approximately 180° F (82° C)
during the brief period of time required to
overcome the fuel shutoff solenoid spring.
With the thermistor removed from the circuit, a ground
path is provided for the fuel shutoff solenoid pull-in coil
through the 329A and 329B Wht wires, the fuel shutoff
relay coil, and the 010F, 010E, 010D and 010C Blk
wires. A ground path for the fuel shutoff solenoid holdin coil is provided through the 010N Blk wire.
A latching circuit is provided to maintain voltage to the
engine run relay after the PTO is ENGAGED. The
latching circuit is energized only if the operator is OFF
the seat, the PTO is DISENGAGED, and the park brake
is ENGAGED. The latching circuit remains energized,
while the park brake is ENGAGED, after the PTO is
ENGAGED. This circuit allows the operator to leave the
seat, with the park brake ENGAGED and the
transmission in NEUTRAL, and then ENGAGE the
PTO.
(See
"ENGINE
SHUTOFF
CIRCUIT
OPERATION").
Fuel is provided to the engine through the Y2 fuel
shutoff solenoid, provided that operating conditions are
met. If the operating criteria are not met, the engine run
relay opens and stops voltage energizing the fuel
shutoff solenoid coils. The fuel shutoff solenoid closes
and fuel to the engine is shut off. (See "ENGINE
SHUTOFF CIRCUIT OPERATION").
NOTE: The S3 transmission neutral switch is shown in
this diagnostic section. This switch is used, in
conjunction with the jumper wire in the X3
connector, for tractors with a hydrostatic (HST)
or SyncReverser (SRT) transmission. For
tractors with a gear shift transmission (CST), a
jumper wire is used in the X2 connector and
the S4 transmission neutral switch is used in
the X3 connector.
4/6/01
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in START position
PTO DISENGAGED
Transmission in NEUTRAL
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red
1
B
2
Off
6
F5 Fuse
5 072B Red
F1
Fuse
072C Red
A
562A Red
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
S5 Rear
PTO Switch
573B
Org
A
X5
Jumper Wire
B
(Operator Off)
Aid
Off
X5
V1 Diode
Block
(Operator On)
5
587B
Org
594
Yel
539B Wht 4
002C
Red
V2
Diode
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
X2
S3 Transmission
Neutral Switch
(HST & SRT)
85
587D Org
7
8 302A Red
K4
Engine
Run
Relay
Y2 Fuel
Shutoff
Solenoid
Red
G1
Battery
Blk
010C Blk
85
87 87A
Off
050C
Blk
546 Lt Blu
Blk
Wht
X4
010D
Blk
30
On
Wht
010F
Blk
86
594
Yel
X4
M1 Starting
Motor
329A
Wht
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
002E
Red
302B Red
302C
Red
M
521
Brn
V1
Diode
Block
010E
Blk
B
587C Org
587A Org
X2
X3
587B
Org
556
Pedal Released Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
X4
329B
Wht
30
86
587D Org
87A 87
319
Wht
010T
Blk
K5
Safety
Relay
86
30
85
87 87A
556 Lt Blu
85
010F
Blk
587C
Org
S7 Park
Brake Switch
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
Powered Circuits
SE2 - IGNITION
4 - 41
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in RUN position
PTO ENGAGED
Transmission ENGAGED
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red 1
F5 Fuse
5 072B Red
2
B
Off
6
F1
Fuse
072C Red
A
562A Red
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
S5 Rear
PTO Switch
573B
Org
A
X5
V2
Diode
Jumper Wire
B
(Operator Off)
(Operator On)
Aid
Off
X5
V1 Diode
Block
539B Wht 4
002C
Red
5
587B
Org
594
Yel
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
X2
K4
Engine
Run
Relay
V1
Diode
Block
010E
Blk
7
8 302A Red
X4
Y2 Fuel
Shutoff
Solenoid
Red
G1
Battery
Blk
010C Blk
329A
Wht
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
85
87 87A
Off
050C
Blk
Blk
X4
010D
Blk
30
On
546 Lt Blu
Wht
010F
Blk
86
594
Yel
Wht
M1 Starting
Motor
002E
Red
302B Red
302C
Red
M
521
Brn
S3 Transmission
Neutral Switch
(HST & SRT)
85
B
587C Org
587A Org
587D Org
X2
X3
587B
Org
556
Pedal Released
Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
X4
329B
Wht
30
86
87A 87
319
Wht
85
S7 Park
Brake Switch
587D Org
010T
Blk
010F
Blk
K5
Safety
Relay
587C
Org
86
30
85
87 87A
556 Lt Blu
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4 - 42
Powered Circuits
SE2 - IGNITION
4/6/01
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in RUN position
PTO DISENGAGED
Park brake ENGAGED
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red 1
F5 Fuse
5 072B Red
2
B
Off
6
F1
Fuse
072C Red
A
562A Red
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
S5 Rear
PTO Switch
573B
Org
X5
A
Jumper Wire
(Operator Off)
(Operator On)
Aid
Off
5
587B
Org
594
Yel
539B Wht 4
002C
Red
B
X5
V1 Diode
Block
V2
Diode
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
X2
S3 Transmission
Neutral Switch
(HST & SRT)
85
587D Org
7
85
8 302A Red
594
Yel
X4
Y2 Fuel
Shutoff
Solenoid
Red
G1
Battery
Blk
010C Blk
87 87A
Off
Blk
X4
010D
Blk
30
546 Lt Blu
Wht
010F
Blk
002E
Red
050C
Blk
On
Wht
M1 Starting
Motor
521
Brn
302B Red
302C
Red
M
K4
Engine
Run 86
Relay
V1
Diode
Block
010E
Blk
B
587C Org
587A Org
X2
X3
587B
Org
556
Pedal Released Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
329A
Wht
K3 Fuel
Shutoff
Relay
X4
329B
Wht
30
86
87A 87
319
Wht
85
587D Org
R2 Variable
Thermistor
010T
Blk
010F
Blk
587C
Org
S7 Park
Brake Switch
K5
Safety
Relay
86
30
85
87 87A
556 Lt Blu
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
Powered Circuits
Latching Circuits
SE2 - IGNITION
4 - 43
FUEL SUPPLY DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
FUEL SUPPLY DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position (Engine NOT running)
• V1 diode block removed from load center
Test/Check Point
• PTO DISENGAGED
• Transmission in NEUTRAL
• Seat switch closed (Operator ON seat)
Normal
If Not Normal
1. Rear PTO switch connector
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
2. Transmission neutral switch
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
3. Diode block socket (terminal 6)
Battery voltage
Check transmission switch. (See
“TRANSMISSION NEUTRAL
SWITCH TEST – HST & SRT”.) Check
518B and 518A Gry wires and
connections.
4. Seat switch
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
5. Diode block socket (terminal 4)
Battery voltage
Check seat switch. (See “SEAT
SWITCH TEST”.) Check 539B Wht
wire and connections.
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO DISENGAGED
6. Engine run relay socket
(terminal 85)
• Transmission in NEUTRAL
• Seat switch open (Operator OFF seat)
• V1 diode block installed; K4 engine run relay removed from load center
Battery voltage
Check diode block (terminals 6 to 5).
(See “DIODE BLOCK TEST”.) Check
521 Brn wire and connections.
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO DISENGAGED
7. Engine run relay socket
(terminal 85)
• Transmission in GEAR
• Seat switch closed (Operator ON seat)
Battery voltage
Check diode block (terminals 4 to 5).
(See “DIODE BLOCK TEST”.)
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO DISENGAGED
8. Fuel solenoid connector
4 - 44
• Transmission in GEAR
• Seat switch closed (Operator ON seat)
• K4 engine run relay installed in load center
Battery voltage
Check 302B and 302C Red wires and
connections.
4/6/01
FUEL SUPPLY DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
072B Red
F5 Fuse
072C Red
562A Red
B
A
562D Red
2
1
S3 Transmission
Neutral Switch
(HST & SRT)
S5 Rear
PTO Switch
S1 Key Switch
X2
012
Red
587A Org
Plug and
Jumper Wire
518B Gry
573B Org
587B Org
505
Dk Grn
573A Org
V2 Diode
S6 Seat Switch
X3
518A Gry
B
86
30
87A
87
K2 Start
Relay
Socket
4
562E Red
F1
Fuse
539B Wht
85
5
002E Red
A
5
010D Blk
1
4
7
010E Blk
010F Blk
2
8
521 Brn
3
6
9
3
V1 Diode Block
(Socket terminal 6)
002C
Red
V1 Diode Block
+12 VDC
Fusible Link
002E
Red
30
87A
87
K4 Engine Run
Relay Socket
86
6
X4
85
Y2 Fuel Shutoff Solenoid
7
302C Red
302B Red
010N Blk
8
302C Red
329B Wht
86
87A
30
R2 Thermistor
87
W1 Battery
Frame
Ground
329A Wht
X4 To Y2
85
010F Blk
4/6/01
K3 Fuel Shutoff Relay
(Socket terminal)
4 - 45
ENGINE SHUTOFF CIRCUIT OPERATION
ENGINE SHUTOFF CIRCUIT
OPERATION
Engine Shutoff Function:
To stop the tractor engine in an unsafe operating
condition.
Operating Conditions:
• Engine running
• Operator on seat
Engine MUST STOP if:
• PTO is ENGAGED, and
• Operator gets out of seat
or;
• Transmission is ENGAGED, and
• Operator gets out of seat
NOTE: If transmission is in NEUTRAL and the PTO is
disengaged, and then the park brake is set, the
operator can leave the seat and the PTO can
be reengaged.
or;
• Transmission is in GEAR, and
• Operator gets out of seat
NOTE: The S3 transmission neutral switch is shown in
this diagnostic section. This switch is used in
conjunction with a jumper wire in the X3
connector for tractors with a hydrostatic (HST)
or SyncReverser (SRT) transmission. For
tractors with a gear (CST) transmission the
jumper wire is used in the X2 connector and
the S4 transmission neutral switch is used in
the X3 connector.
Theory of Operation:
Fuel is supplied to the engine provided that operating
conditions
are
met.
(See
"FUEL
SUPPLY
OPERATION"). If an unsafe condition is created, the
engine will stop by having the fuel supply to the engine
shut off.
The fuel supply is shut off when voltage to the K4
engine run relay coil is removed, its contacts open,
power to the Y2 fuel shutoff solenoid coils is removed
and the solenoid closes.
Power to the K4 engine run relay coil comes from the
V1 diode block (terminal 5), and is provided to the
diode block (terminals 4 or 6) through different circuits.
The different circuits allow for a variety of operating
conditions to exist and maintain fuel supply to the
engine.
4 - 46
ELECTRICAL - NORTH AMERICAN
The main and most direct circuit, provides power to the
K4 engine run relay coil through the key switch, 072B
and 072C Red wires, F5 fuse, 562A and 562E Red
wires, S2 seat switch (operator ON seat), 539B Wht
wire, V1 diode block (terminals 4 to 5), and 521 Brn
wire. This circuit provides voltage to the engine run
relay for normal operation of the tractor.
A second circuit provides power through the key switch,
072B and 072C Red wires, F5 fuse, 562A and 562D
Red wires, rear PTO switch (PTO DISENGAGED),
573A and 573B Org wires, V2 diode, 587B and 587A
Org wires, S3 or S4 transmission neutral switch, 518B
and 518A Gry wires, V1 diode block (terminals 6 to 5),
and 521 Brn wire. This circuit provides voltage to the
engine run relay if the PTO is DISENGAGED and the
transmission is in NEUTRAL, with or without the
operator in the seat.
A third circuit provides power through the park brake
switch, and the K5 and K6 safety relays. The park
brake switch and the K5 and K6 relays, in conjunction
with the PTO switch, create a self-latching circuit. The
PTO must be DISENGAGED, the park brake must be
ENGAGED, and the operator must be OFF the seat to
create the circuit. Once the latch circuit is established
the PTO can be ENGAGED. The latching circuit will
remain energized until the operator gets ON the seat
and the K6 safety relay coil is energized opening the
circuit path through the K6 contacts, or; the park brake
switch is DISENGAGED, eliminating power to the
circuit.
Power is provided to the S7 park brake switch through
the key switch, 072B and 072C Red wires, F5 fuse,
562F Red wire, X5 connector and jumper wire, and 594
Yel wire. With the park brake ENGAGED, power is
provided through the park brake switch and 546 Lt Blu
wire to the K5 safety relay (terminal 30). Power is
provided to the K5 safety relay coil (terminal 86)
through the rear PTO switch (PTO DISENGAGED), the
573A and 573B Org wires, V2 diode, and 587B and
587C Org wires.
With the K5 coil energized, and power to the K5 contact
(terminal 30), power is provided through the K5
contacts and 533 Org wire to the K6 relay (terminal
87A). The power continues through the K6 contacts,
and the 587C and 587D Org wires to the K5 coil
(terminal 86).
The PTO can now be ENGAGED, and power will
remain to the K4 engine run relay through the park
brake switch, latching relay circuit (S7, 546 Blu wire, K5
relay contacts, 533 Org wire, K6 relay contacts, 587C
and 587D Org wires), and the 587A Org wire, S3 or S4
switch, 518B and 518A Gry wires, V1 diode block, and
521 Brn wire.
If the park brake is DISENGAGED without the operator
ON the seat, the engine will stop.
4/6/01
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC
002E Red
S1 Key
Switch
4
002E
Red
012 Red 1
F5 Fuse
5 072B Red
2
B
Off
6
F1
Fuse
072C Red
A
562A Red
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
S5 Rear
PTO Switch
573B
Org
X5
V2
Diode
Jumper Wire
(Operator Off)
Aid
Off
X5
V1 Diode
Block
(Operator On)
539B Wht 4
002C
Red
5
587B
Org
594
Yel
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
587B
Org
Pedal Released 556
Lt Blu
Pedal Depressed
518B Gry
K2
Start
Relay
2
30
87A 87
X3 X3
505
Dk Grn
X2
X2
Jumper
Wire
85
010E
Blk
S3 Transmission
Neutral Switch
(HST & SRT)
V1
Diode
Block
7
8 302A Red
X4
Y2 Fuel
Shutoff
Solenoid
M1 Starting
Motor
G1
Battery
Off
X4
329B
Wht
329A
Wht
K3 Fuel
Shutoff
Relay
30
86
87A 87
85
Blk
010C Blk
85
87 87A
050C
Blk
587D Org
010T
Blk
010F
Blk
587C
Org
S7 Park
Brake Switch
K5
Safety
Relay
86
30
85
87 87A
556 Lt Blu
319
Wht
R2 Variable
Thermistor
30
Blk
X4
010D
Blk
86
On
546 Lt Blu
Wht
010F
Blk
002E
Red
594
Yel
Wht
M
521
Brn
302B Red
302C
Red
Red
K4 Engine
Run Relay
587D Org
86
B
587C Org
587A Org
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE2 - IGNITION
4 - 47
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
• Transmission in NEUTRAL position
• V1 diode block, K2, K4, K5, and K6 removed from load center
• Key switch in RUN position (engine OFF)
NOTE: The S3 transmission neutral switch is shown in this diagnostic section. This switch is used in conjunction
with the jumper wire in the X3 connector for tractors with a hydrostatic (HST) or SyncReverser (SRT)
transmission. For tractors with a gear shift (CST) transmission the jumper wire is used in the X2 connector
and the S4 transmission neutral switch is installed in the X3 connector.
Test/Check Point
Normal
If Not Normal
1. K2 relay socket (terminal 86)
Battery voltage
Ensure PTO is DISENGAGED and transmission is
in NEUTRAL. Check F5 fuse. (See "POWER
CIRCUIT DIAGNOSIS")
2. V1 diode block socket
(terminal 6)
Battery voltage
Check 518A Gry wire and connections.
3. K5 relay socket (terminal 86)
Battery voltage
Check V2 diode. (See "V2 DIODE TEST"), Check
587B and 587C Org wires and connections.
4. K6 relay socket (terminal 30)
Battery voltage
Check 587D Org wire and connections.
5. Park brake switch
Battery voltage
(See "POWER CIRCUIT DIAGNOSIS")
6. Park brake switch
Battery voltage
Test switch. (See "PARK BRAKE SWITCH TEST")
7. K5 relay socket (terminal 30)
Battery voltage
Check 546 Lt Blu wire and connections.
8. Seat switch
Battery voltage
Check 562E Red wire and connections.
Test Conditions:
• Park brake ENGAGED
• PTO DISENGAGED
9. Seat switch
• Seat switch in OPERATOR ON position (pushed in)
• Transmission in NEUTRAL position
• Key switch in RUN position (engine OFF)
Battery voltage
Test seat switch. (See "SEAT SWITCH TEST")
Replace seat switch.
10. V1 diode block socket
(terminal 4)
Battery voltage
Check 539B Wht wire and connections.
11. V1 diode block socket
(terminal 1)
Battery voltage
Check 539A Wht jumper wire and connections.
Test Conditions:
• Park brake ENGAGED
• Operator ON seat
• PTO DISENGAGED
• Transmission in NEUTRAL position
• V1 diode block installed in load center
• Key switch in RUN position (engine OFF)
12. K4 relay socket (terminal 86)
Battery voltage
Test diode block. (See "DIODE BLOCK TEST")
Check 521 Brn wire and connections.
13. K6 relay socket (terminal 86)
Battery voltage
Test diode block. Check 556 Lt Blu wire and
connections.
4 - 48
4/6/01
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S3 Transmission
Neutral Switch
(HST & SRT)
+12 VDC
A
Plug and
Jumper Wire
F5
Fuse
S5 Rear
PTO Switch
562D Red
X2
X3
505 Dk Grn
518B Gry
B 562A
Red
573A
Org
587B Org V2 Diode 573B Org
587A Org
518A Gry
1
S6 Seat Switch
562F
Red
86
30
87A
87
K2 Start
Relay Socket
9
539B Wht
85
010E Blk
10
Plug and
Jumper Wire
11
5
302A Red
2
8
X5
2
S7 Park Brake Switch
V1 Diode Block
(Socket terminal)
+12 VDC
002E
Red
87A
87
30
521
Brn
86
12
594
Yel
3
6
9
W1 Battery
Frame
Ground
8
1
4
7
010D Blk
562E Red
539A
Wht
587C Org
587D
Org
5
556
Lt Blu
6
85
K4 Engine Run
Relay Socket
302A 302B
Red Red
86
86
87A
533 Org
30
4
87
30
87A
87
85
85
302C
Red
546
Lt Blu
3
K6 Safety
Relay Socket
K5 Safety
Relay Socket
7
X4 To Y2
4/6/01
4 - 49
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
Test/Check Point
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
14. K4 relay socket (terminal 86)
Test Conditions:
• Park brake ENGAGED
• Operator ON seat
• PTO DISENGAGED
15. K5 relay socket (terminal 87)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
ELECTRICAL - NORTH AMERICAN
Normal
If Not Normal
• Transmission in NEUTRAL position
• Key switch in RUN position (engine OFF)
Battery voltage
Test diode block. (See "DIODE BLOCK TEST")
Check 521 Brn wire and connections.
• Transmission in NEUTRAL position
• K6 safety relay installed
• Key switch in RUN position (engine OFF)
Battery voltage
Test K6 relay (See "RELAY TEST"), Check 533
Org wire and connections.
• Transmission in NEUTRAL position
• K5 safety relay installed
• Key switch in RUN position (engine OFF)
Test Conditions: AFTER the above conditions are set
• ENGAGE PTO
16. K4 relay socket (terminal 86)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
17. K5 relay socket (terminal 85)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
Battery voltage
Check ground circuit of relays. See next step.
• Gear range lever in NEUTRAL position
• Key switch in OFF position (engine OFF)
• K5 relay removed
Continuity to frame
ground (0.5 ohms or
less)
Check 050E, 050D, and 050C Blk wires and
connections.
• Gear range lever in NEUTRAL position
• K5 safety relay installed
• Key switch in RUN position (engine OFF)
Test Conditions: AFTER the above conditions are set
• PTO ENGAGED
• Check for voltage at K4 relay socket (terminal 86); RELEASE park brake
18. X4 connector to fuel shutoff
solenoid
4 - 50
NO voltage after park
brake is RELEASED
Test K4 relay. (See "RELAY TEST") Replace relay
as needed.
(See "POWER CIRCUIT DIAGNOSIS")
4/6/01
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S3 Transmission
Neutral Switch
(HST & SRT)
+12 VDC
A
Plug and
Jumper Wire
F5
Fuse
S5 Rear
PTO Switch
562D Red
B 562A
Red
X2
X3
505 Dk Grn
587B Org V2 Diode 573B Org
587A Org
518B
Gry
518A Gry
573A
Red
S6 Seat Switch
562F
Red
86
30
87A
87
K2 Start
Relay Socket
539B Wht
85
539A
Wht
010E Blk
1
4
7
010D Blk
Plug and
Jumper Wire
5
302A Red
562E Red
2
8
S7 Park Brake Switch
V1 Diode Block
(Socket terminal)
+12 VDC
002E
Red
87A
87
30
521
Brn
86
14 16
594
Yel
3
6
9
W1 Battery
Frame
Ground
X5
587C Org
587D
Org
556
Lt Blu
85
K4 Engine Run
Relay Socket
546
Lt Blu
13
15
050D Blk
K5 Safety
Relay Socket
85
85
18
30
533 Org
87A
87
30
87A
87
302C
Red
86
86
302A 302B
Red Red
050E Blk
17
K6 Safety
Relay Socket
X4 To Y2
4/6/01
4 - 51
CHARGING CIRCUIT OPERATION
ELECTRICAL - NORTH AMERICAN
CHARGING CIRCUIT OPERATION
TACHOMETER CIRCUIT OPERATION
FUNCTION:
FUNCTION:
To maintain battery voltage between 12.4 and 13.2
volts.
To indicate engine rpm to the operator.
OPERATING CONDITIONS:
OPERATING CONDITIONS:
• Key switch in RUN position
• Engine running
• Key switch in RUN position
• Engine running
SYSTEM OPERATION:
SYSTEM OPERATION:
The charging system consists of the G2 alternator with
an integrated voltage regulator/rectifier. Charging
output is controlled by a regulator/rectifier. The status
of the charge rate is indicated by the H4 discharge
light.
With the key switch in the RUN position, battery
sensing circuit current flows from battery positive
terminal to the starting motor terminal, fusible link,
002C Red wire, F1 fuse, 012 Red wire, S1 key switch,
072B and 072D Red wires to the alternator voltage
regulator/rectifier. The battery sensing circuit allows the
voltage regulator/rectifier to monitor battery voltage.
A rotating permanent magnet in the alternator induces
AC current in the alternator stator coils. The AC current
flows to the voltage regulator/rectifier. The voltage
regulator/rectifier converts AC current to DC current
needed to charge the battery.
If battery voltage is low, the regulator/rectifier allows
DC current to flow to the battery to charge it through
the battery charging circuit (002A Red). When the
battery is fully charged, the voltage regulator/rectifier
stops current flow to the battery.
If the alternator output current falls below system
usage or is insufficient to maintain a preset voltage, the
voltage regulator/rectifier provides current to turn on
the discharge light through the 334 Yel wire, X7
connector, and the control panel circuit board runs.
Pulsed current flows from the "P" terminal of the
alternator to the control panel (X6 connector, terminal
F) through the 325 Dk Grn wire.
HOUR METER CIRCUIT OPERATION
FUNCTION:
To indicate engine hours of use to the operator.
OPERATING CONDITIONS:
• Key switch in RUN position
• Engine running
SYSTEM OPERATION:
The hour meter is integrated into the control panel and
does not have any external wiring. The hour meter
operates only when the engine is running. The hour
meter uses the engine tachometer circuit for power. If
the tachometer is not functioning, the hour meter will
not work. (See "CHARGING CIRCUIT DIAGNOSIS")
for information on tachometer and hour meter
diagnosis.
The alternator is grounded through the mounting
hardware to the engine.
If the voltage regulator is grounded to the alternator
cover, the alternator produces unregulated amperage.
(See "UNREGULATED AMPERAGE TEST").
4 - 52
4/6/01
CHARGING CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
CHARGING CIRCUIT ELECTRICAL SCHEMATIC
002A Red
B
G
IG
4
012 Red
1
2
B
F1
Fuse
P
L
6
5
072B Red
325 Dk Grn
072D Red
3
A
7
Start
Run
Off
Acc.
334
Yel
072A
Red
Aid
Off
X6
002C
Red
G2
Alternator
S1 Key Switch
A
325
Dk Grn
X7
X6
A
F
P2 Hour
Meter
X1
002A
Red
+
Fusible
Link
_
n/min
H4
Discharge
Light
B
P1 Engine
Tachometer
D
Control Panel Circuit Board
X6
M
M1 Starting
Motor
Red
G1
Battery
Blk
050A Blk
050K Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE3 - CHARGING
SE5 - INSTRUMENTATION
4 - 53
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
CHARGING CIRCUIT DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL position
• PTO DISENGAGED
Normal
If Not Normal
1. Battery positive terminal
Battery voltage
Test battery. (See "BATTERY TEST")
2. Starting motor "B" terminal
Battery voltage
Check battery and starting motor cable connections.
3. Alternator "B" terminal
Battery voltage
Check battery negative cable, alternator ground,
connections, and engine ground connections.
Test Conditions:
• Engine OFF
• Park brake ENGAGED
4. Alternator connector (072D
Red wire terminal)
• Disconnect alternator connector
• Key switch in RUN position
Battery voltage
Check 072D and 072B Red wires and connections.
(See "POWER CIRCUIT DIAGNOSIS")
Test Conditions:
• Key switch in RUN position
• Engine OFF
• Park brake ENGAGED
• Connect alternator connector
• Disconnect control panel connectors
5. X6 connector (terminal A)
Battery voltage
Check 072A and 072B Red wires and connections.
6. X6 connector (terminal F)
0.04 VDC
Check 325 Dk Grn wire and connections.
7. X7 connector (terminal A)
0.45 VDC
Check 334 Yel wire and connections.
Test Conditions:
• Park brake ENGAGED
• Transmission in NEUTRAL
• PTO DISENGAGED
• Engine RUNNING
8. Alternator
Minimum 12.2 to
14.8 volts
(See "REGULATED AMPERAGE AND VOLTAGE
TESTS") Replace voltage regulator/rectifier.
9. Battery
Voltage above 12.4 13.2 VDC.
Check for excessive load on electrical system.
4 - 54
4/6/01
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
Fusible Link
002C Red
002B Red
002A Red
2
M1 Starting Motor
F1 Fuse
012 Red
B
A
1 9
S1 Key Switch
072B
Red
072D Red
8
G1 Battery
072A
Red
3
W1 Battery
Frame
Ground
G2 Alternator
Connector
4
325
Dk Grn
050A
Blk
G2 Alternator
334 Yel
072A Red
050K Blk
7
334 Yel
5
072A Red
1
050K Blk
X7-W1 Main Wiring Harness
To Control Panel
050A Blk
4/6/01
6
325 Dk Grn
X6-W1 Main Wiring Harness
To Control Panel
050K Blk
4 - 55
ENGINE OIL PRESSURE LIGHT
ELECTRICAL - NORTH AMERICAN
ENGINE OIL PRESSURE LIGHT
FUEL GAUGE
Function:
Function:
To alert operator of low engine oil pressure.
Inform the operator of the fuel level in the fuel tank.
Operating Condition:
Operating Condition:
• Key switch must be in RUN or START position.
• Key switch must be in RUN or START position.
Theory of Operation:
Theory of Operation:
With the engine OFF and key in RUN position, engine
oil pressure will be below 49 kPa (7.1 psi). The oil
pressure switch will be in the normally closed position.
The closed position completes a circuit path to ground
and illuminates the H7 light. This informs the operator
that the light is functional.
The fuel level in the fuel tank is measured by the B1
fuel gauge sensor. The sensor is a variable resistor.
The resistance is set by movement of a mechanical
linkage connected to a float in the fuel tank. The 5 to
95 ohm variable resistance creates a variable voltage
difference across the P1 fuel gauge. The voltage
difference ranges from approximately 5.72 VDC (fuel
tank FULL) to approximately 0.87 VDC (fuel tank
EMPTY).
The light goes out when the engine oil pressure is at or
above 49 kPa (7.1 psi), opens the B2 engine oil
pressure switch, and removes the ground circuit from
the engine oil pressure light.
ENGINE COOLANT TEMPERATURE
GAUGE
Function:
Inform the operator of engine and coolant operating
temperature.
Operating Condition:
• Key switch must be in RUN or START position.
Theory of Operation:
The engine coolant temperature sensor is a variable
resistor, providing a ground circuit path for the
temperature gauge. As the engine coolant heats, the
resistance decreases. The temperature gauge circuit is
part of the tractor control panel.
The engine coolant temperature sensor resistance is
approximately 40 - 700 ohms.
4 - 56
4/6/01
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC
(0) Off
(1) Hazard
(2) Road
(3) Field
122C Red
122B Red
B
138 Gry
F7 Fuse
A
3
119C Wht
B
S9 Light
Switch
4
012 Red
B
B
1
6
2
5
F1
Fuse
F3
Fuse
3
A
A
119D
Wht
072A Red
072B Red
X6
X6
7
A
Fuse Block
Internal Link
Control Panel Circuit Board
B
Start
Run
Off
Acc.
Aid
Off
002C
Red
t0
Q
S1 Key Switch
X1
P3
Fuel
Gauge
H7 Oil
Pressure
Light
P4 Engine
Coolant
Temperature
Gauge
C
J
E
Fusible
Link
X6
B
050K
Blk
M
D
X6
353
Org
M1 Starting
Motor
G1
Battery
Q
X6
359
Wht
B3 Engine
B2 Engine Oil Coolant
Pressure
Temperature
Switch (NC)
Sensor
B1 Fuel
Gauge
Sensor
Red
X6
347
Pur
P
t0
Blk
050L
Blk
050A Blk
W1 Battery
Frame
Ground
050K Blk
050L Blk
SE2 - IGNITION
4/6/01
SE5 - INSTRUMENTATION
4 - 57
CONTROL PANEL GAUGES DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
CONTROL PANEL GAUGES DIAGNOSIS
Test Conditions:
• Transmission in NEUTRAL
• Park brake ON
• Light switch in ROAD or FIELD position
• X6 to control panel disconnected
• Key switch in RUN position, engine OFF
• PTO in NEUTRAL
Test/Check Point
Normal
If Not Normal
1. X6 connector (terminal A)
Battery voltage
(See "POWER CIRCUIT DIAGNOSIS")
2. Light switch
Battery voltage
Check F3 fuse. Test light switch. (See
"LIGHT SWITCH TEST")
3. X6 connector (terminal B)
Battery voltage
Check 138 Gry, F7 fuse, 119C and 119D
Wht wires and connections.
4. X6 connector (terminal D)
Less than 0.1 ohms
resistance to ground
Check 050K and 050A Blk wires and
connections.
Test Conditions:
• Transmission in NEUTRAL
• PTO in NEUTRAL
• Park brake ON
• X6 to control panel connected
• Key switch in RUN position, engine OFF
• Light switch in OFF position
5. Fuel gauge sensor
Tank empty – approximately
0.1 VDC
Tank full – approximately
5.7 VDC
Check 353 Org wire and connections. Check
battery negative cable, 050L and 050A Blk
wires and connections. Test fuel sensor (See
"FUEL GAUGE SENSOR TEST"). Use a
jumper wire to connect 353 Org wire to
battery frame ground. Fuel gauge should
move to maximum position. Gauge does not
move. - Replace control panel.
6. Engine oil pressure switch
Less than 0.1 VDC
Check 347 Pur wire and connections.Test
switch (See "ENGINE OIL PRESSURE
SWITCH TEST"). Replace switch as
needed.
7. Engine oil pressure switch
(347 Pur wire lead
disconnected)
Less than 0.1 ohms
resistance to ground
Check engine ground. If engine ground OK:
Replace switch.
8. Engine coolant temperature
sensor
Continuity to ground
through sensor – resistance
depends on engine
temperature (40 - 700
ohms). Sensor threads not
corroded.
Disconnect temperature sensor lead. Use a
jumper wire to connect 359 Wht wire to
ground. Temperature gauge should move to
maximum temperature position.
Gauge does not move. - Check 359 Wht wire
and connections. Replace control panel.
Gauge moves. - Replace sensor.
4 - 58
4/6/01
CONTROL PANEL GAUGES DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
072A Red +12 VDC
2
138 Gry
050K Blk
353 Org
4
119D Wht 119C Wht
119D Wht
072A Red
B
353 Org
3
F7 Fuse
A
050K Blk
S9 Light Switch
1
359 Wht
122B
Red
122C Red
B
347
Pur
347 Pur
X6-W1 Main Wiring Harness
To Control Panel
F3 Fuse
+12 VDC
A
359 Wht
5
353
Org
B1 Fuel Gauge Sensor
050K Blk
347
Pur
050L
Blk
359
Wht
6
7
8
050A
Blk
W1 Battery
Frame
Ground
B2 Engine Oil Pressure Switch
4/6/01
B3 Engine Coolant Temperature Switch
4 - 59
CONTROL PANEL INDICATOR LIGHTS
CONTROL PANEL INDICATOR
LIGHTS
ELECTRICAL - NORTH AMERICAN
PARK BRAKE LIGHT
Function:
PTO LIGHT
To alert operator of park brake being ENGAGED.
Function:
Operating Condition:
To alert operator of PTO being ENGAGED.
• Key switch in START or RUN position
• Park brake ENGAGED.
Operating Condition:
• Key switch in START or RUN position
• PTO ENGAGED.
Theory of Operation:
With the key in START or RUN position, battery voltage
is provided to the rear PTO switch through the S1 key
switch, 072B and 072C Red wires, F5 fuse and 562A
and 562D Red wires.
Voltage is also supplied to the K9 rear PTO relay
(terminal 30) through the S1 key switch, 072B and
072C Red wires, F5 fuse, 562A and 562B Red wires.
(See "POWER CIRCUIT DIAGNOSIS").
When the PTO is not engaged, the PTO switch is in the
OFF (normally closed) position. The closed switch
contacts provide voltage to the K9 rear PTO relay coil
(terminal 86) through the 573A and 573C Org wires.
With voltage to the coil, the K9 rear PTO relay contacts
close (terminal 30 to terminal 87). The voltage to the
K9 rear PTO relay contacts (terminal 30) stops. The
contact output (terminal 87) is not connected to any
component.
With the PTO ENGAGED, the rear PTO switch is in the
ON (open) position, and voltage is removed from the
K9 rear PTO relay (terminal 86). With the voltage to the
relay coil removed, the contacts return to the normally
closed position (terminal 30 to terminal 87A), and
voltage is provided through the 574 Yel wire, and X7
connector (terminal A) to the control panel circuit
board. A circuit board run provides voltage to the H3
PTO indicator light.
A ground circuit path for the control panel circuit board
is provided though the X6 connector (terminal D), and
050K and 050A Blk wires.
Theory of Operation:
With the key in START or RUN position, battery voltage
is provided to the park brake switch through the S1 key
switch, 072B and 072C Red wires, F5 fuse and 562A
and 562C Red wires. (See "POWER CIRCUIT
DIAGNOSIS").
With the park brake ENGAGED. the park brake switch
contacts close. Voltage is provided through the park
brake switch contacts (terminals B to C), 586 Lt Blu
wire, and X6 connector (terminal K) to the control panel
circuit board. A circuit board run provides voltage to the
H6 park brake indicator light.
A ground circuit path for the control panel circuit board
is provided though the X6 connector (terminal D), and
050K and 050A Blk wires.
COLD START LIGHT
Function:
To indicate to operator that voltage is being provided to
the manifold heater.
Operating Condition:
• Key switch in ON or START position, and the key
pushed in to the switch to the AID position. (See
"MANIFOLD HEATER OPERATION").
Theory of Operation:
With the key in the START or RUN position, and the key
switch in the AID position, battery voltage is provided to
the H5 cold start light through the 385B and 385A Dk
Grn wires, X7 connector (terminal C), and control panel
circuit board. A circuit board run provides voltage to the
H5 cold start light.
A ground circuit path for the control panel circuit board
is provided though the X6 connector (terminal D), and
050K and 050A Blk wires.
4 - 60
4/6/01
CONTROL PANEL INDICATOR LIGHTS SCHEMATIC
ELECTRICAL - NORTH AMERICAN
CONTROL PANEL INDICATOR LIGHTS SCHEMATIC
S1 Key
Switch
562B
Red
4
012 Red
B
Off
6
1
5 072B Red
2
F1
Fuse
072C Red
A
3
On
F5 Fuse
562A Red
B
B
S5 Rear
PTO Switch
562C
Red
7 385B Dk Grn
A
573A Org
562D Red
A
Start
Run
Off
Acc.
573C 562B
Org Red
86
30
85
87 87A
K9 Rear
PTO
Relay
On
Off
Aid
Off
002C
Red
385A
Dk Grn
B
586 Lt Blu
C
S7 Park
Brake Switch
X7
C
Control Panel Circuit Board
574
Yel
X6
X7
K
B
Fusible
Link
P
B
H6 Park
Brake
Light
H5 Cold
Start
Light
H3 PTO
Light
M
M1 Starting
Motor
D
X6
Red
G1
Battery
Blk
050A Blk
050K Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE5 - INSTRUMENTATION
4 - 61
CONTROL PANEL INDICATOR LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
CONTROL PANEL INDICATOR LIGHTS DIAGNOSIS
Test Conditions:
• Key switch in RUN position, engine OFF
• PTO DISENGAGED
• Transmission in NEUTRAL
Test/Check Point
• S5 rear PTO switch disconnected from wiring harness
• Park brake OFF
• K9 rear PTO relay removed from load center
Normal
If Not Normal
1. PTO switch
Battery voltage
Check F5 fuse. Check 562A and 562D Red
wires and connections.
2. Park brake switch
Battery voltage
Check 562A and 562C Red wires and
connections.
3. Rear PTO relay socket
(terminal 30)
Battery voltage
Check 562A and 562B Red wires and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• S5 rear PTO switch connected to wiring harness
• X6 and X7 to control panel disconnected
• K9 rear PTO relay installed
• PTO DISENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
4. Park brake switch
Battery voltage
Test switch (See "PARK BRAKE SWITCH
TEST"). Replace as needed.
5. X6 connector (K terminal)
Battery voltage
Check 586 Lt Blue wire and connections.
6. Rear PTO switch
Battery voltage
Ensure PTO is disengaged. Test switch (See
"REAR AND MID PTO SWITCH TEST").
Replace switch as needed.
7. X7 connector (B terminal)
Battery voltage
Check 574B and 574AYel wires and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL
• PTO DISENGAGED
• Park Brake ENGAGED
• Connect multimeter to battery frame ground and X7 connector (C terminal). After the connections are made,
push key into switch to the AID position.
8. X7 connector (C terminal)
Battery voltage
Test Conditions:
• Key switch in OFF position
• Transmission in NEUTRAL
• X6 and X7 to control panel disconnected
9. X6 connector (K terminal)
Continuity to battery frame
ground. Less than 0.1 ohms.
Check 385A and 385B Dk Grn wires and
connections. (See "MANIFOLD HEATER
OPERATION").
• PTO DISENGAGED
• Park Brake ENGAGED
Check 050K and 050A Blk wires and
connections.
NOTE: If all of the tests above are performed, and the control panel lamps are good, and the indicator lights still
do not work, replace the control panel.
4 - 62
4/6/01
CONTROL PANEL INDICATOR LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
562B Red
F5 Fuse
072C Red
072B Red
A
562A Red
562D Red
B
562C
Red
S1 Key Switch
385B
Dk Grn
385A Dk Grn
385C
Dk Grn
562D
Red
2
562C Red
1
6
573A
Yel
86
S7 Park Brake Switch
30
87A
87
4
85
586
Lt Blu
S5 Rear
PTO Switch
K1 Manifold Heater
Relay Socket
573C
Yel
9
050K Blk
86
K9 Rear PTO
Relay Socket
85
586 Lt Blu
30
87A
87
5
X6-W1 Main Wiring Harness
To Control Panel
562B
Red
3
7
385A
Dk Grn
574A Yel
8
385A Dk Grn
X7 Main Wiring Harness
To Control Panel
4/6/01
4 - 63
LIGHTS OPERATION (OLD)
LIGHTS OPERATION (OLD)
Light Switch Function:
Provides power to the headlights, tail lights, hazard
lights, work lights and control panel lights, in
combinations depending upon the position the light
switch is placed in.
Operating Conditions:
• Light switch in either HAZARD, ROAD or FIELD
position.
Theory of Operation:
Power for the light switch is provided through the load
center F5 fuse, 122C and 122B Red wires. Power for
the turn signal light switch is provided through the F5
fuse, 122C and 122A Red wires.
Light Switch Hazard Position:
In the HAZARD position, voltage is provided from the
light switch (terminal 2) through the 103A and 103C
Org wires, F8 fuse, and the 118 Gry wire to the X13
Trailer connector (terminal 6). Voltage is also provided
from the light switch (terminal 2) through the 103A and
103B Org wires to the S8 turn signal switch.
Light Switch Road Position:
In the ROAD position, voltage is provided from the light
switch (terminal 2) through the same circuits as when
the light switch is in the HAZARD position.
In addition, voltage is provided from the light switch
(terminal 3) though the 138 Gry wire to the F7 fuse.
The F7 fuse provides voltage to the LH headlight
through the 119C and 119B Wht wires; and to the RH
headlight through the 119C and 119A Wht wires.
Voltage is also provided to the control panel gauge
lights through the 119C and 119D Wht wires and X6
connector (B terminal).
Light Switch Field Position:
In the FIELD position, voltage is removed from the turn
signal switch (terminal 1). However, voltage remains to
the headlights (light switch terminal 3), and is provided
to the work lights (light switch terminal 4).
Voltage is provided from the light switch (terminal 4),
through the 143 Org wire to the F6 fuse. The F6 fuse
provides voltage, through the 147A, 147B and 147D
Pur wires, to the work lights. Voltage is also provided to
the X13 trailer connector (terminal 2) through the 147A
and 147C Pur wires.
4 - 64
ELECTRICAL - NORTH AMERICAN
Turn Signal Switch Function:
Provides intermittent power to the tail lights and hazard
lights.
Operating Conditions:
• Turn signal switch OFF position
• Light switch in either HAZARD or ROAD position;
or, turn signal switch in the LEFT position, light
switch in any position; or, turn signal switch in the
RIGHT position, light switch in any position.
Theory of Operation:
Unswitched power is provided to the turn signal switch
through the 122A Red wire (terminal 2). Switched
power is provided from the light switch (terminal 2)
through the 103A and 103B Org wires (terminal 1).
With the turn signal switch in the OFF position, and the
light switch in either the HAZARD or ROAD position,
voltage enters the turn signal switch through the 103B
Org wire (terminal 1). The voltage from the 103B Org
wire goes to the flasher unit inside the turn signal
switch. The flasher unit produces an intermittent
voltage output that is provided to the center contacts of
both the LH and RH switch. With the turn signal switch
in the OFF position, both the LH and RH switch provide
an intermittent output voltage to the wiring harness
(terminals 3 and 4).
Intermittent voltage is provided to the LH tail light and
LH hazard light through the 125A, 125C and 125D Dk
Grn wires. Intermittent voltage is provided to the RH tail
light and RH hazard light through the 115A, 115C and
115D Dk Grn wires.
Turn Signal Switch Left Position:
With the light switch in any position, and the turn signal
switch in the LEFT position, constant voltage is
provided to the RH switch contact. The contact
provides constant voltage (terminal 4) to the RH tail
light and hazard light. Constant voltage is also provided
from the S8 RH switch contact to the flasher unit in the
turn signal switch. The flasher unit provides intermittent
voltage to the S8 LH switch contact. The intermittent
voltage is provided (terminal 3) to the LH tail light and
hazard light.
Turn Signal Switch Right Position:
With the light switch in any position and the turn signal
switch in the RIGHT position, constant voltage is
provided to the S8 LH switch contact. The contact
provides constant voltage (terminal 3) to the LH tail
light and hazard light. Constant voltage is also provided
from the S8 LH switch contact to the flasher unit in the
turn signal switch. The flasher unit provides intermittent
voltage to the S8 RH switch contact. The intermittent
voltage is provided (terminal 4) to the RH tail light and
hazard light.
4/6/01
LIGHTS ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
LIGHTS ELECTRICAL SCHEMATIC
103B Org
119A Wht
119B Wht
(0) Off
(1) Hazard
(2) Road
103B
Org
(3) Field
010A Blk
010B Blk
1
122C Red
2
B
138 Gry
122A
Red
B
3
A
F7 Fuse
119C Wht
A
F6 Fuse
B
143 Org
4
F5
Fuse
F8 Fuse
103C Org
103A Org
122B Red
A
118 Gry
B
147C Pur
2
147B
Pur
119D
Wht
E8 RH
Work Light
002C
Red
010H Blk
P4 Engine Coolant
Temperature
Gauge
P3 Fuel
Gauge
010K Blk
X16
E7 LH
Work Light
t0
1
X13 Trailer
Connector
X17
X6
Q
6
X16
B
002D
Red
010J Blk
147D Pur
147A Pur
B
S9 Light
Switch
Control Panel Circuit Board
A
E6 RH
Headlight
E5 LH
Headlight
X17
010L Blk
010G Blk
122A Red
Fusible
Link
010L
Blk
010G
Blk
X20
X23
5
B
E2 LH
Hazard
Light
E1 LH
Tail
Light
E3 RH
Tail
Light
E4 RH
Hazard
Light
X21
X18 X19
M1 Starting
Motor
125D
Dk Grn
(0) Right
(1) Off
(2) Left
1 103B Org
Flasher
X22
115D 115C
Dk Grn Dk Grn
M
X13 Trailer
Connector
125C
Dk Grn
115E
Dk Grn
115A Dk Grn
4
125A Dk Grn
3
2
122A Red
Red
125E Dk Grn
3
X13 Trailer
Connector
G1
Battery
125B
Dk Grn
115B
Dk Grn
X7
X7
S8 Turn
Signal Switch
010C Blk
D
E
Blk
050A Blk
050K Blk
X6
H1 RH
Turn
Light
D
Control Panel Circuit Board
010C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
H2 LH
Turn
Light
Unswitched Power
Serial Number Breaks:
–LV4200C327135
–LV4200H320278
–LV4300C335214
–LV4300S336171
–LV4300H330218
–LV4400S334079
–LV4700H340244
Switched Power
SE6 - LIGHTS
4 - 65
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
LIGHTS DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Engine OFF
Test/Check Point
1. Light switch
• Light switch in HAZARD position
• X7 to control panel disconnected
Normal
If Not Normal
Battery voltage
Check F3 fuse (See "POWER CIRCUIT
DIAGNOSIS").
Battery voltage
Check F3 fuse (See "POWER CIRCUIT
DIAGNOSIS").
3. Light switch
Battery voltage
Test light switch (See "LIGHT SWITCH
TEST").
4. Turn signal switch
Battery voltage
Check 103A and 103B Org wires and
connections.
5. Turn signal switch (115A and
125A Dk Grn wires)
Intermittent battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
6. RH hazard light
Intermittent battery voltage
Check 115A and 115C Dk Grn wires and
connections.
7. RH tail light
Intermittent battery voltage
Check 115A and 125D Dk Grn wires and
connections.
8. X7 control panel connector
(terminal D)
Intermittent battery voltage
Check 115A and 115B Dk Grn wires and
connections.
9. LH hazard light
Intermittent battery voltage
Check 125A and 125C Dk Grn wires and
connections.
10. LH tail light
Intermittent battery voltage
Check 125A and 125D Dk Grn wires and
connections.
11. X7 control panel connector
(terminal E)
Intermittent battery voltage
Check 125A and 125B Dk Grn wires and
connections.
2. Turn signal switch
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in ROAD position
• X7 to control panel connected
12. Light switch
Battery voltage
Test light switch. (See "LIGHT SWITCH
TEST").
13. F7 fuse
Battery voltage
Check F7 fuse. Check 138 Gry wire and
connections.
14. RH headlight
Battery voltage
Check 119C and 119A Wht wires and
connections.
15. LH headlight
Battery voltage
Check 119C and 119B Wht wires and
connections.
NOTE: With the light switch in ROAD position, and the turn signal in the OFF position, battery voltage and
intermittent battery voltage will be provided in the same locations as Steps 4 through 11 above. These
voltages are in addition to the voltage at the F7 fuse and RH and LH headlights.
4 - 66
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S9 Light Switch
5
4
122B
Red
103A
Org
122B
Red
103B
Org
122A Red
3
122C
Red
1
12
103C
Org
138
Gry
143
Org
B
147B Pur
To E7 and E8
Work Lights 147D Pur
147A
Pur
5
S8 Turn Signal Switch
115A
Dk Grn
A
F7
Fuse +12 VDC
F6
Fuse
F8
Fuse
B
F3
Fuse
A
A
A
B
2
125A
Dk Grn
B
13
119C Wht
147C
Pur
118 Gry
118 Gry
115E
Dk Grn
14
147C Pur
119A Wht
125E
Dk Grn
E6 RH Headlight
X13 To Trailer
Connector (Option)
15
X7-W1 Main
Wiring Harness
To Control Panel
125B
Dk Grn 11
9
119B Wht
115B
Dk Grn
8
125C
Dk Grn
115C
Dk Grn
E2 LH Hazard Light
125D
Dk Grn
115D
Dk Grn
E5 LH Headlight
E4 RH Hazard Light
115C Dk Grn
6
125C Dk Grn
10
115D Dk Grn
7
125D Dk Grn
E1 LH Tail Light
4/6/01
E3 RH Tail Light
4 - 67
LIGHTS DIAGNOSIS
Test/Check Point
Test Conditions:
• Key switch in OFF position
• Engine OFF
ELECTRICAL - NORTH AMERICAN
Normal
If Not Normal
• Light switch in FIELD position
16. Light switch
Battery voltage
Test light switch (See "LIGHT SWITCH
TEST").
17. F6 fuse
Battery voltage
Check F6 fuse. Check 143 Org wire and
connections.
18. X13 connector
Battery voltage
Check 147A and 147C Pur wires and
connections.
NOTE: With the light switch in FIELD position, and the turn signal in the OFF position, battery voltage will be
provided in the same locations as Steps 12 through 15 above.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in LEFT position
19. Turn signal switch
Battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
20. RH hazard light and RH tail
light
Battery voltage
Check 115A, 115C and 125D Dk Grn wires
and connections.
21. X7 connector (terminal D)
Battery voltage
Check 115A and 115B Dk Grn wires and
connections.
22. Turn signal switch
Intermittent battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
23. LH hazard light and LH tail
light
Intermittent battery voltage
Check 125A, 125C and 125D Dk Grn wires
and connections.
24. X7 connector (terminal E)
Intermittent battery voltage
Check 125A and 125B Dk Grn wires and
connections.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in RIGHT position
25. Turn signal switch
Intermittent battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
26. RH hazard light and RH tail
light
Intermittent battery voltage
Check 115A, 115C and 125D Dk Grn wires
and connections.
27. X7 control panel connector
(terminal D)
Intermittent battery voltage
Check 115A and 115B Dk Grn wires and
connections.
28. Turn signal switch
Battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
29. LH hazard light and LH tail
light
Battery voltage
Check 125A, 125C and 125D Dk Grn wires
and connections.
30. X7 control panel connector
(terminal E)
Battery voltage
Check 125A and 125B Dk Grn wires and
connections.
4 - 68
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S9 Light Switch
22 28
122B
Red
122B
Red
122A Red
122C
Red
16
143
Org
138
Gry
A
F6
Fuse
17
B
147B Pur
To E7 and E8
Work Lights 147D Pur
147A
Pur
B
F3
Fuse
A
19 25
S8 Turn Signal Switch
115A
Dk Grn
A
F7
Fuse
125A
Dk Grn
+12 VDC
B
147C
Pur
115E
Dk Grn
147C Pur
18
125E
Dk Grn
119A Wht
X13 To Trailer
Connector (Option)
E6 RH Headlight
X7-W1 Main
Wiring Harness
To Control Panel
125B
Dk Grn
24 30
21 27
E2 LH Hazard Light
125C Dk Grn
119B Wht
115B
Dk Grn
125C
Dk Grn
115C
Dk Grn
125D
Dk Grn
115D
Dk Grn
E5 LH Headlight
E4 RH Hazard Light
115C Dk Grn
20 26
23 29
115D Dk Grn
125D Dk Grn
E1 LH Tail Light
4/6/01
E3 RH Tail Light
4 - 69
LIGHTS OPERATION (NEW)
LIGHTS OPERATION (NEW)
Light Switch Function:
Provides power to the headlights, tail lights, hazard
lights, work lights and control panel lights, in
combinations depending upon the position the light
switch is placed in.
Operating Conditions:
• Light switch in either HAZARD, ROAD or FIELD
position.
Theory of Operation:
Power for the light switch is provided through the load
center F5 fuse, 122C and 122B Red wires. Power for
the turn signal light switch is provided through the F5
fuse, 122C and 122A Red wires.
Light Switch Hazard Position:
In the HAZARD position, voltage is provided from the
light switch (terminal 2) through the 103 Org wire to the
S8 turn signal switch.
Light Switch Road Position:
In the ROAD position, voltage is provided from the light
switch (terminal 2) through the same circuits as when
the light switch is in the HAZARD position.
In addition, voltage is provided from the light switch
(terminal 3) though the 138A, 138B and 138C Gry
wires to the F7 and F8 fuses. The F7 fuse provides
voltage to the LH headlight through the 119C and 119B
Wht wires, and to the RH headlight through the 119C
and 119A Wht wires. Voltage is also provided to the
control panel gauge lights through the 119C and 119D
Wht wires and X6 connector (B terminal).
The F8 fuse provides voltage to the LH taillight through
the 118A and 118C Gry wires, and the RH taillight
through the 118A and 118B Gry wires. Voltage is also
provided to the X13 trailer connector (terminal 1)
through the 118A and 118D Gry wires.
ELECTRICAL - NORTH AMERICAN
Turn Signal Switch Function:
Provides intermittent power to the tail lights and hazard
lights.
Operating Conditions:
• Turn signal switch OFF position
• Light switch in either HAZARD or ROAD position;
or, turn signal switch in the LEFT position, light
switch in any position; or, turn signal switch in the
RIGHT position, light switch in any position.
Theory of Operation:
Unswitched power is provided to the turn signal switch
through the 122A Red wire (terminal 2). Switched
power is provided from the light switch (terminal 2)
through the 103 Org wire (terminal 1).
With the turn signal switch in the OFF position, and the
light switch in either the HAZARD or ROAD position,
voltage enters the turn signal switch through the 103
Org wire (terminal 1). The voltage from the 103 Org
wire goes to the flasher unit inside the turn signal
switch. The flasher unit produces an intermittent
voltage output that is provided to the center contacts of
both the LH and RH switch. With the turn signal switch
in the OFF position, both the LH and RH switch provide
an intermittent output voltage to the wiring harness
(terminals 3 and 4).
Intermittent voltage is provided to the LH hazard light
through the 125A and 125C Dk Grn wires. Intermittent
voltage is provided to the RH hazard light through the
115A and 115C Dk Grn wires.
Turn Signal Switch Left Position:
With the light switch in any position, and the turn signal
switch in the LEFT position, constant voltage is
provided to the RH switch contact. The contact
provides constant voltage (terminal 4) to the RH hazard
light. Constant voltage is also provided from the S8 RH
switch contact to the flasher unit in the turn signal
switch. The flasher unit provides intermittent voltage to
the S8 LH switch contact. The intermittent voltage is
provided (terminal 3) to the LH hazard light through the
115A and 115C Dk Grn wires.
Light Switch Field Position:
In the FIELD position, voltage is removed from the turn
signal switch (terminal 1). However, voltage remains to
the headlights (light switch terminal 3), and is provided
to the work lights (light switch terminal 4).
Voltage is provided from the light switch (terminal 4),
through the 143 Org wire to the F6 fuse. The F6 fuse
provides voltage, through the 147A, 147B and 147D
Pur wires, to the work lights. Voltage is also provided to
the X13 trailer connector (terminal 2) through the 147A
and 147C Pur wires.
4 - 70
Turn Signal Switch Right Position:
With the light switch in any position and the turn signal
switch in the RIGHT position, constant voltage is
provided to the S8 LH switch contact. The contact
provides constant voltage (terminal 3) to the LH hazard
light. Constant voltage is also provided from the S8 LH
switch contact to the flasher unit in the turn signal
switch. The flasher unit provides intermittent voltage to
the S8 RH switch contact. The intermittent voltage is
provided (terminal 4) to the RH hazard light through the
125A and 125C Dk Grn wires.
4/6/01
LIGHTS ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
LIGHTS ELECTRICAL SCHEMATIC
103 Org
119A Wht
119B Wht
(0) Off
(1) Hazard
E6 RH
Headlight
E5 LH
Headlight
(2) Road
010A Blk
(3) Field
1
F8 Fuse
103 Org 138C Gry
118A Gry
A
B
2
119C Wht
138A Gry 138B
A
B
3
F7 Fuse
143 Org
4
A
B
122B Red
B
122C
Red
122A
Red
B
F5
Fuse
118D Gry
147C Pur
147B
Pur
119D
Wht
Control Panel Circuit Board
2
002C
Red
E8 RH
Work Light
010K Blk
t0
P3 Fuel
Gauge
1
X13 Trailer
Connector
X17
X6
Q
6
X16
B
002D
Red
010J Blk
147D Pur
147A Pur
F6 Fuse
S9 Light
Switch
A
010B Blk
E7 LH
Work Light
P4 Engine Coolant
Temperature
Gauge
X16
010H Blk
X17
010L Blk
010G Blk
122A Red
Fusible
Link
118B 010G
Gry
Blk
118C 010L
Blk
Gry
X21 X23
X18 X20
E3 RH
Tail
Light
E1 LH
Tail
Light
5
E4 RH
Hazard
Light
E2 LH
Hazard
Light
B
X19
(0) Right
(1) Off
(2) Left
1 103 Org
Flasher
115C
Dk Grn
125C
Dk Grn
125D Dk Grn
Red
115D
Dk Grn
X22
M
M1 Starting
Motor
X13 Trailer
Connector
115A Dk Grn
4
125A Dk Grn
3
122A Red
3
X13 Trailer
Connector
G1
Battery
125B
Dk Grn
115B
Dk Grn
X7
X7
S8 Turn
Signal Switch
010C Blk
D
E
Blk
050A Blk
010C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
2
050K Blk
X6
H1 RH
Turn
Light
H2 LH
Turn
Light
D
Control Panel Circuit Board
Unswitched Power
Switched Power
Serial Number Breaks:
LV4200C327136–
LV4200H320279–
LV4300C335215–
LV4300S336172–
LV4300H330219–
LV4400S334080–
LV4700H340245–
SE6 - LIGHTS
4 - 71
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
LIGHTS DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Engine OFF
Test/Check Point
• Light switch in HAZARD position
• X7 to control panel disconnected
Normal
If Not Normal
1. Light switch
Battery voltage
Check F3 fuse (See "POWER CIRCUIT
DIAGNOSIS").
2. Turn signal switch
Battery voltage
Check F3 fuse. (See "POWER CIRCUIT
DIAGNOSIS").
3. Light switch
Battery voltage
Test light switch (See "LIGHT SWITCH
TEST").
4. Turn signal switch
Battery voltage
Check 103 Org wire and connections.
5. Turn signal switch (115A and
125A Dk Grn wires)
Intermittent battery voltage
Test switch (See "TURN SIGNAL SWITCH
TEST"). Replace as needed.
6. RH hazard light
Intermittent battery voltage
Check 115A and 115C Dk Grn wires and
connections.
7. X7 control panel connector
(terminal D)
Intermittent battery voltage
Check 115A and 115B Dk Grn wires and
connections.
8. LH hazard light
Intermittent battery voltage
Check 125A and 125C Dk Grn wires and
connections.
9. X7 control panel connector
(terminal E)
Intermittent battery voltage
Check 125A and 125B Dk Grn wires and
connections.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in ROAD position
• X7 to control panel connected
10. Light switch
Battery voltage
Test light switch. (See "LIGHT SWITCH
TEST").
11. F7 fuse
Battery voltage
Check F7 fuse. Check 138A and 138B Gry
wires and connections.
12. RH headlight
Battery voltage
Check 119C and 119A Wht wires and
connections.
13. LH headlight
Battery voltage
Check 119C and 119B Wht wires and
connections.
14. F8 fuset
Battery voltage
Check F8 fuse. Check 138A and 138C Gry
wires and connections.
15. RH tail light
Battery voltage
Check 118A and 118B Gry wires and
connections.
16. LH tail light
Battery voltage
Check 118A and 118C Gry wires and
connections.
NOTE: With the light switch in ROAD position, and the turn signal in the OFF position, battery voltage and
intermittent battery voltage will be provided in the same locations as Steps 4 through 16 above. These
voltages are in addition to the voltage at the F7 fuse and RH and LH headlights.
4 - 72
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S9 Light Switch
5
4
122B
Red
103
Org
122B
Red
103
Org
122A Red
3
1
138C Gry
143
Org
To E7 and E8
Work Lights B
147B Pur
F8
Fuse
B
147D Pur
14
118A
Gry
B
138B
Gry
A
A
122C
Red
138A
Gry
10
A
F6
Fuse
B
147A
Pur
147C
Pur
F3
Fuse
2
5
S8 Turn Signal Switch
115A
Dk Grn
A
125A
Dk Grn
F7
Fuse +12 VDC
119C Wht
11
118B Gry
118C Gry
118D Gry
118 Gry
115D
Dk Grn
147C Pur
12
125D
Dk Grn
119A Wht
X13 To Trailer
Connector (Option)
X7-W1 Main
Wiring Harness
To Control Panel
125B
Dk Grn 9
8
E6 RH Headlight
13
119B Wht
115B
Dk Grn
7
E2 LH Hazard Light
125C
Dk Grn
115C
Dk Grn
118C
Gry
118B
Gry
E5 LH Headlight
E4 RH Hazard Light
115C Dk Grn
6
125C Dk Grn
118B Gry
118C Gry
16
15
E1 LH Tail Light
4/6/01
E3 RH Tail Light
4 - 73
LIGHTS DIAGNOSIS
Test Conditions:
• Key switch in OFF position
ELECTRICAL - NORTH AMERICAN
• Engine OFF
• Light switch in FIELD position
17. Light switch
Battery voltage
Test light switch.
18. F6 fuse
Battery voltage
Check F6 fuse. Check 143 Org wire
and connections.
19. X13 connector (if used)
Battery voltage
Check 147A and 147C Pur wires
and connections.
NOTE: With the light switch in FIELD position, and the turn signal in the OFF position, battery voltage will be
provided in the same locations as Steps 10 through 16 above.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in LEFT position
20. Turn signal switch
Battery voltage
Test switch (See "TURN SIGNAL
SWITCH TEST"). Replace as
needed.
21. RH hazard light
Battery voltage
Check 115A and 125C Dk Grn
wires and connections.
22. X7 connector (terminal D)
Battery voltage
Check 115A and 115B Dk Grn wires
and connections.
23. Turn signal switch
Intermittent battery voltage
Test switch (See "TURN SIGNAL
SWITCH TEST"). Replace as
needed.
24. LH hazard light
Intermittent battery voltage
Check 125A and 125C Dk Grn
wires and connections.
25. X7 connector (terminal E)
Intermittent battery voltage
Check 125A and 125B Dk Grn wires
and connections.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in RIGHT position
26. Turn signal switch
Intermittent battery voltage
Test switch (See "TURN SIGNAL
SWITCH TEST"). Replace as
needed.
27. RH hazard light
Intermittent battery voltage
Check 115A and 115C Dk Grn
wires and connections.
28. X7 control panel connector
(terminal D)
Intermittent battery voltage
Check 115A and 115B Dk Grn wires
and connections.
29. Turn signal switch
Battery voltage
Test switch (See "TURN SIGNAL
SWITCH TEST"). Replace as
needed.
30. LH hazard light
Battery voltage
Check 125A and 125C Dk Grn
wires and connections.
31. X7 control panel connector
(terminal E)
Battery voltage
Check 125A and 125B Dk Grn wires
and connections.
4 - 74
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S9 Light Switch
23 29
122B
Red
103
Org
122B
Red
103
Org
122A Red
138C Gry
143
Org
B
B
B
147A
Pur
18
F3
Fuse
A
F6
Fuse
F8
Fuse
B
138B
Gry
A
A
14
118A
Gry
122C
Red
138A
Gry
17
20 26
S8 Turn Signal Switch
115A
Dk Grn
A
125A
Dk Grn
F7
Fuse +12 VDC
119C Wht
11
147C
Pur
118B Gry
118C Gry
118D Gry
115D
Dk Grn
147C Pur
19
125D
Dk Grn
119A Wht
X13 To Trailer
Connector (Option)
X7-W1 Main
Wiring Harness
To Control Panel
125B
Dk Grn 25 31
24 30
119B Wht
115B
Dk Grn
22 28
125C
Dk Grn
E2 LH Hazard Light
E6 RH Headlight
E5 LH Headlight
115C
Dk Grn
E4 RH Hazard Light
115C Dk Grn
21 27
125C Dk Grn
E1 LH Tail Light
4/6/01
E3 RH Tail Light
4 - 75
CRUISE CONTROL
CRUISE CONTROL
Cruise Control Function:
Provides an electro-mechanical means to control the
forward speed of the tractor.
Operating Conditions:
• Key switch in RUN position
• Brake not depressed
• Cruise control switch momentarily in ENGAGE
position, and then released to the ON position.
The cruise control will remain ENGAGED until the
brake is depressed; the key switch is turned to the OFF
position; or, the cruise control switch is placed into the
OFF position.
Theory of Operation:
When the Y3 cruise control electromagnet is
energized, the forward pedal is held in whatever
position it is in when the magnet is energized. The
cruise control magnet is energized through the cruise
control relay contacts. The brake switch provides a
latching circuit for the cruise control relay. When the
brake pedal is depressed, the normally open brake
switch contacts open and the latching circuit is
removed. With the latching circuit removed, the cruise
control relay contacts open, and the cruise control
magnet is deenergized - releasing the forward pedal.
ELECTRICAL - NORTH AMERICAN
(terminal 30) to the S11 brake switch and Y3 cruise
control magnet through the 264A Yel wire, X9
connector, W4 wiring harness Yel wires, and X11
connector and X12 connector respectively.
When power is provided to the cruise control magnet, it
is energized and creates a magnetic field that holds the
forward pedal in a locked position.
When power is provided to the S11 brake switch, and
the brake switch contacts are closed (brake NOT
depressed), power is provided through the X11
connector, W4 wiring harness Gry wires, X9 connector
and 238 Gry wire to the cruise control relay (terminal
86). This circuit latches the cruise control relay by
keeping the cruise control relay coil energized.
The latching circuit keeps the cruise control relay coil
energized until the brake pedal is depressed. When the
pedal is depressed, the S11 brake switch contacts
open and power is removed from the cruise control
relay coil.
When the cruise control relay coil is deenergized, the
relay contacts open, and power provided to the cruise
control indicator light and the cruise control magnet is
removed. Without power, the cruise control magnet
releases the forward pedal.
Placing the cruise control switch into the OFF position
stops power to the cruise control relay coil and
contacts.
Power for the cruise control circuit is provided to the X9
connector, from the key switch (terminal 4), through the
209 Wht wire.
Power is provided from the X9 connector to the cruise
control switch through the W4 wiring harness Wht wire,
and X10 connector. The cruise control switch is a
double pole switch with OFF, ON, and momentary
ENGAGE positions.
When the cruise control switch is placed in the
momentary ENGAGE position, power is provided
through the switch, X10 connector, W4 wiring harness
Gry wire, X9 connector, and 238 Gry wire to the K8
cruise control relay (terminal 86). With power provided,
the relay coil energizes and the contacts (terminal 30
and terminal 87) close. At the same time (cruise control
switch placed in the momentary ENGAGE position),
power is provided through the X10 connector, W4
wiring harness Pur wire, X9 connector, and 247 Pur
wire to the K8 cruise control relay contacts (terminal
87).
With the contacts closed, power is provided through the
relay contacts (terminals 87 and 30) to the cruise
control indicator light through the 264B Yel wire, X6
connector (terminal G), and control panel circuit board.
Latching Circuit:
Power is also provided from the cruise control relay
4 - 76
4/6/01
CRUISE CONTROL ELECTRICAL SCHEMATIC
ELECTRICAL - NORTH AMERICAN
CRUISE CONTROL ELECTRICAL SCHEMATIC
W4 Cruise Control
Wiring Harness
Off
On
Engage
S1 Key
Switch
4
012 Red
B
1
2
F1
Fuse
A
Pur
Blk
Wht
209 Wht
X9
6
Wht
A
Gry
X10
S10 Cruise
Control
Switch
5
W4 Cruise Control
Wiring Harness
X10
X10
Gry
S11 Brake
Switch
3
7
Off
002D
Red
Start
Run
Off
Acc.
On
Blu
Gry
Blu
X11
X11
Aid
Off
Gry
002C
Red
H8 Cruise
Indicator
Light
W4 Cruise Control
Wiring Harness
Yel
Fusible
Link
G
X6
264B
Yel
B
K8
Cruise
Control
Relay
86
30
85
87 87A
B
C
D
238 Gry
247 Pur
264A Yel
Pur
Yel
X9
Yel
W5 Cruise Control
Magnet Wiring Harness
M
050G
Blk
M1 Starting
Motor
Red
050F
Blk
Wht
Y3 Cruise
Control
Magnet
050E
Blk
G1
Battery
Blk
W4 Cruise Control
Wiring Harness
050D
Blk
050B Blk
050A Blk
050J Blk
SE1 - STARTING
Blk
050J Blk
X9
SE4 - ACCESSORIES
Wht
X12
050C Blk
W1 Battery
Frame
Ground
4/6/01
X12
E
SE5 - INSTRUMENTATION
4 - 77
CRUISE CONTROL DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
CRUISE CONTROL DIAGNOSIS
Test Conditions:
• Key switch in RUN position, engine OFF
• PTO in NEUTRAL
• Transmission in NEUTRAL
Test/Check Point
• Park brake ENGAGED
• K8 cruise control relay removed
• Disconnect X9 connector
Normal
If Not Normal
32. Key switch
Battery voltage
Test key switch (See "KEY SWITCH TEST").
Replace switch as needed.
33. X9 connector (terminal A)
Battery voltage
Check 209 Wht wire and connections.
Test Conditions:
• X9 connector connected
• Park brake ENGAGED
34. X10 connector (Wht wire
terminal)
• X10, X11 and X12 disconnected
• Key switch in RUN position, engine OFF
Battery voltage
Test Conditions:
• X10 to cruise control switch connected
• Place and hold cruise control switch in ENGAGE position
Check X9, Wht wire, X10 and connections.
• Park brake ENGAGED
• Key switch in RUN position, engine OFF
35. K8 relay socket (terminal 86)
Battery voltage
Ensure cruise control switch is in ENGAGE
position. Test switch (See "CRUISE
CONTROL SWITCH TEST"). Check X10
connector, Gry wire, X9 connector, and 238
Gry wires and connections.
36. K8 relay socket (terminal 87)
Battery voltage
Test cruise control switch. Check X10
connector, Pur wire, X9 connector, and 247
Pur wires and connections.
37. X11 connector (Gry wire)
Battery voltage
Check Gry wire and connections.
Test Conditions:
• Cruise control switch in ON position
38. X6 (terminal G)
• K8 relay installed
Battery voltage
Test K8 cruise control relay.
39. X12 to frame ground (Blk
wire)
Less than 0.1 ohms
resistance
Check Blk wire, X9 connector, and 050J and
050A Blk wires and connections.
40. X9 to X11 to X12 (Yel wires)
Less than 0.1 ohms
resistance
Check Yel wires and connections.
Test Conditions:
• Key switch in OFF position
Test Conditions:
• X11 connected
• Key switch in RUN position (Engine OFF)
41. X12 connector (Yel wire)
4 - 78
Battery voltage
• Cruise control switch in ON position
• Brake pedal NOT depressed
Test brake switch (See "BRAKE SWITCH
TEST").
4/6/01
CRUISE CONTROL DIAGNOSIS
ELECTRICAL - NORTH AMERICAN
S10 Cruise
Control Switch
1
209 Wht
X10 To S10 Cruise
Control Switch
Wht
Gry
3
S1 Key Switch
Pur
X9-W1 Main Wiring
Harness To W4 Cruise
Control Wiring Harness
Wht
Gry
238 Gry
Pur
247
Pur
238
Gry
4
86
264A Yel
2
9
Yel
Blk
30
87A
87
209 Wht
85
5
247 Pur
264A
Yel
050J Blk
X9-W4 Cruise Control
Wiring Harness To W1
Main Wiring Harness
K8 Cruise Control Relay
9
264B
Yel
Gry Yel
6
S11 Brake
Switch
X11 To S11
Brake Switch
7
Y3 Cruise
Control Magnet
264B Yel
X6-W1 Main Wiring Harness
To Control Panel
X12 To Y3 Cruise
Control Magnet
8
Blk
W1 Battery
Frame
Ground
4/6/01
Yel
9 10
4 - 79
TESTS AND ADJUSTMENTS
TESTS AND ADJUSTMENTS
GROUND CIRCUIT TEST
ELECTRICAL - NORTH AMERICAN
appropriate circuit operation description) so that
voltage will be present at the component. Record
voltage. Voltage must be greater than 0, but
less than 1.0 volt. Some components will have a
very small voltage reading on the ground side and
still be operating correctly.
Reason:
To check for open circuits, loose terminal wire crimps,
poor connections, or corrosion in the ground circuit.
Equipment:
• Ohmmeter or Voltmeter
Results:
• If voltage is 0, the component is open.
• If voltage is greater than 1.0 volt, the ground circuit
is bad. Check for open wiring, loose terminal wire
crimps, poor connections, or corrosion in the
ground circuit.
NOTE: The voltmeter method checks ground
connections under load.
Procedure—OHMMETER METHOD:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove engine side covers.
7. Connect ohmmeter negative (black) lead to
negative terminal of battery. Connect meter
positive (red) lead to negative terminal of battery
and record reading.
8. Connect ohmmeter red lead to ground terminal of
circuit (A) or component to be tested that is closest
to the battery negative terminal. Resistance
reading must be the same or very close to as
the battery negative terminal reading. Work
backward from the battery frame ground on the
ground side of the problem circuit until the
resistance reading increases above 0.1 ohms.
The problem is between the last two test points. If
a problem is indicated, disconnect the wiring
harness connector to isolate the wire or
component and check resistance again. Maximum
allowable resistance in the circuit is 0.1 ohms.
Check both sides of the connectors closely, as
disconnecting and connection may temporarily
solve problem.
A
Battery Frame Ground
M91683
Procedure—VOLTMETER METHOD:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to ON position.
4. Engage park brake.
5. Raise hood.
6. Remove engine side covers.
7. Connect voltmeter negative (black) lead to negative
terminal of battery.
8. Connect voltmeter positive (red) lead to ground
terminal of circuit (A) or component to be tested.
Be sure that component circuit is activated (See
4 - 80
4/6/01
BATTERY TEST
ELECTRICAL - TESTS & ADJUSTMENTS
BATTERY TEST
c
CAUTION
9. Check electrolyte level in each battery cell. Add
clean, soft water as needed. If water is added,
charge battery for 20 minutes at 10 amps.
10. Remove surface charge by placing a small load on
the battery for 15 seconds.
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
the eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoid spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 15—30 minutes.
Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 1.9 L (2 qts.).
3. Get medical attention immediately.
Reason:
To check condition of battery and determine battery
voltage.
11. Use an hydrometer to check for a minimum
specific gravity of 1.265 with less than 50 point
variation in each cell at full charge at 26.7°C
(80°F).
Results:
• If all cells are less than 1.175, charge battery at 10
amp rate.
• If all cells are less than 1.225 with less than 50
point variation, charge battery at 10 amp.
• If all cells are more than 1.225 with less than 50
point variation, load test battery.
• If more than 50 point variation between cells,
replace battery.
12. Use a voltmeter or JTO5685 Battery Tester to
check for a minimum battery voltage of 12.4
VDC.
Equipment:
• Hydrometer
• Voltmeter or JTO5685 Battery Tester
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Clean cable ends, battery terminals and top of
battery.
7. Remove battery.
8. Inspect battery terminals and case for breakage or
cracks.
4/6/01
Results:
• If battery voltage is less than 12.4 VDC, charge
battery.
• If battery voltage is more than 12.4 VDC, test
specific gravity. (See Step 12.)
13. Install battery.
4 - 81
CHARGE BATTERY
ELECTRICAL - TESTS & ADJUSTMENTS
CHARGE BATTERY
or bubbles excessively or becomes too warm to
touch.
Reason:
To increase battery charge after the battery has been
discharged.
Results:
Equipment:
• If MORE THAN 50 point variation between cells,
replace battery.
• If LESS THAN 50 point variation between cells, go
to Step 14.
• Battery charger (variable rate).
Procedure:
NOTE:
13. Check specific gravity after 30 minutes (60 minutes
for maintenance-free battery).
See BATTERY TEST in this group before
charging battery.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove engine side covers.
7. Clean cable ends, battery terminals and top of
battery.
8. Remove battery and check water level.
9. Connect variable rate charger to battery.
10. Start charger at SLOW rate. Increase charge rate
ONE setting at a time. Check charger ammeter
after 1 minute at each setting. Maintain 10 amp
charge rate. Use boost setting as necessary.
11. Check if battery is accepting 10 amp charge rate
after 10 minutes at boost setting.
NOTE: If battery was discharged at slow or unknown
rate, charge battery at 10-15 amps for 6-12
hours. (Maintenance-free battery: 4-8 hours).
14. Continue to charge battery until specific gravity is
1.265 points at 26.7°C (80°F).
15. Load test battery.
16. Install battery.
LOAD TEST BATTERY
Reason:
To check condition of battery under load.
Equipment:
• JTO5685 Battery Tester
Procedure:
Battery Charger
and Booster
Results:
• If battery WILL NOT accept 10 amp charge after 10
minutes at boost setting, replace battery.
• If battery is accepting 10 amp charge after 10
minutes at boost setting, and battery did NOT need
water, go to Steps 12 and 13.
• If battery is accepting 10 amp charge after 10
minutes at boost setting, but battery DID need
water or all cells were BELOW 1.175, go to Steps
10 and 11.
12. Set charger at 15 – 25 amps.
IMPORTANT: Decrease charge rate if battery gases
4 - 82
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Clean cable ends, battery terminals and top of
battery.
7. Remove battery.
8. Turn load knob (A) counterclockwise to OFF
position.
9. Connect tester positive (red) cable to battery
positive (+) terminal (B).
10. Connect tester negative (black) cable to battery
negative (–) terminal (C).
11. Turn load knob (A) of tester clockwise (in) until
amperage reading (D) is equal to:
• cold cranking amperage rating of battery (use blue
scale).
or
• three times ampere hour rating (use black scale).
12. Hold for 15 seconds and turn load knob (A) of tester
counterclockwise (out) into OFF position.
4/6/01
UNREGULATED AMPERAGE TEST
ELECTRICAL - TESTS & ADJUSTMENTS
13. Repeat Steps 8 and 9 above and read condition of
battery at DC Volts scale (E).
C
D
E
B
D.C. AMPS
D.C. VOLTS
A
A
M91220
Results:
• If battery DOES NOT pass test and has NOT been
charged, charge battery and retest.
• If battery DOES NOT pass test and HAS BEEN
charged, replace battery.
UNREGULATED AMPERAGE TEST
40 AMP ALTERNATOR
Reason:
3. Insert a small Phillips screwdriver through the hole
(A) in rear cover of alternator to ground the
regulator to the rear cover. Read amperage on
current gun.
Specifications:
Minimum unregulated amperage . . . . . . . . 40 amps
Results:
• If reading does not meet specifications, verify
voltage at the alternator regulated terminal and
good alternator ground. If voltage and ground are
OK, replace the alternator.
To determine charging output of the alternator stator.
Equipment:
REGULATED AMPERAGE AND
VOLTAGE TESTS
• JTO5712 Current Gun
Reason:
Connections:
1. Put JTO5712 Current Gun over alternator Red wire.
Set current gun for DC current.
To determine the regulated voltage (charging) output of
the alternator.
Equipment:
Procedure:
IMPORTANT: Perform this test quickly to prevent
damage to the battery. DO NOT apply full load to
battery for more than 10 seconds.
• JTO5712 Current Gun
• Voltmeter
• JTO5685 Battery Tester
Procedure:
2. Start and run engine at high idle.
4/6/01
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove engine side covers.
7. Disconnect three pin connector from alternator.
4 - 83
STARTING MOTOR SOLENOID TEST
NOTE: Battery must be in a good state of charge.
B
C
D.C. AMPS
D.C. VOLTS
A
ELECTRICAL - TESTS & ADJUSTMENTS
test for unregulated voltage output. If unregulated
voltage output test meets specifications and you
have verified voltage to ground to regulator/
rectifier, replace regulator/rectifier.
• If at any time voltage increase exceeds 14.7 VDC,
replace regulator/rectifier.
STARTING MOTOR SOLENOID TEST
Reason:
To determine if starting motor is defective.
Equipment:
• Jumper wire
JTO5712
Current Gun
M91292
8. Connect JTO5712 Current Gun to voltmeter and put
around positive (red) battery cable going to
starting motor. Set current gun for DC current.
c
CAUTION
This test will cause engine to turn over. Engine
may start. Ensure tractor drive is disengaged.
Ensure PTO is disengaged.
Procedure:
IMPORTANT:
Turn load knob (A) fully
counterclockwise (out) into OFF position
BEFORE making any test connections.
9. Connect battery tester to battery.
IMPORTANT: Perform this test quickly to prevent
damage to battery tester. DO NOT apply full load
to battery for more than 5 – 10 seconds.
10. Turn load knob clockwise (in) until voltage on
voltage tester scale reads 11 volts for 5 seconds
only to partially drain battery.
11. Quickly turn load knob completely counterclockwise (out) to OFF position.
12. Start and run engine at fast idle (2850 rpm).
Battery voltage should read between 12.2 – 15.0
VDC.
13. Turn load knob clockwise (in) until voltage on tester
voltage scale (B) reads 11 volts and look at current
gun for a minimum reading of 13.5 amps.
14. Quickly turn load knob completely counterclockwise (out) to OFF position.
15. After load test, battery voltage (B) should return to
the voltage level prior to test.
1. Park machine on level surface.
2. Place drive in NEUTRAL.
3. Disengage PTO.
4. Turn key switch to OFF position.
5. Engage parking brake.
6. Raise hood.
7. Remove left engine side cover.
8. Disconnect fuel shutoff solenoid wire connector.
9. Disconnect 309 Wht wire from starting motor
solenoid terminal (A).
10. Connect jumper wire to positive (+) battery terminal
and briefly jump to starting motor solenoid terminal
(A).
Results:
• Starting motor runs—solenoid is good, test
cranking circuit wiring.
• Starting motor DOES NOT run—go to next step.
11. Remove rubber boot from terminal (B).
12. Remove plastic cover from terminal (C).
13. Connect jumper wire between starting motor
solenoid large terminals (B and C).
Results:
• If current gun amp reading is BELOW specification,
4 - 84
4/6/01
STARTING MOTOR AMPERAGE DRAW TEST
ELECTRICAL - TESTS & ADJUSTMENTS
13. Turn load knob fully counterclockwise.
A
C
M87365
B
A
M91309
Results:
Results:
• Starting motor runs—replace starter.
• Starting motor DOES NOT run—check battery
cables, then replace starting motor.
• If amperage is greater than 150 amps, test
starting motor No-Load RPM and Amperage to
determine if the starting motor is binding or
damaged.
• If the starting motor is good, check internal engine
components for binding or damage.
STARTING MOTOR AMPERAGE
DRAW TEST
Reason:
To determine the amperage required to crank the
engine and check starter motor operation under load.
Equipment:
• JTO5685 Battery Tester
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove engine front and left side covers.
7. Test ground connections and battery.
8. Disconnect fuel shutoff solenoid connector.
IMPORTANT: Turn load knob (B) fully counterclockwise before making any test connections.
9. Connect JTO5685 Battery Tester (A) to battery.
10. Crank engine and read voltage.
11. Turn key switch to the OFF position. Adjust load
knob until battery voltage reads the same as when
cranking.
12. Read amperage on meter.
4/6/01
4 - 85
NO-LOAD AMPERAGE DRAW AND RPM TESTS
NO-LOAD AMPERAGE DRAW AND
RPM TESTS
STARTING MOTOR
Reason:
To determine if starter is binding or has excessive
amperage draw under no-load.
7. Remove starting motor assembly from tractor and
place starting motor in vice.
8. Connect jumper cables to a 12 volt battery
9. Connect positive (+) cable to solenoid battery
terminal on starting motor.
10. Connect negative (–) cable to starting motor body.
11. Attach Current Gun to positive (+) cable.
IMPORTANT: Complete this test in 20 seconds or
less to prevent starting motor damage.
Equipment:
• JTO2153 Current Clamp
• JT05791 Multitester
• JTO5719 Hand-Held Digital Tachometer
• Jumper Cables
• Jumper wire
Procedure:
NOTE:
ELECTRICAL - TESTS & ADJUSTMENTS
12. Use a jumper wire to briefly connect positive (+)
starting motor terminal to solenoid terminal.
Starting motor should engage and run.
13. Read and record starting motor amperage and
rpm.
Results:
Check that battery is fully charged and of
proper size to ensure accuracy of test.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove left engine side cover.
• If solenoid “clicks” or chatters and starting motor
does not turn, replace starting motor.
• If pinion gear engages and starting motor doesn’t
turn, replace starting motor.
• If starting motor engages and runs, but amperage
is more than 60 Amps at 4440 rpm, repair or
replace starting motor.
• If free-running rpm is less than 4000 rpm, repair
or replace starting motor.
Starting Motor
Terminal
JTO2153
Current Clamp
JTO5791
Multitester
Solenoid
Terminal
M91293
4 - 86
4/6/01
RELAY TEST
ELECTRICAL - TESTS & ADJUSTMENTS
RELAY TEST
Results:
• There should be continuity between terminals A
(30) and E (87).
• If continuity is NOT correct, replace relay.
Reason:
To check relay terminal continuity in the energized and
de-energized condition.
Equipment:
• Ohmmeter or continuity tester
• 12 volt battery and small jumper wires
ENGINE COOLANT TEMPERATURE
SENSOR TEST
Reason:
To verify coolant temperature sensor is functioning
properly.
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Open plastic panel below steering column support.
6. Remove relay from fuse and relay load center.
7. Check terminal continuity using an ohmmeter or
continuity tester.
86
30
87
85
30
87a
A
Equipment:
• Ohmmeter
Procedure:
NOTE: Perform test with engine at room temperature.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove engine side covers.
7. Disconnect 359 Wht wire from engine coolant
temperature sensor.
8. Measure resistance between terminal and sensor
body.
86
D
87a
87
85
C
E
A
B
M91294
M91295
Results:
• There should be continuity between terminals A
(30) and B (87a).
• There should be approximately 80 ohms resistance
between terminals C (85) and D (86).
• There should NOT be continuity between any other
terminals.
8. Connect a small jumper wire from battery positive
(+) terminal to relay terminal C (85). Connect a
small jumper wire from relay terminal D (86) to
battery negative terminal (–).
9. If resistance does not meet specification, replace
coolant temperature switch.
10. Drain engine coolant and remove coolant
temperature switch.
11. Place sensor (A) in antifreeze solution heated to
approximately 96°C (205°F). Measure resistance
while sensor is heated.
12. If resistance does not meet specification, replace
coolant temperature sensor.
Specifications:
Variable Resistance . . . . . . . . . . . . . 40 – 700 ohms
4/6/01
4 - 87
ENGINE OIL PRESSURE SWITCH TEST
ENGINE OIL PRESSURE SWITCH
TEST
Reason:
To determine if engine oil pressure switch is functioning
properly, to warn operator that oil pressure has
dropped below minimum operating pressure.
Equipment:
ELECTRICAL - TESTS & ADJUSTMENTS
Results:
There should be NO continuity between switch terminal
and ground with the engine running.
• If the switch DOES have continuity to engine block
(ground) with engine running, check engine oil
pressure.
• If oil pressure meets specification; replace the oil
pressure switch.
MANIFOLD HEATER TEST
• Ohmmeter
Reason:
Procedure:
To test proper operation of manifold heater.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove right engine side cover.
7. Disconnect 347 Pur wire from oil pressure switch
(A).
8. Connect black lead of ohmmeter to engine block
and red lead of ohmmeter to terminal of switch.
9. Measure resistance between terminal and engine
block.
Equipment:
• Ohmmeter
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove right engine side cover.
7. Remove manifold heater lead from terminal (A).
8. Check continuity across terminal (A) and frame
ground. The reading should be between 0.3 – 0.5
ohms.
A
A
M91345
Results:
• There should be continuity between terminal and
ground.
• If there is NO continuity between terminal and
ground; replace the oil pressure switch.
NOTE: Be sure to apply Pipe Sealant with TEFLON®
to threads of switch anytime it is installed.
M91879
Results:
• If manifold heater does not have between 0.3 – 0.5
ohms resistance, replace heater unit.
® TEFLON is a registered trademark of the DuPont
Company.
10. Start and run engine.
11. Measure resistance between terminal and engine
block.
4 - 88
4/6/01
DIODE BLOCK TEST
ELECTRICAL - TESTS & ADJUSTMENTS
DIODE BLOCK TEST
Results:
Reason:
To verify that diodes in diode block are functioning
properly.
V2 DIODE TEST
Equipment:
• Ohmmeter, continuity tester or diode tester
Terminal positions are indicated on diode
block.
1. Remove diode block from load center.
2. Connect ohmmeter or continuity tester to each
diode as indicated in table.
3. Check for continuity.
A
C
Reason:
To verify that the V2 diode is functioning properly.
Procedure:
NOTE:
• Each diode should have continuity in one direction
only.
• If a diode has continuity in both directions, or has
no continuity, replace diode block.
D
F
E
B
H
NOTE: The V2 diode is soldered in-line and located in
the main wiring harness protective wrap. This
procedure isolates the diode from other
components and allows testing of the diode
without removing it.
Off
On
K
573A Org
S5 Rear
PTO Switch
J
A
573B
Org
V2
Diode
C
B
86
K9 Rear
PTO Relay
587B
Org
E
Dk Grn
F
587A Org
X2
S3 Transmission
Neutral Switch
587D Org
587C
Org
K
D
J
H
86
M91301
K5 Safety
Relay
Continuity:
Red Test
Lead (+)
Black Test
Lead (–)
Continuity
A
B
Yes
C
B
Yes
D
E
Yes
F
E
Yes
H
J
Yes
K
J
Yes
4/6/01
573C Org
30
K6 Safety
Relay
Equipment:
• Ohmmeter, continuity tester or multimeter
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Disconnect main wiring harness connector from
rear PTO switch and from transmission neutral
switch.
6. Remove K5, K6 and K9 relays from load center.
4 - 89
FUSE TEST
ELECTRICAL - TESTS & ADJUSTMENTS
FUSE TEST
K9 Rear PTO Relay
(Socket terminal 86)
K5 Safety Relay
(Socket terminal 86)
Reason:
86
86
To verify that fuse has continuity.
30
87A
87
30
87A
87
Equipment:
85
85
• Ohmmeter or continuity tester
Procedure:
1. Remove fuse from connector.
2. Check visually for broken filament (A).
3. Connect ohmmeter or continuity tester to each end
of fuse.
4. Check for continuity.
A
7. Set multimeter to diode test range.
NOTE:
The multimeter will measure and display
voltage drop across diode when set to diode
test range.
8. Connect multimeter leads to the K5 and K9 relay
sockets, both at terminal 86. Check meter.
9. Reverse position of multimeter leads and retest.
NOTE: If using ohmmeter for test, resistance in one
direction will be approximately 80,000 ohms,
and reading will "fall" during testing. Ohmmeter
reading in opposite direction will be between 4
and 5 mega-ohms and "rise" during testing.
M48391
Results:
• If continuity is not indicated, replace the fuse.
Results:
• Meter should "beep" once in one meter lead
position only.
• Meter has continuous tone in either position, diode
is shorted, replace diode.
• Meter displays "OL" in both positions, diode is
"open", replace diode.
4 - 90
4/6/01
CONTROL PANEL LIGHT TEST
ELECTRICAL - TESTS & ADJUSTMENTS
CONTROL PANEL LIGHT TEST
KEY SWITCH TEST
Reason:
Reason:
To verify that the bulb has continuity.
To verify that key switch functions properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Remove bulb from socket.
2. Check visually for broken filament (A).
3. Connect ohmmeter or continuity tester to each
terminal of bulb.
4. Check for continuity.
A
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Disconnect and lift control panel.
6. Disconnect key switch from wiring harness.
7. Remove key switch from tractor.
8. Use an ohmmeter or continuity tester to test switch
continuity in OFF, RUN, START, and AID (key
pushed in) positions.
4
1
2
E
6
D
5
3
C
7
M48392
Results:
• If continuity is not indicated, replace bulb.
Start
Run
Off
Acc.
Aid
Off
F
Spare
B
A
M91296
Key Switch Continuity:
Switch Position
Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and A
ACCESSORY. . . . . . . . . . . . . . . . . . . . . . . . . .A and B
RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and D
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and D
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and E
AID (Key in RUN position & PUSHED IN) . . .A and B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and D
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and F
Results:
• If any continuity is NOT correct, replace the switch.
4/6/01
4 - 91
LIGHT SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
LIGHT SWITCH TEST
SEAT SWITCH TEST
Reason:
Reason:
To verify that light switch functions properly.
To verify that seat switch functions properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Remove screws securing control panel and lift
control panel.
6. Disconnect light switch connector from harness.
7. Use an ohmmeter or continuity tester to test switch
continuity.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise seat.
6. Disconnect seat switch from wiring harness.
Operator Off
Operator On
3
(0) Off
(1) Hazard
2
(2) Road
(3) Field
A
1
2
B
B
B
1
3
4
4
M91297
Light Switch Continuity:
Switch Position
M91298
Not Used
Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
ROAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
FIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B and 1
7. Check continuity across switch terminals. There
should be no continuity.
8. Depress seat switch plunger. Continuity should
exist between terminals A and B.
Results:
• If any continuity is not correct, replace seat switch.
Results:
• If any continuity is NOT correct, replace the switch.
4 - 92
4/6/01
ELECTRICAL - TESTS & ADJUSTMENTS
TRANSMISSION NEUTRAL SWITCH TEST – CST
TRANSMISSION NEUTRAL SWITCH
TEST – CST
TRANSMISSION NEUTRAL SWITCH
TEST – HST & SRT
Reason:
Reason:
To verify that switch functions properly.
To that verify switch functions properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Place gear selector lever in NEUTRAL.
6. Disconnect neutral start switch from harness.
7. Check for continuity between terminals (A) and (B).
If no continuity exists, ensure that gear selector is
in NEUTRAL.
On
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Place gear range selector lever in NEUTRAL.
6. Disconnect neutral start switch from harness.
NOTE: Switch is normally open. When the pedals are
not pushed, the pedal linkage closes the
contacts. Depressing either forward or reverse
directional pedal allows switch to open.
Off
7. Check for continuity between terminals (A) and (B).
If no continuity exists, ensure that directional
pedals for transmission are not depressed.
Off
On
A
B
M91686
8. If continuity can be obtained when transmission is
in NEUTRAL;
• Place gear selector in any gear,
• Check for continuity through switch. There should
be NO continuity.
9. If continuity does not match specifications:
• Remove switch(es) from transmission housing.
• Test switch(es) for continuity. Each switch is
normally closed. Depress contact ball on end of
switch and check continuity. Switch should be open
(NO continuity with ball depressed.
10. Replace switch if correct continuity can not be
obtained.
Switch Continuity:
Switch Position
Terminal Continuity
B
A
M91343
8. Press down on forward directional pedal. No
continuity should exist between terminal (A) and
terminal (B).
9. Press down on reverse directional pedal. No
continuity should exist between terminal (A) and
terminal (B).
10. If continuity is not correct, replace switch.
11. Adjust switch as needed.
• Switch should close when forward directional pedal
is depressed 0.25 - 0.375 in. (6 - 9 mm).
NORMALLY CLOSED . . . . . . . . . . . . . . . . . . .A and B
BALL DEPRESSED (OPEN). . . . . . . . . . . . . . . . None
4/6/01
4 - 93
TURN SIGNAL SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
TURN SIGNAL SWITCH TEST
HAZARD SWITCH TEST
Reason:
Reason:
To verify that turn signal switch functions properly.
To verify that hazard switch functions properly.
Equipment:
Equipment:
• Ohmmeter
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Remove screws securing control panel, and lift
panel.
6. Disconnect turn signal switch connector from
harness.
7. Use an ohmmeter or continuity tester to test switch
continuity in OFF, L.H., and R.H. positions.
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Engage park brake.
4. Remove plastic kick panel from below steering
column support.
5. Disconnect hazard lights switch connector from
harness.
6. Use an ohmmeter or continuity tester to test switch
continuity in OFF and ON positions.
On
Off
(0) Right
49
(1) Off
(2) Left
Flasher
F
1
A
31
2
49a
49a
B
4
49
L
5
3
30
15
R
31
L
D
R
6
C
E
Turn Signal Switch Continuity:
Switch Position
15
M91299
30
M91687
Hazard Switch Continuity:
Terminal Resistance
OFF
A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms
A to C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms
B to C. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1 ohms
L.H. POSITION
A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . variable
A to C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ohms
A to D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . open
A to E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ohms
A to F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . variable
B to F . . . . . . . . . . . . . . . . . . . . . . . . . . . . .o.1 ohms
R.H. POSITION . . . . . . . . . . . . . . . . . . . . . . . .A and C
Results:
Switch Position
Terminal Continuity
OFF (Depressed) . . . . . . . . . . . . . . . . . . . . 49 and 15
ON (Released). . . . . . . . . . . . . . . . . . . . . . . 49 and 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49a and R
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49a and L
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R and L
49a to 31 . . . . . . . . . . . . . .approximately 24 ohms
R to 31 . . . . . . . . . . . . . . . .approximately 24 ohms
L to 31 . . . . . . . . . . . . . . . .approximately 24 ohms
Results:
• If any resistance value is NOT correct, replace the
switch.
• If any resistance value is NOT correct, replace the
switch.
4 - 94
4/6/01
REAR & MID PTO SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
REAR & MID PTO SWITCH TEST
2-SPEED PTO SWITCH TEST
Reason:
Reason:
To verify that switch functions properly.
To verify that switch functions properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Engage park brake.
4. Disengage PTO.
5. Disconnect switch from wiring harness.
1. Park machine on level surface.
2. Turn key switch to OFF position.
3. Engage park brake.
4. Disengage PTO. Shift 2-speed PTO selector lever
to low (540 rpm) range.
5. Disconnect wiring harness connectors from PTO
540 rpm and 750 rpm speed range switches.
On
Off
On
Off
A
B
M91686
A
B
6. Using an ohmmeter or continuity tester, check
continuity through switch. The switch should be
closed (continuity with rear PTO DISENGAGED),
and the switch should be open (no continuity with
rear PTO engaged).
7. If continuity does not match specifications:
• Remove switch(es) from transmission housing.
• Test switch(es) for continuity. Each switch is
normally closed. Depress contact ball on end of
switch and check continuity. Switch should be open
(NO continuity) with ball depressed.
8. Replace switch if correct continuity can not be
obtained.
Switch Continuity:
Switch Position
M91686
6. Using an ohmmeter or continuity tester, check
continuity through each switch. One switch should
be closed (continuity), and the other switch should
be open (no continuity).
7. Shift 2-speed PTO selector lever to high (750 rpm)
range.
8. Using an ohmmeter or continuity tester, check
continuity through each switch. The continuity
should be reversed through each switch.
9. If continuity does not match specifications:
• Remove switch(es) from transmission housing.
• Test switch(es) for continuity. Each switch is
normally closed. Depress contact ball on end of
switch and check continuity. Switch should be open
(NO continuity) with ball depressed.
10. Replace switch if correct continuity can not be
obtained.
Terminal Continuity
NORMALLY CLOSED . . . . . . . . . . . . . . . . . . .A and B
BALL DEPRESSED (OPEN). . . . . . . . . . . . . . . . None
Switch Continuity:
Switch Position
Terminal Continuity
NORMALLY CLOSED . . . . . . . . . . . . . . . . . . .A and B
BALL DEPRESSED (OPEN) . . . . . . . . . . . . . . . . None
4/6/01
4 - 95
FRONT PTO SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
FRONT PTO SWITCH TEST
FRONT PTO SOLENOID TEST
Reason:
Reason:
To verify that PTO switch functions properly.
To verify that the solenoid coil is operating properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Voltmeter
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Remove plastic kick panel from below steering
column support.
6. Disconnect PTO switch connector from harness.
7. Use an ohmmeter or continuity tester to test switch
continuity.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Remove tunnel cover and rock shaft valve panel.
B
A
ON
A
B
M91689
On
G
Off
B
A
G
H
H
M91221
Results:
8. If resistance does not meet specifications, replace
solenoid.
Switch Continuity:
Switch Position
6. Disconnect PTO solenoid connector.
7. Using an ohmmeter or continuity tester, check if
continuity exists between solenoid terminals.
Terminal Continuity
ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G and H
Results:
Specifications:
A to B. . . . . . . . . . . . . . . . . . . . . . . 8.0 – 9.0 ohms
9. Check for grounds or shorts by connecting tester to
one coil terminal and the other to bare metal of coil
case.
• If continuity is NOT correct, replace the switch.
Results:
• Replace PTO solenoid if continuity is present from
either terminal to solenoid coil case.
4 - 96
4/6/01
CRUISE CONTROL SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
CRUISE CONTROL SWITCH TEST
CRUISE CONTROL MAGNET TEST
Reason:
Reason:
To verify that cruise control switch functions properly.
To verify that cruise control magnet is operating
properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Disconnect and raise control panel.
6. Disconnect cruise control switch connector from
harness.
7. Use an ohmmeter or continuity tester to test switch
continuity.
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Disconnect cruise control magnet connector from
harness.
6. Use an ohmmeter or continuity tester to test magnet
and housing continuity.
Off
On
Engage
B
A
C
B
A
Blk
C
B
A
Wht
M91311
Gry
M91306
Magnet Continuity:
A to B. . . . . . . . . . . . . . . . . . Approximately 20 ohms
A to MAGNET HOUSING . . . . . . . . . . . . . . . . . . None
B to MAGNET HOUSING . . . . . . . . . . . . . . . . . . None
Switch Continuity:
Switch Position
Terminal Continuity
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B
ENGAGE (momentary). . . . . . . . . . . . . . . A, B, and C
Results:
• If resistance and continuity are NOT correct,
replace the magnet.
Results:
• If continuity is NOT correct, or exists in any other
combination than shown above, replace the switch.
4/6/01
4 - 97
BRAKE SWITCH TEST
ELECTRICAL - TESTS & ADJUSTMENTS
BRAKE SWITCH TEST
PARK BRAKE SWITCH TEST
Reason:
Reason:
To verify that switch functions properly.
To verify that switch functions properly.
Equipment:
Equipment:
• Ohmmeter or continuity tester
• Ohmmeter or continuity tester
Test Procedure:
Test Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Disconnect brake switch connector.
5. Use an ohmmeter or continuity tester to test switch
continuity.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Release parking brake.
5. Disconnect brake switch connector.
6. Use an ohmmeter or continuity tester to test switch
continuity.
On
Off
A
A
B
B
D
C
C
B
C
D
M91646
A
M91300
Switch Continuity:
Switch Continuity:
Switch Position
Terminal Continuity
RELEASED . . . . . . . . . . . . . . . . . . . . . . . . . . .B and C
DEPRESSED . . . . . . . . . . . . . . . . . . . . . . . . . .A and B
Switch Position
Terminal Continuity
RELEASED . . . . . . . . . . . . . . . . . . . . . . . . . . .B and C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and D
Results:
• If continuity is NOT correct, or continuity exists in
any other combination than listed above, replace
switch.
Results:
• If continuity is NOT correct, or continuity exists in
any other combination than listed above, replace
switch.
Adjustment Procedure:
1. Release brake pedal.
2. Loosen switch bracket hardware.
3. Move switch until switch plunger closes.
4. Check that switch does not bottom when brake
pedal is released.
5. Tighten bracket hardware.
6. Check that switch opens when brake pedal is
depressed.
4 - 98
Adjustment Procedure:
1. Engage parking brake.
2. Loosen switch bracket hardware.
3. Move switch until switch plunger is about 3 mm (1/8
in.) from bottoming.
4. Check that switch does not bottom when parking
brake is fully set. Increase clearance if needed.
5. Tighten bracket hardware.
6. Check switch operation.
4/6/01
FUEL GAUGE SENSOR TEST
ELECTRICAL - TESTS & ADJUSTMENTS
FUEL GAUGE SENSOR TEST
FUEL SHUTOFF SOLENOID TESTS
Reason:
Reason:
To verify that the fuel gauge sensor is operating
properly.
To verify that the solenoid coils are operating properly.
Equipment:
• Ohmmeter or continuity tester
• Voltmeter
Equipment:
• Ohmmeter or continuity tester
Procedure:
Procedure:
1. Park machine on level surface.
2. Disengage PTO.
3. Engage park brake.
4. Raise hood.
5. Turn key switch to ON position.
6. Disconnect Org wire from fuel sensor and check
fuel gauge. The fuel gauge must drop to EMPTY. If
not, see "POWER CIRCUIT DIAGNOSIS".
7. Short the Org wire to the black wire connector on
the fuel sensor. The gauge must rise to FULL. If
not, test the fuel sensor ground circuit.
8. If the gauge does not correctly indicate fuel levels
based on the two tests above, proceed to step 9.
9. Disconnect fuel gauge sensor wires.
10. Remove sensor from fuel tank.
11. Using an ohmmeter connected to fuel gauge
sensor contacts, check if continuity exists between
terminals. If continuity exists, measure resistance
across terminals as float and float arm are moved
through full range of motion.
1. Park machine on level surface.
2. Disengage PTO.
3. Turn key switch to OFF position.
4. Engage park brake.
5. Raise hood.
6. Remove right engine side cover.
7. Disconnect fuel shutoff solenoid connector.
8. Using an ohmmeter or continuity tester, check if
continuity exists between all solenoid terminals.
A
M87349
C
Org Wire
B
Results:
9. If resistance does not meet specifications, replace
fuel shutoff solenoid.
Blk Wire
Specifications:
Float
M91652
Results:
12. If resistance does not meet specifications, replace
fuel gauge sensor.
Specifications:
Variable Resistance . . . . . . . . . . . . . 5 – 95 ohms
4/6/01
A to B. . . . . . . . . . . . . . . . . . . . . . . . . . . .0.4 ohms
A to C. . . . . . . . . . . . . . . . . . . . . . . . . . .12.4 ohms
B to C. . . . . . . . . . . . . . . . . . . . . . . . . . .12.0 ohms
10. Check for grounds or shorts by connecting tester to
one coil terminal and the other to bare metal of coil
case.
Results:
• Replace fuel shutoff coil if continuity is present.
4 - 99
FUEL SHUTOFF SOLENOID TESTS
ELECTRICAL - TESTS & ADJUSTMENTS
11. Connect fuel shutoff solenoid connector.
12. Listen for click when fuel shutoff solenoid pulls in
when either:
• Operator on seat with or without park brake
engaged and key switch turned to ON position;
or:
• Operator off seat with park brake engaged and key
switch turned to ON position;
Results:
• If click is not heard when fuel shutoff solenoid pulls
in, see "FUEL SUPPLY OPERATION".
4 - 100
4/6/01
ELECTRICAL - EUROPEAN
EUROPEAN ELECTRICAL SECTION
The European road tractors have the same electrical
circuits as the North American tractors with the addition
of lighting circuits required to meet EEC Machinery
Directives.
The main electrical wiring harness is specific to the
European models, and is identical among all of the
European 4200, 4300 and 4400 series tractors.
Lighting additions include the hazard lights switch,
flasher relay, brake lights, position lights, and additional
control panel indicator lights (2-speed PTO, and trailer
indicator lights).
The European tractors have front and 2-speed PTOs
(540 and 750 rpm) with control panel indicator lights.
The European tractor wiring harness contains the
same wires (both color and number) as the North
American tractors, with additional wires required for the
additional circuits.
There are variations between the North American and
European main wiring harnesses in connector to wire
pin locations and numbers. While some circuits such
as the Cranking Circuit may be identical, other circuits
contain differences that require using the diagnosis
sections specific to either North American or European
tractors.
Common components (such as the key switch, fuel
shutoff solenoid, or park brake switch) are cross
referenced to the shared Electrical Tests and
Adjustments
section.
(See
“TESTS
AND
ADJUSTMENTS”). The tests and adjustments given in
this section can be used by any North American or
European service technician.
EUROPEAN ELECTRICAL SECTION
ELECTRICAL SCHEMATIC AND
WIRING HARNESS LEGEND
NOTE: The wiring harness changed at serial numbers:
LV4200E329006–
LV4300E339506–
LV4400E349015–
X3 was eliminated and all neutral transmission
switches now plug into X2.
X15 and the 2-speed PTO wiring harness were
eliminated. X36 and X37 were added to
connect directly to S14 and S15 (540 rpm and
750 rpm PTO switches).
B1—Fuel Gauge Sensor (SE5, W1)
B2—Engine Oil Pressure Switch (SE5, W1)
B3—Engine Coolant Temperature Sensor (SE5, W1)
B4—Horn (SE5, W1)
E1—LH Front Turn/Hazard Light (SE5, W1)
E2—LH RearTurn/Hazard Light (SE5, W1)
E3—RH Front Turn/Hazard Light (SE5, W1)
E4—RH RearTurn/Hazard Light (SE5, W1)
E5—LH Headlight (SE6, W1)
E6—RH Headlight (SE6, W1)
E7—LH Work Light (Option)(SE6, W1)
E8—RH Work Light (Option)(SE6, W1)
E9—LH Front Position Light (SE6, W1)
E10—LH Rear Position Light (SE6, W1)
E11—LH Brake Light (SE6, W1)
E12—RH Front Position Light (SE6, W1)
E13—RH Rear Position Light (SE6, W1)
E14—RH Brake Light (SE6, W1)
E15—License Plate Light (SE6, W1)
F1—Fuse - 30 amp (SE1, W1)
F2—Fuse - 30 amp (Option)(SE4, W1)
F3—Fuse - 30 amp (SE4, W1)
F4—Fuse - 20 amp (SE4, W1)
F5—Fuse - 10 amp (SE1, W1)
F6—Fuse - 20 amp (SE5, W1)
F7—Fuse - 20 amp (SE5, W1)
F8—Fuse - 20 amp (SE6, W1)
F9—Fuse - 20 amp (SE6, W1)
G1—Battery (SE1, W1)
G2—Alternator (SE3, W1)
H1—RH Turn Light (SE5, W1)
H2—LH Turn Light (SE5, W1)
4/6/01
4 - 101
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND
ELECTRICAL - EUROPEAN
H3—(Not Used)
S11—Brake Switch (Option)(SE5, W1)
H4—Discharge Light (SE5, W1)
S12—Horn Switch (SE5, W1)
H5—Cold Start Light (SE5, W1)
S13—Hazard Switch (SE5, W1)
H6—Park Brake Light (SE5, W1)
S14—540 PTO Switch (Option)(SE2, W1)
H7—Engine Oil Pressure Light (SE5, W1)
S15—750 PTO Switch (Option)(SE2, W1)
H8—Cruise Control Indicator Light (SE5, W1)
S16—Brake Switch (SE5, W1)
H9—Mid PTO Light (SE5, W1)
S17—Mid PTO Switch (Option)(SE2, W1)
H10—540 PTO Light (SE5, W1)
S18—Front PTO Switch (Option)(SE2, W1)
H11—750 PTO Light (SE5, W1)
V1—Diode Block (SE2, W1)
H12—Bulb Integrity Light (SE5, W1)
V2—Diode (SE2, W1)
H13—Trailer 1 Light (SE5, W1)
W1—Battery Frame Ground (SE1, W1)
H14—Trailer 2 Light (SE5, W1)
Y1—Starting Motor Solenoid (SE1, W1)
H15—Front PTO Light (SE5, W1)
Y2—Fuel Shutoff Solenoid (SE2, W1)
H16—Backup Alarm (SE2, W1)
Y3—Cruise Control Magnet (Option)(SE5, W1)
K1—Manifold Heater Relay (SE2, W1)
Y4—Front PTO Solenoid (Option)(SE2, W1)
K2—Start Relay (SE1, W1)
K3—Fuel Shutoff Relay (SE2, W1)
CONNECTORS:
K4—Engine Run Relay (SE2, W3)
X1—W1 Main Wiring Harness to Fusible Link (SE1,
W1)
K5—Safety Relay (SE2, W1)
K6—Safety Relay (SE2, W1)
K7—Accessory Relay (SE4, W1)
K8—Cruise Control Relay (Option)(SE5, W1)
K9—Rear PTO Relay (SE2, W1)
K10—Mid PTO Light Relay (Option) (SE2, W1)
K11—Brake Light Relay (SE5, W1)
K12—Flasher Relay (SE5, W1)
M1—Starting Motor (SE1, W1)
P1—Engine Tachometer (SE5, W1)
P2—Hour Meter (SE5, W1)
P3—Fuel Gauge (SE5, W1)
P4—Engine Coolant Temperature Gauge (SE5, W1)
R1—Manifold Heater (SE1, W1)
R2—Variable Thermistor (SE2, W1)
S1—Key Switch (SE1, W1)
S2—Seat Switch (SE1, W1)
S3—Transmission Neutral Switch (HST and SRT)
(SE2, W1)
S4—Transmission Neutral Switch (CST)(SE1, W1)
S5—(Not Used)
S6—Rear PTO Switch (SE2, W1)
S7—Park Brake Switch (SE2, W1)
S8—Turn Signal Switch (SE5, W1)
NOTE: Early Model Tractors: X2 supplied with cap and
jumper wire if X3 is connected to transmission
neutral switch on or gear (CST) tractors.
X3 supplied with cap and jumper wire if X2 is
connected to transmission neutral switch on
hydro (HST)
or SyncReverser™ (SRT)
tractors.
Later Model Tractors: X2 is used for all model
tractors to connect the transmission neutral
start switch.
LV4200E329006–
LV4300E339506–
LV4400E349015–
The 2-speed PTO harness was eliminated and
the main wiring harness connects directly to
the two separate PTO switches (S14 and S15).
connector X15 replaced by X36 and X37.
X2—W1 Main Wiring Harness to W3 HST Neutral Start
Wiring Harness (HST and SRT) (SE2, W1)
X3—W1 Main Wiring Harness to S4 Transmission
Neutral Switch (Gear Only) (SE2, W1)
X4—W1 Main Wiring Harness to W2 Fuel Shutoff
Solenoid Wiring Harness (SE2, W1)
X5—W1 Main Wiring Harness to S17 Mid PTO Switch
(Option) (SE2, W1)
X6—W1 Main Wiring Harness to Control Panel Circuit
Board (SE4/SE5, W1)
S9—Light Switch (SE5, W1)
X7—W1 Main Wiring Harness to Control Panel Circuit
Board (SE4/SE5, W1)
S10—Cruise Control Switch (Option)(SE5, W1)
X8—W1 Main Wiring Harness to Control Panel Circuit
4 - 102
4/6/01
ELECTRICAL - EUROPEAN
ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND
Board (SE5, W1)
Wiring Harness (Option)(SE2, W1)
X9—W1 Main Wiring Harness to W4 Cruise Control
Wiring Harness (SE4, W1)
X35—W8 Front PTO Wiring Harness to Y4 Front PTO
Solenoid (Option)(SE2, W1)
X10—W4 Cruise Control Wiring Harness to S10 Cruise
Control Switch (SE5, W4)
X36—W1 Main Wiring Harness to S14 540 Rear PTO
Switch (SE2, W1) (Later Models)
X11—W4 Cruise Control Wiring Harness to S11 Brake
Switch (SE5, W4)
X37—W1 Main Wiring Harness to S16 750 Rear PTO
Switch (SE2, W1) (Later Models)
X12—W4 Cruise Control Wiring Harness to W5 Cruise
Control Magnet Wiring Harness (SE5, W4)
WIRING HARNESSES:
X13—W1 Main Wiring Harness to W6 Trailer
Connector Wiring Harness (SE5/SE6, W1)
X14—W1 Main Wiring Harness to W6 Trailer
Connector Wiring Harness (SE4, W1)
X15—W1 Main Wiring Harness to W7 2-Speed PTO
Wiring Harness (SE2, W1) (Early Models Only)
X16—W1 Main Wiring Harness to E8 RH Work Light
(Option) (SE6, W1)
X17—W1 Main Wiring Harness to E7 LH Work Light
(Option) (SE6, W1)
X18—W1 Main Wiring Harness to E1 LH FrontTurn/
Hazard Light
W1—Main Wiring Harness
W2—Fuel Shutoff Solenoid Wiring Harness
W3—HST Transmission Neutral Start Wiring Harness included in the W4 Wiring Harness protective
wrap
W4—Cruise Control Wiring Harness (Option)
W5—Cruise Control Magnet Wiring Harness (Option)
W6—Trailer Connector Wiring Harness (Option)
W7—2-Speed PTO Wiring Harness (Early Models
Only)
W8—Front PTO Wiring Harness (Option)
X19—W1 Main Wiring Harness to E2 LH Rear Turn/
Hazard Light
X20—W1 Main Wiring Harness to E9 LH Front Position
Light
X21—W1 Main Wiring Harness to E1 LH FrontTurn/
Hazard Light and E9 LH Front Position Light
X22—W1 Main Wiring Harness to E10 LH Rear
Position Light
X23—W1 Main Wiring Harness to E11 LH Brake Light
X24—W1 Main Wiring Harness to E2 LH Rear Turn/
Hazard Light, E10 LH Rear Position Light, and
E11 LH Brake Light
X25—W1 Main Wiring Harness to E3 RH Front Turn/
Hazard Light
X26—W1 Main Wiring Harness to E4 RH Rear Turn/
Hazard Light
X27—W1 Main Wiring Harness to E13 RH Rear
Position Light
X28—W1 Main Wiring Harness to E14 RH Brake Light
X29—W1 Main Wiring Harness to E4 RH Rear Turn/
Hazard Light, E13 RH Rear Position Light, and
E14 RH Brake Light
X30—W1 Main Wiring Harness to E12 RH Front
Position Light
X31—W1 Main Wiring Harness to E3 RH Front Turn/
Hazard Light and E12 RH Front Position Light
X32—W1 Main Wiring Harness to E15 License Plate
Light
X33—W1 Main Wiring Harness to S16 Brake Switch
X34—W1 Main Wiring Harness to W8 Front PTO
4/6/01
4 - 103
COMPONENT LOCATION – TRACTOR
ELECTRICAL - EUROPEAN
COMPONENT LOCATION – TRACTOR
S9 Light Switch
Control Panel
S18 Front
PTO Switch
(Option)
X6, X7, and X8
S11 Brake Switch
S1 Key Switch
B1 Fuel Gauge Sensor
S8 Turn
Signal
Switch
Y3 Cruise Control Magnet
R1 Manifold Heater
Y2 Fuel Shutoff
Solenoid
Load Center
B3 Engine Coolant
Temperature Sensor
K12 Flasher
W1 Battery
Frame
Ground
(RH Side)
M1 Starting
Motor
X1
Fusible
Link
G2 Alternator
G1 Battery
M91684
4 - 104
4/6/01
COMPONENT LOCATION – TRACTOR
ELECTRICAL - EUROPEAN
E4 RH Rear Turn/Hazard Light
E12 RH Front Position Light
E13 RH Rear Position Light
E14 RH Rear Brake Light
E3 RH Front Turn/Hazard Light
E2 LH Rear
Turn/Hazard Light
E1 LH Front Position Light
X25, X26, X27, X28
X29, X30, and X31
E9 LH Front
Turn/Hazard Light
S13 Hazard
Switch
E10 LH Rear
Position Light
E11 LH Rear
Brake Light
S2 Seat Switch
S3 HST or SRT Transmission
Neutral Switch
X18, X19, X20, X21
X22, X23, and X24
S7 Park Brake Switch
K12 Flasher
X2
S4 CST Transmission
Neutral Switch
4/6/01
M91685A
4 - 105
COMPONENT LOCATION – CONTROLS & LOAD CENTER
ELECTRICAL - EUROPEAN
COMPONENT LOCATION – CONTROLS & LOAD CENTER
H2 LH Turn Light
H1 RH Turn Light
P4 Engine Coolant
Temperature Gauge
P1 Engine Tachometer
P3 Fuel Gauge
H11 750 Rear PTO Light
H9 Mid PTO Light
H15 Front PTO Light
H12 Bulb Integrity
H13 Trailer 1 Light
H14 Trailer 2 Light
H10 540 Rear PTO Light
H8 Cruise Control Light
H5 Cold Start Light
H4 Discharge Light
H6 Park Brake Light
H7 Engine Oil Pressure
Light
P2 Hour Meter
S8 Turn Signal Switch
S12 Horn Switch
O
S10 Cruise Control Switch
S9 Light Switch
I
S18 Front PTO Switch
Control Panel
F9-F12
Fuse
11
K4
K4 Engine
Run
Relay
12
1
10
K3
K3 Fuel
Shutoff
Relay
A
K2
Start
Relay
9
K1
Manifold
Relay
K2
2
B
3
4
K7
Access.
Relay
F1-F9
Fuse
B
A
K1
K6
Safety
Relay
K7
K11
K11 Brake
Light
Relay
K5
Safety
Relay
K6
K10
K10 Mid
PTO Light
Relay
V1
Diode
Block
K5
K9
K9 Rear
PTO
Relay
DB1
K8
K8 Cruise
Control
Relay
M89699
5
6
7
8
Load Center
Relays / Diode Block / Fuses
4 - 106
4/6/01
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(EARLY MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050H
0.5
Blk
K8(85), K10(85)
127C
1.0
Pur
Splice 127, S13
505
0.5
Dk Grn
X2, X3
Circuit
Number
Wire
Size
050J
0.8
Blk
Splice 050, X9
127D
1.0
Pur
Splice 127, K12
518A
0.5
Gry
K2(86), DB1- 6
Color
Termination Points
050K
1.0
Blk
Splice 050, X6
128A
2.0
Gry
F9, Splice 128
518B
0.5
Gry
X3, K2(86)
002A
5.0
Red
M1, G2
050L
0.5
Blk
B1, Splice 050
128B
1.0
Gry
Splice 128, X13
521
0.5
Brn
DB1- 5, K4(86)
002B
5.0
Red
X1 (Fusible Link),
K1(30)
050M
0.5
Blk
K10(85), K11(85)
128C
0.8
Gry
Splice 128, X30
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128D
0.8
Gry
Splice 128, X22
539A
0.5
Wht
DB1- 4, DB1- 1
002C
5.0
Red
X1 (Fusible Link),
Splice 002
072A
1.0
Red
X6, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
539B
0.5
Wht
S2, DB1- 4
002D
5.0
Red
Splice 002, F2
072B
1.0
Red
S1, Splice 072
136B
1.0
Lt Blu
Splice 136, X13
546
0.5
Lt Blu
S7, K5(30)
002E
1.0
Red
Splice 002, K4(30)
072C
0.8
Red
Splice 072, F5
136C
0.8
Lt Blu
Splice 136, X23
556
0.5
Lt Blu
DB1- 2, K6(86)
010A
1.0
Blk
E6, Splice 010a
072D
0.8
Red
Splice 072, G2
136D
0.8
Lt Blu
Splice 136, X28
562A
0.8
Red
F5, Splice 562
010B
1.0
Blk
E5, Splice 010a
072E
0.8
Red
Splice 072, S13
138
2.0
Gry
S9, F7
562B
0.5
Red
Splice 562, K9(30)
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562C
0.5
Red
Splice 562, S7
010D
0.8
Blk
DB1-7, Splice 010a
103A
1.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562D
0.5
Red
Splice 562, X34
010E
0.5
Blk
DB1-7, K2(85)
103B
1.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562E
0.5
Red
Splice 562, S2
010F
0.5
Blk
K2(85), K3(85)
103C
1.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562F
0.5
Red
Splice 562, X5
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562G
0.5
Red
Splice 562, S6
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
2.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X15
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
010Q
0.8
Blk
Splice 010b, X31
010R
0.8
Blk
Splice 010b, X32
010S
0.8
Blk
Splice 010b, X24
010T
(–)
Therm.
K3(85), R2
010U
0.8
Blk
Splice 010a, B4
010V
5.0
Blk
Splice 010a, W1
010X
1.0
Blk
Splice 010a, K12
012
5.0
Red
S1, F1
042A
2.0
Red
F4, Splice 042
042B
1.0
Red
Splice 042, K11(30)
042C
1.0
Red
Splice 042, S13
042D
0.8
Red
Splice 042, X33
050A
2.0
Blk
W1, Splice 050
050B
0.5
Blk
K1(85), Splice 050
050C
0.5
Blk
K1(85), K4(85)
050D
0.5
Blk
K4(85), K5(85)
050E
0.5
Blk
K5(85), K6(85)
050F
0.5
Blk
K6(85), K7(85)
050G
0.5
Blk
K7(85), K8(85)
4/6/01
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
575A
0.5
Dk Grn
S6, K9(86)
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575B
0.5
Dk Grn
S6, X34
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
586
0.5
Lt Blu
S7, X6
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
587A
0.5
Pur
Splice 587, X2
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587B
0.5
Pur
V2, Splice 587
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587C
0.5
Pur
K5(86), Splice 587
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587D
0.5
Pur
K6(30), Splice 587
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
594A
0.5
Yel
K10(86), S7
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594B
0.5
Yel
X5, K10(86)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
737
0.5
Pur
X34, X7
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
743
0.5
Org
K10(87a), X8
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
757
0.5
Pur
X15, X7
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
777
0.5
Pur
X15, X7
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
903
0.8
Org
S12, B4
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
4 - 107
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(EARLY MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050H
0.5
Blk
K8(85), K10(85)
127C
1.0
Pur
Splice 127, S13
505
0.5
Dk Grn
X2, X3
Circuit
Number
Wire
Size
050J
0.8
Blk
Splice 050, X9
127D
1.0
Pur
Splice 127, K12
518A
0.5
Gry
K2(86), DB1- 6
Color
Termination Points
050K
1.0
Blk
Splice 050, X6
128A
2.0
Gry
F9, Splice 128
518B
0.5
Gry
X3, K2(86)
002A
5.0
Red
M1, G2
050L
0.5
Blk
B1, Splice 050
128B
1.0
Gry
Splice 128, X13
521
0.5
Brn
DB1- 5, K4(86)
002B
5.0
Red
X1 (Fusible Link),
K1(30)
050M
0.5
Blk
K10(85), K11(85)
128C
0.8
Gry
Splice 128, X30
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128D
0.8
Gry
Splice 128, X22
539A
0.5
Wht
DB1- 4, DB1- 1
002C
5.0
Red
X1 (Fusible Link),
Splice 002
072A
1.0
Red
X6, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
539B
0.5
Wht
S2, DB1- 4
002D
5.0
Red
Splice 002, F2
072B
1.0
Red
S1, Splice 072
136B
1.0
Lt Blu
Splice 136, X13
546
0.5
Lt Blu
S7, K5(30)
002E
1.0
Red
Splice 002, K4(30)
072C
0.8
Red
Splice 072, F5
136C
0.8
Lt Blu
Splice 136, X23
556
0.5
Lt Blu
DB1- 2, K6(86)
010A
1.0
Blk
E6, Splice 010a
072D
0.8
Red
Splice 072, G2
136D
0.8
Lt Blu
Splice 136, X28
562A
0.8
Red
F5, Splice 562
010B
1.0
Blk
E5, Splice 010a
072E
0.8
Red
Splice 072, S13
138
2.0
Gry
S9, F7
562B
0.5
Red
Splice 562, K9(30)
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562C
0.5
Red
Splice 562, S7
010D
0.8
Blk
DB1-7, Splice 010a
103A
1.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562D
0.5
Red
Splice 562, X34
010E
0.5
Blk
DB1-7, K2(85)
103B
1.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562E
0.5
Red
Splice 562, S2
010F
0.5
Blk
K2(85), K3(85)
103C
1.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562F
0.5
Red
Splice 562, X5
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562G
0.5
Red
Splice 562, S6
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
2.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X15
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
010Q
0.8
Blk
Splice 010b, X31
010R
0.8
Blk
Splice 010b, X32
010S
0.8
Blk
Splice 010b, X24
010T
(–)
Therm.
K3(85), R2
010U
0.8
Blk
Splice 010a, B4
010V
5.0
Blk
Splice 010a, W1
010X
1.0
Blk
Splice 010a, K12
012
5.0
Red
S1, F1
042A
2.0
Red
F4, Splice 042
042B
1.0
Red
Splice 042, K11(30)
042C
1.0
Red
Splice 042, S13
042D
0.8
Red
Splice 042, X33
050A
2.0
Blk
W1, Splice 050
050B
0.5
Blk
K1(85), Splice 050
050C
0.5
Blk
K1(85), K4(85)
050D
0.5
Blk
K4(85), K5(85)
050E
0.5
Blk
K5(85), K6(85)
050F
0.5
Blk
K6(85), K7(85)
050G
0.5
Blk
K7(85), K8(85)
4/6/01
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
575A
0.5
Dk Grn
S6, K9(86)
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575B
0.5
Dk Grn
S6, X34
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
586
0.5
Lt Blu
S7, X6
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
587A
0.5
Pur
Splice 587, X2
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587B
0.5
Pur
V2, Splice 587
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587C
0.5
Pur
K5(86), Splice 587
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587D
0.5
Pur
K6(30), Splice 587
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
594A
0.5
Yel
K10(86), S7
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594B
0.5
Yel
X5, K10(86)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
737
0.5
Pur
X34, X7
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
743
0.5
Org
K10(87a), X8
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
757
0.5
Pur
X15, X7
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
777
0.5
Pur
X15, X7
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
903
0.8
Org
S12, B4
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
4 - 107
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(EARLY MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050H
0.5
Blk
K8(85), K10(85)
127C
1.0
Pur
Splice 127, S13
505
0.5
Dk Grn
X2, X3
Circuit
Number
Wire
Size
050J
0.8
Blk
Splice 050, X9
127D
1.0
Pur
Splice 127, K12
518A
0.5
Gry
K2(86), DB1- 6
Color
Termination Points
050K
1.0
Blk
Splice 050, X6
128A
2.0
Gry
F9, Splice 128
518B
0.5
Gry
X3, K2(86)
002A
5.0
Red
M1, G2
050L
0.5
Blk
B1, Splice 050
128B
1.0
Gry
Splice 128, X13
521
0.5
Brn
DB1- 5, K4(86)
002B
5.0
Red
X1 (Fusible Link),
K1(30)
050M
0.5
Blk
K10(85), K11(85)
128C
0.8
Gry
Splice 128, X30
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128D
0.8
Gry
Splice 128, X22
539A
0.5
Wht
DB1- 4, DB1- 1
002C
5.0
Red
X1 (Fusible Link),
Splice 002
072A
1.0
Red
X6, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
539B
0.5
Wht
S2, DB1- 4
002D
5.0
Red
Splice 002, F2
072B
1.0
Red
S1, Splice 072
136B
1.0
Lt Blu
Splice 136, X13
546
0.5
Lt Blu
S7, K5(30)
002E
1.0
Red
Splice 002, K4(30)
072C
0.8
Red
Splice 072, F5
136C
0.8
Lt Blu
Splice 136, X23
556
0.5
Lt Blu
DB1- 2, K6(86)
010A
1.0
Blk
E6, Splice 010a
072D
0.8
Red
Splice 072, G2
136D
0.8
Lt Blu
Splice 136, X28
562A
0.8
Red
F5, Splice 562
010B
1.0
Blk
E5, Splice 010a
072E
0.8
Red
Splice 072, S13
138
2.0
Gry
S9, F7
562B
0.5
Red
Splice 562, K9(30)
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562C
0.5
Red
Splice 562, S7
010D
0.8
Blk
DB1-7, Splice 010a
103A
1.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562D
0.5
Red
Splice 562, X34
010E
0.5
Blk
DB1-7, K2(85)
103B
1.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562E
0.5
Red
Splice 562, S2
010F
0.5
Blk
K2(85), K3(85)
103C
1.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562F
0.5
Red
Splice 562, X5
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562G
0.5
Red
Splice 562, S6
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
2.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X15
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
010Q
0.8
Blk
Splice 010b, X31
010R
0.8
Blk
Splice 010b, X32
010S
0.8
Blk
Splice 010b, X24
010T
(–)
Therm.
K3(85), R2
010U
0.8
Blk
Splice 010a, B4
010V
5.0
Blk
Splice 010a, W1
010X
1.0
Blk
Splice 010a, K12
012
5.0
Red
S1, F1
042A
2.0
Red
F4, Splice 042
042B
1.0
Red
Splice 042, K11(30)
042C
1.0
Red
Splice 042, S13
042D
0.8
Red
Splice 042, X33
050A
2.0
Blk
W1, Splice 050
050B
0.5
Blk
K1(85), Splice 050
050C
0.5
Blk
K1(85), K4(85)
050D
0.5
Blk
K4(85), K5(85)
050E
0.5
Blk
K5(85), K6(85)
050F
0.5
Blk
K6(85), K7(85)
050G
0.5
Blk
K7(85), K8(85)
4/6/01
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
575A
0.5
Dk Grn
S6, K9(86)
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575B
0.5
Dk Grn
S6, X34
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
586
0.5
Lt Blu
S7, X6
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
587A
0.5
Pur
Splice 587, X2
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587B
0.5
Pur
V2, Splice 587
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587C
0.5
Pur
K5(86), Splice 587
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587D
0.5
Pur
K6(30), Splice 587
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
594A
0.5
Yel
K10(86), S7
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594B
0.5
Yel
X5, K10(86)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
737
0.5
Pur
X34, X7
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
743
0.5
Org
K10(87a), X8
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
757
0.5
Pur
X15, X7
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
777
0.5
Pur
X15, X7
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
903
0.8
Org
S12, B4
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
4 - 107
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
002E Red
002E Red
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
F1
Fuse
072A Red
072E Red
072E Red
072D Red
3 212 Red
7 385B Dk Grn
072C
Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
F5 Fuse
A
S1 Key
Switch
562A Red
B
562E Red
562B Red
A
572A Red
X1
S2 Seat
Switch
518A Gry
562C Red
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
539A Wht
518B Gry
30
86
87A 87
85
K2
Start
Relay
309
Wht
1
7
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
Blk
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
87A 87
319
Wht
R2 Variable
Thermistor
87 87A
574B
Yel
010T
Blk
X34
Y4 PTO
X35
Solenoid Pnk
S15 750 rpm
PTO Switch
Off
X35
W1 Battery
Frame
Ground
010V Blk
B
IG
L
P
G2
Alternator
On
X4
334
Yel
737 Pur
X15
777 Pur
X15
385A Dk Grn
574A Yel
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002E
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
302B Red
587C
Org 546 Lt Blu
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743 594A
Org Yel
On
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
010N Blk
S14 540 rpm
PTO Switch
Off
050C Blk
050A Blk
G
385A Dk Grn
85
010F
Blk
2–Speed PTO (Option)
Pur
050D Blk
594B Yel
Wht
050B
Blk
85
Wht
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
30
587A Org
302B Red
X4
010D
Blk
86
To K11(85)
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302A Red
302C Red
562B
Red
C
757 Pur
X2
505 Dk Grn
385A Dk Grn
M
Org
D
H
050N
Blk
S4 Transmission
Neutral Switch (CST Only)
8
S18 Front
PTO Switch
072D
Red
002A
Red
737 Pur
Wht
574D Yel
Pedal Released
Pedal Depressed
X3
X3
Pur
556 Lt Blu
In Neutral
V1
Diode
Block
A
G1
Battery
Off
X5
X34
On
K9
Rear
PTO
Relay
572B Red 3
010E
Blk
B
A
X34
575B
Dk Grn
575A Dk Grn
S6 Rear
PTO Switch
2
In Gear
M1
Starting
Motor
On
594B
Yel
572B Red
Fusible
Link
Red
G
539B Wht 4
002B Red
Red
B
PTO Off
562F Red
(Operator On)
B
562D Red
X34
562G Red
(Operator Off)
002A Red
W8 Front PTO
Wiring Harness
PTO On
A
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 108
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
002E Red
002E Red
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
F1
Fuse
072A Red
072E Red
072E Red
072D Red
3 212 Red
7 385B Dk Grn
072C
Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
F5 Fuse
A
S1 Key
Switch
562A Red
B
562E Red
562B Red
A
572A Red
X1
S2 Seat
Switch
518A Gry
562C Red
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
539A Wht
518B Gry
30
86
87A 87
85
K2
Start
Relay
309
Wht
1
7
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
Blk
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
87A 87
319
Wht
R2 Variable
Thermistor
87 87A
574B
Yel
010T
Blk
X34
Y4 PTO
X35
Solenoid Pnk
S15 750 rpm
PTO Switch
Off
X35
W1 Battery
Frame
Ground
010V Blk
B
IG
L
P
G2
Alternator
On
X4
334
Yel
737 Pur
X15
777 Pur
X15
385A Dk Grn
574A Yel
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002E
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
302B Red
587C
Org 546 Lt Blu
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743 594A
Org Yel
On
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
010N Blk
S14 540 rpm
PTO Switch
Off
050C Blk
050A Blk
G
385A Dk Grn
85
010F
Blk
2–Speed PTO (Option)
Pur
050D Blk
594B Yel
Wht
050B
Blk
85
Wht
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
30
587A Org
302B Red
X4
010D
Blk
86
To K11(85)
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302A Red
302C Red
562B
Red
C
757 Pur
X2
505 Dk Grn
385A Dk Grn
M
Org
D
H
050N
Blk
S4 Transmission
Neutral Switch (CST Only)
8
S18 Front
PTO Switch
072D
Red
002A
Red
737 Pur
Wht
574D Yel
Pedal Released
Pedal Depressed
X3
X3
Pur
556 Lt Blu
In Neutral
V1
Diode
Block
A
G1
Battery
Off
X5
X34
On
K9
Rear
PTO
Relay
572B Red 3
010E
Blk
B
A
X34
575B
Dk Grn
575A Dk Grn
S6 Rear
PTO Switch
2
In Gear
M1
Starting
Motor
On
594B
Yel
572B Red
Fusible
Link
Red
G
539B Wht 4
002B Red
Red
B
PTO Off
562F Red
(Operator On)
B
562D Red
X34
562G Red
(Operator Off)
002A Red
W8 Front PTO
Wiring Harness
PTO On
A
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 108
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
002E Red
002E Red
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
F1
Fuse
072A Red
072E Red
072E Red
072D Red
3 212 Red
7 385B Dk Grn
072C
Red
Start
Run
Off
Acc.
Aid
Off
002C
Red
F5 Fuse
A
S1 Key
Switch
562A Red
B
562E Red
562B Red
A
572A Red
X1
S2 Seat
Switch
518A Gry
562C Red
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
539A Wht
518B Gry
30
86
87A 87
85
K2
Start
Relay
309
Wht
1
7
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
Blk
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
87A 87
319
Wht
R2 Variable
Thermistor
87 87A
574B
Yel
010T
Blk
X34
Y4 PTO
X35
Solenoid Pnk
S15 750 rpm
PTO Switch
Off
X35
W1 Battery
Frame
Ground
010V Blk
B
IG
L
P
G2
Alternator
On
X4
334
Yel
737 Pur
X15
777 Pur
X15
385A Dk Grn
574A Yel
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002E
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
302B Red
587C
Org 546 Lt Blu
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743 594A
Org Yel
On
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
010N Blk
S14 540 rpm
PTO Switch
Off
050C Blk
050A Blk
G
385A Dk Grn
85
010F
Blk
2–Speed PTO (Option)
Pur
050D Blk
594B Yel
Wht
050B
Blk
85
Wht
Y2 Fuel
Shutoff
Solenoid
385C
002B
Dk Grn Red
30
587A Org
302B Red
X4
010D
Blk
86
To K11(85)
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302A Red
302C Red
562B
Red
C
757 Pur
X2
505 Dk Grn
385A Dk Grn
M
Org
D
H
050N
Blk
S4 Transmission
Neutral Switch (CST Only)
8
S18 Front
PTO Switch
072D
Red
002A
Red
737 Pur
Wht
574D Yel
Pedal Released
Pedal Depressed
X3
X3
Pur
556 Lt Blu
In Neutral
V1
Diode
Block
A
G1
Battery
Off
X5
X34
On
K9
Rear
PTO
Relay
572B Red 3
010E
Blk
B
A
X34
575B
Dk Grn
575A Dk Grn
S6 Rear
PTO Switch
2
In Gear
M1
Starting
Motor
On
594B
Yel
572B Red
Fusible
Link
Red
G
539B Wht 4
002B Red
Red
B
PTO Off
562F Red
(Operator On)
B
562D Red
X34
562G Red
(Operator Off)
002A Red
W8 Front PTO
Wiring Harness
PTO On
A
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 108
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
002D Red
A
212 Red
116 Lt Blu
X33
042D Red
042A Red
Off
B
Blu
F4 Fuse
A
F2
Fuse
B
102
Red
125F Dk Grn
127C Pur
K12
Flasher
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
2
3
127A Pur
146
Lt Blu
A
103C Org
103A Org
2
F7 Fuse
138 Gry
122A
Red
3
A
B
143 Org
4
F6 Fuse
A
147A Pur
A
C
X8 G
E
+
F
_
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
147B
Pur
F8
Fuse
H4
Discharge
Light
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
118A
Gry
128A
Gry
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
P3
Fuel
Gauge
S11 Brake
Switch
On
Blu
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
X32
X20
S12 Horn
Switch
903
Org
B4
Horn
Wht
J
C
P4 Engine
Coolant
Temperature
Gauge
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 L.H.
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 R.H. Front X31
Position Light
E10 L.H. Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 L.H. Front
Position Light
Gry
136B Lt Blu
X6
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
Off
Gry
Blk
E14 R.H.
Brake Light
X6
X10
Gry
Gry
E13 R.H. Rear
Position Light
118D
Gry
H2 L.H.
Turn
Light
Pur
X10
t
0
010K Blk
010H Blk
Blk
Q
H1 R.H.
Turn
Light
Off
On
Engage
Pur
E15 License
Plate Light
X7
X16
E8 R.H. Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
X17
X32
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
Blk
E7 L.H. Work
Light (Option)
X6
1
2
P
Pur
B
B
118E Gry
115B
Dk Grn
X7
X16
B
136A Lt Blu
125B
Dk Grn
147D Pur
A
136A Lt Blu
E5 L.H.
Headlight
103B
Org
119C Wht
S9 Light
Switch
125E Dk Grn
010B Blk
B
212 252
Red Red
050G
Blk
119B Wht
1
125A Dk Grn
S8 Turn
Signal Switch
X6
E6 R.H.
Headlight
(3) Field
115E Dk Grn
6
C2
010A Blk
119A Wht
(2) Road
115A Dk Grn
X6
85
K7
Accessory
Relay
E4 R.H. Rear
Turn/Hazard
Light
115C
115F
115D
Dk Grn Dk Grn Dk Grn
125F
125D 125C
Dk Grn Dk Grn Dk Grn
4
127B Pur
F
K
86
X26
Internal Ground
Connections
(0) Off
(1) Hazard
122B Red
E
325 Dk Grn
586 Lt Blu
122C
Red
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
X8 A
X19
115F Dk Grn
49
737 Pur
87 87A
E3 R.H. Front
Turn/Hazard
Light
E2 L.H. Rear
Turn/Hazard
X25
Light
B
L
31
30
85
S16 Brake
050M Blk
Switch
042C
Red 072E
Red
30
15
R
49
S13
Hazard
Switch
86
Blu
072E Red
On
Off
X33
On
072A Red
072A Red
E1 L.H. Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
SE5 - INSTRUMENTATION
4 - 109
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
002D Red
A
212 Red
116 Lt Blu
X33
042D Red
042A Red
Off
B
Blu
F4 Fuse
A
F2
Fuse
B
102
Red
125F Dk Grn
127C Pur
K12
Flasher
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
2
3
127A Pur
146
Lt Blu
A
103C Org
103A Org
2
F7 Fuse
138 Gry
122A
Red
3
A
B
143 Org
4
F6 Fuse
A
147A Pur
A
C
X8 G
E
+
F
_
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
147B
Pur
F8
Fuse
H4
Discharge
Light
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
118A
Gry
128A
Gry
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
P3
Fuel
Gauge
S11 Brake
Switch
On
Blu
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
X32
X20
S12 Horn
Switch
903
Org
B4
Horn
Wht
J
C
P4 Engine
Coolant
Temperature
Gauge
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 L.H.
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 R.H. Front X31
Position Light
E10 L.H. Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 L.H. Front
Position Light
Gry
136B Lt Blu
X6
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
Off
Gry
Blk
E14 R.H.
Brake Light
X6
X10
Gry
Gry
E13 R.H. Rear
Position Light
118D
Gry
H2 L.H.
Turn
Light
Pur
X10
t
0
010K Blk
010H Blk
Blk
Q
H1 R.H.
Turn
Light
Off
On
Engage
Pur
E15 License
Plate Light
X7
X16
E8 R.H. Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
X17
X32
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
Blk
E7 L.H. Work
Light (Option)
X6
1
2
P
Pur
B
B
118E Gry
115B
Dk Grn
X7
X16
B
136A Lt Blu
125B
Dk Grn
147D Pur
A
136A Lt Blu
E5 L.H.
Headlight
103B
Org
119C Wht
S9 Light
Switch
125E Dk Grn
010B Blk
B
212 252
Red Red
050G
Blk
119B Wht
1
125A Dk Grn
S8 Turn
Signal Switch
X6
E6 R.H.
Headlight
(3) Field
115E Dk Grn
6
C2
010A Blk
119A Wht
(2) Road
115A Dk Grn
X6
85
K7
Accessory
Relay
E4 R.H. Rear
Turn/Hazard
Light
115C
115F
115D
Dk Grn Dk Grn Dk Grn
125F
125D 125C
Dk Grn Dk Grn Dk Grn
4
127B Pur
F
K
86
X26
Internal Ground
Connections
(0) Off
(1) Hazard
122B Red
E
325 Dk Grn
586 Lt Blu
122C
Red
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
X8 A
X19
115F Dk Grn
49
737 Pur
87 87A
E3 R.H. Front
Turn/Hazard
Light
E2 L.H. Rear
Turn/Hazard
X25
Light
B
L
31
30
85
S16 Brake
050M Blk
Switch
042C
Red 072E
Red
30
15
R
49
S13
Hazard
Switch
86
Blu
072E Red
On
Off
X33
On
072A Red
072A Red
E1 L.H. Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
SE5 - INSTRUMENTATION
4 - 109
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
002D Red
A
212 Red
116 Lt Blu
X33
042D Red
042A Red
Off
B
Blu
F4 Fuse
A
F2
Fuse
B
102
Red
125F Dk Grn
127C Pur
K12
Flasher
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
2
3
127A Pur
146
Lt Blu
A
103C Org
103A Org
2
F7 Fuse
138 Gry
122A
Red
3
A
B
143 Org
4
F6 Fuse
A
147A Pur
A
C
X8 G
E
+
F
_
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
147B
Pur
F8
Fuse
H4
Discharge
Light
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
118A
Gry
128A
Gry
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
P3
Fuel
Gauge
S11 Brake
Switch
On
Blu
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
X32
X20
S12 Horn
Switch
903
Org
B4
Horn
Wht
J
C
P4 Engine
Coolant
Temperature
Gauge
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 L.H.
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 R.H. Front X31
Position Light
E10 L.H. Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 L.H. Front
Position Light
Gry
136B Lt Blu
X6
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
Off
Gry
Blk
E14 R.H.
Brake Light
X6
X10
Gry
Gry
E13 R.H. Rear
Position Light
118D
Gry
H2 L.H.
Turn
Light
Pur
X10
t
0
010K Blk
010H Blk
Blk
Q
H1 R.H.
Turn
Light
Off
On
Engage
Pur
E15 License
Plate Light
X7
X16
E8 R.H. Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
X17
X32
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
Blk
E7 L.H. Work
Light (Option)
X6
1
2
P
Pur
B
B
118E Gry
115B
Dk Grn
X7
X16
B
136A Lt Blu
125B
Dk Grn
147D Pur
A
136A Lt Blu
E5 L.H.
Headlight
103B
Org
119C Wht
S9 Light
Switch
125E Dk Grn
010B Blk
B
212 252
Red Red
050G
Blk
119B Wht
1
125A Dk Grn
S8 Turn
Signal Switch
X6
E6 R.H.
Headlight
(3) Field
115E Dk Grn
6
C2
010A Blk
119A Wht
(2) Road
115A Dk Grn
X6
85
K7
Accessory
Relay
E4 R.H. Rear
Turn/Hazard
Light
115C
115F
115D
Dk Grn Dk Grn Dk Grn
125F
125D 125C
Dk Grn Dk Grn Dk Grn
4
127B Pur
F
K
86
X26
Internal Ground
Connections
(0) Off
(1) Hazard
122B Red
E
325 Dk Grn
586 Lt Blu
122C
Red
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
X8 A
X19
115F Dk Grn
49
737 Pur
87 87A
E3 R.H. Front
Turn/Hazard
Light
E2 L.H. Rear
Turn/Hazard
X25
Light
B
L
31
30
85
S16 Brake
050M Blk
Switch
042C
Red 072E
Red
30
15
R
49
S13
Hazard
Switch
86
Blu
072E Red
On
Off
X33
On
072A Red
072A Red
E1 L.H. Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
SE5 - INSTRUMENTATION
4 - 109
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
002D Red
A
212 Red
116 Lt Blu
X33
042D Red
042A Red
Off
B
Blu
F4 Fuse
A
F2
Fuse
B
102
Red
125F Dk Grn
127C Pur
K12
Flasher
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
2
3
127A Pur
146
Lt Blu
A
103C Org
103A Org
2
F7 Fuse
138 Gry
122A
Red
3
A
B
143 Org
4
F6 Fuse
A
147A Pur
A
C
X8 G
E
+
F
_
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
147B
Pur
F8
Fuse
H4
Discharge
Light
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
118A
Gry
128A
Gry
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
P3
Fuel
Gauge
S11 Brake
Switch
On
Blu
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
X32
X20
S12 Horn
Switch
903
Org
B4
Horn
Wht
J
C
P4 Engine
Coolant
Temperature
Gauge
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 L.H.
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 R.H. Front X31
Position Light
E10 L.H. Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 L.H. Front
Position Light
Gry
136B Lt Blu
X6
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
Off
Gry
Blk
E14 R.H.
Brake Light
X6
X10
Gry
Gry
E13 R.H. Rear
Position Light
118D
Gry
H2 L.H.
Turn
Light
Pur
X10
t
0
010K Blk
010H Blk
Blk
Q
H1 R.H.
Turn
Light
Off
On
Engage
Pur
E15 License
Plate Light
X7
X16
E8 R.H. Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
X17
X32
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
Blk
E7 L.H. Work
Light (Option)
X6
1
2
P
Pur
B
B
118E Gry
115B
Dk Grn
X7
X16
B
136A Lt Blu
125B
Dk Grn
147D Pur
A
136A Lt Blu
E5 L.H.
Headlight
103B
Org
119C Wht
S9 Light
Switch
125E Dk Grn
010B Blk
B
212 252
Red Red
050G
Blk
119B Wht
1
125A Dk Grn
S8 Turn
Signal Switch
X6
E6 R.H.
Headlight
(3) Field
115E Dk Grn
6
C2
010A Blk
119A Wht
(2) Road
115A Dk Grn
X6
85
K7
Accessory
Relay
E4 R.H. Rear
Turn/Hazard
Light
115C
115F
115D
Dk Grn Dk Grn Dk Grn
125F
125D 125C
Dk Grn Dk Grn Dk Grn
4
127B Pur
F
K
86
X26
Internal Ground
Connections
(0) Off
(1) Hazard
122B Red
E
325 Dk Grn
586 Lt Blu
122C
Red
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
X8 A
X19
115F Dk Grn
49
737 Pur
87 87A
E3 R.H. Front
Turn/Hazard
Light
E2 L.H. Rear
Turn/Hazard
X25
Light
B
L
31
30
85
S16 Brake
050M Blk
Switch
042C
Red 072E
Red
30
15
R
49
S13
Hazard
Switch
86
Blu
072E Red
On
Off
X33
On
072A Red
072A Red
E1 L.H. Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
SE5 - INSTRUMENTATION
4 - 109
SE6 - LIGHTS
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
F9
SIZE
30A
30A
30A
20A
10A
20A
20A
20A
20A
A
002
002D
002
002
072C
143
138
103C
103B
DIODE BLOCK
B
012
252
122C
042A
562A
147A
119C
118A
128A
#
DB1
329A
010N
302C
146
148
010N
010C
347
125A
302A
302B
302C
E6 R.H. Headlight
119A
521
102
148
G2
Alternator
334
072D
325
002A
010A
573
309
010U
B4 Horn
737
562D
A
B
C
F
G
H
D
C
B
A
E
F
C
B
A
385A
777
144
E
D
334
264B
325
518A
8
010D/010E
9
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
E
F
C
B
A
G
H
J
D
C
B
7
4
6
7
9
3
5
6
8
9
Diode Block
Internal
Relay Socket
Layout
5
2
8
Diode Block
Schematic
A
3
385A
385B
385C
9
Diode Block
Socket Layout
347
586
K
6
4
3
072A
119D
353
050K
138
122B
359
D
7
X6 To Control
Panel Circuit Board
F
103A
143
103A
103B
103C
4
1
042D
5 6
3
2 1
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
A
072B
209 4
86
Relay
Schematic
S9 Light
Switch
2 B
212
122A S12 Horn903
Switch
146
072A
072B
072C 072D
072E
119A
119B 119C
119D
010X
002C
002D
144
127D
K12
Flasher
B
C
010P
115F
X33 To S16
Brake Switch
102
042C
X16 To E8 R.H.
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
010K
127C
072E
125F
136D
128D
115D
050A
050J
050B
050K
050L
122A
122B
122C
587A
587B 587D
587E
042A
042B
042C
042D
V2 Diode
(Soldered
In-Line)
587B
M1 Starting
Motor
002B
X1 To Fusible Link
002C
309
Y1
Starting
Motor
Solenoid
Fusible Link
147D
X28 To E14
R.H. Brake Light
X22 To E10 L.H.
Rear Position Light
X25 To E3 R.H. Front
Turn/Hazard Light
X4 To E4 R.H. Rear
Turn/Hazard Light
118D
X27 To E13 R.H. Rear
Position Lights
010L
X29 To E4 R.H. Rear Turn/Hazard
Light, E13 R.H. Rear Position Light,
010Q
and E14 R.H. Brake Light
X31 To E3 R.H. Front Turn/Hazard
Light and E12 R.H. Front Position
757
Light
777
X15 To W9 2-Speed
PTO Wiring Harness
115C
Relay/Fuse
Load Center
127A
127C 127B
127D
002E
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
7
1
1
3
5
S7 Park
Brake Switch
X3 To S4 Transmission
Neutral Switch
(Gear - CST)
562C
586
573E
594A
546
505
574A
574B
574D
002A
903
6
2
8
757
S8 Turn
Signal Switch
010A
010N
010B
010U
010D
010V
010X
010B
B3 Engine 359
Coolant
Temperature
Sensor
539A/539B
1
E
050A
R1 Manifold Heater
119B
572B
5
W1 Ground
383
G2
Alternator
4
4
125B
115B
X8 To Control
Panel Circuit Board
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
E5 L.H. Headlight
556
X7 To Control
Panel Circuit Board
X9 To W5 Cruise
Control Wiring Harness
X2 To W3 HST
& SRT Neutral Start
050J
Wiring Harness
264A
209
247
587A
238
B2 Engine Oil
505
Pressure
Switch (NC)
127B
115A
127A
050L
539A
3
87
737
353
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
010C 010L
010G 010P
010H 010Q
010J 010R
010K 010S
125A
125D
125B 125E
125C 125F
574A
147A
147B
147D
115A
115B 115D
115C 115E
115F
A
B
C
X32 To E15 License
Plate Light
118E
010R
136C
118D
125D
125C
562G
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 110
D
E
F
C
B
A
010S
010H
147B
010G
X17 To E7 L.H.
Work Light (Option)
X23 To E11
L.H. Brake Light
X27 To E13 R.H.
Rear Position Light
X18 To E1 L.H. Front
Turn/Hazard Light
X19 To E2 L.H. Rear
Turn/Hazard Light
X30 To E12 R.H. Front
Position Lights
X24 To E2 L.H. Rear Turn/Hazard
Light, E10 L.H. Rear Position Light,
and E11 L.H. Brake Light
X21 To E1 L.H. Front Turn/Hazard
Light and E9 L.H. Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
F9
SIZE
30A
30A
30A
20A
10A
20A
20A
20A
20A
A
002
002D
002
002
072C
143
138
103C
103B
DIODE BLOCK
B
012
252
122C
042A
562A
147A
119C
118A
128A
#
DB1
329A
010N
302C
146
148
010N
010C
347
125A
302A
302B
302C
E6 R.H. Headlight
119A
521
102
148
G2
Alternator
334
072D
325
002A
010A
573
309
010U
B4 Horn
737
562D
A
B
C
F
G
H
D
C
B
A
E
F
C
B
A
385A
777
144
E
D
334
264B
325
518A
8
010D/010E
9
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
E
F
C
B
A
G
H
J
D
C
B
7
4
6
7
9
3
5
6
8
9
Diode Block
Internal
Relay Socket
Layout
5
2
8
Diode Block
Schematic
A
3
385A
385B
385C
9
Diode Block
Socket Layout
347
586
K
6
4
3
072A
119D
353
050K
138
122B
359
D
7
X6 To Control
Panel Circuit Board
F
103A
143
103A
103B
103C
4
1
042D
5 6
3
2 1
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
A
072B
209 4
86
Relay
Schematic
S9 Light
Switch
2 B
212
122A S12 Horn903
Switch
146
072A
072B
072C 072D
072E
119A
119B 119C
119D
010X
002C
002D
144
127D
K12
Flasher
B
C
010P
115F
X33 To S16
Brake Switch
102
042C
X16 To E8 R.H.
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
010K
127C
072E
125F
136D
128D
115D
050A
050J
050B
050K
050L
122A
122B
122C
587A
587B 587D
587E
042A
042B
042C
042D
V2 Diode
(Soldered
In-Line)
587B
M1 Starting
Motor
002B
X1 To Fusible Link
002C
309
Y1
Starting
Motor
Solenoid
Fusible Link
147D
X28 To E14
R.H. Brake Light
X22 To E10 L.H.
Rear Position Light
X25 To E3 R.H. Front
Turn/Hazard Light
X4 To E4 R.H. Rear
Turn/Hazard Light
118D
X27 To E13 R.H. Rear
Position Lights
010L
X29 To E4 R.H. Rear Turn/Hazard
Light, E13 R.H. Rear Position Light,
010Q
and E14 R.H. Brake Light
X31 To E3 R.H. Front Turn/Hazard
Light and E12 R.H. Front Position
757
Light
777
X15 To W9 2-Speed
PTO Wiring Harness
115C
Relay/Fuse
Load Center
127A
127C 127B
127D
002E
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
7
1
1
3
5
S7 Park
Brake Switch
X3 To S4 Transmission
Neutral Switch
(Gear - CST)
562C
586
573E
594A
546
505
574A
574B
574D
002A
903
6
2
8
757
S8 Turn
Signal Switch
010A
010N
010B
010U
010D
010V
010X
010B
B3 Engine 359
Coolant
Temperature
Sensor
539A/539B
1
E
050A
R1 Manifold Heater
119B
572B
5
W1 Ground
383
G2
Alternator
4
4
125B
115B
X8 To Control
Panel Circuit Board
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
E5 L.H. Headlight
556
X7 To Control
Panel Circuit Board
X9 To W5 Cruise
Control Wiring Harness
X2 To W3 HST
& SRT Neutral Start
050J
Wiring Harness
264A
209
247
587A
238
B2 Engine Oil
505
Pressure
Switch (NC)
127B
115A
127A
050L
539A
3
87
737
353
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
010C 010L
010G 010P
010H 010Q
010J 010R
010K 010S
125A
125D
125B 125E
125C 125F
574A
147A
147B
147D
115A
115B 115D
115C 115E
115F
A
B
C
X32 To E15 License
Plate Light
118E
010R
136C
118D
125D
125C
562G
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 110
D
E
F
C
B
A
010S
010H
147B
010G
X17 To E7 L.H.
Work Light (Option)
X23 To E11
L.H. Brake Light
X27 To E13 R.H.
Rear Position Light
X18 To E1 L.H. Front
Turn/Hazard Light
X19 To E2 L.H. Rear
Turn/Hazard Light
X30 To E12 R.H. Front
Position Lights
X24 To E2 L.H. Rear Turn/Hazard
Light, E10 L.H. Rear Position Light,
and E11 L.H. Brake Light
X21 To E1 L.H. Front Turn/Hazard
Light and E9 L.H. Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
F9
SIZE
30A
30A
30A
20A
10A
20A
20A
20A
20A
A
002
002D
002
002
072C
143
138
103C
103B
DIODE BLOCK
B
012
252
122C
042A
562A
147A
119C
118A
128A
#
DB1
329A
010N
302C
146
148
010N
010C
347
125A
302A
302B
302C
E6 R.H. Headlight
119A
521
102
148
G2
Alternator
334
072D
325
002A
010A
573
309
010U
B4 Horn
737
562D
A
B
C
F
G
H
D
C
B
A
E
F
C
B
A
385A
777
144
E
D
334
264B
325
518A
8
010D/010E
9
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
E
F
C
B
A
G
H
J
D
C
B
7
4
6
7
9
3
5
6
8
9
Diode Block
Internal
Relay Socket
Layout
5
2
8
Diode Block
Schematic
A
3
385A
385B
385C
9
Diode Block
Socket Layout
347
586
K
6
4
3
072A
119D
353
050K
138
122B
359
D
7
X6 To Control
Panel Circuit Board
F
103A
143
103A
103B
103C
4
1
042D
5 6
3
2 1
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
A
072B
209 4
86
Relay
Schematic
S9 Light
Switch
2 B
212
122A S12 Horn903
Switch
146
072A
072B
072C 072D
072E
119A
119B 119C
119D
010X
002C
002D
144
127D
K12
Flasher
B
C
010P
115F
X33 To S16
Brake Switch
102
042C
X16 To E8 R.H.
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
010K
127C
072E
125F
136D
128D
115D
050A
050J
050B
050K
050L
122A
122B
122C
587A
587B 587D
587E
042A
042B
042C
042D
V2 Diode
(Soldered
In-Line)
587B
M1 Starting
Motor
002B
X1 To Fusible Link
002C
309
Y1
Starting
Motor
Solenoid
Fusible Link
147D
X28 To E14
R.H. Brake Light
X22 To E10 L.H.
Rear Position Light
X25 To E3 R.H. Front
Turn/Hazard Light
X4 To E4 R.H. Rear
Turn/Hazard Light
118D
X27 To E13 R.H. Rear
Position Lights
010L
X29 To E4 R.H. Rear Turn/Hazard
Light, E13 R.H. Rear Position Light,
010Q
and E14 R.H. Brake Light
X31 To E3 R.H. Front Turn/Hazard
Light and E12 R.H. Front Position
757
Light
777
X15 To W9 2-Speed
PTO Wiring Harness
115C
Relay/Fuse
Load Center
127A
127C 127B
127D
002E
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
7
1
1
3
5
S7 Park
Brake Switch
X3 To S4 Transmission
Neutral Switch
(Gear - CST)
562C
586
573E
594A
546
505
574A
574B
574D
002A
903
6
2
8
757
S8 Turn
Signal Switch
010A
010N
010B
010U
010D
010V
010X
010B
B3 Engine 359
Coolant
Temperature
Sensor
539A/539B
1
E
050A
R1 Manifold Heater
119B
572B
5
W1 Ground
383
G2
Alternator
4
4
125B
115B
X8 To Control
Panel Circuit Board
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
E5 L.H. Headlight
556
X7 To Control
Panel Circuit Board
X9 To W5 Cruise
Control Wiring Harness
X2 To W3 HST
& SRT Neutral Start
050J
Wiring Harness
264A
209
247
587A
238
B2 Engine Oil
505
Pressure
Switch (NC)
127B
115A
127A
050L
539A
3
87
737
353
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
010C 010L
010G 010P
010H 010Q
010J 010R
010K 010S
125A
125D
125B 125E
125C 125F
574A
147A
147B
147D
115A
115B 115D
115C 115E
115F
A
B
C
X32 To E15 License
Plate Light
118E
010R
136C
118D
125D
125C
562G
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 110
D
E
F
C
B
A
010S
010H
147B
010G
X17 To E7 L.H.
Work Light (Option)
X23 To E11
L.H. Brake Light
X27 To E13 R.H.
Rear Position Light
X18 To E1 L.H. Front
Turn/Hazard Light
X19 To E2 L.H. Rear
Turn/Hazard Light
X30 To E12 R.H. Front
Position Lights
X24 To E2 L.H. Rear Turn/Hazard
Light, E10 L.H. Rear Position Light,
and E11 L.H. Brake Light
X21 To E1 L.H. Front Turn/Hazard
Light and E9 L.H. Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
FUSE WIRE CONNECTIONS
#
F1
F2
F3
F4
F5
F6
F7
F8
F9
SIZE
30A
30A
30A
20A
10A
20A
20A
20A
20A
A
002
002D
002
002
072C
143
138
103C
103B
DIODE BLOCK
B
012
252
122C
042A
562A
147A
119C
118A
128A
#
DB1
329A
010N
302C
146
148
010N
010C
347
125A
302A
302B
302C
E6 R.H. Headlight
119A
521
102
148
G2
Alternator
334
072D
325
002A
010A
573
309
010U
B4 Horn
737
562D
A
B
C
F
G
H
D
C
B
A
E
F
C
B
A
385A
777
144
E
D
334
264B
325
518A
8
010D/010E
9
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002E
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
E
F
C
B
A
G
H
J
D
C
B
7
4
6
7
9
3
5
6
8
9
Diode Block
Internal
Relay Socket
Layout
5
2
8
Diode Block
Schematic
A
3
385A
385B
385C
9
Diode Block
Socket Layout
347
586
K
6
4
3
072A
119D
353
050K
138
122B
359
D
7
X6 To Control
Panel Circuit Board
F
103A
143
103A
103B
103C
4
1
042D
5 6
3
2 1
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
A
072B
209 4
86
Relay
Schematic
S9 Light
Switch
2 B
212
122A S12 Horn903
Switch
146
072A
072B
072C 072D
072E
119A
119B 119C
119D
010X
002C
002D
144
127D
K12
Flasher
B
C
010P
115F
X33 To S16
Brake Switch
102
042C
X16 To E8 R.H.
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
010K
127C
072E
125F
136D
128D
115D
050A
050J
050B
050K
050L
122A
122B
122C
587A
587B 587D
587E
042A
042B
042C
042D
V2 Diode
(Soldered
In-Line)
587B
M1 Starting
Motor
002B
X1 To Fusible Link
002C
309
Y1
Starting
Motor
Solenoid
Fusible Link
147D
X28 To E14
R.H. Brake Light
X22 To E10 L.H.
Rear Position Light
X25 To E3 R.H. Front
Turn/Hazard Light
X4 To E4 R.H. Rear
Turn/Hazard Light
118D
X27 To E13 R.H. Rear
Position Lights
010L
X29 To E4 R.H. Rear Turn/Hazard
Light, E13 R.H. Rear Position Light,
010Q
and E14 R.H. Brake Light
X31 To E3 R.H. Front Turn/Hazard
Light and E12 R.H. Front Position
757
Light
777
X15 To W9 2-Speed
PTO Wiring Harness
115C
Relay/Fuse
Load Center
127A
127C 127B
127D
002E
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
7
1
1
3
5
S7 Park
Brake Switch
X3 To S4 Transmission
Neutral Switch
(Gear - CST)
562C
586
573E
594A
546
505
574A
574B
574D
002A
903
6
2
8
757
S8 Turn
Signal Switch
010A
010N
010B
010U
010D
010V
010X
010B
B3 Engine 359
Coolant
Temperature
Sensor
539A/539B
1
E
050A
R1 Manifold Heater
119B
572B
5
W1 Ground
383
G2
Alternator
4
4
125B
115B
X8 To Control
Panel Circuit Board
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
E5 L.H. Headlight
556
X7 To Control
Panel Circuit Board
X9 To W5 Cruise
Control Wiring Harness
X2 To W3 HST
& SRT Neutral Start
050J
Wiring Harness
264A
209
247
587A
238
B2 Engine Oil
505
Pressure
Switch (NC)
127B
115A
127A
050L
539A
3
87
737
353
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
010C 010L
010G 010P
010H 010Q
010J 010R
010K 010S
125A
125D
125B 125E
125C 125F
574A
147A
147B
147D
115A
115B 115D
115C 115E
115F
A
B
C
X32 To E15 License
Plate Light
118E
010R
136C
118D
125D
125C
562G
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 110
D
E
F
C
B
A
010S
010H
147B
010G
X17 To E7 L.H.
Work Light (Option)
X23 To E11
L.H. Brake Light
X27 To E13 R.H.
Rear Position Light
X18 To E1 L.H. Front
Turn/Hazard Light
X19 To E2 L.H. Rear
Turn/Hazard Light
X30 To E12 R.H. Front
Position Lights
X24 To E2 L.H. Rear Turn/Hazard
Light, E10 L.H. Rear Position Light,
and E11 L.H. Brake Light
X21 To E1 L.H. Front Turn/Hazard
Light and E9 L.H. Front Position
Light
4/6/01
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(LATER MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050E
0.5
Blk
K5(85), K6(85)
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
Serial Numbers:
050F
0.5
Blk
K6(85), K7(85)
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
LV4200E329006 –
050G
0.5
Blk
K7(85), K8(85)
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
LV4300E339506 –
050H
0.5
Blk
K8(85), K10(85)
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
LV4400E349015 –
050J
0.8
Blk
Splice 050, X9
127C
1.0
Pur
Splice 127, S13
518A
0.5
Gry
K2(86), DB1- 6
050K
1.0
Blk
Splice 050, X6
127D
1.0
Pur
Splice 127, K12
518B
0.5
Gry
X2, K2(86)
050L
0.5
Blk
B1, Splice 050
128A
2.0
Gry
F9, Splice 128
521
0.5
Brn
DB1- 5, K4(86)
050M
0.5
Blk
K10(85), K11(85)
128B
1.0
Gry
Splice 128, X13
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128C
0.8
Gry
Splice 128, X30
539A
0.5
Wht
DB1- 4, DB1- 1
072A
1.0
Red
X6, Splice 072
128D
0.8
Gry
Splice 128, X22
539B
0.5
Wht
S2, DB1- 4
X1 (Fusible Link),
Splice 002
072B
1.0
Red
S1, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
546
0.5
Lt Blu
S7, K5(30)
072C
1.0
Red
Splice 072, F5
136B
1.0
Lt Blu
Splice 136, X13
556
0.5
Lt Blu
DB1- 2, K6(86)
Red
F2, K4(30)
072D
0.8
Red
Splice 072, G2
136C
0.8
Lt Blu
Splice 136, X23
562A
0.8
Red
F5, Splice 562
1.0
Blk
E6, Splice 010a
072E
0.8
Red
Splice 072, S13
136D
0.8
Lt Blu
Splice 136, X28
562B
0.5
Red
Splice 562, K9(30)
010B
1.0
Blk
E5, Splice 010a
072F
0.8
Red
Splice 072,To Cab
138
2.0
Gry
S9, F7
562C
0.5
Red
Splice 562, S7
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562D
0.5
Red
Splice 562, X34
010D
0.8
Blk
DB1-7, Splice 010a
103A
2.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562E
0.5
Red
Splice 562, S2
010E
0.5
Blk
DB1-7, K2(85)
103B
2.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562F
0.5
Red
Splice 562, X5
010F
0.5
Blk
K2(85), K3(85)
103C
2.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562G
0.5
Red
Splice 562, S6
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562H
0.5
Red
Splice 562, H16
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
3.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X36/S14
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
010Q
0.8
Blk
Splice 010b, X31
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
574E
0.5
Yel
Splice 574, X37/S15
010R
0.8
Blk
Splice 010b, X32
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575A
0.5
Dk Grn
S6, K9(86)
010S
0.8
Blk
Splice 010b, X24
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
575B
0.5
Dk Grn
K9(86), X34
010T
(–)
Therm.
K3(85), R2
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
586
0.5
Lt Blu
S7, X6
010U
0.8
Blk
Splice 010a, B4
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587A
0.5
Pur
Splice 587, X2
010V
5.0
Blk
Splice 010a, W1
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587B
0.5
Pur
V2, Splice 587
010X
1.0
Blk
Splice 010a, K12
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587C
0.5
Pur
K5(86), Splice 587
012
5.0
Red
S1, F1
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
587D
0.5
Pur
K6(30), Splice 587
042A
2.0
Red
F4, Splice 042
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594A
0.5
Yel
K10(86), S7
042B
1.0
Red
Splice 042, K11(30)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
594B
0.5
Yel
X5, K10(86)
042C
1.0
Red
Splice 042, S13
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
737
0.5
Pur
X34, X7
042D
0.8
Red
Splice 042, X33
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
743
0.5
Org
K10(87a), X8
050A
2.0
Blk
W1, Splice 050
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
757
0.5
Pur
X15, X37/S15
050B
0.5
Blk
K1(85), Splice 050
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
777
0.5
Pur
X15, X36/S14
050C
0.5
Blk
K1(85), K4(85)
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
903
0.8
Org
S12, B4
050D
0.5
Blk
K4(85), K5(85)
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
Circuit
Number
Wire
Size
Color
Termination Points
002A
5.0
Red
M1, G2
002B
5.0
Red
X1 (Fusible Link),
K1(30)
002C
5.0
Red
002D
2.0
010A
4/6/01
4 - 111
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(LATER MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050E
0.5
Blk
K5(85), K6(85)
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
Serial Numbers:
050F
0.5
Blk
K6(85), K7(85)
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
LV4200E329006 –
050G
0.5
Blk
K7(85), K8(85)
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
LV4300E339506 –
050H
0.5
Blk
K8(85), K10(85)
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
LV4400E349015 –
050J
0.8
Blk
Splice 050, X9
127C
1.0
Pur
Splice 127, S13
518A
0.5
Gry
K2(86), DB1- 6
050K
1.0
Blk
Splice 050, X6
127D
1.0
Pur
Splice 127, K12
518B
0.5
Gry
X2, K2(86)
050L
0.5
Blk
B1, Splice 050
128A
2.0
Gry
F9, Splice 128
521
0.5
Brn
DB1- 5, K4(86)
050M
0.5
Blk
K10(85), K11(85)
128B
1.0
Gry
Splice 128, X13
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128C
0.8
Gry
Splice 128, X30
539A
0.5
Wht
DB1- 4, DB1- 1
072A
1.0
Red
X6, Splice 072
128D
0.8
Gry
Splice 128, X22
539B
0.5
Wht
S2, DB1- 4
X1 (Fusible Link),
Splice 002
072B
1.0
Red
S1, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
546
0.5
Lt Blu
S7, K5(30)
072C
1.0
Red
Splice 072, F5
136B
1.0
Lt Blu
Splice 136, X13
556
0.5
Lt Blu
DB1- 2, K6(86)
Red
F2, K4(30)
072D
0.8
Red
Splice 072, G2
136C
0.8
Lt Blu
Splice 136, X23
562A
0.8
Red
F5, Splice 562
1.0
Blk
E6, Splice 010a
072E
0.8
Red
Splice 072, S13
136D
0.8
Lt Blu
Splice 136, X28
562B
0.5
Red
Splice 562, K9(30)
010B
1.0
Blk
E5, Splice 010a
072F
0.8
Red
Splice 072,To Cab
138
2.0
Gry
S9, F7
562C
0.5
Red
Splice 562, S7
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562D
0.5
Red
Splice 562, X34
010D
0.8
Blk
DB1-7, Splice 010a
103A
2.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562E
0.5
Red
Splice 562, S2
010E
0.5
Blk
DB1-7, K2(85)
103B
2.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562F
0.5
Red
Splice 562, X5
010F
0.5
Blk
K2(85), K3(85)
103C
2.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562G
0.5
Red
Splice 562, S6
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562H
0.5
Red
Splice 562, H16
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
3.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X36/S14
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
010Q
0.8
Blk
Splice 010b, X31
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
574E
0.5
Yel
Splice 574, X37/S15
010R
0.8
Blk
Splice 010b, X32
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575A
0.5
Dk Grn
S6, K9(86)
010S
0.8
Blk
Splice 010b, X24
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
575B
0.5
Dk Grn
K9(86), X34
010T
(–)
Therm.
K3(85), R2
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
586
0.5
Lt Blu
S7, X6
010U
0.8
Blk
Splice 010a, B4
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587A
0.5
Pur
Splice 587, X2
010V
5.0
Blk
Splice 010a, W1
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587B
0.5
Pur
V2, Splice 587
010X
1.0
Blk
Splice 010a, K12
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587C
0.5
Pur
K5(86), Splice 587
012
5.0
Red
S1, F1
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
587D
0.5
Pur
K6(30), Splice 587
042A
2.0
Red
F4, Splice 042
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594A
0.5
Yel
K10(86), S7
042B
1.0
Red
Splice 042, K11(30)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
594B
0.5
Yel
X5, K10(86)
042C
1.0
Red
Splice 042, S13
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
737
0.5
Pur
X34, X7
042D
0.8
Red
Splice 042, X33
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
743
0.5
Org
K10(87a), X8
050A
2.0
Blk
W1, Splice 050
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
757
0.5
Pur
X15, X37/S15
050B
0.5
Blk
K1(85), Splice 050
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
777
0.5
Pur
X15, X36/S14
050C
0.5
Blk
K1(85), K4(85)
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
903
0.8
Org
S12, B4
050D
0.5
Blk
K4(85), K5(85)
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
Circuit
Number
Wire
Size
Color
Termination Points
002A
5.0
Red
M1, G2
002B
5.0
Red
X1 (Fusible Link),
K1(30)
002C
5.0
Red
002D
2.0
010A
4/6/01
4 - 111
WIRE COLOR CODES
ELECTRICAL - EUROPEAN
WIRE COLOR CODES
(LATER MODELS)
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
Circuit
Number
Wire
Size
Color
Termination Points
050E
0.5
Blk
K5(85), K6(85)
125E
1.0
Dk Grn
Splice 125, X13
383
3.0
Org
K1(87), R1
Serial Numbers:
050F
0.5
Blk
K6(85), K7(85)
125F
1.0
Dk Grn
Splice 125, S13
385A
0.8
Dk Grn
Splice 385, X7
LV4200E329006 –
050G
0.5
Blk
K7(85), K8(85)
127A
1.0
Pur
S8, Splice 127
385B
0.8
Dk Grn
S1, Splice 385
LV4300E339506 –
050H
0.5
Blk
K8(85), K10(85)
127B
1.0
Pur
Splice 127, S8
385C
0.5
Dk Grn
Splice 385, K1(86)
LV4400E349015 –
050J
0.8
Blk
Splice 050, X9
127C
1.0
Pur
Splice 127, S13
518A
0.5
Gry
K2(86), DB1- 6
050K
1.0
Blk
Splice 050, X6
127D
1.0
Pur
Splice 127, K12
518B
0.5
Gry
X2, K2(86)
050L
0.5
Blk
B1, Splice 050
128A
2.0
Gry
F9, Splice 128
521
0.5
Brn
DB1- 5, K4(86)
050M
0.5
Blk
K10(85), K11(85)
128B
1.0
Gry
Splice 128, X13
533
0.5
Org
K5(87), K6(87a)
050N
0.5
Blk
K11(85), K9(85)
128C
0.8
Gry
Splice 128, X30
539A
0.5
Wht
DB1- 4, DB1- 1
072A
1.0
Red
X6, Splice 072
128D
0.8
Gry
Splice 128, X22
539B
0.5
Wht
S2, DB1- 4
X1 (Fusible Link),
Splice 002
072B
1.0
Red
S1, Splice 072
136A
2.0
Lt Blu
K11(87), Splice 136
546
0.5
Lt Blu
S7, K5(30)
072C
1.0
Red
Splice 072, F5
136B
1.0
Lt Blu
Splice 136, X13
556
0.5
Lt Blu
DB1- 2, K6(86)
Red
F2, K4(30)
072D
0.8
Red
Splice 072, G2
136C
0.8
Lt Blu
Splice 136, X23
562A
0.8
Red
F5, Splice 562
1.0
Blk
E6, Splice 010a
072E
0.8
Red
Splice 072, S13
136D
0.8
Lt Blu
Splice 136, X28
562B
0.5
Red
Splice 562, K9(30)
010B
1.0
Blk
E5, Splice 010a
072F
0.8
Red
Splice 072,To Cab
138
2.0
Gry
S9, F7
562C
0.5
Red
Splice 562, S7
010C
5.0
Blk
W1, Splice 010b
102
1.0
Red
K12, S13
143
2.0
Org
S9, F6
562D
0.5
Red
Splice 562, X34
010D
0.8
Blk
DB1-7, Splice 010a
103A
2.0
Org
S9, Splice 103
144
0.8
Yel
K12(C3), X8
562E
0.5
Red
Splice 562, S2
010E
0.5
Blk
DB1-7, K2(85)
103B
2.0
Org
Splice 103, F9
146
0.8
Lt Blu
K12(C2), X8
562F
0.5
Red
Splice 562, X5
010F
0.5
Blk
K2(85), K3(85)
103C
2.0
Org
Splice 103, F8
147A
2.0
Pur
F6, Splice 147
562G
0.5
Red
Splice 562, S6
010G
0.8
Blk
Splice 010b, X21
115A
1.0
Dk Grn
S8, Splice 115
147B
0.8
Pur
Splice 147, X17
562H
0.5
Red
Splice 562, H16
010H
0.8
Blk
Splice 010b, X17
115B
0.8
Dk Grn
X7, Splice 115
147D
0.8
Pur
Splice 147, X16
572A
1.0
Red
S1, K2(30)
010J
3.0
Blk
Splice 010b, X13
115C
0.8
Dk Grn
Splice 115, X26
148
0.8
Gry
K12(C), X8
572B
0.8
Red
K2(30), DB1- 3
010K
0.8
Blk
Splice 010b, X16
115D
0.8
Dk Grn
Splice 115, X25
209
0.8
Wht
S1, X9
573
0.5
Org
X34, V2
010L
0.8
Blk
Splice 010b, X29
115E
1.0
Dk Grn
Splice 115, X13
212
0.5
Red
S1, K7(86)
574A
0.5
Yel
Splice 574, X36/S14
010N
1.0
Blk
X4, Splice 010a
115F
1.0
Dk Grn
Splice 115, S13
222
2.0
Red
K7(87), X14
574B
0.5
Yel
K9(87a), Splice 574
010P
1.0
Blk
Splice 010b, S13
116
0.8
Lt Blu
X33, K11(86)
238
0.8
Gry
X9, K8(86)
574D
0.5
Yel
Splice 574, K10(30)
010Q
0.8
Blk
Splice 010b, X31
118A
2.0
Gry
F8, Splice 118
247
0.8
Pur
X9, K8(87)
574E
0.5
Yel
Splice 574, X37/S15
010R
0.8
Blk
Splice 010b, X32
118B
1.0
Gry
Splice 118, X13
252
2.0
Red
F2, K7(30)
575A
0.5
Dk Grn
S6, K9(86)
010S
0.8
Blk
Splice 010b, X24
118C
0.8
Gry
Splice 118, X20
264A
0.8
Yel
K8(30), X9
575B
0.5
Dk Grn
K9(86), X34
010T
(–)
Therm.
K3(85), R2
118D
0.8
Gry
Splice 118, X27
264B
0.8
Yel
K8(30), X6
586
0.5
Lt Blu
S7, X6
010U
0.8
Blk
Splice 010a, B4
118E
0.8
Gry
Splice 118, X32
302A
1.0
Red
DB1- 8, Splice 302
587A
0.5
Pur
Splice 587, X2
010V
5.0
Blk
Splice 010a, W1
119A
1.0
Wht
E6, Splice 119
302B
1.0
Red
K4(87), Splice 302
587B
0.5
Pur
V2, Splice 587
010X
1.0
Blk
Splice 010a, K12
119B
1.0
Wht
E5, Splice 119
302C
1.0
Red
Splice 302, X4
587C
0.5
Pur
K5(86), Splice 587
012
5.0
Red
S1, F1
119C
2.0
Wht
Splice 119, F7
309
1.0
Wht
K2(87), M1
587D
0.5
Pur
K6(30), Splice 587
042A
2.0
Red
F4, Splice 042
119D
0.8
Wht
Splice 119, X6
319
(+)
Therm.
K3(87a), R2
594A
0.5
Yel
K10(86), S7
042B
1.0
Red
Splice 042, K11(30)
122A
1.0
Red
S12, Splice 122
325
0.8
Dk Grn
G2, X6
594B
0.5
Yel
X5, K10(86)
042C
1.0
Red
Splice 042, S13
122B
3.0
Red
S9, Splice 122
329A
1.0
Wht
X4, K3(30)
737
0.5
Pur
X34, X7
042D
0.8
Red
Splice 042, X33
122C
3.0
Red
F3, Splice 122
329B
1.0
Wht
K3(30), K3(86)
743
0.5
Org
K10(87a), X8
050A
2.0
Blk
W1, Splice 050
125A
1.0
Dk Grn
S8, Splice 125
334
0.8
Yel
G2, X7
757
0.5
Pur
X15, X37/S15
050B
0.5
Blk
K1(85), Splice 050
125B
0.8
Dk Grn
X7, Splice 125
347
0.5
Pur
X6, B2
777
0.5
Pur
X15, X36/S14
050C
0.5
Blk
K1(85), K4(85)
125C
0.8
Dk Grn
Splice 125, X19
353
0.5
Org
X6, B1
903
0.8
Org
S12, B4
050D
0.5
Blk
K4(85), K5(85)
125D
0.8
Dk Grn
Splice 125, X18
359
0.5
Wht
X6, B3
Circuit
Number
Wire
Size
Color
Termination Points
002A
5.0
Red
M1, G2
002B
5.0
Red
X1 (Fusible Link),
K1(30)
002C
5.0
Red
002D
2.0
010A
4/6/01
4 - 111
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
072A Red
F1
Fuse
072E Red
3 212 Red
A
7 385B Dk Grn
072F Red
To Cab
F5 Fuse
072C Red
A
S1 Key
Switch
002C
Red
B
562E Red
572A Red
X1
S2 Seat
Switch
518A Gry
30
86
87A 87
85
K2
Start
Relay
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
574D Yel
385A Dk Grn
8
385C
002B
Dk Grn Red
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
87A 87
319
Wht
R2 Variable
Thermistor
X36
87 87A
574B
Yel
X37
574A Yel
574E Yel
010V Blk
On
S15 750 rpm
PTO Switch
334
Yel
777 Pur
X37
385A Dk Grn
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002D
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
X4
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
587C
Org 546 Lt Blu
594A
Yel
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743
Org
On
594A Yel
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
W1 Battery
Frame
Ground
L
P
G2
Alternator
X36
Off
050C Blk
050A Blk
010D Blk
On
B
302B Red
85
010T
Blk
Pnk
S14 540 rpm
PTO Switch
IG
385A Dk Grn
Blk
010F
Blk
Off
050D Blk
594B Yel
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
050B
Blk
85
Wht
Wht
X35
Y4 PTO Wht
Solenoid X35
587A Org
302B Red
Y2 Fuel
Shutoff
Solenoid
G
757 Pur
587A Org
X4
010D
Blk
30
To K11(85)
302A Red
Pur
556 Lt Blu
S3 or S4 Transmission
Neutral Switch
(All Tractors)
M
86
050N
Blk
X2
302C Red
G1
Battery
Off
072D
Red
002A
Red
737 Pur
C
737 Pur
594B
Yel
1
X2
7
M1
Starting
Motor
575A Dk Grn
K9
S6 Rear
Rear
PTO Switch PTO
Relay
X5
X34
562B
Red
On
Engaged
Disengaged
V1
Diode
Block
A
H
Org
D
575B Dk Grn
572B Red 3
010E
Blk
S18 Front
PTO Switch
X34
2
309
Wht
Red
G
562C Red
539A Wht
518B Gry
X34
Pur
B
A
562F Red
572B Red
Fusible
Link
PTO Off
Red
A
539B Wht 4
002B Red
X34
562G Red
(Operator On)
B
B
562B Red
562A Red
W8 Front PTO
Wiring Harness
PTO On
562H Red
(Operator Off)
002A Red
002D Red
H16 Backup Alarm
562D Red
Start
Run
Off
Acc.
Aid
Off
072E Red
072D Red
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010N/010U/010X Blk
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 112
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
072A Red
F1
Fuse
072E Red
3 212 Red
A
7 385B Dk Grn
072F Red
To Cab
F5 Fuse
072C Red
A
S1 Key
Switch
002C
Red
B
562E Red
572A Red
X1
S2 Seat
Switch
518A Gry
30
86
87A 87
85
K2
Start
Relay
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
574D Yel
385A Dk Grn
8
385C
002B
Dk Grn Red
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
87A 87
319
Wht
R2 Variable
Thermistor
X36
87 87A
574B
Yel
X37
574A Yel
574E Yel
010V Blk
On
S15 750 rpm
PTO Switch
334
Yel
777 Pur
X37
385A Dk Grn
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002D
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
X4
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
587C
Org 546 Lt Blu
594A
Yel
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743
Org
On
594A Yel
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
W1 Battery
Frame
Ground
L
P
G2
Alternator
X36
Off
050C Blk
050A Blk
010D Blk
On
B
302B Red
85
010T
Blk
Pnk
S14 540 rpm
PTO Switch
IG
385A Dk Grn
Blk
010F
Blk
Off
050D Blk
594B Yel
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
050B
Blk
85
Wht
Wht
X35
Y4 PTO Wht
Solenoid X35
587A Org
302B Red
Y2 Fuel
Shutoff
Solenoid
G
757 Pur
587A Org
X4
010D
Blk
30
To K11(85)
302A Red
Pur
556 Lt Blu
S3 or S4 Transmission
Neutral Switch
(All Tractors)
M
86
050N
Blk
X2
302C Red
G1
Battery
Off
072D
Red
002A
Red
737 Pur
C
737 Pur
594B
Yel
1
X2
7
M1
Starting
Motor
575A Dk Grn
K9
S6 Rear
Rear
PTO Switch PTO
Relay
X5
X34
562B
Red
On
Engaged
Disengaged
V1
Diode
Block
A
H
Org
D
575B Dk Grn
572B Red 3
010E
Blk
S18 Front
PTO Switch
X34
2
309
Wht
Red
G
562C Red
539A Wht
518B Gry
X34
Pur
B
A
562F Red
572B Red
Fusible
Link
PTO Off
Red
A
539B Wht 4
002B Red
X34
562G Red
(Operator On)
B
B
562B Red
562A Red
W8 Front PTO
Wiring Harness
PTO On
562H Red
(Operator Off)
002A Red
002D Red
H16 Backup Alarm
562D Red
Start
Run
Off
Acc.
Aid
Off
072E Red
072D Red
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010N/010U/010X Blk
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 112
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
002A Red
002 Fuse Block Internal Link
002 Fuse Block Internal Link
4
209 Wht
209 Wht
012 Red 1
6 572A Red
2
5 072B Red
B
212 Red
212 Red
072A Red
072A Red
F1
Fuse
072E Red
3 212 Red
A
7 385B Dk Grn
072F Red
To Cab
F5 Fuse
072C Red
A
S1 Key
Switch
002C
Red
B
562E Red
572A Red
X1
S2 Seat
Switch
518A Gry
30
86
87A 87
85
K2
Start
Relay
Off
S17 Mid PTO
Switch
X5 (Option)
V1 Diode
Block
539A Wht
5
On
521
Brn
518A Gry 6
574D Yel
385A Dk Grn
8
385C
002B
Dk Grn Red
010F
Blk
86
Y1
Starting
Motor
Solenoid
85
30
87 87A
383
Org
R1 Manifold
Heater
Blk
87A 87
319
Wht
R2 Variable
Thermistor
X36
87 87A
574B
Yel
X37
574A Yel
574E Yel
010V Blk
On
S15 750 rpm
PTO Switch
334
Yel
777 Pur
X37
385A Dk Grn
573
Org
521
Brn
V2
Diode
K4
Engine
Run
Relay
587B
Org 587D Org
002D
Red
86
30
85
87 87A
325
Dk Grn
586 Lt Blu
050C 302B
Red
Blk
X4
574D
Yel
K10 Mid
PTO Light
Relay
86
30
85
87 87A
587C
Org 546 Lt Blu
594A
Yel
K5
Safety
Relay
86
30
85
87 87A
587D
Org
556
Lt Blu
86
30
85
87 87A
K6
Safety
Relay
209
Wht
533 Org
743
Org
On
594A Yel
Off
546 Lt Blu
050E Blk
050F Blk
050F Blk
586 Lt Blu
586 Lt Blu
562C Red
S7 Park
Brake Switch
010N
Blk
743 Org
050M Blk
050M Blk
050C Blk
050H Blk
050J/050K Blk
050L Blk
010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
050H Blk
W1 Battery
Frame
Ground
L
P
G2
Alternator
X36
Off
050C Blk
050A Blk
010D Blk
On
B
302B Red
85
010T
Blk
Pnk
S14 540 rpm
PTO Switch
IG
385A Dk Grn
Blk
010F
Blk
Off
050D Blk
594B Yel
X4
K1
329A 329B
Manifold
Wht
Heater
30 86
K3 Fuel
Relay
Shutoff
Relay
050B
Blk
85
Wht
Wht
X35
Y4 PTO Wht
Solenoid X35
587A Org
302B Red
Y2 Fuel
Shutoff
Solenoid
G
757 Pur
587A Org
X4
010D
Blk
30
To K11(85)
302A Red
Pur
556 Lt Blu
S3 or S4 Transmission
Neutral Switch
(All Tractors)
M
86
050N
Blk
X2
302C Red
G1
Battery
Off
072D
Red
002A
Red
737 Pur
C
737 Pur
594B
Yel
1
X2
7
M1
Starting
Motor
575A Dk Grn
K9
S6 Rear
Rear
PTO Switch PTO
Relay
X5
X34
562B
Red
On
Engaged
Disengaged
V1
Diode
Block
A
H
Org
D
575B Dk Grn
572B Red 3
010E
Blk
S18 Front
PTO Switch
X34
2
309
Wht
Red
G
562C Red
539A Wht
518B Gry
X34
Pur
B
A
562F Red
572B Red
Fusible
Link
PTO Off
Red
A
539B Wht 4
002B Red
X34
562G Red
(Operator On)
B
B
562B Red
562A Red
W8 Front PTO
Wiring Harness
PTO On
562H Red
(Operator Off)
002A Red
002D Red
H16 Backup Alarm
562D Red
Start
Run
Off
Acc.
Aid
Off
072E Red
072D Red
050J/050K Blk
050L Blk
010C/010R/010H/010G/010S/010J/010P/010K/010L/010Q Blk
010A/010B/010N/010U/010X Blk
Unswitched Power
SE2 - IGNITION
SE1 - STARTING
4 - 112
Switched Power
Secondary Switched Power
SE3 - CHARGING
4/6/01
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
212 Red
B
Off
050M Blk
F4 Fuse
072A Red
116 Lt Blu
X33
042D Red
042A Red
Blu
X33
86
On
072A Red
E1 LH Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
30
Blu
072E Red
On
Off
002D Red
A
F2
Fuse
B
102
Red
042C
Red 072E
Red
125F Dk Grn
127C Pur
K12
Flasher
49
X8 A
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
125F
125D 125C
Dk Grn Dk Grn Dk Grn
2
3
127A Pur
146
Lt Blu
A
X8 G
E
B
4
F6 Fuse
A
147A Pur
A
A
C
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
_
147B
Pur
F8
Fuse
118A
Gry
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
X7
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
S11 Brake
Switch
On
Blu
Gry
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
Blk
X32
X20
J
C
X6
S12 Horn
Switch
903
Org
B4
Horn
Wht
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 LH
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 RH Front X31
Position Light
E10 LH Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 LH Front
Position Light
Gry
E13 RH Rear
Position Light
118D
Gry
P4 Engine
Coolant
Temperature
Gauge
010K Blk
010H Blk
136B Lt Blu
Off
X10
Gry
Gry
E14 RH
Brake Light
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
0
H2 LH
Turn
Light
Pur
X10
t
P3
Fuel
Gauge
X6
Off
On
Engage
Pur
Blk
Q
H1 RH
Turn
Light
X16
E8 RH Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
Blk
E15 License
Plate Light
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
X17
X32
X6
1
2
P
Pur
E7 LH Work
Light (Option)
118E Gry
115B
Dk Grn
X7
X16
B
B
128A
Gry
136A Lt Blu
125B
Dk Grn
147D Pur
B
S9 Light
Switch
125E Dk Grn
H4
Discharge
Light
212 252
Red Red
050G
Blk
A
143 Org
136A Lt Blu
+
F
X6
85
K7
Accessory
Relay
3
E5 LH
Headlight
103B
Org
119C Wht
B
F
K
86
F7 Fuse
138 Gry
010B Blk
103C Org
103A Org
2
122A
Red
125A Dk Grn
S8 Turn
Signal Switch
X6
119B Wht
1
115E Dk Grn
6
C2
E6 RH
Headlight
(3) Field
115A Dk Grn
4
127B Pur
115C
115F
115D
Dk Grn Dk Grn Dk Grn
010A Blk
119A Wht
(2) Road
122B Red
E
325 Dk Grn
586 Lt Blu
X26
Internal Ground
Connections
(0) Off
(1) Hazard
E4 RH Rear
Turn/Hazard
Light
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
737 Pur
X19
115F Dk Grn
L
31
87 87A
122C
Red
B
30
15
R
49
S13
Hazard
Switch
85
S16 Brake
050M Blk
Switch
E3 RH Front
Turn/Hazard
Light
E2 LH Rear
Turn/Hazard
X25
Light
SE5 - INSTRUMENTATION
4 - 113
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
212 Red
B
Off
050M Blk
F4 Fuse
072A Red
116 Lt Blu
X33
042D Red
042A Red
Blu
X33
86
On
072A Red
E1 LH Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
30
Blu
072E Red
On
Off
002D Red
A
F2
Fuse
B
102
Red
042C
Red 072E
Red
125F Dk Grn
127C Pur
K12
Flasher
49
X8 A
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
125F
125D 125C
Dk Grn Dk Grn Dk Grn
2
3
127A Pur
146
Lt Blu
A
X8 G
E
B
4
F6 Fuse
A
147A Pur
A
A
C
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
_
147B
Pur
F8
Fuse
118A
Gry
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
X7
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
S11 Brake
Switch
On
Blu
Gry
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
Blk
X32
X20
J
C
X6
S12 Horn
Switch
903
Org
B4
Horn
Wht
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 LH
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 RH Front X31
Position Light
E10 LH Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 LH Front
Position Light
Gry
E13 RH Rear
Position Light
118D
Gry
P4 Engine
Coolant
Temperature
Gauge
010K Blk
010H Blk
136B Lt Blu
Off
X10
Gry
Gry
E14 RH
Brake Light
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
0
H2 LH
Turn
Light
Pur
X10
t
P3
Fuel
Gauge
X6
Off
On
Engage
Pur
Blk
Q
H1 RH
Turn
Light
X16
E8 RH Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
Blk
E15 License
Plate Light
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
X17
X32
X6
1
2
P
Pur
E7 LH Work
Light (Option)
118E Gry
115B
Dk Grn
X7
X16
B
B
128A
Gry
136A Lt Blu
125B
Dk Grn
147D Pur
B
S9 Light
Switch
125E Dk Grn
H4
Discharge
Light
212 252
Red Red
050G
Blk
A
143 Org
136A Lt Blu
+
F
X6
85
K7
Accessory
Relay
3
E5 LH
Headlight
103B
Org
119C Wht
B
F
K
86
F7 Fuse
138 Gry
010B Blk
103C Org
103A Org
2
122A
Red
125A Dk Grn
S8 Turn
Signal Switch
X6
119B Wht
1
115E Dk Grn
6
C2
E6 RH
Headlight
(3) Field
115A Dk Grn
4
127B Pur
115C
115F
115D
Dk Grn Dk Grn Dk Grn
010A Blk
119A Wht
(2) Road
122B Red
E
325 Dk Grn
586 Lt Blu
X26
Internal Ground
Connections
(0) Off
(1) Hazard
E4 RH Rear
Turn/Hazard
Light
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
737 Pur
X19
115F Dk Grn
L
31
87 87A
122C
Red
B
30
15
R
49
S13
Hazard
Switch
85
S16 Brake
050M Blk
Switch
E3 RH Front
Turn/Hazard
Light
E2 LH Rear
Turn/Hazard
X25
Light
SE5 - INSTRUMENTATION
4 - 113
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
212 Red
B
Off
050M Blk
F4 Fuse
072A Red
116 Lt Blu
X33
042D Red
042A Red
Blu
X33
86
On
072A Red
E1 LH Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
30
Blu
072E Red
On
Off
002D Red
A
F2
Fuse
B
102
Red
042C
Red 072E
Red
125F Dk Grn
127C Pur
K12
Flasher
49
X8 A
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
125F
125D 125C
Dk Grn Dk Grn Dk Grn
2
3
127A Pur
146
Lt Blu
A
X8 G
E
B
4
F6 Fuse
A
147A Pur
A
A
C
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
_
147B
Pur
F8
Fuse
118A
Gry
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
X7
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
S11 Brake
Switch
On
Blu
Gry
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
Blk
X32
X20
J
C
X6
S12 Horn
Switch
903
Org
B4
Horn
Wht
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 LH
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 RH Front X31
Position Light
E10 LH Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 LH Front
Position Light
Gry
E13 RH Rear
Position Light
118D
Gry
P4 Engine
Coolant
Temperature
Gauge
010K Blk
010H Blk
136B Lt Blu
Off
X10
Gry
Gry
E14 RH
Brake Light
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
0
H2 LH
Turn
Light
Pur
X10
t
P3
Fuel
Gauge
X6
Off
On
Engage
Pur
Blk
Q
H1 RH
Turn
Light
X16
E8 RH Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
Blk
E15 License
Plate Light
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
X17
X32
X6
1
2
P
Pur
E7 LH Work
Light (Option)
118E Gry
115B
Dk Grn
X7
X16
B
B
128A
Gry
136A Lt Blu
125B
Dk Grn
147D Pur
B
S9 Light
Switch
125E Dk Grn
H4
Discharge
Light
212 252
Red Red
050G
Blk
A
143 Org
136A Lt Blu
+
F
X6
85
K7
Accessory
Relay
3
E5 LH
Headlight
103B
Org
119C Wht
B
F
K
86
F7 Fuse
138 Gry
010B Blk
103C Org
103A Org
2
122A
Red
125A Dk Grn
S8 Turn
Signal Switch
X6
119B Wht
1
115E Dk Grn
6
C2
E6 RH
Headlight
(3) Field
115A Dk Grn
4
127B Pur
115C
115F
115D
Dk Grn Dk Grn Dk Grn
010A Blk
119A Wht
(2) Road
122B Red
E
325 Dk Grn
586 Lt Blu
X26
Internal Ground
Connections
(0) Off
(1) Hazard
E4 RH Rear
Turn/Hazard
Light
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
737 Pur
X19
115F Dk Grn
L
31
87 87A
122C
Red
B
30
15
R
49
S13
Hazard
Switch
85
S16 Brake
050M Blk
Switch
E3 RH Front
Turn/Hazard
Light
E2 LH Rear
Turn/Hazard
X25
Light
SE5 - INSTRUMENTATION
4 - 113
SE6 - LIGHTS
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
ELECTRICAL - EUROPEAN
MAIN ELECTRICAL SCHEMATIC–4200/4300/4400 EUROPEAN
042B Red
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
212 Red
B
Off
050M Blk
F4 Fuse
072A Red
116 Lt Blu
X33
042D Red
042A Red
Blu
X33
86
On
072A Red
E1 LH Front
Turn/Hazard
Light
K11 Brake
Light Relay
X18
30
Blu
072E Red
On
Off
002D Red
A
F2
Fuse
B
102
Red
042C
Red 072E
Red
125F Dk Grn
127C Pur
K12
Flasher
49
X8 A
49a
31
010X
Blk
X7
777 Pur
B
385A Dk Grn
334 Yel
C
A
757 Pur
F
C3
C
144
Yel
148
Gry
127D Pur
125F
125D 125C
Dk Grn Dk Grn Dk Grn
2
3
127A Pur
146
Lt Blu
A
X8 G
E
B
4
F6 Fuse
A
147A Pur
A
A
C
119D
Wht
X13 Trailer
Connector
F9
Fuse
A
_
147B
Pur
F8
Fuse
118A
Gry
30
H6 Park
Brake
Light
87 87A
H15 Front
PTO Light
H11 750
PTO Light
H10 540
PTO Light
H12 Bulb
Integrity
Light
H8 Cruise
Indicator
Light (Option)
222
Red
X14 Trailer
Connector
H9 Mid
PTO Light
A
P1 Engine
Tachometer
X7
Blk
X6
D
X8
X9
264B
Yel
209 Wht
050F Blk
743
Org
743 Org
050M Blk
K8
Cruise
Control
Relay
86
30
85
87 87A
209 Wht
Wht
238 Gry
247 Pur
264A Yel
Gry
Pur
Yel
050J Blk
Blk
X10
Wht
S11 Brake
Switch
On
Blu
Gry
Gry
Y3 Cruise
Control
Magnet
Blu
X11
X11
X12
X12
050G Blk
050H Blk
050H Blk
050J/050K Blk
050L Blk
122A
Red
Blk
X32
X20
J
C
X6
S12 Horn
Switch
903
Org
B4
Horn
Wht
X27
X28
136D Lt Blu
Gry
X6
353
Org
347
Pur
359
Wht
X21
010L Blk
X29
Lt Blu
X13 Trailer
Connector
118B Gry
B1 Fuel
Gauge
Sensor
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L
Blk
P
128B Gry
128C Gry
t0
X22
136C Lt Blu
X30
Gry
X23
Gry
Lt Blu
E
D
Blk
010Q Blk
010S Blk
Blk
X24
E11 LH
Brake Light
050K Blk
050L Blk
010R/010H/010G/010S/010K/010L/010Q Blk
010A/010B Blk
010R/010H/010G/010S/010P/010K/010L/010Q Blk
010A/010B/010U/010X Blk
Control Panel Circuit Board
SE4 - ACCESSORIES
4/6/01
B
E12 RH Front X31
Position Light
E10 LH Rear
Position Light
128D
Gry
010G Blk
Blk
E
X6
Q
010U
Blk
Wht
010R Blk
E9 LH Front
Position Light
Gry
E13 RH Rear
Position Light
118D
Gry
P4 Engine
Coolant
Temperature
Gauge
010K Blk
010H Blk
136B Lt Blu
Off
X10
Gry
Gry
E14 RH
Brake Light
050K
Blk
CRUISE CONTROL (Option)
247 Pur
H7 Oil
Pressure
Light
0
H2 LH
Turn
Light
Pur
X10
t
P3
Fuel
Gauge
X6
Off
On
Engage
Pur
Blk
Q
H1 RH
Turn
Light
X16
E8 RH Work
Light (Option)
X17
Blk
D
D
S10 Cruise
Control
Switch
G
B
010J
Blk
H13 Trailer
1 Light
Blk
E15 License
Plate Light
118C Gry
H5 Cold
Start
Light
P2 Hour
Meter
n/min
H14 Trailer
2 Light
X17
X32
X6
1
2
P
Pur
E7 LH Work
Light (Option)
118E Gry
115B
Dk Grn
X7
X16
B
B
128A
Gry
136A Lt Blu
125B
Dk Grn
147D Pur
B
S9 Light
Switch
125E Dk Grn
H4
Discharge
Light
212 252
Red Red
050G
Blk
A
143 Org
136A Lt Blu
+
F
X6
85
K7
Accessory
Relay
3
E5 LH
Headlight
103B
Org
119C Wht
B
F
K
86
F7 Fuse
138 Gry
010B Blk
103C Org
103A Org
2
122A
Red
125A Dk Grn
S8 Turn
Signal Switch
X6
119B Wht
1
115E Dk Grn
6
C2
E6 RH
Headlight
(3) Field
115A Dk Grn
4
127B Pur
115C
115F
115D
Dk Grn Dk Grn Dk Grn
010A Blk
119A Wht
(2) Road
122B Red
E
325 Dk Grn
586 Lt Blu
X26
Internal Ground
Connections
(0) Off
(1) Hazard
E4 RH Rear
Turn/Hazard
Light
136A
Lt Blu
(0) Right
(1) Off
(2) Left
1
Flasher
5
072A
Red
49a
010P
Blk
737 Pur
X19
115F Dk Grn
L
31
87 87A
122C
Red
B
30
15
R
49
S13
Hazard
Switch
85
S16 Brake
050M Blk
Switch
E3 RH Front
Turn/Hazard
Light
E2 LH Rear
Turn/Hazard
X25
Light
SE5 - INSTRUMENTATION
4 - 113
SE6 - LIGHTS
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
Serial Numbers for Wiring Harness Use: FUSE WIRE CONNECTIONS
#
SIZE
A
B
LV4200E329006–
F1
30A
002C
012
LV4300E339506–
F2
30A
002D
252
LV4400E349015–
F3
30A
002
122C
F4
F5
F6
F7
F8
F9
20A
10A
20A
20A
20A
20A
002
072C
143
138
103C
103B
DIODE BLOCK
#
DB1
146
148
E
F
G
H
D
C
B
A
D
E
F
C
B
A
385A
777
144
347
125A
010D
W1 Ground
R1 Manifold Heater
E5 LH Headlight
119B
G2
Alternator
010B
B3 Engine 359
Coolant
Temperature
Sensor
E6 RH Headlight
119A
G2
Alternator
002A
521
334
264B
325
385A
385B
385C
G
H
J
C
B
309
903
010U
B4 Horn
737
562D
A
B
C
V2 Diode
(Soldered
In-Line)
103A
143
309
Y1
Starting
Motor
Solenoid
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A/575B
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
127A
M1 Starting
Motor
002B
X1 To Fusible Link
002C
Fusible Link
4
6
7
9
3
5
Relay Socket
Layout
6
8
9
Diode Block
Internal
5
2
8
Diode Block
Schematic
S9 Light
Switch
1
042D
072B
209
5 6
4
3
2 1
86
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
B
C
010P
115F
X33 To S16
Brake Switch
010K
127C
072E
125F
136D
128D
H16 Backup
Alarm
115D
115C
Relay/Fuse
Load Center
562H
X16 To E8 RH
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
102
042C
118D
127C 127B
127D
002E
587B
3
Relay
Schematic
A
050A
050J
050B
050K
050L
002C
002D
010X
4
212
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
010D/010E
9
A
2 B
S8 Turn
Signal Switch
122A S12 Horn903
Switch
7
Diode Block
Socket Layout
347
586
K
9
010L
587A
122A
587C
122B 587B
587D
122C
042A 042C
042B
042D
X3 To Transmission
Neutral Switch
(All Tractors)
587A
518B
574A
574B
574D
574E
072F
002A
573
518A
8
072A
119D
353
050K
138
122B
D
103A
103B
103C
127B
115A
146
K12
Flasher
F
6
4
Cab
Power
010A
7
1
1
3
5
7
X6 To Control
Panel Circuit Board
3
072A
302A
072B
072C 072D
302B
010A
072E
010B
010U
302C
010N
010V
119A
010X
119B 119C
119D
144
102
148
334 127D
072D
325
6
2
8
E
050A
383
5
539A/539B
1
359
127A
010C
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
572B
757
X9 To W5 Cruise
Control Wiring Harness
050J
264A
209
247
238
010V
302C
4
4
125B
115B
X8 To Control
Panel Circuit Board
B2 Engine Oil
Pressure
Switch (NC)
010N
556
X7 To Control
Panel Circuit Board
042A
562A
147A
119C
118A
128A
353
329A
539A
3
87
737
050L
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
S7 Park
Brake Switch
562C
586
594A
546
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
562H
147A
010C 010L
147B
010G 010P
147D
010H 010Q
010J 010R
010K 010S
X32 To E15 License
Plate Light
010R
115A
115B 115D
115C 115E
115F
118E
136C
118C
125D
125C
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 114
D
E
F
C
B
A
X28 To E14
RH Brake Light
X22 To E10 LH
Rear Position Light
X25 To E3 RH Front
Turn/Hazard Light
X4 To E4 RH Rear
Turn/Hazard Light
X27 To E13 RH Rear
Position Lights
X29 To E4 RH Rear Turn/Hazard
Light, E13 RH Rear Position Light,
and E14 RH Brake Light
X31 To E3 RH Front Turn/Hazard
Light and E12 RH Front Position
Light
X36 To S14
010Q
540 PTO Switch
574A
777
574E
757 X37 To S15
750 PTO Switch
125A
125D
125B 125E
125C 125F
562G
147D
010S
010H
147B
010G
X17 To E7 LH
Work Light (Option)
X23 To E11
LH Brake Light
X27 To E13 RH
Rear Position Light
X18 To E1 LH Front
Turn/Hazard Light
X19 To E2 LH Rear
Turn/Hazard Light
X30 To E12 RH Front
Position Lights
X24 To E2 LH Rear Turn/Hazard
Light, E10 LH Rear Position Light,
and E11 LH Brake Light
X21 To E1 LH Front Turn/Hazard
Light and E9 LH Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
Serial Numbers for Wiring Harness Use: FUSE WIRE CONNECTIONS
#
SIZE
A
B
LV4200E329006–
F1
30A
002C
012
LV4300E339506–
F2
30A
002D
252
LV4400E349015–
F3
30A
002
122C
F4
F5
F6
F7
F8
F9
20A
10A
20A
20A
20A
20A
002
072C
143
138
103C
103B
DIODE BLOCK
#
DB1
146
148
E
F
G
H
D
C
B
A
D
E
F
C
B
A
385A
777
144
347
125A
010D
W1 Ground
R1 Manifold Heater
E5 LH Headlight
119B
G2
Alternator
010B
B3 Engine 359
Coolant
Temperature
Sensor
E6 RH Headlight
119A
G2
Alternator
002A
521
334
264B
325
385A
385B
385C
G
H
J
C
B
309
903
010U
B4 Horn
737
562D
A
B
C
V2 Diode
(Soldered
In-Line)
103A
143
309
Y1
Starting
Motor
Solenoid
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A/575B
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
127A
M1 Starting
Motor
002B
X1 To Fusible Link
002C
Fusible Link
4
6
7
9
3
5
Relay Socket
Layout
6
8
9
Diode Block
Internal
5
2
8
Diode Block
Schematic
S9 Light
Switch
1
042D
072B
209
5 6
4
3
2 1
86
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
B
C
010P
115F
X33 To S16
Brake Switch
010K
127C
072E
125F
136D
128D
H16 Backup
Alarm
115D
115C
Relay/Fuse
Load Center
562H
X16 To E8 RH
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
102
042C
118D
127C 127B
127D
002E
587B
3
Relay
Schematic
A
050A
050J
050B
050K
050L
002C
002D
010X
4
212
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
010D/010E
9
A
2 B
S8 Turn
Signal Switch
122A S12 Horn903
Switch
7
Diode Block
Socket Layout
347
586
K
9
010L
587A
122A
587C
122B 587B
587D
122C
042A 042C
042B
042D
X3 To Transmission
Neutral Switch
(All Tractors)
587A
518B
574A
574B
574D
574E
072F
002A
573
518A
8
072A
119D
353
050K
138
122B
D
103A
103B
103C
127B
115A
146
K12
Flasher
F
6
4
Cab
Power
010A
7
1
1
3
5
7
X6 To Control
Panel Circuit Board
3
072A
302A
072B
072C 072D
302B
010A
072E
010B
010U
302C
010N
010V
119A
010X
119B 119C
119D
144
102
148
334 127D
072D
325
6
2
8
E
050A
383
5
539A/539B
1
359
127A
010C
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
572B
757
X9 To W5 Cruise
Control Wiring Harness
050J
264A
209
247
238
010V
302C
4
4
125B
115B
X8 To Control
Panel Circuit Board
B2 Engine Oil
Pressure
Switch (NC)
010N
556
X7 To Control
Panel Circuit Board
042A
562A
147A
119C
118A
128A
353
329A
539A
3
87
737
050L
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
S7 Park
Brake Switch
562C
586
594A
546
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
562H
147A
010C 010L
147B
010G 010P
147D
010H 010Q
010J 010R
010K 010S
X32 To E15 License
Plate Light
010R
115A
115B 115D
115C 115E
115F
118E
136C
118C
125D
125C
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 114
D
E
F
C
B
A
X28 To E14
RH Brake Light
X22 To E10 LH
Rear Position Light
X25 To E3 RH Front
Turn/Hazard Light
X4 To E4 RH Rear
Turn/Hazard Light
X27 To E13 RH Rear
Position Lights
X29 To E4 RH Rear Turn/Hazard
Light, E13 RH Rear Position Light,
and E14 RH Brake Light
X31 To E3 RH Front Turn/Hazard
Light and E12 RH Front Position
Light
X36 To S14
010Q
540 PTO Switch
574A
777
574E
757 X37 To S15
750 PTO Switch
125A
125D
125B 125E
125C 125F
562G
147D
010S
010H
147B
010G
X17 To E7 LH
Work Light (Option)
X23 To E11
LH Brake Light
X27 To E13 RH
Rear Position Light
X18 To E1 LH Front
Turn/Hazard Light
X19 To E2 LH Rear
Turn/Hazard Light
X30 To E12 RH Front
Position Lights
X24 To E2 LH Rear Turn/Hazard
Light, E10 LH Rear Position Light,
and E11 LH Brake Light
X21 To E1 LH Front Turn/Hazard
Light and E9 LH Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
Serial Numbers for Wiring Harness Use: FUSE WIRE CONNECTIONS
#
SIZE
A
B
LV4200E329006–
F1
30A
002C
012
LV4300E339506–
F2
30A
002D
252
LV4400E349015–
F3
30A
002
122C
F4
F5
F6
F7
F8
F9
20A
10A
20A
20A
20A
20A
002
072C
143
138
103C
103B
DIODE BLOCK
#
DB1
146
148
E
F
G
H
D
C
B
A
D
E
F
C
B
A
385A
777
144
347
125A
010D
W1 Ground
R1 Manifold Heater
E5 LH Headlight
119B
G2
Alternator
010B
B3 Engine 359
Coolant
Temperature
Sensor
E6 RH Headlight
119A
G2
Alternator
002A
521
334
264B
325
385A
385B
385C
G
H
J
C
B
309
903
010U
B4 Horn
737
562D
A
B
C
V2 Diode
(Soldered
In-Line)
103A
143
309
Y1
Starting
Motor
Solenoid
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A/575B
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
127A
M1 Starting
Motor
002B
X1 To Fusible Link
002C
Fusible Link
4
6
7
9
3
5
Relay Socket
Layout
6
8
9
Diode Block
Internal
5
2
8
Diode Block
Schematic
S9 Light
Switch
1
042D
072B
209
5 6
4
3
2 1
86
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
B
C
010P
115F
X33 To S16
Brake Switch
010K
127C
072E
125F
136D
128D
H16 Backup
Alarm
115D
115C
Relay/Fuse
Load Center
562H
X16 To E8 RH
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
102
042C
118D
127C 127B
127D
002E
587B
3
Relay
Schematic
A
050A
050J
050B
050K
050L
002C
002D
010X
4
212
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
010D/010E
9
A
2 B
S8 Turn
Signal Switch
122A S12 Horn903
Switch
7
Diode Block
Socket Layout
347
586
K
9
010L
587A
122A
587C
122B 587B
587D
122C
042A 042C
042B
042D
X3 To Transmission
Neutral Switch
(All Tractors)
587A
518B
574A
574B
574D
574E
072F
002A
573
518A
8
072A
119D
353
050K
138
122B
D
103A
103B
103C
127B
115A
146
K12
Flasher
F
6
4
Cab
Power
010A
7
1
1
3
5
7
X6 To Control
Panel Circuit Board
3
072A
302A
072B
072C 072D
302B
010A
072E
010B
010U
302C
010N
010V
119A
010X
119B 119C
119D
144
102
148
334 127D
072D
325
6
2
8
E
050A
383
5
539A/539B
1
359
127A
010C
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
572B
757
X9 To W5 Cruise
Control Wiring Harness
050J
264A
209
247
238
010V
302C
4
4
125B
115B
X8 To Control
Panel Circuit Board
B2 Engine Oil
Pressure
Switch (NC)
010N
556
X7 To Control
Panel Circuit Board
042A
562A
147A
119C
118A
128A
353
329A
539A
3
87
737
050L
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
S7 Park
Brake Switch
562C
586
594A
546
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
562H
147A
010C 010L
147B
010G 010P
147D
010H 010Q
010J 010R
010K 010S
X32 To E15 License
Plate Light
010R
115A
115B 115D
115C 115E
115F
118E
136C
118C
125D
125C
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 114
D
E
F
C
B
A
X28 To E14
RH Brake Light
X22 To E10 LH
Rear Position Light
X25 To E3 RH Front
Turn/Hazard Light
X4 To E4 RH Rear
Turn/Hazard Light
X27 To E13 RH Rear
Position Lights
X29 To E4 RH Rear Turn/Hazard
Light, E13 RH Rear Position Light,
and E14 RH Brake Light
X31 To E3 RH Front Turn/Hazard
Light and E12 RH Front Position
Light
X36 To S14
010Q
540 PTO Switch
574A
777
574E
757 X37 To S15
750 PTO Switch
125A
125D
125B 125E
125C 125F
562G
147D
010S
010H
147B
010G
X17 To E7 LH
Work Light (Option)
X23 To E11
LH Brake Light
X27 To E13 RH
Rear Position Light
X18 To E1 LH Front
Turn/Hazard Light
X19 To E2 LH Rear
Turn/Hazard Light
X30 To E12 RH Front
Position Lights
X24 To E2 LH Rear Turn/Hazard
Light, E10 LH Rear Position Light,
and E11 LH Brake Light
X21 To E1 LH Front Turn/Hazard
Light and E9 LH Front Position
Light
4/6/01
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
MAIN WIRING HARNESS–4200/4300/4400 EUROPEAN
Serial Numbers for Wiring Harness Use: FUSE WIRE CONNECTIONS
#
SIZE
A
B
LV4200E329006–
F1
30A
002C
012
LV4300E339506–
F2
30A
002D
252
LV4400E349015–
F3
30A
002
122C
F4
F5
F6
F7
F8
F9
20A
10A
20A
20A
20A
20A
002
072C
143
138
103C
103B
DIODE BLOCK
#
DB1
146
148
E
F
G
H
D
C
B
A
D
E
F
C
B
A
385A
777
144
347
125A
010D
W1 Ground
R1 Manifold Heater
E5 LH Headlight
119B
G2
Alternator
010B
B3 Engine 359
Coolant
Temperature
Sensor
E6 RH Headlight
119A
G2
Alternator
002A
521
334
264B
325
385A
385B
385C
G
H
J
C
B
309
903
010U
B4 Horn
737
562D
A
B
C
V2 Diode
(Soldered
In-Line)
103A
143
309
Y1
Starting
Motor
Solenoid
302A
86
–––
30
Relay #
86
85
30
87
87A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
385C
518A/518B
329B
521
587C
556
212
238
575A/575B
594A/594B
116
050B/050C
010E/010F
010F/010T
050C/050D
050D/050E
050E/050F
050F/050G
050G/050H
050N
050H/050M
050M/050N
002B
572A/572B
329A/329B
002D
546
587D
252
264A/264B
562B
574D
042B
383
309
–––
302B
533
–––
222
247
–––
–––
136A
–––
–––
319
–––
–––
533
–––
–––
574B
743
–––
85
87A
127A
M1 Starting
Motor
002B
X1 To Fusible Link
002C
Fusible Link
4
6
7
9
3
5
Relay Socket
Layout
6
8
9
Diode Block
Internal
5
2
8
Diode Block
Schematic
S9 Light
Switch
1
042D
072B
209
5 6
4
3
2 1
86
30
85
87 87A
572A
385B
7
S1 Key
8
Switch
012
S13 Hazard
Switch
116
B
C
010P
115F
X33 To S16
Brake Switch
010K
127C
072E
125F
136D
128D
H16 Backup
Alarm
115D
115C
Relay/Fuse
Load Center
562H
X16 To E8 RH
Work Light (Option)
S6 Mid PTO
Switch
594B
562F
102
042C
118D
127C 127B
127D
002E
587B
3
Relay
Schematic
A
050A
050J
050B
050K
050L
002C
002D
010X
4
212
D
575B
573
X34 To W9 Front
PTO Wiring Harness
(Option)
010D/010E
9
A
2 B
S8 Turn
Signal Switch
122A S12 Horn903
Switch
7
Diode Block
Socket Layout
347
586
K
9
010L
587A
122A
587C
122B 587B
587D
122C
042A 042C
042B
042D
X3 To Transmission
Neutral Switch
(All Tractors)
587A
518B
574A
574B
574D
574E
072F
002A
573
518A
8
072A
119D
353
050K
138
122B
D
103A
103B
103C
127B
115A
146
K12
Flasher
F
6
4
Cab
Power
010A
7
1
1
3
5
7
X6 To Control
Panel Circuit Board
3
072A
302A
072B
072C 072D
302B
010A
072E
010B
010U
302C
010N
010V
119A
010X
119B 119C
119D
144
102
148
334 127D
072D
325
6
2
8
E
050A
383
5
539A/539B
1
359
127A
010C
X4 To W2 Fuel
Shutoff Solenoid
Wiring Harness
572B
757
X9 To W5 Cruise
Control Wiring Harness
050J
264A
209
247
238
010V
302C
4
4
125B
115B
X8 To Control
Panel Circuit Board
B2 Engine Oil
Pressure
Switch (NC)
010N
556
X7 To Control
Panel Circuit Board
042A
562A
147A
119C
118A
128A
353
329A
539A
3
87
737
050L
2
RELAYS
2
743
B1
Fuel Gauge
Sensor
1
ELECTRICAL - EUROPEAN
118A
118B
118C
118D
118E
S7 Park
Brake Switch
562C
586
594A
546
562E
539B
S2 Seat
Switch
128A
128B
128C
128D
562A
136A
562B
136B
562C
136C
562D
136D
562E
562F
562G
562H
147A
010C 010L
147B
010G 010P
147D
010H 010Q
010J 010R
010K 010S
X32 To E15 License
Plate Light
010R
115A
115B 115D
115C 115E
115F
118E
136C
118C
125D
125C
575A
S17 Rear
PTO Switch
B
136B
128B
010J
128C
A
222
X14 To W7
Trailer Connector
125E
115E
Wiring Harness
118B
X13 To W7 Trailer
Connector Wiring Harness
4 - 114
D
E
F
C
B
A
X28 To E14
RH Brake Light
X22 To E10 LH
Rear Position Light
X25 To E3 RH Front
Turn/Hazard Light
X4 To E4 RH Rear
Turn/Hazard Light
X27 To E13 RH Rear
Position Lights
X29 To E4 RH Rear Turn/Hazard
Light, E13 RH Rear Position Light,
and E14 RH Brake Light
X31 To E3 RH Front Turn/Hazard
Light and E12 RH Front Position
Light
X36 To S14
010Q
540 PTO Switch
574A
777
574E
757 X37 To S15
750 PTO Switch
125A
125D
125B 125E
125C 125F
562G
147D
010S
010H
147B
010G
X17 To E7 LH
Work Light (Option)
X23 To E11
LH Brake Light
X27 To E13 RH
Rear Position Light
X18 To E1 LH Front
Turn/Hazard Light
X19 To E2 LH Rear
Turn/Hazard Light
X30 To E12 RH Front
Position Lights
X24 To E2 LH Rear Turn/Hazard
Light, E10 LH Rear Position Light,
and E11 LH Brake Light
X21 To E1 LH Front Turn/Hazard
Light and E9 LH Front Position
Light
4/6/01
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS
ELECTRICAL - EUROPEAN
W2 FUEL SHUTOFF SOLENOID WIRING HARNESS
Blk
Wht
Wht
X4 To W1 Main Wiring Harness
M76875
Y2 Fuel Shutoff Solenoid
W3 HST NEUTRAL START WIRING HARNESS
(Note: Included in W4 Cruise Control Wiring Harness protective wrap)
Dk Grn
Dk Grn
W3 HST & SRT NEUTRAL START WIRING HARNESS
Gry
To X2 W1 Main
Wiring Harness
4/6/01
Gry
To S3 Transmission
Neutral Switch (Hydro - HST)
4 - 115
W4 CRUISE CONTROL WIRING HARNESS
ELECTRICAL - EUROPEAN
W4 CRUISE CONTROL WIRING HARNESS
NOTE: Connector X2, and the Dk Grn and Gry wires are
the W3 HST & SRT Neutral Start Wiring Harness.
Dk Grn
To S3 Neutral
Start Switch
X2 To W1 Main
Wiring Harness
Dk Grn
W3 HST & SRT Neutral Start Wiring Harness
Gry
Gry
Wht
X9 To W1 Main
Wiring Harness
Blk
Yel
Gry
Yel
Gry
Yel
Gry
Blk
Gry
Pur
Yel
Yel
X12 To Y3 Cruise
Control Magnet
X11 TO S11
Brake Switch
Wht
Pur
Gry
X10 To S10 Cruise
Cruise Control Switch
Gry
Yel
S11 Brake
Switch
S10 Cruise
Control Switch
X11 To W4 Cruise
Control Wiring Harness
X10 To W4 Cruise
Control Wiring Harness
W5 CRUISE CONTROL MAGNET WIRING HARNESS
Wht
Wht
X12 To W4 Cruise Control
Wiring Harness
Y4 Cruise
Control Magnet
4 - 116
4/6/01
W6 TRAILER CONNECTOR WIRING HARNESS
ELECTRICAL - EUROPEAN
W6 TRAILER CONNECTOR WIRING HARNESS
115 Dk Grn
118 Gry
136 Lt Blu
125 Dk Grn
128 Gry
To Trailer Ground Wire
To LH
Position Light
To RH Turn
Signal Light
To RH & LH
Brake Lights
To LH Turn
Signal Light
To RH
Position Light
118
115
136
125
128
X13 To W1 Main
Wiring Harness
010
222
To Trailer
Power
010 Blk
X14 To W1 Main
Wiring Harness
X35 Trailer
Connector
222 Red
Circuit
Number
Wire
Size
Color
Termination Points
Main Harness Connection
010
3.0
Blk
X35 - Pin 3, Ground Wire Socket
X14 (to 010J Blk)
115
1.0
Dk Grn
X35 - Pin 4, RHTurn Signal Light
Socket
X13 (to 115E Dk Grn)
118
1.0
Gry
X35 - Pin 5, LH Position Light Pin
X13 (to 118B Gry)
125
1.0
Dk Grn
X35 - Pin 1, LHTurn Signal Light Pin
X13 (to 125E Dk Grn)
128
1.0
Gry
X35 - Pin 7, RH Position Light Pin
X13 (to 128B Gry)
136
1.0
Lt Blu
X35 - Pin 6, LH and RH Brake Lights
Socket
X13 (to 136B Lt Blu)
222
2.0
Red
X35 - Pin 2, Power Wire Socket
(Accessory)
X14 (to 222 Red)
4/6/01
4 - 117
W7 2–SPEED PTO WIRING HARNESS
ELECTRICAL - EUROPEAN
W7 2–SPEED PTO WIRING HARNESS
Early Models Only:
–LV4200E329005
–LV4300E339505
–LV4400E349014
Pur
Yel
To S14 540 rpm
PTO Switch
Yel
To S15 750 rpm
PTO Switch
Pur
Yel
X15 to W1 Main
Wiring Harness
S14 PTO Switch, and
S15 PTO Switch
W8 FRONT PTO WIRING HARNESS
562 Red
737 Pur
737 Pur
737
010 Blk
X35 To Y4
PTO Solenoid
575 Dk Grn
573 Org
To S18 Front
PTO Switch
575 Dk Grn
573 Org
A
562 Red
B
C
D
To Frame
Ground
737 Pur
X34 To W1 Main
Wiring Harness
S18 Front
PTO Switch
Pnk
Wht
X35 To W8 Front
PTO Wiring Harness
4 - 118
Y4 PTO
Solenoid
4/6/01
TROUBLESHOOTING
ELECTRICAL - EUROPEAN
Check ground circuit
●
Test battery and battery
connections
●
●
●
●
●
See Manifold heater Circuit
Diagnosis
●
See Fuel Supply Circuit
Diagnosis
●
●
See Charging Circuit
Diagnosis
●
See Control Panel Indicator
Diagnosis
●
4/6/01
●
●
●
●
●
●
See Lights Circuit Diagnosis
Check for shorted circuit
Fuel gauge does not work properly
●
Headlight problem
See Cranking Circuit
Diagnosis
Instrument lights problems
●
Engine will not run when operator
leaves seat
●
Engine coolant temperature light
problem
See Engine Shutoff Circuit
Diagnosis
Discharge light problem
●
Battery goes dead, discharges or
overcharges
●
Engine oil light problem
Engine cranks but will not start
See Power Circuit Diagnosis
Check or
Solution
Improper component operating with
switch
Starter cranking problems
Problem or
Symptom
Engine will not shut off
TROUBLESHOOTING
●
●
●
4 - 119
THEORY AND DIAGNOSIS
THEORY AND DIAGNOSIS
POWER CIRCUIT OPERATION
Function:
Provides unswitched and switched power to the
primary components whenever the battery is
connected.
The power circuits are divided among the unswitched
power circuit, switched power circuits (key switch in
RUN, START, or AID positions), and secondary
switched power circuits. The secondary switched
power circuits become energized when switched power
circuits energize relays, providing current paths to the
secondary circuits. The secondary power circuits would
not be energized if the relays controlling the current
path(s) failed.
Detailed Theory of Operation, Schematics, and
Troubleshooting of
Unswitched Power:
Voltage must be present at the following components
with the key switch in the OFF position:
• Battery Positive Terminal
• Starting Motor Terminal B
• F1 Fuse
• Key Switch Terminal 1
• Alternator Terminal B
• Manifold Heater Relay Terminal 30
• Engine Run Relay Terminal 30
• F2 Fuse
• Accessory Relay Terminal 30
• F3 Fuse
• Light Switch Terminal B
• Horn Switch
• F4 Fuse
• Hazard Switch Terminal 30
• Brake Switch
The positive battery cable connects the battery to the
starting motor bolt (terminal B). The starting motor bolt
is used as the 12 Volt DC tie point for the rest of the
electrical system.
The battery cables and the starting motor tie point
connections must be good for the vehicle electrical
system to work properly. The ground cable and positive
cable connections are equally important. Proper
starting motor operation depends on these cables and
connections to carry high current.
With the exception of the alternator B terminal, the
electrical circuit is protected by the fusible link beyond
the starting motor tie point. The fusible link is a short
piece of wire that is designed to fail if current load is too
high or a short occurs.
4 - 120
ELECTRICAL - EUROPEAN
Switched Power - Run:
In addition to the voltage present at the locations of the
unswitched power circuits, voltage must be present at
the following components with the key switch in the
RUN ("ON") position, transmission in NEUTRAL,
PTO(s) in NEUTRAL, park brake ENGAGED, and
operator NOT ON seat:
• Key Switch Terminals 3, 4, and 5
• Alternator Terminal IG
• F5 Fuse
• X5 Connector (562F Red wire)
NOTE: X5 connector has jumper wire installed (562F
Red to 594B Yel) unless Mid PTO option is
installed (includes S6 switch).
• S6 Rear PTO Switch
• X34 Connector (562D Red & 575B Dk Grn)
NOTE: X34 connector has jumper wire installed (575B
Dk Grn to 573 Org) unless Front PTO option is
installed (includes S18 switch).
• K9 Rear PTO Relay Terminals 30 and 86
• K10 Mid PTO Light Relay Socket Terminal 86
• Park Brake Switch Terminals A, B, C and D
• K5 Safety Relay Terminals 86 and 30
• K6 Safety Relay Terminal 30
• Seat Switch
• X9 Connector Terminal A
• Cruise Control Switch
• Hazard Switch Terminal 15
• K12 Flasher Terminal 49
• X6 Connector Terminals A and K
• X7 Connector Terminal A
• K7 Accessory Relay Terminal 86
• X2 Connector (587A Org wire); or, X3 Connector
(505 Dk Grn wire)
NOTE:
The S4 Transmission Neutral Switch is
installed in collar shift gear drive (CST)
tractors; a jumper wire is installed in the X2
connector, and the S3 Transmission Neutral
Switch is not used.
In hydrostatic drive (HST) and SyncReverser™
(SRT) tractors the S3 Transmission Neutral
Switch is used, and a jumper wire is installed in
the X3 connector - eliminating the S4 switch.
• Start Relay Terminal 86
• Diode Block Terminal 6
• Engine Run Relay Terminal 86
4/6/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
002 Fuse Block Internal Link
6
5 072B Red
2
B
F1
Fuse
212 Red
212 Red
072A Red
072A Red
072E Red
072E Red
PTO On
PTO Off
7
Start
Run
Off
Acc.
X34
072C
Red
002A
Red
A
B
562E Red
Off
On
562F Red
(Operator Off)
562C Red
86
S6 Rear
PTO Switch
85
85
30
K4
V1 Diode Engine
Block
Run
Relay
87 87A
383
Org
K1 Manifold
Heater
Relay
86
30
Fusible
Link
B
518B Gry
30
87A 87
87 87A
7
8
V1
Diode
Block
Y1
Starting
Motor
Solenoid
SE1 - STARTING
85
87 87A
S10 Cruise
Control
Switch
S16 Brake
Switch
222
Red
116
Lt Blu
K11 Brake
Light Relay
49
072A
Red
+
85
87 87A
K12
Flasher
(0) Off
(1) Hazard
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
30
87 87A
85
K5
Safety
Relay
587D
Org
86
85
30
87 87A
533 Org
On
K6
Safety
Relay
X6
X6
X6
353
Org
347
Pur
359
Wht
Q
Off
3
4
S9 Light
Switch
t0
P
B1 Fuel
Gauge
Sensor
122A
Red
2
B
E
J
C
86
30
P3
Fuel
Gauge
587D Org
546 Lt Blu
1
t0
Q
H4
Discharge
Light
594A Yel
86
_
587C
Org
K10 Mid
PTO Light
Relay
Wht
30
(3) Field
Pedal Depressed
587A Org
594B Yel
X4
86
A
X6
122B
Red
V2
Diode
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302C
Red
122C
Red
X33
S12 Hazard
Switch
X14 Trailer
Connector
Pedal Released
X2
505 Dk Grn
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
546 Lt Blu
A
Y2 Fuel
Shutoff
Solenoid
Unswitched Power
30
A
15
(2) Road
594B
Yel
302B Red
302A Red
86
X7
On
30
49
A
Wht
Off
102
Red
K7
Accessory
Relay
587B
Org
S4 Transmission
Neutral Switch (CST)
Red
4/6/01
X3
334
Yel
X10
87 87A
S17 Mid PTO
Switch (Option)
85
M
M1
Starting
Motor
In Gear
X3
86
K2 Start
Relay
042D
Red
On Off
X5
85
P
30
On
Off
F2
Fuse
B
212 252
Red Red
G2
Alternator
Wht
573
Org
In Neutral
R1 Manifold
Heater
042B Red
042C
Red
A
L
Off
On
Engage
002E
Red
521 Brn
5
573
Org
K9 Rear
PTO Relay
X5
86
042A Red
072E Red
IG
B
575A Dk Grn
002E Red
518A Gry 6
S18 Front
PTO Switch
(Option)
575B
Dk Grn
(Operator On)
S2 Seat
Switch
X9
A
562G Red
562A Red
S1 Key
Switch
X1
B
F4 Fuse
072D
Red
G
X34
X34
562B Red
F5 Fuse
Aid
Off
002C
Red
002B Red
A
X33
562D Red
002A
Red
B
072D Red
3 212 Red
A
A
002D Red
209 Wht
4 209 Wht
012 Red 1
F3 Fuse 122C Red
002 Fuse Block Internal Link
562C Red
B
D
586 Lt Blu
586 Lt Blu
X6 K
C
S7 Park
Brake Switch
Switched Power
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 121
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
002 Fuse Block Internal Link
6
5 072B Red
2
B
F1
Fuse
212 Red
212 Red
072A Red
072A Red
072E Red
072E Red
PTO On
PTO Off
7
Start
Run
Off
Acc.
X34
072C
Red
002A
Red
A
B
562E Red
Off
On
562F Red
(Operator Off)
562C Red
86
S6 Rear
PTO Switch
85
85
30
K4
V1 Diode Engine
Block
Run
Relay
87 87A
383
Org
K1 Manifold
Heater
Relay
86
30
Fusible
Link
B
518B Gry
30
87A 87
87 87A
7
8
V1
Diode
Block
Y1
Starting
Motor
Solenoid
SE1 - STARTING
85
87 87A
S10 Cruise
Control
Switch
S16 Brake
Switch
222
Red
116
Lt Blu
K11 Brake
Light Relay
49
072A
Red
+
85
87 87A
K12
Flasher
(0) Off
(1) Hazard
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
30
87 87A
85
K5
Safety
Relay
587D
Org
86
85
30
87 87A
533 Org
On
K6
Safety
Relay
X6
X6
X6
353
Org
347
Pur
359
Wht
Q
Off
3
4
S9 Light
Switch
t0
P
B1 Fuel
Gauge
Sensor
122A
Red
2
B
E
J
C
86
30
P3
Fuel
Gauge
587D Org
546 Lt Blu
1
t0
Q
H4
Discharge
Light
594A Yel
86
_
587C
Org
K10 Mid
PTO Light
Relay
Wht
30
(3) Field
Pedal Depressed
587A Org
594B Yel
X4
86
A
X6
122B
Red
V2
Diode
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302C
Red
122C
Red
X33
S12 Hazard
Switch
X14 Trailer
Connector
Pedal Released
X2
505 Dk Grn
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
546 Lt Blu
A
Y2 Fuel
Shutoff
Solenoid
Unswitched Power
30
A
15
(2) Road
594B
Yel
302B Red
302A Red
86
X7
On
30
49
A
Wht
Off
102
Red
K7
Accessory
Relay
587B
Org
S4 Transmission
Neutral Switch (CST)
Red
4/6/01
X3
334
Yel
X10
87 87A
S17 Mid PTO
Switch (Option)
85
M
M1
Starting
Motor
In Gear
X3
86
K2 Start
Relay
042D
Red
On Off
X5
85
P
30
On
Off
F2
Fuse
B
212 252
Red Red
G2
Alternator
Wht
573
Org
In Neutral
R1 Manifold
Heater
042B Red
042C
Red
A
L
Off
On
Engage
002E
Red
521 Brn
5
573
Org
K9 Rear
PTO Relay
X5
86
042A Red
072E Red
IG
B
575A Dk Grn
002E Red
518A Gry 6
S18 Front
PTO Switch
(Option)
575B
Dk Grn
(Operator On)
S2 Seat
Switch
X9
A
562G Red
562A Red
S1 Key
Switch
X1
B
F4 Fuse
072D
Red
G
X34
X34
562B Red
F5 Fuse
Aid
Off
002C
Red
002B Red
A
X33
562D Red
002A
Red
B
072D Red
3 212 Red
A
A
002D Red
209 Wht
4 209 Wht
012 Red 1
F3 Fuse 122C Red
002 Fuse Block Internal Link
562C Red
B
D
586 Lt Blu
586 Lt Blu
X6 K
C
S7 Park
Brake Switch
Switched Power
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 121
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - RUN / AID
002A Red
002 Fuse Block Internal Link
6
5 072B Red
2
B
F1
Fuse
212 Red
212 Red
072A Red
072A Red
072E Red
072E Red
PTO On
PTO Off
7
Start
Run
Off
Acc.
X34
072C
Red
002A
Red
A
B
562E Red
Off
On
562F Red
(Operator Off)
562C Red
86
S6 Rear
PTO Switch
85
85
30
K4
V1 Diode Engine
Block
Run
Relay
87 87A
383
Org
K1 Manifold
Heater
Relay
86
30
Fusible
Link
B
518B Gry
30
87A 87
87 87A
7
8
V1
Diode
Block
Y1
Starting
Motor
Solenoid
SE1 - STARTING
85
87 87A
S10 Cruise
Control
Switch
S16 Brake
Switch
222
Red
116
Lt Blu
K11 Brake
Light Relay
49
072A
Red
+
85
87 87A
K12
Flasher
(0) Off
(1) Hazard
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
30
87 87A
85
K5
Safety
Relay
587D
Org
86
85
30
87 87A
533 Org
On
K6
Safety
Relay
X6
X6
X6
353
Org
347
Pur
359
Wht
Q
Off
3
4
S9 Light
Switch
t0
P
B1 Fuel
Gauge
Sensor
122A
Red
2
B
E
J
C
86
30
P3
Fuel
Gauge
587D Org
546 Lt Blu
1
t0
Q
H4
Discharge
Light
594A Yel
86
_
587C
Org
K10 Mid
PTO Light
Relay
Wht
30
(3) Field
Pedal Depressed
587A Org
594B Yel
X4
86
A
X6
122B
Red
V2
Diode
X2
S3 Transmission
Neutral Switch
(HST & SRT)
302C
Red
122C
Red
X33
S12 Hazard
Switch
X14 Trailer
Connector
Pedal Released
X2
505 Dk Grn
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
546 Lt Blu
A
Y2 Fuel
Shutoff
Solenoid
Unswitched Power
30
A
15
(2) Road
594B
Yel
302B Red
302A Red
86
X7
On
30
49
A
Wht
Off
102
Red
K7
Accessory
Relay
587B
Org
S4 Transmission
Neutral Switch (CST)
Red
4/6/01
X3
334
Yel
X10
87 87A
S17 Mid PTO
Switch (Option)
85
M
M1
Starting
Motor
In Gear
X3
86
K2 Start
Relay
042D
Red
On Off
X5
85
P
30
On
Off
F2
Fuse
B
212 252
Red Red
G2
Alternator
Wht
573
Org
In Neutral
R1 Manifold
Heater
042B Red
042C
Red
A
L
Off
On
Engage
002E
Red
521 Brn
5
573
Org
K9 Rear
PTO Relay
X5
86
042A Red
072E Red
IG
B
575A Dk Grn
002E Red
518A Gry 6
S18 Front
PTO Switch
(Option)
575B
Dk Grn
(Operator On)
S2 Seat
Switch
X9
A
562G Red
562A Red
S1 Key
Switch
X1
B
F4 Fuse
072D
Red
G
X34
X34
562B Red
F5 Fuse
Aid
Off
002C
Red
002B Red
A
X33
562D Red
002A
Red
B
072D Red
3 212 Red
A
A
002D Red
209 Wht
4 209 Wht
012 Red 1
F3 Fuse 122C Red
002 Fuse Block Internal Link
562C Red
B
D
586 Lt Blu
586 Lt Blu
X6 K
C
S7 Park
Brake Switch
Switched Power
Secondary Switched Power
SE2 - IGNITION
P
Control Panel Circuit Board
SE3 - CHARGING
4 - 121
H6 Park
Brake
Light
SE4 - ACCESSORIES
SE5 - INSTRUMENTATION
SE6 - LIGHTS
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
002 Fuse Block Internal Link
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
B
042A Red
002D Red
4
012 Red
6
1
5
2
B
F1
Fuse
3
A
7
F4 Fuse
572A Red
072B Red
072A Red
072A Red
072E Red
072E Red
X33
PTO On
PTO Off
385B
Dk Grn
X34
072C
Red
A
B
562E Red
(Operator Off)
S1 Key
Switch
562C Red
S6 Rear
PTO Switch
S2 Seat
Switch
334
Yel
86
5 521 Brn
518A Gry 6
X1
002E
Red
30
K4
Engine
Run
Relay
87 87A
383
Org
86
85
X5
87 87A
572A
Red
518B Gry
30
K2 Start
Relay
B
87A 87
85
572B Red 3
2
M
M1
Starting
Motor
Y1
Starting
Motor
Solenoid
V1
Diode
Block
594B Yel
30
87 87A
85
K10 Mid
PTO Light
Relay
86
30
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
(2) Road
K5
Safety
Relay
2
B
3
4
122A
Red
S9 Light
Switch
E
J
X6
X6
353
Org
347
Pur
359
Wht
587D
Org
86
30
85
87 87A
K6
Safety
Relay
Q
B1 Fuel
Gauge
Sensor
D
586 Lt Blu
586 Lt Blu
t0
P
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
X6 K
C
S7 Park
Brake Switch
SE2 - IGNITION
(0) Off
(1) Hazard
546 Lt Blu
B
Switched Power
87 87A
Off
562C Red
Y2 Fuel
Shutoff
Solenoid
85
1
X6
On
A
SE1 - STARTING
P3
Fuel
Gauge
H4
Discharge
Light
533 Org
Wht
30
t0
Q
C
594A Yel
86
K12
Flasher
587D Org
86
Red
Unswitched Power
_
587C
Org
302B Red
X4
K11 Brake
Light Relay
49
556 Lt Blu
302C
Red
116
Lt Blu
S12 Hazard
Switch
A
+
556 Lt Blu
8 302A Red
X33
122B
Red
546 Lt Blu
7
87 87A
122C
Red
(3) Field
X2
S3 Transmission
Neutral Switch
(HST & SRT)
X3
S4 Transmission
Neutral Switch (CST)
86
S16 Brake
Switch
573
Org
Pedal Depressed
587A Org
X2
85
X6
Pedal Released
505 Dk Grn
30
A
587B
Org
In Gear
X3
86
X7
V2
Diode
594B
Yel
In Neutral
R1 Manifold
Heater
87 87A
S17 Mid PTO
Switch (Option)
30
15
072A
Red
K9 Rear
PTO Relay
On Off
On
102
Red
30
85
Off
30
49
K7
Accessory
Relay
X5
002B Red
Fusible
Link
P
G2
Alternator
573
Org
On
Off
F2
Fuse
252
Red
575A Dk Grn
V1 Diode
Block
85
S18 Front
PTO Switch
(Option)
575B
Dk Grn
042C
Red
B
L
(Operator On)
002E Red
K1 Manifold
Heater
Relay
Off
On
562F Red
IG
B
562G Red
562A Red
A
072D
Red
G
X34
X34
562B Red
F5 Fuse
86
002A
Red
562D Red
Aid
Off
002C
Red
042D
Red
072E Red
072D Red
Start
Run
Off
Acc.
002A
Red
042B Red
P
Control Panel Circuit Board
Secondary Switched Power
SE3 - CHARGING SE4 - ACCESSORIES
4 - 122
H6 Park
Brake
Light
SE5 - INSTRUMENTATION
SE6 - LIGHTS
4/6/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
002 Fuse Block Internal Link
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
B
042A Red
002D Red
4
012 Red
6
1
5
2
B
F1
Fuse
3
A
7
F4 Fuse
572A Red
072B Red
072A Red
072A Red
072E Red
072E Red
X33
PTO On
PTO Off
385B
Dk Grn
X34
072C
Red
A
B
562E Red
(Operator Off)
S1 Key
Switch
562C Red
S6 Rear
PTO Switch
S2 Seat
Switch
334
Yel
86
5 521 Brn
518A Gry 6
X1
002E
Red
30
K4
Engine
Run
Relay
87 87A
383
Org
86
85
X5
87 87A
572A
Red
518B Gry
30
K2 Start
Relay
B
87A 87
85
572B Red 3
2
M
M1
Starting
Motor
Y1
Starting
Motor
Solenoid
V1
Diode
Block
594B Yel
30
87 87A
85
K10 Mid
PTO Light
Relay
86
30
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
(2) Road
K5
Safety
Relay
2
B
3
4
122A
Red
S9 Light
Switch
E
J
X6
X6
353
Org
347
Pur
359
Wht
587D
Org
86
30
85
87 87A
K6
Safety
Relay
Q
B1 Fuel
Gauge
Sensor
D
586 Lt Blu
586 Lt Blu
t0
P
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
X6 K
C
S7 Park
Brake Switch
SE2 - IGNITION
(0) Off
(1) Hazard
546 Lt Blu
B
Switched Power
87 87A
Off
562C Red
Y2 Fuel
Shutoff
Solenoid
85
1
X6
On
A
SE1 - STARTING
P3
Fuel
Gauge
H4
Discharge
Light
533 Org
Wht
30
t0
Q
C
594A Yel
86
K12
Flasher
587D Org
86
Red
Unswitched Power
_
587C
Org
302B Red
X4
K11 Brake
Light Relay
49
556 Lt Blu
302C
Red
116
Lt Blu
S12 Hazard
Switch
A
+
556 Lt Blu
8 302A Red
X33
122B
Red
546 Lt Blu
7
87 87A
122C
Red
(3) Field
X2
S3 Transmission
Neutral Switch
(HST & SRT)
X3
S4 Transmission
Neutral Switch (CST)
86
S16 Brake
Switch
573
Org
Pedal Depressed
587A Org
X2
85
X6
Pedal Released
505 Dk Grn
30
A
587B
Org
In Gear
X3
86
X7
V2
Diode
594B
Yel
In Neutral
R1 Manifold
Heater
87 87A
S17 Mid PTO
Switch (Option)
30
15
072A
Red
K9 Rear
PTO Relay
On Off
On
102
Red
30
85
Off
30
49
K7
Accessory
Relay
X5
002B Red
Fusible
Link
P
G2
Alternator
573
Org
On
Off
F2
Fuse
252
Red
575A Dk Grn
V1 Diode
Block
85
S18 Front
PTO Switch
(Option)
575B
Dk Grn
042C
Red
B
L
(Operator On)
002E Red
K1 Manifold
Heater
Relay
Off
On
562F Red
IG
B
562G Red
562A Red
A
072D
Red
G
X34
X34
562B Red
F5 Fuse
86
002A
Red
562D Red
Aid
Off
002C
Red
042D
Red
072E Red
072D Red
Start
Run
Off
Acc.
002A
Red
042B Red
P
Control Panel Circuit Board
Secondary Switched Power
SE3 - CHARGING SE4 - ACCESSORIES
4 - 122
H6 Park
Brake
Light
SE5 - INSTRUMENTATION
SE6 - LIGHTS
4/6/01
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
ELECTRICAL - EUROPEAN
POWER CIRCUIT ELECTRICAL SCHEMATIC - START
002A Red
002 Fuse Block Internal Link
F3 Fuse 122C Red
002 Fuse Block Internal Link
A
B
A
B
042A Red
002D Red
4
012 Red
6
1
5
2
B
F1
Fuse
3
A
7
F4 Fuse
572A Red
072B Red
072A Red
072A Red
072E Red
072E Red
X33
PTO On
PTO Off
385B
Dk Grn
X34
072C
Red
A
B
562E Red
(Operator Off)
S1 Key
Switch
562C Red
S6 Rear
PTO Switch
S2 Seat
Switch
334
Yel
86
5 521 Brn
518A Gry 6
X1
002E
Red
30
K4
Engine
Run
Relay
87 87A
383
Org
86
85
X5
87 87A
572A
Red
518B Gry
30
K2 Start
Relay
B
87A 87
85
572B Red 3
2
M
M1
Starting
Motor
Y1
Starting
Motor
Solenoid
V1
Diode
Block
594B Yel
30
87 87A
85
K10 Mid
PTO Light
Relay
86
30
85
87 87A
P4 Engine
Coolant
Temperature
Gauge
H7 Oil
Pressure
Light
(2) Road
K5
Safety
Relay
2
B
3
4
122A
Red
S9 Light
Switch
E
J
X6
X6
353
Org
347
Pur
359
Wht
587D
Org
86
30
85
87 87A
K6
Safety
Relay
Q
B1 Fuel
Gauge
Sensor
D
586 Lt Blu
586 Lt Blu
t0
P
B2 Engine Oil B3 Engine
Coolant
Pressure
Temperature
Switch (NC)
Sensor
S12 Horn
Switch
X6 K
C
S7 Park
Brake Switch
SE2 - IGNITION
(0) Off
(1) Hazard
546 Lt Blu
B
Switched Power
87 87A
Off
562C Red
Y2 Fuel
Shutoff
Solenoid
85
1
X6
On
A
SE1 - STARTING
P3
Fuel
Gauge
H4
Discharge
Light
533 Org
Wht
30
t0
Q
C
594A Yel
86
K12
Flasher
587D Org
86
Red
Unswitched Power
_
587C
Org
302B Red
X4
K11 Brake
Light Relay
49
556 Lt Blu
302C
Red
116
Lt Blu
S12 Hazard
Switch
A
+
556 Lt Blu
8 302A Red
X33
122B
Red
546 Lt Blu
7
87 87A
122C
Red
(3) Field
X2
S3 Transmission
Neutral Switch
(HST & SRT)
X3
S4 Transmission
Neutral Switch (CST)
86
S16 Brake
Switch
573
Org
Pedal Depressed
587A Org
X2
85
X6
Pedal Released
505 Dk Grn
30
A
587B
Org
In Gear
X3
86
X7
V2
Diode
594B
Yel
In Neutral
R1 Manifold
Heater
87 87A
S17 Mid PTO
Switch (Option)
30
15
072A
Red
K9 Rear
PTO Relay
On Off
On
102
Red
30
85
Off
30
49
K7
Accessory
Relay
X5
002B Red
Fusible
Link
P
G2
Alternator
573
Org
On
Off
F2
Fuse
252
Red
575A Dk Grn
V1 Diode
Block
85
S18 Front
PTO Switch
(Option)
575B
Dk Grn
042C
Red
B
L
(Operator On)
002E Red
K1 Manifold
Heater
Relay
Off
On
562F Red
IG
B
562G Red
562A Red
A
072D
Red
G
X34
X34
562B Red
F5 Fuse
86
002A
Red
562D Red
Aid
Off
002C
Red
042D
Red
072E Red
072D Red
Start
Run
Off
Acc.
002A
Red
042B Red
P
Control Panel Circuit Board
Secondary Switched Power
SE3 - CHARGING SE4 - ACCESSORIES
4 - 122
H6 Park
Brake
Light
SE5 - INSTRUMENTATION
SE6 - LIGHTS
4/6/01
ELECTRICAL - EUROPEAN
Secondary Switched Power - Run:
Voltage must be present at the following components
with the key switch in the RUN ("ON") position,
transmission in NEUTRAL, PTO(s) in NEUTRAL, park
brake ENGAGED, and operator NOT ON seat:
POWER CIRCUIT ELECTRICAL SCHEMATIC
• Start Relay Terminal 87
• Starting Motor Terminal A
See "CRANKING CIRCUIT OPERATION".
• K5 Safety Relay Terminal 87
• K6 Safety Relay Terminal 87A
• Engine Run Relay Terminal 87
• X4 Connector (302C Red wire)
Switched Power - Aide:
Voltage must be present at the following components
with the key switch in the AID position (key pushed in
when placed in the RUN or START position).
• Key Switch Terminal 7
• Manifold Heater Relay Terminal 86
These circuits are controlled by the key switch and are
protected by the fusible link and the F1 fuse.
Secondary Switched Power - Aide:
Voltage must be present at the following components
with the key switch in the AID position (key pushed in
when placed in the RUN or START position):
• Manifold Heater Relay Terminal 87
• Manifold Heater
See "MANIFOLD HEATER OPERATION".
Switched Power - Start:
Voltage must be present at the following components
with the key switch in the START position, transmission
in NEUTRAL, PTO(s) in NEUTRAL, park brake
ENGAGED, and operator NOT ON seat:
• Key Switch Terminals 5 and 6
• Start Relay Terminal 30
• Diode Block Terminal 3
• K6 Safety Relay Terminal 86
• Start Relay Coil (If start criteria are met)
NOTE:
These components are in addition to the
components that would have switched power
with the key switch in the RUN position.
Voltage would not be present at the cruise
control switch, or at the accessory relay
(terminal 86) with the key switch in the START
position.
Secondary Switched Power - Start:
Voltage must be present at the following components
with the key switch in the START position, transmission
in NEUTRAL, PTO(s) in NEUTRAL, park brake
ENGAGED, and operator NOT ON seat:
4/6/01
4 - 123
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
POWER CIRCUIT DIAGNOSIS
Test Conditions: (For Unswitched Power)
• Key switch in OFF position
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
If Not Normal
1. Starting motor battery (B)
terminal
Battery voltage
Check cable to battery. Test battery.
2. Alternator (B terminal)
Battery voltage
Check 002A Red cable and
connections.
3. Fuse block (F1 fuse)
Battery voltage
Check fusible link, 002C Red wire and
connections.
4. Fuse block (F3 fuse)
Battery voltage
Check internal fuse connection in load
center (tie to F1 fuse).
5. Fuse block (F4 fuse)
Battery voltage
Check internal fuse connection in load
center (tie to F1 fuse).
6. Fuse block (F2 fuse)
Battery voltage
Check 002D Red wire and
connections.
7. Accessory relay socket
Battery voltage
Check F2 fuse, 252 Red wire and
connections.
8. Hazard switch connector
Battery voltage
Check F4 fuse, 042A and 042C Red
wires and connections.
9. X33 connector to S16 brake
switch
Battery voltage
Check F4 fuse, 042A and 042D Red
wires and connections.
10. Brake light relay socket
(terminal 30)
Battery voltage
Check F4 fuse, 042A and 042B Red
wires and connections.
11. Light switch
Battery voltage
Check F3 fuse, 122C and 122B Red
wires and connections.
12. Horn switch
Battery voltage
Check F3 fuse, 122C and 122A Red
wires and connections.
13. Key switch
Battery voltage
Check F1 fuse, 012 Red wire and
connections.
14. Engine run relay socket
(terminal 30)
Battery voltage
Check fusible link, 002E Red wire and
connections.
15. Manifold heater relay socket
(terminal 30)
Battery voltage
Check fusible link, 002B Red wire and
connections.
4 - 124
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
002A Red
2
002C Red
002B Red
Fusible Link
G2 Alternator
1
M1 Starting Motor
G1 Battery
3
6
4
5
1
2
3
4
A
86
30
87A
87
002B Red
B
9
10
A
85
15
5
8
7
11
12
B
K1 Manifold Heater Relay
(Socket terminal 30)
042A
Red
252
Red
7
86
Fuseblock
S13 Hazard
Switch Connector
86
30
87A
85
87
042C
Red
30
87A
87
002E Red
14
6
85
K4 Engine Run Relay
(Socket terminal 30)
K7 Accessory Relay
(Socket terminal 30)
8
042D
Red
122C Red
042B
Red
85
12
122A Red
30
87
87A
S1 Key Switch
13
9
86
012 Red
X33 To S16 Brake Switch
10
K11 Brake Light Relay
(Socket terminal 30)
122B Red
S12 Horn Switch
11
4/6/01
S9 Light Switch
4 - 125
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
Test Conditions: (For Switched Power)
• Key switch in RUN position
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
If Not Normal
16. Key switch
Battery voltage
Test key switch (See "KEY SWITCH
TEST"). Replace switch as necessary.
17. Key switch
Battery voltage
Test key switch.
18. Key switch
Battery voltage
Test key switch.
19. Fuseblock (F5 fuse)
Battery voltage
Check 072B and 072C Red wires and
connections.
20. Seat switch
Battery voltage
Check F5 fuse, 562A and 562E Red
wires and connections.
21. Park brake switch
Battery voltage
Check 562C Red wire and
connections.
22. Mid PTO switch (Option)
Battery voltage
Check 562F Red wire and
connections.
23. Mid PTO switch (Option)
Battery voltage
Ensure Mid PTO is DISENGAGED.
Test switch (See "REAR AND MID
PTO SWITCH TEST").
24. Mid PTO relay socket (terminal
86)
Battery voltage
Check 594B Yel wire and connections.
25. Park brake switch
Battery voltage
Check 594A Yel wire and connections.
26. Park brake switch
Battery voltage
Ensure park brake is ENGAGED. Test
switch. (See "PARK BRAKE SWITCH
TEST").
27. K5 Safety relay socket
(terminal 30)
Battery voltage
Check 546 Lt Blu wire and
connections.
28. S6 rear PTO switch
Battery voltage
Check 562G Red wire and
connections.
29. K9 rear PTO relay socket
(terminal 86)
Battery voltage
Ensure PTO is DISENGAGED. Check
575A Dk Grn wire and connections.
Test rear PTO switch. (See "REAR
AND MID PTO SWITCH TEST").
30. PTO switch (X34 if Front PTO
option is not installed)
Battery voltage
Check S6 switch. Check 575B Dk Grn
wire, X34 and connections.
31. PTO switch
Battery voltage
Ensure PTO switch is in OFF position.
Test switch (See "FRONT PTO
SWITCH TEST").
32. K6 safety relay (terminal 30)
Battery voltage
Check 573 Org wire, V2 diode (See
"V2 DIODE TEST"), 587B and 587D
Org wires and connections.
4 - 126
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
16
072C Red
072B Red
209 Wht
19
A
17
1
212 Red
S1 Key Switch
B
18
3
2
9
10
A
6
5
4
11
8
7
12
Fuseblock
B
562A
Red
575A Dk Grn
29
S2 Seat Switch
86
S6 Rear
PTO Switch
30
87A
87
562G
Red
85
562B
Red
K9 Rear PTO Relay
(Socket terminal 30 & 86)
28
562A
Red
562E Red
20
562C Red
S18 Front PTO
Switch (OFF)
(Option)
562F
Red
562D Red
575B
Dk Grn
573
Org
S7 Park Brake Switch
25
30
31
594A Yel
546 Lt Blu
V2
Diode
26
587B
Org
K10 Mid PTO Relay
(Socket terminal 86)
85
X5 (Installed with cap and jumper wire
if mid PTO option is not installed)
27
86
86
30
87A
87
30
87A
87
85
85
K5 Safety Relay
(Socket terminal 86)
30
546
Lt Blu
87A
87
24
587C
Org
33
4/6/01
86
594B Yel
587D Org
21
23
S17 Mid PTO Switch
(Option)
32
K6 Safety Relay
(Socket terminal 30)
22
4 - 127
POWER CIRCUIT DIAGNOSIS
Test/Check Point
33. K5 safety relay (terminal 86)
ELECTRICAL - EUROPEAN
Normal
Battery voltage
If Not Normal
Check 587C Org wires and
connections.
NOTE: The following three steps are for Hydro (HST) and SyncReverser (SRT) tractors. The X3 connector is
fitted with a plug and jumper wire. For Gear Collar Shift (CST) tractors see step 36.
34. S3 transmission neutral switch
Battery voltage
Check 573 Org wire, V2 diode (See
"V2 DIODE TEST"), 587B and 587A
Org wires and connections.
35. S3 transmission neutral switch
Battery voltage
Ensure forward pedal linkage is
depressing switch, adjust switch
position if needed. Test switch. (See
"TRANSMISSION NEUTRAL
SWITCH TEST– HST&SRT").
36. Start relay socket (terminal 86)
Battery voltage
Check X3 connector and jumper wire,
505 Dk Grn wire, X4 and connections.
Check 518B Gry wire and
connections.
NOTE: The following two steps are for Gear Collar Shift (CST) tractors only.
37. X3 to S3 Transmission neutral
switch (Early Models)
X2 to S3 Transmission neutral
switch (Later Models)
Battery voltage
Check 573 Org wire, V2 diode, 587B
and 587A Org wires, X2 connector
and jumper wire, and 505 Dk Grn
wire.
38. Start relay socket (terminal 30)
Battery voltage
Ensure transmission is in NEUTRAL.
Test S4 transmission switch. (See
"TRANSMISSION NEUTRAL
SWITCH TEST– CST") Check 518B
Gry wire and connections.
39. Diode block socket (terminal 6)
Battery voltage
Check 518A Gry wire and
connections.
40. Engine run relay socket
(terminal 86)
Battery voltage
Ensure diode block is fully seated.
Test diode block (See "DIODE BLOCK
TEST"). Check 521 Brn wire and
connections.
Test Conditions: (For Secondary Switched) Power
NOTE: The following test is for the fuel solenoid that receives power after a relay is activated. This circuit needs
to have all of the relays in place to perform this test.
• Key switch in RUN position
• Engine OFF
41. X4 connector to fuel shutoff
solenoid
4 - 128
• Park brake ENGAGED
• Transmission in NEUTRAL
• PTO DISENGAGED
• Fuel solenoid DISCONNECTED
Battery voltage
Note: Battery voltage can not be
tested at the diode block socket.
The diode block needs to be in
place.
Ensure K4 engine run relay coil is
powered. See step 40. Check engine
run relay (See "RELAY TEST").Check
302B and 302C Red wires and
connections.
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
S18 Front PTO
Switch (OFF)
(Option)
Hydro (HST) and SyncReverser (SRT) Power Circuit
37 Later CST Models
34
X2
587A Org
32
86
W3 Neutral Start
Wiring Harness
573
Org
30
87A
87
85
587D
587B
Org
Org
HST & SRT
Circuit
Plug and
Jumper Wire
Wire
587A Org
X3
518B
Gry
587C Org
33
S3 Transmission Neutral
Switch (HST and SRT)
505
Dk Grn
V2
Diode
K6 Safety Relay
(Socket terminal 30)
35
86
30
87A
87
CST
Circuit
85
587A
Org
Gear (CST) Power Circuit
X2
V1 Diode Block
(Socket terminal 6)
1
Plug and
Jumper Wire
Wire
505
Dk Grn
5
302A Red
4
7
K5 Safety Relay
(Socket terminal 86)
2
8
3
6
9
X3 To S4
518A Gry
39
40
37
521
Brn
86
S4 Transmission Neutral
Switch (CST)
30
87A
85
302C
Red
87
302B Red
518B
Gry
K4 Engine Run Relay
(Socket terminal 86)
518B
Gry
Early Models Only:
– LV4200E329005
– LV4300E339505
– LV4400E349014
36 38
86
41
30
87A
87
85
X4 To Y2 Fuel
Shutoff Solenoid
4/6/01
K2 Start Relay
(Socket terminal 86)
4 - 129
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
Test Conditions: (For Switched Power - continued)
• Key switch in ON position
• Engine OFF
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
If Not Normal
42. Park brake switch
Battery voltage
Ensure park brake is set. Check
voltage from 562C Red wire. Test
switch (See "PARK BRAKE SWITCH
TEST").
43. X6 connector to control panel
Battery voltage
Check 586 Lt Blu wire and
connections.
44. X6 connector to control panel
Battery voltage
Check 072A Red wire and
connections.
45. Alternator IG Terminal
Battery voltage
Check 072B and 072D Red wires and
connections.
46. Key switch
Battery voltage
Test key switch (See "KEY SWITCH
TEST").
47. X9 connector
Battery voltage
Check 209 Wht wire and connections.
4 - 130
4/6/01
POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
072C Red
A
1
B
2
9
3
4
10
A
5
6
7
11
8
12
B
Fuseblock
562A
Red
562C
Red
586 Lt Blu
072C
Red
S7 Park Brake Switch
42
X6 W1 Main Wiring Harness
To Control Panel
44
072A
Red
43
072B Red
209 Wht
S1 Key Switch
072D Red
G2 Alternator
Connector
46
45
G2 Alternator
209 Wht
47
X9 To W4 Cruise
Control Wiring Harness
4/6/01
4 - 131
CRANKING CIRCUIT OPERATION
ELECTRICAL - EUROPEAN
CRANKING CIRCUIT OPERATION
MANIFOLD HEATER OPERATION
Function:
Function:
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
To provide an added source of heat for combustion.
Operating Conditions:
Operating Conditions:
• Key switch in START position
• Transmission in NEUTRAL
• Rear PTO DISENGAGED (disengages mid PTO)
c
CAUTION
To avoid injury, ALWAYS engage parking brake
when starting or cranking the engine.
Theory of Operation:
The power circuit (fusible link, 002C Red wire, F1 fuse,
and 012 Red wire) provides voltage to the key switch.
When placed in the START position the key switch
provides voltage to the K2 start relay contact (572A
Red to terminal 30 of start relay).
The start relay coil is energized through a circuit
consisting of the key switch (terminal 5), 072B and
072C Red wires, F5 fuse, 562A and 562G Red wires,
rear PTO switch (PTO DISENGAGED), 575B Dk Grn
wire, X34 and jumper wire (S18 front PTO switch if
option is installed), 573 Org wire, V2 diode, 587B and
587A Org wires, S3 transmission neutral switch, 505
Dk Grn wire, X3 with jumper wire, and 518B Gry wire
on HST and SRT tractors; or, X2 with jumper wire, 505
Dk Grn wire, S4 transmission neutral switch, and 518B
Gry wire on CST tractors.
NOTE:
The S4 Transmission Neutral Switch is
installed in collar shift gear drive (CST)
tractors; a jumper wire is installed in the X2
connector, and the S3 Transmission Neutral
Switch is not used.
In hydrostatic drive (HST) and SyncReverser™
(SRT) tractors the S3 Transmission Neutral
Switch is used, and a jumper wire is installed in
the X3 connector - eliminating the S4 switch.
• Key switch must be in the START or RUN position
and key pushed into switch to the AID position.
Theory of Operation:
The ignition system is designed to inject diesel fuel into
the piston cylinder where heat from compression
ignites the fuel and air mixture.
When starting a cold engine, compression may not
provide enough heat to ignite the fuel. The manifold
heater is installed to provide added heat to the
incoming combustion air.
The manifold heater is energized (heated) when the
key switch is placed in the AID position. The key can be
pushed into the AID position with the key in either the
START or RUN position. The manifold may be
preheated by pushing in the key, with the switch in the
RUN position, for up to 3 seconds before turning the
key to the START position.
When the key switch is in the AID position, current is
provided to the K1 manifold heater relay coil (terminal
86) through the 385B and 385C Dk Grn wires. When
the relay coil is energized, the relay contacts close and
unswitched power (002B Red wire - terminal 30) flows
through the contacts and 383 Org wire to the manifold
heater.
The H5 cold start indicator light in the control panel
provides a visual indication that the key is in the AID
position and the manifold heater relay is being
energized.
With the key in the START or RUN position, and the key
switch in the AID position, battery voltage is provided to
the H5 start light through the 385B and 385A Dk Grn
wires, X6 connector (terminal K), and control panel
circuit board.
A ground circuit path for the control panel circuit board
is provided though the X6 connector (terminal D), and
050K and 050A Blk wires.
When the start relay coil is energized, the relay
contacts close and current flows to the starting motor
solenoid (309 Wht).
With the starting motor solenoid energized the starting
motor solenoid contacts close and high current from
the battery passes through the battery cable and
solenoid contacts to the starting motor. The starting
motor cranks the engine.
4 - 132
4/6/01
CRANKING CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
CRANKING CIRCUIT ELECTRICAL SCHEMATIC
S1 Key
Switch
4
012 Red
1
B
Off
6 572A Red
5 072B Red
2
F1
Fuse
072C Red
F5 Fuse
A
3
562A Red
X34
B
S6 Rear
PTO Switch
7 385B Dk Grn
A
Start
Run
Off
Acc.
002C
Red
002B Red
572A Red
X2
S3 Transmission
Neutral Switch
587A
Org
587A
Org
X3
518B
Gry
518B Gry
87
V2
Diode
Pedal Released
X2
Jumper
Wire
86
573
Org
Pedal Depressed
X3
30
X34
587B
Org
HST and SRT TRACTORS
and CST (Later Models)
Aid
Off
Fusible
Link
Jumper
Wire
On
575B Dk Grn
562G Red
587A
Org
518B
Gry
K2
Start
Relay
X2
Jumper
Wire
In Neutral
In Gear
X2
505 Dk Grn
309
Wht
B
X3
010E
Blk
X3
S4 Transmission
Neutral Switch
A
V1
Diode
Block
CST TRACTORS (Early Models)
Early Models Only:
– LV4200E329005
– LV4300E339505
– LV4400E349014
7
M
385A Dk Grn
M1
Starting
Motor
Y1
Starting
Motor
Solenoid
385C
002B
Dk Grn Red
010D
Blk
86
30
Red
87a
X7
C
K1
Manifold
Heater
Relay
383
Org
R1 Manifold
Heater
G1
Battery
H5 Cold
Start
Light
Blk
010C Blk
050A Blk
050B Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE2 - IGNITION
4 - 133
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
CRANKING CIRCUIT DIAGNOSIS
Test Conditions:
• PTO(s) DISENGAGED
• Key switch in START position
• Park brake ENGAGED
• K2 start relay unplugged
• Transmission in NEUTRAL
Test/Check Point
Normal
If Not Normal
1. Key switch
Battery voltage
(See "POWER CIRCUIT DIAGNOSIS") Test
switch. (See "KEY SWITCH TEST") Replace
key switch as necessary.
2. F5 fuse
Battery voltage
Check 072B and 072C Red wires and
connections.
3. S6 rear PTO switch
Battery voltage
Check F5 fuse. Check 562A and 562G Red
wires and connections.
4. S18 rear PTO switch
Battery voltage
Check 575B Dk Grn wire and connections.
Ensure PTO is disengaged. Check S6 switch
(See "REAR AND MID PTO SWITCH TEST").
5. S18 rear PTO switch
Battery voltage
Ensure PTO switch is in OFF position. Test
switch (See "FRONT PTO SWITCH
TEST").Replace switch as needed.
6. Transmission neutral switch
Battery voltage
Check 573 Org wire, V2 diode (See "V2 DIODE
TEST"), 587B and 587A Org wires, and X2
connector.
7. Transmission neutral switch
Battery voltage
Check switch*. (See "TRANSMISSION
NEUTRAL SWITCH TEST – CST") or (See
"TRANSMISSION NEUTRAL SWITCH TEST –
HST&SRT") Adjust or replace switch as needed.
8. K2 start relay socket (terminal
86)
Battery voltage
Check 505 Dk Grn wire, X3 connector and
jumper wire, and 518B Gry wire and
connections.*
9. K2 start relay socket (terminal
30)
Battery voltage
Check 572A Red wire and connections.
Test Conditions:
• Park brake ENGAGED
• Transmission in NEUTRAL
• Disconnect wiring harness connector to fuel solenoid
• K2 start relay plugged in
• PTO(s) DISENGAGED
• Key switch in START position
cCAUTION: Engine may start during this procedure. Disconnect fuel shutoff solenoid.
10. Starting motor
Battery voltage
Check 309 Wht wire and connections. Check K2
start relay (See "RELAY TEST").Replace relay
as needed.
* Note: This procedure is for HST and SRT tractors. For CST tractors, jumper wire is installed in X2 and S4 neutral
transmission switch is installed and connected to X3.
4 - 134
4/6/01
CRANKING CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
002C Red
1
572A Red
072B Red
2
072C Red
A
1
S1 Key Switch
012 Red
2
3
B
10
6
5
4
8
7
B
A
9
11
12
HST and SRT Wiring Shown
Fuseblock
6
562A
Red
S3 Transmission
Neutral Switch
(HST and SRT)
562G
Red
3
575B
Dk Grn
7
X2
505 Dk Grn
Plug and
Jumper Wire
587A
Org
4
S18 Front
PTO Switch
(OFF)
To S6
5
573
Org
587B Org
X3
V2 Diode
518B
Gry
8
86
572A
Red
30
87A
87
85
9
M1 Starting Motor
K2 Start Relay
002C Red
X1
Fusible Link
10
309 Wht
G1 Battery
W1 Battery Frame Ground
4/6/01
4 - 135
MANIFOLD HEATER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
MANIFOLD HEATER CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Key switch in OFF position
• Unplug K1 manifold heater relay
Test/Check Point
Normal
If Not Normal
1. Key switch
Battery voltage
(See "POWER CIRCUIT
DIAGNOSIS").
2. Manifold heater relay socket
Battery voltage
Check 002B Red wire and
connections. (See "POWER CIRCUIT
DIAGNOSIS").
Test Conditions:
• Park brake ENGAGED
• Unplug K2 start relay
• Unplug K1 manifold heater relay
• Key switch in RUN position; key in AID position (pushed in)
3. Key switch
Battery voltage
Check key switch (See "KEY SWITCH
TEST"). Replace switch as needed.
4. Manifold heater relay socket
Continuous battery voltage while
key switch is in AID position
Check 385B and 385C Dk Grn wires
and connections.
5. X6 connector to control panel
Continuous battery voltage while
key switch is in AID position
Check 385B and 385A Dk Grn wires
and connections.
Test Conditions:
• Park brake ENGAGED
• Unplug K2 start relay
• Plug K1 manifold heater relay into socket
• Key switch in RUN position; key in AID position (pushed in)
6. Manifold heater
Battery voltage
Check 383 Org wire and connections.
Check K1 relay (See "RELAY TEST").
Replace relay as needed.
Test Conditions:
• Park brake ENGAGED
• Change meter to ohm scale
• Meter negative lead connected to frame ground
• Key switch in OFF position
7. Manifold heater module
4 - 136
Maximum 0.1 ohm resistance
Check manifold heater element.
Replace manifold heater as needed.
4/6/01
MANIFOLD HEATER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
S1 Key Switch
R1 Manifold Heater
3
385B Dk Grn
6 7
1
383 Org
012 Red
385B
Dk Grn
4
385A Dk Grn
385C
Dk Grn
86
2
30
87
87A
002B Red
85
5
385A Dk Grn
X7 Main Wiring Harness
To Control Panel
K1 Manifold Heater
Relay Socket
383 Org
B
F1
Fuse
A
002C Red
002B Red
Fusible Link
M1 Starting Motor
G1 Battery
W1 Battery Frame Ground
4/6/01
4 - 137
FUEL SUPPLY OPERATION
FUEL SUPPLY OPERATION
Function:
To start or stop the supply of fuel to the engine.
Operating Conditions (Starting Tractor):
• Key switch must be in the START position.
• Operator ON seat
• PTO in NEUTRAL
• Transmission in NEUTRAL
Operating Conditions (Running Tractor):
• Key switch must be in the RUN position.
• Operator ON seat
• PTO ENGAGED
• Transmission in any GEAR
Operating Conditions (Running Tractor):
• Key switch must be in the RUN position.
• Operator ON seat
• PTO DISENGAGED
• Park brake ENGAGED
Operator can leave seat.
ELECTRICAL - EUROPEAN
The initial high current flows through the 329A Wht wire
to the K3 fuel pull-in relay (terminal 30), through the
contacts, and through the 319 Wht wire to the R2
variable thermistor. The thermistor has a low
resistance to the current initially. As the current flows
through the thermistor, it heats up and the resistance
through it increases.
While the current flow through the thermistor is
reduced, the voltage difference across the thermistor is
increased. When the voltage difference is increased
enough to activate the coil of the fuel pull-in relay (329B
Wht), the coil opens the relay contacts and the variable
thermistor is removed from the circuit.
NOTE: The variable thermistor will heat to a maximum
temperature of approximately 180° F (82° C)
for the brief period of time required to
overcome the fuel shutoff solenoid spring.
With the thermistor removed from the circuit, a ground
path is provided for the fuel shutoff solenoid pull-in coil
through the 329A and 329B Wht wires, the fuel pull-in
relay coil, and the 010F, 010E, 010D and 010C Blk
wires. A ground path for the fuel shutoff solenoid holdin coil is provided through the 010N Blk wire.
The fuel system is designed to inject fuel into the piston
cylinder where heat from compression ignites the fuel
and air mixture.
A latching circuit is provided to maintain voltage to the
engine run relay after the PTO is ENGAGED. The
latching circuit is energized only if the operator is OFF
the seat, the PTO is DISENGAGED, and the park brake
is ENGAGED. The latching circuit remains energized
while the park brake is ENGAGED after the PTO is
ENGAGED. This circuit allows the operator to leave the
seat, with the park brake ENGAGED and the
transmission in NEUTRAL, and ENGAGE the PTO.
(See "ENGINE SHUTOFF CIRCUIT OPERATION").
Fuel is provided to the engine when the fuel shutoff
solenoid is energized. The fuel shutoff solenoid
contains two coils to open the fuel valve. The pull-in
coil, in conjunction with the hold-in coil, overcomes the
spring loaded fuel valve. The hold-in coil keeps the fuel
valve open after the pull-in coil current is reduced
through the R2 thermistor.
Fuel is provided to the engine through the Y2 fuel
shutoff solenoid provided that operating conditions are
met. If the operating criteria are not met, the engine run
relay opens and stops voltage energizing the fuel
shutoff solenoid coils. The fuel shutoff solenoid closes
and fuel to the engine is stopped. (See "ENGINE
SHUTOFF CIRCUIT OPERATION").
• PTO can be ENGAGED
Fuel Supply Theory of Operation
The fuel shutoff solenoid is initially energized and
pulled in when the engine run relay contacts close.
Voltage is provided to both of the fuel shutoff solenoid
coils (pull-in and hold-in), which provide enough pull on
the solenoid plunger to overcome the shutoff solenoid
spring.
The fuel shutoff solenoid pull-in coil needs a high
current pulse through it to overcome the solenoid
spring. After the solenoid opens (overcomes the
spring) a lower current will hold the solenoid open. The
combination of the K3 fuel shutoff relay and R2 variable
thermistor provide a means to reduce the current flow
through the fuel shutoff solenoid pull-in coil after the
solenoid opens.
4 - 138
NOTE: The S4 transmission neutral switch is shown in
this diagnostic section. This switch is used in
conjunction with the jumper wire in the X2
connector for tractors with a gear (CST)
transmission. For tractors with a hydro shift or
SyncReverser™ transmission, the jumper wire
is used in the X3 connector and the S3
transmission neutral switch is connected to the
X2 connector.
4/6/01
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in START position
PTO DISENGAGED
Transmission in NEUTRAL
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red
1
B
2
Off
6
F5 Fuse
5 072B Red
F1
Fuse
072C Red
A
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
562A Red
S6 Rear
PTO Switch
573B
Org
A
X5
Jumper Wire
B
(Operator Off)
X5
V1 Diode
Block
(Operator On)
Aid
Off
5
587B
Org
594
Yel
539B Wht 4
002C
Red
V2
Diode
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
587D Org
X2
K4
Engine
Run
Relay
V1
Diode
Block
010E
Blk
7
8 302A Red
Y2 Fuel
Shutoff
Solenoid
G1
Battery
Blk
010C Blk
87 87A
Off
050C
Blk
Blk
X4
010D
Blk
85
546 Lt Blu
Wht
010F
Blk
30
On
Wht
M1 Starting
Motor
86
594
Yel
X4
M
329A
Wht
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
002E
Red
302B Red
302C
Red
Red
521
Brn
S3 Transmission
Neutral Switch
(HST & SRT)
85
B
587C Org
587A Org
X2
X3
587B
Org
556
Pedal Released Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
X4
329B
Wht
30
86
87A 87
319
Wht
85
587D Org
010T
Blk
010F
Blk
587C
Org
S7 Park
Brake Switch
K5
Safety
Relay
86
30
85
87 87A
556 Lt Blu
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
Powered Circuits
SE2 - IGNITION
4 - 139
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in RUN position
PTO ENGAGED
Transmission ENGAGED
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red
1
B
2
Off
6
F5 Fuse
5 072B Red
F1
Fuse
072C Red
A
562A Red
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
S6 Rear
PTO Switch
573B
Org
A
X5
V2
Diode
Jumper Wire
B
(Operator Off)
(Operator On)
Aid
Off
X5
V1 Diode
Block
539B Wht 4
002C
Red
5
587B
Org
594
Yel
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
X2
587D Org
K4
Engine
Run
Relay
V1
Diode
Block
010E
Blk
7
8 302A Red
Y2 Fuel
Shutoff
Solenoid
Red
G1
Battery
Blk
010C Blk
Off
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
87 87A
Blk
X4
329A
Wht
85
050C
Blk
546 Lt Blu
Wht
010D
Blk
30
On
Wht
010F
Blk
86
594
Yel
X4
M1 Starting
Motor
002E
Red
302B Red
302C
Red
M
521
Brn
S3 Transmission
Neutral Switch
(HST & SRT)
85
B
587C Org
587A Org
X2
X3
587B
Org
556
Pedal Released
Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
X4
329B
Wht
30
86
87A 87
319
Wht
85
S7 Park
Brake Switch
587D Org
010T
Blk
010F
Blk
K5
Safety
Relay
587C
Org
86
30
85
87 87A
556 Lt Blu
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4 - 140
Powered Circuits
SE2 - IGNITION
4/6/01
FUEL SUPPLY ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
FUEL SUPPLY ELECTRICAL SCHEMATIC
002E Red
Conditions: Key switch in RUN position
PTO DISENGAGED
Park brake ENGAGED
Operator ON seat
S1 Key
Switch
002E
Red
4
012 Red
1
B
2
Off
6
F5 Fuse
5 072B Red
F1
Fuse
072C Red
A
B
3
A
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
On
573A Org
562D Red
562A Red
S6 Rear
PTO Switch
573B
Org
X5
A
Jumper Wire
(Operator Off)
(Operator On)
Aid
Off
5
587B
Org
594
Yel
539B Wht 4
002C
Red
B
X5
V1 Diode
Block
V2
Diode
521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
518B Gry
K2
Start
Relay
30
87A 87
587D Org
X2
V1
Diode
Block
010E
Blk
7
85
8 302A Red
On
Wht
Y2 Fuel
Shutoff
Solenoid
M1 Starting
Motor
G1
Battery
Blk
010C Blk
30
87 87A
050C
Blk
Off
546 Lt Blu
Blk
Wht
010F
Blk
002E
Red
594
Yel
X4
M
521
Brn
302B Red
302C
Red
Red
K4
Engine
Run
86
Relay
S3 Transmission
Neutral Switch
(HST & SRT)
85
B
587C Org
587A Org
X2
X3
587B
Org
556
Pedal Released Lt Blu
Pedal Depressed
Jumper 505
Wire
Dk Grn
X3
86
2
X4
010D
Blk
329A
Wht
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
X4
329B
Wht
30
86
587D Org
87A 87
319
Wht
010T
Blk
K5
Safety
Relay
86
30
85
87 87A
556 Lt Blu
85
010F
Blk
587C
Org
S7 Park
Brake Switch
010N
Blk
K6
Safety
Relay
86
30
85
87 87A
533
Org
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
Latching Circuits
Powered Circuits
SE2 - IGNITION
4 - 141
FUEL SUPPLY DIAGNOSIS
ELECTRICAL - EUROPEAN
FUEL SUPPLY DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position (Engine NOT running)
• V1 diode block removed from load center
Test/Check Point
• PTO DISENGAGED
• Transmission in NEUTRAL
• Seat switch closed (Operator ON seat)
Normal
If Not Normal
1. Rear PTO switch
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
2. Transmission neutral switch
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
3. Diode block socket (terminal 6)
Battery voltage
Check transmission switch. (See
“TRANSMISSION NEUTRAL
SWITCH TEST – HST & SRT”.) Check
518B and 518A Gry wires and
connections.
4. Seat switch
Battery voltage
(See “POWER CIRCUIT
DIAGNOSIS”.)
5. Diode block socket (terminal 4)
Battery voltage
Check seat switch. (See “SEAT
SWITCH TEST”.) Check 539B Wht
wire and connections.
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO(s) DISENGAGED
6. Engine run relay socket
(terminal 86)
• Transmission in NEUTRAL
• Seat switch open (Operator OFF seat)
• Install V1 diode block; Remove K4 engine run relay
Battery voltage
Check diode block (terminals 6 to 5).
(See “DIODE BLOCK TEST”.) Check
521 Brn wire and connections.
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO switch OFF
7. Engine run relay socket
(terminal 86)
• Transmission in GEAR
• Seat switch closed (Operator ON seat)
• Install V1 diode block; Remove K4 engine run relay
Battery voltage
Check diode block (terminals 4 to 5).
(See “DIODE BLOCK TEST”.)
Test Conditions:
• Park brake ENGAGED
• Key switch in RUN position
• PTO(s) DISENGAGED
• X4 disconnected
8. X4 fuel solenoid connector
4 - 142
• Transmission in GEAR
• Seat switch closed (Operator ON seat)
• Install K4 engine run relay
Battery voltage
Check 302B and 302C Red wires and
connections.
4/6/01
FUEL SUPPLY DIAGNOSIS
ELECTRICAL - EUROPEAN
F5 Fuse
072C Red
072B Red
S3 Transmission
Neutral Switch
(HST & SRT)
2
562A Red
B
A
S6 Rear
PTO Switch
562G Red
S1 Key Switch
1
575B
Dk Grn
012
Red
S18 Front
PTO Switch
(OFF)
X2
587B Org
587A Org
Plug and
Jumper Wire
X3
573 Org
505
Dk Grn
V2 Diode
S6 Seat Switch
518B Gry
518A Gry
86
30
87A
87
K2 Start
Relay
Socket
4
B
F1
Fuse
85
A
562E Red
5
002E Red
518A
Gry
5
010D Blk
1
7
010E Blk
539B Wht
4
010F Blk
2
8
521 Brn
3
6
9
+12 VDC
002C
Red
3
V1 Diode Block
(Socket terminals)
Fusible Link
6 7
86
30
87A
87
K4 Engine Run
Relay Socket
302A
Red
002E
Red
V1 Diode Block
85
X4 To Y2
8
302C Red
302B Red
010N Blk
329B Wht
86
87A
30
R2 Thermistor
87
W1 Battery
Frame
Ground
329A Wht
85
010F Blk
4/6/01
K3 Fuel Shutoff
Relay Socket
Y2 Fuel Shutoff Solenoid
X4
4 - 143
ENGINE SHUTOFF CIRCUIT OPERATION
ENGINE SHUTOFF CIRCUIT
OPERATION
Engine Shutoff Function:
To prevent the tractor engine from running in an unsafe
condition.
Operating Conditions:
• Engine running
• Operator on seat
Engine MUST STOP if:
• PTO is ENGAGED, and
• Operator gets out of seat
or;
• Transmission is ENGAGED, and
• Operator gets out of seat
NOTE: If transmission is in NEUTRAL and the PTO is
disengaged, and then the park brake is set, the
operator can leave the seat and the PTO can
be reengaged.
or;
• Transmission is in GEAR, and
• Operator gets out of seat
NOTE: The S3 transmission neutral switch is shown in
this diagnostic section. This switch is used in
conjunction with the jumper wire in the X3
connector for HST and SyncReverser tractors.
For CST tractors, the jumper wire is used in the
X2 connector and the S4 transmission neutral
switch is used in the X3 connector.
Theory of Operation:
Fuel is supplied to the engine through the operation of
the K3 fuel shutoff relay and the Y2 fuel shutoff
solenoid, provided that operating conditions are met.
(See "FUEL SUPPLY OPERATION").
When the operating conditions exist, and the engine is
running, the engine shutoff circuit is used to maintain
safe operation of the tractor. If an unsafe condition is
created, the engine will stop by having the fuel supply
to the engine shut off.
The fuel supply is shut off when voltage to the K4
engine run relay coil is stopped, its contacts open, and
power to the Y2 fuel shutoff solenoid coils is stopped
and the solenoid valve closes.
Power to the K4 engine run relay coil comes from the
V1 diode block (terminal 5), and is provided to the
4 - 144
ELECTRICAL - EUROPEAN
diode block (terminals 4 or 6) through several different
circuits that allow for a variety of operating conditions to
exist and maintain fuel supply to the engine.
The main, and most direct, circuit provides power to the
K4 engine run relay coil through the key switch, 072B
and 072C Red wires, F5 fuse, 562A and 562E Red
wires, S2 seat switch (operator ON seat), 539B Wht
wire, V1 diode block (terminals 4 to 5), and 521 Brn
wire. This circuit provides voltage to the engine run
relay for normal operation of the tractor.
A second circuit provides power to the K4 engine run
relay coil through the key switch, 072B and 072C Red
wires, F5 fuse, 562A and 562B Red wires, rear PTO
switch (OFF position), 575B Dk Grn wire, X34 (jumper
wire or S5 PTO switch), 573 Org wire, V2 diode, 587B
and 587A Org wires, S3 or S4 transmission neutral
switch, 518B and 518A Gry wires, V1 diode block
(terminals 6 to 5), and 521 Brn wire. This circuit
provides voltage to the engine run relay if the PTO is
DISENGAGED, and the transmission is in NEUTRAL,
with or without the operator in the seat.
A third circuit provides power to the K4 engine run relay
coil through the park brake switch and the K4 and K5
safety relays. The park brake switch and the K4 and K5
relays, in conjunction with the PTO switch, create a
self-latching circuit. The PTO must be DISENGAGED,
the park brake must be ENGAGED, and the operator
must be OFF the seat to create the circuit. Once the
latch circuit is established the PTO can be ENGAGED.
The circuit will remain latched until the park brake is
released or the operator is ON the seat. Power through
this circuit will keep the K4 engine run relay coil
energized only if the transmission is in NEUTRAL.
Power is provided to the S7 park brake switch through
the key switch, 072B and 072C Red wires, F5 fuse,
562F Red wire, X5 connector and jumper wire, and
594A and 594B Yel wires. With the park brake
ENGAGED, power is provided through the park brake
switch and 546 Lt Blu wire to the K5 safety relay
(terminal 30). Power is provided to the K5 safety relay
coil (terminal 86) through the rear PTO switch (PTO
DISENGAGED), 575B Dk Grn wire, X34 (jumper wire
or S5 PTO switch), 573 Org wire, 575B Dk Grn wire,
X34 (jumper wire or S5 PTO switch), 573 Org wire, V2
diode, and 587B and 587C Org wires.
With the K5 coil energized, and power to the K5 contact
(terminal 30), power is provided through the K5
contacts and 533 Org wire to the K6 contacts (terminal
87A). The power continues through the K6 contacts,
and the 587D and 587C Org wires to the K5 coil
(terminal 86). The PTO can now be ENGAGED and
power will remain to the K4 engine run relay through
the park brake switch, latching relay circuit, and the
same circuit path as provided by the PTO switch
without the latching circuit.
The latching circuit will remain energized until the
operator gets ON the seat and the K6 safety relay coil
is energized, opening the circuit path through the K6
contacts, or; the park brake switch is DISENGAGED
eliminating power to the circuit.
4/6/01
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
ENGINE SHUTOFF CIRCUIT ELECTRICAL SCHEMATIC
002E Red
S1 Key
Switch
002E
Red
4
012 Red
1
B
2
PTO Off
PTO On
575B Dk Grn
6
F5 Fuse
5 072B Red
F1
Fuse
072C Red
A
3
A
562G Red
562A Red
B
X34
562F
Red
562E Red
7
S2 Seat
Switch
Start
Run
Off
Acc.
S6 Rear
PTO Switch
X34
X5
573
Org
Jumper Wire
(Operator Off)
Aid
Off
X5
V1 Diode
Block
(Operator On)
594B
Yel
539B Wht 4
002C
Red
Jumper
Wire
5 521 Brn
518A Gry 6
X1
539A Wht 1
Fusible
Link
K2
Start
Relay
In Gear
505
Dk Grn
X2
587A Org
Jumper
Wire
X3
S4 Transmission
Neutral Switch
(CST Only)
87
587C Org
7
8 302A Red
X4
Y2 Fuel
Shutoff
Solenoid
M1 Starting
Motor
Red
G1
Battery
X4
010D
Blk
329A
Wht
K3 Fuel
Shutoff
Relay
R2 Variable
Thermistor
Blk
010C Blk
30
87
Bake On
Brake Off
546 Lt Blu
050C
Blk
Blk
Wht
010F
Blk
86
594A
Yel
Wht
M
K4
Engine
Run
Relay
002E
Red
K10 Mid PTO
Light Relay
302B Red
302C
Red
521
Brn
587D
Org
86
V1
Diode
Block
010E
Blk
B
X2
X3
86
30
587B
Org
556
Lt Blu
In Neutral
518B Gry
V2
Diode
2
X4
329B
Wht
30
K5
Safety
Relay
86
587C Org
86
30
87
556 Lt Blu
87
319
Wht
010T
Blk
587D
Org
S7 Park
Brake Switch
010F
Blk
010N
Blk
K6
Safety
Relay
86
30
533
Org
87a
050E Blk
050D Blk
050C Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE2 - IGNITION
4 - 145
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
• Gear range lever in NEUTRAL position
• Remove V1, K2, K4, K5, and K6 from load center
• Key switch in RUN position (engine OFF)
NOTE: The S3 transmission neutral switch is shown in this diagnostic section. This switch is used in conjunction
with the jumper wire in the X3 connector for tractors with a hydrostatic transmission. For tractors with a
gear shift transmission the jumper wire is used in the X2 connector and the S4 transmission neutral switch
is used in the X3 connector.
Test/Check Point
Normal
If Not Normal
1. K2 relay socket (terminal 86)
Battery voltage
Ensure PTO(s) is DISENGAGED and transmission
is in NEUTRAL. (See "POWER CIRCUIT
DIAGNOSIS").
2. V1 diode block socket
(terminal 6)
Battery voltage
Check 518A Gry wire and connections.
3. K5 relay socket (terminal 86)
Battery voltage
Check 587D Org wire and connections.
4. K6 relay socket (terminal 30)
Battery voltage
Check 587C Org wire and connections.
5. Park brake switch
Battery voltage
(See "POWER CIRCUIT DIAGNOSIS").
6. Park brake switch
Battery voltage
Test switch (See "PARK BRAKE SWITCH TEST").
7. K5 relay socket (terminal 30)
Battery voltage
Check 546 Lt Blu wire and connections.
8. Seat switch
Battery voltage
Check 562E Red wire and connections.
Test Conditions:
• Park brake ENGAGED
• PTO DISENGAGED
9. Seat switch
• Push and hold seat switch plunger into OPERATOR ON position
• Transmission in NEUTRAL position
• Key switch in RUN position (engine OFF)
Battery voltage
Test seat switch (See "SEAT SWITCH
TEST").Replace seat switch.
10. V1 diode block socket
(terminal 4)
Battery voltage
Check 539B Wht wire and connections.
11. V1 diode block socket
(terminal 1)
Battery voltage
Check 539A Wht jumper wire and connections.
Test Conditions:
• Park brake ENGAGED
• Operator ON seat
• PTO DISENGAGED
• Transmission in NEUTRAL position
• Install V1 diode block in load center
• Key switch in RUN position (engine OFF)
12. K4 relay socket (terminal 86)
Battery voltage
Test diode block (See "DIODE BLOCK TEST").
Check 521 Brn wire and connections.
13. K6 relay socket (terminal 86)
Battery voltage
Test diode block. Check 556 Lt Blu wire and
connections.
4 - 146
4/6/01
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
+12 VDC
A
S6 Rear
PTO Switch
Jumper Wire
F5
Fuse
S4 Transmission
Neutral Switch
(CST Only)
X3
S18 Front
PTO Switch
(OFF)
505 Dk Grn
518B Gry
B
575B
Dk Grn
X2
587A Org
562G Red
573 Org
587B Org
562A
Red
V2 Diode
518A Gry
1
S6 Seat Switch
562F
Red
86
9
87A
87
30
539B Wht
K2 Start
Relay Socket
85
562E Red
010E Blk
X5
86
2
85
86
002E
Red
30
+12 VDC
87A
87
30
521
Brn
87A
87
3
6
9
2
V1 Diode Block
(Socket terminal)
12
594B
Yel
5
8
W1 Battery
Frame
Ground
Jumper Wire
(or S17 Switch)
11
302A Red
010V
Blk
8
1
4
7
010D Blk
539A
Wht
10
587D Org
K10 Mid PTO
Relay Socket
594A
Yel
587C
Org
556
Lt Blu
5
85
K4 Engine Run
Relay Socket
6
13
86
86
533 Org
87A
87
87A
87
30
4
30
302A 302B
Red Red
85
85
302C
Red
S7 Park Brake Switch
3
K6 Safety
Relay Socket
K5 Safety
Relay Socket
546
Lt Blu
7
X4 To Y4
4/6/01
4 - 147
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
Test/Check Point
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
14. K4 relay socket (terminal 86)
Test Conditions:
• Park brake ENGAGED
• Operator ON seat
• PTO DISENGAGED
15. K5 relay socket (terminal 87)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
ELECTRICAL - EUROPEAN
Normal
If Not Normal
• Transmission in NEUTRAL position
• Install V1 diode block in load center
• Key switch in RUN position (engine OFF)
Battery voltage
Test diode block (See "DIODE BLOCK TEST").
Check 521 Brn wire and connections.
• Transmission in NEUTRAL position
• Install K6 safety relay in load center
• Key switch in RUN position (engine OFF)
Battery voltage
Test K6 relay (See "RELAY TEST"). Check 533
Org wire and connections.
• Transmission in NEUTRAL position
• Install K5 safety relay in load center
• Key switch in RUN position (engine OFF)
Test Conditions:
• After the above conditions are set:
• Place PTO shift lever in position to ENGAGE PTO
16. K4 relay socket (terminal 86)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
17. K5 relay socket (terminal 85)
Test Conditions:
• Park brake ENGAGED
• Operator OFF seat
• PTO DISENGAGED
Battery voltage
Check ground circuit of relays. See next step.
• Gear range lever in NEUTRAL position
• Key switch in OFF position (engine OFF)
• Remove K5 relay
Continuity to frame
ground (0.5 ohms or
less)
Check 050E, 050D, and 050C Blk wires and
connections.
• Gear range lever in NEUTRAL position
• Install K5 safety relay in load center
• Key switch in RUN position (engine OFF)
Test Conditions:
• After the above conditions are set:
• Place PTO shift lever in position to ENGAGE PTO
• Check for voltage at K4 relay socket (terminal 86); RELEASE park brake
18. X4 connector to fuel shutoff
solenoid
4 - 148
NO voltage after park
brake is RELEASED
Test K4 relay (See "RELAY TEST"). Replace relay
as needed.
(See "POWER CIRCUIT DIAGNOSIS").
4/6/01
ENGINE SHUTOFF CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
+12 VDC
A
S6 Rear
PTO Switch
Jumper Wire
F5
Fuse
S4 Transmission
Neutral Switch
(CST Only)
575B
Dk Grn
X2
S18 Front
PTO Switch
(OFF)
X3
518B Gry
587A Org
505 Dk Grn
B
562G Red
573 Org
562A
Red
V2 Diode
587B Org
518A Gry
S6 Seat Switch
562F
Red
86
87A
87
30
539B Wht
K2 Start
Relay Socket
85
562E Red
539A
Wht
010E Blk
85
86
002E
Red
30
+12 VDC
87A
87
30
521
Brn
87A
87
3
6
9
V1 Diode Block
(Socket terminal)
14 16
594B
Yel
86
2
8
010V
Blk
W1 Battery
Frame
Ground
X5
5
302A Red
Jumper Wire
(or S17 Switch)
1
4
7
010D Blk
587D Org
K10 Mid PTO
Relay Socket
594A
Yel
587C
Org
556
Lt Blu
85
K4 Engine Run
Relay Socket
S7 Park Brake Switch
15
30
546
Lt Blu
85
K6 Safety
Relay Socket
533 Org
87A
85
18
87
30
87A
87
302C
Red
86
86
302A 302B
Red Red
K5 Safety
17
Relay Socket
X4 To Y4
4/6/01
4 - 149
CHARGING CIRCUIT OPERATION
ELECTRICAL - EUROPEAN
CHARGING CIRCUIT OPERATION
TACHOMETER CIRCUIT OPERATION
FUNCTION:
FUNCTION:
To maintain battery voltage between 12.4 and 13.2
volts.
To indicate engine rpm to the operator.
OPERATING CONDITIONS:
OPERATING CONDITIONS:
The key switch must be in the RUN position with the
engine running for the charging system to operate.
The key switch must be in the RUN position with the
engine running for the tachometer to operate.
SYSTEM OPERATION:
SYSTEM OPERATION:
The charging system consists of the G2 alternator with
an integrated voltage regulator/rectifier. Charging
output is controlled by a regulator/rectifier. The status
of the charge rate is indicated by the H4 discharge
light.
With the key switch in the RUN position, battery
sensing circuit current flows from battery positive
terminal to the starting motor terminal, fusible link, X1,
002C Red wire, F1 fuse, 012 Red wire, S1 key switch,
072B and 072D Red wires to the alternator voltage
regulator/rectifier. The battery sensing circuit allows the
voltage regulator/rectifier to monitor battery voltage.
A rotating permanent magnet in the alternator induces
AC current in the alternator stator coils. The AC current
flows to the voltage regulator/rectifier. The voltage
regulator/rectifier converts AC current to DC current
needed to charge the battery.
If battery voltage is low, the regulator/rectifier allows
DC current to flow to the battery to charge it through
the battery charging circuit (002A Red). When the
battery is fully charged, the voltage regulator/rectifier
stops current flow to the battery.
If the alternator output current falls below system
usage or is insufficient to maintain a preset voltage, the
voltage regulator/rectifier provides current to turn on
the discharge light through the 334 Yel wire, X7
connector, and the control panel circuit board runs.
Pulsed current flows from the "P" terminal of the
alternator to the control panel (X6 connector, terminal
F) through the 325 Dk Grn wire.
HOURMETER CIRCUIT OPERATION
FUNCTION:
To indicate engine hours of use to the operator.
OPERATING CONDITIONS:
The key switch must be in the RUN position with the
engine running for the hourmeter to operate.
SYSTEM OPERATION:
The hourmeter is integrated into the control panel and
does not have any external wiring. The hourmeter
operates only when the engine is running. The
hourmeter uses the engine tachometer circuit for
power. If the tachometer is not functioning, the
hourmeter will not work. See "CHARGING CIRCUIT
DIAGNOSIS" for information on tachometer and
hourmeter diagnosis.
The alternator is grounded through the mounting
hardware to the engine.
If the voltage regulator is grounded to the alternator
cover, the alternator produces unregulated amperage.
(See "UNREGULATED AMPERAGE TEST")
4 - 150
4/6/01
CHARGING CIRCUIT ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
CHARGING CIRCUIT ELECTRICAL SCHEMATIC
002A Red
B
G
IG
4
012 Red
1
2
B
F1
Fuse
G2
Alternator
P
L
6
5
072B Red
072D Red
325 Dk Grn
3
A
7
Start
Run
Off
Acc.
072A
Red
Aid
Off
X6
002C
Red
S1 Key Switch
A
334
Yel
325
Dk Grn
X7
X6
A
F
P2 Hour
Meter
X1
002A
Red
+
Fusible
Link
_
n/min
H4
Discharge
Light
B
P1 Engine
Tachometer
D
Control Panel Circuit Board
X6
M
M1 Starting
Motor
Red
G1
Battery
Blk
050A Blk
050K Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
SE3 - CHARGING
SE5 - INSTRUMENTATION
4 - 151
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
CHARGING CIRCUIT DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Park brake ENGAGED
Test/Check Point
• Gear range lever in NEUTRAL position
• PTO DISENGAGED
Normal
If Not Normal
1. Battery positive terminal
Battery voltage (12.4
- 13.2 volts)
Test battery. (See "BATTERY TEST")
2. Starting motor "B" terminal
Battery voltage
Check battery and starting motor cable connections.
3. Alternator "B" terminal
Battery voltage
Check battery negative cable, alternator ground,
connections, and engine ground connections.
Test Conditions:
• Engine OFF
• Park brake ENGAGED
4. Alternator connector (072D
Red wire terminal)
• Alternator connector removed from alternator
• Key switch in RUN position
Battery voltage
Check 072D and 072B Red wires and connections
(See "POWER CIRCUIT DIAGNOSIS").
Test Conditions:
• Key switch in RUN position
• Engine OFF
• Park brake ENGAGED
• Alternator connector connected
• X6 and X7 connectors to control panel disconnected
5. X6 connector (terminal A)
Battery voltage
Check 072A and 072B Red wires and connections.
6. X6 connector (terminal F)
0.04 VDC
Check 325 Dk Grn wire and connections.
7. X7 connector (terminal A)
0.45 VDC
Check 334 Yel wire and connections.
Test Conditions:
• Park brake ENGAGED
• Transmission in NEUTRAL
• PTO DISENGAGED
• Engine RUNNING
8. Alternator
Minimum 12.2 to
13.8 volts
(See "REGULATED VOLTAGE AND AMPERAGE
TESTS"). Replace voltage regulator/rectifier.
9. Battery
Voltage above
normal battery
voltage.
Check for excessive load on electrical system.
4 - 152
4/6/01
CHARGING CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
002C Red
002B Red
Fusible Link
002A Red
2
M1 Starting Motor
F1 Fuse
012 Red
B
A
1 9
072B
Red
S1 Key Switch
072D Red
8
G1 Battery
072A
Red
3
W1 Battery
Frame
Ground
G2 Alternator
Connector
4
325
Dk Grn
050A
Blk
G2 Alternator
334 Yel
072A Red
050K Blk
7
334 Yel
5
072A Red
1
050K Blk
X7 Main Wiring Harness
To Control Panel
050A Blk
4/6/01
6
325 Dk Grn
X6 Main Wiring Harness
To Control Panel
050K Blk
4 - 153
ENGINE OIL PRESSURE LIGHT
ELECTRICAL - EUROPEAN
ENGINE OIL PRESSURE LIGHT
FUEL GAUGE
Function:
Function:
To alert operator of low engine oil pressure.
Inform the operator of the fuel level in the fuel tank.
Operating Condition:
Operating Condition:
The key switch must be in RUN or START position.
The key switch must be in RUN or START position.
Theory of Operation:
Theory of Operation:
With the engine OFF and key in RUN position, engine
oil pressure will be below 49 kPa (7.1 psi). The oil
pressure switch will be in the normally closed position.
The closed position completes a circuit path to ground
and illuminates the H7 light. This informs the operator
that the light is functional.
The fuel level in the fuel tank is measured by the B1
fuel gauge sensor. The sensor is a variable resistor.
The resistance is set by movement of a mechanical
linkage connected to a float in the fuel tank. The 5 to
110 ohm variable resistance creates a variable voltage
difference across the P1 fuel gauge. The voltage
difference ranges from approximately 5.72 VDC (fuel
tank FULL) to approximately 0.87 VDC (fuel tank
EMPTY).
The light goes out when the engine oil pressure is at or
above 49 kPa (7.1 psi), opens the B2 engine oil
pressure switch, and removes the ground circuit from
the engine oil pressure light.
ENGINE COOLANT TEMPERATURE
GAUGE
Function:
Inform the operator of engine and coolant operating
temperature.
Operating Condition:
The key switch must be in RUN or START position.
Theory of Operation:
The engine coolant temperature sensor is a variable
resistor, providing a ground circuit path for the
temperature gauge. As the engine coolant heats, the
resistance decreases. The temperature gauge circuit is
part of the tractor control panel.
The engine coolant temperature sensor resistance is
approximately 40 - 700 ohms.
4 - 154
4/6/01
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
CONTROL PANEL GAUGES ELECTRICAL SCHEMATIC
(0) Off
(1) Hazard
(2) Road
(3) Field
122C Red
122B Red
B
138 Gry
F7 Fuse
A
3
119C Wht
B
S9 Light
Switch
4
012 Red
5
2
B
B
6
1
F1
Fuse
F3
Fuse
3
X6
A
A
119D
Wht
072A Red
072B Red
X6
7
A
Fuse Block
Internal Link
Control Panel Circuit Board
B
Start
Run
Off
Acc.
Aid
Off
002C
Red
t0
Q
S1 Key Switch
X1
P3
Fuel
Gauge
H7 Oil
Pressure
Light
C
J
Fusible
Link
X6
B
050K
Blk
M
D
X6
353
Org
M1 Starting
Motor
P4 Engine
Coolant
Temperature
Gauge
E
X6
X6
347
Pur
359
Wht
Red
G1
Battery
Q
P
t0
Blk
050A Blk
W1 Battery
Frame
Ground
050K Blk
B2 Engine Oil
Pressure
Switch (NC)
B3 Engine
Coolant
Temperature
Sensor
050L Blk
SE2 - IGNITION
4/6/01
B1 Fuel
Gauge
Sensor
SE5 - INSTRUMENTATION
4 - 155
CONTROL PANEL GAUGES DIAGNOSIS
ELECTRICAL - EUROPEAN
CONTROL PANEL GAUGES DIAGNOSIS
Test Conditions:
• X6 connector to control panel disconnected
• Key switch in RUN position, engine OFF
• PTO in NEUTRAL
Test/Check Point
• Transmission in NEUTRAL
• Park brake ON
• Light switch in ROAD or FIELD position
Normal
If Not Normal
1. X6 connector (terminal A)
Battery voltage
(See "POWER CIRCUIT DIAGNOSIS")
2. Light switch
Battery voltage
Check F3 fuse. Test light switch (See "LIGHT
SWITCH TEST").
3. X6 connector (terminal B)
Battery voltage
Check 119C and 119D Wht wires and
connections.
4. X6 connector (terminal D)
Less than 0.1 ohms
resistance to ground
Check 050K and 050A Blk wires and
connections.
Test Conditions:
• Transmission in NEUTRAL
• PTO in NEUTRAL
• Park brake ON
• X6 connected to control panel
• Key switch in RUN position, engine OFF
• Light switch in OFF position
5. Fuel gauge sensor
Tank full – approximately
0.1 volts DC
Tank empty – approximately
5.0 volts DC
Check 353 Org wire and connections. Check
battery negative cable, 050L and 050A Blk
wires and connections. Test fuel sensor (See
"FUEL GAUGE SENSOR TEST"). Use a
jumper wire to connect 353 Org wire to
battery frame ground. Fuel gauge should
move to maximum position. Gauge does not
move. - Replace control panel.
6. Engine oil pressure switch
Less than 0.1 volts DC
Check 347 Pur wire and connections.Test
switch (See "ENGINE OIL PRESSURE
SWITCH TEST"). Replace switch as
needed.
7. Engine oil pressure switch
(347 Pur wire lead
disconnected)
Less than 0.1 ohms
resistance to ground
Check engine ground. If engine ground OK:
Replace switch.
8. Engine coolant temperature
sensor
Continuity to ground
through sensor – resistance
depends on engine
temperature (40 - 700
ohms). Sensor threads not
corroded.
Disconnect temperature sensor lead. Use a
jumper wire to connect 359 Wht wire to
ground. Temperature gauge should move to
maximum temperature position.
Gauge does not move. - Check 359 Wht wire
and connections. Replace control panel.
Gauge moves. - Replace sensor.
4 - 156
4/6/01
CONTROL PANEL GAUGES DIAGNOSIS
ELECTRICAL - EUROPEAN
072A Red +12 VDC
2
050K Blk
353 Org
4
119D Wht
119D Wht
353 Org
3
072A Red
119C Wht
050K Blk
1
S9 Light Switch
359 Wht
122B
Red
347
Pur
347 Pur
X6 Main Wiring Harness
To Control Panel
+12 VDC
359 Wht
5
353
Org
B1 Fuel Gauge Sensor
050K Blk
347
Pur
050L
Blk
359
Wht
6
7
8
050A
Blk
W1 Battery
Frame
Ground
B2 Engine Oil Pressure Switch
4/6/01
B3 Engine Coolant Temperature Switch
4 - 157
REAR PTO OPERATION
ELECTRICAL - EUROPEAN
REAR PTO OPERATION
2-SPEED PTO LIGHTS
REAR PTO SWITCH AND LIGHT
Function:
Function:
Switch: To control the PTO light and act as part of the
ignition safety circuit. (See "ENGINE SHUTOFF
CIRCUIT OPERATION").
Light: To alert operator of rear PTO being ENGAGED.
Operating Condition:
The PTO shifter must be placed in ENGAGED position.
NOTE: If the Mid PTO option is not installed in the
tractor, a jumper wire is installed in the X5
connector which replaces the S17 mid PTO
switch. If the 2-Speed PTO is not installed in
the tractor, a jumper wire is installed in the X15
connector (574A Yel to 777 Pur) which
replaces the S14 and S15 PTO switches. If the
Front PTO option is not installed in the tractor,
a jumper wire is installed in the X34 connector
(575B Dk Grn to 573 Org) to allow ignition and
operation of the engine.
Theory of Operation:
With the key in START or RUN position, battery voltage
is provided to the S6 rear PTO switch through the F5
fuse and 562A and 562G Red wires. Battery voltage is
also provided to the K9 rear PTO light relay (terminal
30).
When the rear PTO is DISENGAGED, voltage is
provided to the K9 rear PTO relay coil (terminal 86)
through the rear PTO switch contacts and 575A Dk Grn
wire. With voltage provided to the K9 coil, the coil
energizes and opens the relay contacts. The open
contacts prevent current flow to the rear PTO indicator
light.
Power is also provided through the rear PTO switch
(PTO DISENGAGED) to the engine cranking circuit,
(See "CRANKING CIRCUIT OPERATION") and engine
safety shut-off circuit (See "ENGINE SHUTOFF
CIRCUIT OPERATION") through the 575B Dk Grn wire
and X34 connector.
When the PTO is ENGAGED, the S6 rear PTO switch
contacts open, the K9 relay coil is deenergized, and the
relay contacts close. Voltage is provided through the
relay contacts, 574B and 574A Yel wires, X15
connector and jumper wire, 777 Pur wire and X7
connector to the control panel circuit board illuminating
the H10 PTO indicator light. A ground circuit path for
the control panel circuit board is provided though the
X6 connector (terminal D), and 050K and 050A Blk
wires.
4 - 158
To alert operator of rear PTO being ENGAGED, and
which speed range is selected.
Operating Condition:
The rear PTO must be ENGAGED, and the rear PTO
range selector must be placed in either the 540 rpm
range or the 750 rpm range.
Theory of Operation (Early Models):
With the key in START or RUN position and the rear
PTO ENGAGED, battery voltage is provided to the X15
connector through the F5 fuse, 562A and 562B Red
wires, K9 rear PTO light relay contacts, and 574B and
574A Yel wires. (See "REAR PTO SWITCH AND
LIGHT" Theory of Operation.)
The W7 2-speed PTO wiring harness provides voltage
to each of the PTO speed range switches (S14 - 540
rpm switch and S15 - 750 rpm switch).
When the rear PTO range selector is placed in the 540
rpm position, the S14 540 rpm PTO switch is closed,
and provides a current path through the switch, X15
connector, 777 Pur wire, and X7 connector (terminal B)
to the control panel circuit board. A circuit board run
provides voltage to the H10 540 PTO indicator light.
When the rear PTO range selector is placed in the 750
rpm position, the S15 750 rpm PTO switch is closed,
and provides a current path through the switch, X15
connector, 757 Pur wire, and X7 connector (terminal F)
to the control panel circuit board. A circuit board run
provides voltage to the H11 750 PTO indicator light.
Theory of Operation (Later Models):
With the key in START or RUN position and the rear
PTO ENGAGED, battery voltage is provided to the X36
and X37 connectors through the F5 fuse, 562A and
562B Red wires, K9 rear PTO light relay contacts,
574B, 574A and 574EYel wires.
When the rear PTO range selector is placed in the 540
rpm position, the S14 540 rpm PTO switch is closed,
and provides a current path through the switch, X36
connector, 777 Pur wire, and X7 connector (terminal B)
to the control panel circuit board. A circuit board run
provides voltage to the H10 540 PTO indicator light.
When the rear PTO range selector is placed in the 750
rpm position, the S15 750 rpm PTO switch is closed,
and provides a current path through the switch, X37
connector, 757 Pur wire, and X7 connector (terminal F)
to the control panel circuit board. A circuit board run
provides voltage to the H11 750 PTO indicator light.
4/6/01
REAR PTO ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
REAR PTO ELECTRICAL SCHEMATIC
562D Red
X34
B
X34
A
S18 Front PTO
(Option Not Installed)
4
012 Red
B
Off 575B
Dk Grn
On
6
1
5 072B Red 072C Red
2
F1
Fuse
F5 Fuse
A
3
562G Red
562A Red
X34
B
562F Red
S6 Rear
PTO Switch
7
A
Jumper
Wire
Start
Run
Off
Acc.
D
X34
C
573
Org
575A
Dk Grn
562B Red
K9 Rear
PTO Light
Relay
Aid
Off
002C
Red
S1 Key
Switch
86
87a 87
85
To Ignition
and Start
Circuits
574B
Yel
562F
Red
574D Yel
X5
Jumper
Wire
Fusible
Link
30
Mid PTO (Option
Not Installed)
574A Yel
W7 2–Speed PTO
Wiring Harness
(Early Models Only)
X5
X15
594B Yel
On
574D
Yel
Off
S15 750 rpm
PTO Switch
B
K10 Mid
PTO Light
Relay
86
30
85
87 87a
S14 540 rpm
PTO Switch
M
On Off
X15
M1 Starting
Motor
Red
X15
743
Org
757
Pur
777
Pur
737
Pur
X8
X7
X7
X8
D
F
B
A
H9 Mid
PTO Light
H11 750
PTO Light
H10 540
PTO Light
H15 Front
PTO Light
G1
Battery
Blk
050A Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
050K Blk
K
X6
Control Panel Circuit Board
SE5 - INSTRUMENTATION
4 - 159
REAR PTO ELECTRICAL CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
REAR PTO ELECTRICAL CIRCUIT DIAGNOSIS
Test Conditions:
• K9 relay removed from socket
• S5 rear PTO switch disconnected from wiring harness
• Park brake ENGAGED
• Key switch in RUN position, engine OFF
• Rear PTO DISENGAGED
• Transmission in NEUTRAL
Test/Check Point
Normal
If Not Normal
1. S6 rear PTO switch connector
Battery voltage
Check F5 fuse. Check 562A and 562G Red
wires and connections.
2. K9 Rear PTO relay socket
(terminal 30)
Battery voltage
Check F5 fuse. Check 562A and 562B Red
wires and connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL
• S5 rear PTO switch connected to main wiring harness
3. K9 Rear PTO relay socket
(terminal 86)
Battery voltage
• Rear PTO DISENGAGED
• Park Brake ENGAGED
• K9 relay removed from socket
Ensure rear PTO is DISENGAGED. Test S6
switch (See "REAR AND MID PTO SWITCH
TEST"). Replace as needed. Check 575A Dk
Grn wire and connections.
Test Conditions: (Continued from previous step)
• Rear PTO ENGAGED
4. K9 Rear PTO relay socket
(terminal 86)
0.0 VDC
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL
• K9 rear PTO light relay installed in socket
5. X15 connector to W7 wiring
harness
Battery voltage
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL
• Disconnect X7 to control panel circuit board
6. X7 connector to control panel
circuit board
4 - 160
Battery voltage
Ensure rear PTO is ENGAGED. Test S6
switch. (See "REAR AND MID PTO SWITCH
TEST"). Replace as needed.
• Rear PTO ENGAGED
• Park Brake ENGAGED
• X15 disconnected
Check K9 relay (See "RELAY TEST"). Check
574B and 574AYel wires, X15 connector.
• Rear PTO ENGAGED
• Park Brake ENGAGED
• X15 connected
Check X15 connector, W7 wiring harness,
and 777 Pur wire and connections. (See "2
SPEED PTO DIAGNOSIS EARLY
MODELS").
4/6/01
REAR PTO ELECTRICAL CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN
562B Red
F5 Fuse
072C Red
072B Red
A
562A Red
562G Red
B
562F Red
S1 Key Switch
1
X5
S6 Rear
PTO Switch
Plug and Jumper Wire
(Mid PTO Option Not Installed)
To S6 Rear
PTO Switch
575A
Dk Grn
2
594B
Yel
3 4
86
30
87A
87
30
87A
85
86
87
574B Yel
574D Yel
85
K9 Rear PTO
Relay Socket
K10 Mid PTO
Relay Socket
574A
Yel
5
574A Yel
777
Pur
X15 Main Wiring Harness
To W7 2-Speed PTO
Wiring Harness
Early Models Only:
– LV4200E329005
– LV4300E339505
– LV4400E349014
757
Pur
6
777 Pur
X7 Main Wiring Harness
To Control Panel
4/6/01
4 - 161
2-SPEED PTO DIAGNOSIS (Early Models)
ELECTRICAL - EUROPEAN
2-SPEED PTO DIAGNOSIS (Early Models)
Test Conditions:
• Key switch in RUN position, engine OFF
• Rear PTO ENGAGED
• X15 disconnected
Test/Check Point
1. X15 connector to W7 2-speed
PTO wiring harness
• Transmission in NEUTRAL
• Park brake OFF
Normal
Battery voltage
Test Conditions:
• Key switch in RUN position, engine OFF
• X15 to W7 wiring harness connected
• W7 wiring harness to S14 and S15 disconnected
If Not Normal
(See "REAR PTO ELECTRICAL CIRCUIT
DIAGNOSIS").
• Rear PTO ENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
2. W7 wiring harness connector
to S14 540 rpm PTO switch
Battery voltage
Check W7 wiring harness wires and
connections.
3. W7 wiring harness connector
to S15 750 rpm PTO switch
Battery voltage
Check W7 wiring harness wires and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• X15 to W7 wiring harness connected
• W7 wiring harness to S14 and S15 connected
• 2-speed PTO selector lever placed in 540 rpm position
• Rear PTO ENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
• X7 to control panel disconnected
4. X7 (777 pur wire)
Battery voltage
Check 777 Pur wire and connections.Test
S14 540 rpm switch (See "2– SPEED PTO
SWITCH TEST"). Replace switch as needed.
5. X7 (757 pur wire)
Battery voltage
Check 757 Pur wire and connections.Test
S15 750 rpm switch (See "2– SPEED PTO
SWITCH TEST"). Replace switch as needed.
4 - 162
4/6/01
2-SPEED PTO DIAGNOSIS (Early Models)
ELECTRICAL - EUROPEAN
562B Red
072B Red
F5 Fuse
072C Red
A
562G Red
562A Red
B
S6 Rear
PTO Switch
562F Red
S1 Key Switch
K10 Mid PTO
Relay Socket
X5
86
594B Yel
30
87A
87
Plug and Jumper Wire
(Mid PTO Option Not Installed)
575A
Dk Grn
85
86
574D
Yel
30
87
85
Early Models:
–LV4200E329005
–LV4300E339505
–LV4400E349014
87A
W7 2-Speed PTO Wiring Harness
574B Yel
K9 Rear PTO
Relay Socket
3
574A
Yel
X15
2
1
574A Yel
X15 Main Wiring Harness
To W7 2-Speed PTO
Wiring Harness
S15 750 rpm
PTO Switch
S14 540 rpm
PTO Switch
777
Pur
757
Pur
4
777 Pur
5
757 Pur
X7 Main Wiring Harness
To Control Panel
4/6/01
4 - 163
2-SPEED PTO DIAGNOSIS (Later Models)
ELECTRICAL - EUROPEAN
2-SPEED PTO DIAGNOSIS (Later Models)
Test Conditions:
• Key switch in RUN position, engine OFF
• Rear PTO ENGAGED
• X36 disconnected
• X37 disconnected
Test/Check Point
• Transmission in NEUTRAL
• Park brake OFF
Normal
If Not Normal
1. X36 connector to S14
Battery voltage
Check 574B and 574EYel wires and
connections (See "REAR PTO ELECTRICAL
CIRCUIT DIAGNOSIS").
2. X37 connector to S15
Battery voltage
Check 574B and 574AYel wires and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• X36 and X37connected
• W7 wiring harness to S14 and S15 disconnected
• Rear PTO ENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
3. W7 wiring harness connector
to S14 540 rpm PTO switch
Battery voltage
Check W7 wiring harness wires and
connections.
4. W7 wiring harness connector
to S15 750 rpm PTO switch
Battery voltage
Check W7 wiring harness wires and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• X36 and X37 connected to PTO switches
• 2-speed PTO selector lever placed in 540 rpm position
• X7 to control panel disconnected
5. X7 (777 pur wire)
Battery voltage
Test Conditions:
• Key switch in RUN position, engine OFF
• X36 and X37 connected to PTO switches
• 2-speed PTO selector lever placed in 750 rpm position
• X7 to control panel disconnected
6. X7 (757 pur wire)
4 - 164
Battery voltage
• Rear PTO ENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
Check 777 Pur wire and connections.Test
S14 540 rpm switch (See "2–SPEED PTO
SWITCH TEST"). Replace switch as needed.
• Rear PTO ENGAGED
• Park Brake ENGAGED
• Transmission in NEUTRAL
Check 757 Pur wire and connections.Test
S15 750 rpm switch (See "2–SPEED PTO
SWITCH TEST"). Replace switch as needed.
4/6/01
2-SPEED PTO DIAGNOSIS (Later Models)
ELECTRICAL - EUROPEAN
562B Red
F5 Fuse
072C Red
072B Red
A
562G Red
562A Red
B
S6 Rear
PTO Switch
562F Red
S1 Key Switch
K10 Mid PTO
Relay Socket
X5
86
594B Yel
30
87A
87
Plug and Jumper Wire
(Mid PTO Option Not Installed)
575A
Dk Grn
85
86
574D
Yel
30
87A
87
85
574E Yel
574B Yel
K9 Rear PTO
Relay Socket
574A
Yel
Later Models:
LV4200E329006–
LV4300E339506–
LV4400E349015–
X37
574E Yel
1
757
Pur
X36
574A Yel
2
777
Pur
S14 540 rpm
PTO Switch
4
777 Pur
5
757 Pur
S15 750 rpm
PTO Switch
X7 Main Wiring Harness
To Control Panel
4/6/01
4 - 165
MID & FRONT PTO OPERATION
ELECTRICAL - EUROPEAN
MID & FRONT PTO OPERATION
FRONT PTO SWITCH, SOLENOID AND LIGHT
MID PTO LIGHT
Function:
Function:
Switch: To control the front PTO light and PTO
solenoid, and act as part of the ignition safety circuit.
(See "ENGINE SHUTOFF CIRCUIT OPERATION").
To alert operator of mid PTO being ENGAGED.
Light: To alert operator of front PTO being ENGAGED.
Operating Condition:
Operating Condition:
The rear PTO and the mid PTO must be ENGAGED.
The rear PTO must be ENGAGED and the front PTO
switch placed in the ON position.
Theory of Operation:
With the key in START or RUN position, battery voltage
is provided to the S6 rear PTO switch through the F5
fuse and 562A and 562G Red wires. Voltage is also
provided to the X5 connector and S17 mid PTO switch
through the F5 fuse and 562A and 562F Red wires,
and the K9 rear PTO light relay (terminal 30) through
the 562A and 562B Red wires.
When the rear PTO is ENGAGED, the S6 rear PTO
switch contacts open, the K9 relay coil is deenergized,
and the relay contacts close. Voltage is provided
through the relay contacts, 574B and 574D Yel wires to
the K10 mid PTO light relay contacts (terminal 30).
When the mid PTO relay coil is energized, the relay
contacts are open and voltage at the relay contacts
(terminal 30) is not passed through the contacts.
When the mid PTO is ENGAGED, the S17 mid PTO
switch contacts are opened, and voltage to the K10 mid
PTO relay coil is removed from the coil. The mid PTO
light relay contacts close, and voltage is provided
through the contacts to the 743 Org wire and X8
connector (terminal D). A circuit board run provides
voltage to the H9 mid PTO indicator light.
NOTE: Both the K9 rear PTO light relay coil and the
K10 mid PTO light relay coil have to be
DEENERGIZED to allow a circuit path from the
F5 fuse to the H9 mid PTO light.
Theory of Operation:
The front PTO is electrically operated, and can not be
operated if the rear PTO is ENGAGED.
With the key in START or RUN position, battery voltage
is provided to the S6 rear PTO switch through the F5
fuse and 562A and 562G Red wires. Voltage is also
provided to the X34 connector and S18 front PTO
switch through the F5 fuse and 562A and 562D Red
wires
With the rear PTO DISENGAGED, voltage is provided
through the rear PTO switch contacts to the X34
connector and S18 front PTO switch through the 575B
Dk Grn wire.
With the rear PTO DISENGAGED and the S18 front
PTO switch in the OFF position, voltage is provided to
the engine cranking circuit, (See "CRANKING
CIRCUIT OPERATION").and engine safety shut-off
circuit
(See
"ENGINE
SHUTOFF
CIRCUIT
OPERATION"). through the 562G Red wire, rear PTO
switch, 575B Dk Grn wire, X34, front PTO switch, X34,
and 573 Org wire.
When the front PTO switch is placed in the ON position
(rear PTO DISENGAGED), voltage is supplied through
the front PTO switch and front PTO wiring harness to
the Y4 PTO solenoid. Voltage is also supplied through
the front PTO wiring harness, 737 Pur wire, X8
connector (terminal A) and control panel circuit board
to the H15 front PTO light.
When the tractor is not equipped with the front PTO
option, a jumper is installed into the X34 connector,
which connects the 575B Dk Grn wire to the 573 Org
ignition start wire. This allows the tractor to start when
the rear PTO switch is in the OFF position.
4 - 166
4/6/01
MID & FRONT PTO ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
MID & FRONT PTO ELECTRICAL SCHEMATIC
W8 Front PTO Wiring Harness
PTO On
X34
562D Red
575B Dk Grn
X34
B Red
PTO Off
Pur
S18 Front
PTO Switch
Pur
A
4
012 Red
B
Off
6
1
5 072B Red 072C Red
2
F1
Fuse
F5 Fuse
A
3
Pnk
S6 Rear
PTO Switch
575A
Dk Grn
Start
Run
Off
Acc.
Y4 PTO
Solenoid
562B Red
Wht
X35
K9 Rear
PTO Light
Relay
Aid
Off
002C
Red
30
86
87a 87
85
D
562F
Red
S1 Key
Switch
S17 Mid PTO
Switch (Option)
C
X34
Jumper
Used When
No Front
PTO Installed
To Ignition
and
Start
574E Yel
Circuits
574B
Yel
574D Yel
On
X34
573
Org
X5
Fusible
Link
X35
Pur
562G Red
562A Red
B
562F Red
7
A
Org
On
Off
574A
Yel
X15 or X36
X5
594B Yel
574D
Yel
B
K10 Mid
PTO Light
Relay
X37
Jumper
Wire
86
30
85
87 87a
2–Speed PTO
PTO (Option
Not Installed)
M
M1 Starting
Motor
Red
743
Org
777
Pur
737
Pur
X8
X7
X8
D
B
F
A
H9 Mid
PTO Light
H10 540
PTO Light
H11 750
PTO Light
H15 Front
PTO Light
G1
Battery
Blk
050A Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
050K Blk
K
X6
Control Panel Circuit Board
SE5 - INSTRUMENTATION
4 - 167
MID AND FRONT PTO DIAGNOSIS
ELECTRICAL - EUROPEAN
MID AND FRONT PTO DIAGNOSIS
Test Conditions:
• Key switch in RUN position, engine OFF
• Rear PTO DISENGAGED
• Mid and Front PTOs DISENGAGED
• X34 to W8 front PTO wiring harness
disconnected
Test/Check Point
• Transmission in NEUTRAL, Park brake ENGAGED
• K9 and relay removed from socket
• X5 to S17 mid PTO switch disconnected
• X8 to control panel disconnected
Normal
If Not Normal
1. K9 Rear PTO socket
(terminal 86)
Battery voltage
Check F5 fuse. Ensure rear PTO is
DISENGAGED. Test S6 switch (See "REAR
AND MID PTO SWITCH TEST"). Check
562A and 562F Red wires, and 575A Dk Grn
wire and connections.
2. K9 Rear PTO socket
(terminal 30)
Battery voltage
Check 562B Red wire and connections.
3. X5 (562G Red wire)
Battery voltage
Check 562F Red wire and connections.
4. X34 (562D Red wire)
Battery voltage
Check 562D Red wire and connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL, Park Brake ENGAGED
• X5 to S17 mid PTO switch connected
• K10 relay removed from socket
• All PTOs DISENGAGED
• PTO switch in OFF position
• K9 relay installed in socket
5. K10 Mid PTO relay socket
(terminal 30)
Battery voltage
Ensure rear PTO is DISENGAGED. Test rear
PTO relay (See "RELAY TEST"). Check
594B and 574DYel wires and connections.
6. K10 Mid PTO relay socket
(terminal 86)
Battery voltage
Ensure mid PTO is DISENGAGED. Test S17
switch. Check 594B Yel wire and
connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL, Park Brake ENGAGED
• X34 connector to W8 wiring harness disconnected
• Mid PTO ENGAGED
• K10 mid PTO relay installed
7. X8 (743 Org wire)
Battery voltage
Test mid PTO relay. Replace relay as
needed. Check 743 Org wire and
connections.
8. X34 (575B Dk Grn wire)
Battery voltage
Check 575B Dk Grn wire and connections.
Test Conditions:
• Key switch in RUN position, engine OFF
• Transmission in NEUTRAL, Park Brake ENGAGED
9. X8 (737 Pur wire)
4 - 168
Battery voltage
• X34 to W8 wiring harness connected
• Rear PTO switch in ON position
Test front PTO switch. (See "FRONT PTO
SWITCH TEST"). Check 737 Pur wire and
connections. Check W8 wiring harness wires
and connections.
4/6/01
MID AND FRONT PTO DIAGNOSIS
ELECTRICAL - EUROPEAN
562B Red
F5 Fuse
072C Red
072B Red
A
562A Red
562G Red
B
S6 Rear
PTO Switch
562F Red
562D
Red
S1 Key Switch
3
594B
Yel
X5 To S17
2
5
86
S17 Mid
PTO Switch
575A
Dk Grn
575B
Dk Grn
1
30
87A
87
86
85
30
87A
87
574D Yel
574B Yel
K9 Rear PTO
Relay Socket
85
6
K10 Mid PTO
Relay Socket
To Ignition
and Start
Circuits
ON
Jumper Used
When Front PTO
Is Not Installed
Pur
573 Org
562D 575B
Red Dk Grn
4
8
737
Pur
X34 To W8 Front
PTO Wiring Harness
743
Org
Org
S18 Front
PTO Switch
Red
9
737 Pur
X35 To Y4
PTO Solenoid
X34 To W1 Main
Wiring Harness
Pur
W8 Front PTO Wiring Harness
743 Org
7
X8 Main Wiring Harness
To Control Panel
4/6/01
4 - 169
LIGHT SWITCH OPERATION
ELECTRICAL - EUROPEAN
LIGHT SWITCH OPERATION
In the FIELD position, power is removed from the
position lights and license plate light (terminal 2).
Function:
Power is provided to the headlights and control panel
gauge lights (terminal 3).
Provides power to the headlights, tail lights, hazard
lights, work lights and panel lights, dependent upon the
position the light switch is placed in.
Power is provided to the RH and LH work lights
(terminal 4).
Operating Conditions:
Light switch must be in either HAZARD, ROAD or
FIELD position.
Power is provided from the light switch (terminal 4),
through the 143 Org wire to the F6 fuse. The F6 fuse
provides power to the RH work light through the 147A
and 147D Pur wires, and to the LH work light through
the 147A and 147B Pur wires.
Theory of Operation:
BRAKE LIGHTS OPERATION
Unswitched power to the light switch is provided
through the load center F3 fuse, 122C and 122B Red
wires. (See "POWER CUICUIT DIAGNOSIS").
Function:
Light Switch in Hazard Position:
In the HAZARD position, power is provided to the LH
and RH position lights (front and rear), and the license
plate light.
In the HAZARD position, power is provided from the
light switch (terminal 2) through the 103A and 103C
Org wires to the F8 fuse, and 103A and 103B Org wires
to the F9 fuse.
From the F8 fuse, power is provided through the 118A
and 118E Gry wires to the license plate light; the 118A
and 118C Gry wires to the LH front position light; the
118A and 118D Gry wires to the RH rear position light,
and through the 118A and 118B Gry wires to the X13
trailer connector (terminal B).
From the F9 fuse, power is provided through the 128A
and 128B Gry wires to the X13 trailer connector
(terminal D); the 128A and 128C Gry wires to the RH
front position light, and through the 128A and 128D Gry
wires to the LH rear position light.
Provides power to the brake lights.
Operating Conditions:
The brake pedal must be depressed.
Theory of Operation:
Unswitched power is provided to the S16 brake switch
through the F4 fuse, 042A and 042D Red wires, and to
the K11 brake light relay (terminal 30) through the F4
fuse, 042A and 042B Red wires.
When the brake pedal is depressed, the brake switch
closes. The closed brake switch contacts provide
power to the brake light relay coil (terminal 86). When
the brake light relay coil is energized, the relay contacts
close. The closed contacts provide a current path to the
RH brake light through the 136A and 136D Lt Blu wires,
the LH brake light through the 136A and 136C Lt Blue
wires; and, the X13 trailer connector (terminal E)
though the 136A and 136B Lt Blue wires.
Light Switch in Road Position:
In the ROAD position, power is provided from the light
switch (terminal 2) through the same circuits as the
light switch is in the HAZARD position.
In addition, power is provided to the LH and RH
headlights, and the control panel fuel and temperature
gauge lights.
Power is provided from the light switch (terminal 3)
though the 138 Gry wire to the F7 fuse. The F7 fuse
provides voltage to the LH headlight through the 119C
and 119B Wht wires, and the RH headlight through the
119C and 119A Wht wires. Power is also provided to
the control panel gauge lights through the 119C and
119D Wht wires, X6 connector (B terminal) and the
control panel circuit board.
Light Switch in Field Position:
4 - 170
4/6/01
LIGHT SWITCH ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
LIGHT SWITCH ELECTRICAL SCHEMATIC
010A Blk
119A Wht
(0) Off
(1) Hazard
E6 RH
Headlight
(2) Road
(3) Field
119B Wht
010B Blk
1
103A Org
103C Org
2
B
F7 Fuse
138 Gry
A
3
B
143 Org
119C Wht
X6
B
F3
Fuse
A
Pur
Blk
X17
Pur
Blk
B
128A
Gry
118A
Gry
118E Gry
X32
P4 Engine Coolant
Temperature
Gauge
Gry
X32
Blk
E15 License
Plate Light
X20
X27
Off
On
Blu
X33
X1
Fusible
Link
E9 LH Front
Position Light
Gry
Blk
136D Lt Blu
Blu
X28
Gry
010G Blk
010L Blk
Blk
X29
Lt Blu
S16 Brake
Switch
X33
E14 RH
Brake Light
116
Lt Blu
X13 Trailer
Connector
B
118B Gry
E
136B Lt Blu
K11 Brake
Light Relay
B
010R Blk
E13 RH Rear
Position Light
118D
Gry
042B Red
042D
Red
002C
Red
010H Blk
X21
B 042A
Red
002 Fuse
Block
Internal Link
010K Blk
E7 LH Work
Light (Option)
118C Gry
A
X16
E8 RH Work
Light (Option)
X17
F4 Fuse
A
D
128B Gry
136A
Lt Blu
128C Gry
M
Red
147B
Pur
F8
Fuse
F9
Fuse
B
t0
P3 Fuel
Gauge
X16
147D Pur
119D
Wht
A
Q
B
147A Pur
B
S9 Light
Switch
Control Panel
122B
Circuit Board
Red
122C
Red
103B
Org
F6 Fuse
A
4
E5 LH
Headlight
X22
136C Lt Blu
Gry
X23
Gry
010Q Blk
Blk
E12 RH Front X31
Position Light
E10 LH Rear
Position Light
128D
Gry
M1 Starting
Motor
X30
010S Blk
Blk
X24
Lt Blu
E11 LH
Brake Light
G1
Battery
Blk
010R / 010H / 010G / 010S / 010K / 010L / 010Q Blk
010C Blk
010V Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
010A / 010B Blk
Unswitched Power
Switched Power
SE6 - LIGHTS
4 - 171
TURN SIGNAL SWITCH OPERATION
TURN SIGNAL SWITCH OPERATION
Turn Signal Switch Function:
Provides intermittent power (from K12 flasher) to either
the LH front and rear turn/hazard lights, or the RH front
and rear turn/hazard lights. Also provides intermittent
power to the control panel turn indicator lights.
Operating Conditions:
Key switch in the ON position, hazard switch in the OFF
position, and turn signal switch in either LEFT or
RIGHT position.
Theory of Operation:
Unswitched power is provided to the hazard switch
(terminal 30) through the F4 fuse, 042A and 042C Red
wires. Switched power is provided from the key switch
(terminal 5) through the 072B and 072E Red wires to
the hazard switch (terminal 15).
With the hazard switch in the OFF position, the
switched power is provided through the hazard switch
(terminal 15 to terminal 49) and 102 Red wire to the
K12 flasher (terminal 49).
The internal circuits of the K12 flasher provide an
intermittent output (terminal 49a) if a circuit path is
provided through a load component to the battery
frame ground. The flasher unit in the turn signal switch
is not used in this application. Placing the turn signal
switch in either the RIGHT or LEFT position provides a
circuit path through a load component (turn/hazard
lights) to ground.
Right Turn Signal Theory of Operation:
With the turn signal switch in the RIGHT position, and
the hazard switch in the OFF position, voltage from the
K12 flasher (terminal 49a) enters the turn signal switch
(terminal 4) through the 127D and 127B Pur wires. The
turn signal switch completes a current path through the
switch contacts (terminal 4 to terminal 5). From the turn
signal switch (terminal 5), voltage is provided to the RH
front turn/hazard light through the 115A and 115D Dk
Grn wires, the RH rear turn/hazard light through the
115A and 115C Dk Grn wires, the X13 trailer connector
(terminal A) through the 115A and 115E Dk Grn wires,
the control panel RH turn light through the 115A and
115B Dk Grn wires, and the hazard switch (terminal R)
through the 115A and 115F Dk Grn wires.
Each of the turn/hazard lights has a ground connection
to the battery frame ground. When power is supplied to
the turn/hazard lights, a complete circuit path is
formed. When the circuit is formed, the internal circuits
in the K12 flasher provide an intermittent voltage
output. This intermittent voltage is provided to the turn/
hazard lights through the circuit paths described above.
4 - 172
ELECTRICAL - EUROPEAN
Left Turn Signal Theory of Operation:
With the turn signal switch in the LEFT position, and
the hazard switch in the OFF position, voltage from the
K12 flasher (terminal 49a) enters the turn signal switch
(terminal 3) through the 127D and 127A Pur wires. The
turn signal switch completes a current path through the
switch contacts (terminal 3 to terminal 6). From the turn
signal switch (terminal 6), voltage is provided to the LH
front turn/hazard light through the 125A and 125D Dk
Grn wires, the LH rear turn/hazard light through the
125A and 125C Dk Grn wires, the X13 trailer connector
(terminal C) through the 125A and 125E Dk Grn wires,
the control panel LH turn light through the 125A and
125B Dk Grn wires, and the hazard switch (terminal L)
through the 125A and 125F Dk Grn wires.
Each of the turn/hazard lights has a ground connection
to the battery frame ground. When power is supplied to
the turn/hazard lights, a complete circuit path is
formed. When the circuit is formed, the internal circuits
in the K12 flasher provide an intermittent voltage
output. This intermittent voltage is provided to the turn/
hazard lights through the circuit paths described above.
HAZARD SWITCH OPERATION
Hazard Switch Function:
Provides intermittent power (from K12 flasher) to all of
the turn/hazard lights.
Operating Conditions:
Hazard switch in ON position.
Theory of Operation:
With the hazard switch in the ON position, unswitched
power is provided through the hazard switch (terminal
30 to terminal 49) and 102 Red wire to the K12 flasher
(terminal 49). The internal circuits of the K12 flasher
provide an intermittent output (terminal 49a) if a circuit
path is provided through a load component to the
battery frame ground.
The circuit path is created when the K12 flasher output
power is provided through the 127D and 127C Pur
wires to the hazard switch input (terminal 49a). The
contacts in the hazard switch (terminal 49a to terminals
R and L) complete the circuit path to all of the turn/
hazard lights through the 115 Dk Grn and 125 Dk Grn
wires to the LH front and rear turn/hazard lights, the RH
front and rear turn/hazard lights, the X13 trailer
connector (terminals C and A) and both of the control
panel turn indicator lights.
The hazard switch has an internal indicator light that is
provided with intermittent power from the K12 flasher.
4/6/01
TURN/HAZARD LIGHTS ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
TURN/HAZARD LIGHTS ELECTRICAL SCHEMATIC
042B Red
Off
On
X33
042D Red
042A Red
Blu
B
012 Red
1
B
2
F4
Fuse
5
F1
Fuse
A
072B Red
116 Lt Blu
K11 Brake
Light Relay
072E Red
3
Start
Run
Off
Acc.
E3 RH Front
Turn/Hazard
Light
E1 LH Front
Turn/Hazard
Light
7
A
002 Fuse
Block Internal
Link
S16 Brake
Switch
042C
Red
6
X33
Blu
4
S1 Key
Switch
002C
Red
On
Off
125D 125C
Dk Grn Dk Grn
072E
Red
102 Red
X19
X18
S13
Hazard
Switch
Aid
Off
E2 LH Rear
Turn/Hazard
X25
Light
115C
115D
Dk Grn Dk Grn
30
49
15
R
L
115F Dk Grn
115E Dk Grn
125F Dk Grn
127C Pur
125E Dk Grn
49A
31
A
C
102
Red
X26
E4 RH Rear
Turn/Hazard
Light
K12
Flasher
X13 Trailer
Connector
49
X1
Fusible
Link
010P
Blk
49a
31
C3
C
010X
Blk
144
Yel
148
Gry
(0) Right
(1) Off
(2) Left
1
Flasher
5
127D Pur
C2
115A
Dk Grn
127B Pur 4
146
Lt Blu
2
127A Pur 3
B
125A
Dk Grn
6
S8 Turn
Signal Switch
125B Dk Grn
M
X8
Red
115B
Dk Grn
M1 Starting
Motor
G1
Battery
Blk
010C Blk
X7
X7
G E
F
2
D
E
1
H14 Trailer H12 Bulb
H13 Trailer
2 Light
Integrity Light 1 Light
H1 RH
Turn
Light
H2 LH
Turn
Light
Control Panel Circuit Board
010V Blk
W1 Battery
Frame
Ground
SE1 - STARTING
4/6/01
Unswitched Power
Switched Power
SE6 - LIGHTS
4 - 173
LIGHTS DIAGNOSIS
ELECTRICAL - EUROPEAN
LIGHTS DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Engine OFF
Test/Check Point
• Light switch in ROAD position
• X6 connector to control panel disconnected
Normal
If Not Normal
1. Light switch
Battery voltage
Check F3 fuse. (See "POWER CIRCUIT
DIAGNOSIS").
2. Light switch
Battery voltage
Test light switch. (See "LIGHT SWITCH
TEST").
3. F7 fuse
Battery voltage
Check F7 fuse. Check 138 Gry wire and
connections.
4. RH headlight
Battery voltage
Check 119A and 119C Wht wires and
connections.
5. LH headlight
Battery voltage
Check 119A and 119B Wht wires and
connections.
6. X6 control panel connector
(terminal B)
Battery voltage
Check 119A and 119D Wht wires and
connections.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in HAZARD position
• X6 to control panel connected
7. Light switch
Battery voltage
Test light switch. (See "LIGHT SWITCH
TEST").
8. X6 to license plate light
Battery voltage
Check F8 fuse. Check 103A and 103C Org
wires and connections. Check 118A and
118E Gry wires and connections.
9. RH rear position light
Battery voltage
Check 118D Gry wire and connections.
Check X27 connector and Gry wire.
10. X13 (terminal B)
Battery voltage
Check 118B Gry wire and connections.
11. LH front position light
Battery voltage
Check 118C Gry wire and connections.
Check X20 connector and Gry wire.
12. RH front position light
Battery voltage
Check F9 fuse. Check 128A and 128C Gry
wires and connections. Check X30
connector and Gry wire.
13. LH rear position light
Battery voltage
Check 128D Gry wire and connections.
Check X22 connector and Gry wire.
14. X13 (terminal D)
Battery voltage
Check 128B Gry wire and connections.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
15. X33 connector
4 - 174
• X33 to S16 brake switch disconnected
• K11 brake light relay removed from socket
Battery voltage
Check F4 fuse. (See "POWER CIRCUIT
DIAGNOSIS").
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - EUROPEAN
F3 Fuse
122C Red
+12 VDC
A
B
122B
Red
+12 VDC
S9 Light Switch
3
1
A
F4
Fuse
119C Wht
B
119A Wht
F7
Fuse
7
138 Gry
B
042A
Red
042B Red
042D
Red
4
A
119B Wht
119D Wht
6
2
103A
Org
E6 RH Headlight
E5 LH Headlight
5
103C Org
15
103B
Org
A
F8
Fuse
A
F9
Fuse
X33 To S16
Brake Switch
116
Lt Blu
X6 Main Wiring Harness
To Control Panel
B
118A
Gry
B
118E Gry
128A
Gry
118C Gry
128C Gry
118E
Gry
128B Gry
17
86
30
87A
87
85
136A Lt Blu
18
128D 118C
Gry
Gry
X22
E10 LH Rear
Position Light
E11 LH
Brake Light
20
X20
X6 To License
Plate Light
14
136B
Lt Blu
128B
Gry
136C Lt Blu
13
8
X13
To Trailer
16
K11 Brake Light
Relay Socket
128D
Gry
118B
Gry
118B 10
Gry
X23
E12 RH Front
Position Light
E9 LH Front
Position Light
128C
Gry
11
12
118C
Gry
136B 128C
Lt Blu Gry
118D
Gry
136D
Lt Blu
X20
X30
X27
E13 RH Rear
Position Light
E14 RH
Brake Light
9
118D
Gry
19
136C
Lt Blu
136D
Lt Blu
4/6/01
4 - 175
LIGHTS DIAGNOSIS
Test/Check Point
16. Brake light relay socket
(terminal 30)
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
17. Brake light relay socket
(terminal 86)
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
ELECTRICAL - EUROPEAN
Normal
Battery voltage
If Not Normal
Check F4 fuse. Check 042A and 042B Red
wires and connections.
• X33 to S16 brake switch connected
• Depress brake pedal, or:
Manually close and hold S16 brake switch
Battery voltage
Ensure brake is depressed.Test brake
switch (See "BRAKE SWITCH TEST").
Check 116 Lt Blu wire and connections.
• Brake light relay installed in socket
• Depress brake pedal, or:
Manually close and hold S16 brake switch
18. X13 (terminal E)
Battery voltage
Ensure brake is depressed. Check 136A
and 136B Lt Blu wires and connections.
Test brake light relay. (See "RELAY
TEST"). Replace as needed.
19. RH brake light
Battery voltage
Check 136D Lt Blu wire and connections.
Check X20 connector.
20. LH brake light
Battery voltage
Check 136C Lt Blu wire and connections.
Check X23 connector.
Test Conditions:
• Key switch in ON position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in OFF position
• K12 flasher disconnected from wiring harness
• Hazard switch disconnected from wiring harness
21. Key switch (terminal 5)
Battery voltage
Test switch. (See "KEY SWITCH TEST").
Replace as needed.
22. Hazard switch connector
Battery voltage
Check 072B and 072E Red wires and
connections.
23. F4 fuse
Battery voltage
Replace F4 fuse.
24. Hazard switch connector
Battery voltage
Check 042A and 042C Red wires and
connections.
25. Hazard switch connector
Continuity to ground
(0.2 ohms or less)
Check 010P and 010C Blk wires and
connections.
Test Conditions:
• Key switch in ON position
• Engine OFF
• Turn signal switch in OFF position
• Hazard switch connected to wiring harness
• Hazard switch in OFF position
26. K12 flasher connector
Continuity to ground
(0.2 ohms or less)
Check 010X and 010V Blk wire and
connections.
27. K12 flasher connector
Battery voltage
Check 102 Red wire and connections.
4 - 176
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - EUROPEAN
+12 VDC
21
S13 Hazard Switch
072B Red
072E Red
A
49
F4
Fuse
B
S1 Key Switch
49a
23
31
042A
Red
L
R
30
15
042C
Red
102 Red
S13 Hazard Switch Connector
127C Pur
102 Red
010P Blk
072E Red
28
29
127A Pur
127B Pur
127C
Pur
24
127C
Pur
042C Red
010P Blk
072E Red
127D
Pur
010C Blk
010P Blk
010V Blk
010X Blk
25
22
K12 Flasher Connector
26
010X Blk
W1 Battery
Frame
Ground
K12 Flasher
102 Red
27
4/6/01
4 - 177
LIGHTS DIAGNOSIS
Test/Check Point
Test Conditions:
• Key switch in ON position
• Engine OFF
ELECTRICAL - EUROPEAN
Normal
If Not Normal
• Hazard switch in OFF position
• Turn signal switch in OFF position
• K12 flasher connected to wiring harness
28. Turn signal switch
(terminal 3)
7.5 to 8.0 VDC
Check 127D and 127A Pur wires and
connections. Ensure voltage to flasher and
flasher ground connection - see steps 26
and 27. Replace flasher unit.
29. Turn signal switch
(terminal 4)
7.5 to 8.0 VDC
Check 127D and 127B Pur wires and
connections. See previous step.
Test Conditions:
• Key switch in OFF position
• Engine OFF
• Light switch in OFF position
• Hazard switch in ON position
• X7 connector disconnected from control panel
NOTE: Intermittent voltage to the turn/hazard lights, trailer connector, and control panel indicator lights is
provided through the hazard switch when the hazard switch is in the ON position (Steps 30 to 41).
Intermittent voltage to the LH or R. H. turn hazard lights, trailer connector, and control panel indicator
light(s) is provided through the turn signal switch when the switch is placed in either the LH or RH
position and the hazard switch is in the OFF position (Steps 42 to 45).
30. K12 flasher connector
Intermittent battery voltage
Test hazard switch. (See "HAZARD
SWITCH TEST"). Replace switch as
needed.
31. Hazard switch
Intermittent battery voltage
Test hazard switch. See previous step.
32. Hazard switch
Intermittent battery voltage
Test hazard switch. See previous step.
33. Hazard switch
Intermittent battery voltage
Check 127D and 127C Pur wire and
connections.
34. X7 control panel connector
(terminal D)
Intermittent battery voltage
Check 115F and 115B Dk Grn wires and
connections.
35. X7 control panel connector
(terminal E)
Intermittent battery voltage
Check 125F and 125B Dk Grn wires and
connections.
36. X13 trailer connector
(terminal A)
Intermittent battery voltage
Check 115F and 115E Dk Grn wires and
connections.
37. X13 trailer connector
(terminal C)
Intermittent battery voltage
Check 125F and 125E Dk Grn wires and
connections.
38. RH rear turn/hazard light
Intermittent battery voltage
Check 115F and 115C Dk Grn wires, X26
connector and connections.
39. RH front turn/hazard light
Intermittent battery voltage
Check 115F and 115D Dk Grn wires, X25
connector and connections.
40. LH rear turn/hazard light
Intermittent battery voltage
Check 125F and 125C Dk Grn wires, X19
connector and connections.
41. LH front turn/hazard light
Intermittent battery voltage
Check 125F and 125D Dk Grn wires, X18
connector and connections.
4 - 178
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - EUROPEAN
102
Red
31
127C Pur
32
127A Pur
S13 Hazard Switch
127B Pur
042C Red
(12 VDC Unswitched)
072E Red (12 VDC Switched)
28
33
29
127D
Pur
S8 Turn Signal Switch
125A
Dk Grn
115A
Dk Grn
125F
Dk Grn
115F
Dk Grn
102 Red
125F Dk Grn
30
K12 Flasher
125B Dk Grn
X7 Main Wiring Harness
To Control Panel
115E Dk Grn
36
115E
Dk Grn
35
37
125E
Dk Grn
X13
To Trailer
34
115B
Dk Grn
125E Dk Grn
125C
Dk Grn
X19
125B
Dk Grn
115D
Dk Grn
125D
Dk Grn
X25
X18
115C
Dk Grn
X26
E2 LH Rear
Turn/Hazard
Light
E3 RH Front
Turn/Hazard
Light
41
40
125C
Dk Grn
4/6/01
125D
Dk Grn
E1 LH Front
Turn/Hazard
Light
E4 RH Rear
Turn/Hazard
Light
39
115D
Dk Grn
38
115C
Dk Grn
4 - 179
LIGHTS DIAGNOSIS
Test/Check Point
Test Conditions:
• Key switch in ON position
• Engine OFF
• Light switch in OFF position
ELECTRICAL - EUROPEAN
Normal
If Not Normal
• Turn signal switch in RIGHT turn position
• Hazard switch in OFF position
• X7 connector disconnected from control panel
NOTE: The following steps to test the turn signal circuits DO NOT cover testing of each component. If a
component is not covered in the diagnosis, refer to hazard switch test steps 38 to 41.
42. Turn signal switch
Intermittent battery voltage
Test turn signal switch (See "TURN
SIGNAL SWITCH TEST"). Replace switch
as needed.
43. X13 connector
Intermittent battery voltage
Check 115A and 115E Dk Grn wires and
connections.
Test Conditions:
• Key switch in ON position
• Engine OFF
• Light switch in OFF position
• Turn signal switch in LEFT turn position
• Hazard switch in OFF position
• X7 connector disconnected from control panel
44. Turn signal switch
Intermittent battery voltage
Test turn signal switch (See "TURN
SIGNAL SWITCH TEST"). Replace switch
as needed.
45. X13 connector
Intermittent battery voltage
Check 125A and 125E Dk Grn wires and
connections.
4 - 180
4/6/01
LIGHTS DIAGNOSIS
ELECTRICAL - EUROPEAN
102
Red
127C Pur
S13 Hazard Switch
127A Pur
042C Red
(12 VDC Unswitched)
072E Red (12 VDC Switched)
127B Pur
44
42
125A
Dk Grn
127D
Pur
S8 Turn Signal Switch
115A
Dk Grn
125F
Dk Grn
115F
Dk Grn
102 Red
125F Dk Grn
K12 Flasher
125B Dk Grn
X7 Main Wiring Harness
To Control Panel
115E Dk Grn
43
115E
Dk Grn
45
125E
Dk Grn
X13
To Trailer
125B
Dk Grn
115B
Dk Grn
125E Dk Grn
125C
Dk Grn
X19
115D
Dk Grn
125D
Dk Grn
X25
X18
115C
Dk Grn
X26
E2 LH Rear
Turn/Hazard
Light
E3 RH Front
Turn/Hazard
Light
125C
Dk Grn
4/6/01
125D
Dk Grn
E1 LH Front
Turn/Hazard
Light
115D
Dk Grn
E4 RH Rear
Turn/Hazard
Light
115C
Dk Grn
4 - 181
CRUISE CONTROL
ELECTRICAL - EUROPEAN
CRUISE CONTROL
Latching Circuit:
Cruise Control Function:
Power is also provided from the cruise control relay
(terminal 30) to the S11 brake switch and Y3 cruise
control magnet through the 264A Yel wire, X9
connector, W4 wiring harness Yel wires, and X11
connector and X12 connector respectively.
Provides an electro-mechanical means to control the
forward speed of the tractor.
Operating Conditions:
• Key switch in RUN position
• Brake not depressed
• Cruise control switch momentarily in ENGAGE
position, and then released to the ON position.
The cruise control will remain ENGAGED until the
brake is depressed; the key switch is turned to the OFF
position; or, the cruise control switch is placed into the
OFF position.
Theory of Operation:
When the Y3 cruise control electromagnet is
energized, the forward pedal is held in whatever
position it is in when the magnet is energized. The
cruise control magnet is energized through the cruise
control relay contacts. The brake switch provides a
latching circuit for the cruise control relay. When the
brake pedal is depressed, the normally open brake
switch contacts open and the latching circuit is
removed. With the latching circuit removed, the cruise
control relay contacts open, and the cruise control
magnet is deenergized - releasing the forward pedal.
When power is provided to the cruise control magnet, it
is energized and creates a magnetic field that holds the
forward pedal in a locked position.
When power is provided to the S11 brake switch, and
the brake switch contacts are closed (brake NOT
depressed), power is provided through the X11
connector, W4 wiring harness Gry wires, X9 connector
and 238 Gry wire to the cruise control relay (terminal
86). This circuit latches the cruise control relay by
keeping the cruise control relay coil energized.
The latching circuit keeps the cruise control relay coil
energized until the brake pedal is depressed. When the
pedal is depressed, the S11 brake switch contacts
open and power is removed from the cruise control
relay coil.
When the cruise control relay coil is deenergized, the
relay contacts open, and power provided to the cruise
control indicator light and the cruise control magnet is
removed. Without power, the cruise control magnet
releases the forward pedal.
Placing the cruise control switch into the OFF position
stops power to the cruise control relay coil and
contacts.
Power for the cruise control circuit is provided to the X9
connector, from the key switch (terminal 4), through the
209 Wht wire.
Power is provided from the X9 connector to the cruise
control switch through the W4 wiring harness Wht wire,
and X10 connector. The cruise control switch is a
double pole switch with OFF, ON, and momentary
ENGAGE positions.
When the cruise control switch is placed in the
momentary ENGAGE position, power is provided
through the switch, X10 connector, W4 wiring harness
Gry wire, X9 connector, and 238 Gry wire to the K8
cruise control relay (terminal 86). With power provided,
the relay coil energizes and the contacts (terminal 30
and terminal 87) close. At the same time (cruise control
switch placed in the momentary ENGAGE position),
power is provided through the X10 connector, W4
wiring harness Pur wire, X9 connector, and 247 Pur
wire to the K8 cruise control relay contacts (terminal
87).
With the contacts closed, power is provided through the
relay contacts (terminals 87 and 30) to the cruise
control indicator light through the 264B Yel wire, X6
connector (terminal G), and control panel circuit board.
4 - 182
4/6/01
CRUISE CONTROL ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN
CRUISE CONTROL ELECTRICAL SCHEMATIC
W4 Cruise Control
Wiring Harness
Off
On
Engage
S1 Key
Switch
4
012 Red
B
1
2
F1
Fuse
A
Wht
209 Wht
Wht
S10 Cruise
Control
Switch
5
X10
Gry
X10
X9
6
W4 Cruise Control
Wiring Harness
Pur
Blk
X10
Gry
3
7
Off
002D
Red
Start
Run
Off
Acc.
On
Blu
Gry
Blu
X11
Aid
Off
Gry
002C
Red
H8 Cruise
Indicator
Light
X1
Fusible
Link
X11
S11 Brake
Switch
W4 Cruise Control
Wiring Harness
Yel
G
X6
264B
Yel
B
K8
Cruise
Control
Relay
86
30
85
87 87a
238 Gry
247 Pur
264A Yel
Pur
Yel
X9
Yel
M
050G
Blk
M1 Starting
Motor
Red
050F
Blk
Wht
Y3 Cruise
Control
Magnet
050E
Blk
G1
Battery
Blk
W4 Cruise Control
Wiring Harness
050D
Blk
050B Blk
050A Blk
050J Blk
SE1 - STARTING
Wht
X12
050C Blk
W1 Battery
Frame
Ground
4/6/01
X12
Blk
050J Blk
X9
SE4 - ACCESORIES
SE5 - INSTRUMENTATION
4 - 183
CRUISE CONTROL DIAGNOSIS
ELECTRICAL - EUROPEAN
CRUISE CONTROL DIAGNOSIS
Test Conditions:
• Key switch in RUN position, engine OFF
• PTO in NEUTRAL
• Transmission in NEUTRAL
Test/Check Point
• Park brake ENGAGED
• Remove K8 cruise control relay
• Disconnect X9 connector
Normal
If Not Normal
46. Key switch
Battery voltage
Test key switch (See "KEY SWITCH TEST").
Replace switch as needed.
47. X9 connector (terminal A)
Battery voltage
Check 209 Wht wire and connections.
Test Conditions:
• Reconnect X9 connector
• Disconnect X10, X11 and X12 connectors
48. X10 connector (Wht wire
terminal)
Battery voltage
Check X9 connector, Wht wire and
connections, and X10 connector.
Test Conditions:
• Reconnect X10 connector to cruise control switch
• Place and hold cruise control switch in ENGAGE position
49. K8 relay socket (terminal 86)
Battery voltage
Ensure cruise control switch is in ENGAGE
position. Test switch. (See "CRUISE
CONTROL SWITCH TEST"). Check X10
connector, Gry wire, X9 connector, and 238
Gry wires and connections.
50. K8 relay socket (terminal 87)
Battery voltage
Test cruise control switch. Check X10
connector, Pur wire, X9 connector, and 247
Pur wires and connections.
51. X11 connector (Gry wire)
Battery voltage
Check Gry wire and connections.
Test Conditions:
• Place cruise control switch in ON position
52. K8 relay socket (terminal 30)
Battery voltage
Test cruise control switch.
Test Conditions:
• Place key switch in OFF position
53. X12 to frame ground (Blk
wire)
Less than 0.1 ohms
resistance
Check Blk wire, X9 connector, and 050J and
050A Blk wires and connections.
54. X9 to X11 to X12 (Yel wires)
Less than 0.1 ohms
resistance
Check Yel wires and connections.
Test Conditions:
• Reconnect X11 connector
• Key switch in ON position (Engine OFF)
55. X12 connector (Yel wire)
4 - 184
Battery voltage
• Cruise control switch in ON position
• Brake pedal NOT depressed
Test brake switch. (See "BRAKE SWITCH
TEST").
4/6/01
CRUISE CONTROL DIAGNOSIS
ELECTRICAL - EUROPEAN
S10 Cruise
Control Switch
1
209 Wht
X10 To S10 Cruise
Control Switch
Wht
Gry
3
S1 Key Switch
Pur
X9-W1 Main Wiring
Harness To W4 Cruise
Control Wiring Harness
Wht
Gry
238 Gry
Pur
247
Pur
238
Gry
4
86
264A Yel
2
9
Yel
Blk
30
87A
87
209 Wht
85
5
247 Pur
264A
Yel
050J Blk
X9-W4 Cruise Control
Wiring Harness To W1
Main Wiring Harness
K8 Cruise Control Relay
9
264B
Yel
Gry Yel
6
S11 Brake
Switch
X11 To S11
Brake Switch
7
Y3 Cruise
Control Magnet
264B Yel
X6-W1 Main Wiring Harness
To Control Panel
X12 To Y3 Cruise
Control Magnet
8
Blk
W1 Battery
Frame
Ground
4/6/01
Yel
9 10
4 - 185
EUROPEAN CAB ELECTRICAL SECTION
ELECTRICAL - EUROPEAN
EUROPEAN CAB ELECTRICAL
SECTION
The European road-homologated tractors fitted with
operator’s cabs have a main wiring harness that is
specific to tractors fitted with cabs. The cab harness is
the same for the 4500 and 4600 European models, and
meet EEC Machinery Directives.
The cab tractors have most of the same electrical
circuits as found on the standard European tractors.
The differences to the main tractor harness are as
follows:
• The addition of an ignition circuit to trigger the cab
power relays (located in the cab overhead console).
• The removal of the work lamp circuits from the main
tractor harness. (The work lamps are controlled by cab
mounted switches.)
All power for the cab is taken from the battery terminal
on the starting motor. A large 60 amp plug-in fuse is
located on the left side engine shroud, and protects all
the cab power circuits. Smaller plug-in fuses located in
the cab overhead console protect individual cab
circuits.
The front and rear turn signals, licence plate lamp, and
trailer connector, are powered through the main tractor
harness, the same as for the European tractor.
Schematics and diagnosis for these circuits start on
page 4-91.
Most cab electrical repairs can be diagnosed by
lowering the cab overhead console, and accessing the
component control switches, relays, and fuses. Repairs
to harnesses for rear turn signals, licence plate lamp,
trailer connector, rear work lamp, and beacon, can be
accessed under padding behind operator’s seat.
Only major damage to cab harness would require lifting
cab up from tractor to perform repairs. (See
Miscellaneous Section for Cab Removal)
4 - 186
4/6/01
COMPONENT LOCATION – CAB ELECTRICAL
ELECTRICAL - EUROPEAN CAB
COMPONENT LOCATION – CAB ELECTRICAL
D
C
E
B
F
H
G
A
I
J
M
K
L
N
P
O
Q
A. Right Front Work Lamp
F. Right Rear Work Lamp
J. Cab Power Relays
O. Cab X2 Connector
B. X2 Connector
G. Rear Wiper Motor
K. Front Wiper Motor
P. Cab Main Fuse
C. Cab Fuse Panel
H. Left Rear Work Lamp
L. Left Front Work Lamp Q. Starter Battery
Terminal
M. Dome Lamp
D. Cab Switch Panel
E. Fan Blower Motor
4/6/01
I. Washer Pump Control
Module
N. Washer Pump Motor
4 - 187
CAB SCHEMATIC AND WIRING HARNESS LEGEND
ELECTRICAL - EUROPEAN CAB
CAB SCHEMATIC AND WIRING
HARNESS LEGEND
CAB WIRING HARNESS CONNECTORS:
A1—Radio
X2—W1 Tractor Main Harness to W9 Cab Main
Harness Ignition Signal
B5—Left Radio Speaker
B6—Right Radio Speaker
E16—Dome Lamp
E17—Cab Front Work Lamps
E18—Cab Rear Work Lamps
E19—Cab Warning Beacon Lamp
E20—Left Front Cab Turn/Hazard Lamp
X1—W1 Tractor Main Harness–Fusible Link to Fuse #1
X3—W9 Cab Main Harness to Cab Fuse Panel
WIRING HARNESSES:
W9—Cab Main Harness
W10—Cab Left RearTurn Signal Harness
W11—Cab Right Rear Turn Signal Harness
E21—Right Front Cab Turn/Hazard Lamp
E22—Left Rear Cab Turn/Hazard Lamp
E23—Right Rear Cab Turn/Hazard Lamp
E24—Cab License Plate Lamp
F10—Main Cab Fuse - 60 Amp
F11—Cab Fuse #1 - 15 Amp - Wiper/Washer
F12—Cab Fuse #2 - 4 Amp - Radio & Dome Lamp
F13—Cab Fuse #3 - 10 Amp - Fan Blower
F14—Cab Fuse #4 - 30 Amp - Work Lamps
F15—Cab Fuse #5 - Beacon
F16—Cab Fuse #6 - Unused
G1—Battery
K13—Cab Power Relay, Front
K14—Cab Power Relay, Rear
K15—Washer Pump Control Module
M1—Starting Motor
M2—Cab Fan Blower Motor
M3—Rear Wiper Motor
M4—Washer Pump Motor
M5—Front Wiper Motor
S1—Key Switch
S17—Cab Fan Blower Switch
S18—Cab Front Work Lamp Switch
S19—Cab Rear Work Lamp Switch
S20—Cab Warning Beacon Switch
S21—Rear Wiper/Washer Switch
S22—Front Wiper/Washer Switch
W1—Battery Frame Ground
W2—Cab Frame Ground
4 - 188
4/6/01
CAB ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN CAB
CAB ELECTRICAL SCHEMATIC
4
012 Red
1
2
F1
Fuse
6
072F Red
072B Red
5
X2
3
M3
Rear
Wiper
Motor
#12 Yel
7
Start
Run
Off
Acc.
Brn
30
86
K13
Front
Power
Relay
Aid
Off
X1
87
K14
Rear
Power
Relay
85
Red
30
86
87
85
Red
Brn
#14 Grn
#4 Red
002C
Red
F13 Cab
Fuse
#3
X3
A1
Radio
Red
F14 Cab
Fuse
#4
F15 Cab
Fuse
#5
X3
X3
X3
F16
Cab
Fuse
#6
Off
On
S17
Fan
Switch
High-Low-Off
S18
Front
Work
Lamps
Switch
Brn
Blk
Brn
#32 Blk
(High)
On Off
On Off
S19
Rear
Work
Lamps
Switch
On Off
Wht/
Blk
Wash-On-Off
Pur
S22 Front Wiper/
Washer Switch
M
M2 Fan
Blower
Motor
#46
Red
E18
Rear
Work
Lamps
E17
Front
Work
Lamps
Brn
Brn
#45 Grn
#44 Yel
Blk/Wht
#31 Wht
(Low)
Brn
E19
Beacon
Lamp
Brn
M
Brn
Brn
W1 Battery
Frame
Ground
Park
Module
M5 Front
Wiper Motor
W2 Cab
Frame
Ground
Unswitched Power
Switched Power
Secondary Switched Power
SE2 - CAB
SE1 - TRACTOR
4/6/01
Brn/Blu
Blk
E16
Dome
Lamp
M4
Washer
Pump
Blu
S20
Beacon
Switch
Red
Red
Red
G1
Battery
M
Wht
Blu
Grn
Brn
M1
Starting
Motor
Yel
Wht
K15
Washer Pump
Control Module
X3
Grn
B
M
Yel
F11 Cab
Fuse #1
F12
Cab
Fuse
#2
X3
Yel
Red
F10
60 Amp
Cab Fuse
Wash-On-Off
X3
X3
S21
Rear
Wiper/
Washer
Switch
#13
Red
Yel
#9 Red
Fusible
Link
Park
Module
M
S1
Key
Switch
4 - 189
Device Control Power
CAB ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN CAB
CAB ELECTRICAL SCHEMATIC
4
012 Red
1
2
F1
Fuse
6
072F Red
072B Red
5
X2
3
M3
Rear
Wiper
Motor
#12 Yel
7
Start
Run
Off
Acc.
Brn
30
86
K13
Front
Power
Relay
Aid
Off
X1
87
K14
Rear
Power
Relay
85
Red
30
86
87
85
Red
Brn
#14 Grn
#4 Red
002C
Red
F13 Cab
Fuse
#3
X3
A1
Radio
Red
F14 Cab
Fuse
#4
F15 Cab
Fuse
#5
X3
X3
X3
F16
Cab
Fuse
#6
Off
On
S17
Fan
Switch
High-Low-Off
S18
Front
Work
Lamps
Switch
Brn
Blk
Brn
#32 Blk
(High)
On Off
On Off
S19
Rear
Work
Lamps
Switch
On Off
Wht/
Blk
Wash-On-Off
Pur
S22 Front Wiper/
Washer Switch
M
M2 Fan
Blower
Motor
#46
Red
E18
Rear
Work
Lamps
E17
Front
Work
Lamps
Brn
Brn
#45 Grn
#44 Yel
Blk/Wht
#31 Wht
(Low)
Brn
E19
Beacon
Lamp
Brn
M
Brn
Brn
W1 Battery
Frame
Ground
Park
Module
M5 Front
Wiper Motor
W2 Cab
Frame
Ground
Unswitched Power
Switched Power
Secondary Switched Power
SE2 - CAB
SE1 - TRACTOR
4/6/01
Brn/Blu
Blk
E16
Dome
Lamp
M4
Washer
Pump
Blu
S20
Beacon
Switch
Red
Red
Red
G1
Battery
M
Wht
Blu
Grn
Brn
M1
Starting
Motor
Yel
Wht
K15
Washer Pump
Control Module
X3
Grn
B
M
Yel
F11 Cab
Fuse #1
F12
Cab
Fuse
#2
X3
Yel
Red
F10
60 Amp
Cab Fuse
Wash-On-Off
X3
X3
S21
Rear
Wiper/
Washer
Switch
#13
Red
Yel
#9 Red
Fusible
Link
Park
Module
M
S1
Key
Switch
4 - 189
Device Control Power
CAB ELECTRICAL SCHEMATIC
ELECTRICAL - EUROPEAN CAB
CAB ELECTRICAL SCHEMATIC
4
012 Red
1
2
F1
Fuse
6
072F Red
072B Red
5
X2
3
M3
Rear
Wiper
Motor
#12 Yel
7
Start
Run
Off
Acc.
Brn
30
86
K13
Front
Power
Relay
Aid
Off
X1
87
K14
Rear
Power
Relay
85
Red
30
86
87
85
Red
Brn
#14 Grn
#4 Red
002C
Red
F13 Cab
Fuse
#3
X3
A1
Radio
Red
F14 Cab
Fuse
#4
F15 Cab
Fuse
#5
X3
X3
X3
F16
Cab
Fuse
#6
Off
On
S17
Fan
Switch
High-Low-Off
S18
Front
Work
Lamps
Switch
Brn
Blk
Brn
#32 Blk
(High)
On Off
On Off
S19
Rear
Work
Lamps
Switch
On Off
Wht/
Blk
Wash-On-Off
Pur
S22 Front Wiper/
Washer Switch
M
M2 Fan
Blower
Motor
#46
Red
E18
Rear
Work
Lamps
E17
Front
Work
Lamps
Brn
Brn
#45 Grn
#44 Yel
Blk/Wht
#31 Wht
(Low)
Brn
E19
Beacon
Lamp
Brn
M
Brn
Brn
W1 Battery
Frame
Ground
Park
Module
M5 Front
Wiper Motor
W2 Cab
Frame
Ground
Unswitched Power
Switched Power
Secondary Switched Power
SE2 - CAB
SE1 - TRACTOR
4/6/01
Brn/Blu
Blk
E16
Dome
Lamp
M4
Washer
Pump
Blu
S20
Beacon
Switch
Red
Red
Red
G1
Battery
M
Wht
Blu
Grn
Brn
M1
Starting
Motor
Yel
Wht
K15
Washer Pump
Control Module
X3
Grn
B
M
Yel
F11 Cab
Fuse #1
F12
Cab
Fuse
#2
X3
Yel
Red
F10
60 Amp
Cab Fuse
Wash-On-Off
X3
X3
S21
Rear
Wiper/
Washer
Switch
#13
Red
Yel
#9 Red
Fusible
Link
Park
Module
M
S1
Key
Switch
4 - 189
Device Control Power
CAB WIRING HARNESS
ELECTRICAL - EUROPEAN CAB
CAB WIRING HARNESS
X2
Tractor
Ignition
E19
Beacon
E18
Left Rear
Work Lamp
M3 Rear
Wiper Motor
E18
Right Rear
Work Lamp
Right
Speaker
M1
Starting
Motor
K13
Front
Power
Relay
K14
Rear
Power
Relay
F10
60 Amp
Cab Fuse
E16 Dome
Lamp
E17
Left Front
Work Lamp
A1
Radio
(Power)
A1 Radio
(Speaker)
M4
Washer
Pump
Left
Speaker
M5
Front
Wiper
Motor
M2 Fan
Blower
Motor
E17
Right Front
Work Lamp
X3
Connector
K15
Washer Pump
Control Module
W2 Cab
Frame
Ground
S20
S17
S21
Beacon Fan
Rear
Switch Switch Wiper/
Washer
Switch
4 - 190
S22
Front
Wiper/
Washer
Switch
E18
Rear
Work
Lamp
Switch
E17
Front
Work
Lamp
Switch
4/6/01
CAB WIRING HARNESS
ELECTRICAL - EUROPEAN CAB
CAB WIRING HARNESS
X2
Tractor
Ignition
E19
Beacon
E18
Left Rear
Work Lamp
M3 Rear
Wiper Motor
E18
Right Rear
Work Lamp
Right
Speaker
M1
Starting
Motor
K13
Front
Power
Relay
K14
Rear
Power
Relay
F10
60 Amp
Cab Fuse
E16 Dome
Lamp
E17
Left Front
Work Lamp
A1
Radio
(Power)
A1 Radio
(Speaker)
M4
Washer
Pump
Left
Speaker
M5
Front
Wiper
Motor
M2 Fan
Blower
Motor
E17
Right Front
Work Lamp
X3
Connector
K15
Washer Pump
Control Module
W2 Cab
Frame
Ground
S20
S17
S21
Beacon Fan
Rear
Switch Switch Wiper/
Washer
Switch
4 - 190
S22
Front
Wiper/
Washer
Switch
E18
Rear
Work
Lamp
Switch
E17
Front
Work
Lamp
Switch
4/6/01
CAB WIRING HARNESS
ELECTRICAL - EUROPEAN CAB
CAB WIRING HARNESS
X2
Tractor
Ignition
E19
Beacon
E18
Left Rear
Work Lamp
M3 Rear
Wiper Motor
E18
Right Rear
Work Lamp
Right
Speaker
M1
Starting
Motor
K13
Front
Power
Relay
K14
Rear
Power
Relay
F10
60 Amp
Cab Fuse
E16 Dome
Lamp
E17
Left Front
Work Lamp
A1
Radio
(Power)
A1 Radio
(Speaker)
M4
Washer
Pump
Left
Speaker
M5
Front
Wiper
Motor
M2 Fan
Blower
Motor
E17
Right Front
Work Lamp
X3
Connector
K15
Washer Pump
Control Module
W2 Cab
Frame
Ground
S20
S17
S21
Beacon Fan
Rear
Switch Switch Wiper/
Washer
Switch
4 - 190
S22
Front
Wiper/
Washer
Switch
E18
Rear
Work
Lamp
Switch
E17
Front
Work
Lamp
Switch
4/6/01
ELECTRICAL - EUROPEAN CAB
W10 CAB LEFT TURN SIGNAL WIRING HARNESS
W10 CAB LEFT TURN SIGNAL WIRING HARNESS
E22
Left Rear
Turn/Hazard
Lamp
To W1 Tractor
Main Harness
E20
Left Front
Turn/
Hazard
Lamp
W11 CAB RIGHT TURN SIGNAL WIRING HARNESS
To W1 Tractor
Main Harness
4/6/01
E24 License
Plate Lamp
E23
Right Rear
Turn/Hazard
Lamp
E21
Right Front
Turn/
Hazard
Lamp
4 - 191
CAB ELECTRICAL TROUBLESHOOTING
ELECTRICAL - EUROPEAN CAB
Check cab main 60 amp fuse.
●
Check cab power relays are
energized when ignition is on.
●
See “Light Switch Operation” in
European Electrical Section.
See “W7 Trailer Connector Wiring
Harness” in European Electrical
Section.
4 - 192
Cab trailer connector not powered.
Washer pump not operating.
No power at radio and dome lamp.
No power at wipers and washers.
Cab fan blower motor not operating.
Cab work lamps not operating.
●
Check F11 cab fuse #1.
Check pump washer module.
●
●
Check F13 cab fuse #3.
Check F12 cab fuse #2.
●
●
Check F14 cab fuse #4.
Check cab frame ground behind
operator’s seat.
Cab license plate lamp has no power.
Check or
Solution
Cab turn signals not operating.
Problem or
Symptom
No cab power. All cab circuits dead.
CAB ELECTRICAL TROUBLESHOOTING
●
●
●
●
4/6/01
THEORY AND DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
THEORY AND DIAGNOSIS
CAB POWER CIRCUIT OPERATION
NOTE:
See cab electrical schematic for reference
while reading this page.
Switched Power:
When the key switch is moved to the ON position,
control current is sent to the cab via the 072F Red
ignition circuit, which pulls in the K13 Front and K14
Rear Power Relays in the overhead console of the cab.
The 072F circuit is specific to cab tractors, and is taken
from the 072 ignition node shown on the main
European tractor schematic.
Function:
Secondary Switched Power:
Provides power to the cab components whenever the
battery is connected.
With the cab power relays pulled in and closed, cab
power can flow from the F10 60 amp cab fuse, (located
in the left-rear engine compartment), through the cab
relays, to the cab fuse panel.
The unswitched power is direct to the cab from the
tractor battery.
The switched power is controlled by the tractor ignition
circuit, and is only powered when key switch is in RUN,
START, or AID positions. It energizes the cab power
relays, closing the contacts and allowing current to flow
to the cab fuse panel.
The K13 front power relay controls the power for cab
fuses 1–3, (radio, dome lamp, wiper/washers, and
blower fan)
The secondary switched power is the current from the
cab power relays, through the cab fuse panel, and into
the cab switches.
If fuses are good, power flows to the cab switch panel,
radio power connector, dome lamp, and washer pump
control module.
The device control power is the current from a switch to
a specific device, which will activate a device directly, or
will control a relay which controls a device. It is the
power directly controlled by the operator to turn
something on or off.
Unswitched Power:
Battery voltage must be present at the following
components with the key switch in the OFF position:
The K14 rear power relay controls power for cab fuses
4–6, (work lamps, and optional safety beacon).
Device Control Power:
Individual switches on the cab switch panel route
power to the specific electrical devices. All circuits are
grounded at cab frame ground, behind operator’s seat.
The washer pump is energized by the washer pump
control module, located in the cab overhead console.
It’s operation is covered separately in this section.
• Battery Positive Terminal
• Starting Motor Terminal B
• Cab Main 60 Amp Fuse
• F1 Tractor Ignition Fuse
• Key Switch Terminal 1
• Cab Power Relays
• Cab Radio Connector
If battery power is not available at the above points,
refer back to the “Power Circuit Operation” section of
the European Electrical section for theory and
diagnosis of tractor power circuits.
4/6/01
4 - 193
CAB POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
CAB POWER CIRCUIT DIAGNOSIS
Test Conditions:
• Key switch in OFF position
• Park brake ENGAGED
• Transmission in NEUTRAL
• PTO DISENGAGED
Test/Check Point
Normal
If Not Normal
1. Starting motor battery (B) terminal
12.4 - 13.2 VDC
Check cable to battery. Test battery.
2. Tractor fuse panel—F1 fuse.
12.4 - 13.2 VDC
Check fusible link, 002C Red wire and
connections.
3. Key switch 012 Red wire.
12.4 - 13.2 VDC
Check F1 fuse, 012 Red wire and
connections.
4. 60 amp cab main fuse.
12.4 - 13.2 VDC
Check Red wire and connections between
cab main fuse and starting motor B
terminal.
5. #9 Red wire at terminal #30 of cab
power relays.
#4 Red wire at cab radio connector.
12.4 - 13.2 VDC
Check #9 Red wire from cab main fuse in
engine compartment to cab overhead
console.
Test Conditions:
• Key switch in ON position
• Park brake ENGAGED
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
If Not Normal
6. X2 connector of 072F circuit
behind tractor fuse panel.
12.4 - 13.2 VDC
See “Power Circuit Diagnosis” in
European Electrical section.
7. #86 terminal (red wire) of front
and rear cab power relays.
12.4 - 13.2 VDC
Check Red Ignition Wire from tractor
X2 connector to cab overhead console.
8. #85 terminal (brn wire) of front
and rear cab power relays.
Continuity to cab frame ground
located behind operator’s seat.
Repair cab frame ground wire.
9. Cab power relays
12.4 - 13.2 VDC at relay terminals If power is at terminal 30 and 86, but
30 (red), 86 (red), and 87 (red).
not at 87, relay is burned out. Replace
relay.
10. All fuses in cab fuseblock
12.4 - 13.2 VDC
11. Cab switches in overhead
console.
12.4 - 13.2 VDC at back of switch Check wires from cab fuse panel to cab
panel at wire terminals and
switch panel through X3 connector.
cavities marked at right.
4 - 194
If no power on any side of any fuse:
Check red wires between power relays
and cab fuse panel.
If power on only one side of a fuse:
Replace fuse.
If only power to three fuses (1-3 or 4-6):
One power relay is defective.
4/6/01
CAB POWER CIRCUIT DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
Cab Fuse
Panel
10
Cab Switch Panel
X2
Connector
Wht
Red
Red
Blu
Yel
#12
Yel
#44
Red
K14 Rear
Power
Relay
K13 Front
Power
Relay
9
9
7
7
11
85
30
87
Brn
87
Brn
Red
85
86
86
30
Red
8
Red
8
5
5
Red
5
Red #4 To
A1 Radio
Connector
Red
Red
6
X2
072F
Red
#9
Red
F10
60 Amp
Cab Fuse
S1
Key
Switch
4
3
G1
Battery
012
Red
M1
Starting
Motor
2
Red
1
F1
Tractor
Fuse
#1
002C Red
4/6/01
1
Fusible Link
4 - 195
CAB WIPER DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
CAB WIPER DIAGNOSIS
Test Conditions:
• Engine OFF
• Key switch in RUN position
• Transmission in NEUTRAL
• PTO DISENGAGED
• Park Brake ENGAGED
WIPER MOTOR CIRCUIT DIAGNOSIS
Test/Check Point
Normal
If Not Normal
1. F11 cab fuse #1
12.4 - 13.2 VDC on both sides
of fuse.
No power on 1 side of fuse: Replace fuse.
No power on both side of fuse:
See ”Cab Power Circuit Diagnosis” section
2. Yel wire from cab fuse panel,
through X3 connector, to front
and rear wiper switches.
12.4 - 13.2 VDC
Repair Cab fuse panel, X3 connector
terminals, or Yel wire to front and rear wiper
switches.
3. Wiper switch to ON (middle)
position.
12.4 - 13.2 VDC at red wire on
back of wiper switch (front or
rear), and to wiper motor.
No power at back of switch: replace switch.
No power at wiper motor: repair red wire.
Turn wiper switch back to OFF position before performing step 4.
4. Brn wire at wiper motor.
Continuity to ground.
Repair Brn ground wire to wiper motor.
If normal, replace wiper motor.
WIPER MOTOR PARK CIRCUIT DIAGNOSIS
Test/Check Point
Normal
If Not Normal
Perform steps 1–4 above to check power circuit before performing with step 5.
Turn key switch to ON position before performing step 5.
5. #44 Yel wire from front wiper
switch to front wiper motor.
12.4 - 13.2 VDC
Repair #44 wire.
6. #12 Yel wire from rear wiper
switch to rear wiper motor.
12.4 - 13.2 VDC
Repair #12 wire.
7. Brn wire at wiper motor.
Continuity to ground.
Repair Brn ground wire.
8. Grn wire from wiper motor to
wiper switch. (One Grn wire
for each wiper.)
12.4 - 13.2 VDC when wiper
arm is not in parked position.
Circuit remains powered after
switch is moved to OFF
position, until arm is parked.
0 VDC when arm is parked.
No voltage: (Wiper will not park) Replace
wiper motor.
Constant voltage (Wiper will not stop)
Replace wiper motor.
4 - 196
4/6/01
CAB WIPER DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
1
Cab Fuse #1
Cab Fuse
Panel
Yel 2
X3 Connector
3
S22
Front
Wiper
Switch
3
S21
Rear
Wiper
Switch
2
Yel
3
#46
Red
#44
Yel
#45
Grn
M3
Rear
Wiper
Motor
3
#13
Red
#12
Yel
6
5
8
#14
Grn
To M5
Front
Wiper
Motor
8
Brn
4/6/01
4
7
4 - 197
CAB WASHER PUMP DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
CAB WASHER PUMP DIAGNOSIS
Test Conditions:
• Engine OFF
• Key switch in RUN position
Test/Check Point
• Transmission in NEUTRAL
• PTO DISENGAGED
Normal
• Park Brake ENGAGED
If Not Normal
1. F11 cab fuse #1
12.4 - 13.2 VDC
No power on both sides of fuse:
See ”Cab Power Circuit Diagnosis” section.
No power on one side of fuse: Replace fuse.
2. Yel wire at washer pump
control module.
12.4 - 13.2 VDC
Repair Yel wire from cab fuse panel, through
X3 connector, to pump control module.
3. Brn wire at washer pump
control module.
Continuity to ground.
Repair Brn ground wire.
4. Wht wire at washer pump
control module.
12.4 - 13.2 VDC when rear
washer switch is depressed.
Repair Wht wire from rear washer switch to
pump control module.
5. Wht/Blk wire at washer pump
control module.
12.4 - 13.2 VDC when front
washer switch is depressed.
Repair Wht/Blk wire from rear washer switch
to pump control module.
6. Brn/Blu wire at washer pump
control module.
12.4 - 13.2 VDC when key
switch is ON, except when
front washer switch is
depressed.
Replace washer pump control module.
7. Blu wire at washer pump
control module
12.4 - 13.2 VDC when key
switch is ON, except when
rear washer switch is
depressed.
Replace washer pump control module.
8. Brn/Blu and Blu wires at
washer pump.
Both wires should have 12.4
- 13.2 VDC when checked
between wire and ground.
When rear washer switch is
pushed, Blu wire becomes
ground and pump operates.
When front washer switch is
pushed, Brn/Blu wire
becomes ground, and pump
reverses.
If not operating, remove wiring harness and
test pump with a 12 volt battery. If pump
works, repair wires between pump and
control module.
If pump does not run, replace pump.
4 - 198
4/6/01
CAB WASHER PUMP DIAGNOSIS
ELECTRICAL - EUROPEAN CAB
1 Cab Fuse #1
Cab Fuse
Panel
S21
Rear Wiper/
Washer Switch
S22
Front Wiper/
Washer Switch
X3
Connector
Cab Switch
Panel
Yel
Wht
Wht/Blk
Brn
8
3
Brn/Blu
K15 Washer
Pump Control
Module
2
7
Blu
5
6
4
M4
Washer
Pump
4/6/01
4 - 199
CAB WASHER PUMP DIAGNOSIS
4 - 200
ELECTRICAL - EUROPEAN CAB
4/6/01
CONTENTS
GEAR POWER TRAIN
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4200 – CLUTCH (CST AND SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4200 – PINION SHAFT AND COUNTER SHAFT (CST and SST) . . . . . . . . . . . . . . . 6
4200 – 3 SPEED TRANSMISSION (CST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4200 – 3 SPEED SYNCRO TRANSMISSION (SST) . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRACTOR SPLITTING (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COLLAR SHIFT (CST) TRACTION CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . 17
COLLAR SHIFT (CST) TRACTION CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . 18
INPUT SHAFT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRACTION CLUTCH INSTALLATION (CST or SST) . . . . . . . . . . . . . . . . . . . . . . . . 20
CLUTCH SHIMMING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SNUBBER SHIMMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLUTCH SHAFT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-SPEED TRANSMISSION REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-SPEED TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION . . . . . . . . . . . . . . . . 35
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . 42
4/6/01
5-1
NOTES
5-2
GEAR POWER TRAIN
4/6/01
SPECIFICATIONS
GEAR POWER TRAIN
SPECIFICATIONS
GENERAL SPECIFICATIONS
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9x3 SST Collar Shift
Number of Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forward, 3 Reverse
Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L (6.3 gal)
Clutch Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.780 in.)
REPAIR SPECIFICATIONS
TORQUE SPECIFICATIONS
SCV Port Tube Hydraulic Line Nuts . . . . . . . . . . . . . . . . . . . . 40 - 57 N•m (30 - 43 lb-ft)
Gear Housing to Transmission Housing Cap Screws . . . . 126 - 154 N•m (95 - 115 lb-ft)
Front Clutch Cover To Housing (Tunnel) Cap Screws . . . . . . . 23 - 29 N•m (17 - 22 lb-ft)
Clutch Hub to Transmission Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
SPECIAL OR ESSENTIAL TOOLS
Part Number
Part Name
JT07335-1,2,3
Splitting Stands and Brackets
JDG1259
Clutch Shimming Fixture
JDG 1262
Detent Ball Tool
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
OTHER MATERIALS
4/6/01
Number
U.S./Canadian
Name
Use
TY6305
John Deere Clean and Cure Primer
Clean form in place gasket surfaces.
TY16021
John Deere Form in Place Gasket
Between axle and differential
housings, transmission tunnel etc.
TY6333
Moly High Temperature EP Grease
TY22034
John Deere SuperLube®
TY9370 (#242
LOCTITE®)
Thread Lock and Sealer
(Medium Strength)
On dowel pins and certain cap screws.
5-3
COMPONENT LOCATION
GEAR POWER TRAIN
COMPONENT LOCATION
4200 – CLUTCH (CST AND SST)
13
14
15
17
16
18
19
20
21
7
8
22
23
9
24
10
11
12
1
2
3
26
4
28
27
25
5
34
6
29
30
31
35
33
32
26
27
36
37
M95091A
5-4
4/6/01
4200 – CLUTCH (CST AND SST)
GEAR POWER TRAIN
1. Ball Bearing
12. Piston
23. Pin
34. Spring
2. Snap Ring
13. Clutch Plates
24. Lift Arm
35. Seal
3. Gear
14. Hub
25. Clutch Cover
36. Shaft
4. Snap Ring
15. Washer
26. Pin
37. Plug
5. Input Shaft
16. Nut
27. Bearing
6. Ball Bearing
17. Spring (4)
28. Cap
7. Spacer
18. Plate
29. Cap Screw
8. Bearing
19. Cap Screw (4 used)
30. Cap
9. Bearing Race
20. Bearing
31. Pin
10. Clutch Basket
21. Snubber
32. Seal
11. Washer
22. Shims
33. Ball
4/6/01
5-5
4200 – PINION SHAFT AND COUNTER SHAFT (CST and SST)
GEAR POWER TRAIN
4200 – PINION SHAFT AND COUNTER SHAFT (CST and SST)
10
6
9
5
8
7
11
4
2
3
13
1
11
12
20
19
18
16
17
15
14
M95092
1. Shaft
6. Cap Screw
11. Spring Pin (2 used)
16. Gear (33T)
2. Gear
7. Dowel Pin (2 used)
12. Sleeve
17. Spacer
3. Bearing
8. Bearing
13. Pinion Shaft (24T)
18. Gear (38T)
4. Thrust Washer
9. Coupler
14. Snap Ring
19. Gear (26T)
15. Ball Bearing (2 used)
20. Countershaft
5. Bearing Housing
5-6
10. Shaft
4/6/01
4200 – 3 SPEED TRANSMISSION (CST)
GEAR POWER TRAIN
4200 – 3 SPEED TRANSMISSION (CST)
11
9
10
8
7
6
5
18
4
3
2
19
1
12
23
24
25
13
26
27
21
14
22
15
20
16
17
M95287A
1. Snap Ring
8. Gear
15. Thrust Washer
22. Rail
2. Gear
9. Thrust Washer
16. Ball Bearing
23. Cap Screw (2)
3. Ball (2 used)
10. Ball Bearing
17. Snap Ring
24. Plate
4. Shaft
11. Snap Ring
18. Gate (2 used)
25. Pin
5. Gear
12. Collar (2)
19. Rail
26. Spring (2)
6. Snap Ring
13. Hub (2)
20. Fork (2 used)
27. Ball (2)
7. Bearing
14. Gear
21. Insert (4 used)
28.
4/6/01
5-7
4200 – 3 SPEED SYNCRO TRANSMISSION (SST)
GEAR POWER TRAIN
4200 – 3 SPEED SYNCRO TRANSMISSION (SST)
8
7
6
13
12
11
4
1
2
5
17
3
4
2
3
10
15
16
9
6
12
9
14
18
33
2
35
34
36
11
10
37
31
30
25
28
24
22
23
26
29
32
MX8736
27
21
20
19
5-8
4/6/01
4200 – 3 SPEED SYNCRO TRANSMISSION (SST)
GEAR POWER TRAIN
1. Snap Ring
11. Fork (2)
21. Gear
31. Bearing Housing
2. Ball Bearing
12. Pin (2)
22. Spacer
32. Ball & Spring (2)
3. Thrust Washer (2)
13. Rail
23. Gear
33. Plate
4. Ball (2)
14. Gear
24. Gear
34. Cap Screw (2)
5. Gear
15. Gear
25. Shaft
35. Gate (2)
6. Synchronizer Assy
16. Bearing
26. Shaft
36. Pin (2)
7. Gear
17. Snap Ring
27. Gear
37. Pin
8. Shaft
18. Rail
28. Bearing
38.
9. Snap Ring
19. Snap Ring
29. Thrust Washer
39.
20. Ball Bearing
30. Dowel Pin
40.
10. Insert (4 used)
4/6/01
5-9
CLUTCH PEDAL AND LINKAGE
GEAR POWER TRAIN
CLUTCH PEDAL AND LINKAGE
1
2
3
4
5
6
7
8
9
10
11
12
15
13
17
18
14
16
19
21
20
22
23
24
25
1. Shaft
8. Pedal
15. Cap Screw (Stop)
22. Rod
2. Bearing
9. Clutch Spring
16. Washer
23. Lever
3. Bushing
10. Snap Ring
17. Bracket
24. Washer
4. Spacer
11. Thrust Washer
18. Lock Nut
25. Cotter Pin
5. Snap Ring
12. Lock Nut
19. Rod
6. Thrust Washer
13. Spherical Rod End
20. Nut
7. Bushing
14. Cap Screw
21. Turnbuckle
5 - 10
4/6/01
TESTS AND ADJUSTMENTS
GEAR POWER TRAIN
TESTS AND ADJUSTMENTS
REPAIR
CLUTCH ADJUSTMENT
TRACTOR SPLITTING (FRONT)
Procedure:
NOTE: It is not necessary to remove the bell housing
from the engine unless engine is being
removed. Split the tractor between the tunnel
and bell housing as outlined in the story below.
Prepare the Tractor:
20 mm (0.78 in.)
C
D
B
A
1. If the linkage or pedal have been removed or
disturbed, complete all steps. If the linkage has not
been removed or disturbed, complete only steps
three, seven, and eight.
2. Remove cotter pin (A) and disconnect the clutch rod
from the clutch arm (B).
3. Hold turnbuckle (C) on the clutch linkage and
loosen lock nuts (D).
4. Move the clutch lever up until the clutch shaft
contacts the clutch lift lever (no freeplay).
5. Hold the clutch lever at this position and adjust the
turnbuckle until the linkage will enter the clutch
arm hole.
6. Install the clutch rod, washer and cotter pin.
7. Adjust the turnbuckle until the clutch pedal has 20
mm (0.780 in.) free travel, measured at center of
clutch pedal face.
8. Hold the turnbuckle and tighten the lock nuts.
4/6/01
1. Remove any mid or front attachments and mid or
front PTO shaft.
2. Park tractor on a level surface. Engage park brake,
shut off engine.
3. Disconnect battery negative terminal.
4. Remove floor mat.
5. Remove operator’s platform. (See "OPERATORS
PLATFORM" in Miscellaneous section.)
6. Remove LH and RH closeout panels.
7. Remove seat and seat platform. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section.)
8. Remove fenders. (See "REAR FENDERS" in
Miscellaneous section.)
9. Cycle all hydraulic controls to relieve system
pressure.
c CAUTION
To avoid injury from escaping hydraulic oil under
pressure, relieve the pressure in the system by
stopping the engine and operating all hydraulic
control valves.
NOTE: Hydraulic reservoir contains approximately 24L
(6.3 gal) of oil. Have a suitable container ready
to catch drain oil.
10. Drain hydraulic reservoir.
11. If tractor is equipped with an SCV, raise RH rear of
tractor and support on suitable stands.
12. Remove RH rear wheel and tire.
5 - 11
TRACTOR SPLITTING (FRONT)
GEAR POWER TRAIN
E
A
D
M91391
• Disconnect four work port tubes (A) from SCV.
C
B
M94685
14. Disconnect brake return spring (C) from brake
lever. Remove spring.
15. Disconnect lower brake rod (D) from brake lever.
16. Side Mount Parking Brake Only: Disconnect park
brake rod (E) from brake lever.
M91867
F
• Remove two cap screws (B) and two spacers that
attach tube support bracket to frame. Remove tube
support bracket and tubes as an assembly.
• Install RH rear wheel and tire.
13. Locate and disconnect all electrical connectors
attaching wiring harness to switches and lights on
rear half of tractor. Unfasten wiring harness from
cable clips and move harness away from rear half
of tractor.
M95001
17. Remove five cap screws (F) and LH operator’s
platform support.
G
D
C
M91982
5 - 12
4/6/01
TRACTOR SPLITTING (FRONT)
GEAR POWER TRAIN
18. Disconnect hydraulic pressure tube (G) at rear gear
pump.
H
K
M94834
J
19. Remove cap screw (H) and hydraulic pressure tube
clamp.
M95006
21. If equipped: Remove 4-WD drive shaft and
couplers by removing spring pin (J) and sliding
coupler onto shaft until clear of stub shaft. Repeat
at other end of drive shaft.
22. Remove oil filter.
23. Disconnect oil tube (K) from clutch housing/filter.
I
M91995
L
20. Disconnect hydraulic supply tube (I) at SCV or
manifold block. Remove tube.
M94813
24. Loosen hose clamp and disconnect suction tube (L)
from manifold.
4/6/01
5 - 13
TRACTOR SPLITTING (FRONT)
GEAR POWER TRAIN
28. Release park brake and place gear shift in
NEUTRAL.
29. Gently pry around edges of flanges to separate
tractor halves.
30. Roll tractor halves apart.
Assemble Tractor Sections:
NOTE: Splines on all drive shafts and couplers must
be aligned before tractor sections are bolted
together.
M
M95007
25. Remove cotter pin and washer, and disconnect
linkage rod (M) from clutch lever.
1. Align splines on transmission drive shaft and engine
flywheel.
2. Move tractor sections together and retain with nine
cap screws. Tighten cap screws to 126 - 154 N•m
(95 - 115 lb-ft).
3. Remove cap screws retaining splitting stands to
tractor sections. Remove splitting stands.
L
JTO 7335
M94813
M94831
NOTE: When attaching JTO 7335 splitting stands to
tunnel section, use the supplied right angle
brackets, and attach to holes in underside of
tunnel section.
26. Using suitable cap screws, attach four JTO 7335
splitting stands to tractor sections. Adjust splitting
stands so that wheels contact the floor, and are
parallel to the tractor wheels.
27. Remove nine cap screws connecting tunnel to
flywheel housing. Note length and locations of cap
screws when removing.
4. Connect suction tube (L) to manifold. Tighten hose
clamp.
I
M91995
IMPORTANT:
Check for, and disconnect any
additional accessory wires or hydraulic tubes
connecting rear half to front half before splitting
tractor.
5 - 14
5. Install hydraulic supply tube (L) to tractor. Connect
hydraulic supply tube to SCV or manifold block.
Tighten tube nut to 55 - 79 N•m (40 - 59 lb-ft).
4/6/01
TRACTOR SPLITTING (FRONT)
GEAR POWER TRAIN
I
F
M95001
M91995
6. Install hydraulic supply tube to tractor. Connect
hydraulic supply tube (I) to SCV or manifold block.
Tighten tube nut to 55 - 79 N•m (40 - 59 lb-ft).
9. Install LH operator’s platform support. Retain with
five cap screws (F).
K
G
J
M91982
M95006
7. Connect hydraulic pressure tube (G) to rear gear
pump. Tighten tube nut to 55 - 79 N•m (40 - 59 lbft).
H
10. Connect oil tube to clutch cover on transmission.
Tighten to 40 - 57 N•m (30 - 43 lb-ft).
11. Install a new hydraulic oil filter.
12. If equipped, install 4-WD drive shaft and couplers.
Slide couplers onto shafts, and retain with spring
pins (J).
M94834
8. Install cap screw (H) and hydraulic pressure tube
clamp.
4/6/01
5 - 15
TRACTOR SPLITTING (FRONT)
GEAR POWER TRAIN
E
A
D
M91391
C
M94685
13. Attach lower brake rod (D) to brake lever. Retain
with pin, or pin, cotter pin, and washer.
14. Side Mount Parking Brake Only: Attach park
brake rod (E) to brake lever. Retain with clip pin.
15. Install brake return spring (C) to brake lever and
ROPS cap screw.
16. Route wiring harness through cable clips. Locate
and connect all electrical connectors attaching
wiring harness to switches and lights on rear half
of tractor.
B
19. Connect four work port tubes (A) to SCV. Tighten
tube nuts to 40 - 57 N•m (30 - 43 lb-ft).
20. Connect battery negative (–) terminal.
21. Install fenders. (See "REAR FENDERS" in
Miscellaneous section).
22. Install kick plate. (See "KICK PLATE" in
Miscellaneous section).
23. Install seat and seat platform. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section).
24. Install LH and RH closeout panels.
25. Install operator’s platform. (See "OPERATOR’S
PLATFORM" in the Miscellaneous section).
26. Install floor mat.
27. Refill hydraulic oil reservoir to proper level.
28. Bleed air from hydraulic system. (See
"HYDRAULIC SYSTEM BLEED PROCEDURE" in
Hydraulics section).
M91867
17. If tractor is equipped with an SCV, install SCV tube
support bracket and tubes as an assembly. Install
two cap screws (B) and two spacers to attach tube
support bracket to frame.
18. Raise RH rear of tractor and support on suitable
stands. Remove RH rear wheel and tire.
5 - 16
4/6/01
COLLAR SHIFT (CST) TRACTION CLUTCH REMOVAL
GEAR POWER TRAIN
COLLAR SHIFT (CST) TRACTION
CLUTCH REMOVAL
D
Procedure:
1. Perform tractor split between flywheel housing and
tunnel housing. (See "TRACTOR SPLITTING
FRONT").
E
M95284
A
5. Alternately loosen clutch spring plate retaining cap
screws (D) in small increments and remove plate
(E).
M95028A
2. Remove eight cap screws securing clutch cover to
tunnel housing.
3. Remove clutch cover.
F
M95285
6. Remove clutch retaining nut (F) and slide clutch off
of shaft.
H
B
C
M95331
G
4. Remove clutch lifter pin (B) and clutch snubber (C).
NOTE: There are shims on both sides of the clutch
snubber. Retain all shims for possible use
during reassembly.
M95313
7. Remove bearing race (G) and spacer (H).
4/6/01
5 - 17
COLLAR SHIFT (CST) TRACTION CLUTCH DISASSEMBLY
GEAR POWER TRAIN
8. Inspect parts for wear or damage replace as
needed.
C
COLLAR SHIFT (CST) TRACTION
CLUTCH DISASSEMBLY
Special or Required Tools:
• Calipers
• Bearing Drivers
Procedure:
M95040
B
2. Remove hub and clutch plates from basket.
C
G
E
A
M95038
NOTE: The clutch piston and hub may only be
assembled one way to operate properly. There
are small assembly marks (A) on them, but you
may find it helpful to mark the piston post (B)
and hub (C) with a marking pen.
M95039
B
D
M95053
3. Inspect needle bearing (E), race (G), and thrust
washer for wear or damage.
NOTE: If bearing is being replaced, replace race and
thrust washer also.
4. If replacement of bearing is necessary, drive
bearing out with appropriate bearing driver. When
installing new bearing, drive only on the side that
the numbers are stamped on. Drive bearing in until
it is slightly below flush on both sides.
1. Mark piston post (B) and piston (D) with permanent
marking pen for reassembly.
5 - 18
4/6/01
COLLAR SHIFT (CST) TRACTION CLUTCH DISASSEMBLY
GEAR POWER TRAIN
7. Clean spring plate bearing (G) in suitable solvent.
Dry with compressed air.
8. Inspect bearing for discolored or burned balls and/
or races. Check balls and races for spalling or
cracking. Roll bearing by hand to check for rough
turning or excessive looseness or play between
balls and races. Replace bearing as required.
Front Towards
Flat Side of
Spring Plate
Back Towards
Raised Side of
Spring Plate
M95054
5. Measure thickness of entire clutch plate pack.
Minimum thickness: 42.3 mm (1.66 in.) If clutch
pack measures less than minimum
specification, replace clutch pack.
M95060
IMPORTANT: Bearing is designed for side loads
and must be installed in the proper direction as
shown.
M95055
6. Inspect friction areas of hub and piston for wear.
Replace parts as needed.
M95056
G
9. Measure no load length of each spring. If spring
length is less than 51.3 mm (2.02 in.), replace
spring.
M95057
IMPORTANT:
DO NOT spin bearings using
compressed air. Damage to bearing balls, cage
and races could result.
4/6/01
5 - 19
INPUT SHAFT DISASSEMBLY
GEAR POWER TRAIN
INPUT SHAFT DISASSEMBLY
Special or Required Tools:
• Bearing Puller
Procedure:
M95067
5. Inspect gear teeth for damage. Inspect splines and
bearing areas of shaft for wear or damage.Replace
parts as required.
TRACTION CLUTCH INSTALLATION
(CST or SST)
M95061
1. Using a bearing puller and press, remove bearings.
IMPORTANT:
DO NOT spin bearings using
compressed air. Damage to bearing balls, cage
and races could result.
2. Clean bearings in suitable solvent. Dry with
compressed air.
3. Inspect bearings for discolored or burned ball and/
or races. Check balls and races for spalling or
cracking. Roll bearing by hand to check for rough
turning or excessive looseness or play between
balls and races. Replace bearings as required.
NOTE: Gasket surfaces must be absolutely clean
down to bare metal for form-in-place gasket to
work properly. Scrape old material off with a
sharp gasket scraper and then use a chemical
gasket remover to clean mounting surfaces.
Procedure:
1. Remove any old gasket material from clutch cover
and transmission housing tunnel.
A
M95334
A
2. If input shaft (A) was removed, slide input shaft into
transmission tunnel. Turn input shaft and make
sure input shaft is properly engaged in PTO shaft
splined collar.
M95064
4. Remove snap rings (A) and slide gear from shaft.
5 - 20
4/6/01
GEAR POWER TRAIN
TRACTION CLUTCH INSTALLATION (CST or SST)
Clutch Assembly:
M95072
M95071
1. Lay hub assembly on workbench with splined hub
facing up.
2. Install a clutch friction disc, then metal plate, then
disk, then plate etc.
3. Line up tabs on clutch discs.
MX1386
NOTE: There are two styles of metal clutch plates. The
old style on the left has dimples on the surface.
The new "wavy plate" style on the right has a
smooth surface. Do not mix the two styles
together.
M95074
4. Line up assembly marks and put piston on hub
assembly.
NOTE: The clutch piston and hub may only be
assembled one way to operate properly. Make
sure assembly marks are lined up.
4/6/01
5 - 21
TRACTION CLUTCH INSTALLATION (CST or SST)
GEAR POWER TRAIN
8. Slide spacer (C) and bearing race (D) onto clutch
shaft.
Gap
E
Incorrect
M95069
F
M95285
Correct
M95068
5. Verify proper assembly by making sure piston
contacts clutch plates.
B
9. Make sure the thrust washer is properly positioned
in the clutch assembly. While applying pressure to
the clutch parts to keep the thrust washer in place,
slide clutch on shaft.
10. Install belleville washer (E) with side marked "OUT"
toward outside.
11. Install nut (F), flat side out, and tighten to 135 N•m
(100 lb-ft).
G
H
M95081
M95284
6. Place thrust washer (B) on clutch.
7. Slide clutch basket down over clutch assembly.
12. Install a spring (G) on each of the four posts and
then spring retainer (H) on the clutch. Secure
spring retainer with four cap screws and tighten
cap screws to 11 N•m (98 lb-in.).
D
C
M95329
5 - 22
4/6/01
CLUTCH SHIMMING PROCEDURE
GEAR POWER TRAIN
CLUTCH SHIMMING PROCEDURE
Measure Clutch Housing:
Measure Clutch:
Tool Required:
• JDG 1259 Clutch Shim Fixture
1. Position clutch cover assembly with opening up.
Tool Required:
• JDG 1259 Clutch Shim Fixture
B
A
M95333
1. Install lifter pin (A) without any shims or the clutch
snubber.
2. Seat the clutch back toward the transmission by
tapping the assembly lightly with a soft mallet.
M95340
2. Turn clutch pedal control lever clockwise to the
disengaged position (B). Lifter lever will be in the
raised position when the clutch pedal control lever
is in the correct position.
A
JDG 1259
M95335
3. Install JDG 1259 over the lifter pin of the clutch. The
overall height of the fixture must be known before
installation. The JDG 1259 is 177.8 mm (7.00 in)
high.
4. Measure from the top of the fixture to the top of the
lifter pin and record the measurement.
5. Subtract this number from the height of the
fixture.This is dimension "A".
6. Write this measurement on the clutch with a
marking pen.
4/6/01
Dimension
"B"
M95153
5 - 23
CLUTCH SHIMMING PROCEDURE
GEAR POWER TRAIN
3. Measure dimension "B" from the bottom of the
pocket in each lifter lever to the face of the
housing.
Example:
Inch:
JDG 1259 Fixture*
177.80
7.000
Fixture To Pin Measurement
–51.31
–2.021
Dimension "A"
126.49
4.979
Clutch Cover Measurement
132.98
5.234
+9.50
+0.375
–17.78
–0.700
+3.00
+0.118
Dimension "B"
127.70
5.027
Dimension "B"
127.70
5.027
–126.49
–4.979
Dimension "A" - Dimension "B"
1.21
0.048
Value C (Min. Shim Thickness)
1.21
0.048
Ball Size
Bar Size (JDG 1259 Fixture*)
Add
Minus Dimension "A"
Shim Tolerance
M95043A
mm:
Value C (Max. Shim Thickness)
+ 0.3
–0.00
1.51
+ 0.012
–0.000
0.060
*If any other fixture is used, do not use this value
• Place a 9.5 mm (0.375 in.) diameter ball in the lifter
lever pocket.
• Place the 17.78 mm (0.700 in.) thick bar across the
housing.
• Measure from the top of the bar to the top of the
ball in the lifter lever pocket. Record measurement.
Add the size of the ball 9.5 mm (0.375 in.) and
subtract the size of the bar 17.78 mm (0.700 in.) to
recorded measurement. Add 3mm (0.118 in.). This
is dimension "B".
4. Install shims on lifter pin.
Determining Correct Amount of Shims:
1. Subtract dimension "A" from dimension "B" to
determine value "C" which can be zero or greater.
2. If "C" is zero, assemble without shims.
3. If "C" is greater than zero, add shims equal to
dimension "C" + 0.3/- 0.0mm (+0.012 /- 0.000 in.)
between the lifter pin and the bearing.
5 - 24
4/6/01
SNUBBER SHIMMING PROCEDURE
GEAR POWER TRAIN
SNUBBER SHIMMING PROCEDURE
5. Install snubber shims (D) to the lifter pin.
NOTE: The drive clutch must be properly shimmed
before shimming the snubber.
E
M95365
A
6. Install clutch shims (E) on the lifter pin and slide
lifter pin and snubber into clutch bearing.
Installing Clutch Cover
C
B
M95341
1. Install clutch shims (determined from previous
procedure), snubber (A) without snubber shims,
and lifter pin (B).
2. Hold snubber and lifter pin firmly against front of
clutch and measure the gap between the snubber
fingers and lifter pin shoulder with a feeler gauge
(C).
IMPORTANT: Mating surfaces must be completely
clean of gasket material. Use a single edged
razor blade and gasket removing compound to
clean surfaces to bare metal.
1. Clean form in place gasket material from mating
surface with a gasket scraper or single sided razor
blade and gasket removing compound.
2. Install new input shaft oil seal.
NOTE: The gap should not be less than 1.14 mm
(0.045 in.) or more than 1.40 mm (0.055 in).
3. Subtract 1.27 mm (0.050 in.) from measurement in
previous step. This is the thickness of shim pack to
be used between the front surface of clutch
snubber and bottom surface of lifter pin shoulder.
4. Measure shims to be installed individually, do not
measure with the shims stacked together.
D
M95288
3. Mark position of snubber locating tabs on clutch
housing.
M95042B
4/6/01
5 - 25
SNUBBER SHIMMING PROCEDURE
GEAR POWER TRAIN
Snubber Check Procedure: (Optional: Check if
transmission is removed from differential housing,)
NOTE: Check should be made with transmission in
horizontal position.
M95332
4. Hold clutch cover on center tunnel housing and
place marks where clutch housing is marked.
NOTE: Four of the slots on the snubber are larger than
the others. The larger slots must be lined up
with the tabs on the clutch housing.
5. Line up larger slots on clutch snubber with marks
on center section.
6. Place a 1/16 in. uniform bead of TY16021 John
Deere Form-in-Place Gasket around the mating
surface of the clutch cover.
IMPORTANT: Clutch cover must come up against
hollow dowels on each side, before cap screws
are installed, or the snubber is not positioned
correctly. Check position of snubber slots and
re-align as needed.
1
7
6
3
M95021
NOTE: Check must be made with transmission in 2nd
gear. If shifter is not on the unit, turn shift rod
counterclockwise and push in, or if shift rod
and cover are not on trans, top fork rod should
be in forward position.
1. Place transmission in 2nd gear.
2. Attach a dial or pointer type torque wrench to output
shaft of transmission.
3. Engage clutch and rotate the output shaft at
approximately 10 rpm. Observe torque while
rotating shaft. Torque should be approximately 9.5
N•m (84 lb-in.). Record reading.
4. Fully disengage the clutch, thus applying the
snubber, and repeat step three. Record the
observed torque.
5. Subtract the reading from step three from the
reading from step four. The results must be greater
than 5.4 N•m (48 lb-in.) but not exceed 8.1 N•m
(72 lb-in.).
6. If the results are not within this range, re-shim the
snubber accordingly. That is, add shims to
increase torque, or remove shims to decrease
torque.
4
5
2
8
M95028A
7. Install clutch cover, and tighten cap screws to 28
N•m (20 lb-ft) in sequence shown.
5 - 26
4/6/01
CLUTCH SHAFT REMOVAL AND INSTALLATION
GEAR POWER TRAIN
CLUTCH SHAFT REMOVAL AND
INSTALLATION
Removal:
1. Split tractor between flywheel housing and tunnel
(See "TRACTOR SPLITTING FRONT").
2. Remove six cap screws and clutch housing (See
"COLLAR SHIFT AND SYNC SHIFT TRACTION
CLUTCH REMOVAL").
C
M95210
5. Remove shift shaft seal (C) in housing.
A
M95289
D
3. Remove pin (A) from clutch housing.
M95288
6. Inspect lift lever (D) for wear or damage. Replace if
needed.
B
Installation:
1. Install a new shift shaft seal in housing.
B
M95290
4. Remove clutch shaft (B) from housing.
M95290
2. Install clutch shaft into housing.
3. Align clutch shaft properly to allow installation of
retaining pin.
4/6/01
5 - 27
3-SPEED TRANSMISSION REMOVAL
GEAR POWER TRAIN
C
A
M95156
M95289
5. If not already done, remove drive shaft (C).
4. Install clutch shaft retaining pin (A) into clutch
housing.
F
3-SPEED TRANSMISSION REMOVAL
Procedure:
1. Split tractor between the tunnel and the differential
housing. (See "TRACTOR SPLITTING REAR" in
the Final Power Train section).
2. Remove tunnel from the flywheel housing. (See
"TRACTOR SPLITTING FRONT").
3. Remove traction clutch. (See "COLLAR SHIFT
AND SYNC SHIFT TRACTION CLUTCH
REMOVAL").
E
M94868
6. If equipped, rotate 4-WD shift lever (E) until shoe
(F) clears shift collar.
B
A
M95313
4. Remove bearing race (A) and spacer (B) from shaft.
M94869
7. Remove shaft, gear, and shift collar as an assembly.
5 - 28
4/6/01
3-SPEED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
3-SPEED TRANSMISSION
DISASSEMBLY
G
K
J
F
H
M94870
8. Remove spring pin (G) and slide shift shaft out of
tunnel.
9. Inspect bearing (H) for wear or damage. Replace if
necessary.
10. Inspect shoe (F) for wear or damage. Replace if
necessary.
M95292
13. Remove two spring pins (J) and two shift gate
blocks (K).
L
M
M95031
M95155
14. Remove two cap screws (L) and cover plate (M).
11. On LH side of tunnel, remove four cap screws and
shifter assembly.
N
I
O
M95283
M95032
15. Remove interlock pin (N).
12. Remove two cap screws (I) and three speed
transmission.
4/6/01
5 - 29
3-SPEED TRANSMISSION DISASSEMBLY
O
GEAR POWER TRAIN
Q
P
M95293
NOTE: Do not push shift rods too far into guide block
(O). Guide block contains two detent balls and
springs which may be lost.
M95295
16. Using a plastic mallet, drive both shift rods toward
gears and shafts. Tap on end of output shaft to
loosen shafts and gears, and remove reverse shaft
and pinion shaft from bearing plate.
18. Remove cap screw (P) and idler shaft (Q)
assembly.
Q
M95296
19. Remove thrust washer, gear, and bearing from
shaft. Inspect parts for wear or damage. Replace
as needed.
O
M95294
17. Rotate assembly away from shift forks, and remove.
M95163
5 - 30
4/6/01
GEAR POWER TRAIN
3-SPEED TRANSMISSION DISASSEMBLY
NOTE: Use care when removing shift rods from guide
block (O). Guide block contains two detent
balls and springs which may be lost.
1. Using a suitable puller, or press, remove bearing
from end of pinion shaft.
2. Inspect bearing for wear or damage. Replace if
needed.
20. Remove two shift rods and forks from guide block.
26T
33T
R
38T
M95164
21. Inspect shift fork inserts for wear or damage.
Replace if necessary.
M95167
3. Using a suitable puller, or press, remove bearing,
33 tooth gear, spacer (R), 38 tooth gear, and 26
tooth gear from pinion shaft.
Pinion Shaft Assembly:
Assembly is the reverse of disassembly.
• Lubricate parts liberally with hydraulic oil before
assembling.
• Install 38 tooth gear with larger flange facing toward
spacer.
Output Shaft Disassembly:
O
M96165
22. Remove two detent balls and springs from guide
block (O). Inspect parts for wear or damage.
Replace parts as needed.
Pinion Shaft Disassembly:
T
S
M95297
1. Remove snap ring (S).
2. Using a suitable puller or press, remove bearing (T)
from end of shaft.
M95166
4/6/01
5 - 31
3-SPEED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
M95298
3. Remove thrust washer.
M95301
6. Remove roller bearing.
U
M95299
M95302
4. Remove ball from hole in shaft.
7. Remove snap ring (U).
36T
M95303
M95300
8. Remove shift collar.
5. Remove 36 tooth gear.
5 - 32
4/6/01
3-SPEED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
11. Remove bearing from other end of shaft.
M95304
M95307
9. Remove shift collar hub.
12. Remove thrust washer.
M95308
13. Remove ball.
43T
M95305
36T
10. Remove 43 tooth gear.
M95309
14. Remove 36 tooth gear.
M95306
4/6/01
5 - 33
3-SPEED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
31T
M95311
15. Remove shift collar.
M95312
18. Remove 31 tooth gear.
W
V
M95310
16. Remove snap ring (V).
17. Remove shift collar hub (W).
5 - 34
4/6/01
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
GEAR POWER TRAIN
3-SPEED (CST) TRANSMISSION
ASSEMBLY/INSTALLATION
Output Shaft Assembly:
IMPORTANT: Lubricate all parts liberally with clean
hydraulic oil during assembly.
Pinion Shaft Assembly:
IMPORTANT:
Lubricate parts liberally
hydraulic oil before assembling.
with
26T
31T
R
38T
M95167
M95312
NOTE: Install 38 tooth gear with larger flange facing
toward spacer (R).
1. Install 31 tooth gear onto output shaft.
1. Using a press, install 26 tooth gear, 38 tooth gear,
spacer (R), 33 tooth gear, and bearing to pinion
shaft.
W
V
M95166
M95310
2. Using a press, install bearing onto end of pinion
shaft.
IMPORTANT: Shift collar hub should be placed on
shaft with four oil grooves facing up.
2. Install shift collar hub (W), and retain with snap ring
(V).
4/6/01
5 - 35
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
GEAR POWER TRAIN
M95307
M95311
6. Install thrust washer.
3. Install shift collar.
36T
M95306
M95309
7. Using a press, or suitable bearing driver and a softfaced mallet, install bearing to end of shaft.
4. Install 36 tooth gear.
M95308
5. Install ball into hole in shaft.
43T
M95305
8. On other end of shaft, install 43 tooth gear.
5 - 36
4/6/01
GEAR POWER TRAIN
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
M95304
M95301
IMPORTANT: Shift collar hub should be placed on
shaft with four oil grooves facing up.
12. Install roller bearing.
9. Install shift collar hub.
36T
M95303
M95300
10. Install shift collar.
13. Install 36 tooth gear.
U
M95302
11. Install snap ring (U).
4/6/01
M95299
14. Install ball into hole in shaft.
5 - 37
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
GEAR POWER TRAIN
Assembly:
M95298
O
15. Install thrust washer.
M95192
1. Install guide block (O) to bearing plate. Do not
install cap screws at this time.
NOTE: New style bearing plates and guide blocks are
a one piece casting and step one above is not
necessary.
S
T
M95297
16. Using a press, or a suitable driver and a soft-faced
mallet, install bearing (T) onto end of shaft. Retain
with snap ring (S).
M95193
2. Install one spring and detent ball into guide block.
Using a pin punch, compress the spring and hold
ball while installing shift rod and fork assembly. Be
sure shift rod and fork assembly is installed into
correct hole.
3. Repeat for second shift rod and fork / detent ball
and spring.
5 - 38
4/6/01
GEAR POWER TRAIN
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
Q
M95296
4. Install bearing, gear, and thrust washer onto idler
shaft (Q).
M95294
Q
7. Install output shaft into bearing plate, and rotate to
install onto shift forks.
P
M95295
5. Install idler shaft (Q) to bearing plate. Retain with
cap screw (P).
6. Rotate shift rods to correct positions.
M95293
8. Install pinion shaft, and output shaft into bearing
plate. Using a plastic mallet, tap shafts, gears, and
two shift rods into bearing plate.
4/6/01
5 - 39
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
GEAR POWER TRAIN
Installation:
N
I
M95032
O
M95283
9. Properly align shift rods, and install interlock pin (N)
into guide block (O).
L
1. Align two bearings and two shift rods with holes in
tunnel. Install transmission into housing and retain
with two cap screws (I).
IMPORTANT: Replace O-rings and seals. Used Orings and seals will leak.
M
M95031
10. Install cover plate (M) and retain with two cap
screws (L).
M95199
2. Install a new 4-WD drive shaft seal at front of
tunnel.
K
J
M95292
11. Install two shift gate blocks (K). Retain with two
spring pins (J).
M94876
3. Install a new 4-WD shift shaft seal into tunnel.
5 - 40
4/6/01
3-SPEED (CST) TRANSMISSION ASSEMBLY/INSTALLATION
GEAR POWER TRAIN
G
C
M94870
M95156
4. Slide 4-WD shift shaft into tunnel and through shift
arm. Retain shift arm to shaft with spring pin (G).
7. Install drive shaft (C).
M95155
M94869
5. Insert 4-WD drive shaft assembly into tunnel.
8. On LH side of tunnel, install shifter assembly and
retain with four cap screws.
F
B
A
M95313
E
M94868
6. Engage shoe (F) to shift collar and rotate 4-WD
shift lever (E) to draw 4-WD shaft into place.
4/6/01
9. Install spacer (B) and bearing race (A) to input
shaft.
10. Install clutch. (See "COLLAR SHIFT AND SYNC
SHIFT TRACTION CLUTCH INSTALLATION").
5 - 41
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
11. Assemble tractor tunnel and differential housing
sections. (See "TRACTOR SPLITTING REAR" in
the Final Power Train section.)
12. Assemble tractor flywheel housing and tunnel
sections. (See "TRACTOR SPLITTING FRONT").
GEAR POWER TRAIN
N
3 SPEED SYNCHRONIZED
TRANSMISSION DISASSEMBLY
MX1366
3. Remove interlock pin (N).
J
K
MX1347
O
MX1373
1. Remove two spring pins (J) and two shift gate
blocks (K).
L
NOTE: Do not push shift rods too far into shift rod
housing (O). Housing contains two detent balls
and springs which may be lost.
4. Using a plastic mallet, drive both shift rods toward
gears and shafts. Tap on end of output shaft to
loosen shafts and gears, and remove reverse shaft
and pinion shaft from bearing plate.
M
MX1369
2. Remove two cap screws (L) and cover plate (M).
5 - 42
4/6/01
GEAR POWER TRAIN
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
MX1368
R
MX1371
5. Rotate assembly away from shift forks, and remove.
NOTE: Use care when removing shift rods from shift
rod housing. Cover holes (R) in guide block to
avoid loosing detent balls and springs.
8. Remove two shift rods and forks from guide block.
P
Q
MX1365
MX1367
6. Remove cap screw (P) and idler shaft and gear
assembly (Q).
9. Remove two detent balls and springs from shift rod
housing (O). Inspect parts for wear or damage.
Replace parts as needed.
Q
M95296
7. Remove thrust washer, gear, and bearing from
shaft. Inspect parts for wear or damage. Replace
as needed.
4/6/01
M95164
5 - 43
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
10. Inspect shift fork inserts for wear or damage.
Replace if necessary.
Pinion Shaft Disassembly:
GEAR POWER TRAIN
• Install 38 tooth gear with raised side of hub facing
toward spacer as shown.
1. Install 26 tooth gear, 38 tooth gear, spacer (R), and
33 tooth gear. Press bearings onto pinion shaft.
Output Shaft Disassembly:
MX1359
1. Using a suitable puller, or press, remove bearings
from pinion shaft.
2. Inspect bearings for wear or damage. Replace if
needed.
33T
T
S
26T
R
M95297
1. Remove snap ring (S).
2. Using a suitable puller or press, remove bearing (T)
from end of shaft.
38T
MX1360
3. Slide 33 tooth gear, spacer (R), 38 tooth gear, and
26 tooth gear from pinion shaft.
Pinion Shaft Assembly:
Assembly is the reverse of disassembly.
• Lubricate parts liberally with hydraulic oil before
assembling.
M95298
3. Remove thrust washer.
MX1361
5 - 44
4/6/01
GEAR POWER TRAIN
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
6. Remove bearing (A) and brass synchronizer ring
(B).
D
C
M95299
MX1350
4. Remove ball from hole in shaft.
7. Remove snap ring (C) and synchronizer assembly
(D).
36T
E
M95300
5. Remove 36 tooth gear.
MX1349
A
8. Remove 43 tooth gear and brass synchronizer ring
(E).
B
MX1348
4/6/01
5 - 45
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
I
J
MX1351
MX1353
11. Remove snap ring (I) and synchronizer assembly
(J).
9. Remove bearing from other end of shaft.
H
F
G
MX1352
K
10. Remove thrust washer (F), ball (G), and gear (H).
MX1354
12. Remove gear and brass synchronizer ring (K).
MX1355
13. Inspect shaft for wear or damage on all machined
areas. Check all splines. Replace shaft if needed.
5 - 46
4/6/01
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
16. Check all synchronizer parts for wear or damage.
L
MX1356
14. Check gear teeth (L) for wear, chips, or breaks.
Replace as needed.
N
MX1358
MX1362
17. Check brass synchronizer ring for worn or missing
teeth (N) .
M
Synchronizer Wear Measurement Procedure:
C
B
D
E
15. Remove two retainer springs (M) from synchronizer
assembly.
A
MX1363
MX8739
1. Mark the synchronizer rings and synchronizers for
location on the shaft. It is important that each
synchronizer ring be measured against the gear it
was assembled to.
2. Position gear on a stable surface with the
synchronizer cone up. Install the corresponding
synchronizer ring (A) and synchronizer (B) to the
4/6/01
5 - 47
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
gear. Place the opposite gear (C) on top of the
synchronizer for added weight to stabilize the
synchronizer ring during measurements.
3. Measure the gap between the gear and the
synchronizer ring (D) with a feeler gage (E) at 3
positions around the ring approximately 120
degrees apart. The three measurements must be
within 0.18mm (0.007 in.) of each other. If the
measurements do not meet this criteria, reposition
the synchronizer ring on the gear. Repeat
measurements and repositioning until the 0.18mm
(0.007 in.) criteria is met.
4. The synchronizer ring gap is the average of the final
measurements at the three positions. Replace
synchronizer if clutching teeth are worn or the gap
is less than 0.25mm (0.010 in.)
NOTE: Synchronizer
assembly
and
brass
synchronizer
rings
are
not
serviced
individually. If any parts are needed, entire
assembly must be replaced.
MX1364
2. Make sure slots are aligned with detent blocks
when installing brass ring to synchronizer
assembly.
Output Shaft Assembly:
IMPORTANT: Lubricate all parts liberally with clean
hydraulic oil during assembly.
B
A
31T
MX1353
M95312
IMPORTANT: Synchronizer assembly should be
placed on shaft with four oil grooves facing up.
3. Install synchronizer assembly with oil grooves (A)
facing up, and retain with snap ring (B).
1. Install 31 tooth gear onto output shaft.
5 - 48
4/6/01
GEAR POWER TRAIN
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
6. On other end of shaft, install 43 tooth gear.
A
H
D
E
F
G
C
MX1352
MX1348
4. Install 36 tooth gear (H), and ball (G). Install thrust
washer (F) with wider side toward gear.
IMPORTANT: Synchronizer should be placed on
shaft with four oil grooves (A) facing up.
7. Install synchronizer assembly (D), snap ring (C),
and bearing (E).
M95306
5. Using a press, or suitable bearing driver and a softfaced mallet, install bearing to end of shaft.
M95299
8. Install 36 tooth gear and install ball into hole in
shaft.
43T
M95305
4/6/01
5 - 49
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
Assembly:
M95298
M95193
9. Install thrust washer.
1. Hold the ball and spring in with a punch and install
the shift rod assembly.
2. Repeat for second shift rod.
Q
S
T
M95296
M95297
3. Install bearing, gear, and thrust washer onto idler
shaft (Q).
10. Using a press, or a suitable driver and a soft-faced
mallet, install bearing (T) onto end of shaft. Retain
with snap ring (S).
P
Q
MX1365
4. Install idler shaft (Q) to bearing plate. Retain with
cap screw (P).
5 - 50
4/6/01
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
5. Rotate shift rods to correct positions.
8. Properly align shift rods, and install interlock pin (N)
into shaft housing (O).
MX1368
L
M
MX1369
9. Install cover plate (M) and retain with two cap
screws (L).
6. Install output shaft into bearing plate and shift forks.
K
J
MX1347
7. Install pinion shaft, and output shaft into bearing
plate. Using a plastic mallet, tap shafts, gears, and
two shift rods into bearing plate.
MX1366
MX1373
10. Install two shift gate blocks (K). Retain with two
spring pins (J).
N
O
4/6/01
5 - 51
3 SPEED SYNCHRONIZED TRANSMISSION DISASSEMBLY
GEAR POWER TRAIN
Installation:
I
M95283
1. Align two bearings and two shift rods with holes in
tunnel. Install transmission into housing and retain
with two cap screws (I).
5 - 52
4/6/01
CONTENTS
HYDROSTATIC POWER TRAIN
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC HOSES AND LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRANSMISSION MAIN PUMP CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION BACK PLATE AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDROSTATIC CONTROL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDROSTATIC SYSTEM SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDROSTATIC PEDAL AND NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 17
HYDROSTATIC PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHARGE PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HYDRAULIC SYSTEM BLEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TRACTOR SPLITTING (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDROSTATIC TRANSMISSION REMOVAL & INSTALLATION. . . . . . . . . . . . . . . . 26
HYDROSTATIC TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HYDROSTATIC PUMP DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HYDROSTATIC PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
HYDROSTATIC PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDROSTATIC MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HYDROSTATIC MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CONTROL LINKAGE REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
4/6/01
6-1
NOTES
6-2
HYDROSTATIC POWER TRAIN
4/6/01
HYDROSTATIC POWER TRAIN
SPECIFICATIONS
SPECIFICATIONS
General
Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 L (6.8 gal)
Pump or Motor Roller Bearing (From Back Plate to Top Surface of Bearing) . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 mm ± 0.2 mm (0.090 in. ± 0.010 in.)
Roller Bearing in Motor Housing (Recess From Top of Counterbore) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm ± 0.3 mm (0.078 in. ± 0.015 in.)
Spring Pin in Back Plate (From Back Plate to Top Surface of Pin) . . . 4.4 mm (0.017 in.)
HYDROSTATIC PUMP
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EATON
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pump
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77122RAA
Displacement (variable) (maximum/rev) . . . . . . . . . . . . . . . . 40.6 cm3/rev (2.48 in3/rev)
Displacement (engine at 2700 rpm) . . . . . . . . . . . . . . . . . . . . . 109.7 L/min (28.99 gpm)
Pressure Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41368 kPa (6000 psi)
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690 - 1034 kPa (100 - 150 psi)
HYDROSTATIC MOTOR
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EATON
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Displacement Axial Piston Motor
Displacement (fixed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.6 cm3/rev (2.48 cu in./rev)
TORQUE SPECIFICATIONS
Pump To Back Plate Mounting Cap Screws . . . . . . . . . . . . . . 53 - 57 N•m (39 - 42 lb-ft)
Motor To Back Plate Mounting Cap Screws . . . . . . . . . . . . 10 - 14 N•m (87 - 123 lb-in.)
Forward and Reverse Pressure Relief Valve . . . . . . . . . . 135 - 149 N•m (100 - 110 lb-ft)
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . 37 - 41 N•m (27 - 30 lb-ft)
Charge Pressure Diagnostic Port Plug . . . . . . . . . . . . . . . 13 - 16 N•m (115 - 142 lb-in.)
Pump Side Passage Plugs on Back Plate. . . . . . . . . . . . . 13 - 16 N•m (115 - 142 lb-in.)
Motor Side Passage Plug on Back Plate. . . . . . . . . . . . . . . . . 28 - 33 N•m (21 - 24 lb-ft)
Transmission To Tunnel Mounting Screws. . . . . . . . . . . . . 126 - 154 N•m (95 - 115 lb-ft)
Tunnel To Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . 126 - 154 N•m (95 - 115 lb-ft)
Tunnel To Differential Housing. . . . . . . . . . . . . . . . . . . . . . 126 - 154 N•m (95 - 115 lb-ft)
SCV Pressure Tube to Pump . . . . . . . . . . . . . . . . . . . . . . . . . 55 - 79 N•m (40 - 59 lb-ft)
SCV Pressure Tube to SCV . . . . . . . . . . . . . . . . . . . . . . . . . . 55 - 79 N•m (40 - 59 lb-ft)
SCV Work Port Tubes to SCV . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 57 N•m (30 - 43 lb-ft)
Charge Pressure Tubes to Transmission Adapters . . . . . . . . . 55 - 79 N•m (40 - 59 lb-ft)
Cam Plate Bearing Caps Cap Screws . . . . . . . . . . . . . . . . . . 37 - 42 N•m (27 - 31 lb-ft)
Tunnel Section to Differential Housing Cap Screws . . . . . 126 - 154 N•m (95 - 115 lb-ft)
Tunnel Section to Clutch Housing Cap Screws . . . . . . . . . 126 - 154 N•m (95 - 115 lb-ft)
4/6/01
6-3
SPECIAL OR ESSENTIAL TOOLS
HYDROSTATIC POWER TRAIN
SPECIAL OR ESSENTIAL TOOLS
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the European
Microfiche Tool Catalog (MTC).
Part Number
Part Name
JT07335-1,2,3
Splitting Stands and Brackets
JT03344
2,000 kPa (300 psi) Gauge
JT03362
68947 kPa (10,000 psi) Gauge
JT03364
Hose With Quick Coupler
JTO3017
Hose With Quick Coupler
JT03240
7/16-20 M 37° X 7/16-20 M 37° Elbow
JT03264
Quick Coupler F X 7/16-20 F 37° Adaptor
JT05480
Quick Coupler M X M14-1.5 ORB Adaptor
6-4
4/6/01
OTHER MATERIALS
HYDROSTATIC POWER TRAIN
OTHER MATERIALS
Number
U.S.A./Canadian
Name
Use
Petroleum Grease
John Deere Clean and Cure Primer
Pump and Motor Reassembly
TY16021
John Deere High Flex Form-In-Place
Gasket
Hydrostatic Transmission to Tunnel
Seal
TY15934
John Deere General Purpose Gasket
Dressing
Sealing Gaskets and Hoses
UN6419
JD Plus 4®, TurfGard®, HyGard®
Transmission/Hydraulic Oil
Pump and Motor Reassembly
4/6/01
6-5
COMPONENT LOCATION
HYDROSTATIC POWER TRAIN
COMPONENT LOCATION
HYDRAULIC HOSES AND LINES
5
6
1
4
7
3
2
8
9
1. Hydraulic Oil Cooler
2. Front Gear Pump
3. Suction Tube Elbow (Oil Supply)
6-6
4. Steering (Charge Pressure) Supply Line
5. Steering Control Unit (SCU)
6. Steering Return Line
7. Hydrostatic Unit
8. Oil Filter
9. Cooler Return Line
4/6/01
HYDROSTATIC TRANSMISSION
HYDROSTATIC POWER TRAIN
HYDROSTATIC TRANSMISSION
5
4
3
1
2
6
7
10
8
M94782
9
1. Input Shaft From Engine
5. Drive Shaft, PTO Clutch
2. Control Lever
6. Hydrostatic Motor
3. Backplate
7. Charge Pressure Relief Valve
4. Drive Shaft to Transmission
8. Oil Filter Mount
4/6/01
9. For.& Rev. Relief Valves
10. Hydrostatic Pump
6-7
TRANSMISSION MAIN PUMP CASE
HYDROSTATIC POWER TRAIN
TRANSMISSION MAIN PUMP CASE
1
2
3
12
4
11
7
10
9
6
8
5
14
13
15
27
18
17
16
19
20
21
22
23
24
25
26
M94780
1. Cap Screws (6)
2. Washers (6)
3. Cover
4. Seal
5. O-ring
6. Bearing and Cone
7. Shims
6-8
8. Housing
9. Cam Plate
10. Cam Washer
11. Rotating Assembly
12. Valve Plate
13. Bearing and Cone
14. O-ring
15. Cover
16. Plug
17. O-ring
18. Bearing
19. Snap Ring
20. Thrust Washer
21. Thrust Bearing
22. Thrust Washer
23. Snap Ring
24. Seal Washer
25. Seal
26. Snap Ring
27. Shaft
4/6/01
TRANSMISSION BACK PLATE AND MOTOR
HYDROSTATIC POWER TRAIN
TRANSMISSION BACK PLATE AND MOTOR
6
3
5
4
2
1
7
8
9
10
11
12
13
35
34
20
22
33
14
30
15
31
16
19
32
17
18
21
31
30
29
27
28
26
25
24
23
M94781
1. Bearing
2. Gasket
3. Pin
4. Pin
5. Backplate
6. Cap Screw
7. Bearing
8. Plug and O-Ring
9. Pin
4/6/01
10. Spring
11. Poppet
12. Spring
13. Plunger
14. Poppet
15. Spring
16. Shims
17. O-Ring
18. Plug
19. Filter Head
20. O-Rings
21. Relief Valves, Forward
and Reverse
22. Plugs
23. Valve Plate
24. Rotating Assembly
25. Cam Washer
26. Motor Housing
27. Cap Screw
28. Bearing
29. Shaft
30. Snap Ring (2)
31. Thrust Washer (2)
32. Thrust Bearing
33. Seal Washer
34. Seal
35. Snap Ring
6-9
HYDROSTATIC CONTROL LINKAGE
HYDROSTATIC POWER TRAIN
HYDROSTATIC CONTROL LINKAGE
3
4
5
2
1
6
8
7
18
17
9
13
16
15
14
12
11
10
7
20
19
19
19
21
22
23
24
25
2
29
25
23
30
36
37
30
32
36
28
27
26
28
33
28
28
34
31
35
40
42
41
43
44
38
45
39
57
34
51
52
54
28
33
47
34
49
28
2
28
48
32
6 - 10
33
30
50
55
56
28
46
58
53
32
33
28
4/6/01
HYDROSTATIC CONTROL LINKAGE
HYDROSTATIC POWER TRAIN
1. Bracket
16. Nut
31. Shaft, Reverse
46. Switch, Neutral
2. Lock Nut
17. Housing
32. Cap Screw
47. Nut
3. Cap Screw
18. Cap Screw
33. Ball Joint
48. Rod, Reverse
4. Lever, Reverse
19. Snap Ring
34. Spacer
49. Lever, Speed Control
5. Nut
20. Lever
35. Rod, Forward
50. Strap
6. Pedal, Reverse
21. Key
36. Ball Bearing
51. Carriage Bolt
7. Carriage Bolt
22. Spacer
37. Washer
52. Lubrication Fitting
8. Screw
23. Bushing
38. Cap
53. Pin
9. Pedal
24. Washer
39. Lever, Neutral Control
54. Flange Nut
10. Plate
25. Bushing
40. Cap Screw
55. Spring
11. Magnet
26. Lubrication Fitting
41. Eccentric
56. Bushing
12. Spring
27. Lever, Forward
42. Seal
57. Rod
13. Pin
28. Nut
43. Pivot
58. Clevis
14. Stud
29. Dampener
44. Screw
15. Guide
30. Cap Screw
45. Cap Screw
4/6/01
6 - 11
HYDROSTATIC SYSTEM SCHEMATIC
HYDROSTATIC POWER TRAIN
HYDROSTATIC SYSTEM SCHEMATIC
Steering Cylinder
To Transmission Tunnel
Left (L)
Right (R)
Left
Right
Relief Valve
10342 kPa
1500 psi
P
POWER
STEERING VALVE
T
Steering Wheel
Engine
8.2 cm3/rev
Gear Pump
(Front)
150 Mesh
Intake Filter
Sump
6 - 12
Sump Oil
Charge Pressure/Tunnel Lubrication Oil
High Pressure Oil
Steering Oil
4/6/01
HYDROSTATIC SYSTEM SCHEMATIC
HYDROSTATIC POWER TRAIN
HYDROSTATIC SYSTEM SCHEMATIC (continued)
Oil Filter
Oil Cooler
Oil Cooler
Relief
Valve
Relief
Valve
413-689 kPa
60-100 psi
69-206 kPa
10-30 psi
SPIN-ON FILTER
WITH BYPASS
Charge
Relief
Valve
689-1034 kPa
100-150 psi
System
Relief
Valve
41368-42885 kPa
6000-6220 psi
HST
Hydraulic
Pump
System
Relief
Valve
41368-42885 kPa
6000-6220 psi
Test Port
Hydraulic
Motor
Test Port
HYDROSTATIC TRANSMISSION
Make-Up/Closed Loop Relief Oil
High Pressure Oil
Sump Oil
Charge Pressure Oil
4/6/01
6 - 13
TROUBLESHOOTING
HYDROSTATIC POWER TRAIN
●
●
●
Low charge pressure (see Tests
and Adjustments Section)
●
●
●
Main drive pressure relief valve
stuck open (see Tests &
Adjustments Section)
●
●
●
Air in system (See
“HYDRAULIC SYSTEM BLEED
PROCEDURE”.)
●
●
●
●
●
●
●
Hydrostatic motor output
pressure too low (see Tests and
Adjustments Section)
Internal pump or motor damage
or excessive wear
●
●
Parking brake engaged or
malfunctioning
●
●
Pump centering mechanism not
properly adjusted
Gearbox malfunction (see Gear
Power Train Section)
●
Servo valve malfunctioning
●
●
●
●
●
●
Pedal Neutral Position Not
Properly Adjusted
Hydrostatic Control Linkage
Worn or Damaged
6 - 14
Tractor Does Not Move
When Forward or Reverse
Pedal are Pressed
Hydraulic level low in transaxle
Tractor Moves Without
Pressing Forward or
Reverse Pedals
●
Wheels rotate in one
direction only
Low power
Check flex plate coupling
between engine and pump
Check or
Solution
Noisy pump or motor
Sluggish response to
changes in speed
Problem or
Symptom
Wheels on machine will not
rotate
TROUBLESHOOTING
●
●
●
●
●
●
4/6/01
DIAGNOSTICS
HYDROSTATIC POWER TRAIN
DIAGNOSTICS
Test Conditions:
• Operator in seat
• Key switch in RUN position
Test/Check Point
1. Control pedals.
Normal
Pedals should move freely.
If Not Normal
Check linkage from pedals to pump.
Test Conditions:
• Start engine and run at slow idle.
Test/Check Point
2. Directional pedals are in
neutral position.
Normal
If Not Normal
Machine should not creep forward or
backward.
Adjust centering of pump control
pedals.
3. Move forward or reverse pedal
slowly from neutral to
maximum travel speed
position.
Machine should accelerate smoothly
forward or backwards.
Check fluid reservoir for proper fluid
level.
Check hydraulic tubing, and
connections for leaks.
Perform system flow and pressure
checks to verify proper operation of
charge pump and hydrostatic pump.
4. Control pedal in full forward
position.
Machine should move forward.
Check pedals and forward/reverse
linkage for damage.
Check forward drive pressure relief
valve.
5. Control pedal in full reverse
position.
Machine should move backward.
Check pedals and forward/reverse
linkage for damage.
Check reverse drive pressure relief
valve.
4/6/01
6 - 15
THEORY OF OPERATION
HYDROSTATIC POWER TRAIN
THEORY OF OPERATION
rotated from center determines the direction of fluid
flow (forward or reverse). The number of degrees the
cam plate is deflected, determines how much fluid will
be displaced (speed).
HYDROSTATIC SYSTEM
Function:
The hydrostatic system provides a means to transfer
power from the engine to the final drive for the wheels.
It also provides infinitely variable speed control, forward
or reverse, by foot pedal operation.
Principles of Operation:
The hydrostatic system is a closed loop fluid power
system that consists of a charge pump on the left front
side of the engine, and an EATON piston pump/motor
assembly, which is driven by a flexible coupler attached
to the flywheel.
• Hydrostatic Pump
The hydrostatic pump (A) is an axial piston, variable
displacement piston pump. It is mounted directly to the
front of the tunnel. The input shaft (B) splines are
driven by the flexible coupler attached to the engine
flywheel.
Fluid flow is controlled by changing the angle of the
cam plate (C). This angle is controlled by the operator
through a mechanical linkage. Moving the respective
directional pedal will move the position of the cam
plate.
Moving the cam plate off center changes the distance
the pistons (D) travel inside the piston bore of the
rotating assembly. The direction that the cam plate is
A
C
The hydrostatic pump provides hydraulic fluid to the
hydrostatic motor through the back plate (E). Hydraulic
fluid in the power train circulates in a closed loop. Fluid
leaves the hydrostatic pump and flows through the
hydrostatic motor and is returned to the hydrostatic
pump, not the reservoir. Fluid that leaves this closed
loop circuit, such as case drain, is replenished by fluid
from the charge pump. Fluid may also be dumped from
the high pressure side of the loop to the low pressure
side if the tractor encounters a heavy load or stalls out.
This happens through the high pressure relief valves
(F).
• Charge Pump
The charge pump is a gear type positive displacement
pump mounted to the left front side of the engine.
This pump provides pressurized fluid to the SCU
(Steering Control Unit). Return oil from the SCU is
routed through the filter mounted to the front of the
back plate, and then into the hydrostatic pump to
provide replacement fluid to the closed loop of the
hydrostatic transmission.
• Hydrostatic Motor
The hydrostatic motor (G) is a high torque axial piston
motor. The motor is located on the rear of the back
plate. The hydrostatic motor drives the input shaft for a
three speed range gear transmission which transfers
power to the wheels. (See Final Drive Section.)
E
B
G
D
E
High Pressure
6 - 16
4/6/01
TESTS AND ADJUSTMENTS
HYDROSTATIC POWER TRAIN
TESTS AND ADJUSTMENTS
HYDROSTATIC PEDAL AND
NEUTRAL ADJUSTMENT
D
Reason:
To ensure that tractor does not move unless forward or
reverse pedal is depressed.
B
Procedure:
1. Operate the hydrostatic control pedals. They should
return by themselves to the neutral position. If
pedals do not operate properly, check pedals and
linkage for damage or wear.
2. Start engine and run at low idle.
3. Place range shift lever in LOW gear. Gradually
increase engine speed to full throttle.Tractor
should not move. If tractor moves, note direction,
and adjust neutral return lever (A) as follows:
c CAUTION
Severe injury or death can result if engine is not
shut off when performing neutral adjustment.
4. Shut engine OFF. Engage park brake.
C
A
M94994
6. Loosen the locking cap (B) screw that holds the
eccentric (C) to the transmission.
7. Using a wrench, rotate the eccentric to move the
roller (D) down to eliminate reverse, or up to
eliminate forward movement or "creep".
8. Tighten the locking cap screw.
9. Start engine and run at low idle.
10. Place range shift lever in LOW gear. Gradually
increase engine speed to full throttle.Tractor
should not move. If tractor moves, repeat steps 4
through 10 until movement is eliminated.
HYDROSTATIC PUMP PRESSURE
TEST
B
Reason:
To ensure that internal parts of hydrostatic pump are
not worn excessively, and the relief valves are
operating properly.
C
Equipment:
M94893
5. On the right side of the tractor, below the forward
and reverse control pedals, locate the locking cap
screw (B) and eccentric (C). The eccentric must be
turned to perform the neutral adjustment.
4/6/01
• JT03362 - 10,000 psi Gauge
• JT03364 - Hose With Quick Coupler
• JT03240 - 7/16-20 M 37° X 7/16-20 M 37° Elbow
• JT03264 - Quick Coupler F X 7/16-20 F 37°
Adaptor
• JT05480 - Quick Coupler M X M14-1.5 ORB
Adapter
6 - 17
HYDROSTATIC PUMP PRESSURE TEST
HYDROSTATIC POWER TRAIN
6. Cycle all controls to relieve any pressure that may
be in the hydraulic system.
JT03362
A
B
JT03240
JT05480
JT03264
M95002
JT03364
M91847
IMPORTANT: Make sure that the hydraulic fluid is
visible in sight glass. Insufficient hydraulic fluid
could cause system to run dry and damage
pump and motor.
7. Locate forward test port (A) and reverse test port
(B) on hydrostatic transmission inside tunnel
opening.
8. Remove test port plugs.
9. Install one JT05480 male quick coupler into each
test port.
10. Attach JT03362 gauge and hose assembly as
shown to each test port adaptor.
IMPORTANT: Do not allow valves to relieve for
more than 10 seconds or hydraulic oil may
overheat.
Procedure:
1. Park tractor on a level surface.
2. Turn key switch to OFF position.
3. Make sure 4-WD lever is in unlocked 2-WD position.
M91944
c CAUTION
AVOID SUDDEN TRACTOR MOVEMENT. Tractor
could move suddenly causing severe injury or
damage to equipment during test procedure.
Perform test in open area. Keep all personnel
away from front or rear of tractor.
11. Position gauges so they can be read from
operator’s seat.
12. Perform test from operator’s seat. Make sure park
brake is engaged and press right and left brake
pedals. Place range transmission shift lever in "C"
(high) position. Start engine and run at full throttle.
4. Start engine and run until hydraulic oil is warm.
5. Stop engine.
6 - 18
4/6/01
HYDROSTATIC POWER TRAIN
CHARGE PUMP PRESSURE TEST
c CAUTION
JT03362
JT03240
If brakes fail to prevent wheels from turning,
STOP TEST IMMEDIATELY. Repair or adjust
brakes as necessary before resuming test. (See
Brake Section.)
JT05480
13. Slowly depress forward directional pedal and
observe gauge. Gauge should slowly rise to
approximately 41368 kPa ± 1378 kPa (6000 psi ±
200 psi) and relief valve will open with an audible
squealing noise.
14. Repeat same procedure with reverse pedal.
JT03264
JT03017
M95005
Specifications:
• Pump pressure should reach approximately 41368
kPa ± 1378 kPa (6000 psi ± 200 psi) in either
direction and then relieve.
Procedure:
Results:
• If pressure will not reach 41368 kPa Maximum
(6000 psi Maximum) in either direction, check
charge pressure. (See "CHARGE PUMP
PRESSURE TEST").
• If charge pressure is good and hydrostatic pump
pressure will not get up to relief pressure
hydrostatic pump is worn or damaged.
• If pressure reaches 41368 kPa (6000 psi) in one
direction and not the other, one of the relief valves
is defective or the seat is leaking.
1. Park tractor on a level surface and set park brake.
2. Turn key switch to OFF position.
3. Shift transmission to NEUTRAL.
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
4. Cycle all controls to relieve any pressure that may
be in the hydraulic system.
CHARGE PUMP PRESSURE TEST
Reason:
A
To ensure that charge pump is operating at specified
pressure to supply oil to hydrostatic pump.
Equipment:
• JT03344 - 2,000 kPa (300 psi) Gauge
• JT03017 - Hose With Quick Coupler
• JT03240 - 7/16-20 M 37° X 7/16-20 M 37° Elbow
• JT03264 - Quick Coupler F X 7/16-20 F 37°
Adaptor
• JT05480 - Quick Coupler M X M14-1.5 ORB
Adaptor
M95002
NOTE: 4-WD shaft removed for clarity.
4/6/01
6 - 19
HYDRAULIC SYSTEM BLEED PROCEDURE
HYDROSTATIC POWER TRAIN
5. Underneath the tractor, at the front of the tunnel,
locate the hydrostatic transmission. Remove the
plug in the charge pressure test port (A).
6. Assemble test equipment as shown and install to
test port.
7. Start engine and run at high idle.
8. Check pressure reading on gauge.
Specifications:
Charge Pressure . . . .690 - 1034 kPa (100 - 150 psi)
Results:
• Charge pressure should reach 690 - 1034 kPa (100
- 150 psi).
• If pressure reading of 690 - 1034 kPa (100 - 150
psi) cannot be obtained, the mesh inlet filter may
be restricted, the suction line may be restricted or
leaking air, or front hydraulic pump may be
defective.
HYDRAULIC SYSTEM BLEED
PROCEDURE
M91946
3. Disconnect electrical connector to fuel shutoff
solenoid.
4. Turn the key to START and hold for 10 seconds.
Turn the key to OFF.
5. Reconnect wires to fuel shutoff solenoid.
6. Raise tractor front end and support on suitable
stands.
7. Start the engine and run at low idle.
Reason:
To remove air trapped in the hydraulic system which will
prevent proper operation.
Procedure:
IMPORTANT: If steering fails to respond, or pump
pressure is not being delivered to steering
control unit (SCU), shut engine off and check to
see that steering hoses are connected to the
correct SCU ports.
IMPORTANT: If contamination is found in hydraulic
system filter or inside reservoir, flush entire
hydraulic system.
8. Slowly turn the steering wheel left and right until
wheels turn smoothly indicating that any trapped
air has been bled back to the reservoir.
NOTE: Fill the hydraulic oil filter with new oil before
installing.
IMPORTANT: If rockshaft fails to react to lift
control lever movement, shut engine off and
check hose clamps on suction tube elbow and
manifold to ensure that they are properly
tightened.
1. Install a new hydraulic oil filter.
2. Fill the transaxle with specified JDM J20D
(preferred) or J20C oil to the proper level in sight
glass.
6 - 20
9. Operate rockshaft several times until it operates
smoothly.
10. Stop the engine and check the hydraulic reservoir
oil level. Fill as needed. Check all line connections
for leaks; tighten if necessary.
11. Lower the tractor to the ground.
12. Drive tractor in forward and reverse several times
until transmission operates smoothly.
4/6/01
REPAIR
HYDROSTATIC POWER TRAIN
REPAIR
TRACTOR SPLITTING (FRONT)
A
NOTE: It is not necessary to remove the flywheel
housing from the engine unless engine is
being removed. Split the tractor between the
tunnel and flywheel housing as outlined in the
story below.
M91391
Prepare the Tractor:
1. Remove any mid or front attachments and mid or
front PTO shaft.
2. Park tractor on a level surface. Engage park brake,
shut off engine.
3. Disconnect battery negative terminal.
4. Remove floor mat.
5. Remove operator’s platform. (See "OPERATOR’S
PLATFORM" in Miscellaneous section.)
6. Remove LH and RH closeout panels.
7. Remove seat and seat platform. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section.)
8. Remove fenders. (See "REAR FENDERS" in
Miscellaneous section.)
9. Cycle all hydraulic controls to relieve system
pressure.
• Disconnect four work port tubes (A) from SCV.
B
c CAUTION
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.
NOTE: Hydraulic reservoir contains approximately
26 L (6.8 gal) of oil. Have a suitable container
ready to catch drain oil.
M91867
• Remove two cap screws (B) and two spacers that
attach tube support bracket to frame. Remove tube
support bracket and tubes as an assembly.
• Install RH rear wheel and tire.
12. Locate and disconnect all electrical connectors
attaching wiring harness to switches and lights on
rear half of tractor. Unfasten wiring harness from
cable clips and move harness away from rear half
of tractor.
10. Drain hydraulic reservoir.
11. If tractor is equipped with an SCV:
• Raise RH rear of tractor and support on suitable
stands.
• Remove RH rear wheel and tire.
D
4/6/01
C
6 - 21
TRACTOR SPLITTING (FRONT)
HYDROSTATIC POWER TRAIN
17. Remove cap screw (G) and hydraulic pressure tube
clamp.
E
H
D
M91995
C
M94685
18. Disconnect hydraulic supply tube (H) at SCV or
manifold block. Remove tube.
13. Disconnect brake return spring (C) from brake
lever. Remove spring.
14. Disconnect lower brake rod (D) from brake lever.
15. Side Mount Parking Brake Only: Disconnect park
brake rod (E) from brake lever.
I
M95006
F
M91982
19. If equipped: Remove 4-WD drive shaft and
couplers by removing spring pin (I) and sliding
coupler onto shaft until clear of stub shaft. Repeat
at other end of drive shaft.
20. Remove hydraulic oil filter.
16. Disconnect hydraulic pressure tube (F) at rear gear
pump.
G
J
M94834
6 - 22
M95000
4/6/01
TRACTOR SPLITTING (FRONT)
HYDROSTATIC POWER TRAIN
21. Disconnect two hydrostatic charge pressure tubes
(J) from hydrostatic transmission.
NOTE: Tractor shown split for clarity.
24. Remove clip pin (M) and disconnect clevis from
hydrostatic control linkage (N). Remove neutral
return spring, rod (O), and clevis as an assembly.
25. Disconnect neutral switch connector (P).
K
M95001
22. Remove five cap screws (K) and LH operator’s
platform support.
JTO7335
L
M94831
NOTE: When attaching JTO7335 splitting stands to
tunnel section, use the supplied right angle
brackets, and attach to holes in underside of
tunnel section.
M94813
23. Loosen hose clamp and disconnect suction tube
(L) from manifold.
26. Using suitable cap screws, attach four JTO7335
splitting stands to tractor sections. Adjust splitting
stands so that wheels contact the floor, and are
parallel to the tractor wheels.
NOTE: It is not necessary to remove top center cap
screw on tunnel section when splitting tractor.
It retains hydrostatic transmission to tunnel
section.
P
27. Remove nine cap screws connecting tunnel to
flywheel housing. Note length and locations of cap
screws when removing.
N
IMPORTANT:
Check for, and disconnect any
additional accessory wires or hydraulic tubes
connecting rear half to front half before splitting
tractor.
O
M
4/6/01
M98490
28. Release park brake and place gear shift in
NEUTRAL.
6 - 23
TRACTOR SPLITTING (FRONT)
HYDROSTATIC POWER TRAIN
29. Gently pry around edges of flanges to separate
tractor halves.
30. Roll tractor halves apart.
L
Assemble Tractor Sections:
NOTE: Splines on all drive shafts and couplers must
be aligned before tractor sections are bolted
together.
1. Align splines on hydrostatic transmission drive shaft
and engine flywheel.
2. Move tractor sections together and retain with nine
cap screws. Tighten cap screws to 126 - 154 N•m
(95 - 115 lb-ft).
3. Remove cap screws retaining splitting stands to
tractor sections. Remove splitting stands.
M94813
6. Connect suction tube (L) to manifold. Tighten hose
clamp.
P
K
M95001
O
M
M98490
NOTE: Tractor shown split for clarity.
7. Install LH operator’s platform support. Retain with
five cap screws (K).
c CAUTION
Tensioned spring. Wear eye protection and
gloves when disconnecting spring to reduce the
risk of personal injury.
O
J
4. Install neutral return spring, rod (O), and clevis as
an assembly. Attach clevis to hydrostatic control
linkage and retain with clip pin (M).
5. Connect neutral switch connector (P).
M95000
6 - 24
4/6/01
TRACTOR SPLITTING (FRONT)
HYDROSTATIC POWER TRAIN
8. Connect two hydrostatic charge pressure tubes (J)
to hydrostatic transmission. Tighten to 40 - 57 N•m
(30 - 43 lb-ft). Check opposite ends of both tubes
to make sure they are tight.
9. Install a new hydraulic oil filter.
12. Connect hydraulic pressure tube (F) to rear gear
pump. Tighten tube nut to 55 - 79 N•m (40 - 59 lbft).
G
I
M94834
M95006
13. Install cap screw (G) and hydraulic pressure tube
clamp.
10. If equipped, install 4-WD drive shaft and couplers.
Slide couplers onto shafts, and retain with spring
pin (I).
E
H
D
M91995
C
11. Install hydraulic supply tube (H) to tractor. Connect
hydraulic supply tube to SCV or manifold block.
Tighten tube nut to 55 - 79 N•m (40 - 59 lb-ft).
M94685
14. Attach lower brake rod (D) to brake lever. Retain
with pin, or pin, cotter pin, and washer.
15. Side Mount Parking Brake Only: Attach park
brake rod (E) to brake lever. Retain with clip pin.
16. Install brake return spring (C) to brake lever and
ROPS cap screw.
17. Route wiring harness through cable clips. Locate
and connect all electrical connectors attaching
wiring harness to switches and lights on rear half
of tractor.
F
M91982
4/6/01
6 - 25
HYDROSTATIC TRANSMISSION REMOVAL & INSTALLATION HYDROSTATIC POWER TRAIN
HYDROSTATIC TRANSMISSION
REMOVAL & INSTALLATION
B
Removal:
1. Park tractor on level surface. Stop engine and
release hydraulic pressure by operating all
controls.
c CAUTION
Avoid injury from escaping hydraulic oil under
pressure. Relieve system pressure by stopping
engine and operating all hydraulic controls.
M91867
18. If tractor is equipped with an SCV, install SCV tube
support bracket and tubes as an assembly. Install
two spacers and cap screws (B) to attach tube
support bracket to frame.
19. Raise RH rear of tractor and support on suitable
stands. Remove RH rear wheel and tire.
2. Separate tractor engine and tunnel sections. (See
"TRACTOR SPLITTING FRONT").
B
A
A
C
M91391
M94940
20. Connect four work port tubes (A) to SCV. Tighten
tube nuts to 40 - 57 N•m (30 - 43 lb-ft).
21. Connect battery negative (–) terminal.
22. Install fenders. (See "REAR FENDERS" in
Miscellaneous section.)
23. Install kick plate. (See "KICK PLATE" in
Miscellaneous Section.)
24. Install seat and seat platform. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section.)
25. Install LH and RH closeout panels.
26. Install operator’s platform. (See "OPERATOR’S
PLATFORM" in Miscellaneous section.)
27. Install floor mat.
28. Refill hydraulic oil reservoir to proper level.
29. Bleed air from hydraulic system. (See
"HYDRAULIC SYSTEM BLEED PROCEDURE").
6 - 26
3. Remove two cap screws (A), spacers, and lock
nuts, and disconnect transmission forward (B) and
reverse (C) control rods.
c CAUTION
Hydrostatic transmission weighs approximately
34 kg (75 lb). Attach a suitable lifting device to
transmission before removing cap screws.
NOTE: One cap screw is removed from the top of the
tunnel section, from the outside.
4/6/01
HYDROSTATIC POWER TRAIN
HYDROSTATIC TRANSMISSION DISASSEMBLY
4. Remove five cap screws attaching transmission to
tunnel section. Note length and location of cap
screws when removing.
HYDROSTATIC TRANSMISSION
DISASSEMBLY
NOTE: Oil may drain from the pump and motor unit
after it is removed. Have a suitable container
ready to catch excess oil.
B
5. Gently pry around edges of flanges to break
sealant. Remove transmission.
NOTE: Drive shaft may come out with transmission. If
removed with transmission, remove from
transmission, and install into tunnel and range
transmission.
A
Installation:
Installation is the reverse of removal.
• Clean flanges of transmission and tunnel before
applying sealant.
• Apply TY16021 sealant to flanges of transmission
where it contacts the tunnel.
• Tighten cap screws attaching transmission to
tunnel to 126 - 154 N•m (95 - 115 lb-ft).
IMPORTANT: If neutral adjustment locking cap
screw was loosened, neutral adjustment
procedure
must
be
performed.
See
"HYDROSTATIC
PEDAL
AND
NEUTRAL
ADJUSTMENT".
4/6/01
M94941
IMPORTANT: The pump body and motor body are
aluminum and can be easily damaged by steel
tools. Be careful to not damage machined
surfaces. Do not use screwdriver or other sharp
objects to pry pump or motor body from back
plate.
1. Remove eight socket head cap screws (A) securing
the hydrostatic motor to the back plate.Tap the
motor housing with a plastic mallet to loosen it
from the valve plate. Keep the assembly level or tip
output end down to keep the rotating assembly
from sliding off of shaft. Pull the motor housing,
shaft, and rotating assembly away from back plate.
2. Remove four socket head cap screws (B) securing
the pump to the back plate. Remove pump.
6 - 27
HYDROSTATIC TRANSMISSION DISASSEMBLY
HYDROSTATIC POWER TRAIN
Back Plate Disassembly:
D
F
C
E
M94942
M94957
3. Remove cap screw (C) and nut. Remove speed
control lever (D) and neutral switch as an
assembly.
NOTE: Pump and motor valve plates are very similar
in appearance, but are not interchangeable.
Note shape of valve plates when removing.
Valve plates are not fastened to back plate, but
may adhere slightly because of oil between the
machined surfaces.
5. Remove valve plates from the back plate.
6. Remove two dowel pins (E).
NOTE: Unless spring pin (F) used to locate valve plate
is damaged or loose, do not remove. If
replacement is necessary, use care not to
scratch the machined surfaces of the back
plate.
M94943
I
4. Remove gasket from pump assembly.
G
H
M94944
6 - 28
4/6/01
HYDROSTATIC TRANSMISSION DISASSEMBLY
HYDROSTATIC POWER TRAIN
7. Mark the forward (G) and reverse (H) relief valves
and their ports to ensure they go into the correct
holes during assembly. Remove the relief valves
from the back plate. Clean the relief valves in a
suitable solvent, and check for damaged springs or
seats.
9. Remove the charge pressure relief valve (I) and
check for damage or debris in spring or seating
areas. Clean or replace parts as required.
J
M94944
M89652
NOTE: The relief valves are dual purpose valves.
Each valve contains two springs. A weak
spring (check valve when other circuit is in use)
and a strong spring (6000 psi relief valve).
Valves cannot be adjusted, and there are no
serviceable parts inside. If any malfunction is
suspected, replace the relief valve.
IMPORTANT: To avoid damage to needle bearings
when removing or installing, press only against
side of bearing with lettering.
When removing bearings from the back plate,
be extremely careful to not damage machined
surfaces.
10. Inspect pump side needle bearing (J). Bearing
should spin freely, and needles should not fall out
of bearing cage. If replacement is necessary,
press bearing out from the motor side of the
housing.
8. Examine the relief valve faces, and the seats in the
back plate. The faces of the check valve and the
seats in the back plate should be free of burrs and
defects.
K
IMPORTANT: Damage to pump may occur if charge
pressure relief valve and cooler bypass valve
springs are accidentally swapped. Keep valves
and springs separated or label them to prevent
mix-up.
L
M
I
M94975
M94945
4/6/01
11. On the motor side of the back plate, remove the
cooler bypass valve (K) and check for damage or
debris in spring or seating areas. Clean or replace
parts as required.
6 - 29
HYDROSTATIC TRANSMISSION DISASSEMBLY
12. Remove the filter bypass valve (L) and check for
damage or debris in spring or seating areas. Clean
or replace parts as required.
13. Inspect the motor side needle bearing (M). Bearing
should spin freely, and needles should not fall out
of bearing cage. If replacement is necessary,
remove using a suitable blind hole puller.
HYDROSTATIC POWER TRAIN
Back Plate Assembly:
1. On motor side of the back plate, install the filter
bypass valve. Tighten to 16 - 20 N•m (12 - 15 lbft).
NOTE: Cooler bypass valve spring and charge relief
valve spring could accidentally be mixed up.
Charge relief valve spring is thicker.
2. Install the cooler bypass valve. Tighten to 28 - 33
N•m (21 - 24 lb-ft).
IMPORTANT: Old O-rings, gaskets, and seals will
leak. Always install new O-rings, gaskets, and
seals during assembly.
N
M94944
14. Remove three plugs (N) from pump side, and one
plug from motor side of back plate, and clean out
oil passages using a suitable solvent and
compressed air.
3. Install new O-ring to plug. Install plug. Tighten plug
to 28 - 33 N•m (21 - 24 lb-ft).
4. On pump side of back plate, install new O-rings to
three plugs. Install plugs. Tighten to 13 - 16 N•m
(115 - 142 lb-in.).
5. Install forward and reverse relief valves in ports
marked at disassembly. Tighten to 135 - 149 N•m
(100 - 110 lb-ft).
6. Install charge pressure relief valve. Tighten to 37 41 N•m (27 - 30 lb-ft).
7. Install two dowel pins.
F
Q
2.3 mm
(0.09 in.)
P
O
4.4 mm
(0.17 in.)
M91662
M94946
NOTE: If neutral adjustment cap screw (O) is
loosened, neutral adjustment procedure must
be performed. See "HYDROSTATIC PEDAL
AND NEUTRAL ADJUSTMENT".
15. Inspect pivot (P) and cam followers (Q) on neutral
return lever for smooth operation. Replace parts
as needed.
6 - 30
8. If the bearings were removed from the back plate,
press new ones into position using a suitable
bearing driver. The numbers on the bearing should
face the outside of the back plate. Press the
bearing in until 2.3 mm ± 0.2 mm (0.090 in. ±
0.010 in.) of the race remains above the surface of
the back plate.
9. If removed, install the spring pin (F) that is used to
position the valve plate. Allow the pin to protrude
from the back plate approximately 4.4 mm
(0.17 in.).
4/6/01
HYDROSTATIC PUMP DISASSEMBLY
HYDROSTATIC POWER TRAIN
HYDROSTATIC PUMP
DISASSEMBLY
Procedure:
A
M94943
3. Remove gasket from pump assembly.
M94941
IMPORTANT: The pump body is aluminum and can
be easily damaged by steel tools. Be careful to
not damage machined surfaces. Do not use
screwdriver or other sharp objects to pry pump
body from back plate.
1. If not already done, remove four socket head cap
screws (A) securing the pump to the back plate.
Tap pump body with a plastic mallet to remove
pump.
E
D
M94947
4. Remove the rotating assembly (D) from the
housing.
5. If the pistons (E) did not come out with the piston
block, remove the pistons along with the spider
and pivot.
B
5
4
3
C
2
1
M58106
M94957
2. Remove cap screw (B) and nut. Remove speed
control lever (C) and neutral switch as an
assembly.
4/6/01
1. Pistons
4. Pins and Retainer
2. Spider
5. Piston Block
3. Pivot
6 - 31
HYDROSTATIC PUMP DISASSEMBLY
Piston Block Disassembly:
NOTE: Disassembling the piston block assembly is not
necessary unless the spring or pins are
damaged.
c CAUTION
HYDROSTATIC POWER TRAIN
2. Place the socket (D), then a washer (E) over the
threaded end of the cap screw.
3. Screw on nut and slightly compress the spring
inside the piston block.
4. Using snap ring pliers, remove the internal retaining
ring (F).
5. Carefully back off nut until spring tension is relieved.
6. Remove the nut, washer, and cap screw.
F
The spring inside the piston block is
compressed and should not be removed without
compressing the spring first. Use the following
procedure to remove the spring safely.
The following parts will be needed to disassemble
the piston block:
H
J
G
2 ea. . . . . . . . . . . . . 3/8 ID x 1-1/4 in. OD flat washers
1 ea. . . . . . . . . . . . . . . . . . . 3/8 x 5 in. N.C. cap screw
1 ea. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. N.C. nut
1 ea. . . . . . . . . . 1/2 in. drive socket with 1-1/8 in. OD
I
M56625
7. Remove washers (G), spring (H), pins (I), and pin
retainer (J).
8. Inspect parts for wear or damage. Replace if
needed.
Assembly is the reverse of disassembly.
B
A
C
Shaft Removal and Disassembly:
M76099
1. Place a flat washer (A) over the 3/8 x 5 in. cap
screw (B). Install cap screw through spline end of
piston block so that the washer rests on the three
pins (C).
A
E
D
B
F
M94948
1. Remove the internal snap ring (A) retaining the seal
(B).
M76100
6 - 32
4/6/01
HYDROSTATIC PUMP DISASSEMBLY
HYDROSTATIC POWER TRAIN
NOTE: Use care when pressing shaft out of housing to
prevent shaft from falling to floor and being
damaged.
2. Press the shaft out of the housing from the back
plate side until the seal releases from the bore.
E
5
M94950
8
7
3. Remove bearing cones (E) from both ends of the
control shaft. Inspect bearing cones for smooth
operation, wear, or damage. Replace parts as
needed.
6
2
3
4
M57918
1
1. Internal Snap Ring
5. Thrust Washer
2. Seal
6. Thrust Bearing
3. Washer
7. External Snap Ring
4. External Snap Ring
8. Main Shaft
F
3. Remove the seal (2) and washer (3).
4. Remove the snap ring (4) from the shaft. Remove
thrust washers (5) and thrust bearing (6).
G
M94952
Control Disassembly:
4. Replace seal (F) in shaft end cover.
5. Inspect bearing cups (G) for wear or damage.
Replace bearings as needed.
D
B
H
A
C
M94949
M94953
1. Remove three cap screws (A) and shaft end cap
(B).
2. Remove three cap screws (C) and plain end cap
(D).
4/6/01
6. Remove cam plate assembly (H) from housing.
6 - 33
HYDROSTATIC PUMP INSPECTION
HYDROSTATIC POWER TRAIN
HYDROSTATIC PUMP INSPECTION
I
A
M94976
M94954
1. Inspect the bronze side of the valve plate (A) for
wear. Replace the valve plate if any wear, scoring,
or scratches exist.
7. Remove shim (I).
J
M94955
8. Remove thrust plate (J).
K
B
M91665a
2. Inspect the piston block surface (B) that makes
contact with the valve plate. This surface should be
smooth and free of deep scratches.
3. Check the piston movement in the block bore. If the
pistons are sticky in the bore, examine the bore for
scoring or contamination.
M94956
9. Inspect needle bearing (K) in housing. If the
needles remain in the cage and spin freely, there is
no need to replace them. If replacement is
necessary, bearings may be removed with a
bearing driver.
6 - 34
4/6/01
HYDROSTATIC PUMP ASSEMBLY
HYDROSTATIC POWER TRAIN
HYDROSTATIC PUMP ASSEMBLY
E
1. Clean all parts in a suitable solvent and dry with lint
free rag.
IMPORTANT: Due to extremely tight tolerances
and finish of internal surfaces it is very
important to maintain absolute cleanliness
during pump assembly. Coat all internal
surfaces with clean 10W30 motor oil when
assembling.
D
C
M89651
4. Inspect the outside of the pistons. Replace if scored
or worn.
5. Inspect the shoes. Replace if loose on the ball end
of the pistons, or if shoe face area (C) is worn or
damaged.
6. Inspect the spider (D). Replace if worn in the area
where it contacts the pivot (E).
7. Inspect the pivot. Replace if worn or damaged.
8. Examine the machined surfaces of the back plate.
Replace if scored or damaged.
Housing and Shaft Assembly:
K
M94956
F
F
1. If the needle bearing (K) was removed from the
housing, the new one can be pressed from the
outside inward until the bearing race is recessed in
the bore approximately 2.0 mm ± 0.3 mm (0.078
in. ± 0.15 in.). Be sure that the numbers on the
bearing race are facing to the outside of the
housing.
I
G
H
M76112
9. Inspect the shaft for damage on the bearing
surfaces (F) or in the splined areas.
10. Inspect thrust bearing (G) and thrust washers (H)
for wear.
11. Inspect the servo piston for scratches and wear.
12. Replace seal (I). Replace worn or damaged parts
as required.
J
M94955
2. Apply a small amount of grease to back of thrust
plate (J) and install thrust plate into cam plate.
4/6/01
6 - 35
HYDROSTATIC PUMP ASSEMBLY
HYDROSTATIC POWER TRAIN
I
M94954
3. Install shim (I).
M94974
IMPORTANT: Old O-rings, gaskets, and seals will
leak. Always install new O-rings, gaskets, and
seals during assembly.
H
6. Install new O-rings on shaft end cap and plain end
cap.
D
B
M94953
4. Install cam plate assembly (H) into housing.
M94949
E
7. Install plain end (D) and shaft end (B) caps. Retain
with cap screws.
8. Rotate control shaft and feel for smooth operation.
Check for end play. If there is end play, remove
shaft end cap and increase shim thickness until
there is no end play.
M94950
5. Install bearing cones (E) to both ends of the control
shaft.
6 - 36
NOTE: Control shaft turning force measurement is
taken while shaft is turning. Amount of force
required to begin turning shaft is higher.
4/6/01
HYDROSTATIC PUMP ASSEMBLY
HYDROSTATIC POWER TRAIN
9. Using a suitable torque wrench, measure the
amount of force required to turn the control shaft.
While the shaft is turning, the amount of turning
force should be 25 ± 5 lb-in. Increase, or decrease
the amount of shim on the shaft end of the cam
plate until the force required is within the
specification.
housing until the seal is below the retaining ring
groove. Secure shaft into housing with internal
snap ring (A).
Rotating Assembly Installation:
1. If the piston block assembly was disassembled
complete the following. If not, skip to step 10.
F
5
H
8
7
6
2
3
J
4
G
M57918
1
I
M56625
1. Internal Snap Ring
5. Thrust Washer
2. Seal
6. Thrust Bearing
3. Washer
7. External Snap Ring
4. External Snap Ring
8. Main Shaft
10. Install the external snap ring (7), thrust washer (5),
and thrust bearing (6) on the shaft. Install the
outside thrust washer (5) and external snap ring
(4).
11. Install the washer (3) and a new (2) seal onto the
shaft.
2. Install the three pins (I) in oversize grooves in spline
end of piston block with the heads facing inside of
the block.
3. Install the pin retainer (J).
4. Install the washers (G) and spring (H).
5. Using same tools used to compress spring during
disassembly of block, install washer, spring,
second washer, cap screw and nut in the piston
block.
6. Compress spring.
7. Install retaining ring (F).
8. Remove spring compression tools from the piston
block.
M91671
A
E
B
M94948
12. Install the shaft assembly into the housing. Using
the appropriate size socket, or a clean piece of
pipe, tap the shaft seal (B) into the bore in the
4/6/01
6 - 37
HYDROSTATIC MOTOR DISASSEMBLY
HYDROSTATIC POWER TRAIN
9. Place an appropriate size socket in the hole in the
piston block to keep the pivot (E) in place while
installing the pistons. Slide the pivot down so that
the flat side rests on the top of the three pins.
10. With the pistons in place in the spider, lower the
pistons into the piston block.
NOTE: It is not necessary to put the pistons in the
original position. Any piston can be installed in
any hole.
M94977
M94947
11. Tilt the pump housing so that the open end is facing
slightly downward.
12. Slide the rotating assembly up the shaft until it
meshes with the splines on the shaft.
16. Install the pump assembly onto the back plate
assembly. Make sure valve plate and gasket stay
in position. Tighten the socket head cap screws to
53 - 57 N•m (39 - 42 lb-ft).
HYDROSTATIC MOTOR
DISASSEMBLY
A
M94973
M94941
13. Apply a small amount of grease to the steel side of
the valve plate to hold it in place during pump
installation.
14. Install pump valve plate on back plate.
15. Place a new gasket on the pump.
6 - 38
4/6/01
HYDROSTATIC MOTOR DISASSEMBLY
HYDROSTATIC POWER TRAIN
IMPORTANT: The motor body is aluminum and can
be easily damaged by steel tools. Be careful to
not damage machined surfaces. Do not use
screwdriver or other sharp objects to pry motor
body from back plate.
Rotating Unit Removal and Disassembly:
1. If not already done, remove motor from back plate.
Remove eight socket head cap screws (A)
securing the motor to the back plate. Tap the motor
housing with a plastic mallet to loosen it from the
valve plate. Keep the assembly level or tip output
end down to keep the rotating assembly from
sliding off of shaft. Pull the motor housing, shaft,
and rotating assembly away from back plate.
B
M91679
D
1. Invert the motor and remove the rotating assembly
from the housing.
2. If the pistons did not come out with piston block,
remove the pistons along with the spider and pivot.
C
M94942
NOTE: Pump and motor valve plates are very similar
in appearance, but are not interchangeable.
Note shape of valve plates when removing.
Valve plates are not fastened to back plate, but
may adhere slightly because of oil between the
machined surfaces.
2. Remove valve plate (B) from the back plate.
3. Remove two dowel pins (C).
NOTE: Unless spring pin (D) used to locate valve plate
is damaged or loose, do not remove. If
replacement is necessary, use care not to
scratch the machined surfaces of the back
plate.
4/6/01
M94978
3. Remove cam washer from back of motor housing.
6 - 39
HYDROSTATIC MOTOR DISASSEMBLY
HYDROSTATIC POWER TRAIN
Shaft Removal and Disassembly:
5
8
7
6
2
4
3
M57918
1
D
M91677
1. Remove the internal snap ring (D) retaining the
seal.
1. Internal Snap Ring
5. Thrust Washer
2. Seal
6. Thrust Bearing
3. Washer
7. External Snap Ring
4. External Snap Ring
8. Main Shaft
3. Remove the seal (2) and washer (3).
4. Remove the retaining ring (4) from the shaft.
Remove thrust washers (5) and thrust bearing (6).
M76112
6
5
5. Inspect the shaft for damage in the bearing and
spline area.
6. Inspect the thrust bearing (6) and washers (5) for
wear.
M91676
2. Gently tap the shaft with a plastic hammer as
shown until the seal releases from the housing.
NOTE: Use care when removing shaft from housing to
prevent shaft from falling to floor and being
damaged.
6 - 40
Hydrostatic Motor Inspection:
1. Inspect the needle bearings in the back plate and
the motor housing. If the needles remain in the
cage and spin freely, there is no need to replace
them.
2. If the needle bearing in the motor housing needs to
be replaced, it can be pressed out with the
appropriate size bearing driver. If the bearing in
the back plate must be replaced it must be pulled
out with a slide hammer or blind hole puller.
4/6/01
HYDROSTATIC MOTOR DISASSEMBLY
HYDROSTATIC POWER TRAIN
IMPORTANT: When removing bearing from back
plate, be extremely careful to not damage
machined surfaces.
8. Inspect the piston shoes for a snug fit on the ball
end of the pistons. Check the face of the shoes for
a flat smooth surface.
9. Examine the spider for wear in the pivot area.
10. Examine the pivot to ensure smoothness and no
signs of wear.
M76105
M94978
3. Inspect the bronze side of the valve plate for wear.
Replace the valve plate if any wear, scoring, or
scratches exist.
4. Inspect the piston block surface that makes contact
with the valve plate. This surface should be
smooth and free of deep scratches.
5. Check the piston movement in the piston block
bore. If the pistons are sticky in the bores examine
the bores for scoring or contamination.
11. Inspect the cam washer shoe surface. It should be
free of scratches and wear marks.
IMPORTANT: Piston face damage can be caused
by towing unit, dry start-up, or loss of charge
pressure.
Piston Block Disassembly:
E
NOTE: Disassembling the piston block assembly is not
necessary unless the spring or pins are
damaged.
F
c CAUTION
The spring inside the piston block is
compressed and should not be removed without
compressing the spring first. Use the following
procedure to remove the spring safely.
M56554
6. Remove the pistons (E) and spider (F) assembly.
7. Examine the outside of the pistons for finish
condition. They should not show wear or deep
scratches.
4/6/01
The following parts will be needed to disassemble
the piston block:
2 ea. . . . . . . . . . . . .3/8 ID x 1-1/4 in. OD flat washers
1 ea. . . . . . . . . . . . . . . . . . . 3/8 x 5 in. N.C. cap screw
1 ea. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. N.C. nut
1 ea. . . . . . . . . .1/2 in. drive socket with 1-1/8 in. OD
6 - 41
HYDROSTATIC MOTOR ASSEMBLY
HYDROSTATIC POWER TRAIN
F
B
A
H
C
J
G
I
M76099
M56625
12. Place a flat washer (A) over the 3/8 x 5 in. cap
screw (B). Install cap screw through spline end of
piston block so that the washer rests on the three
pins (C).
18. Remove washers (G), spring (H), pins (I), and pin
retainer (J).
19. Inspect the spring inside the piston block for
damage. Inspect pins for straightness.
E
HYDROSTATIC MOTOR ASSEMBLY
D
F
M76100
13. Place the socket (D), then a washer (E) over the
threaded end of the cap screw.
14. Screw on nut and slightly compress the spring
inside the piston block.
15. Using snap ring pliers, remove the internal retaining
ring (F).
16. Carefully back off nut until spring tension is
relieved.
17. Remove the nut, washer, and cap screw.
IMPORTANT: Due to extremely tight tolerances,
and finish of internal surfaces, it is very
important to maintain absolute cleanliness
during the assembly of the motor. Coat all
internal surfaces with clean 10W30 motor oil
when assembling.
Main Shaft Bearing Installation:
NOTE: All needle bearings are pressed in with
numbers facing out.
A
M94975
6 - 42
4/6/01
HYDROSTATIC MOTOR ASSEMBLY
HYDROSTATIC POWER TRAIN
1. If the needle bearing (A) was removed from the
back plate, a new one can be pressed in, numbers
up, using the correct size bearing driver. The back
plate bearing should be pressed in until 2.3 mm ±
0.2 mm (0.090 in. ± 0.010 in.) is left above the
bore.
M91675
B
A
4.4 mm
(0.17 in.)
2.3 mm
± 0.2 mm
(0.09 in.
± 0.010 in.)
M91662
2. If spring pin (B) that is used to position the valve
plate was removed or damaged, install a new one.
Allow the pin to protrude from the back plate
approximately 4.4 mm (0.17 in.).
4. Apply some grease to the "THIS SIDE DOWN" side
of the cam washer before installing into motor
housing so it will stay in place while installing
rotating assembly.
Cam Plate and Shaft Installation:
5
8
7
6
2
3
4
M57918
1
C
1. Internal Snap Ring
5. Thrust Washer
2. Seal
6. Thrust Bearing
3. Washer
7. External Snap Ring
4. External Snap Ring
8. Main Shaft
M91682
3. The housing bearing (C) should be pressed on the
numbered side, from the outside of the housing
inward, until the numbered end is recessed 2.0
mm ± 0.3 mm (0.078 in. ± 0.015 in.) in the
housing bore.
4/6/01
5. Install the inside snap ring (7), thrust washer (5),
and thrust bearing (6) on shaft. Install the outside
thrust washer and snap ring (4).
6. Install the shaft into the housing. Install the washer
(3) and the new shaft seal (2). Secure them with
the retaining ring (1).
6 - 43
HYDROSTATIC MOTOR ASSEMBLY
HYDROSTATIC POWER TRAIN
Rotating Unit Assembly and Installation:
1. If the piston block assembly was disassembled
complete the following. If not, skip to step 10.
NOTE: It is not necessary to put the pistons in the
original position. Any piston can be installed in
any hole.
F
H
J
G
I
M56625
2. Install the three pins (I) in oversize grooves in spline
end of piston block with the heads facing inside of
the block.
3. Install the pin retainer (J).
4. Install the washers (G) and spring (H).
5. Using same tools used to compress spring during
disassembly of block install washer, spring, second
washer, cap screw and nut in the piston block.
6. Compress spring.
7. Install retaining ring (F).
8. Remove spring compression tools from the piston
block.
M91679
11. Tilt the motor housing so that the open end is facing
slightly downward.
12. Slide the rotating unit up the shaft until it meshes
with the splines on the shaft.
B
D
C
M94942
M91805
9. Place an appropriate size socket in the hole in the
piston block to keep the pivot in place while
installing the pistons. Slide the pivot down so that
the flat side rests on the top of the three pins.
10. With the pistons in place in the spider, lower the
pistons into the piston block.
6 - 44
13. If removed, install the spring pin (D) in the back
plate used to retain the valve plate. Allow the pin to
protrude from the back plate approximately 4.4
mm (0.17 in.).
14. If removed, install two dowel pins (C).
15. Apply a small amount of grease to the steel side of
valve plate (B) to hold it in place for installation.
Place the valve plate in position on the back plate
with steel side against back plate.
4/6/01
HYDROSTATIC POWER TRAIN
CONTROL LINKAGE REMOVAL & INSTALLATION
B
A
M94979
IMPORTANT: Install motor housing with cam plate
slope marking as shown. If installed incorrectly
the tractor will go backwards when forward
pedal is depressed.
16. Install the motor assembly onto the back plate
assembly with the cam plate marking as shown.
Make sure that the valve plate and cam washer
stay in position.
IMPORTANT:
Damage to pump may occur if
retaining cap screws are not tightened evenly,
and in a criss-crossing pattern to keep pump
mounting flange and back plate parallel.
M94957
18. Install speed control lever (B) and neutral switch as
an assembly. Retain with cap screw (A) and nut.
CONTROL LINKAGE REMOVAL &
INSTALLATION
Removal:
17. Install eight socket head cap screws to retain motor
to back plate. Tighten evenly in a criss-crossing
pattern so that pump mounting flange and back
plate remain parallel. Tighten to 10 - 14 N•m
(87 - 123 lb-in.).
A
A
M91861
1. Remove four nuts and carriage bolts (A) securing
forward pedal to pedal arm and reverse pedal to
pedal arm. Remove pedals.
4/6/01
6 - 45
CONTROL LINKAGE REMOVAL & INSTALLATION
HYDROSTATIC POWER TRAIN
7. Split tractor between tunnel and clutch housing.
(See "TRACTOR SPLITTING FRONT").
C
H
B
M94983
I
M98490
G
2. Remove two cap screws (B), lock nuts, and spacer
(C), and disconnect control rods from pedal
assembly.
8. If not already done, remove clip pin (G) and
disconnect clevis from neutral return lever (H).
Remove clevis, rod (I), and neutral return spring as
an assembly.
E
J
F
D
L
M
F
M94986
K
3. Remove lock nut (D), washer, and lower half of
rubber isolator (E) securing operator’s platform to
bracket.
4. Support operator platform bracket and pedal
assembly, and remove three cap screws (F) that
secure bracket to tunnel.
5. Lower pedal assembly and bracket as a unit, and
remove from cap screw on operator’s platform.
6. Inspect components for wear or damage. Replace
as needed.
M94940
9. Mark transmission forward (J) and reverse (K) rods
for correct location and orientation when
assembling. Remove two cap screws (L), two
spacers (M), and two lock nuts. Remove
transmission forward and reverse control rods.
NOTE: The following procedures describe the removal
of control linkage located inside the flywheel
housing.
6 - 46
4/6/01
CONTROL LINKAGE REMOVAL & INSTALLATION
HYDROSTATIC POWER TRAIN
P
R
T
M94987
S
Q
O
N
M94992
10. Remove two screws (N) and disconnect wiring
harness from neutral switch (O).
11. Remove two cap screws (P), lock nuts, and spacer
(Q), and remove neutral switch.
12. Inspect cam follower (R), neutral switch roller (S),
and neutral return lever pivot (T) for smooth
operation. Lubricate or replace parts as needed.
Assembly:
Assembly is the reverse of disassembly.
• Inspect all components for wear, damage, and
smooth operation. Replace as needed.
• Install new nylon lock nuts where removed. Old lock
nuts may become loose over time.
4/6/01
6 - 47
CONTROL LINKAGE REMOVAL & INSTALLATION
6 - 48
HYDROSTATIC POWER TRAIN
4/6/01
CONTENTS
SYNCREVERSER™ POWER TRAIN
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4300 / 4400 – CLUTCHES AND COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4300 / 4400 – 4 SPEED TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SHIFT LEVER AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SRT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 SPEED TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SRT CLUTCH LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SRT SHIFT LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRACTOR SPLITTING (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SYNCREVERSER TRACTION CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 17
SYNCREVERSER TRACTION CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . 18
INPUT SHAFT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SYNCREVERSER TRACTION CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . 20
CLUTCH SHIMMING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SNUBBER SHIMMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLUTCH AND FORWARD/REVERSE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-SPEED TRANSMISSION REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4-SPEED TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4-SPEED TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4-SPEED TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4/6/01
7-1
NOTES
7-2
SYNCREVERSER™ POWER TRAIN
4/6/01
SPECIFICATIONS
SYNCREVERSER™ POWER TRAIN
SPECIFICATIONS
GENERAL SPECIFICATIONS
Hydraulic Reservoir Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L (6.3 gal)
REPAIR SPECIFICATIONS
SyncReverser Clutches
SyncReverser Clutch Pack (Minimum Thickness). . . . . . . . . . . . . . . 42.34 mm (1.66 in.)
Clutch Spring (minimum free length). . . . . . . . . . . . . . . . . . . . . . . . . . 51.3 mm (2.02 in.)
TORQUE SPECIFICATIONS
SCV Port Tube Hydraulic Line Nuts . . . . . . . . . . . . . . . . . . . . 40 - 57 N•m (30 - 43 lb-ft)
Gear Case To Gear Case Cap Screws . . . . . . . . . . . . . . . 126 - 154 N•m (95 - 115 lb-ft)
Front Clutch Cover To Housing (Tunnel) Cap Screws . . . . . . . . 23-29 N•m (17 - 22 lb-ft)
Clutch Hub to Transmission Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 N•m (100 lb-ft)
SPECIAL OR ESSENTIAL TOOLS
Part Number
Part Name
JDG 1259
Clutch Shimming Fixture
JTO 7335-1,2,3
Splitting Stands and Brackets
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
OTHER MATERIALS
4/6/01
Number
U.S./Canadian
Name
Use
TY6305
John Deere Clean and Cure Primer
Clean mating surfaces, helps speed
curing.
TY16021
John Deere Form in Place Gasket
Between axle and differential
housings, transmission tunnel etc.
TY9370
(#242 LOCTITE®)
Thread Lock and Sealer
(Medium Strength)
On dowel pins and certain cap screws.
7-3
4300 / 4400 – CLUTCHES AND COVER
SYNCREVERSER™ POWER TRAIN
4300 / 4400 – CLUTCHES AND COVER
12
10
7
2
4
3
5
8
13
14
11
9
6
16
17 18
1
19
20
15
35
38
30
34
4
2
21
39
22
23
35
37
24
25
36
35
26
34
33
32
27
31
30
28
29
M94988
1. Lift Lever
11. Washer (2)
21. Gear
31. Shaft
2. Lifter Pin
12. Hub (2)
22. Bearing
32. Seal
3. Shim(s) Clutch Snubber
13. Clutch Plates (18)
23. Race
33. Seal
4. Shim(s) Clutch Adj.
14. Clutch Plates (16)
24. Basket
34. Bearing
5. Clutch Snubber
15. Gear
25. Washer
35. Dowel Pin
6. Bearing
16. Bearing
26. Piston
36. Clutch Cover
7. Cap Screw
17. Shaft
27. Spring Pin
37. Seal
8. Plate
18. Gear
28. Lever
38. Cap
9. Spring(8)
19. Snap Ring
29. Shaft
20. Bearing
30. Bearing
39. Filter Bypass
Valve
Assembly
10. Nut (2)
7-4
4/6/01
4300 / 4400 – 4 SPEED TRANSMISSION
SYNCREVERSER™ POWER TRAIN
4300 / 4400 – 4 SPEED TRANSMISSION
8
10
9
7
6
5
4
11
3
35
36
2
37
1
12
2
11
40
13
41
38
42
43
39
44
25
30
26
26
27
28
14
29
15
16
26
17
26
24
32
18
33
34
16
30
19
31
23
22
20
21 Note: Part 21 is cast with 39 in later models
M94993
1. Snap Rings
10. Shaft
19. Cap Screw
28. Shaft
37. Shaft
2. Bearing
11. Pin
20. Plate
29. Gear
38. Dowel Pin
3. Gear
12. Pinion Shaft
21. Support
30. Synchronizer
39. Support
4. Spacer
13. Sleeve
22. Spring (2)
31. Snap ring
40. Snap Ring
5. Gear
14. Gate
23. Ball
32. Gear
41. Ball Bearing
6. Gear
15. Rail
24. Pin
33. Ball Bearing
42. Snap Ring
7. Shaft
16. Fork
25. Sleeve
34. Snap Ring
43. Bearing
8. Bearing
17. Insert
26. Ring
35. Cap Screw
44. Gear
9. Coupler
18. Rail
27. Gear
36. Ball Bearing
4/6/01
7-5
CLUTCH PEDAL AND LINKAGE
SYNCREVERSER™ POWER TRAIN
CLUTCH PEDAL AND LINKAGE
1
2
3
4
5
6
7
8
9
10
11
12
15
13
17
18
14
16
19
20
21
22
23
24
25
1. Shaft
8. Pedal
15. Cap Screw (Stop)
22. Rod
2. Bearing
9. Clutch Spring
16. Washer
23. Lever
3. Bushing
10. Snap Ring
17. Bracket
24. Washer
4. Spacer
11. Thrust Washer
18. Lock Nut
25. Cotter Pin
5. Snap Ring
12. Lock Nut
19. Rod
6. Thrust Washer
13. Spherical Rod End
20. Nut
7. Bushing
14. Cap Screw
21. Turnbuckle
7-6
4/6/01
SHIFT LEVER AND LINKAGE
SYNCREVERSER™ POWER TRAIN
SHIFT LEVER AND LINKAGE
1
15
14
16
2
20
21
4
3
5
22
9
17
7
6
6
10
23
3
11
3
12
24
25
3
3
13
18
19
14
1. Knob
8. Support
15. Washer
22. Ball Joint
2. Lever, Control
9. Bearing
16. Bellcrank
23. Rod
3. Pin, Spring
10. Nut
17. Link
24. Washer
4. Lever
11. Joint, Universal
18. Bushing
25. Pin, Cotter
5. Screw
12. Cam
19. Shaft
6. Plunger
13. Joint, Universal
20. Bushing
7. Nut, Flange
14. Nut, Lock
21. Bolt
4/6/01
7-7
THEORY OF OPERATION
SYNCREVERSER™ POWER TRAIN
THEORY OF OPERATION
The clutches are wet type, and are lubricated and
cooled by a stream of pressurized oil directed at the
inside of the clutch from holes in the clutch cover.
SRT OPERATION
The power is directed into the 4 speed transmission by
the clutch that is selected with the forward / reverse
selector shaft (A). The selector shaft has a hole for
each lifter lever pin (C), that aligns with one of the pins
when the forward or reverse position is selected. When
the clutch shaft (B) is turned to the engaged position
the pin can drop into hole in the selector shaft, and that
clutch will engage. If a hole is not aligned with the pin,
the pin rests on the shaft, and the clutch cannot
engage. The holes are arranged so that only one clutch
can engage at a time and neither clutch can engage
the neutral position.
Function:
The SRT transmission consists of two clutches rotating
in opposite directions, and clutch shafts that provide a
mechanical means to select the forward or reverse
clutch.
Major Components:
A
• Clutch Pedal / Linkage
• Clutch Shaft
• Direction Selector Shaft
• Forward / Reverse Clutches
B
M95090
B
A
C
7-8
C
4/6/01
4 SPEED TRANSMISSION OPERATION
SYNCREVERSER™ POWER TRAIN
4 SPEED TRANSMISSION
OPERATION
TESTS AND ADJUSTMENTS
Function:
SRT CLUTCH LINKAGE
ADJUSTMENT
To transfer power from the directional clutches to the
range transmission at various speeds controlled by the
operator.
Reason:
To ensure that forward and reverse clutches engage
fully, and to prevent clutch slippage and overheating.
Theory of Operation:
When the SRT transmission is engaged in either
forward or reverse, there is rotation of the input shaft
(A) going into the transmission. There are four gears on
the shaft.
There are four corresponding gears on the driven shaft
(B) that are constantly meshed to the four gears on the
input shaft. The four gears on the driven shaft turn
independently from the driven shaft. Two synchromesh
collars (C) are splined to the driven shaft (B) and can
be shifted individually forward or backward to engage
the one of the gears to the driven shaft.
The driven shaft transfers power to the range
transmission.
3rd Gear
4th Gear
NOTE: Both clutches are operated off of the same
shaft and may not wear at equal rates. The
procedure below must be followed to properly
adjust pedal free travel.
Procedure:
1. Remove LH engine side panel.
2. Depress clutch pedal and position forward/reverse
lever in forward position. Release pedal.
3. Measure clutch pedal free travel and record
reading.
4. Depress clutch pedal and position forward/reverse
lever in reverse position. Release pedal.
5. Measure clutch pedal free travel and record
reading.
2nd Gear
1st Gear
A
C
C
Forward and Reverse
Clutch Shafts
4/6/01
B
To Range
Transmission
7-9
SRT SHIFT LINKAGE ADJUSTMENT
SYNCREVERSER™ POWER TRAIN
6. Place the directional lever in the position it was in
where the least free travel was measured.
B
13-17mm
(0.5 - 0.7 in.)
A
106.5 - 110mm
(4.19 - 4.33 in.)
Total Travel
A
M94984
7. Free travel should be 13 - 17mm (0.5 - 0.7 in.) If not
in specification loosen lock nuts (A) on turnbuckle
and adjust turnbuckle until 13 - 17mm (0.5 - 0.7
in.) is obtained. Hold turnbuckle and tighten lock
nuts.
8. Adjust clutch pedal stop (B) until clutch pedal has
106.5 - 110 mm (4.19 - 4.33 in.) of movement.
9. Depress clutch pedal and position forward/reverse
lever in opposite position. Release pedal. Measure
free travel in clutch pedal. Free travel should be
less than 25 mm (1.0 in.). If not in specification
clutches are worn and must be inspected or
replaced and re-shimmed. (See “CLUTCH
SHIMMING PROCEDURE” on page 22 and
“SNUBBER SHIMMING PROCEDURE” on
page 25.)
7 - 10
SRT SHIFT LINKAGE ADJUSTMENT
Reason:
To ensure that forward and reverse clutches engage
properly and that neutral is in the proper position on the
lever and safety switches.
Procedure:
1. Remove LH engine side panel.
2. Remove LH cowl panel.
3. Place SRT shift lever in center (neutral) position.
Make sure the neutral safety switch is depressed.
4. Loosen nut (A) locking ball joint (B) to rod.
4/6/01
SRT SHIFT LINKAGE ADJUSTMENT
SYNCREVERSER™ POWER TRAIN
B
D
C
8. Adjust ball joint (B) on shift rod up or down until it
aligns with hole in bellcrank and secure with nut
(D). Tighten locking nut (C).
9. Make sure the neutral safety switch is still
depressed, if not re-adjust linkage.
10. Securely hold ball joint and tighten locking nut (A).
A
M94985
5. Loosen lock nut (C) on shift rod and remove nut (D)
securing ball joint to bellcrank.
6. Depress clutch pedal and ensure shift arm of SRT
is in center (NEUTRAL) position. You should be
able to feel the detent ball hold the shaft in the
neutral position.
D
C
B
A
7. Place the forward/reverse shifter in neutral position.
Make sure neutral switch is depressed.
4/6/01
7 - 11
REPAIR
SYNCREVERSER™ POWER TRAIN
REPAIR
TRACTOR SPLITTING (FRONT)
A
NOTE: It is not necessary to remove the flywheel
housing from the engine unless engine is being
removed. Split the tractor between the tunnel
and flywheel housing as outlined in the story
below.
M91391
Prepare the Tractor:
1. Remove any mid or front attachments and mid or
front PTO shaft.
2. Park tractor on a level surface. Engage park brake,
shut off engine.
3. Disconnect battery negative (–) terminal.
4. Remove floor mat.
5. Remove operator’s platform. (See “OPERATOR’S
PLATFORM” on page8 in Miscellaneous Section.)
6. Remove LH and RH closeout panels.
7. Remove seat and seat platform. (See “SEAT AND
SEAT SUPPORT” on page5 in Miscellaneous
Section.)
8. Remove fenders. (See “REAR FENDERS” on
page 6 in Miscellaneous Section.)
9. Cycle all hydraulic controls to relieve system
pressure.
• Disconnect four work port tubes (A) from SCV.
B
M91867
c CAUTION
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.
NOTE: Hydraulic reservoir contains approximately 24
L (6.3 gal) of oil. Have a suitable container
ready to catch drain oil.
• Remove two cap screws (B) and two spacers that
attach tube support bracket to frame. Remove tube
support bracket and tubes as an assembly.
• Install RH rear wheel and tire.
12. Locate and disconnect all electrical connectors
attaching wiring harness to switches and lights on
rear half of tractor. Unfasten wiring harness from
cable clips and move harness away from rear half
of tractor.
10. Drain hydraulic reservoir.
11. If tractor is equipped with an SCV:
• Raise RH rear of tractor and support on suitable
stands.
• Remove RH rear wheel and tire.
D
7 - 12
C
4/6/01
TRACTOR SPLITTING (FRONT)
SYNCREVERSER™ POWER TRAIN
17. Disconnect hydraulic pressure tube (G) at rear gear
pump.
E
H
D
M94834
C
M94685
13. Disconnect brake return spring (C) from brake
lever. Remove spring.
14. Disconnect lower brake rod (D) from brake lever.
15. Side Mount Parking Brake Only: Disconnect park
brake rod (E) from brake lever.
18. Remove cap screw (H) and hydraulic pressure tube
clamp.
I
M91995
F
M95001
19. Disconnect hydraulic supply tube (I) at SCV or
manifold block. Remove tube.
16. Remove five cap screws (F) and LH operator’s
platform support.
K
G
J
M91982
4/6/01
M95006
7 - 13
TRACTOR SPLITTING (FRONT)
SYNCREVERSER™ POWER TRAIN
20. If equipped: Remove MFWD drive shaft and
couplers by removing spring pin (J) and sliding
coupler onto shaft until clear of stub shaft. Repeat
at other end of drive shaft.
21. Remove oil filter.
22. Disconnect oil tube (K) from clutch housing/filter.
L
M94831
M94813
23. Loosen hose clamp and disconnect suction tube (L)
from manifold.
M
NOTE: When attaching JTO 7335 splitting stands to
tunnel section, use the supplied right angle
brackets, and attach to holes in underside of
tunnel section.
25. Using suitable cap screws, attach four JTO 7335
splitting stands to tractor sections. Adjust splitting
stands so that wheels contact the floor, and are
parallel to the tractor wheels.
26. Remove nine cap screws connecting tunnel to
flywheel housing. Note length and locations of cap
screws when removing.
O
IMPORTANT:
Check for, and disconnect any
additional accessory wires or hydraulic tubes
connecting rear half to front half before splitting
tractor.
N
M95007
24. Remove cotter pins (M) and disconnect linkage
rods from clutch lever (N) and forward/reverse
lever (O).
27. Release park brake and place gear shift in
NEUTRAL.
28. Gently pry around edges of flanges to separate
tractor halves.
29. Roll tractor halves apart.
Assemble Tractor Sections:
NOTE: Splines on all drive shafts and couplers must
be aligned before tractor sections are bolted
together.
7 - 14
4/6/01
TRACTOR SPLITTING (FRONT)
SYNCREVERSER™ POWER TRAIN
1. Align splines on transmission drive shaft and engine
flywheel.
2. Move tractor sections together and retain with nine
cap screws. Tighten cap screws to 126 - 154 N•m
(95 - 115 lb-ft).
3. Remove cap screws retaining splitting stands to
tractor sections. Remove splitting stands.
L
G
M91982
6. Connect hydraulic pressure tube (G) to rear gear
pump. Tighten tube nut to 55 - 79 N•m (40 - 59 lbft).
M94813
H
4. Connect suction tube (L) to manifold. Tighten hose
clamp.
M94834
I
7. Install cap screw (H) and hydraulic pressure tube
clamp.
M91995
5. Install hydraulic supply tube to tractor. Connect
hydraulic supply tube (I) to SCV or manifold block.
Tighten tube nut to 55 - 79 N•m (40 - 59 lb-ft).
F
M95001
8. Install LH operator’s platform support. Retain with
five cap screws (F).
4/6/01
7 - 15
TRACTOR SPLITTING (FRONT)
SYNCREVERSER™ POWER TRAIN
B
K
J
M91867
M95006
9. Connect oil tube to clutch cover on transmission.
Tighten to 40 - 57 N•m (30 - 43 lb-ft).
10. Install a new hydraulic oil filter.
11. If equipped, install MFWD drive shaft and couplers.
Slide couplers onto shafts, and retain with spring
pins (J).
16. If tractor is equipped with an SCV, install SCV tube
support bracket and tubes as an assembly. Install
two cap screws (B) and two spacers to attach tube
support bracket to frame.
17. Raise RH rear of tractor and support on suitable
stands. Remove RH rear wheel and tire.
A
E
M91391
D
C
M94685
12. Attach lower brake rod (D) to brake lever. Retain
with pin, or pin, cotter pin, and washer.
13. Side Mount Parking Brake Only: Attach park
brake rod (E) to brake lever. Retain with clip pin.
14. Install brake return spring (C) to brake lever and
ROPS cap screw.
15. Route wiring harness through cable clips. Locate
and connect all electrical connectors attaching
wiring harness to switches and lights on rear half
of tractor.
7 - 16
18. Connect four work port tubes (A) to SCV. Tighten
tube nuts to 40 - 57 N•m (30 - 43 lb-ft).
19. Connect battery negative (–) terminal.
20. Install fenders. (See “REAR FENDERS” on page 6
in Miscellaneous section.)
21. Install kick plate. (See “KICK PLATE” on page 8 in
Miscellaneous section.)
22. Install seat and seat platform. (See “SEAT AND
SEAT SUPPORT” on page5 in Miscellaneous
section.)
23. Install LH and RH closeout panels.
24. Install operator’s platform. (See “OPERATOR’S
PLATFORM” on page8 in the Miscellaneous
section.)
25. Install floor mat.
26. Refill hydraulic oil reservoir to proper level.
27. Bleed air from hydraulic system. (See
“HYDRAULIC SYSTEM BLEED PROCEDURE” on
page 25 in the Hydraulics section.)
4/6/01
SYNCREVERSER TRACTION CLUTCH REMOVAL
SYNCREVERSER™ POWER TRAIN
SYNCREVERSER TRACTION
CLUTCH REMOVAL
Procedure:
1. Perform tractor split between flywheel housing and
tunnel housing. (See “TRACTOR SPLITTING
(FRONT)” on page12.)
D
M95013
5. Alternately loosen eight retaining cap screws in
small increments and remove spring retainer
plates (D).
A
M95028
2. Remove eight cap screws securing clutch cover to
tunnel housing.
3. Remove clutch cover.
E
M95014
6. Mark clutches so they can be installed in their
original position.
7. Remove clutch retaining nuts (E) and slide clutches
off of shafts.
F
C
B
M95009
4. Remove clutch lifter pins (B) and clutch snubber
(C).
IMPORTANT: There are shims on both sides of the
clutch snubber and behind the head of the lifter
pin on the other clutch. Note location and retain
all shims for possible use during reassembly.
M95015
8. Mark clutch gears for reassembly.
9. Simultaneously slide gears off of shafts and remove
input shaft (F).
4/6/01
7 - 17
SYNCREVERSER TRACTION CLUTCH DISASSEMBLY
NOTE: The PTO shaft may or may not come out with
the input shaft. It is easier to install with the
clutch gears removed. Just place it back on the
input shaft splines and guide it in, making sure
it engages into PTO clutch.
SYNCREVERSER™ POWER TRAIN
B
SYNCREVERSER TRACTION
CLUTCH DISASSEMBLY
Special or Required Tools:
• Calipers
• Bearing Drivers
M95040
Procedure:
2. Remove hub (B) and clutch plates from basket.
A
B
M95038
M95053
NOTE: The clutch piston and hub may only be
assembled one way to operate properly. There
are small assembly marks on them, but you
may find it helpful to mark the piston post (A)
and hub with a marking pen.
3. Inspect needle bearing, race, and thrust washer for
wear or damage.
NOTE: If bearing is being replaced, replace race and
thrust washer also.
A
4. If replacement of bearing is necessary, drive
bearing out with appropriate bearing driver. When
installing new bearing, drive only on the side that
the numbers are stamped on. Drive bearing in until
it is slightly below flush on both sides.
M95039
1. Mark piston post and piston with permanent
marking pen for reassembly.
7 - 18
4/6/01
SYNCREVERSER™ POWER TRAIN
SYNCREVERSER TRACTION CLUTCH DISASSEMBLY
7. Clean spring retainer plate bearings in suitable
solvent. Dry with compressed air.
8. Inspect both bearings for discolored or burned balls
and/or races. Check balls and races for spalling or
cracking. Roll bearing by hand to check for rough
turning or excessive looseness or play between
balls and races. Replace bearings as required.
M95054
5. Measure thickness of entire clutch plate pack.
Minimum thickness: 42.34 mm (1.66 in.) Replace
clutch pack if below minimum thickness.
M95060
Front Towards Flat
Side of Spring Plate
M95055
Back Towards Raised
Side of Spring Plate
NOTE: Bearings are designed for side loads and must
be installed in the proper direction as shown.
6. Inspect friction areas of hub and piston for wear.
Replace parts as needed.
M95056
9. Measure no load length of each spring. If spring
length is less than 51.3 mm (2.02 in.), replace
spring.
M95057
IMPORTANT:
DO NOT spin bearings using
compressed air. Damage to bearing balls, cage
and races could result.
4/6/01
7 - 19
INPUT SHAFT DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
INPUT SHAFT DISASSEMBLY
M95067
Special or Required Tools:
• Bearing Puller
Procedure:
5. Inspect gear teeth for damage. Inspect splines and
bearing areas of shaft for wear or damage.
Replace parts as required.
SYNCREVERSER TRACTION
CLUTCH INSTALLATION
M95061
NOTE: Gasket surfaces must be absolutely clean
down to bare metal for form-in-place gasket to
work properly. Scrape old material off with a
sharp gasket scraper and then use a chemical
gasket remover to clean mounting surfaces.
1. Using a bearing puller and press, remove bearings.
Procedure:
IMPORTANT:
DO NOT spin bearings using
compressed air. Damage to bearing balls, cage
and races could result.
1. Remove any old gasket material from clutch cover
and transmission housing tunnel.
2. Assemble input shaft if not already assembled.
2. Clean bearings in suitable solvent. Dry with
compressed air.
3. Inspect both bearings for discolored or burned ball
and/or races. Check balls and races for spalling or
cracking. Roll bearing by hand to check for rough
turning or excessive looseness or play between
balls and races. Replace bearings as required.
NOTE: Make sure PTO shaft is properly installed into
PTO clutch splines.
A
A
M95015
M95064
3. Simultaneously slide gears onto shafts and input
shaft into transmission. Raised side of gear hubs
go toward bearings. Turn input shaft (A) and make
sure PTO shaft is properly installed.
4. Remove snap rings (A) and slide gear from shaft.
7 - 20
4/6/01
SYNCREVERSER™ POWER TRAIN
SYNCREVERSER TRACTION CLUTCH INSTALLATION
Clutch Assembly:
M95071
M95074
4. Lay hub assembly on workbench with splined hub
facing up.
7. Line up assembly marks and put piston on hub
assembly.
NOTE: The clutch piston and hub may only be
assembled one way to operate properly. Make
sure assembly marks are lined up.
Gap
Incorrect
M95072
M95069
5. Install a clutch friction disc, then metal plate, then
disk, then plate etc.
6. Line up tabs on clutch discs.
Correct
M95068
8. Verify proper assembly by making sure piston
contacts clutch plates.
4/6/01
7 - 21
CLUTCH SHIMMING PROCEDURE
SYNCREVERSER™ POWER TRAIN
13. Install belleville washer (E) with side marked "out"
toward outside.
14. Install nuts (F), flat side out, and tighten to 135 N•m
(100 lb-ft).
C
B
G
M95081
H
9. Place thrust washer (B) on clutch.
10. Slide clutch basket (C) down over clutch assembly.
M95013
15. Install a spring (G) on each of the eight posts and
then a spring retainer plate (H) on each clutch.
Tighten cap screws to 11 N•m (98 lb-in.)
D
CLUTCH SHIMMING PROCEDURE
Measure Clutches:
Tool:
M95082
• JDG 1259 Clutch Shimming Fixture
11. Slide bearing races (D) onto clutch shafts.
E
E
A
F
F
M95014
B
M95086
1. Mark the clutches "1" and "2" with a marking pen.
2. Install lifter pins (A and B) as shown without any
shims or the clutch snubber under (A).
3. Seat the clutches back toward the transmission by
tapping each assembly lightly with a soft mallet.
12. Make sure the thrust washer is properly positioned
in the clutch assembly. While applying pressure to
the clutch parts to keep the thrust washer in place,
slide clutches on shafts.
7 - 22
4/6/01
CLUTCH SHIMMING PROCEDURE
SYNCREVERSER™ POWER TRAIN
JDG 1259
B
Dimension
"A"
M95085
C
4. Install JDG 1259 Clutch Shimming Fixture over
the lifter pin (B) of the clutch. The overall height of
the fixture must be known before installation. The
JDG 1259 is 177.8 mm (7.00 in.) high.
5. Measure from the top of the fixture to the top of the
lifter pin with a depth micrometer or calipers and
record the measurement.
6. Subtract this number from the height of the fixture.
7. Record number and repeat steps four through six
for the other clutch. These are dimensions "A".
8. Write the measurement for each clutch on the
clutch with a marking pen.
M95090
3. Turn clutch pedal control lever (C) clockwise to the
disengaged position. Both lifter levers (D) in figure
M95010 above will be in the raised position when
the clutch pedal control lever is in the disengaged
position.
Measure Clutch Housing:
Tool:
Dimension
"B"
• JDG 1259
D
M95153
M95010
4. Measure dimension "B" from the bottom of the
pocket in each lifter lever to the face of the
housing.
1. Position clutch cover assembly with opening up.
2. Identify and mark the location of clutch "1" and "2"
as shown.
4/6/01
7 - 23
CLUTCH SHIMMING PROCEDURE
SYNCREVERSER™ POWER TRAIN
NOTE: Due to shim sizes of 0.25mm (0.010 in.)
0.50mm (0.20 in.) and 1.0mm (0.039 in.) it
may not be possible to shim to an equal value
of "C". The goal is to have the shim pack as
close to dimension "C" as possible without
being less than "C" and not exceed "C" by
more than 0.3 mm (0.012 in.).
Example:
E
mm:
Inch:
JDG 1259 Fixture*
177.80
7.000
Fixture To Pin Measurement
–51.31
–2.021
Dimension "A"
126.49
4.979
Clutch Cover Measurement
132.98
5.234
+9.50
+0.375
–17.78
–0.700
+3.00
+0.118
Dimension "B"
127.70
5.027
Dimension "B"
127.70
5.027
–126.49
–4.979
Dimension "A" - Dimension "B"
1.21
0.048
Value C (Min. Shim Thickness)
1.21
0.048
M95010
• Place a 9.53 mm (0.375 in.) diameter ball in the
pocket (E) of each lifter lever.
Ball Size
Bar Size (JDG 1259 Fixture*)
Add
Minus Dimension "A"
Shim Tolerance
Value C (Max. Shim Thickness)
+ 0.3
–0.00
1.51
+ 0.012
–0.000
0.060
*If any other fixture is used, do not use this value
M95043
4. Install shims on lifter pins.
• Place the 17.78 mm (0.700 in.) thick bar across the
housing.
• Measure from the top of the bar to the top of the
ball in each lifter lever pocket. Record
measurement. Add the size of the ball 9.5 mm
(0.375 in.) and subtract the size of the bar 17.78
mm (0.700 in.) to recorded measurement. This will
be dimension "B", write this sum on each lifter
lever.
Determining Correct Amount of Shims:
NOTE: Calculate each clutch separately.
1. Subtract dimension "A" from dimension "B" to
determine value "C" which can be zero or greater.
2. If "C" is zero, assemble without shims.
3. If "C" is greater than zero, add shims equal to
dimension "C" + 0.3/- 0.0mm (+0.012 /- 0.000 in.)
between the lifter pin and the bearing.
7 - 24
4/6/01
SNUBBER SHIMMING PROCEDURE
SYNCREVERSER™ POWER TRAIN
SNUBBER SHIMMING PROCEDURE
5. Install snubber shims to the lifter pin.
NOTE: The drive clutch must be properly shimmed
before shimming the snubber.
B
C
A
M95365
M95121
1. Install clutch shims (determined from previous
procedure), lifter pin (A), and snubber (B) without
snubber shims.
2. Hold snubber and lifter pin firmly against front of
clutch and measure the gap between the snubber
fingers and lifter pin shoulder with a feeler gauge
(C).
NOTE: The gap should not be less than 1.40 mm
(0.055 in.) or more than 1.65 mm (0.065 in).
3. Subtract 1.5 mm (0.059 in.) from measurement in
previous step. This is the minimum thickness of
shim pack to be used between the front surface of
clutch snubber and bottom surface of lifter pin
shoulder.
4. Measure shims to be installed individually, do not
measure with the shims stacked together.
6. Insert lifter pin through the snubber.
7. Install clutch shims on the lifter pin and slide lifter
pin and snubber into clutch bearing.
Installing Clutch Cover:
IMPORTANT: Mating surfaces must be completely
clean of gasket material. Use a single edged
razor blade and gasket removing compound to
clean surfaces to bare metal.
1. Clean form in place gasket material from mating
surface with a gasket scraper or single sided razor
blade and gasket removing compound.
2. Install new input shaft oil seal.
D
M95010
M95042B
4/6/01
7 - 25
SNUBBER SHIMMING PROCEDURE
SYNCREVERSER™ POWER TRAIN
3. Mark position of snubber locating tab (D) on clutch
housing.
8. Install clutch cover and tighten cap screws to 28
N•m (20 lb-ft) in sequence shown.
Snubber Check Procedure: (Optional: Check if
transmission is removed from differential housing.)
NOTE: Check should be made with transmission in
horizontal position.
M95123
NOTE: Four of the slots on the snubber are larger than
the others. The larger slots must be lined up
with the tabs on the clutch housing.
4. Hold clutch cover on center tunnel housing and
place a mark on the center tunnel housing that
aligns with the mark on the clutch housing.
5. Line up larger slots on clutch snubber with marks
on center tunnel housing.
6. Place a 1/16 in. uniform bead of TY16021 John
Deere Form- in- Place Gasket around the mating
surface of the clutch cover.
7. Position forward reverse shaft so that pin for
number two lifter arm drops into hole. Apply force
to shift shaft so that lifter arm will be held in
position and not fall away from shaft while
installing clutch cover.
IMPORTANT: Clutch cover must come up against
hollow dowels on each side or the snubber is
not positioned correctly. Check position of
snubber slots and re-align as needed.
1
7
6
3
4
5
2
7 - 26
8
M95028
E
M95021
NOTE: Check must be made with transmission in 2nd
gear. If shifter is not on the unit, turn shift rod
(E) counterclockwise and push in, or if shift rod
and cover are not on trans, top fork rod should
be in forward position.
1. Place transmission in 2nd gear.
2. Attach a dial or pointer type torque wrench to output
shaft of transmission.
3. Engage forward clutch and rotate the output shaft at
approximately 10 rpm. Observe torque while
rotating shaft. Torque should be approximately 9.5
N•m (84 lb-in.). Record reading.
4. Fully disengage the clutch, thus applying the
snubber, and repeat step three. Record the
observed torque.
5. Subtract the reading from step three from the
reading from step four. The results must be greater
than 5.4 N•m (48 lb-in.) but not exceed 8.1 N•m
(72 lb-in.).
6. If the results are not within this range, re-shim the
snubber accordingly. That is, add shims to
increase torque, or remove shims to decrease
torque.
Clutch Shimming Bench Test (SRT Models):
1. Select a suitable handle for clutch lever (adjustable
wrench). Rotate clutch lever upward to stop. Place
speed section and range section in high gear.
Rotate sync shuttle lever upward 30 degrees from
horizontal (neutral detent) to the forward drive
4/6/01
CLUTCH AND FORWARD/REVERSE SHAFTS
SYNCREVERSER™ POWER TRAIN
position. Release clutch lever back to the engaged
position. Use a locking pliers to rotate the input
shaft clockwise-- the axles should rotate forward.
2. Rotate clutch lever up to stop. Rotate sync shuttle
lever downward 30 degrees below horizontal
(neutral position) to the reverse drive position.
Release clutch lever back to the engaged position.
Rotate input shaft clockwise-- the axles should
rotate in reverse.
3. Rotate clutch lever up to stop. Rotate sync shuttle
lever upward to horizontal (Neutral Detent). You
should be able to feel a slight detent in this
position. Release clutch lever to engage position.
CLUTCH AND FORWARD/REVERSE
SHAFTS
D
E
M95210
5. Inspect two shift shaft bushings (D) in housing for
wear or damage. Replace if needed.
6. Replace shift shaft seal (E) in housing.
Removal:
1. Split tractor between flywheel housing and tunnel
(See “TRACTOR SPLITTING (FRONT)” on
page 12.)
2. Remove six cap screws and clutch housing (See
“SYNC REVERSER TRACTION CLUTCH
REMOVAL” on page18.)
F
M95211
A
7. Inspect lift levers (F) for wear or damage. Replace if
needed.
M95217
3. Remove pin (A) from clutch housing.
B
C
B
C
M95212
M95209
4. Remove clutch shaft (B) and forward / reverse shaft
(C) from housing.
4/6/01
8. Remove forward / reverse shaft (C) from clutch
shaft (B).
7 - 27
CLUTCH AND FORWARD/REVERSE SHAFTS
SYNCREVERSER™ POWER TRAIN
NOTE: Detent pin was coated with thread locking
sealant during assembly at the factory.
1. Using a locking pliers or pipe wrench, grip detent
pin by threads and remove.
G
M95213
H
9. Replace seal (G) in end of clutch shaft.
Detent Pin Removal and Installation:
M95216
IMPORTANT: Do not remove detent pin unless
replacement is needed. Detent pin cannot be
removed without damaging threads on pin
assembly. If removed, pin must be replaced.
2. Coat threads of new detent pin (H) with TY9370
thread locking compound and install into housing.
3. Compress detent pin and install clutch and forward /
reverse shafts into housing.
4. Adjust depth of pin until forward / reverse shaft has
proper detent feel without binding.
H
M95215
M95215
1. To inspect detent pin, use a mallet and a suitable
drift to drive out expansion plug. Inspect detent pin
for wear or damage. Check for proper operation.
5. Install a new expansion plug.
H
M95214
7 - 28
4/6/01
4-SPEED TRANSMISSION REMOVAL
SYNCREVERSER™ POWER TRAIN
4-SPEED TRANSMISSION REMOVAL
Installation:
Procedure:
I
M95214
1. Split tractor between flywheel housing and tunnel.
(See “TRACTOR SPLITTING (FRONT)” on
page 12.)
2. Split tractor between tunnel and differential housing.
(See “TRACTOR SPLITTING (REAR)” on page 32
in the Final Drive Power Train section.)
3. Remove forward and reverse clutches. (See
“SYNCREVERSER TRACTION CLUTCH
REMOVAL” on page17.)
1. Remove plug (I).
2. Using a screwdriver, depress detent pin, and install
clutch and forward / reverse shafts into housing.
3. Install plug.
M95023
Clutch Lever in
Disengaged
Position
4. Label gears for correct orientation during reassembly. Remove gears.
M95090
4. Position clutch control lever to the disengaged
position.
M95155
A
5. On LH side of tunnel, remove four cap screws and
shifter assembly.
M95217
5. Align clutch and forward / reverse shafts so that
retainer pin can be installed without damage to
shafts. Install retainer pin.
4/6/01
7 - 29
4-SPEED TRANSMISSION REMOVAL
SYNCREVERSER™ POWER TRAIN
D
A
C
E
M94870
M95156
9. Remove spring pin (D) and slide shift shaft out of
tunnel.
10. Inspect bearing (E) for wear or damage. Replace if
necessary.
11. Inspect shoe (C) for wear or damage. Replace if
necessary.
6. Remove drive shaft (A).
C
B
F
M94868
7. Rotate MFWD shift lever (B) until shoe (C) clears
shift collar.
M95157
12. Remove two cap screws (F) and 4-speed
transmission assembly.
M94869
8. Remove shaft, gear, and shift collar as an assembly.
7 - 30
4/6/01
4-SPEED TRANSMISSION DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
4-SPEED TRANSMISSION
DISASSEMBLY
I
G
A
H
F
B
M95158
1. Remove two spring pins (A) and shift gate blocks
(B).
M95159
NOTE: Do not push shift rods too far into guide block.
Guide block contains two detent balls and
springs which may be lost.
4. Using a plastic mallet, drive both shift rods (F)
toward gears and shafts.Tap on end of output
shaft (G) to loosen shafts and gears, and remove
reverse shaft (H) and pinion shaft (I) from bearing
plate.
C
D
M95031
2. Remove two cap screws (C) and cover plate (D).
E
G
M95162
5. Rotate output shaft (G) away from shift forks, and
remove.
M95032
3. Remove interlock pin (E).
4/6/01
7 - 31
4-SPEED TRANSMISSION DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
J
M95168
9. Inspect bearings on reverse shaft for wear or
damage. To replace, use a suitable bearing puller
or press.
Pinion Shaft Disassembly:
M95163
NOTE: Use care when removing shift rods from guide
block (J). Guide block contains two detent balls
and springs which may be lost.
6. Remove two shift rods and forks from guide block.
M95166
1. Using a suitable puller, or press, remove bearing
from end of pinion shaft.
2. Inspect bearing for wear or damage. Replace if
needed.
M95164
33T
26T
7. Inspect shift fork inserts for wear or damage.
Replace if necessary.
J
K
38T
M95167
3. Using a suitable puller, or press, remove bearing,
33 tooth gear, spacer (K), 38 tooth gear, and 26
tooth gear from pinion shaft.
M96165
Pinion Shaft Assembly:
Assembly is the reverse of disassembly.
8. Remove two detent balls and springs from guide
block (J). Inspect parts for wear or damage.
Replace parts as needed.
7 - 32
• Lubricate parts liberally with hydraulic oil before
assembling.
• Install 38 tooth gear with larger flange facing toward
spacer.
4/6/01
SYNCREVERSER™ POWER TRAIN
4-SPEED TRANSMISSION DISASSEMBLY
Output Shaft Disassembly:
3. Remove thrust washer.
L
M95172
M95169
4. Remove ball from hole in shaft.
1. Remove snap ring (L).
56T
M95173
5. Remove 56 tooth gear.
M95170
2. Using a suitable puller or press, remove bearing
from end of shaft.
M95174
6. Remove synchronizer ring.
M95171
4/6/01
7 - 33
4-SPEED TRANSMISSION DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
M95175
7. Remove roller bearing.
M95178
10. Remove shift collar from hub.
M
M95191
8. Remove snap ring (M) and shift collar assembly.
M95179
11. Remove three inserts.
M95177
9. Remove spring from each side of shift collar.
M95180
7 - 34
4/6/01
4-SPEED TRANSMISSION DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
12. Remove synchronizer ring.
M95184
43T
M95181
13. Remove 43 tooth gear.
16. Remove ball.
36T
M95185
M95182
17. Remove 36 tooth gear.
14. From opposite end of shaft, remove bearing.
M95183
15. Remove thrust washer.
4/6/01
7 - 35
4-SPEED TRANSMISSION DISASSEMBLY
SYNCREVERSER™ POWER TRAIN
M95178
M95186
21. Remove shift collar from hub.
18. Remove snap ring.
M95179
M95187
22. Remove three inserts.
19. Remove shift collar.
M95177
20. Remove one spring from each side of shift collar.
7 - 36
M95188
23. Remove synchronizer ring.Check all synchronizer
parts for wear or damage.
4/6/01
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
N
31T
M95189
MX1358
24. Check brass synchronizer ring for worn or missing
teeth (N) .
26. Remove 31 tooth gear.
27. Visually inspect all parts for wear, cracks or
discoloration.
4-SPEED TRANSMISSION
ASSEMBLY
Pinion Shaft Assembly:
MX1415
25. To measure synchronizer wear, lay brass ring on
gear and measure gap between gear and brass
ring with a feeler gauge. If gap is less than 0.25
mm (0.010 in.), replace synchronizer assembly.
IMPORTANT:
Lubricate parts liberally
hydraulic oil before assembling.
33T
with
26T
NOTE: Synchronizer
assembly
and
brass
synchronizer
rings
are
not
serviced
individually. If any parts are needed, entire
assembly must be replaced.
K
38T
M95167
NOTE: Install 38 tooth gear with larger flange facing
toward spacer.
1. Using a press, install 26 tooth gear, 38 tooth gear,
spacer (K), 33 tooth gear, and bearing to pinion
shaft.
4/6/01
7 - 37
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
M95166
2. Using a press, install bearing onto end of pinion
shaft.
M95188
2. Install synchronizer ring with notches facing up.
Output Shaft Assembly:
IMPORTANT: Lubricate all parts liberally with clean
hydraulic oil during assembly.
M95179
31T
M95189
1. Install 31 tooth gear.
M95178
3. Install three inserts onto shift collar hub, and into
shift collar.
7 - 38
4/6/01
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
M95177
4. Install two springs to retain detent inserts in shift
collar.
M95186
6. Retain shift collar to shaft with snap ring.
36T
M95187
NOTE: When installing shift collar onto shaft, be sure
inserts on shift collar align properly with slots in
synchromesh ring and four oil grooves on shift
collar face out.
M95185
7. Install 36 tooth gear.
5. Install assembled shift collar onto output shaft.
4/6/01
7 - 39
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
M95184
43T
8. Install ball into hole in shaft.
M95181
11. On opposite end of shaft, install 43 tooth gear.
M95183
9. Retain ball with thrust washer.
M95180
12. Install synchronizer ring onto gear with slots facing
up.
M95182
10. Dip bearing in hydraulic oil. Using a press, install
bearing onto end of shaft.
7 - 40
4/6/01
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
M
M95191
M95179
NOTE: When installing shift collar onto shaft, be sure
inserts on shift collar align properly with slots in
synchromesh ring and four oil grooves on shift
collar face out.
15. Install assembled shift collar onto shaft, and retain
with snap ring (M).
M95178
13. Install three inserts onto shift collar hub. Install hub
and inserts into shift collar.
M95175
16. Install roller bearing.
M95177
M95174
14. Install two springs to retain detent inserts in shift
collar.
17. Install shift collar.
4/6/01
7 - 41
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
56T
M95173
M95170
18. Install 56 tooth gear.
21. Dip bearing in hydraulic oil. Using a press, install
bearing onto end of shaft.
L
M95172
19. Install ball into hole in shaft.
M95169
22. Install snap ring (L).
23. Check gears on output shaft. All three gears should
rotate on shaft.
M95171
20. Retain ball with thrust washer.
7 - 42
4/6/01
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
Gear and Shifter Assembly:
M95192
1. Install guide block to bearing plate. Do not install
cap screws at this time.
G
M95162
4. Install output shaft / gears assembly (G) onto shift
forks.
M95194
M95193
2. Install one spring and detent ball into guide block.
Using a pin punch, compress the spring and hold
ball while installing shift rod and fork assembly. Be
sure shift rod and fork assembly is installed into
correct hole.
3. Repeat for second shift rod and fork / detent ball
and spring.
4/6/01
5. Install pinion shaft onto output shaft. Install reverse
shaft, pinion shaft, and output shaft into bearing
plate at the same time using a plastic mallet.
NOTE: Guide block will pull away from bearing plate
when installing shafts and gears.
7 - 43
4-SPEED TRANSMISSION ASSEMBLY
SYNCREVERSER™ POWER TRAIN
B
A
M95195
M95198
6. Slide guide block on shift rods and install to bearing
plate.
9. Install two gate blocks (B) onto rods. Retain with
spring pins (A).
10. Test transmission operation by moving the shift
forks and rotating the output and pinion shafts to
ensure that all four speeds of the transmission
operate smoothly and correctly.
E
M95196
7. Move shift rods / forks to center (Neutral) position
and install interlock pin (E).
D
E
M95197
8. Install retainer plate (D). Retain with two cap screws
(C).
7 - 44
4/6/01
4-SPEED TRANSMISSION INSTALLATION
SYNCREVERSER™ POWER TRAIN
4-SPEED TRANSMISSION
INSTALLATION
M94876
A
13. Install a new MFWD shift shaft seal into tunnel.
B
M95157
11. Align three bearings and two shift rods with holes in
tunnel. Install transmission into housing and retain
with two cap screws (A).
IMPORTANT: Replace O-rings and seals. Used Orings and seals will leak.
M94870
14. Slide shift shaft into tunnel and through shift arm.
Retain shift arm to shaft with spring pin (B).
M95199
12. Install a new MFWD drive shaft seal at front of
tunnel.
M94869
15. Insert MFWD drive shaft assembly into tunnel.
4/6/01
7 - 45
4-SPEED TRANSMISSION INSTALLATION
C
SYNCREVERSER™ POWER TRAIN
18. Apply TY16021 John Deere Form In Place Gasket
to shifter assembly mounting surface. Make sure
shifter pin is positioned correctly in shift gates.
Install shifter assembly and retain with four cap
screws.
D
M94868
M95023
16. Engage shoe (C) to shift collar and rotate MFWD
shift lever (D) to draw MFWD shaft into place.
E
19. Install gears to forward and reverse shafts in
positions marked prior to disassembly.
20. Install forward and reverse clutches. (See
“SYNCREVERSER TRACTION CLUTCH
INSTALLATION” on page20.)
21. Assemble tractor tunnel and differential housing
sections. (See “TRACTOR SPLITTING (REAR)”
on page32 in the Final Drive PowerTrain section.)
22. Assemble tractor flywheel housing and tunnel
sections. (See “TRACTOR SPLITTING (FRONT)”
on page12.)
M95156
17. Install drive shaft (E).
M95155
7 - 46
4/6/01
CONTENTS
FINAL DRIVE POWER TRAIN
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AXLE SHAFT AND BRAKE - LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AXLE SHAFT AND BRAKE - RIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RANGE SHIFT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVE SHAFT (FOR MFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MFWD AXLE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MFWD FINAL DRIVE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MFWD DIFFERENTIAL COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER TRANSMISSION — RANGE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TESTS & ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIFFERENTIAL BACKLASH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MFWD OUTPUT SHAFT REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . 23
MFWD DRIVE SHAFT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . 25
MFWD FINAL DRIVE COVER REMOVAL & INSPECTION . . . . . . . . . . . . . . . . . . . 25
MFWD FINAL DRIVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MFWD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MFWD SPINDLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MFWD FINAL DRIVE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MFWD SPINDLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MFWD DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRACTOR SPLITTING (REAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
RANGE TRANSMISSION REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . 37
FINAL DRIVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
FINAL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FINAL DRIVE DISASSEMBLY, INSPECTION & ASSEMBLY . . . . . . . . . . . . . . . . . . 54
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DIFFERENTIAL LOCK REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . 58
PTO COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PTO BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PTO CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REAR PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2-SPEED PTO (EUROPEAN ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
MID PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4/6/01
8-1
CONTENTS CONTINUED
FINAL DRIVE POWER TRAIN
Page
MID PTO DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PTO THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
POWER TRANSMISSION – PTO CLUTCH AND BRAKE . . . . . . . . . . . . . . . . . . . .
POWER TRANSMISSION – REAR PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRANSMISSION – 2 -SPEED PTO (EUROPEAN ONLY) . . . . . . . . . . . . .
POWER TRANSMISSION – MID PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
68
69
70
PTO TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PTO DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PTO REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REAR PTO SHAFTS AND GEARS REMOVAL AND INSTALLATION . . . . . . . . . . .
REAR PTO SHAFTS & GEARS DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . .
2-SPEED PTO SHAFTS AND GEARS DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . .
2-SPEED PTO SHAFTS AND GEARS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . .
PTO CLUTCH AND BRAKE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . .
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . .
MID PTO REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MID PTO DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
72
74
78
82
86
88
94
95
4/6/01
FINAL DRIVE POWER TRAIN
SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Transaxle Oil:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere J20D
Capacity (CST, SST and SRT Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 L (6.3 gal)
Capacity (HST Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 L (6.8 gal)
PTO Speeds (At 2700 Engine rpm)
Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 rpm
Front PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
MFWD Oil:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere J20D
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 L (7.4 qt)
REPAIR SPECIFICATIONS
PTO Clutch/Brake Specifications:
Minimum Clutch Pack Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 mm (1.632 in.)
Minimum Brake Pack Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.53 mm (0.454 in.)
Pinion and Ring Gear Specifications:
Differential Ring Gear Backlash . . . . . . . . . . . . . . . . .0.10 - 0.30 mm (0.004 - 0.012 in.)
Front Wheel Alignment:
Toe In Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - 3 mm (0.0 - 0.12 in.)
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13°
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10°
Steering Angle:
Inward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54°
Outward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62°
4/6/01
8-3
TORQUE SPECIFICATIONS
FINAL DRIVE POWER TRAIN
TORQUE SPECIFICATIONS
PTO Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Final Drive toTransmission Housing Cap Screws . . . . . . . . . . . . . . 305 N•m (225 lb-ft)
Ring Gear Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Pinion Shaft Lock Nut (Lower and Upper) . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
Mid PTO Housing to Transmission Housing . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft))
Front Axle MFWD
(Loctite® Number If Required)
Front Wheel Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . .118 - 147 N•m (87 - 108 lb-ft)
Final Drive Cover Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . .30 - 38 N•m (22 - 28 lb-ft)
Differential Carrier to MFWD Housing Cap Screw (262) . . . . .61 - 68 N•m (45 - 50 lb-ft)
Drive Shaft Boot Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Snug Only
Tie Rod Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85- 95 lb-ft)
Tie Rod Socket (262) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 - 129 N•m (85 - 95 lb-ft)
Differential Ring Gear Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Differential Bearing Retainer Cap Screws . . . . . . . . . . . . . . . .54 - 68 N•m (40 - 50 lb-ft)
Pinion Retaining Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 - 176 N•m (120 - 130 lb-ft)
MFWD Housing to Spindle Housing Cap Screw (262) . . .286 - 316 N•m (211 - 233 lb-ft)
SPECIAL OR ESSENTIAL TOOLS
Part Number
Part Name
JT07335-1,2,3
Splitting Stands and Brackets
JDG 1260
Range Transmission Detent Ball Installer
NOTE: Order tools according to information given in the U.S. SERVICE-GARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).
8-4
4/6/01
OTHER MATERIALS
FINAL DRIVE POWER TRAIN
OTHER MATERIALS
4/6/01
Number
U.S./Canadian
Name
Use
TY6305
John Deere Clean and Cure Primer
Cleans parts and speeds cure of sealant.
TY15130 / TY15934
John Deere Sealant
Seals transaxle and final drive case
halves.
TY6333
Moly High Temperature EP Grease
TY22034
John Deere SuperLube ®
TY9370 / TY9477
(#242 LOCTITE®)
Thread Lock and Sealer
(Medium Strength)
TY6304
(#515 LOCTITE®)
Loctite Sealant
Seals the final drive housings to the
transmission housing, and front axle final
drive cover to the final drive housing.
Also applied to the outer surface of the
wheel seals.
#262 LOCTITE®
Loctite Thread Lock and Sealer
(High Strength)
Apply to front axle spindle housing cap
screws and to the MFWD housing cap
screws.
T43514
(#277 LOCTITE®)
Loctite Thread Lock and Sealer
(High Strength)
Apply to threads of pinion shaft retaining
pin and to threads of ring gear retaining
cap screws.
TY15941
(#620 LOCTITE®)
Loctite Retaining Compound
(High Strength)
Seals front axle final drive housing cap.
TY16021
John Deere High Flex Form-InPlace Gasket
Sealing Flange Assemblies
TY15934
John Deere General Purpose
Gasket Dressing
Sealing Gaskets and Hoses
8-5
COMPONENT LOCATION
FINAL DRIVE POWER TRAIN
COMPONENT LOCATION
AXLE SHAFT AND BRAKE - LEFT
2
1
3
1
4
5
6
7
10
8
11
9
12
13
24
24
14
24
22
25
17
25
16
25
15
23
21
20
19
M94709
18
8-6
4/6/01
AXLE SHAFT AND BRAKE - LEFT
FINAL DRIVE POWER TRAIN
1. Dowel Pin
8. Axle Shaft
15. O-Ring
22. Balls (5 or 7 Used)
2. Housing
9. Brake Arm
16. Brake Shaft
23. Actuator Plate
3. Cap Screw (6 Used)
10. Spring Pin
17. Cap Screw (5 Used)
24. Friction Disk
4. Bearing
11. Cap Screw (2 Used)
18. Bearing
25. Brake Plate
5. Seal
12. Snap Ring
19. Pinion Shaft
6. Bearing Retainer
13. Gear (73T)
20. Retainer Plate
7. Cap Screw (3 used)
14. Bearing
21. Spring (3 Used)
4/6/01
8-7
AXLE SHAFT AND BRAKE - RIGHT
FINAL DRIVE POWER TRAIN
AXLE SHAFT AND BRAKE - RIGHT
6
1
7
8
2
9
4
10
3
5
11
29
12
20
13
14
19
15
21
16
2
16
16
2
18
22
17
23
17
3
17
31
24
25
35
30
26
28
2
27
10
32
33
34
M94707
8-8
4/6/01
AXLE SHAFT AND BRAKE - RIGHT
FINAL DRIVE POWER TRAIN
1. Differential Lock Arm
10. Bearing
19. Pinion Shaft
28. Seal
2. Spring Pin
11. Snap Ring
20. Bearing
29. Cap Screw (2 used)
3. Washer
12. Cap Screw
21. Differential Lock Shaft
30. Bearing Retainer
4. Snap Ring
13. Retainer Plate
22. Shift Fork
31. Axle Shaft
5. Seal
14. Balls (5 or 7 Used)
23. Spring
32. O-Ring
6. Cap Screw (5 Used)
15. Actuator Plate
24. Shift Collar
33. Brake Shaft
7. Housing
16. Brake Plate
25. Housing
34. Brake Arm
8. Dowel Pin
17. Friction Disk
26. Shim
35. Cap Screw (3 Used)
9. Gear (73T)
18. Springs (3 Used)
27. Bearing
4/6/01
8-9
RANGE SHIFT TRANSMISSION
FINAL DRIVE POWER TRAIN
RANGE SHIFT TRANSMISSION
1
2
3
6
4
5
7
8
9
10
18
19
17
14
22
20
3
11
9
16
7
10
21
15
13
8
23
12
24
23
25
26
27
28
29
30
32
31
30
33
34
35
36
37
38
39
46
40
37
47
42
41
48
49
43
50
37
45
44
46
51
52
53
M95029
8 - 10
4/6/01
RANGE SHIFT TRANSMISSION
FINAL DRIVE POWER TRAIN
1. Cap
15. Lever
29. Splined Sleeve
43. Nut
2. Lever
16. Shift Block
30. Shift Collar
44. Washer
3. Spring Pin
17. Detent Ball
31. Spacer
45. Gear, 23 or 25
Tooth (MFWD)
4. Shaft
18. Spring
32. Gear, 36 Tooth
46. Bearing
5. Cap Screw (8
Used)
19. Pin
33. Splined Sleeve
47. Shaft With Gear, 14
Tooth
6. Ring Gear
20. Snap Ring (2 Used)
34. Spacer
48. Gear, 28 Tooth
7. Thrust Washer
21. Detent Shaft
35. Gear, 20 Tooth
49. Spacer
8. Gear
22. E-Clip
36. Spacer
50. Gear, 44 Tooth
9. Gear
23. Shift Fork
37. Bearing Assembly
51. Snap Ring
10. Thrust Washer
24. Pinion
38. Gasket
52. Gear, 34 Tooth
11. Screw
25. Bearing
39. Bearing Plate
53. Snap Ring
12. Differential Carrier
26. Spacer
40. Bearing
13. Cross Shaft
27. Gear, 50 Tooth
41. Retainer
14. Washer (8 Used)
28. Sleeve
42. Cap Screw (4 Used)
4/6/01
8 - 11
DIFFERENTIAL LOCK
FINAL DRIVE POWER TRAIN
DIFFERENTIAL LOCK
1
2
3
4
1
5
6
7
8
14
7
13
12
11
10
M95044
9
1. Washer
5. Seal
2. Snap Ring
6. Shaft
10. Bearing
3. Shift Fork
7. Spring Pin (3 Used)
11. Housing
4. Spring
8. Lever
12. Cap Screw (5 Used)
8 - 12
9. Shim
13. Shift Collar
14. Shaft
4/6/01
DRIVE SHAFT (FOR MFWD)
FINAL DRIVE POWER TRAIN
DRIVE SHAFT (FOR MFWD)
1
3
4
2
13
5
12
6
11
7
14
9
3
10
8
15
16
17
M95045A
18
19
1. Plug
6. Washer
11. Spring
16. Bearing
2. Snap Ring
7. Seal
12. Shoe
17. Bearing
3. Spring Pin
8. Lever
13. Lever
18. Snap Ring
4. Shaft
9. Gear, 25 or 27 Tooth
14. Ball
19. Seal
5. Bearing
4/6/01
10. Collar, Shift
15. Shaft
8 - 13
MFWD AXLE COMPONENT LOCATION
FINAL DRIVE POWER TRAIN
MFWD AXLE COMPONENT LOCATION
7
6
4
1
3
2
5
8
39
9
10
16
19
18
17
11
20
40
26
22
21
27
23
12
13
24
25
14
15
29
31
33
28
35
30
32
37
M91839
34
36
38
8 - 14
4/6/01
FINAL DRIVE POWER TRAIN
MFWD AXLE COMPONENT LOCATION
1. Axle Housing
11. Axle Shaft
21. Bearing Cup
31. Bearing Cone
2. Seal
12. Snap Ring (2)
22. Bearing Cone
32. O-ring
3. Washer
13. Shim(s) (A/R)
23. Bearing Cone (2)
33. Spacer
4. Bushing
14. Ball Bearing (2)
24. Bearing Cup (2)
34. Seal
5. Axle Support
15. Bevel Gear (12T)
25. Cap Screw (12 used
on A20BZ103-1,
S20BZ105-1,
S20BZ109-1
10 used on
S20BZ107-1
35. Nut
6. Nut
16. Dowel Pin (2)
26. Differential Housing
36. Bushing
7. Cap Screw
17. Drain Plug
27. Seal
37. Bushing (All except
S20BZ107-1 Axle)
8. Dip Stick/Filler Cap
18. Bearing Retainer (2)
28. Spacer
38. Axle Support
9. Cap Screw(8)
19. Cap Screw (4)
29. Shim(s) (A/R)
39. O-Ring (All except
S20BZ107-1 Axle)
20. Shim(s) (A/R)
30. Bearing Cup
40. Axle ID Number
10. Lock Washer (8)
NOTE: The axles are identified by numbers that are stamped into the housing on the dip stick pad (40). Always use
the axle number when ordering parts.
4/6/01
8 - 15
MFWD FINAL DRIVE COMPONENT LOCATION
FINAL DRIVE POWER TRAIN
MFWD FINAL DRIVE COMPONENT LOCATION
2
3
26
4
27
28
1
27
26
29
30
5
6
9
31
10
7
32
19
17
11
8
20
12
22
13
23
24
14
15
16
21
18
25
M91837
33
34
NOTE: Use drawing above (M91937) for
axles with final drives that use a nut
to hold the hub shaft , numbered
A20BZ103-1, S20BZ105-1.
35
36
37
Use the drawing to right (MX1438)
for axles with final drives that use a
snap ring to hold the hub shaft,
numbered S20BZ107-1, S20BZ1091.
38
39
40
41
32
MX1438
8 - 16
4/6/01
MFWD DIFFERENTIAL COMPONENT LOCATION
FINAL DRIVE POWER TRAIN
1. Axle Housing
12. Snap Ring
23. Washer
34. Snap Ring
2. Bevel Gear (15T)
13. Ball Bearing
24. Shim(s) (A/R)
35. Ball Bearing
3. Ball Bearing
14. Snap Ring
25. Bevel Gear (41T)
36. Gear
4. Spindle Housing
15. Bevel Gear (12T)
26. Bearing Cone (2)
37. Spacer
5. Seal
16. Shim(s) (A/R)
27. Bearing Cup (2)
38. Ball Bearing
6. Bearing Cone
17. Lock Washer
28. Outer Drive Cover
39. Cover
7. Bearing Cup
18. Snap Ring
29. Seal
40. Seal
8. Spindle Shaft
19. Seal
30. Hub Shaft
41. Hub Shaft
9. Bearing Cup
20. Final Drive Housing
31. Washer (8)
10. Bearing Cone
21. Cap
32. Cap Screw (8)
11. Nut
22. Spindle Nut
33. Knuckle
MFWD DIFFERENTIAL COMPONENT LOCATION
1
2
13
11
14
7
3
19. Cap Screw
12 used on:
A20BZ103-1,
S20BZ105-1,
S20BZ109-1
10 used on:
S20BZ107-1
8
4
12
5
9
16
6
17
15
10
18
20
M91838
19
1. Cap Screw (4)
6. Pinion (11T)
11. Thrust Washer (2)
16. Bearing Cone
2. Bearing Retainer (2)
7. Ring Gear (41T)
12. Bevel Gear (2)
17. Bearing Cup
3. Bearing Cup (2)
8. Pinion Shaft
13. Washer (2)
18. Shim(s) (A/R)
4. Bearing Cone (2)
9. Pin
14. Pinion Bevel Gear (2)
19. Cap Screw
15. Cap Screw (10)
20. Differential Housing
5. Shim(s) (A/R)
4/6/01
10. Differential Case
8 - 17
THEORY OF OPERATION
FINAL DRIVE POWER TRAIN
THEORY OF OPERATION
POWER TRANSMISSION — RANGE TRANSMISSION
24 Tooth Gear (Gear)
30 Tooth Gear (Hydro)
Drive
Shaft
44 Tooth Gear (Gear)
39 Tooth Gear (Hydro)
28 Tooth Gear
14 Tooth Gear (Gear)
18 Tooth Gear (Hydro)
Counter Shaft
Pinion Shaft
Pinion Gear
34 Tooth (Gear)
27 Tooth (Hydro)
23 Tooth Gear (Gear)
Shift Collar
36 Tooth Gear
20 Tooth Gear (Gear)
25 Tooth Gear (Hydro)
Shift Collar
50 Tooth Gear (Gear)
45 Tooth Gear (Hydro)
Ring Gear
Input Power
Power Transfer
Pinion Power
4-WD Power Transfer
A-range Power Transferr
B-range Power Transfer
C-range Power Transfer
8 - 18
4/6/01
FINAL DRIVE POWER TRAIN
POWER TRANSMISSION — RANGE TRANSMISSION
Function:
The range transmission provides a means for
transferring engine power to the differential pinion gear
at three different gear ratios.
Theory (Gear):
Power is provided to the range shift transmission
through the drive shaft which is splined to the output
shaft of the collar shift, SST or SRT transmission. The
24 tooth gear is in constant mesh with the 34 tooth
gear. The 34 tooth gear is splined to the counter shaft.
Power is transmitted through the 24 tooth gear to the
34 tooth gear, and to the counter shaft. In order for
power to be transferred to the pinion shaft, the operator
must select a range; A, B, or C.
A-range:
The counter shaft is a shaft and 14 tooth gear
machined as a single part. This 14 tooth gear is in
constant mesh with the 50 tooth gear on the pinon
shaft. The 50 tooth gear rotates freely on the pinion
shaft. When the operator selects A range, the two shift
collars are moved by a mechanical linkage to the
rearmost position. The front shift collar does not
engage a gear. The rear shift collar engages the cogs
of the 50 tooth gear, linking the gear to the splined
collar below the shift collar, transmitting power from the
counter shaft, through the 14 tooth gear, 50 tooth gear,
shift collar, splined collar, and into the pinion shaft, and
finally to the pinion gear.
B-range:
The 28 tooth gear is splined to the counter shaft, and is
in constant mesh with the 36 tooth gear on the pinion
shaft. The 36 tooth gear rotates freely on the pinion
shaft. When the operator selects B range, the two shift
collars are moved by a mechanical linkage slightly
forward. The front shift collar does not engage a gear.
The rear shift collar engages the cogs of the 36 tooth
gear, linking the gear to the splined collar below the
shift collar, transmitting power from the counter shaft,
through the 28 tooth gear, 36 tooth gear, shift collar,
splined collar, and into the pinion shaft, and finally to
the pinion gear.
C-range:
The 44 tooth gear is splined to the counter shaft, and is
in constant mesh with the 20 tooth gear on the pinion
shaft. The 20 tooth gear rotates freely on the pinion
shaft. When the operator selects C range, the two shift
collars are moved by a mechanical linkage to the far
forward position. The rear shift collar slides completely
onto the 36 tooth gear cogs, and does not engage the
splined collar below it. The front shift collar engages
the cogs of the 20 tooth gear, linking the gear to the
splined collar below the shift collar, transmitting power
from the counter shaft, through the 44 tooth gear, 20
tooth gear, shift collar, splined collar, and into the pinion
shaft, and finally to the pinion gear.
constant mesh with the 45 tooth gear on the pinon
shaft. The 45 tooth gear rotates freely on the pinion
shaft. When the operator selects low range, the two
shift collars are moved by a mechanical linkage to the
rearmost position. The front shift collar does not
engage a gear. The rear shift collar engages the cogs
of the 45 tooth gear, linking the gear to the splined
collar below the shift collar, transmitting power from the
counter shaft, through the 18 tooth gear, 45 tooth gear,
shift collar, splined collar, and into the pinion shaft, and
finally to the pinion gear.
B-range:
The 28 tooth gear is splined to the counter shaft, and is
in constant mesh with the 36 tooth gear on the pinion
shaft. The 36 tooth gear rotates freely on the pinion
shaft. When the operator selects medium range, the
two shift collars are moved by a mechanical linkage
slightly forward. The front shift collar does not engage a
gear. The rear shift collar engages the cogs of the 36
tooth gear, linking the gear to the splined collar below
the shift collar, transmitting power from the counter
shaft, through the 28 tooth gear, 36 tooth gear, shift
collar, splined collar, and into the pinion shaft, and
finally to the pinion gear.
C-range:
The 39 tooth gear is splined to the counter shaft, and is
in constant mesh with the 25 tooth gear on the pinion
shaft. The 25 tooth gear rotates freely on the pinion
shaft. When the operator selects high range, the two
shift collars are moved by a mechanical linkage to the
far forward position. The rear shift collar slides
completely onto the 36 tooth gear cogs, and does not
engage the splined collar below it. The front shift collar
engages the cogs of the 25 tooth gear, linking the gear
to the splined collar below the shift collar, transmitting
power from the counter shaft, through the 39 tooth
gear, 25 tooth gear, shift collar, splined collar, and into
the pinion shaft, and finally to the pinion gear.
Theory (Hydro):
Power is provided to the range shift transmission
through the drive shaft which is splined to the motor
shaft of the hydrostatic transmission. The 30 tooth gear
is in constant mesh with the 27 tooth gear. The 27 tooth
gear is splined to the counter shaft. Power is
transmitted through the 30 tooth gear to the 27 tooth
gear, and to the counter shaft. In order for power to be
transferred to the pinion shaft, the operator must select
a range; low, medium, or high.
A-range:
The counter shaft is a shaft and 18 tooth gear
machined as a single part. This 18 tooth gear is in
4/6/01
8 - 19
TROUBLESHOOTING CHART
FINAL DRIVE POWER TRAIN
Range Transmission Will Not
Engage
Range Transmission Will Not Stay
Engaged
Range Transmission Noisy In Gear
TROUBLESHOOTING CHART
Cogs On Gear or Shift Collar Damaged or
Worn/ No Longer Serviceable
●
●
Drive Shaft Gear or Counter Shaft Gear
Worn/ No Longer Serviceable
●
●
●
Low/Medium/High Gears Worn/ No Longer
Serviceable
●
●
●
●
●
MFWD Will Not Stay Engaged
Cogs On MFWD Shift Collar or Gear
Damaged or Worn/ No Longer Serviceable
●
●
Front Differential or Final Drive Worn or
Damaged
8 - 20
MFWD Noisy
●
Pinion and Ring Gear Worn or Damaged
Differential Noisy
●
Bearings On Pinion Shaft/Counter Shaft
Worn or Damaged
●
●
Detent Ball Spring Broken
Shift Linkage Worn or Damaged
One Gear Will Not Engage
MFWD Shift Linkage Worn or Damaged
Check or
Solution
Range Transmission Noisy In
Neutral
MFWD Will Not Engage
Problem or
Symptom
●
●
●
●
●
4/6/01
DIAGNOSIS
FINAL DRIVE POWER TRAIN
DIAGNOSIS
Test/Check Point
Normal
If Not Normal
A. Range Shift Lever
Smooth operation, engages gear.
Lubricate linkage. Replace
damaged parts.
B. Rear Wheels
Smooth, quiet operation in forward
or reverse motion, wheels do not
scrub when turning.
Check differential locking lever
disengages when not depressed.
Replace damaged parts in
differential.
C. Differential Locking Lever
Smooth operation, engages
differential lock.
Lubricate linkage. Replace
damaged parts.
D. Front Wheels (MFWD)
Smooth, quiet operation in forward
or reverse motion, wheels do not
scrub excessively when turning.
Replace damaged parts in front
differential.
E. MFWD Lever
Smooth operation, engages MFWD.
Lubricate linkage or replace
damaged parts.
4/6/01
8 - 21
TESTS & ADJUSTMENTS
FINAL DRIVE POWER TRAIN
TESTS & ADJUSTMENTS
To Adjust Backlash:
DIFFERENTIAL BACKLASH
ADJUSTMENT
Reason:
To place the differential ring gear in proper relationship
with the differential input pinion shaft.
IMPORTANT: Always check and adjust backlash
after pinion shaft adjustment has been made.
(See "ADJUST PINION DEPTH"). Do not adjust
backlash unless the ring gear was replaced or
the amount of shims are in question.
1. If not already removed, remove right hand final
drive (See "FINAL DRIVE REMOVAL").
2. Remove brake disks and plates (See "BRAKE
DISASSEMBLY AND INSPECTION" in Brake
section).
3. Remove differential lock fork (See "DIFFERENTIAL
LOCK REMOVAL AND INSTALLATION").
B
Procedure:
1. While slowly rotating the differential housing carrier,
use a soft faced mallet to lightly tap the face of the
ring gear to move it and the carrier toward the right
side of the tractor.
NOTE: This is to ensure that the carrier and bearings
are properly seated.
A
C
M94797
4. If not already done, remove differential lock collar
(B).
5. Remove RH brake/differential lock collar housing
(C).
D
M94798
M94812
2. Attach dial indicator (A) to the transmission
housing.
3. Locate the contact point of the dial indicator toward
the outer part of the ring gear tooth and as close to
90° to the tooth as possible.
4. While holding the differential pinion shaft stationary
at the pinion, rotate the ring gear and note the
backlash reading on the dial indicator.
5. Rotate ring gear 1/2 turn, and recheck backlash.
6. Remove shim(s) (D) located behind bearing
housing to decrease backlash, or add shim(s) to
increase backlash.
NOTE: For each 0.001" of shim added, backlash will
increase approximately 0.0007".
Shims are available in 0.07 mm (0.003 in.),
0.13 mm (0.005 in.), and 0.25 mm (0.010 in.)
and 0.5 mm (0.020 in.) thicknesses.
7. Install differential carrier and recheck backlash after
removing or installing shims.
Specification:
Backlash . . . . . . . . 0.10 - 0.30 mm (0.004 - 0.012 in.)
8 - 22
4/6/01
REPAIR
FINAL DRIVE POWER TRAIN
REPAIR
Remove Shift Shaft:
MFWD OUTPUT SHAFT REMOVAL
AND INSTALLATION
Removal:
1. Split tractor at rear of tunnel. (See "DIFFERENTIAL
LOCK REMOVAL/INSTALLATION").
C
B
B
D
M94870
4. Remove spring pin (C) and slide shift shaft out of
tunnel.
5. Inspect bearing (D) for wear or damage. Replace if
necessary.
6. Inspect shoe (B) for wear or damage. Replace if
necessary.
A
M94868
2. Rotate shift lever (A) until shoe (B) clears shift
collar.
IMPORTANT: Old O-rings, gaskets, and seals will
leak. When servicing, always install new Orings, gaskets, and seals.
M94876
7. Replace shift shaft seal.
M94869
3. Remove shaft, gear, and shift collar as an assembly.
4/6/01
Installation:
Installation is the reverse of removal.
• Install a new shift shaft seal before installing shift
shaft.
8 - 23
MFWD OUTPUT SHAFT REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
NOTE: Shift collar retains two steel balls under spring
pressure. Use care when removing collar to
prevent balls from being lost.
Disassemble MFWD Drive Shaft:
E
M94871
1. Using a suitable puller, remove bearing from end of
shaft. Inspect bearing for smooth operation,
damage, or wear. Replace as necessary.
F
M94874
4. Wrap shaft in a shop towel to prevent balls (E) from
being lost. Remove shift collar (F).
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
E
F
M94875
5. Remove two steel balls and spring from shaft.
M94872
Assemble MFWD Drive Shaft:
Assembly is the reverse of disassembly.
• Install two steel balls and spring to shaft using a
suitable hose clamp to compress spring and hold
balls in place while shift collar is being installed.
2. Remove washer.
Front Seal and Bearing Replacement:
M94873
3. Remove gear.
8 - 24
1. Split tractor between bell housing and tunnel
sections. (See "TRACTOR SPLITTING FRONT") in
the Hydrostatic Power Train section for HST
tractors; "TRACTOR SPLITTING FRONT" in the
Gear Power Train section for CST or SST tractors;
or "TRACTOR SPLITTING FRONT" in the
SyncReverser Power Train section for SRT
tractors.)
2. Using a suitable tool, remove seal from tunnel and
end of shaft.
3. Remove snap ring retaining bearing. Remove
bearing. Inspect bearing for damage or wear.
Replace if needed.
4. Install bearing.
4/6/01
MFWD DRIVE SHAFT REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
IMPORTANT: Old O-rings, gaskets, and seals will
leak. When servicing, always install new Orings, gaskets, and seals.
MFWD FINAL DRIVE COVER
REMOVAL & INSPECTION
5. Using a suitable driver, install a new seal.
TAPERED BEARINGS (Axles Marked A20BZ103-1,
S20BZ105-1)
MFWD DRIVE SHAFT REMOVAL
AND INSTALLATION
NOTE: The axles are identified by numbers that are
stamped into the housing on the dip stick pad.
1. Drain the differential and the final drive housing
being serviced.
2. Raise and support the final drive being serviced.
3. Remove the wheel and tire from the final drive.
4. Remove eight cap screws and washers. Separate
the final drive cover and hub shaft from the final
drive housing.
Removal:
B
NOTE: The final drive cover is sealed to the final drive
housing. It may be necessary to pry the cover
from the housing using the two reliefs on the
sides of the cover.
A
1
M95006
2
3
4
5
1. Remove the spring pins (A) from the drive shaft
splined couplers (front and rear).
2. Support the drive shaft and slide the splined
couplers on to the drive shaft splines (B). Remove
drive shaft from the tractor.
6
7
8
Installation:
Installation is the reverse of removal.
9
M91837b
10
11
12
1. Final Drive Housing
7. Washer (8)
2. Retaining Nut
8. Cap Screw (8)
3. Washer
9. Bearing Cup (2)
4. Shim(s)
10. Bearing Cone (2)
5. Bevel Gear (41T)
11. Seal
6. Final Drive Cover
12. Hub Shaft
5. Secure the wheel end of the hub shaft. Remove and
discard the retaining nut.
6. Press the hub shaft from the final drive cover,
bearings, and bevel gear.
7. Disassemble the remaining components from the
final drive cover assembly.
8. Clean and inspect all parts. Replace any
unserviceable components.
4/6/01
8 - 25
MFWD FINAL DRIVE COVER INSTALLATION
BALL BEARINGS (Axles Marked S20BZ107-1,
S20BZ109-1)
NOTE: The axles are identified by numbers that are
stamped into the housing on the dip stick pad.
FINAL DRIVE POWER TRAIN
• With the load applied, measure the dimension
between the gear face and the end of the hub
shaft.
• Select the same thickness shim as the measured
dimension, and install the shim(s) to the shaft.
1. The first four steps are the same as the units with
tapered bearings.
2. Secure the wheel end of the hub shaft. Remove the
snap ring.
1
2
3
1
2
3
4
5
6
7
8
9
5
M94673a
10
MX1438
1. Final Drive Housing
6. Ball Bearing
2. Snap Ring
7. Final Drive Cover
3. Ball Bearing
8. Seal
4. Bevel Gear (41T)
9. Hub Shaft
5. Spacer
10. Cap Screw (8)
3. Press the hub shaft from the final drive cover,
bearings, and bevel gear.
4. Clean and inspect all parts. Replace any
unserviceable components.
MFWD FINAL DRIVE COVER
INSTALLATION
TAPERED BEARINGS
1. Install the outer hub bearing cup to the bearing
cone.
2. Coat the outer surface of a new hub seal with John
Deere Sealant TY6304. Replace the hub seal.
3. Install the hub shaft to the bearing cones, bevel
gear, and final drive cover.
4. To adjust the bearings:
• Apply 1200 lbs axial load on the web of the bevel
gear, while rolling and oscillating the bearings. This
insures proper seating of the bearing.
8 - 26
4
1. Nut
4. Shim
2. Bevel Gear (41T)
5. Hub shaft
3. Washer
• Assemble the washer and old nut to the hub shaft.
Tighten the nut to 447 - 488 N•m (330 - 360 lb-ft).
• Verify that the rolling torque of the cover is 1.4 - 4.1
N•m (15 - 35 lb-in.).
• If the rolling torque is not correct, repeat the
previous steps.
• If the rolling torque is correct, apply LOCTITE 262
to the threads, and assemble the washer and new
nut to the hub shaft. Tighten the nut to 447 - 488
N•m (330 - 360 lb-ft).
IMPORTANT: The retaining nut on the hub shaft is
a special “torque prevailing” nut. ALWAYS
replace this nut - DO NOT reuse.
NEVER tighten a torque prevailing nut with an
impact wrench.
ALWAYS use a torque wrench to correctly
tighten torque prevailing nuts.
5. Apply John Deere Sealant TY6304 to the mating
surface of the final drive cover. Install the final drive
cover to the final drive housing. Tighten the cap
screws to 30 - 38 N•m (22 - 28 lb-ft).
BALL BEARINGS
1. Coat the outer surface of a new hub seal with John
Deere Sealant TY6304. Replace the hub seal.
2. Install the hub shaft through the seal and cover.
4/6/01
MFWD REMOVAL
FINAL DRIVE POWER TRAIN
3. Place the ball bearing, spacer, bevel gear, and ball
bearing on the hub shaft. Secure with snap ring.
4. Apply John Deere Sealant TY6304 to the mating
surface of the final drive cover. Install the final drive
cover to the final drive housing. Tighten the cap
screws to 30 - 38 N•m (22 - 28 lb-ft).
6. Lower the axle from the frame with a floor jack. Set
the axle on a workbench or blocks to disassemble.
7. Inspect the axle pivots for wear or damage.
MFWD SPINDLE SHAFT
Removal and Disassembly:
MFWD REMOVAL
1. Remove the differential drive shaft.
2. Label and remove the power steering hoses from
the steering cylinder.
3. Raise the front of the tractor. Support the frame.
4. Support the MFWD with a floor jack.
M89686
1. Carefully remove the spindle cap from the housing.
A
M89677
5. Remove the axle support mounting cap screws (A).
A
M89687
2. Remove the snap ring (A) from the spindle shaft.
M89678
4/6/01
M89688
8 - 27
MFWD FINAL DRIVE HOUSING
FINAL DRIVE POWER TRAIN
3. Remove the shim(s), and lower bevel gear (12T)
from the spindle shaft. Save any shim(s) from
between the spacer and the lower bevel gear.
5. Install the final drive cover to the final drive housing.
6. To set the backlash of the lower final drive, shim the
lower bevel gear to 0.64 - 0.76 mm (0.025 - 0.030
in.) of end play to achieve 0.13 - 0.18 mm 0.005 0.007 backlash.
7. Apply John Deere TY15941 retaining compound to
the final drive housing cap, and install the cap.
MFWD FINAL DRIVE HOUSING
Disassembly:
M89689
4. Remove the lower bevel gear from the spindle shaft.
1. Remove the final drive cover. (See "MFWD FINAL
DRIVE COVER REMOVAL AND INSPECTION").
2. Remove the final drive spindle shaft. (See "MFWD
SPINDLE SHAFT").
3. Remove and discard the retaining nut from the final
drive housing.
4. Remove the final drive housing from the spindle
housing, and put the final drive housing in a vise.
5. Remove the bearing cups and bearing cones from
the spindle housing and from the final drive
housing.
6. Clean and inspect all components. Replace any
unserviceable components.
Assembly:
B
M89690
5. Remove the snap ring (B) from the spindle housing.
M89691
6. Remove the spindle shaft and bearing from the
spindle housing.
7. Remove the snap ring and bearing from the spindle
shaft. Inspect all parts, and replace components
as necessary.
Assembly and Installation:
1. Install the bearing and snap ring to the spindle
shaft.
2. Install the spindle shaft assembly to the final drive
housing.
3. Install the internal snap ring to the final drive
housing.
4. Install the lower bevel gear (12T), shim(s), and the
snap ring to the spindle shaft.
8 - 28
1. Replace the final drive housing seal.
2. Install the bearing cups and cones to the housing.
3. Install a new bearing retaining nut to the final drive
housing. To correctly install the nut:
• Hand start the nut until it comes in contact with the
bearing.
• Apply 18 - 23 Kg (40 - 50 lbs) compressive force to
the socket, while tightening the nut to 108.5 N•m
(80 lb-ft) of torque. Oscillate the final drive housing
several times to seat the bearing.
• Loosen the nut one half turn (180°).
IMPORTANT: Retighten the nut to 20 - 27 N•m (15 20 lb-ft). The retaining nut securing the bearing
to the spindle housing is a torque prevailing nut.
ALWAYS replace this nut- DO NOT reuse.
NEVER tighten a torque prevailing nut with an
impact wrench.
ALWAYS use a torque wrench to correctly
tighten torque prevailing nuts.
4. Install the spindle shaft. (See "Assembly and
Installation").
5. Install the final drive cover. ((See "MFWD FINAL
DRIVE COVER INSTALLATION").
4/6/01
MFWD SPINDLE HOUSING
FINAL DRIVE POWER TRAIN
MFWD SPINDLE HOUSING
Removal and Disassembly:
1. Remove the final drive housing. (See "MFWD
FINAL DRIVE COVER REMOVAL AND
INSPECTION").
2. Remove four cap screws fastening the spindle
housing to the MFWD housing.
3. Remove the internal snap ring from the spindle
housing.
4. Remove the bearing and axle gear (12T) assembly
from the spindle housing.
5. Remove the bearing and upper bevel gear (15T)
assembly from the spindle housing.
6. If necessary press the bearings from the gears.
NOTE: The bearings are pressed onto the gears, and
are slip fits into the housing.
7. Clean and inspect all parts. Replace any
unserviceable parts.
Assembly and Installation:
1. Install the bearing and upper bevel gear (15T)
assembly to the spindle housing.
2. Install the bearing and axle gear (12T) assembly to
the spindle housing.
3. Install the internal snap ring to the spindle housing.
4. Set the backlash of the axle gear:
• Measure the distance between the bearing and the
snap ring at several locations.
1
2
3
5. Apply John Deere TY6304 sealant to the mating
surfaces of the MFWD housing and the spindle
housing.
6. Install the spindle housing to the MFWD housing:
• Apply Loctite® 262 to the threads, and install four
cap screws fastening the spindle housing to the
MFWD housing.
• Tighten the cap screws to 286 - 316 N•m (211 - 233
lb-ft).
7. Install the final drive housing. (See "ASSEMBLY").
MFWD DIFFERENTIAL
Removal and Disassembly:
1. Remove both final drive housings from the MFWD.
(See "MFWD FINAL DRIVE COVER").
2. Remove both axle shafts from the MFWD housing.
3. Remove the MFWD drive shaft. (See "MFWD
DRIVE SHAFT REMOVAL AND INSTALLATION).
4. Remove twelve cap screws fastening the differential
cover to the MFWD housing.
5. Remove the differential cover and differential case
from the MFWD housing.
6. Remove the cap screws for the bearing caps.
7. Remove the differential case from the differential
cover.
8. Remove ten cap screws. Remove the ring gear from
the differential case.
NOTE: The differential case and internal parts comes
as an assembly. If any damage is apparent
there is no need to disassemble the case, the
whole assembly must be replaced.
9. If internal damage is suspected disassemble the
differential case assembly and inspect all parts.
NOTE: Remove the differential case bearings only if
necessary. Make sure shims between the
bearings and the differential case are retained
and marked as to which side they were on so
they may be installed to their original position.
4
M94673a
1. Shim
3. Axle Gear (12T)
2. Bearing
4. Snap Ring
• Shim the bearing and axle gear to 0.15 - 0.28 mm
(0.006 - 0.011 in.) of end play, to achieve 0.10 0.20 mm (0.004 - 0.008 in.) backlash.
4/6/01
10. Clean and inspect all parts and check parts for
wear. Replace any unserviceable parts.
11. Remove the pinion nut. Do not discard the nut at
this time.
12. Remove the differential pinion from the differential
cover.
IMPORTANT: The pinion retaining nut is a special
“torque prevailing” nut. ALWAYS replace this
nut DO NOT reuse.
NEVER tighten a torque prevailing nut with an
impact wrench.
ALWAYS use a torque wrench to correctly
tighten torque prevailing nuts.
8 - 29
MFWD DIFFERENTIAL
FINAL DRIVE POWER TRAIN
13. Disassemble the pinion shaft assembly.
NOTE: The ring gear and pinion gear are serviced as
an assembly. If either the ring gear or pinion
has wear or damage both must be replaced.
14. Clean and inspect all parts and check parts for
wear. Replace any unserviceable parts.
Assembly and Installation:
8
7
5
• If the pinion is being replaced, notice the (+) or (–)
number (A) on the end of the pinion gear. This
indicates the best running position of each
particular gear set in thousandths of an inch. If the
number on the new set is not the same as the
number on the one being replaced, adjust the
height by adding or removing inner shim(s) (5)
from the original shim pack according to the
dimension etched in the head of the pinion.
• Example: If the old pinion reads +2 and the new
pinion is marked –1, add 0.003 in. shims to the
original shim pack.
6
4
3
2
1
13 12
11
10
9
M91838a
B
1. Nut
8. Pinion
2. O-ring
9. Outer Shim
3. Spacer
10. Bearing Cup
4. Cover
11. Bearing Cone
5. Inner Shim
12. Spacer
6. Bearing Cup
13. Seal
MX1027
NOTE: Number (B) on pinion and ring gear indicate
matched set.
7. Bearing Cone
1. Assemble the bearing cone (7) to the pinion (8).
• The inner shim(s) (5) are under the bearing cup (6)
and set the pinion height. If the original pinion is
being used, use the original shims, or install new
shims the same thickness as the original shims.
2. Assemble the inner bearing cup (6) and any shims
(5) in the differential cover.
3. Install the pinion (8) in the differential cover:
• Place the pinion in the cover, and install the spacer
(3), outer shim (9), bearing cone (11), O-ring (2),
seal (13), spacer (12), and the old nut (1).
4. Tighten the old pinion nut to 258 - 285 N•m (190 210 lb-ft), and check the rotation of the pinion:
• It should require 0.8 - 1.4 N•m (7 - 12 lb-in.) of
torque to rotate on the pinion.
• If the pinion does not turn within specification,
adjust the shim pack. Add shims if torque is too
high, remove shims if torque is too low.
• When the pinion is shimmed correctly replace the
old pinion retaining nut with a new pinion retaining
nut. Tighten the new nut to 258 - 285 N•m (190 210 lb-ft), and recheck the rotation of the pinion.
A
B
MX1027
8 - 30
4/6/01
MFWD DIFFERENTIAL
FINAL DRIVE POWER TRAIN
C
D
E
M
J
F
K
G
H
I
L
M91838b
M91838D
NOTE: The differential case and all parts shown above
are serviced as an assembly only.
5. Install the washers (C) to the side gears (D) and
install side gears into differential case (I).
6. Install concave washers (E) onto pinion gears (F).
Install pinion gears to side gears and turn gears to
align with hole in differential case. Install shaft (G)
and secure with roll pin (H).
M91838c
7. Install the ring gear to the differential case. Tighten
the ring gear bolts to 79 - 88 N•m (58 - 65 lb-ft).
NOTE: There may be several shims on each side of
differential case.
8. If bearings (J) were removed, place original shims
(K) or new shims equaling the same thickness, on
the same side of the differential assembly (L) they
were removed from. Install new bearings on the
differential assembly.
9. Install the bearing caps (M). Tighten the cap screws
for the bearing caps to 54 - 68 N•m (40 - 50 lb-ft).
• The bearing shim(s) (K), control the differential gear
backlash and the preload of the bearings. If the
original differential case, bearings, and gear set
are being used, install the original shims, or new
shims totalling the original thickness.
• If the differential case bearings or gear set are
being replaced, set the bearing preload and gear
backlash by adding or removing shim(s) between
the ring gear side bearing and differential case.
• Shim the bearings to a preload of 0.03 - 0.08 mm
(0.001- 0.004 in.).
10. Install the differential case assembly to the
differential cover. Check gear backlash with a dial
indicator.
• Gear backlash is adjusted by changing the shim
pack thickness on the ring gear side bearing.
Removing shims increases backlash, adding
shims decreases backlash.
IMPORTANT: Whatever shim thickness is added to
one side of the differential case must be
removed from the other side. Or whatever shims
are removed from one side must be added to the
other to keep bearing preload from changing.
11. Adjust backlash to specification.
Specification:
Backlash . . . . . . . . 0.03 - 0.08 mm (0.001 - 0.004 in.)
4/6/01
8 - 31
TRACTOR SPLITTING (REAR)
FINAL DRIVE POWER TRAIN
TRACTOR SPLITTING (REAR)
12. Apply John Deere Sealant TY6304 to the
differential cover.
A
13. Install the differential cover to the MFWD housing.
14. Apply John Deere TY9370 thread lock and sealer
to the six screws (4 on S20BZ107-1 axles) (A) on
the outside of the differential cover. Tighten the
cap screws to specification.
Specification:
Differential Cover Bolts . . 61 - 68 N•m (45 - 50 lb-ft).
Prepare the Tractor:
1. Remove any mid or front attachments and mid or
front PTO shaft.
2. Park tractor on a level surface and set park brake.
3. Remove seat and seat support. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section).
4. Remove kick plate. (See "KICK PLATE" in
Miscellaneous section.)
5. Remove operator’s platform. (See "OPERATOR’S
PLATFORM" in Miscellaneous section).
6. Remove fenders. (See "REAR FENDERS" in
Miscellaneous section).
7. Remove LH and RH closeout panels. (See "SEAT
CLOSEOUT PANELS" in Miscellaneous section.)
8. Disconnect the battery negative terminal.
9. Cycle all hydraulic controls to relieve system
pressure.
c
CAUTION
CAUTION: To avoid injury from escaping
hydraulic oil under pressure, relieve the
pressure in the system by stopping the engine
and operating all hydraulic control valves.
NOTE: Hydraulic reservoir contains approximately 26
L (6.8 gal) of oil. Have a suitable container
ready to catch drain oil.
10. Drain hydraulic reservoir.
11. Locate and disconnect all electrical connectors
attaching wiring harness to switches and lights on
rear half of tractor. Unfasten wiring harness from
cable clips and move harness away from rear half
of tractor.
B
A
M94685
12. Disconnect lower brake rods at rear brake levers.
• (A) Straight Rod and Clevis Style
• (B) Turnbuckle Rod and Pin Style
8 - 32
4/6/01
TRACTOR SPLITTING (REAR)
FINAL DRIVE POWER TRAIN
D
H
E
C
M91995
M94686
(Hydrostatic Model Shown)
NOTE: On hydrostatic models, differential lock lever
(C) is located on the LH side of the tractor. On
gear models, it is located on the RH side.
16. Disconnect hydraulic pressure tube (H) at SCV
(Selective Control Valve) or manifold block, and
move tube aside.
13. Remove cotter pin (D) and washer, and disconnect
differential lock rod (E) from lever. Move rod aside.
F
I
M91391
M94834
17. If equipped, disconnect SCV work port tubes (I) at
SCV.
14. Remove cap screw (F) and SCV pressure tube
clamp.
K
J
M91867
G
M91982
18. Remove two cap screws (J) and two spacers (K)
that attach tube support bracket to frame. Remove
tube support bracket and tubes as an assembly.
15. Disconnect pressure tube (G) at rear gear pump.
4/6/01
8 - 33
TRACTOR SPLITTING (REAR)
FINAL DRIVE POWER TRAIN
M
L
M94813
19. Remove two cap screws (L) and disconnect suction
tube manifold from differential housing.
IMPORTANT:
Check for, and disconnect any
additional accessory wires or hydraulic tubes
connecting rear half to front half before splitting
tractor.
Splitting the Tractor:
M94830
3. Remove all cap screws (M) attaching tunnel section
to differential housing. Note length and locations of
cap screws when removing.
4. Gently pry around edges to separate tractor halves.
5. Roll engine and tunnel section away from
differential housing.
Assemble Tractor Halves:
JTO 7335
N
M94891
M94831
1. Using four suitable cap screws, secure two JTO
7335 splitting stands to the tunnel, or engine
section of the tractor. Adjust splitting stands so that
wheels contact the floor, and are parallel to the
tractor wheels.
2. Using suitable stands or an overhead crane,
support the differential housing of the tractor to
prevent it from tipping.
8 - 34
1. If removed, install PTO drive shaft (N) to tunnel
(front) section of tractor.
4/6/01
TRACTOR SPLITTING (REAR)
FINAL DRIVE POWER TRAIN
D
E
C
O
P
M94686
M94832
(Hydrostatic Model Shown)
2. Install drive shaft (O) and coupler (P) to tunnel
(front) section of tractor.
3. Clean mating surfaces of tunnel and differential
housing to remove old sealant.
4. Apply a bead of sealant to flanges of one of the
tractor sections.
5. Roll front section of tractor to rear section.
6. Align tractor halves:
• Adjust splitting stands as required to align shafts,
locator bushings, and cap screw holes.
• Engage rear PTO.
• Using a suitable wire hook, lift and support the PTO
drive shaft while applying light pressure to the
tractor halves until PTO shaft engages splines on
clutch/brake coupler. If necessary, rotate PTO stub
shaft at rear of tractor to align splines on shaft with
coupler.
• If necessary, use a suitable wire hook to raise drive
shaft slightly to align gear teeth and shaft end with
gears and bearing in bearing plate.
7. Move tractor sections together and retain with cap
screws in locations as noted during disassembly.
Tighten cap screws to 126 - 154 N•m (95 - 115 lbft).
8. Remove splitting stands.
4/6/01
NOTE: On hydrostatic models, differential lock lever is
located on the LH side of the tractor. On gear
models, it is located on the RH side.
9. Reconnect differential lock rod (E) to lever (C).
Install washer and a new cotter pin (D).
B
A
M94685
10. Reconnect lower brake rods at rear brake levers.
• (A) Straight Rod and Clevis Style - Insert pin
through clevis and brake lever, and secure with
washer and cotter pin.
• (B) Turnbuckle Rod and Pin Style - Insert end of rod
through brake lever and secure with washer and
cotter pin.
8 - 35
TRACTOR SPLITTING (REAR)
FINAL DRIVE POWER TRAIN
F
L
M94834
M94813
11. Install a new gasket, and attach suction tube
manifold to differential housing. Retain with two
cap screws (L).
14. Install tube clamp to SCV pressure tube. Retain
with cap screw (F).
K
J
G
M91867
M91982
12. Attach SCV pressure tube to rear gear pump.
Tighten tube nut (G) to 55 - 79 N•m (40 - 59 lb-ft).
15. Install tube support bracket and tubes as an
assembly. Install two spacers (K) and two cap
screws (J) that attach tube support bracket to
frame.
H
I
M91995
13. Attach SCV pressure tube to SCV. Tighten tube nut
(H) to 55 - 79 N•m (40 - 59 lb-ft).
M91391
16. Connect SCV work port tubes (I) to SCV. Tighten
tube nuts to 40 - 57 N•m (30 - 43 lb-ft).
17. Route wiring harness to rear of tractor. Connect
electrical connectors as marked at disassembly.
8 - 36
4/6/01
FINAL DRIVE POWER TRAIN
RANGE TRANSMISSION REMOVAL AND INSTALLATION
18. Install operator’s platform. (See "OPERATORS
PLATFORM" in Miscellaneous section).
19. Install kick plate. (See "KICK PLATE" in
Miscellaneous section.)
20. Install seat support. (See "SEAT AND SEAT
SUPPORT" in Miscellaneous section.)
21. Install seat.
22. Install fenders. (See "REAR FENDERS" in
Miscellaneous section.)
23. Install LH and RH closeout panels. (See "SEAT
CLOSE OUT PANELS" in Miscellaneous section.)
24. Connect the battery negative terminal.
25. Refill hydraulic oil reservoir to proper level.
26. Bleed air from hydraulic system. (See
"HYDRAULIC SYSTEM BLEED PROCEDURE" in
Hydraulic section.)
RANGE TRANSMISSION REMOVAL
AND INSTALLATION
C
M94846
3. Remove spring pin (C) from shift lever arm. Push
shift shaft into case as far as it will go.
Removal:
1. Split tractor at rear of tunnel. (See "TRACTOR
SPLITTING REAR".)
B
D
A
E
M94832
2. Remove drive shaft (A) and coupler from bearing
plate (B) as an assembly.
M94833
4. Remove four cap screws (D) from bearing plate.
Remove detent shaft locking plate (E) and pull out
detent shaft (arrow).
NOTE: Ball and spring for shift detent will fall into
differential housing.
5. Pry around edges of cover to loosen shafts and
bearings. Do not attempt to remove at this time.
4/6/01
8 - 37
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
8. Retrieve ball and spring from differential case.
Disassembly:
F
M94848
6. Using a suitable pin punch or screwdriver, rotate
shift fork assembly (F) on shift collars to clear
housing during removal.
NOTE: This will not work on all tractors. If you are
unable to rotate the assembly from the lever,
you must remove the rockshaft assembly to
gain access to the spring pin which retains the
lever to the shaft. After removing the spring pin
you can rotate the shifter block to allow
transmission removal from the housing.
M94839
1. Remove shim pack from transmission cover and
gears.
G
H
M94840
2. Remove snap ring (G) from end of counter shaft.
Remove 34 tooth gear (H).
M94862
7. Remove range transmission with shift forks as an
assembly.
8 - 38
4/6/01
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
Differential Pinion Shaft Removal & Disassembly:
L
I
K
M94814
M94841
1. Remove two nuts (K) and washer from end of pinion
shaft. Remove 23 or 25 tooth gear (L).
3. Using a press or plastic mallet, remove counter
shaft (I) and gears from bearing plate as an
assembly.
(44 T)
J
M
(28 T)
M94815
2. Using a press or a plastic mallet, remove pinion
shaft (M) from outer bearing cone and bearing
plate.
M94842
4. Remove 44 tooth gear, spacer (J), and 28 tooth
gear from counter shaft.
5. Using a suitable puller or press, remove bearing.
Inspect bearing for smooth operation, wear, or
damage. Replace as necessary.
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
4/6/01
M94843
8 - 39
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
3. Inspect outer bearing for smooth operation, wear, or
damage. Replace as necessary.
IMPORTANT:
DO NOT spin bearings using
compressed air. Damage to bearing balls, cage,
and races could result.
N
M94845
NOTE: It is not necessary to remove snap ring from
bearing to remove bearing from bearing plate.
Snap ring locates bearing to proper depth.
M94817
6. Using a suitable bearing driver and plastic mallet or
press, remove drive shaft bearing from bearing
plate. Inspect bearing for smooth operation, wear,
or damage. Replace as necessary.
4. Remove spacer washer (N) from pinion shaft.
Inspect inner bearing for smooth operation, wear,
or damage. Replace as necessary.
O
M94818
M94844
5. Remove snap ring (O) and counter shaft bearing
from bearing plate. Inspect bearing for smooth
operation, wear, or damage. Replace as
necessary.
8 - 40
7. Using a suitable puller or press, remove inner
bearing cone and spacer from pinion shaft.
4/6/01
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
(36 T)
(20 T)
P
M94822
M94819
11. Remove 36 tooth gear.
8. Remove 20 tooth gear and bushing (P).
M94823
M94820
12. Remove bushing.
9. Remove shift collar.
M94821
10. Remove splined sleeve.
4/6/01
M94824
13. Remove shift collar.
8 - 41
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
16. Remove bushing.
M94825
14. Remove splined sleeve.
M94828
17. Remove spacer.
(50 T)
M94826
15. Remove 50 tooth gear.
M94829
18. Using a suitable puller or press, remove bearing
from pinion shaft. Inspect bearing for smooth
operation, wear, or damage. Replace as
necessary.
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
Assembly:
M94827
8 - 42
1. Inspect all parts to ensure that they are in good
condition. Replace as necessary. Dip press-fit parts
in hydraulic oil before assembling.
2. Press bearing onto pinion shaft.
3. Install spacer.
4/6/01
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
4. Install bushing.
5. Install 50 tooth gear.
6. Install splined sleeve.
7. Install shift collar.
8. Install bushing.
9. Install 36 tooth gear.
10. Install splined sleeve.
11. Install shift collar.
O
M94844
15. If removed, install counter shaft bearing into
bearing plate. Retain with snap ring (O).
(20 T)
P
M94819
12. Install bushing (P), and 20 tooth gear.
M94845
16. If removed, install drive shaft bearing into bearing
plate as shown using a press.
M94818
N
13. Install spacer on top of gear.
14. Using a suitable bearing driver or press, install
bearing onto shaft with the flat side towards the
spacer.
M94817
17. Install spacer washer (N) on top of bearing cone.
4/6/01
8 - 43
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
(44 T)
J
(28 T)
M
M94815
18. Install pinion shaft (M) with gears through bearing
plate and outer bearing cone. Press or drive outer
bearing cone onto shaft until it contacts the spacer
washer.
M94842
22. Press bearing onto end of counter shaft. Install 28
tooth gear, spacer (J), and 44 tooth gear onto
shaft.
L
I
K
M94814
19. Install 23 or 25 tooth gear (L).
NOTE: Apply Loctite® to inner and outer nuts when
installing.
20. Install washer and inner nut. Tighten nut to 136
N•m (100 lb-ft). Rotate the pinion shaft back and
forth to seat bearing while tightening.
21. Install outer nut (K). Tighten nut to 136 N•m (100
lb-ft).
8 - 44
M94841
23. Using a press, or plastic mallet, install counter shaft
(I) into bearing and bearing plate.
4/6/01
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
G
(34 T)
M94840
24. Install 34 tooth gear onto end of shaft. Retain with
snap ring (G).
Adjust Pinion Depth:
M94839
NOTE: Adjust pinion depth only if ring gear and pinion
were replaced. If ring and pinion were not
replaced, use same shim pack, or same
number of shims as were removed at
disassembly.
2. Install the shim pack onto the bearing plate, and
check measurement from bearing face to shim
pack to be sure that it is within specification.
Installation:
NOTE: Complete shift fork assembly if shift fork was
disassembled.
M94857
M94859
1. Measure from the mounting face of the bearing
plate to the rear of the bearing on the pinion shaft.
Calculate the amount of shims required to bring this
dimension within specification, and make up the
appropriate shim pack.
1. Install detent ball and spring into shift fork
assembly.
NOTE: Shims are 0.25 mm (0.010 in.) each.
Specification:
Pinion Depth . 168.58 - 168.84 mm (6.637 - 6.647 in.)
4/6/01
8 - 45
RANGE TRANSMISSION REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
M94860
2. Insert JDG 1260 detent ball tool into shift fork to
retain ball and spring during installation.
IMPORTANT: Shift forks are each marked with an
"F". This marking should face bearing plate
(front of tractor).
M94862
JDG 1260
4. Remove guide bushings from differential housing
and install to bearing plate to hold shim pack in
place during installation.
5. While holding shift fork assembly in place, install
range transmission to differential housing. If
necessary, use detent shaft and cap screws to
help with alignment. Check to make sure counter
shaft bearing is properly aligned with bore at rear
of differential housing while installing.
6. Using a plastic mallet, tap on end of pinion shaft to
seat bearing in differential housing bore.
M94861
3. Install shift fork assembly to shift collars on range
transmission.
8 - 46
IMPORTANT: Damage to bearings or transmission
may result if pinion bearing and counter shaft
bearing are not properly aligned when
tightening
four
cap
screws
retaining
transmission to differential housing.
7. Carefully tighten four cap screws evenly to draw the
assembly into place.
4/6/01
FINAL DRIVE POWER TRAIN
RANGE TRANSMISSION REMOVAL AND INSTALLATION
E
F
M94847
M94848
10. Remove lower left cap screw, and install detent
shaft retainer plate. Install cap screw. Do not
tighten cap screws at this time.
11. Remove suction filter from bottom of differential
housing.
8. Rotate shift fork assembly (F) into place. Be sure
shift fork pin engages slot in shift lever inside case.
JDG 1260
M94858
M94863
9. Insert detent shaft into hole in cover. Align shift fork
assembly through MFWD bearing hole and push
detent shaft through shift fork and into rear of
differential housing. Detent shaft tool JDG 1260
will drop into bottom of differential housing.
4/6/01
12. Using a magnetic pickup or similar tool, retrieve
JDG 1260 detent ball tool from differential housing.
8 - 47
FINAL DRIVE REMOVAL
FINAL DRIVE POWER TRAIN
FINAL DRIVE REMOVAL
Left Hand Final Drive Removal:
C
NOTE: Hydrostatic model tractor has differential
locking lever located on left hand final drive
housing.
c CAUTION
M94864
13. Pull shift shaft out, and install shift lever arm. Install
spring pin (C). Check shift lever for proper
operation.
14. Remove lower left cap screw and install detent
shaft retainer plate (E). Install cap screw.
15. Tighten four cap screws retaining range
transmission to 50 - 60 N•m (36 - 44 lb-ft).
16. Adjust differential backlash. (See "DIFFERENTIAL
BACKLASH ADJUSTMENT").
17. Assemble tractor halves. (See "TRACTOR
SPLITTING REAR").
Unexpected tractor movement. Front axle pivot
will allow tractor to tilt. Make sure tunnel and
opposite final drive are adequately supported
before removing final drive.
1. Raise rear of tractor and support on suitable stands.
2. Remove draft arms and adjustable sway bars. (See
"THREE POINT HITCH" in Miscellaneous
section.)
3. Remove wheel and tire.
A
M94684
4. Remove four cap screws (A) and nuts retaining
ROPS to final drive housing. If necessary, support
ROPS using an overhead crane. Remove lower
support plate.
C
8 - 48
B
4/6/01
FINAL DRIVE REMOVAL
FINAL DRIVE POWER TRAIN
c CAUTION
D
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
C
K
B
M94685
5. Disconnect brake return spring (B) from brake lever.
Remove spring.
6. Disconnect lower brake rod (C) from brake lever.
7. Side Mount Parking Brake Only: Disconnect park
brake rod (D) from brake lever.
E
M94687
F
H
11. Remove eight cap screws (K) securing final drive to
transmission housing.
12. Gently pry around edges of cover and remove final
drive from transmission housing.
G
Right Hand Final Drive Removal:
I
NOTE: Gear tractors have differential locking lever
located on right hand final drive housing.
J
c CAUTION
M94686
8. (HST Model) Remove cotter pin (E) and washer and
disconnect differential lock rod (F) from differential
lock lever (G).
9. (HST Model) Remove roll pin (H) and differential
lock lever from shaft.
10. Remove roll pin (I) and brake lever (J) from shaft.
4/6/01
Avoid unexpected tractor movement. Front axle
pivot will allow tractor to tilt. Make sure tunnel
and opposite final drive are adequately
supported before removing final drive.
1. Raise rear of tractor and support on suitable stands.
2. Remove draft arms and adjustable sway bars. (See
"THREE POINT HITCH" in Miscellaneous
section.)
3. Remove wheel and tire.
8 - 49
FINAL DRIVE REMOVAL
FINAL DRIVE POWER TRAIN
Q
T
M
R
S
L
N
U
V
M94701
4. Disconnect brake return spring (L) from brake lever.
Remove spring.
5. Side Mount Parking Brake Only: Disconnect park
brake rod (M) from brake lever.
6. Disconnect lower brake rod (N) from brake lever.
O
M94703
8. (CST Model) Remove cotter pin (Q) and washer
and disconnect differential lock rod (R) from
differential lock lever (S).
9. (CST Model) Remove roll pin (T) and differential
lock lever from shaft.
10. Remove roll pin (U) and brake lever (V) from shaft.
c CAUTION
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
W
P
M94702
7. Remove four cap screws (O) and nuts retaining
ROPS to final drive housing. If necessary, support
ROPS using an overhead crane. Remove lower
support plate (P).
M94704
8 - 50
4/6/01
FINAL DRIVE INSTALLATION
FINAL DRIVE POWER TRAIN
11. Remove eight cap screws (W) securing final drive
to transmission housing.
12. Gently pry around edges of cover and remove final
drive from transmission housing.
IMPORTANT: Be sure that pinion shaft bottoms out
in brake plates and disks before installing final
drive assembly. Damage to final drive, brake
parts, and differential may result from improper
installation.
FINAL DRIVE INSTALLATION
Left Hand Final Drive Installation:
c CAUTION
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
Y
X
M94700
M94693
1. Install a new differential lock shaft seal (X) into final
drive housing.
3. Install pinion shaft (Y) through brake plates and
disks, and into differential carrier.
4. Make sure mating surfaces of final drive and
transmission housing are clean and dry. Apply a
bead of LOCTITE™ 515 sealant to the flanges of
the final drive housing.
c CAUTION
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
Y
M94688
2. Remove pinion shaft (Y) from final drive assembly.
4/6/01
8 - 51
FINAL DRIVE INSTALLATION
FINAL DRIVE POWER TRAIN
O
W
M94687
5. Install final drive onto transmission housing and
retain with eight cap screws (W). Apply Loctite®
515 to indicated (arrow) cap screw. Tighten cap
screws to 305 N•m (225 lb-ft).
M94684
9. Align ROPS base plate with pin (arrow) on final
drive housing. Install lower support plate and
retain with four cap screws (O) and nuts. Tighten
cap screws and nuts to specification.
E
Torque Specification:
F
H
Cap Screws and Nuts . . . . . . . . 305 N•m (225 lb-ft).
G
M
I
J
N
M94686
6. (HST Model) Install differential lock lever (G) onto
shaft. Retain with roll pin (H).
7. (HST Model) Attach differential lock rod (F) to
differential lock lever. Retain with cotter pin (E) and
washer.
8. Install brake lever (J) onto brake shaft. Retain with
roll pin (I).
8 - 52
L
M94685
10. Attach lower brake rod (N) to brake lever. Retain
with pin, or pin, cotter pin, and washer.
11. Side Mount Parking Brake Only: Attach park
brake rod (M) to brake lever. Retain with clip pin.
12. Install brake return spring (L) to brake lever and
ROPS cap screw.
4/6/01
FINAL DRIVE INSTALLATION
FINAL DRIVE POWER TRAIN
Right Hand Final Drive Installation:
c CAUTION
c CAUTION
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
Final drive/axle housings weigh approximately
34 kg (75 lbs.) each. If necessary, use a suitable
lifting device or get assistance before removing
cap screws securing final drive to transmission
housing.
W
Z
M94706
1. Install a new differential lock shaft seal (Z) into final
drive housing.
M94704
IMPORTANT: Be sure that pinion shaft bottoms out
in brake plates and disks before installing final
drive assembly. Damage to final drive, brake
parts, and differential may result from improper
installation.
4. Install final drive onto transmission housing and
retain with eight cap screws (W). Apply Loctite®
515 to indicated (arrow) cap screw. Tighten cap
screws to 305 N•m (225 lb-ft).
Q
T
R
S
U
M94703
V
M94705
2. Install pinion shaft through brake plates, disks, and
differential lock collar, and into differential carrier.
3. Make sure mating surfaces of final drive and
transmission housing are clean and dry. Apply a
bead of LOCTITE® 515 sealant to the flanges of
the final drive housing.
4/6/01
5. (CST Model) Install differential lock lever (S) onto
shaft. Retain with roll pin (T).
6. (CST Model) Attach differential lock rod (R) to
differential lock lever. Retain with cotter pin (Q) and
washer.
8 - 53
FINAL DRIVE DISASSEMBLY, INSPECTION & ASSEMBLY
7. Install brake lever (V) onto brake shaft. Retain with
roll pin (U).
O
FINAL DRIVE POWER TRAIN
FINAL DRIVE DISASSEMBLY,
INSPECTION & ASSEMBLY
NOTE: Hydrostatic model left hand final drive is shown
in the following story. Right hand drive
disassembly, inspection and assembly is
basically the same.
1. Remove final drive to be serviced from the machine.
(See FINAL DRIVE REMOVAL).
P
M94702
A
8. Align ROPS base plate with pin on final drive
housing. Install lower support plate (P) and retain
with four cap screws (O) and nuts. Tighten to 305
N•m (225 lb-ft).
B
M94688
2. Remove snap ring (A) retaining gear to axle shaft.
Remove gear.
3. Remove pinion shaft (B) from bearing.
4. Using a press, remove axle shaft from final drive
housing.
M
C
L
N
M94701
9. Attach lower brake rod (N) to brake lever. Retain
with clevis pin or pin, cotter pin, and washer.
10. Side Mount Parking Brake Only: Attach park
brake rod (M) to brake lever. Retain with clip pin.
11. Install brake return spring (L) to brake lever and
ROPS cap screw.
8 - 54
M94689
5. Remove three cap screws (C) and seal retainer
plate.
4/6/01
DIFFERENTIAL
FINAL DRIVE POWER TRAIN
Assembly:
Parts are assembled
disassembly.
in
the
reverse
order
of
IMPORTANT: Replace O-rings and seals. Used Orings and seals will leak.
• Lubricate bearings with transmission oil before
installing into housing.
DIFFERENTIAL
Removal:
M94690
6. Remove seal and outer axle bearing. Inspect
bearings for smooth operation, excessive wear, or
damage. Replace as required.
1. Remove right hand final drive. (See "FINAL DRIVE
REMOVAL").
2. Remove brake assembly. (See “BRAKE
DISASSEMBLY AND INSPECTION” on page 19 of
the Brakes section.)
3. Remove differential lock fork. (See "DIFFERENTIAL
LOCK REMOVAL AND INSTALLATION").
A
D
E
M94691
7. Remove inner axle shaft bearing (D). Inspect
bearing for wear or damage. Replace if necessary.
8. Using a suitable puller, remove pinion shaft bearing
(E). Inspect bearing for smooth operation,
excessive wear, or damage. Replace as required.
M94797
4. If not already done, remove differential lock collar
(A).
5. Remove RH brake/differential lock collar housing.
F
M94693
M94798
9. Remove differential lock shaft seal (F).
6. Remove shims.
4/6/01
8 - 55
DIFFERENTIAL
FINAL DRIVE POWER TRAIN
D
B
M94801
M94799
7. Remove differential carrier (B) from left pinion shaft
and transmission housing.
Disassembly:
3. Remove bearing (D).
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
4. Inspect bearing for smooth operation, wear, or
damage. Replace if necessary.
C
E
M94800
1. Remove bearing (C) from differential.
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
2. Inspect bearing for smooth operation, wear, or
damage. Replace if necessary.
8 - 56
M94802
NOTE: Cap screws retaining ring gear to differential
housing are held in place with LOCTITE®
5. Remove eight cap screws (E).
6. Using a plastic mallet, separate ring gear from
differential housing.
4/6/01
DIFFERENTIAL
FINAL DRIVE POWER TRAIN
H
F
M94803
7. Locate pinion shaft retaining pin (F). Heat retaining
pin and differential carrier to melt thread locking
adhesive. Remove pin.
G
K
H
M94807
10. Remove two bevel gears (H) and two thrust
washers (K) from differential housing.
11. Clean all components in a suitable solvent.
12. Inspect all parts for wear or damage. Replace as
required.
Assembly:
M94804
8. Remove pinion shaft (G) from differential housing.
Assembly of the differential is the reverse of
disassembly.
• Apply LOCTITE® 277 to threads of pinion shaft
retaining pin.
• Apply LOCTITE® 277 to threads of ring gear
retaining cap screws.
• Tighten 10 mm ring gear retaining cap screws to 68
N•m (50 lb-ft).
• Adjust backlash of differential. (See
"DIFFERENTIAL BACKLASH ADJUSTMENT").
I
H
J
M94806
9. Rotate bevel gears (H) and remove differential
pinion gears (I) and cupped pinion washers (J)
from differential housing.
4/6/01
8 - 57
DIFFERENTIAL LOCK REMOVAL AND INSTALLATION
DIFFERENTIAL LOCK REMOVAL
AND INSTALLATION
Removal:
1. Remove rockshaft assembly. (See "ROCKSHAFT
ASSEMBLY") in Hydraulic section.)
2. Remove RH final drive assembly. (See "FINAL
DRIVE REMOVAL").
FINAL DRIVE POWER TRAIN
NOTE: Spring is under tension.
8. Remove roll pin (F) from LH side of spring.
9. Remove remaining roll pin (G) between spring and
shift fork.
H
A
D
B
C
M94795
IMPORTANT: Note the number of shims and their
location on either side of snap ring (H) to aid in
reassembly.
M94686
3. (HST Model) Remove cotter pin (A) and washer and
disconnect differential lock rod (B) from differential
lock lever (C).
4. (HST Model) Remove roll pin (D) and differential
lock lever from shaft.
5. Remove rear PTO shafts and gears. (See REAR
PTO SHAFTS AND GEARS REMOVAL AND
INSTALLATION").
6. Remove PTO clutch/brake assembly. (See "PTO
CLUTCH AND BRAKE REMOVAL AND
INSTALLATION").
10. Slide shaft to right, and remove from differential
housing.
11. Remove washer, spring, and shift fork from center
of differential housing. Remove shift collar from RH
side of differential housing.
G
F
E
M94796
7. Remove roll pin (E) from RH side of shift fork.
8 - 58
4/6/01
DIFFERENTIAL LOCK REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
Installation:
A
B
D
C
Installation of the differential lock fork is the reverse of
removal.
NOTE: When installing shims, adjust shift fork (A) so
that there is approximately 0.51 - 2.0 mm
(0.020 - 0.080 in.) (B) of space between the
differential carrier (C) and the shift collar (D).
4/6/01
8 - 59
PTO COMPONENT LOCATION
FINAL DRIVE POWER TRAIN
PTO COMPONENT LOCATION
PTO BRAKE
2
1
4
3
5
6
7
9
8
10
12
11
15
13
14
16
18
23
19
17
20
21
22
24
25
26
27
M95033A
28
29
8 - 60
4/6/01
PTO BRAKE
FINAL DRIVE POWER TRAIN
1. O-Ring
9. Collar
17. Bearing Plate
25. Spring (4)
2. Lever
10. Shaft
18. Bearing
26. Lifter Assembly
3. Cap Screw
11. Washer
19. Basket
27. Cap Screw
4. Shaft
12. Bearing
20. Retainer
28. Snap Ring
5. Shift Fork
13. Snap Ring
21. Piston
29. Washer
6. Sleeve
14. Snap Ring
22. Disk, Friction
30.
7. Shoe
15. Cap Screw
23. Plate, Separator
8. Spring
16. Dowel Pin
24. Hub
4/6/01
8 - 61
PTO CLUTCH
FINAL DRIVE POWER TRAIN
PTO CLUTCH
9
10
4
3
2
2
2
2
2
2
5
2
5
2
5
2
5
5
1
5
5
6
5
7
7
8
M95034
1. Retainer
4. Spring
7. Bearing
2. Disk, Friction
5. Plate, separator
8. Snap Ring
3. Hub
6. Housing
9. Cap Screw
8 - 62
10. Lever Assembly
4/6/01
REAR PTO
FINAL DRIVE POWER TRAIN
REAR PTO
10
9
12
11
7
6
14
13
8
5
15
13
4
3
17
18
16
19
2
20
1
18
M95035
21
1. Bearing
7. Bearing
13. Sight Glass
19. Snap Ring
2. Snap Ring
8. Seal
14. Cap Screw
20. Gear, 51 Tooth
3. Gear, 70 Tooth
9. Cover
15. Plug
21. Idler Shaft
4. Shaft
10. Cap Screw
16. Bushing
5. Bearing
11. Retainer
17. O-Ring
6. Shaft W/Gear, 14
Tooth
12. Screw
18. Bearing
4/6/01
8 - 63
2-SPEED PTO (EUROPEAN ONLY)
FINAL DRIVE POWER TRAIN
2-SPEED PTO (EUROPEAN ONLY)
14
13
16
15
12
1
11
2
17
18
3
10
19
9
38
8
4
7
4
37
35
18
5
34
36
6
33
32
7
7
22
23
31
21
20
24
30
6
24
29
25
M95037
26
27
28
1. Lever
11. Shaft
21. O-Ring
31. Shaft
2. Cap Screw
12. O-Ring
22. Seal
32. Lever
3. Shaft
13. Cover
23. Gear, 69 Tooth
33. Shift Fork
4. Spring Pin
14. Cap Screw
24. Bearing
34. Spring
5. Cap
15. Retainer
25. Gear, 51 Tooth
35. Ball
6. Snap Ring
16. Screw
26. Pinion Shaft
36. Dowel Pin
7. Bearing
17. Sight Glass
27. Shift Collar
37. Lever
8. Thrust Washer
18. Cap Screw
28. Thrust Washer
38. O-Ring
9. Pinion Shaft
19. Plug
29. Bearing
20. Bushing
30. Gear, 65 Tooth
10. Bearing
8 - 64
4/6/01
MID PTO
FINAL DRIVE POWER TRAIN
MID PTO
2
3
1
4
5
6
7
8
14
15
10
16
12
13
17
9
11
18
19
20
M95036
1. Lever
6. Spring
11. Bearing
16. Snap Ring
2. Spring Pin
7. Shaft
12. Shift Fork
17. Shaft
3. Shaft
8. Pin
13. Gear, 25 Tooth
18. Seal
4. Housing
9. Lever
14. Snap Ring
19. Retainer
15. Bearing
20. Screw
5. Ball
4/6/01
10. Pin
8 - 65
MID PTO DRIVE SHAFT
FINAL DRIVE POWER TRAIN
MID PTO DRIVE SHAFT
4
6
5
4
3
2
1
7
8
9
10
11
12
13
14
M95046
1. Cap
5. Gear, 25 Tooth
2. Shaft
6. Sleeve
10. Shaft W/18 Tooth Gear
3. Spring Pin
7. Plug
11. Gear, 27 Tooth
4. Thrust Washer
8. Snap Ring
12. Bearing
8 - 66
9. Bearing
13. Snap Ring
14. Plug
4/6/01
PTO THEORY OF OPERATION
FINAL DRIVE POWER TRAIN
PTO THEORY OF OPERATION
POWER TRANSMISSION – PTO
CLUTCH AND BRAKE
Brake Housing
Clutch Pack
Brake Pack
Clutch Housing
Brake Hub
Lever
Clutch Hub
Lever
Engine
Input
Shaft
PTO
Driveshaft
Brake Spring
Clutch Spring
Input Power
Power Transfer
Brake Piston
Clutch Piston
Function:
The PTO clutch provides a means for disengaging the
PTO output shaft from the engine. The PTO brake is
provided to positively stop the rotation of the PTO
system when the PTO clutch is disengaged. The PTO
clutch and PTO brake work simultaneously. Both mid
and rear PTOs are affected by the operation of the PTO
clutch and PTO brake.
Theory:
The PTO clutch and PTO brake are engaged or
disengaged by the operator through a mechanical
linkage which moves a shift collar.
The PTO brake is a spring loaded multi-plate wet brake
and is normally engaged, preventing the PTO clutch
shaft from rotating. The PTO clutch is a multi-plate wet
clutch and is normally disengaged.
position. This turns the levers on the PTO brake,
compressing the brake springs. This releases spring
pressure on the brake piston and brake pack, and
disengages the brake. At the same time, the levers on
the clutch are released, allowing the springs in the
clutch to expand, pressing the clutch piston against the
clutch pack, and engaging the PTO clutch. Pressure
applied to the clutch pack locks the plates (splined to
the clutch hub), to the friction disks (locked to the clutch
housing). Power is transferred from the input shaft to
the clutch housing, through the clutch plates and disks,
to the clutch hub, and finally to the PTO drive shaft.
A locking tab on the outside of the brake housing
allows the PTO drive shaft to rotate approximately
330°, which, in turn allows the PTO stub shaft to rotate
approximately 65° to aid in aligning the splines of an
attachment driveshaft during hook-up.
When the PTO lever is moved to the forward (engaged)
position, the shift collar is moved to the rearward
4/6/01
8 - 67
POWER TRANSMISSION – REAR PTO
FINAL DRIVE POWER TRAIN
POWER TRANSMISSION – REAR
PTO
14 Tooth Gear
PTO Pinion Shaft
PTO Drive Shaft
(From Clutch/Brake
Unit)
69 Tooth Gear
PTO Stub Shaft
51 Tooth Gear
Idler Shaft
Input Power
PTO Power
Mid PTO Power Transfer
Function:
The rear PTO provides a means for transferring engine
power to rear mounted attachments.
Theory:
clockwise when looking at the end of the PTO shaft
from the rear of the tractor. The rear PTO runs
independently of the tractor forward or rearward
motion, or rate of travel. Speed of the PTO is
dependent on engne RPM. The rear PTO is limited to
580 RPM at maximum engine speed.
Power is provided to the PTO gear power train through
PTO clutch and PTO drive shaft. Power is not
transferred until the operator engages the PTO lever
(See “POWER TRANSMISSION — PTO CLUTCH
AND BRAKE”.) The PTO driveshaft turns in a counterclockwise direction and is coupled directly to the PTO
pinion shaft. The PTO pinion shaft is a shaft and 14
tooth gear machined as a single part. This 14 tooth
gear is in constant mesh with the 70 tooth gear which is
splined to the PTO stub shaft, and rotates in a
clockwise direction. The rear PTO always turns
8 - 68
4/6/01
FINAL DRIVE POWER TRAIN
POWER TRANSMISSION – 2 -SPEED PTO (EUROPEAN ONLY)
POWER TRANSMISSION – 2 -SPEED
PTO (EUROPEAN ONLY)
14 Tooth Gear
18 Tooth Gear
PTO Shaft (From
Clutch/Brake Unit)
PTO Pinion Shaft
69 Tooth Gear
PTO Stub Shaft
65 Tooth Gear
Shift Collar
Idler Shaft
Input Power
Power Transfer (750 RPM)
Power Transfer (540 RPM)
51 Tooth Gear
PTO Power
Mid PTO Power Transfer
Function:
The rear PTO provides a means for transferring engine
power to rear mounted attachments.
Theory:
Power is provided to the PTO gear power train through
PTO clutch and PTO drive shaft. Power is not
transferred until the operator engages the PTO lever
(See “POWER TRANSMISSION – PTO CLUTCH AND
BRAKE”.) The PTO driveshaft turns in a counterclockwise direction and is coupled directly to the PTO
pinion shaft. The PTO pinion shaft is a shaft with a 14
tooth, and 18 tooth gear machined as a single part.
The 14 tooth gear is in constant mesh with the 69 tooth
gear. The 18 tooth gear is in constant mesh with the 65
tooth gear. Both the 65 and 69 tooth gears rotate freely
on the PTO stub shaft. Power is not transferred to the
PTO stub shaft until the shift collar is moved to engage
one of the two gears.
4/6/01
When the operator moves the PTO speed control lever
from the center (neutral) position to the HIGH or LOW
position, it moves the shift collar through a mechanical
linkage. The shift collar couples the PTO stub shaft to
the 65 or 69 tooth gear, transferring power from the
pinion shaft, through the gear to the shift collar, and to
the stub shaft.
The rear PTO always turns clockwise when looking at
the end of the PTO shaft from the rear of the tractor.
The rear PTO runs independently of the tractor forward
or rearward motion, or rate of travel. Speed of the PTO
is dependent on engne RPM. The rear PTO is limited to
580 RPM at maximum engine speed (low speed) and
800 RPM (high speed).
8 - 69
POWER TRANSMISSION – MID PTO
FINAL DRIVE POWER TRAIN
POWER TRANSMISSION – MID PTO
14 Tooth Gear
PTO Drive Shaft
Shift Fork
Mid PTO
Stub Shaft
69 Tooth Gear
Rear PTO Stub Shaft
25 Tooth Gear
SIDE VIEW
Mid PTO
Stub Shaft
25 Tooth Gear
51 Tooth Gear
Idler Shaft
27 Tooth Gear
25 Tooth
Gear
Idler Shaft
TOP VIEW
Mid PTO
Input Power
Drive Shaft
Rear PTO Power
Mid PTO Power Transfer
Mid PTO Power
Function:
The mid PTO provides a means for transferring engine
power to mid mount attachments such as a mower
deck. It also provides a means for engaging and
disengaging engine power to the mid PTO stub shaft.
Theory:
Power is provided to the mid PTO through the 70 tooth
gear which is splined to the rear PTO shaft and rotates
in
a
clockwise
direction.
(See
“POWER
TRANSMISSION – REAR PTO”.) Power is not
transferred until the operator engages PTO lever. (See
“POWER TRANSMISSION – PTO CLUTCH AND
BRAKE”.) A 51 tooth gear is in constant mesh with the
70 tooth gear, and is in constant mesh with the 18 tooth
8 - 70
18 Tooth Gear
SIDE VIEW
gear on the mid PTO drive shaft. The mid PTO drive
shaft rotates in a clockwise direction. Power is
transmitted through the mid PTO drive shaft to the 25
tooth gear, which is splined to the drive shaft, and is in
constant mesh with the 27 tooth gear. The 27 tooth
gear is splined to the PTO stub shaft and rotates in a
clockwise direction.
When the operator selects the mid PTO; a shift fork
moves the 25 tooth gear, which is splined to the PTO
stub shaft, to the rear-most position, engaging the teeth
of the 27 tooth gear, and allowing power to be
transmitted from the 27 tooth gear, through the 25 tooth
gear, and to the mid PTO stub shaft.
4/6/01
PTO TROUBLESHOOTING CHART
FINAL DRIVE POWER TRAIN
PTO clutch worn/ no longer serviceable
●
●
●
PTO brake worn/ no longer serviceable
Cogs on gear or shift collar worn/ no
longer serviceable
●
Gears worn/ no longer serviceable
●
●
●
●
●
●
●
●
●
●
Detent ball spring broken
Shift linkage worn or damaged
PTO does not stop quickly enough
after it is disengaged
PTO noisy
PTO slips
2 speed PTO will not stay engaged
2 speed PTO will not engage
Mid PTO does not stay engaged
Check or
Solution
Mid PTO does not engage
Rear PTO does not engage
Problem or
Symptom
Rear PTO will not stay engaged
PTO TROUBLESHOOTING CHART
●
●
●
●
PTO DIAGNOSIS
Test/Check Point
Normal
If Not Normal
A. PTO Lever
Smooth operation, engages PTO.
Lubricate linkage. Replace
damaged parts.
B. Mid PTO Lever
Smooth operation, engages PTO.
Lubricate linkage. Replace
damaged parts.
C. 2-Speed PTO Lever
Smooth operation, engages PTO.
Lubricate linkage. Replace
damaged parts.
D. Linkage
Not bent or binding.
Lubricate linkage or replace
damaged parts.
4/6/01
8 - 71
PTO REPAIR
FINAL DRIVE POWER TRAIN
PTO REPAIR
REAR PTO SHAFTS AND GEARS
REMOVAL AND INSTALLATION
D
Removal:
D
1. Park tractor on a level surface, shut off engine, and
set park brake.
2. If necessary, remove center lift link, draft arms, and
adjustable draft links.
M94711
A
6. Remove four cap screws (D) and rear PTO shield
support bracket.
M94710
E
3. Remove two cap screws (A), spacers, nuts, and
rear PTO shield assembly.
B
C
M94711
4. Remove two cap screws (B) and rear draw bar
bracket (C).
NOTE: Capacity of the hydraulic system is
approximately 26 liters (6.8 gal) for HST
models; or 24 liters (6.3 gal) for CST, SST
and SRT models.
5. Drain hydraulic oil from reservoir.
8 - 72
M94711
NOTE: Top center and bottom center cap screws in
rear cover are longer.
7. Remove eight cap screws (E).
8. If necessary, loosen two rearmost cap screws
attaching final drive housings to differential
housing (arrows).
9. Gently pry around edges of cover to break sealant.
Wobble shaft and pull at the same time to remove
rear cover, shafts and gears as a unit.
4/6/01
FINAL DRIVE POWER TRAINREAR PTO SHAFTS AND GEARS REMOVAL AND INSTALLATION
NOTE: If equipped, mid PTO shaft may come out of
differential housing with rear cover, or may fall
into differential housing.
Installation:
Installation is the reverse of removal.
IMPORTANT: Replace all O-rings, gaskets, and
seals. Used or damaged O-rings, gaskets and
seals will leak.
• Thoroughly clean mating surfaces of rear cover and
transmission housing to remove all traces of old
gasket material.
• If tractor is equipped with two speed PTO, place
shift arm in forward position when installing. Make
sure shift fork pin engages shift arm yoke.
• Lay a bead of TY16021 Sealant on flange surfaces
of differential housing.
• Two longer cap screws are placed in the top center
and bottom center holes.
• If tractor is equipped with a mid PTO, follow steps
outlined below.
• Tighten cap screws retaining rear cover to 40 N•m
(30 lb-ft).
M94732
2. Install shaft and gear into roller bearing in rear
cover.
Mid PTO equipped tractors:
G
F
M94731
1. Remove mid PTO shaft from bottom of differential
housing. When shaft is removed, gear may fall into
differential housing. Retrieve gear and install on
front end of shaft.
4/6/01
M94733
H
3. If equipped, disconnect wiring harness connector
(F) from mid PTO switch.
4. Remove five cap screws (G) and mid PTO gear box
(H) from right side of differential housing.
5. Install cover with shafts and gears as an assembly
into differential housing. Do not install cap screws
at this time.
8 - 73
REAR PTO SHAFTS & GEARS DISASSEMBLY AND ASSEMBLY FINAL DRIVE POWER TRAIN
8. Install PTO guard support (K) and ten cap screws
(M). Install the two longer cap screws (L) in the
location shown. Tighten all cap screws to 40 N•m
(30 lb-ft).
9. If loosened, tighten two rearmost cap screws
attaching final drive housings to differential
housing (arrows).
10. Clean mating surfaces of mid PTO gear case and
differential housing.
11. Lay a bead of TY16021 Sealant on flange surfaces
of differential housing.
12. Install mid PTO gear case to differential housing,
and retain with five cap screws. Tighten cap
screws to 55 N•m (40 lb-ft).
13. If equipped, connect mid PTO wiring harness.
I
J
REAR PTO SHAFTS & GEARS
DISASSEMBLY AND ASSEMBLY
M94734
6. Slide gear (I) on mid PTO shaft forward slightly to
make sure it will mesh with gear in differential
housing.
7. Using a piece of stiff wire formed into a hook or
other suitable tool, lift mid PTO shaft slightly to
align end of shaft with bearing (J) in front of
differential housing. Install cover with shafts and
gears into differential housing. If equipped with a
2-speed PTO, check to make sure that shift fork
engages shift lever and linkage.
NOTE: For 2-speed PTO disassembly procedure, (See
2 SPEED PTO SHAFTS AND GEARS
DISASSEMBLY.)
1. Remove rear PTO drive shaft and gears as an
assembly. (See "REAR PTO SHAFTS AND GEARS
REMOVAL AND INSTALLATION").
A
C
K
M
M95276
M
L
2. Remove pinion shaft (A).
M94711
8 - 74
4/6/01
FINAL DRIVE POWER TRAIN REAR PTO SHAFTS & GEARS DISASSEMBLY AND ASSEMBLY
B
M94713
3. Remove cap screw (B) from cover that retains the
idler shaft (C). Remove idler shaft, 51 tooth gear,
and bearings as an assembly.
M95279
5. Inspect inner output shaft bearing for smooth
operation, wear or damage. Replace if needed.
6. Inspect 70 tooth gear for wear or damage. Replace
if needed.
70T
D
M95277
4. Using a plastic mallet, remove output shaft (D), 70
tooth gear, and bearings from rear cover.
M95280
7. Inspect outer output shaft bearing for smooth
operation, wear or damage. Replace if needed.
E
M94715
4/6/01
8 - 75
REAR PTO SHAFTS & GEARS DISASSEMBLY AND ASSEMBLY FINAL DRIVE POWER TRAIN
8. Remove O-ring (E) from end of idler shaft. Remove
gear.
H
F
M94729
M94716
9. Remove bearings from gear. If necessary, remove
snap ring (F). Inspect bearings for smooth
operation, wear or damage. Replace if needed.
12. Inspect pinion shaft bearing (H) in cover for smooth
operation, wear or damage. Replace if needed.
Assembly:
IMPORTANT:
DO NOT spin bearing using
compressed air. Damage to bearing balls, cage,
and races could result.
G
NOTE: Before beginning assembly, be sure that all
components are clean, and in good condition.
IMPORTANT: Use liberal amounts of transmission
oil to lubricate components as they are
assembled. DO NOT use grease or other heavy
lubricants unless they are specifically called for.
M94722
1. Clean mating surface of rear cover to remove old
gasket material.
10. Remove two screws and seal retainer (G).
11. Using a suitable seal driver, remove seal.
IMPORTANT: If sight glass is removed, it must be
installed so that the holes are vertical and
horizontal (see alignment lines in photo above).
M94728
1. Install bearings and snap ring into 51 tooth gear.
8 - 76
4/6/01
FINAL DRIVE POWER TRAIN REAR PTO SHAFTS & GEARS DISASSEMBLY AND ASSEMBLY
4. If removed, install snap ring (I) onto output shaft.
Install 70 tooth gear against snap ring.
5. Install inner and outer bearings.
E
H
J
M94715
2. Install idler gear onto idler shaft.
IMPORTANT: Replace all O-rings, gaskets, and
seals. Used or damaged O-rings, gaskets, and
seals will leak.
3. Install a new O-ring (E) onto idler shaft.
M94729
6. If removed, install pinion shaft bearing (H) into
cover.
7. Using a suitable driver, install a new PTO shaft seal
(J) in cover.
70T
M95280
M95277
8. Install output shaft, gear and bearings into cover as
an assembly. Use care to avoid damaging shaft
seal.
I
M95279
4/6/01
8 - 77
2-SPEED PTO SHAFTS AND GEARS DISASSEMBLY
FINAL DRIVE POWER TRAIN
A
G
M94713
9. Install seal retainer (G) and secure with two cap
screws.
A
M94712
C
2. Remove pinion shaft.
B
M95276
M94713
10. Install idler shaft (C) and gear into cover. Retain
with cap screw.
11. Install pinion shaft (A) into cover.
3. Remove cap screw (B) from cover that retains the
idler shaft.
NOTE: Check shafts to ensure that they are properly
installed in cover; if bearings are not fully
seated in cover, cover may break when PTO is
installed onto transmission housing and
attaching cap screws are tightened.
2-SPEED PTO SHAFTS AND GEARS
DISASSEMBLY
NOTE: The following procedure is for a tractor
equipped with a mid-PTO. Tractors
equipped with a mid-PTO are similar.
1. Remove rear PTO drive shaft and gears as an
assembly. ((See "REAR PTO SHAFTS AND
GEARS REMOVAL AND INSTALLATION").
8 - 78
not
C
M94714
4/6/01
2-SPEED PTO SHAFTS AND GEARS DISASSEMBLY
FINAL DRIVE POWER TRAIN
4. Remove idler shaft (C) and gear as an assembly.
smooth operation, wear, or damage. Replace as
necessary.
D
F
M94718
M94715
8. If necessary, remove snap ring (F) from hole in
cover.
5. Remove O-ring (D) from end of idler shaft. Remove
gear.
G
E
M94716
M94719
6. Remove bearings from gear. If necessary, remove
snap ring (E). Inspect bearings for smooth
operation, wear or damage. Replace if needed.
9. Slide shift collar up and remove 2-speed shift fork
and shaft (G) from cover.
M94717
7. (Mid PTO Equipped Tractors) Remove roller bearing
from bottom hole in cover. Inspect bearing for
4/6/01
8 - 79
2-SPEED PTO SHAFTS AND GEARS DISASSEMBLY
FINAL DRIVE POWER TRAIN
J
I
H
M94722
M94720
NOTE: Ball and spring in shift fork may jump and be
lost. Use care when removing shift shaft from
fork.
12. Remove two screws and seal retainer (J).
13. Using a suitable seal driver, remove seal.
NOTE: If sight glass is removed, it must be installed so
that the holes are vertical and horizontal (see
photo).
10. Remove shift shaft (H), ball, and spring from shift
fork. If necessary, remove snap ring (I).
K
M94723
M94721
11. Using a plastic mallet, remove PTO stub shaft and
gears from cover as an assembly.
8 - 80
14. Using a suitable puller, remove bearing (K) from
end of PTO shaft. Inspect bearings for smooth
operation, wear or damage. Replace as necessary.
4/6/01
FINAL DRIVE POWER TRAIN
2-SPEED PTO SHAFTS AND GEARS DISASSEMBLY
smooth operation, wear or damage. Replace as
necessary.
N
L
M94724
M94727
15. Remove washer (L) and gear from shaft.
18. Remove washer (N). Remove large gear and
bearings as an assembly.
M
M94725
16. Remove shift collar (M).
M94728
19. Remove bearings from gear. Inspect bearings for
smooth operation, wear or damage. Replace as
necessary.
M94726
17. Remove bearing from drive end of shaft. If
necessary, clean surface of shaft to remove paint
for easier bearing removal. Inspect bearing for
4/6/01
8 - 81
2-SPEED PTO SHAFTS AND GEARS ASSEMBLY
FINAL DRIVE POWER TRAIN
J
O
M94722
M94729
20. Remove pinion shaft bearing (O) from cover.
Inspect bearing for smooth operation, wear or
damage. Replace if needed.
2-SPEED PTO SHAFTS AND GEARS
ASSEMBLY
2. Install seal retainer plate (J) to rear cover, secure
with two screws.
NOTE: If sight glass is removed, it must be installed so
that the holes are vertical and horizontal (see
photo).
3. If removed, install sight glass into rear cover.
O
P
M94730
M94729
1. Using a suitable driver, install a new PTO stub shaft
seal (P) into rear cover until flush with outer
surface.
4. Install pinion shaft bearing (O) into rear cover.
M94717
8 - 82
4/6/01
FINAL DRIVE POWER TRAIN
2-SPEED PTO SHAFTS AND GEARS ASSEMBLY
5. If equipped, install mid-pto roller bearing into rear
cover.
M
M94725
9. Install shift collar (M) onto 69 tooth gear.
M94728
6. Install bearings and snap ring into 69 tooth gear.
N
L
M94724
M94727
10. Install 65 tooth gear and washer (L) onto stub shaft.
7. Install 69 tooth gear and washer (N) onto stub shaft.
K
M94723
M94726
8. Install bearing.
4/6/01
11. Install bearing (K) onto end of stub shaft.
8 - 83
2-SPEED PTO SHAFTS AND GEARS ASSEMBLY
FINAL DRIVE POWER TRAIN
G
M94719
M94721
12. Install stub shaft and gears into rear cover.
14. Slide shift collar up, and slide shift fork into groove
on collar. Install shift fork and shaft (G) as an
assembly into rear cover.
E
M94716
M94720
15. Install bearings and snap ring (E) into idler gear.
13. Assemble shift shaft, ball, and spring into shift fork.
D
M94715
16. Install idler gear onto idler shaft.
8 - 84
4/6/01
FINAL DRIVE POWER TRAIN
2-SPEED PTO SHAFTS AND GEARS ASSEMBLY
17. Install a new O-ring (D) onto idler shaft.
19. Install pinion shaft (A) into rear cover.
20. Install drive shaft and gears to tractor. ((See "REAR
PTO SHAFTS AND GEARS REMOVAL AND
INSTALLATION").
C
M94714
B
M94713
18. Install idler shaft (C) with gear into rear cover.
Retain with cap screw (B). Tighten cap screw to 55
N•m (40 lb-ft).
A
M94712
4/6/01
8 - 85
PTO CLUTCH AND BRAKE REMOVAL AND INSTALLATION
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE
REMOVAL AND INSTALLATION
Removal:
1. Remove rear PTO drive shaft and gears. ((See
"REAR PTO SHAFTS AND GEARS REMOVAL
AND INSTALLATION").
G
A
B
F
M94738
6. Remove cap screw (F) and locking plate (G).
C
H
M94735
I
2. If equipped, remove 2-speed PTO shift shaft (A).
3. If not already done, remove PTO stub shaft (B).
4. Remove four cap screws (C) and bearing plate.
D
E
M94736
7. Remove two spring pins (H) retaining shift fork to
shaft (I).
8. Slide shaft out of case until clear of shift fork.
NOTE: PTO drive shaft may or may not come out of
tunnel with clutch/brake unit.
M94737
5. Remove cotter pin (D) and washer, and disconnect
PTO control rod (E) from lever at differential
housing.
M94739
9. Remove PTO clutch/brake assembly and shift fork
as a unit.
8 - 86
4/6/01
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE REMOVAL AND INSTALLATION
NOTE: When installing bearing plate onto clutch/brake
assembly, it may be necessary to align brake
plate tabs to allow housing to be properly
installed on brake pack.
J
10. If PTO brake basket needs replacement, remove
three cap screws (J) from bearing plate.
MX1398
L
K
13. Install oil deflector as shown, securing with upper
left cap screw. Tighten cap screws retaining
bearing plate to specification.
Specification:
Bearing Plate Cap Screws. . . . . . . 80 N•m (60 lb-ft).
11. Remove retainer (K) and brake basket (L).
Installation:
Installation is the reverse of removal.
MX1393
12. Install clutch shift fork with leg for safety switch on
left side as shown.
4/6/01
8 - 87
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE
DISASSEMBLY AND ASSEMBLY
Procedure:
A
M94744
M94741
1. Remove shaft and coupler from clutch/brake
assembly.
2. If necessary, remove spring pin (A) and splined
coupler from end of shaft.
5. Using a suitable puller, remove two bearings from
clutch housing.
B
D
M94742
3. Remove shift pins (B) and check pins with a
magnet. If the magnet sticks to the pins they are
the old style steel pins and should be replaced with
new aluminum/bronze pins.
M94745
6. Remove snap ring (D) from end of shaft.
E
C
M94743
4. Remove clutch housing (C) from clutch/brake
assembly.
M94746
7. Using a suitable puller, remove bearing.
8. Remove washer (E).
8 - 88
4/6/01
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
H
M94747
9. Remove clutch assembly from shaft.
M94750
F
G
13. Turn clutch over, and remove piston (H) from hub.
M94748
10. Remove four cap screws (F) retaining clutch lifter.
11. Inspect levers (G) for smooth operation, damage, or
wear. If necessary, replace clutch lifter.
M94751
14. Remove friction disks and separator plates from
hub.
15. Inspect disks and friction plates for wear,
discoloration, scoring or warping. Measure clutch
pack thickness. If clutch pack does not meet
minimum specification, replace pack as a unit.
Specification (Minimum):
Clutch Pack. . . . . . . . . . . . . . . . . 41.4 mm (1.632 in.)
M94749
12. Remove four springs.
M94755
16. Using a suitable puller, remove bearing from brake
end of shaft.
4/6/01
8 - 89
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
L
K
I
M94759
M94756
NOTE: Shift collar spring is slightly compressed. If
snap ring is hard to remove, push down on
brake to compress spring slightly before
removing snap ring.
21. Remove four cap screws (K) retaining brake lifter to
brake assembly. Remove brake lifter.
22. Inspect levers (L) for smooth operation, damage, or
wear. If necessary, replace brake lifter assembly.
17. Remove snap ring (I) retaining brake to shaft.
18. Remove washer.
M94757
19. Remove brake assembly from shaft.
M94760
23. Remove four springs.
J
M94758
20. Remove spring retainer (J), spring, and shift collar.
M94761
24. Remove hub.
8 - 90
4/6/01
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
M94762
25. Remove separator plates and friction disks.
26. Inspect separator plates and friction disks for wear,
discoloration, scoring or warping. Measure plate
and disk thickness. If plates or disks do not meet
minimum thickness specification, replace brake
plate pack as a unit.
M94763
1. Install piston into brake housing, and assemble
brake pack starting with a friction disk, followed by a
separator plate, followed by a disk, plate, disk.
H
Specification (Minimum):
Brake Pack . . . . . . . . . . . . . . . . 11.53 mm (0.454 in.)
Assembly:
NOTE: Friction disks in brake pack have external tabs.
Separator plates have internal splines.
IMPORTANT: Soak clutch and brake disks in
hydraulic oil for one (1) hour before assembling
clutch or brake packs. Failure to complete this
step will result in premature clutch failure.
M94764
2. Install hub (H) into brake disks and plates.
M94765
M94762
3. Install four springs.
4/6/01
8 - 91
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
K
Gap
M94766
Incorrect
4. Install brake lifter. Retain with four cap screws (K).
Tighten cap screws to 13 N•m (115 lb-in.).
M94752
Correct
M94753
M94751
NOTE: Friction disks in clutch pack have external tabs.
Separator plates have internal splines.
5. Install a friction disk onto hub, followed by a
separator plate, disk, plate, disk, etc., until all nine
disks, and eight plates are in place on hub.
NOTE: Piston should be installed so that it rests on
brake plates and disks (see photo).
6. Install piston to hub, plates, and disks.
M94749
7. Turn clutch assembly over, and install four springs.
8 - 92
4/6/01
FINAL DRIVE POWER TRAIN
PTO CLUTCH AND BRAKE DISASSEMBLY AND ASSEMBLY
F
M94747
12. Install clutch assembly onto shaft.
M94748
8. Install clutch lifter, and retain with four cap screws
(F). Tighten cap screws to 13 N•m (115 lb-in.).
E
J
M94758
M94746
9. Assemble shift collar, spring, spring retainer (J),
and brake assembly onto shaft.
13. Install washer and bearing onto shaft. Using a
suitable seal driver or press, press the bearing
onto the shaft until the snap ring groove is visible
above the bearing.
D
I
M94756
M94745
10. Install washer.
11. Push down on brake assembly to compress spring,
and install snap ring (I).
4/6/01
14. Install snap ring (D).
8 - 93
MID PTO REMOVAL AND INSTALLATION
NOTE: It may be necessary to align disk splines to
allow brake housing to be properly installed.
FINAL DRIVE POWER TRAIN
MID PTO REMOVAL AND
INSTALLATION
Removal:
1. Remove rear cover, and rear PTO shafts and gears.
(See "REAR PTO SHAFTS AND GEARS
REMOVAL AND INSTALLATION").
M94731
M94767
15. Install brake pack of clutch/brake assembly into
brake housing on bearing plate to ensure that tabs
on friction disks are properly aligned.
16. Remove clutch/brake assembly from bearing plate.
17. If removed, install splined coupling to PTO shaft.
Retain with spring pin.
18. Install PTO shaft and coupler to clutch/brake
assembly.
19. Install PTO clutch/brake assembly. (See "PTO
CLUTCH AND BRAKE REMOVAL AND
INSTALLATION".)
2. Remove mid PTO shaft from bottom of differential
housing. When shaft is removed, gear may fall into
differential housing. Retrieve gear.
B
A
M94733
3. Remove cotter pin (A), and disconnect mid PTO rod
(B).
8 - 94
4/6/01
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
MID PTO DISASSEMBLY AND
ASSEMBLY
D
Disassembly:
1. Remove mid PTO housing. (See "MID PTO
REMOVAL AND INSTALLATION").
C
E
M94733
4. If equipped, disconnect wiring harness from mid
PTO switch (C).
5. Remove five cap screws (D) and mid PTO gear box
from right side of differential housing.
Installation:
F
M94768
2. Remove two screws (E) and seal retainer (F).
G
M94769
3. Remove seal (G) from output shaft.
M94732
1. Install shaft and gear into roller bearing in rear
cover.
2. Install cover with shafts and gears as an assembly
into differential housing. Do not install cap screws
at this time.
Installation is the reverse of removal.
• Tighten five cap screws securing mid PTO housing
to differential housing to 36 - 44 N•m (27 - 33 lbft).
H
M94771
NOTE: Replace O-rings. Old O-rings will leak.
4. Remove snap ring (H) from groove in mid PTO
case.
4/6/01
8 - 95
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
M94775
M94770
9. Remove inner shift arm and shaft.
5. Remove shaft and bearing from case as an
assembly.
K
I
M94773
6. Remove snap ring (I) retaining bearing to shaft.
7. Using a suitable puller or press, remove bearing
from shaft. Inspect bearing for smooth operation,
wear or damage. Replace if necessary.
M94776
10. Tilt shift fork (K), and remove gear.
J
M94774
8. Remove spring pin (J) from shift lever. Remove shift
lever.
8 - 96
4/6/01
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
L
M94779
M
13. Using a suitable puller, remove inner bearing (M)
from case. Inspect bearing for smooth operation,
wear or damage. Replace if necessary.
Assembly:
M94777
11. Using a pin punch, remove pin (L) that holds detent
shaft in case.
NOTE: Liberally lubricate all press-fit parts with
hydraulic oil to aid assembly.
1. Install inner bearing (M) into case. If necessary, use
a suitable driver and plastic mallet.
NOTE: Shift fork retains a steel ball under spring
pressure. Use care to prevent ball from being
lost.
M94783
M94778
12. Using a large pin punch, remove detent shaft and
two expansion plugs from housing. Remove shift
fork, steel ball, and spring.
4/6/01
2. Apply general purpose grease to ball and spring to
aid in assembly.
3. Install ball and spring into shift fork.
4. Install detent shaft into mid PTO case and shift fork:
• Using a pin punch or other suitable tool, push down
on ball to compress spring.
• Install detent shaft into mid PTO case and shift fork.
8 - 97
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
K
L
M94776
8. Install gear onto shift fork (K).
M94777
5. Install pin (L) that holds detent shaft in case.
6. If removed, install mid PTO switch.
M94775
NOTE: Replace seals and O-rings. Old seals and Orings will leak.
M94784
9. Install a new O-ring onto shift arm. Install shift arm
into case.
7. Install a new expansion plug into case at each end
of detent shaft.
8 - 98
4/6/01
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
J
M94774
10. Install shift lever onto shaft and retain with spring
pin (J).
M94770
12. Install shaft and bearing into case and drive gear.
H
I
M94771
13. Install snap ring (H) to retain shaft to case.
M94773
11. Using a press, install bearing onto shaft. Retain
with snap ring (I).
G
M94769
14. Using a suitable driver, install a new seal (G).
15. Install mid PTO assembly. (See "MID PTO
REMOVAL AND INSTALLATION").
4/6/01
8 - 99
MID PTO DISASSEMBLY AND ASSEMBLY
FINAL DRIVE POWER TRAIN
E
F
M94768
16. Install seal retainer (F) and secure with two screws
(E).
8 - 100
4/6/01
CONTENTS
STEERING
CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
6
7
STEERING SYSTEM SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TOE-IN ADJUSTMENT 4-WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TOE-IN ADJUSTMENT (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CYLINDER REMOVAL (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CYLINDER INSTALLATION (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING WHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CONTROL UNIT (SCU) REMOVAL AND INSTALLATION . . . . . . . . . . . 13
TILT STEERING MECHANISM REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . 13
TIE ROD REMOVAL AND INSTALLATION (EARLY 4-WD) . . . . . . . . . . . . . . . . . . . . 14
TIE ROD REMOVAL AND INSTALLATION (2-WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TIE ROD REMOVAL AND INSTALLATION (LATE 4-WD) . . . . . . . . . . . . . . . . . . . . . 15
TIE ROD DISASSEMBLY AND ASSEMBLY (2-WD). . . . . . . . . . . . . . . . . . . . . . . . . 15
4/6/01
9-1
NOTES
9-2
STEERING
4/6/01
STEERING
SPECIFICATIONS
SPECIFICATIONS
Steering:
Steering Wheel OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 mm (14.0 in.)
Front Steering Angle: Maximum Inward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54°
Front Steering Angle: Maximum Outward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62°
Maximum Rotation of Steering Wheel - Steering at Maximum Right or Left and
Constant Torque Applied to Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 rpm
Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 3 mm (0 - 0.125 in.)
Lubrication Interval:
Tie Rod Ends, Front Axle Pivot Pin (Normal Conditions) . . . . . . . . . . . . Every 50 hours
Tie Rod Ends, Front Axle Pivot Pin (Dusty Conditions). . . . . . . . . . . . . . Every 10 hours
TORQUE SPECIFICATIONS
Steering Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 49 N•m (29 - 36 lb-ft)
Wheel Mounting Bolts:
Front and Rear Wheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft)
Front wheels (Model 4200 Equipped With 4.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Front Wheels (Model 4300 Equipped With 5.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Steering Cylinder Hose Ends
Hose to Cylinder Adaptor . . . . . . . . . . . . . . . . . . . . . . . 17 - 24 N•m (150 - 212 lb-in.)
Tube Nut to Hose at Cylinder . . . . . . . . . . . . . . . . . . . . . . . 33 - 47 N•m (24 - 34 lb-ft)
SCU Hose Ends
Cylinder Tube to Hose at SCU . . . . . . . . . . . . . . . . . . . . . . 33 - 47 N•m (24 - 34 lb-ft)
Pressure or Return Tube to Hose at SCU. . . . . . . . . . . . . . 40 - 58 N•m (30 - 42 lb-ft)
Steering Cylinder Hose to Adaptor Fitting on SCU . . . . 17 - 24 N•m (150 - 212 lb-in.)
Pressure or Return Hose to Adaptor Fitting on SCU . . . . . 33 - 47 N•m (24 - 34 lb-ft)
SCU to Tractor Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 38 N•m (22 - 28 lb-ft)
Adaptor Fittings to SCU Ports . . . . . . . . . . . . . . . . . . . . . . 14 - 16 N•m (124 - 142 lb-in.)
Tie Rod to Spindle Arm Nut (2-WD) . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Tie Rod to Spindle Arm Nut (4-WD) . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Tie Rod to Steering Cylinder Rod . . . . . . . . . . . . . . . . . . . . 115 - 129 N•m (85 - 95 lb-ft)
Steering Cylinder (Dual End):
Steering Cylinder to Mounting Bracket . . . . . . . . . . . . . . . . . . . . 25-31 N•m (18-22 lb-ft)
LH Bracket to Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-122 N•m (85-90 lb-ft)
Steering Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-37 N•m (19-27 lb-ft)
Ball Joint to Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-129 N•m (85-95 lb-ft)
Steering Cylinder (Single End):
Cylinder to Spindle Arm Castle Nuts. . . . . . . . . . . . . . . . . . . . 115-129 N•m (85-95 lb-ft)
Hose Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-37 N•m (19-27 lb-ft)
Steering Cylinder to Mounting Bracket Cap Screws . . . . . . . . 31 - 38 N•m (22 - 28 lb-ft)
Steering Cylinder Bracket to
Front Axle Cap Screws and Nuts . . . . . . . . . . . . . . . . . 126 - 154 N•m (94 - 115 lb-ft)
4/6/01
9-3
STEERING COMPONENT LOCATION
STEERING
STEERING COMPONENT LOCATION
7
3
2
6
4
R
L
E
PT
5
1
2
1
3
5
16
17
8
9
10
11
12
13
15
14
1. Pressure Hose
7. Steering Wheel
13. Left Turn Hose
2. Left Turn Hose
8. Hydrostatic Transmission
14. Rod End (To Tie Rod)
3. Right Turn Hose
9. Cartridge Filter
15. Steering Cylinder
4. Plug
10. Engine Mounted Hydraulic Pump
16. Hydraulic Oil Cooler
5. Return Hose (Tank)
11. Pressure Line (to SCU)
6. Steering Control Unit (SCU)
12. Right Turn Hose
17. Suction Tube Elbow
(Reservoir to Pump)
9-4
4/6/01
THEORY OF OPERATION
STEERING
THEORY OF OPERATION
All Models:
The front hydraulic pump supplies hydraulic pressure to
the steering control unit (SCU). The SCU utilizes an
open center control valve to operate the steering
cylinder. When the steering wheel is turned, the SCU
directs hydraulic pressure to the appropriate steering
cylinder hose, pushing the steering cylinder ram, which
pivots the front spindles and wheels. The SCU has no
relief valve. The SCU and steering cylinder are not
rebuildable, and must be replaced as complete units.
Hydrostatic Model:
the tractor, or directly to the hydrostatic unit. Oil
entering the hydrostatic unit passes through a cartridge
filter. The hydrostatic unit is a combination motor and
pump, and operates as a closed loop. Most of the
hydraulic oil delivered to this unit passes by the charge
pressure relief valve, and returns to the reservoir. A
small amount of oil flows through the hydrostatic unit,
providing internal lubrication, then returns to the
reservoir.
Gear or SyncReverser Model
Excess oil from the SCU passes through the filter and
returns to the reservoir.
Excess oil from the SCU passes through a tee fitting on
the left side of the tractor, in front of the fuse panel. Oil
travels either to the oil cooler, mounted in the front of
3
2
4
R
L
1
E
PT
5
6
Gear or SyncReverser Transmissions Without Oil Cooler
1. Pressure Hose
3. Right Turn Hose
5. Return Hose (Tank)
2. Left Turn Hose
4. Plug
6. CST or SRT To Reservoir
4/6/01
9-5
TROUBLESHOOTING CHART
STEERING
●
Toe-in incorrect
●
Steering control unit mounting
loose
●
●
●
●
●
●
●
Wheel bearings worn or lost
lubrication
●
Wheel bearing retaining nut
loose
●
Tire out-of-round, size incorrect
or air pressure incorrect
●
●
●
Steering wheel and/or shaft
splines worn or stripped
●
Steering wheel nut loose,
stripped, or missing
●
Steering cylinder rod (tie rod)
bent or damaged
●
Front axle pivot weak or
unstable
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
SCU leaking internally
●
●
●
Steering cylinder leaking
internally
●
●
●
Tilt steering locking mechanism
worn or damaged
9-6
Front wheels “plow” loose soil to
sides
●
●
Steering wheel turns, but wheels
do not
●
●
Noise during turns or over rough
terrain
Tie rod ends loose, or worn
●
Steering wheel spins freely
●
Steering wheel tilt does not lock
●
Steering wheel pulls upward
Steering shimmies or vibrates
●
Steering locks in hard left or right
turns
Steering wanders
Spindles and/or spindle
bearings worn or not lubricated
sufficiently
Check or
Solution
Steers hard left, right or both
Steering pulls in one direction
Problem or
Symptom
Wheel bearing noise
TROUBLESHOOTING CHART
●
4/6/01
DIAGNOSIS
STEERING
DIAGNOSIS
Test/Check Point
1. Rims
Normal
If Not Normal
Runout not excessive.
Replace rims.
Wheel bolts tight.
Tighten to specification.
Runout not excessive.
Remount or replace tires.
Tires properly inflated.
Inflate tires to proper pressure.
3. Wheel bearings
Wheels rotate freely without rough
spots.
Replace bearings.
4. Pinion shaft and hub shaft
Assemblies tight and turn smoothly.
Tighten or replace assemblies.
5. Final drive housing
Fastened securely.
Tighten fasteners to specification.
6. Front axle mounting pivot
Pivot bushing not worn or binding.
Replace bushing.
7. Tie rod
Castle nuts tight.
Tighten castle nuts install cotter pin.
Tie rod (steering cylinder rod)
straight, toe-in correct.
Replace worn or damaged steering
cylinder, adjust toe-in.
Assembly fastened securely.
Tighten cylinder.
Operates from stop-to-stop smoothly
with little effort, not leaking.
Replace cylinder.
Fastened securely to frame.
Fasten securely.
Not leaking.
Tighten fittings, replace SCU.
Installed properly, nut torqued to
specification.
Install and tighten properly.
No cracks or breaks.
Replace as necessary.
2. Tires
8. Steering cylinder
9. Steering control unit
10. Steering wheel
4/6/01
9-7
STEERING SYSTEM SCHEMATIC
STEERING
STEERING SYSTEM SCHEMATIC
Steering Cylinder
Left (L)
Right (R)
Left
Right
Relief Valve
10342 kPa
1500 psi
P
POWER
STEERING VALVE
T
Steering Wheel
Engine
7.5 or 8.2 cm3/rev
Gear Pump
(Front)
To Transmission Tunnel
150 Mesh
Intake Filter
Sump
9-8
4/6/01
TESTS AND ADJUSTMENTS
STEERING
TESTS AND ADJUSTMENTS
STEERING SYSTEM TEST
TOE-IN ADJUSTMENT 4-WD
(EARLY 4-WD)
Reason:
Reason:
To check steering control unit and steering cylinder
operation and check for internal leakage.
Tools:
• Torque wrench
• Caps for hydraulic lines
Procedure:
1. Run the tractor until the hydraulic fluid is at
operating temperature.
2. Turn the steering wheel to the full right position.
Apply constant torque to the steering wheel
retaining nut, and count the steering wheel
rotations in one minute.
3. Repeat the procedure turning the steering wheel to
the full left position.
4. Stop engine.
To ensure proper wheel tracking when turning, and to
prevent tire scrub and premature tire wear.
Tools:
• Wrenches
• Tape Measure
• Tire scribing tool
Procedure:
NOTE: If both tie rod ends were removed, screw-in the
rod end until the distance from the lock nut to
the end of the threads is approximately 22 mm
(.875 in). Tighten the lock nuts.
Measure
Results:
• If the rotation in left or right hand direction
exceeded five rotations in one minute, the
steering system has internal leakage. To
determine whether it’s the SCU or cylinder that is
leaking, proceed as follows:
Procedure:
1. Label and remove both left and right hydraulic
hoses at the steering cylinder.
2. Cap the ends of both hoses.
3. Repeat the SCU test.
Results:
• If the rotation speed is now below five rotations in
one minute, replace the steering cylinder.
• If the rotation speed remains above five rotations in
one minute, replace the SCU.
Measure
M91357
1. Jack up front axle so tires are off of floor.
2. Rotate tire by hand and scribe a line near the center
of each of the front tires.
3. Measure and record the distance between the lines
at the front and the rear of the tire at about axle
height. The front measurement should be 0-3 mm
(0-0.125 in.) less than the rear measurement.
4. If measurement is not correct, loosen jam nuts on
tie rod ends and turn the threaded portion of the
rod end using a wrench to increase or decrease
the amount of toe until the measured dimension is
within specifications.
5. Tighten the jam nuts.
Specification:
Toe In . . . . . . . . . . . . . . . . . . . . . 0-3 mm (0-0.125 in.)
4/6/01
9-9
TOE-IN ADJUSTMENT (2-WD)
(LATE 4-WD)
STEERING
TOE-IN ADJUSTMENT (2-WD)
Reason:
To ensure proper wheel tracking when turning, and to
prevent tire scrub and premature tire wear.
Tools:
A
B
• Wrenches
• Tape Measure
• Pliers
Procedure:
Measure
MX1190
NOTE: Make sure wheels are pointing straight ahead.
1. Jack up front axle so tires are off of floor.
2. Rotate tire by hand and scribe a line near the center
of each of the front tires.
3. Measure and record the distance between the lines
at the front and the rear of the tire at about axle
height. The front measurement should be 0-3 mm
(0-0.125 in.) less than the rear measurement.
NOTE: One of the tie rod ends and jam nut has left
hand threads.
4. If measurement is not correct, loosen jam nuts (A)
on both ends of tie rod and turn the tie rod (B)
using a wrench to increase or decrease the
amount of toe until the measured dimension is
within specifications.
5. Tighten the jam nuts.
Measure
M91751
1. Jack up front axle so tires are off of floor.
2. Rotate tire by hand and scribe a line near the center
of each of the front tires.
3. Measure and record the distance between the lines
at the front and the rear of the tire at about axle
height. Measurement at front of tire should be
slightly less than measurement at rear (toed in).
4. Compare measurement to specifications, and
adjust tie rod to increase or decrease the amount
of toe until the dimension is within specifications.
5. Tighten the lock nut.
Specification:
Toe In . . . . . . . . . . . . . . . . . . . . . 0-3 mm (0-0.125 in.).
Specification:
Toe In. . . . . . . . . . . . . . . . . . . . . 0-3 mm (0-0.125 in.)
9 - 10
4/6/01
REPAIR
STEERING
REPAIR
6. Remove six cap screws (A) and lock washers (B)
attaching LH bracket to steering cylinder and
remove attaching bracket from cylinder.
7. Inspect the steering cylinder for leaks, cracks, rod
straightness and smooth operation.
STEERING CYLINDER
(DUAL CYLINDER ENDS - 4-WD)
1. Label and remove both steering hoses from the
steering cylinder.
NOTE:
The steering cylinder has no serviceable
components. If the cylinder leaks or does not
meet specifications, the unit must be replaced.
1
Installation:
2
3
4
6
8
7
5
M91328
1. Tie Rod
5. Tie Rod
2. LH Bracket
6. RH Bracket
3. Cylinder Rod
7. Cap Screw
4. Cylinder Rod
8. Lock Washer
1. Install the LH mounting bracket onto the steering
cylinder and secure with 6 cap screws. Tighten to
specification.
2. Install the steering cylinder into RH bracket, and
secure LH bracket to the front axle with two cap
screws.Tighten to specification.
3. Connect the steering hoses to the cylinder and
Tighten to specification.
4. Attach ball joints to steering cylinder rod and tighten
to specification.
5. Bleed the hydraulic system if required.
6. Adjust toe-in. (See “TOE IN ADJUSTMENT”).
Specification:
Steering Cylinder to
Mounting Bracket . . . . . . . .25-31 N•m (18-22 lb-ft)
LH Bracket to Front Axle . .115-122 N•m (85-90 lb-ft)
Steering Hoses . . . . . . . . . . . .26-37 N•m (19-27 lb-ft)
Ball Joint to Cylinder Rod .115-129 N•m (85-95 lb-ft)
2. Place a wrench on each of the tie rods on the ends
of the cylinder rod, and turn to remove one side.
3. Place a wrench on the flats, or a suitable tool
through the hole in the end of the cylinder rod
where the ball joint was removed to prevent the
cylinder rod from turning.
4. Place a wrench on the remaining ball joint, and
remove.
5. Remove three cap screws and lock washers on LH
bracket attaching steering cylinder and bracket to
front axle. Move steering cylinder to left to remove
from RH bracket. Remove cylinder.
A
B
M91331
4/6/01
9 - 11
STEERING CYLINDER
STEERING
STEERING CYLINDER
(SINGLE CYLINDER END - 4-WD)
Removal:
B
1. Label and disconnect both steering hoses (A) from
the steering cylinder.
2. Place a wrench on each of the tie rods (C) on the
ends of the cylinder rod (B), and turn to remove
one side.
3. Place a wrench on the flats, or a suitable tool
through the hole in the end of the cylinder rod
where the tie rod was removed to prevent the
cylinder rod from turning.
4. Place a wrench on the remaining tie rod, and
remove.
5. Remove three cap screws, lock washers, and nuts
attaching steering cylinder and LH bracket to front
axle. Move steering cylinder to left to remove from
RH bracket. Remove cylinder.
A
STEERING CYLINDER
INSTALLATION (2-WD)
MX0979
NOTE: Cylinder ball end studs are tapered. Use a tie
rod end removal tool to avoid damaging
threads if cylinder is to be re used.
1. Mark hoses (A) and disconnect from cylinder.
2. Remove cotter pins and castle nuts (B).
3. Remove cylinder.
Installation:
1. Inspect rubber boots on ends of cylinder. Replace
boots if necessary.
2. Install cylinder and tighten castle nuts to
specification. If slots in castle nut do not line up
with cotter pin hole, continue tightening nut until
next slot lines up.
3. Connect hoses to cylinder.
Specification:
Castle Nuts . . . . . . . . . . . . .115-129 N•m (85-95 lb-ft)
Hose Ends . . . . . . . . . . . . . . .26-37 N•m (19-27 lb-ft)
STEERING CYLINDER REMOVAL
(2-WD)
M95282
A
B
B
C
9 - 12
1. Install the steering cylinder into RH bracket, and
secure LH bracket to the front axle with three cap
screws, lock washers, and nuts. Tighten cap
screws to 126 - 154 N•m (94 - 115 lb-ft).
2. Attach cylinder end to spindle arm. Secure with
castle nut. Tighten to 115 - 129 N•m (85 - 95 lb-ft).
Install cotter pin to secure nut.
3. Connect steering hoses to fittings on cylinder.
Tighten connectors to 17 - 24 N•m (150 - 212 lbin.).
4. Adjust toe-in. (See “TOE IN ADJUSTMENT 2WD”)
STEERING WHEEL REMOVAL AND
INSTALLATION
Removal:
1. Remove steering wheel center cap .
2. Remove lock nut.
3. Remove steering wheel. If necessary, use a
suitable puller.
Installation:
NOTE:
Lubricate the steering shaft splines with
general purpose grease before installing
steering wheel to allow easy removal.
1. Remove white center cap plastic retaining ring from
steering wheel.
2. Install steering wheel and retain with nut. Tighten
steering wheel nut to specification.
3. Install plastic retaining ring to steering wheel center
cap.
4. Install center cap and retaining ring to steering
wheel.
4/6/01
STEERING CONTROL UNIT (SCU) REMOVAL AND INSTALLATION
STEERING
Specification:
Steering Wheel Nut . . . . . . . 39-49 N•m (29-36 lb-ft).
STEERING CONTROL UNIT (SCU)
REMOVAL AND INSTALLATION
Removal:
1. Remove the steering wheel.
2. Remove the control panel. (See “CONTROL
PANEL” in miscellaneous section.).
3. Remove the control panel lower shroud.
A
screws and star washers. Tighten to specification.
4. Install the hydraulic hoses to the adapter fittings.
Tighten cylinder hoses to specification. Tighten
pressure and return hoses to specification.
5. Install the control panel lower shroud.
6. Install the control panel.
7. Install the steering wheel.
8. Fill the hydraulic system to the proper level; bleed
the system if required.
Specification:
SCU Adapter Fittings . . . 14-19 N•m (124-168 lb-in.).
SCU Mounting Cap Screws . 30-38 N•m (22-28 lb-ft).
Small Hoses To SCU . . . 19-27 N•m (168-240 lb-in.).
Large hoses To SCU . . . . . . 40-57 N•m (30-42 lb-ft).
TILT STEERING MECHANISM
REMOVAL AND INSTALLATION
B
Removal:
1. Remove steering wheel. (See “STEERING WHEEL
REMOVAL AND INSTALLATION”).
2. Remove control panel. (See “CONTROL PANEL” in
miscellaneous section.).
3. Remove control panel lower shroud.
M91329
4. Label and remove the hydraulic hoses.
5. Remove four cap screws (A) and star washers.
Remove the SCU from the tractor.
6. If necessary, remove adapter fittings (B) from the
SCU.
C
A
NOTE: The SCU has no serviceable components. If
the SCU does not meet specifications, the unit
must be replaced.
D
B
Installation:
1. If adapter fittings were removed, inspect O-rings in
adapter fittings for cracks or damage. Replace if
required.
2. Install adapter fittings to the SCU ports. Tighten to
specification.
NOTE: Unevenly or improperly torquing cap screws
attaching SCU to tractor can result in distortion
of the valve body, and premature failure of the
SCU.
M91330
4. Disconnect tilt return spring (A) from tilt column.
5. Lift up on the tilt locking lever to release lock.
6. Hold tilt locking lever and remove lock nut (B).
Remove tilt locking lever (C).
NOTE: Locking screw (D) has left-hand thread into
steering column.
3. Install the SCU to the tractor. Fasten with four cap
4/6/01
9 - 13
TIE ROD REMOVAL AND INSTALLATION (EARLY 4-WD)
7. Remove locking screw.
Installation:
1. Install locking screw to steering column. Tighten
enough to lock column in place.
2. Install tilt locking lever into position on locking screw
splines.
3. Test locking mechanism to be sure that steering
column will lock in position securely, and tilt locking
lever will not interfere with lower control panel
shroud. Adjust if required.
4. Install lock nut and tighten.
TIE ROD REMOVAL AND
INSTALLATION (EARLY 4-WD)
STEERING
fitting to end of ball joint nut equals that recorded
before removal. Tighten locking nut.
3. Attach tie rod to cylinder rod and torque to
specification.
4. Attach tie rod to spindle arm.
5. Install castle nut and torque to specification.
Specification:
Tie Rod End To Cylinder 115 - 129 N•m (85 - 95 lb-ft)
Castle Nut . . . . . . . . . . . .115 - 129 N•m (85 - 95 lb-ft)
6. Install a new cotter pin.
7. Lubricate tie rod end using general purpose grease.
Follow lubrication procedure outlined in the
maintenance section of the operator’s manual.
8. Adjust toe-in. (See “TOE IN ADJUSTMENT 4WD”).
Removal:
1. Measure distance (A) from lubrication fitting on tie
rod end to end of ball joint nut on steering cylinder
rod. Record measurement.
2. Place a wrench on each of the nuts on the ends of
the tie rods, and turn to remove one side.
3. If necessary, place a wrench on the flats or a
suitable tool in the hole in the end of the cylinder
rod where the tie rod was removed to prevent the
cylinder rod from turning. Place a wrench on the
remaining tie rod nut, and remove tie rod.
TIE ROD REMOVAL AND
INSTALLATION (2-WD)
Removal:
C
A
B
A
C
M91331
B
M91757
M91331
1. Remove cotter pin (A) and castle nut (B) from each
rod end attaching tie rod to spindle arm.
2. Using a ball joint separator, disconnect ball joint end
from spindle arm (C). Remove tie rod.
Installation:
4. Remove cotter pin (B).
5. Remove castle nut (C).
6. Using a ball-joint separator, separate tie rod from
spindle arm.
7. Remove tie rod.
Installation:
1. If installing ball joint previously used, inspect boot
for damage. If necessary, replace tie rod.
2. If installing a new tie rod, loosen locking nut, and
adjust tie rod until measurement from lubrication
9 - 14
1. If installing ball joint previously used, inspect boot. If
boot is damaged, or in poor condition, replace tie
rod end.
2. Insert threaded end of ball joint into hole in spindle
arm.
3. Install castle nut to rod end.
4. Tighten castle nut to 115 - 129 N•m (85 - 95 lb-ft).
5. Install cotter pin.
6. Lubricate tie rod end using general purpose grease.
Follow lubrication procedure outlined in the
maintenance section of the operator’s manual.
4/6/01
TIE ROD REMOVAL AND INSTALLATION (LATE 4-WD)
STEERING
7. Adjust toe-in. (See “TOE IN ADJUSTMENT 2WD”).
B
TIE ROD REMOVAL AND
INSTALLATION (LATE 4-WD)
A
MX1401
M91751
A
1. Remove cotter pins from castle nuts (A) and
remove castle nuts.
2. Using a tie rod end separator, remove tie rod ends
from spindles.
NOTE: If removing tie rod ends, one of the tie rod ends
and jam nut has left hand threads.
Installation:
1. Inspect tie rod end boots. If necessary, replace
boots.
2. Insert tie rod ends into holes in spindle arms.
3. Install two castle nuts to rod ends.
4. Tighten castle nuts (A) to specification.
5. Install the cotter pins. If slots in castle nuts don’t
align with holes after torquing, tighten nuts until
next slot aligns.
6. Lubricate tie rod ends using general purpose
grease. Follow lubrication procedure outlined in
the maintenance section of the operator’s manual.
7. Adjust toe-in. See toe in adjustment in this section.
2. Measure length (A) of tie rod from clamped tube
end to lubrication fitting on rod end. Record
measurement.
3. Loosen cap screw and nut (B) on tie rod clamp.
4. Remove rod end from tie rod tube.
5. Loosen locking nut on adjustable rod end.
6. Unscrew adjustable rod end from tie rod.
7. Inspect ball joints for damage, wear, and smooth
operation. Replace if necessary.
Assembly:
1. If installing ball joint previously used, inspect boot. If
necessary, replace tie rod end.
2. If removed, thread locking nut onto adjustable tie
rod end.
3. Install threaded rod end into tie rod so that
approximately half the threads are showing.
4. Install plain rod end into tie rod. Measure from end
of tie rod tube to lubrication fitting on tie rod end.
Install so that dimension is same as that recorded
before disassembly. Tighten clamp to retain rod
end in tie rod tube.
5. Adjust toe-in. See toe in adjustment in this section.
Specification:
Castle Nuts . . . . . . . . . . . . . 75-108 N•m (55-80 lb-ft).
TIE ROD DISASSEMBLY AND
ASSEMBLY (2-WD)
Disassembly:
1. Remove ball joint boots from ball joints and clean
parts thoroughly using a suitable solvent.
4/6/01
9 - 15
TIE ROD DISASSEMBLY AND ASSEMBLY (2-WD)
9 - 16
STEERING
4/6/01
CONTENTS
BRAKES
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE - SIDE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PARKING BRAKE - SIDE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PARKING BRAKE - CONSOLE MOUNT (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PARKING BRAKE - CONSOLE MOUNT (CST - SST - SRT) . . . . . . . . . . . . . . . . . . . 9
BRAKE PEDALS AND LINKAGE – HST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE PEDALS AND LINKAGE – HST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BRAKE PEDALS AND LINKAGE – CST AND SRT . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE PEDALS AND LINKAGE – CST AND SRT . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15
16
17
BRAKE PEDAL ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PARKING BRAKE ADJUSTMENT - SIDE MOUNT. . . . . . . . . . . . . . . . . . . . . . . . . . 18
PARKING BRAKE ADJUSTMENT - CONSOLE MOUNT . . . . . . . . . . . . . . . . . . . . . 18
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BRAKE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BRAKE PEDAL REMOVAL AND INSTALLATION - HST . . . . . . . . . . . . . . . . . . . . . . 21
BRAKE PEDAL REMOVAL AND INSTALLATION - CST AND SRT. . . . . . . . . . . . . . 24
PARKING BRAKE LINKAGE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . 26
4/6/01
10 - 1
NOTES
10 - 2
BRAKES
4/6/01
SPECIFICATIONS
BRAKES
SPECIFICATIONS
Brakes:
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wet Multiple Disk
Brake Pedal Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 - 76 mm (2.5 - 3.0 in.)
Pedal Free Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 - 35 mm (1.06 - 1.38 in.)
Total Brake Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 - 64 mm (2.0 - 2.5 in.)
Pedal Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.08 in.) or Less
Friction Disk and Plate Pack Thickness (Minimum). . . . . . . . . . . . . 16.51 mm (0.650 in.)
Transaxle Oil:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere J20D
Capacity (Hydrostatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 L (6.8 gal)
Capacity (Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 L (6.3 gal)
Torque Specifications:
Wheel Mounting Bolts:
Front and Rear Wheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft)
Front wheels (Model 4200 Equipped With 4.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Front Wheels (Model 4300 Equipped With 5.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Master Brake Link Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 - 71 N•m (48 - 52 lb-ft)
Set Screw On Master Brake Pedal (To Shaft) . . . . . . . . . . 20 - 25 N•m (177 - 221 lb-in.)
Clutch Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
LH Brake Lever Cap Screw (CST & SRT Only). . . . . . . . . . . . 36 - 44 N•m (27 - 33 lb-ft)
Additional Materials:
Thread Sealant (General Purpose) . . . . . . . . . . . . . . . . . . . . . . . . .TY9370 6 ml (0.2 oz)
Sealant (For Flanges) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TY16021 50 ml (1.7 oz)
4/6/01
10 - 3
COMPONENT LOCATION
BRAKES
COMPONENT LOCATION
BRAKE HOUSING
1
2
3
4
5
6
5
2
6
4
3
1
M95048
1. Brake Arm
2. Brake Cam
3. Brake Retainer Plate
4. Balls (7 used)
5. Actuator Plate
6. Friction Disks and Plates
10 - 4
4/6/01
PARKING BRAKE - SIDE MOUNT
BRAKES
PARKING BRAKE - SIDE MOUNT
1
3
2
4
3
9
8
7
4
6
5
M95025
1. 2 Speed PTO Lever (European)
2. Brake Shaft Assembly
3. Clevis
4. Park Brake Cable
5. Link
6. Release Button
7. Handle
8. Ratchet
9. Brake Lever
4/6/01
10 - 5
PARKING BRAKE - SIDE MOUNT
BRAKES
PARKING BRAKE - SIDE MOUNT
1
2
13
12
11
3
4
5
14
10
9
6
8
15
16
7
7
17
32
4
3
31
30
24
13
27
29
22
23
28
20
18
21
19
20
11
26
10
25
14
16
15
M95027
10 - 6
4/6/01
PARKING BRAKE - SIDE MOUNT
BRAKES
10. Knob, 2 Speed PTO
(Europe)
18. Link
26. Cap Screw
34. Strap
11. Lever, 2 Speed PTO
(Europe)
19. Pin, Clevis
27. Arm
35. Cap Screw
12. Washer
20. Clevis
28. Washer
36. Nut
13. Bearing
21. Arm
29. Cotter Pin
37. Nut
14. Bracket
22. Spring Pin
30. Link
38. Spacer
15. Shaft
23. Cable
31. Cap Screw
39. Nut
16. Cotter Pin
24. Shoulder Bolt
32. Cap Screw
40. Bracket
17. Cap Screw
25. Lock Nut
33. Handbrake Lever
41. Switch
4/6/01
10 - 7
PARKING BRAKE - CONSOLE MOUNT (HST)
BRAKES
PARKING BRAKE - CONSOLE MOUNT (HST)
1
3
2
4
6
5
7
8
9
13
12
16
10
11
15
9
14
12
8
13
1. Park Brake Linkage
5. Extension Spring
9. Upper Brake Rod
13. Lever
2. Cam Lever
6. Pedal, HST
10. Pedal, Brake
14. Turnbuckle
3. Pivot Bolt
7. Shaft, Brake
11. Pedal, Brake
15. Brake Lever
4. Engagement Lever
8. Lower Brake Rod
12. Shaft
16. Support
10 - 8
4/6/01
PARKING BRAKE - CONSOLE MOUNT (CST - SST - SRT)
BRAKES
PARKING BRAKE - CONSOLE MOUNT (CST - SST - SRT)
1
3
11
2
4
5
7
9
8
13
12
11
16
6
9
12
13
15
8
14
1. Park Brake Linkage
5. Extension Spring
9. Upper Brake Rod
13. Lever
2. Cam Lever
6. Pedal, Clutch
10. Pedal, Brake
14. Turnbuckle
3. Pivot Bolt
7. Shaft, Brake
11. Pedal, Brake
15. Brake Lever
4. Engagement Lever
8. Lower Brake Rod
12. Shaft
16. Support
4/6/01
10 - 9
BRAKE PEDALS AND LINKAGE – HST
BRAKES
BRAKE PEDALS AND LINKAGE – HST
1
2
3
4
5
6
7
7
6
12
8
13
10
9
14
15
38
40
37
16
11
38
39
17
41
23
19
21
5
36
9
18
19
24
25
22
21
26
27
20
26
25
28
3
23
28
25
26
25
29
35
26
16
5
21
23
24
34
15
30
17
13
33
32
12
31
M95017
10 - 10
4/6/01
BRAKE PEDALS AND LINKAGE – HST
BRAKES
1. Nut
12. Cotter Pin
23. Cotter Pin
34. Nut
2. Washer
13. Washer
24. Washer
35. Shaft
3. Pedal, Master
14. Lever
25. Lever
36. Cap Screw
4. Key
15. Clevis
26. Bushing
37. Rod, RH Upper
5. Spring
16. Pin
27. Shaft
38. Nut
6. Bushing
17. Rod, Lower
28. Washer
39. Nut
7. Bushing
18. Washer
29. Shaft
40. T-Pin
8. Spacer
19. Cap Screw
30. Brake Arm
41. Rod, LH Upper
9. Sleeve
20. Lever
31. Pedal, LH
10. Washer
21. Nut
32. Snap Ring
11. Tube
22. Pedal, RH
33. Bushing
BRAKE PEDALS AND LINKAGE – HST
1
2
3
4
5
8
12
7
11
6
10
9
M95047
1. Master Brake Pedal
2. Right Brake Tube and Link
3. Brake Return Spring
4. Brake Pedal Pivot Shaft Assembly
5. Brake Return Spring
6. Brake Pedals
7. Lower Brake Rods
8. Brake Arm
9. Bellcrank
10. Upper Brake Rods
4/6/01
11. Master Brake Link
12. T-Pin
10 - 11
BRAKE PEDALS AND LINKAGE – CST AND SRT
BRAKES
BRAKE PEDALS AND LINKAGE – CST AND SRT
1
2
6
3
4
5
7
1
2
8
25
6
9
24
10
23
11
22
19
20
21
26
30
19
12
18
27
26
17
15
16
23
14
13
28
22
27
27
26
29
10
9
31
1
6
36
32
2
33
48
1
34
47
16
13
35
46
45
43
44
42
29
41
30
40
14
27
28
39
23
19
19
26
27
37
22
23
M95016
38
26
10 - 12
27
22
4/6/01
BRAKE PEDALS AND LINKAGE – CST AND SRT
BRAKES
1. Snap Ring
13. Pin
25. Washer
37. Spacer
2. Washer
14. Clevis
26. Cotter Pin
38. Shaft
3. Bushing
15. Arm, RH Brake
27. Washer
39. Cotter Pin
4. Key
16. Spring
28. Cotter Pin
40. Washer
5. Pedal, RH Brake
17. Spring Pin
29. Rod, Lower
41. Lever
6. Spring
18. Leaf Spring
30. Rod, Upper
42. Rod, Clutch
7. Washer
19. Bushing
31. Spacer
43. Nut
8. Nut
20. Arm, Pedal Locking
32. Pedal, Clutch
44. Turnbuckle
9. Bushing
21. Shaft
33. Lever
45. Stud
10. Bushing
22. Lever
34. Washer
46. Cap Screw
11. Pedal, LH Brake
23. Nut
35. Cap Screw
47. Rod End
12. Shaft
24. Bushing
36. Arm, LH Brake
48. Nut
BRAKE PEDALS AND LINKAGE – CST AND SRT
1
2
3
6
5
11
4
9
10
7
8
M94708
1. Brake Pedal
2. Brake Pedal Pivot Shaft
3. Brake Pedal Return Spring
4. Clutch Pedal
5. Lower Brake Rod
6. Brake Arm
7. Brake Return Spring
8. Bellcrank
9. Upper Brake Rod
10. Clutch rod
4/6/01
11. Upper Brake Rod
10 - 13
BRAKE THEORY OF OPERATION
BRAKES
BRAKE THEORY OF OPERATION
The mechanical wet disk brakes operate on each rear
wheel of the tractor. The brakes are engaged by the
operator applying pressure to the brake pedals. When
pressure is applied to a brake pedal, the pedal pulls the
front brake rod up. The brake rod pulls on the bellcrank
which pivots, pulling on the lower brake rod. The lower
brake rod pulls on the brake lever (A) on the final drive
housing.
Inside the housing, the cam (B) on the brake lever
pushes against a tab (C) on the brake actuator. The
brake actuator is rotated, moving angled ramps against
captive steel balls (D). As the actuator rotates, the balls
and ramps force the actuator against the friction disks
(E) and plates (F), and in turn the differential housing.
The friction plates are held in position by the cam which
rests in a U-shaped slot. The friction disks are splined
to the axle shaft. The friction between the friction disks
and the friction plate/differential housing slows or stops
the rear drive wheels.
the links on the pedal shaft assembly allows the master
brake pedal to brake both sides simultaneously.
The side mount parking brake uses cables extending
from the park brake shaft assembly down to the brake
levers on the final drive case, and is engaged with the
park brake lever. It operates independently of the brake
pedals. The parking brake lever is pulled up, pulling the
link which turns the park brake shaft. On the park brake
shaft are two cam arms which pull the park brake
cables. The park brake cables pull the brake levers (A)
on the final drive case. The park brake is locked in
position by a ratchet on the park brake lever. The brake
disks are held in position until the park brake release
button is pushed, and the park brake lever is pushed
down.
The dash mount parking brake mechanically latches
the brake foot pedal in position after it is pressed down
by the operator. Its operation is dependent on use of
the brake pedal.
Removing pressure from the pedal allows the brake
arm return spring and brake pedal return spring to pull
the pedal back to the original position, releasing the
brakes. On the hydrostatic model, an interlock between
C
B
E
F
D
A
M95049
10 - 14
4/6/01
TROUBLESHOOTING CHART
BRAKES
●
Brake return spring weak/ damaged/
missing
Brake linkage damaged/ binding
●
●
●
●
●
●
●
●
●
Brake lever cam and/ or actuator worn
●
●
●
Actuator/ balls/ housing worn or damaged
●
●
●
●
●
●
Brake friction/ stationary plates worn or
damaged
Replace brake arm seal
4/6/01
Oil leaking from final drive case at
brake arm
Brakes worn/ no longer serviceable
●
Noise during braking
●
Excessive pedal travel
Brakes improperly adjusted
Check or
Solution
Brakes not effective
Steering pulls in one direction
Problem or
Symptom
Brakes drag (tractor will not move)
or slow to release
TROUBLESHOOTING CHART
●
●
10 - 15
DIAGNOSIS
BRAKES
DIAGNOSIS
Test/Check Point
1. Pedals
Normal
If Not Normal
Smooth operation
Grease pedal shaft assembly/
linkage. Inspect for damage.
Free play 27 - 35 mm (1.06 - 1.38
in.) Total brake pedal travel 63 - 76
mm (2.5 - 3.0 in.)
Pedal differential 2 mm (0.08 in.) or
less
Adjust to specification.
2. Friction material
Friction disk not excessively worn
Replace parts as required.
3. Linkage
Not bent or binding
Adjust to specification, replace
damaged parts.
4. Actuator and housing
Smooth operation, not worn
Replace worn parts.
5. Steel balls
Not pitted or scored
Replace worn parts.
6. Park brake lever
Smooth operation, not binding
Adjust to specifications, replace
damaged parts.
10 - 16
4/6/01
TESTS AND ADJUSTMENTS
BRAKES
TESTS AND ADJUSTMENTS
necessary, install an 8 X 20 mm set screw into
pedal. Apply TY9370 thread sealant to lock
screw in place.
BRAKE PEDAL ADJUSTMENT
NOTE: (Hydrostatic Model) The locking nuts located
on the upper brake rod T-pins at the brake
pedal assembly should not be used as an
adjustment point. All adjustment should be
performed at the rear of the tractor on the
lower brake rod clevises attached to the
transmission brake arms.
E
F
Reason:
To set the brake linkage free play to allow full pedal
movement and full application of the brake disks on the
rear axle shafts. The brakes are adjusted using
adjustable clevises to lengthen or shorten the brake
rods.
Tools:
M91325
• Ruler
• Pliers
Procedure:
Tractors were manufactured with two different types of
brake adjusters. Choose the procedure that is
appropriate for your model.
Clevis-Type Adjusters:
C
D
65 - 76 mm
(2.5 - 3.0 in.)
2. Remove cotter pin (C), washer (D), and clevis pin
(E) to disconnect clevis (F) from transmission
brake arm.
3. Turn clevis on rod to adjust free play.
4. Adjust the LH and RH clevis until the pedal free play
is 27 - 35 mm (1.06 - 1.37 in.), and the total brake
pedal stroke is 63 - 76 mm (2.5 - 3.0 in.).
5. The difference between left and right side pedal
free play (pedal differential) should be less than
2 mm (0.08 in).
Turnbuckle-Type Adjusters:
B
B
A
M95275
A
1. (CST or SRT Models) Check brake pedals (A) to
ensure that they are at the same height. Adjust as
required using set screws (B) on brake pedal.
M95275
NOTE: Adjuster screws may not be factory installed. If
4/6/01
10 - 17
PARKING BRAKE ADJUSTMENT - SIDE MOUNT
1. (CST or SRT Models) Check brake pedals (A) to
ensure that they are at the same height. Adjust as
required using set screws (B) on brake pedal.
NOTE: Adjuster screws may not be factory installed. If
necessary, install an 8 X 20 mm set screw into
pedal. Apply TY9370 thread sealant to lock
screw in place.
C
C
D
BRAKES
PARKING BRAKE ADJUSTMENT SIDE MOUNT
1. To adjust the parking brake:
• Remove the clevis pin attaching the park brake
cable to the park brake shaft (RH) or brake lever on
the final drive housing (LH).
• Loosen the locking nut which locks the clevis to the
cable.
• Turn the clevis.
2. Adjust clevis on the left brake so that the park brake
begins to engage with 3 clicks of park brake lever
travel. The park brake should be fully engaged at 4
or 5 clicks. Reattach clevis.
3. Remove right brake clevis pin, and repeat
procedure on right brake. Reattach clevises.
IMPORTANT: Improper park brake adjustment can
cause excessive heat and wear on brakes. Be
sure brakes disengage fully when the park
brake lever is released.
4. Release the park brake, and check to ensure that
the tractor rolls freely with the park brake
disengaged.
65 - 76 mm
(2.5 - 3.0 in.)
M91325
2. Loosen locking nuts (C) on lower brake rod
turnbuckle (D).
3. Turn turnbuckle on rod to adjust free play.
4. Adjust the LH and RH turnbuckle until the pedal free
play is 27 - 35 mm (1.06 - 1.37 in.), and the total
brake pedal stroke is 63 - 76 mm (2.5 - 3.0 in.).
5. The difference between left and right side pedal
free play (pedal differential) should be less than
2 mm (0.08 in).
PARKING BRAKE ADJUSTMENT CONSOLE MOUNT
The parking brake operation with the console mounted
on off knob is dependent on the brake pedal
adjustment. Proper adjustment of the brake pedal
linkage ensures proper operation of the parking brake.
(See “BRAKE PEDAL ADJUSTMENT”).
Results:
If the brakes are adjusted correctly:
• The wheel brakes will begin engagement when the
pedals are depressed 27 - 35 mm (1.06 - 1.37 in.).
10 - 18
4/6/01
REPAIR
BRAKES
REPAIR
3. Remove five cap screws (B) and actuator assembly
(C).
BRAKE DISASSEMBLY AND
INSPECTION
E
1. Remove the final drive from the tractor. (See “FINAL
DRIVE REMOVAL” in Final Drive PowerTrain
section.)
D
M94697
4. Remove friction disks (D) and plates (E).
5. Measure plate and disk pack thickness.
Specification:
A
M94705
Friction Disk and Plate Pack
Thickness (Minimum). . . . . . 16.51 mm (0.650 in.)
2. (RH Only) Remove pinion shaft (A) from
transmission housing.
F
IMPORTANT: Brake plates and disks may fall out
when actuator is removed. Use care to prevent
damage to disks and plates.
G
B
B
C
M94695
6. Remove cam shaft (F).
7. Replace O-ring (G).
M94694
4/6/01
10 - 19
BRAKE ASSEMBLY
BRAKES
H
J
M94698
K
M94699
8. Lay actuator assembly on bench and remove three
springs (H).
NOTE: Be certain the steel balls locate into the ramps
of the actuator.
I
J
1. Dip the steel balls (J) in transmission oil. Install
steel balls into brake retainer plate (K).
NOTE: Actuator plate will only fit onto steel balls and
retainer plate one way. Align actuator plate and
retainer plate so that spring tangs line up.
2. Install actuator plate onto steel balls and retainer
plate.
M94699
H
9. Remove actuator plate (I) and seven steel balls (J).
10. Inspect all parts for wear or damage. Replace any
worn or damaged components.
BRAKE ASSEMBLY
IMPORTANT: If installing new friction disks, soak
friction disks in hydraulic oil for 1 hour before
assembling.
M94698
3. Install three springs (H) onto spring tangs.
10 - 20
4/6/01
BRAKE PEDAL REMOVAL AND INSTALLATION - HST
BRAKES
BRAKE PEDAL REMOVAL AND
INSTALLATION - HST
F
E
Removal:
G
1. Remove cowl panels. (See “COWL PANEL” in
Miscellaneous section.)
D
.
A
B
M94696
IMPORTANT: If installing new friction disks, soak
friction disks in hydraulic oil for one hour before
assembling.
4. Dip the friction plates and the friction disks in
transmission oil. Install a brake plate (E) into final
drive housing, followed by a disk (D), plate, disk,
plate, disk.
5. Install a new O-ring (G) onto brake cam shaft (F),
and install cam shaft into final drive housing.
B
C
M91312
2. Remove snap ring (A) from end of brake pedal pivot
shaft (B).
B
c CAUTION
C
Brake return spring is under high tension. Wear
safety glasses and gloves when removing or
installing spring from pedal.
3. Disconnect brake return spring (C) from left brake
pedal.
4. Remove left brake pedal.
D
M94694
6. Dip brake actuator (C) in hydraulic oil and install into
final drive housing. Retain with five cap screws (B).
Tighten cap screws to 43 N•m (32 lb-ft).
7. Install the final drive housing to the transaxle. (See
“FINAL DRIVE INSTALLATION” in Final Drive
Power Train section.)
E
M91979
5. Remove cotter pin (D) and washer, and disconnect
lower brake rod (E) from bellcrank.
4/6/01
10 - 21
BRAKE PEDAL REMOVAL AND INSTALLATION - HST
BRAKES
6. Turn bellcrank and move upper brake rod and T-pin
(F) away from brake lever.
L
H
G
F
M91314
I
14. Remove bushing (L).
M91313
M
7. Remove jam nut (G) on brake pedal pivot shaft.
NOTE: T-pin location on brake rod is set at the factory.
If the T-pin must be replaced, measure and
note location before removing. Install newT-pin
so that it is in the same location.
8. Move left brake rod and T-pin clear of brake shaft
assembly.
9. Remove master brake link (H).
10. Disconnect brake return spring (I) from right brake
pedal.
M91315
15. Remove two flanged bushings (M).
K
J
M91318
11. Remove washer (J).
12. Loosen two set screws (K) on right brake pedal.
13. Remove right brake pedal.
10 - 22
4/6/01
BRAKE PEDAL REMOVAL AND INSTALLATION - HST
BRAKES
If the T-pin must be replaced, measure and
note location before removing. Install new T-pin
so that it is in the same location.
R
P
S
Q
T
1. Install the pedal shaft assembly into tractor frame
and attach the master brake pedal return spring.
2. On RH side of tractor, connect upper brake rod (Q)
and T-pin (R) to brake pedal assembly.
3. Connect lower brake rod (O) to bellcrank, and retain
with washer and cotter pin (N).
4. Loosen the locking nut (S) and tighten the adjuster
cap screw (T) on the master brake pedal so that
the T-pin (P) is evenly supported by the RH brake
link and the adjuster bolt. TheT-pin should be
level.
5. On LH side of tractor, install two flanged bushings
(M), plain bushing (L) and RH brake pedal.
c CAUTION
O
Brake return spring is under high tension. Wear
safety glasses and gloves when removing or
installing spring from pedal.
N
M91950
16. On RH side of tractor, remove cotter pin (N) and
washer and disconnect front of lower brake rod (O)
from bellcrank. Move T-pin (P) and upper brake rod
(Q) away from brake pedals.
17. Disconnect master brake return spring (R) from
brake pedal.
18. Remove master brake pedal and brake pedal shaft
from tractor as an assembly.
19. Inspect all parts for wear or damage. Replace any
worn or damaged components.
NOTE: If lubrication fitting on RH side of brake pedal
assembly is removed or replaced, DO NOT
over tighten. Lubrication fitting will bind against
master brake shaft. Test by depressing RH
brake pedal with brake return springs in place;
watch for master brake pedal movement. If
master brake pedal moves when RH brake
pedal is depressed, lubrication fitting is too
tight.
6. Attach RH brake return spring (I).
7. Install washer (J), master brake link (H) and jam nut
(G). Tighten jam nut to 65 - 71 N•m (48 - 52 lb-ft).
8. Tighten two set screws (K) on RH brake pedal to
20 - 25 N•m (177 - 221 lb-in.).
9. Move LH brake T-pin (F) and upper brake rod into
position on master brake link (H).
10. Install LH brake pedal. Retain with snap ring (A).
11. Attach LH brake pedal return spring (C).
12. Attach lower brake rod (E) to bellcrank and retain
with washer and cotter pin (D).
13. Loosen the locking nut and tighten the adjuster cap
screw on the LH brake pedal so thatthe T-pin is
evenly supported by the master brake link and the
adjuster bolt. The T-pin should be level.
NOTE:
If the parking brake has been removed,
complete the parking brake installation and
adjustment before adjusting the service
brakes.
14. Adjust the brakes. (See “BRAKE PEDAL
ADJUSTMENT”).
Installation:
Installation is the reverse of removal.
NOTE: T-pin location on brake rod is set at the factory.
4/6/01
10 - 23
BRAKE PEDAL REMOVAL AND INSTALLATION - CST AND SRT
BRAKE PEDAL REMOVAL AND
INSTALLATION - CST AND SRT
BRAKES
7. Remove cap screw (E) and nut holding clutch rod
end (F) to clutch pedal. Disconnect clutch rod and
set aside.
8. Remove snap ring (G) and washer.
9. Remove clutch pedal.
Removal:
1. Remove side panels.
.
C
H
A
D
M91793
B
M91791
10. Remove washer (H).
2. Remove cotter pin (A) and washer from end of
brake rod.
3. Disconnect brake rod (B) from brake lever.
4. Remove cap screw (C) and washer from end of
brake pedal pivot shaft.
5. Remove brake lever from end of brake pedal pivot
shaft.
I
c CAUTION
M91800
Clutch return spring is under high tension. Wear
safety glasses and gloves when removing or
installing spring from pedal.
11. Remove snap ring (I) and washer.
6. Disconnect clutch return spring (D) from clutch
pedal.
J
G
M91799
12. Remove spacer (J).
E
F
M91792
10 - 24
4/6/01
BRAKE PEDAL REMOVAL AND INSTALLATION - CST AND SRT
BRAKES
L
O
P
K
M91798
M91797
13. Remove washer (K) and two flanged bushings (L).
17. Remove two brake pedals (O) and pedal shaft (P)
from right side of tractor as an assembly.
18. Inspect all parts for wear or damage. Replace any
worn or damaged components.
c CAUTION
Brake return spring is under high tension. Wear
safety glasses and gloves when removing or
installing spring from pedal.
Installation:
Installation is the reverse of removal.
c CAUTION
M
Clutch and brake return springs are under high
tension. Wear safety glasses and gloves when
removing or installing springs from pedals.
N
M91795
14. On right side of tractor, disconnect brake return
springs (M) from left and right brake pedals.
15. Remove cotter pin (N) and washer from RH brake
rod.
16. Disconnect RH brake rod from brake pedal.
1. Install the pedal shaft assembly into tractor frame
and attach the two brake pedal return springs (M).
2. Attach RH brake rod to the brake pedal. Retain with
washer and cotter pin (N).
3. On LH side of tractor, install two flanged bushings
(L), washer (K), spacer (J), and clutch pedal.
Retain with washer and snap ring (I).
4. Attach clutch rod (F) to clutch pedal and retain with
cap screw (E) and nut. Tighten nut to 36 - 44 N•m
(27 - 33 lb-ft).
5. Install LH brake lever. Retain with cap screw (C)
and washer. Tighten cap screw to 36 - 44 N•m
(27 - 33 lb-ft).
6. Attach LH brake rod (B) to brake lever. Retain with
washer and cotter pin (A).
7. Attach clutch pedal return spring (D).
NOTE:
If the parking brake has been removed,
complete the parking brake installation and
adjustment before adjusting the service
brakes.
8. Adjust the brakes. ((See “BRAKE PEDAL
ADJUSTMENT”).)
4/6/01
10 - 25
PARKING BRAKE LINKAGE REMOVAL AND INSTALLATION
BRAKES
PARKING BRAKE LINKAGE
REMOVAL AND INSTALLATION
I
H
Side Mount Parking Brake:
1. Remove seat. (See “SEAT AND SEAT SUPPORT”
in Miscellaneous section.)
2. Remove five cap screws and LH closeout panel.
3. Remove five cap screws and RH closeout panel.
4. Raise RH rear of tractor and support on a suitable
stand.
5. Remove RH rear wheel and tire.
6. Remove RH fender. (See “REAR FENDERS” in
Miscellaneous section.)
7. Unplug wiring harness connector from park brake
switch.
8. If equipped, remove cotter pin and washer and
disconnect two-speed PTO rod at final drive
housing.
A
E
F
G
M91990
12. On LH side of tractor, remove cotter pin (E) and
washer, and disconnect differential lock rod (F)
from pedal (G).
13. Remove cotter pin (H) and washer, and disconnect
range shift lever rod (I) from shift arm at final drive
housing.
K
L
B
M91992
J
9. Remove spring locking pin (A) and disconnect LH
park brake clevis (B) from brake arm on final drive
housing.
M91991
14. On LH side of tractor, remove two cap screws (J)
that attach park brake lever to bracket.
15. Remove five cap screws (K) and two spacers (L)
that attach park brake assembly to rockshaft valve
cover. Remove park brake lever and linkage as an
assembly.
16. Inspect all parts for wear and damage. Replace as
required.
D
C
Installation:
M91993
Installation is the reverse of removal.
• After installing, adjust park brake. (See “PARKING
BRAKE ADJUSTMENT - SIDE MOUNT”).
10. Remove spring locking pin and disconnect RH park
brake clevis (C) from brake arm on park brake
shaft.
11. Remove two cap screws (D) attaching park brake
shaft pivot bracket to rockshaft housing.
10 - 26
4/6/01
PARKING BRAKE LINKAGE REMOVAL AND INSTALLATION
BRAKES
Dash Mount Parking Brake:
1. Remove RH upper cowl panel. (See “COWL
PANEL” in MISCELLANEOUS section.)
B
C
A
D
MX1411
2. Disconnect return spring (A) from bracket (B).
3. Remove cotter pin (C) and washer from parking
brake actuator rod. Remove rod.
4. Remove bolts (D) and nuts securing bracket and
pivot lever.
5. Remove bracket and lever.
6. Inspect all parts for wear or damage. Pay particular
attention to engagement teeth on lever. Replace
parts as required.
Installation is the reverse of removal.
4/6/01
10 - 27
PARKING BRAKE LINKAGE REMOVAL AND INSTALLATION
10 - 28
BRAKES
4/6/01
CONTENTS
HYDRAULICS
CONTENTS
Page
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCKSHAFT COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC SYSTEM COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROCKSHAFT PLUNGER ASSEMBLY AND CONTROL LEVER . . . . . . . . . . . . . . . . 8
ROCKSHAFT PISTON, RATE OF DROP VALVE, AND RELIEF VALVES . . . . . . . . 10
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ROCKSHAFT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SCV VALVE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC PUMP COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC PUMP COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDRAULICS (GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDRAULICS (SCV) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HYDRAULICS (ROCKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSISDIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 SPOOL SCV HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1 SPOOL SCV AND MANIFOLD BLOCK HYDRAULIC SCHEMATIC . . . . . . . . . . . 21
ROCKSHAFT HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
STEERING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HYDROSTATIC (HST) TRANSMISSION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . 24
TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HYDRAULIC SYSTEM BLEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RATE OF DROP/STOP VALVE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
LIFT ARMS ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SYSTEM PRESSURE/FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SYSTEM PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
STEERING PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ROCKSHAFT LIFT CYCLE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ROCKSHAFT LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ROCKSHAFT POSITION FEEDBACK LINKAGE ADJUSTMENT . . . . . . . . . . . . . . 29
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HYDRAULIC GEAR PUMP REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . 30
GEAR PUMP DISASSEMBLY & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
GEAR PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ROCKSHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ROCKSHAFT LIFT ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4/6/01
11 - 1
CONTENTS CONTINUED
HYDRAULICS
ROCKSHAFT DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SELECTIVE CONTROL VALVE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . 46
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY . . . 47
11 - 2
4/6/01
SPECIFICATIONS
HYDRAULICS
SPECIFICATIONS
HYDRAULIC SPECIFICATIONS
Hydraulic Oil:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . John Deere J20D
Capacity (CST and SRT Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.0 L (6.3 gal)
Capacity (HST Tractors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.0 L (6.8 gal)
4200
4300
4400
Measurements at:
Engine 2600 rpm
Engine 2600 rpm
Engine 2600 rpm
Type
Open System
Open System
Open System
Working Pressure
14650 kPa (2125 psi)
17235 kPa (2500 psi)
17235 kPa (2500 psi)
Pump
Gear Type
Gear Type
Gear Type
Front Pump Capacity
19.3 L/min (5.1 gpm)
8.2 cm3/rev
19.3 L/min (5.1 gpm)
8.2 cm3/rev
19.3 L/min (5.1 gpm)
8.2 cm3/rev
Rear Pump Capacity
27.6 L/min (7.3 gpm)
11.9 cm3/rev
31.4 L/min (8.3 gpm)
13.5 cm3/rev
31.4 L/min (8.3 gpm)
13.5 cm3/rev
Rockshaft Lift Cycle Time
2-1/2 to 3 sec.
2-1/2 to 3 sec.
2-1/2 to 3 sec.
Rockshaft Drop Cycle
Time
2-1/2 to 3 sec.
2-1/2 to 3 sec.
2-1/2 to 3 sec.
Maximum Lift Arm Drop
in 5 Minutes With Rate of
Drop/Stop Valve Closed
51 mm (2 in.)
51 mm (2 in.)
51 mm (2 in.)
Maximum Lift Arm Raise
Height (Measured from
top of left PTO shield to
center of pin in end of lift
arm.)
350 ± 3 mm
(13.8 ± 0.12 in.)
350 ± 3 mm
(13.8 ± 0.12 in.)
350 ± 3 mm
(13.8 ± 0.12 in.)
REPAIR SPECIFICATIONS
Rockshaft Specifications:
Splined Sleeve Minimum OD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.5 mm (1.832 in.)
Bushing Maximum ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 mm (1.738 in.)
Lift Arms:
Lift Arm Raise Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°
Lift Arm Lower Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
Maximum Variance Between Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5°
4/6/01
11 - 3
SPECIFICATIONS
HYDRAULICS
Gear Pump:
Shaft Bushing Maximum ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.15 mm (0.754 in.)
Shaft Bearing Surface Minimum OD . . . . . . . . . . . . . . . . . . . . . . . 18.95 mm (0.746 in.)
Bushing Minimum Thickness - Steering (Front) . . . . . . . . . . . . . . . 13.57 mm (0.534 in.)
Bushing Minimum Thickness - Implement (Rear) . . . . . . . . . . . . . 19.02 mm (0.749 in.)
Drive/Idler Gear Minimum Thickness
Front Pump (Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43 mm (0.371 in.)
4200 Rear Pump (Implement) . . . . . . . . . . . . . . . . . . . . . . . . . . 14.99 mm (0.590 in.)
4300/4400 Rear Pump (Implement) . . . . . . . . . . . . . . . . . . . . . . 17.63 mm (0.694 in.)
TORQUE SPECIFICATIONS
J-Tube Nuts (SCV or Manifold Block to Rockshaft) . . . . . . . . .81 - 89 N•m (60 - 67 lb-ft)
SCV Tube to Quick Disconnect Coupler. . . . . . . . . . . . . . . . . .51 - 57 N•m (38 - 42 lb-ft)
SCV Work Port Tubes to Adaptor Fittings . . . . . . . . . . . . . . . .51 - 57 N•m (38 - 42 lb-ft)
Manifold Block, or SCV Valve to Tunnel Cap Screws . . . . . . . . . . . . . . . 63 N•m (47 lb-ft)
Adapter Fitting to Pump (Front Pump) . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Pump to SCU Tube Nut (Front Gear Pump) . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Suction Tube Elbow Cap Screws (Front Gear Pump) . . . . . . . . . . . . . . 9 N•m (84 lb-in.)
Adapter Fitting to Pump (Rear Gear Pump). . . . . . . . . . . . . . . . . . . . . 28 N•m (21 lb-ft)
Pump to SCV Tube Nuts (Rear Gear Pump) . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Pump to Mounting Plate Cap Screws (Front or Rear Gear Pump) . . 22 N•m (192 lb-in.)
Pump Cover Cap Screws - M8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N•m (240 lb-in.)
Pump Cover Cap Screws - M10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Rockshaft Cap Screws (10.9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)
Rockshaft Cap Screws (8.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (40 lb-ft)
Rockshaft Cylinder Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N•m (60 lb-ft)
Lift Arm to Splined Shaft Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft)
Rockshaft Valve to Rockshaft Housing Cap Screws . . . . . . . . . . . . . . . 47 N•m (35 lb-ft)
SCV Torque Specifications:
Cover Socket Head Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.)
Valve Spring Retainer Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.)
Load Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Lever Assembly Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
11 - 4
4/6/01
OTHER MATERIALS
HYDRAULICS
OTHER MATERIALS
Number
U.S.A./Canadian
Name
TY6305
John Deere Clean and Cure Primer
TY16021
John Deere High Flex Form-InPlace Gasket
Sealing Flange Assemblies
TY15934
John Deere General Purpose
Gasket Dressing
Sealing Gaskets and Hoses
UN6419
JDM J20D HyGard® Oil
Transmission/Hydraulic Oil
4/6/01
Use
11 - 5
COMPONENT LOCATION
HYDRAULICS
COMPONENT LOCATION
ROCKSHAFT COMPONENT LOCATION
1
5
4
6
2
3
7
8
9
11
10
1. Lift Control Lever
5. RH Lift Arm
2. Rockshaft Relief Valve
6. LH Lift Arm
10. Lift Control Lever
3. Check Valve
7. Cam Plate
11. Rate of Drop/Stop Valve
4. Rockshaft Housing
8. Lift Arm Position Feedback Rod
11 - 6
9. Rockshaft Inlet
4/6/01
HYDRAULIC SYSTEM COMPONENT LOCATION
HYDRAULICS
HYDRAULIC SYSTEM COMPONENT LOCATION
1
9
8
1
9
2
8
3
7
5
6
4
NOTE: Top view shows new SCV shift controls and hydraulic tubing configuration. See “SELECTIVE CONTROL
VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY” on page47.
1. Selective Control Valve (SCV)
4. Suction Tube
7. Suction Manifold
2. Rockshaft Pressure Tube
5. Rear Pump (Implement)
8. Work Port Tubes
3. Pressure Tube
6. Front Pump (Steering)
9. System Relief Valve
4/6/01
11 - 7
ROCKSHAFT PLUNGER ASSEMBLY AND CONTROL LEVER
HYDRAULICS
ROCKSHAFT PLUNGER ASSEMBLY AND CONTROL LEVER
1
2
3
5
8
7
6
9
4
13
14
10
15
12
11
16
17
19
21
18
17
40
38
39
20
37
22
41
42
37
23
36
24
43
25
44
28
26
27
29
35
30
28
31
29
32
33
34
32
32
33
11 - 8
4/6/01
HYDRAULICS
ROCKSHAFT PLUNGER ASSEMBLY AND CONTROL LEVER
1. Knob
13. Bracket
25. O-Ring
37. Washer
2. Lever
14. Tube
26. Adapter Fitting
38. Cotter Pin
3. Cap Screw
15. Limiter
27. O-Ring
39. Feedback Arm
4. Extension
16. Friction Washer
28. O-Ring
40. Feedback Rod
5. Nut
17. Nut
29. Washer
41. Plug
6. Control Arm
18. Link
30. Control Shaft
42. O-Ring
7. Washer
19. Washer
31. Key
43. Plug
8. Washer
20. Snap Ring
32. Snap Ring
44. O-Ring
9. Cap Screw
21. Plug
33. Washer
10. Belleville Washer
22. O-Ring
34. Link
11. Washer
23. Housing
35. Cap Screw
12. Bushing
24. Cap Screw
36. Spring Pin
4/6/01
11 - 9
ROCKSHAFT PISTON, RATE OF DROP VALVE, AND RELIEF VALVES
HYDRAULICS
ROCKSHAFT PISTON, RATE OF DROP VALVE, AND RELIEF VALVES
13
9
10
8
11
12
14
7
6
15
16
5
4
17
18
3
19
21
20
2
22
1
1. Knob
7. Relief Valve
13. Piston Ring (Inner)
19. Spool
2. Shaft
8. O-Ring
14. Piston Ring (Outer)
20. Spring Pin
3. Cap Screw
9. Plug
15. Piston
21. O-Ring
4. Stem
10. Spring
16. O-Ring
22. O-Ring
5. Washer
11. Ball
17. Cover
6. O-Ring
12. O-Ring
18. O-Ring
11 - 10
4/6/01
LIFT ARMS
HYDRAULICS
LIFT ARMS
7
2
6
5
1
4
3
8
3
9
4
10
11
5
6
7
12
13
14
15
1. Washer
5. Splined Sleeve
9. Spring Pin
13. Lever Arm
2. Lift Arm
6. Bushing
10. Cam Plate
14. Piston Rod
3. Washer
7. O-Ring
11. Cap Screw
15. Spring Pin
4. O-Ring
8. Lift Arm
12. Splined Cross Shaft
4/6/01
11 - 11
ROCKSHAFT CONTROL VALVE
HYDRAULICS
ROCKSHAFT CONTROL VALVE
1
2
1
3
4
5
7
6
1. O-Ring
3. Socket Head Cap Screw
5. Cap Screw
2. Control Valve
4. Cover
6. Cap Screw
11 - 12
7. Spacer
4/6/01
SCV VALVE COMPONENT LOCATION
HYDRAULICS
SCV VALVE COMPONENT LOCATION
8
7
6
5
4
2
9
3
1
31
32
10
30
29
28
12
11
13
14
15
16
19
17
18
20
21
23
22
24
25
26
27
1. Seal
9. Valve Body
17. Detent Cap
25. Spring
2. Backing Washer
10. O-Ring
18. Spring Retainer
26. Spacer
3. O-Ring
11. Cap Screw
19. Ball
27. Spool
4. Valve Body
12. End Cap
20. Spring
28. Relief Valve
5. Spring
13. Gasket
21. Ball (4 used)
29. O-Ring
6. O-Ring
14. Plug
22. Spool
30. Backing Washer
7. Plug, Check Valve
15. Spring Retainer
23. Plug
31. O-Ring
8. Cap Screw
16. Spring
24. Spring Retainer
32. Backing Washer
4/6/01
11 - 13
HYDRAULIC PUMP COMPONENT LOCATION
HYDRAULICS
HYDRAULIC PUMP COMPONENT LOCATION
STEERING AND HYDROSTATIC CHARGE PRESSURE (FRONT)
1
2
3
4
5
6
9
7
10
8
11
18
7
5
15
17
6
16
14
4
13
12
1. Cap Screw
6. Formed O-Ring
11. Idler Gear
16. Adaptor Fitting
2. Lock Washer
7. Bushings
12. Seal
17. O-Ring
3. Cover
8. O-Ring
13. Cover
18. Pump Body
4. O-Ring
9. Cap Screw
14. Drive Gear
5. Backing Rings
11 - 14
10. Suction Tube Elbow
15. O-Ring
4/6/01
HYDRAULIC PUMP COMPONENT LOCATION
HYDRAULICS
HYDRAULIC PUMP COMPONENT LOCATION
SCV, PTO, AND ROCKSHAFT WORKING PRESSURE (REAR)
1
3
2
4
5
6
7
8
9
16
7
5
13
15
6
14
12
4
11
10
1. Cap Screw
5. Backing Rings
2. Lock Washer
6. Formed O-Ring
10. Seal
14. Adaptor Fitting
3. Cover
7. Bushings
11. Cover
15. O-Ring
4. O-Ring
8. Suction Tube
12. Drive Gear
16. Housing
4/6/01
9. Idler Gear
13. O-Ring
11 - 15
TROUBLESHOOTING CHART
HYDRAULICS
●
●
Rockshaft Rate of Drop/Stop Valve
Improperly Adjusted or Faulty
●
●
Lift Control Lever Friction Improperly
Adjusted (See "ROCKSHAFT
DISASSEMBLY AND ASSEMBLY")
Rear Gear Pump Faulty
●
●
●
●
●
PTO Valve Faulty
11 - 16
●
●
●
●
●
●
SCV Faulty
Rockshaft Position Feedback Linkage
Improperly Adjusted (See
"ROCKSHAFT POSITION FEEDBACK
LINKAGE ADJUSTMENT")
●
Raising Lift Arms Engages Relief Valve
Draft Arms Do Not Raise To Full Height
●
PTO Stops Too Slowly
Rockshaft Does Not Operate Smoothly
●
PTO Slips or Loses Power
Rockshaft Does Not Maintain Position
●
PTO Does Not Operate
Rockshaft Will Not Lower
Rockshaft Control Valve Faulty
Check or
Solution
SCV Attachment Does Not Operate Smoothly
Rockshaft Will Not Raise
Problem or
Symptom
SCV Attachment Does Not Operate
TROUBLESHOOTING CHART
●
●
4/6/01
THEORY OF OPERATION
HYDRAULICS
THEORY OF OPERATION
C
HYDRAULICS (GENERAL)
B
Function:
The hydraulic system provides the following:
• A means of raising and lowering equipment
attached to the three point hitch.
• A means of operating equipment attached to the
work ports of the selective control valve (SCV) (if
equipped).
• Pressure to lubricate the forward and reverse
clutches (SyncReverser™ transmission model).
• Hydrostatic transmission charge pressure (HST
Model).
• Pressure to operate the power steering system.
D
A
HYDRAULICS (SCV) (OPTIONAL)
Function:
The selective control valve (SCV) provides a means of
operating equipment attached to the work ports of the
valve via the quick-disconnect fittings attached to the
mounting plate on the tractor frame.
Theory:
The SCV system consists of a gear pump (A), and a 1
spool or 3 spool cartridge type valve (B).
When the SCV control lever is moved, mechanical
linkage moves the valve spool, opening the valve and
allowing oil to flow to one of the work ports. Tubes
attached to the work ports route oil pressure to quickdisconnect fittings (D) to which the attachment is
connected. Oil flows through these fittings into the
connecting hoses of the attachment, operating the
attachment. A mechanical locking device is attached to
the valve control lever to prevent lever movement when
the attachment is not in use.
Operation:
An 11.9 cm3/rev (4200) or 13.5 cm3/rev (4300/4400) per
revolution dual gear pump (rear pump) is mounted on
the left side of the engine and is gear driven off the
engine camshaft.
Oil is drawn from the transaxle sump through a 150
mesh screen by the gear pump. Oil is pumped, under
pressure, into the SCV.
The SCV consists of a 1 spool or 3 spool directional
control valve operated by a control lever (C) mounted to
the right side of the operator’s seat. An optional auxiliary
control lever for operating the third spool of the 3 spool
SCV may also be located on the right hand fender.
4/6/01
11 - 17
HYDRAULICS (ROCKSHAFT)
HYDRAULICS
HYDRAULICS (ROCKSHAFT)
Function:
The rockshaft provides a means of raising and lowering
equipment attached to the three point hitch.
It also provides a means of setting specific operating
depths for tillage equipment.
Theory:
The rockshaft hydraulic system consists a gear pump, a
system pressure relief valve located inside the SCV or
the manifold block (if equipped), a directional control
valve, (under the cover on the left side of the rockshaft
housing) and a lift cylinder, connected to two lift arms
through the rockshaft.
Rockshaft functions; up, down, and depth are controlled
by the operator using the rockshaft control lever (D),
mounted to the right of the operator seat. Moving the lift
control lever to the full back position will operate the
spool in the rockshaft control valve allowing oil to flow
into the cylinder. This in turn rotates the rockshaft and
raises the lift arms (E) to their full up position. Moving
the lift control lever to the full forward position will
operate the spool in the rockshaft control valve allowing
oil to flow out of the cylinder. This in turn rotates the
rockshaft and lowers the lift arms to their full down
position.
A movable mechanical stop is provided on the lift
control lever mechanism to allow the operator to limit
the movement of the lift control lever. This allows the
operator to repeatedly set the range of movement of the
lift arms thus controlling the height at which any
attachments operate.
Operation:
An 11.9 cm3/rev (4200) or 13.5 cm3/rev (4300/4400) per
revolution dual gear pump (rear pump) is mounted on
the left side of the engine and is gear driven off the
engine camshaft.
Oil is drawn from the transaxle sump through a 150
mesh screen by the gear pump. Oil is pumped, under
pressure, to the SCV (if equipped) or manifold block and
into the inlet port (A) of the rockshaft. System pressure
is controlled by an adjustable system pressure relief
valve mounted in the SCV or manifold block. The
system pressure relief valve vents back to the
transmission sump through the rockshaft housing. Oil
then passes through the rockshaft housing to the
rockshaft control valve.
D
E
A
C
B
The rockshaft control valve is located under a cover (B)
on the left side of the rockshaft housing. The rockshaft
housing contains an operator adjustable rate of
drop/stop control valve (C), lift cylinder, high pressure
relief valve, and a safety pressure relief valve.
11 - 18
4/6/01
DIAGNOSISDIAGNOSIS
HYDRAULICS
DIAGNOSISDIAGNOSIS
Test Conditions:
• Tractor sitting on level ground outdoors in an area
clear of obstructions.
• Hydraulic oil in reservoir at proper level.
• Speed range selector in "NEUTRAL".
Test/Check Point
• Park brake engaged.
• Engine running at high idle (2920 ± 25 rpm).
• Sufficient weight on lift arms to allow self-lowering.
• Rockshaft rate of drop/stop valve fully open.
Normal
If Not Normal
1. Move rockshaft lift control to
full raise (rearward) position.
Lift arms raise to full lift height.
Perform Rockshaft Position
Feedback Adjustment. (See
"ROCKSHAFT POSITION
FEEDBACK LINKAGE
ADJUSTMENT")
2. Move rockshaft lift control to
full lower (forward) position.
Lift arms lower to full down position.
Open rockshaft rate of drop/stop
valve fully. Make sure draft sensing
control lever (if equipped) is in the
full forward position. Perform
Rockshaft Position Feedback
Adjustment.
(See "ROCKSHAFT POSITION
FEEDBACK LINKAGE
ADJUSTMENT")
4/6/01
11 - 19
3 SPOOL SCV HYDRAULIC SCHEMATIC
HYDRAULICS
3 SPOOL SCV HYDRAULIC SCHEMATIC
To Rockshaft
P
PB
T
System Pressure
Relief Valve
4200
14651 kPa(2125 psi)
4300/4400
17236 kPa (2500 psi)
To Steering
11.9 cm3/rev (4200)
13.5 cm3/rev
(4300/4400)
8.2 cm3/rev
Gear Pump
Gear Pump
Load Check Valve
Engine
B
A
Load Check Valve
150 Mesh
Intake Filter
D
Sump Oil
SCV Work Port Oil
High Pressure Oil
Rockshaft Pressure Oil
C
Load Check Valve
F
E
3 SPOOL SELECTIVE CONTROL VALVE (SCV)
11 - 20
4/6/01
1 SPOOL SCV AND MANIFOLD BLOCK HYDRAULIC SCHEMATIC
HYDRAULICS
1 SPOOL SCV AND MANIFOLD BLOCK HYDRAULIC SCHEMATIC
To Rockshaft
P
T
PB
4200
14651 kPa(2125 psi)
4300/4400
17236 kPa (2500 psi)
System
Pressure
Relief
Valve
11.9 cm3/rev (4200)
13.5 cm3/rev
(4300/4400)
Load Check Valve
Gear Pump
Engine
B
A
SINGLE SCV VALVE
To Rockshaft
From PTO Valve
P
PB
T
System
Pressure
Relief
Valve
Test Port
4200
14651 kPa(2125 psi)
4300/4400
17236 kPa (2500 psi)
MANIFOLD BLOCK
Sump Oil
SCV Work Port Oil
Rockshaft Pressure Oil
4/6/01
NOTE: The manifold block can be replaced
by either the 1 spool selective control valve
or the 3 spool selective control valve
11 - 21
ROCKSHAFT HYDRAULIC SCHEMATIC
HYDRAULICS
ROCKSHAFT HYDRAULIC SCHEMATIC
From SCV Valve or Manifold Block
100 Mesh
Screen
Unload Valve
48 kPa
(7 psi)
Lowering Valve
Load Check Valve
Flow
Control
Valve
Main Spool Valve
ROCKSHAFT
CONTROL
VALVE
Rate of Drop/Stop Valve
Rockshaft
Relief Valve
20684 kPa
(3000 psi)
PISTON COVER
ROCKSHAFT
Sump Oil
Rockshaft Cylinder Oil
Rockshaft Pressure Oil
Rockshaft Work Pressure Oil
11 - 22
Cylinder
4/6/01
STEERING SCHEMATIC
HYDRAULICS
STEERING SCHEMATIC
Steering Cylinder
Left (L)
Right (R)
Left
Right
Relief Valve
10342 kPa
1500 psi
P
POWER
STEERING VALVE
T
To Transmission Tunnel
Steering Wheel
Engine
8.2 cm3/rev
Gear Pump
(Front)
150 Mesh
Intake Filter
Sump
4/6/01
Sump Oil
Charge Pressure/Tunnel Lubrication Oil
High Pressure Oil
Steering Oil
11 - 23
HYDROSTATIC (HST) TRANSMISSION SCHEMATIC
HYDRAULICS
HYDROSTATIC (HST) TRANSMISSION SCHEMATIC
Oil Filter
Oil Cooler
Oil Cooler
Relief
Valve
Relief
Valve
413-689 kPa
60-100 psi
69-206 kPa
10-30 psi
SPIN-ON FILTER
WITH BYPASS
Charge
Relief
Valve
689-1034 kPa
100-150 psi
System
Relief
Valve
41368-42885 kPa
6000-6220 psi
HST
Hydraulic
Pump
System
Relief
Valve
41368-42885 kPa
6000-6220 psi
Test Port
Hydraulic
Motor
Test Port
HYDROSTATIC TRANSMISSION
Make-Up/Closed Loop Relief Oil
High Pressure Oil
Sump Oil
Charge Pressure Oil
11 - 24
4/6/01
TESTS AND ADJUSTMENTS
HYDRAULICS
TESTS AND ADJUSTMENTS
8. Slowly turn the steering wheel left and right until
wheels turn smoothly indicating that any trapped
air has been bled back to the reservoir.
HYDRAULIC SYSTEM BLEED
PROCEDURE
Reason:
To remove air trapped in the hydraulic system which will
prevent proper operation.
Procedure:
IMPORTANT: If contamination is found in hydraulic
system filter or inside reservoir, flush entire
hydraulic system.
NOTE: Fill the new hydraulic oil filter with new oil
before installing.
1. Install a new hydraulic oil filter.
2. Fill the transaxle with specified JDM J20D
(preferred) or J20C oil to the proper level on
dipstick.
IMPORTANT: If rockshaft fails to react to lift control
lever movement, shut engine off and check hose
clamps on suction tube elbow and manifold to
ensure that they are properly tightened.
9. Operate rockshaft several times until it operates
smoothly.
10. Stop the engine and check the hydraulic reservoir
oil level. Fill as needed. Check all line connections
for leaks; tighten if necessary.
11. Lower the tractor to the ground.
12. (HST Model) Drive tractor in forward and reverse
several times until transmission operates smoothly.
RATE OF DROP/STOP VALVE
ADJUSTMENT
Reason:
To ensure that lift arms lower rear attachment
completely and lower it at a safe rate of speed.
Equipment:
• BW13586 Ballast Box
A
Procedure:
M91946
3. Disconnect connector (A) to fuel shutoff solenoid.
4. Turn the key to START and hold for 10 seconds.
Turn the key to OFF.
5. Reconnect wires to fuel shutoff solenoid.
6. Raise tractor front end and support on suitable
stands.
7. Start the engine and run at low idle.
1. Park tractor on a level surface and set park brake.
2. Shift transmission to "neutral".
3. Install BW13586 ballast box, or approximately 227
kg (500 lb), on the three point hitch.
4. Start engine and run at fast idle (2500-2700 rpm).
5. Put lift control lever in full UP position.
6. Raise weight as high as it will go.
7. Close rate of drop/stop valve.
8. Put lift control lever in full DOWN position.
9. Open rate of drop stop valve 1-1/2 to 2 turns.
10. Time duration of drop cycle from full up to full down.
Specifications:
Rockshaft Drop Time . . . . . . . . . . 2-1/2 to 3 seconds
Results:
IMPORTANT: If steering fails to respond, or pump
pressure is not being delivered to steering
control unit (SCU), shut engine off and check to
see that steering hoses are connected to the
correct SCU ports.
4/6/01
If the weight lowers slower than specified time, open
rockshaft rate of drop/stop valve until specification is
met. If weight drop time will not meet specification, the
11 - 25
LIFT ARMS ADJUSTMENT
HYDRAULICS
rate of drop/stop valve may be clogged or faulty, or the
rockshaft control valve may be faulty. (See
"ROCKSHAFT DISASSEMBLY AND ASSEMBLY").
Procedure:
LIFT ARMS ADJUSTMENT
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
1. Park tractor on a level surface and set park brake.
2. Shift transmission to NEUTRAL.
Reason:
To ensure that lift arms are operating through the
correct range of motion.
Procedure:
1. Park tractor on a level surface and set park brake.
2. Shift transmission to NEUTRAL.
3. Start engine and use hydraulics to rotate rockshaft
to full UP position.
4. Using angle gage, check lift arms against
specifications. If not correct, remove lift arm and
reset. (See "ROCKSHAFT DISASSEMBLY AND
ASSEMBLY").
5. Compare angle of second lift arm with first, they
should be within 5° of each other. If not, reset lift
arms on splines and/or replace rockshaft. (See
"ROCKSHAFT DISASSEMBLY AND
ASSEMBLY").
Specifications:
Lift Arm Raise Angle . . . . . . . . . . . . . . . . . . . . . . . 50°
Lift Arm Lower Angle. . . . . . . . . . . . . . . . . . . . . . . 20°
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . 70°
Maximum Variance Between Lift Arms . . . . . . . . . 5°
SYSTEM PRESSURE/FLOW TEST
Reason:
To ensure that hydraulic pump pressure and flow are
maintained at sufficient levels for rockshaft and SCV
attachment operation, and to determine if hydraulic
pump is worn.
Equipment:
3. Cycle all controls to relieve any pressure that may
be in the hydraulic system.
4. Remove hydraulic tube between rear pump and
SCV valve.
5. Connect test equipment between rear pump and
PTO valve. Open valve on flow meter fully.
6. Start engine and run at high idle (2500-2700 rpm).
c CAUTION
Do not close valve on flow meter fully. Pump
pressure may exceed working pressure of hose.
7. Slowly close valve on flow meter until working
pressure is reached. Record flow reading on
gauge.
Specifications (Minimum):
System Pressure (4200). . . . . . 14651 kPa (2125 psi)
System Pressure (4300-4400) . 17236 kPa (2500 psi)
System Flow (4200) . . . . . . . . 27.66 L/min (7.3 gpm)
System Flow (4300-4400). . . . . 31.4 L/min (8.3 gpm)
Results:
• Pressure too Low: If system pressure reading
cannot be reached, mesh filter may be restricted.
Suction line may be restricted or leaking air. Pump
may be worn. (See "GEAR PUMP DISASSEMBLY
AND INSPECTION").
• Flow too low: Mesh filter may be restricted.
Suction line may be restricted or leaking air. Pump
may be worn. (See "GEAR PUMP DISASSEMBLY
AND INSPECTION").
• JT05689 - Adapter Fitting (1-1/16-12 M 37° X 1-14
F ORFS) (2 Required)
• JT03012 - Adapter Fitting (3/4 F NPT X 1-1/16-12 F
37° Sw) (2 Required)
• JT05984 - In-Line Flow Meter With Pressure Gauge
• JT03377 - Hose (3/4 M NPT X 3/4 M NPT X 10’) (2
Required)
11 - 26
4/6/01
HYDRAULICS
SYSTEM PRESSURE ADJUSTMENT
SYSTEM PRESSURE ADJUSTMENT
Results:
NOTE: On tractors equipped with a manifold block in
place of an SCV, system pressure is set at the
factory, and should not require adjustment.
Reason:
To adjust hydraulic pressure so that system pressure is
maintained at correct levels to perform work without
causing damage to the hydraulic system.
A
Equipment:
• JT05689 - Adapter Fitting (1-1/16-12 M 37° X 1-14
F ORFS) (2 Required)
• JT03012 - Adapter Fitting (3/4 F NPT X 1-1/16-12 F
37° Sw) (2 Required)
• JT05984 - In-Line Flow Meter With Pressure Gauge
• JT03377 - Hose (3/4 M NPT X 3/4 M NPT X 10’) (2
Required)
• Pressure too low: Turn system pressure relief
valve (A) clockwise until pressure reading is within
specification.
NOTE: If system pressure will not meet specification,
pump may be worn. Perform system
pressure/flow test (See "SYSTEM PRESSURE
FLOW TEST").
Procedure:
1. Park tractor on a level surface and set park brake.
2. Shift transmission to NEUTRAL.
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
3. Cycle all controls to relieve any pressure that may
be in the hydraulic system.
4. Remove hydraulic tube between rear pump and
SCV valve.
5. Connect test equipment between rear pump and
SCV valve. Open valve on flow meter fully.
6. Start engine and run at high idle (2500-2700 rpm).
7. Move SCV control lever to open SCV valve to a
closed work port (dead head).
8. Check pressure reading on gauge.
Specifications:
System Pressure (4200) . . . . . 14651 kPa (2125 psi)
System Pressure (4300, 4400) 17237 kPa (2500 psi)
• Pressure too high: Turn system pressure relief
valve counter-clockwise until pressure reading is
within specification.
STEERING PRESSURE
ADJUSTMENT
Reason:
To ensure that steering pump pressure is maintained at
correct level for steering without causing damage to the
system, and to determine if hydraulic pump is worn.
Equipment:
• JT03375 - Adapter Fitting (7/16-20 M 37° X 9/16-18
M ORFS)
• JT03117 - 0-14000 kPa (0-2000 psi) Pressure
Gauge
• JT03017 Hose w/Quick Disconnect Fitting
Procedure:
1. Park tractor on a level surface and set park brake.
2. Shift transmission to NEUTRAL.
IMPORTANT: Make sure to relieve system pressure
before loosening any system lines or hoses.
3. Cycle all controls to relieve any pressure that may
be in the hydraulic system.
4/6/01
11 - 27
ROCKSHAFT LIFT CYCLE TEST
4. Remove hydraulic hose on left side of steering
cylinder.
5. Attach gauge to left steering hose.
HYDRAULICS
ROCKSHAFT LIFT CYCLE TEST
Reason:
NOTE: Turning steering wheel to the right will cause
hydraulic oil to leak out of disconnected
cylinder port. Turn wheel only to left when
performing test.
6. Start engine and run at high idle (2500-2700 rpm).
7. Turn steering wheel to the left. While turning wheel,
check pressure reading on gauge.
To ensure that hydraulic system is functioning correctly
and capable of lifting rated load.
Equipment:
• BW13586 Ballast Box
Procedure:
Specifications:
Pressure . . . . . . . 10342 kPa ± 10% (1500 psi ± 10%)
Results:
• No pressure: Steering hoses may be incorrectly
connected to the SCU. Check hose connections.
• Pressure too low: Relief valve in SCU may be
stuck open or defective; perform steering system
test, (See "STEERING SYSTEM TEST" in
Steering section), or gear pump may be worn;
disassemble and inspect pump. (See "GEAR
PUMP DISASSEMBLY AND INSPECTION").
• Pressure too high: Relief valve in SCU may be
clogged or defective.
227 kg
(500 lbs)
1. Park tractor on a level surface and set park brake.
2. Shift transmission to NEUTRAL.
3. Install BW13586 ballast box, or approximately 227
kg (500 lb), on the three point hitch.
4. Open rate of drop/stop valve completely.
5. Start engine and run at fast idle (2500-2700 rpm).
6. Move lift control lever to full UP position.
7. Time duration of lift cycle from full down to full up.
Specifications
Rockshaft Lift Time . . . . . . . . . . . . . . .2-1/2 to 3 sec.
Results:
If the weight raises slower than specified there may be
internal leakage in the lift cylinder or rockshaft control
valve.
11 - 28
4/6/01
ROCKSHAFT LEAKAGE TEST
HYDRAULICS
ROCKSHAFT LEAKAGE TEST
ROCKSHAFT POSITION FEEDBACK
LINKAGE ADJUSTMENT
Reason:
Reason:
To ensure that hydraulic system is functioning
correctly and capable of lifting rated load.
To ensure that draft arms raise to maximum lift height
without engaging relief valve.
Equipment:
Procedure:
• BW13586 Ballast Box
1. Position tractor on a level surface and set park
brake.
2. Shift transmission to NEUTRAL.
3. Position lift control lever in the full forward (down)
position and provide enough weight on lift arms to
allow self lowering.
4. Start engine.
5. Move lift control lever to full raise position (back).
Procedure:
C
227 kg
(500 lbs)
350±3 mm
(13.8±0.12 in.)
1. Park tractor on a level surface and set park brake.
2. Shift transmission to "neutral".
3. Install BW13586 ballast box, or approximately 227
kg (500 lb), on the three point hitch.
4. Start engine and run at fast idle (2500-2700 rpm).
5. Put lift control lever in full UP position.
6. Raise weight as high as it will go.
7. Close rate of drop/stop valve.
8. Shut off engine.
9. Measure distance weight drops in five minutes.
10. Restart engine, open rate of drop/stop valve fully
and raise weight to full UP position.
11. Shut off engine.
12. Measure distance weight drops in five minutes.
Specifications
Maximum Drop in Five Minutes . . . . . 51 mm (2 in.)
Results:
If the weight drops farther than specified distance with
the stop/drop valve closed (first test) there may be
leakage in the cylinder, relief valve or drop/stop valve.
If the weight drops farther with the drop/stop valve
open (second test) than it did in the first test, there may
be leakage in the rockshaft control valve.
4/6/01
D
B
M95008
A
NOTE: Make sure the PTO shield is in place, and is in
good condition before performing adjustment.
Make sure rubber bumper (A) is in place on
PTO shield.
6. Using a tape measure, measure from the top of the
PTO shield (B) to the center of the pin (C) in end of
lift arm. Lift arm should raise to 350±3 mm
(13.8±0.12 in.) as shown, without engaging the
relief valve. Check that there is 25.4 mm (1 in.) of
slack above the vertical height.
7. If specification is not met, lengthen the lift arm
position feedback rod (D) to increase, or shorten to
reduce the maximum height until within
specification. The relief valve should not engage.
11 - 29
REPAIR
HYDRAULICS
REPAIR
HYDRAULIC GEAR PUMP REMOVAL
& INSTALLATION
D
The hydraulic pumps are the same on both hydrostatic
and gear drive tractors. The only difference in the
removal and installation of the two is in the specific
routing of the individual pressure hoses/tubes.
The two gear pumps are identical in design, but each
uses different suction tube attaching methods, and they
have different displacements.
E
M91334
Removal:
1. Remove engine side panels.
2. (Front Pump Only) If necessary, remove exhaust
pipe from muffler.
B
A
7. Remove two long and two short socket head cap
screws (E) securing pump to engine drive housing.
8. Remove pump.
9. If necessary, remove fitting from pressure side of
pump body.
10. (Front Pump Only) If necessary, remove two cap
screws (F) and suction tube elbow.
Installation:
C
IMPORTANT: Replace all O-rings, gaskets, and
seals. Used or damaged O-rings, gaskets and
seals will leak.
C
M91982
3. Loosen hose clamp (A) on suction tube manifold.
4. Disconnect suction tube manifold from pump.
5. (Rear Pump Only) Loosen two remaining hose
clamps (B) on suction tube manifold. Remove
manifold.
6. Disconnect pressure tube (C) from fitting on bottom
of pump.
11 - 30
1. Install new O-rings on both ends of adapter fitting
and secure to pump body. Tighten front pump
adapter fitting to 21 N•m (180 lb-in.). Tighten rear
pump adapter fitting to 28 N•m (21 lb-ft).
2. (Front Pump Only) Install new O-ring on suction
tube elbow, and secure to pump with two cap
screws. Tighten to 9 N•m (84 lb-in.).
3. Install new gasket on front cover where pump
attaches to engine drive housing.
4. Align splines on pump input shaft with splines on
engine drive. Insert pump into engine housing.
5. Secure pump with four socket head cap screws.
Tighten to 22 N•m (192 lb-in.).
6. Attach pressure tube to adapter fitting. Tighten tube
nut on front pump to 50 N•m (37 lb-ft). Tighten
tube nut on rear pump to 69 N•m (51 lb-ft).
7. Inspect suction tube manifold for damage or
cracking. Replace if necessary.
8. Attach suction tube manifold to pump. Secure with
hose clamps.
4/6/01
GEAR PUMP DISASSEMBLY & INSPECTION
HYDRAULICS
GEAR PUMP DISASSEMBLY &
INSPECTION
C
D
1. Remove pump from engine. (See "HYDRAULIC
GEAR PUMP REMOVAL AND INSTALLATION").
A
M91337
M91335
2. Remove two large and two small socket head cap
screws (A) and lock washers securing pump cover
to pump body.
3. Remove pump cover.
4. Inspect pump cover for wear or damage. If
necessary, replace pump.
6. Remove O-ring (C) and formed O-ring gaskets (D).
7. Remove front cover.
8. Inspect front cover for scoring, wear, or damage. If
necessary, replace pump.
E
C
B
M91340
9. Inspect front cover shaft seal (E) for cracks, wear, or
damage. If necessary, replace seal.
M91336
F
5. Remove two backing washers (A).
M91338
10. Remove two backing washers (F).
4/6/01
11 - 31
GEAR PUMP ASSEMBLY
HYDRAULICS
18. Inspect inside of bushings for scoring or excessive
scratching. Measure bearing surfaces. Replace
bushings if damaged or not within specifications.
19. Inspect pump body internal surfaces for scoring or
excessive scratching. Replace pump if damaged.
H
G
Specifications:
M91339
11. Remove O-ring (G) and formed O-ring gaskets (H).
Shaft Bushing Maximum ID. . . 19.15 mm (0.754 in.)
Shaft Bearing Surface:
Minimum OD . . . . . . . . . . . . . 18.95 mm (0.746 in.)
Bushing Minimum Thickness Steering (Front) . . . . . . . . . . 13.57 mm (0.534 in.)
Bushing Minimum Thickness Implement (Rear) . . . . . . . . . 19.02 mm (0.749 in.)
Drive/Idler Gear Minimum Thickness:
Front Pump (Steering) . . . . . . 9.43 mm (0.371 in.)
4200 Rear Pump (Implement)14.99 mm (0.590 in.)
4300/4400 Rear Pump
(Implement). . . . . . . . . . . . . . 17.63 mm (0.694 in.)
GEAR PUMP ASSEMBLY
J
036 or 372
I
I
038 or 374
K
038 or 374
M91341
036 or 372
NOTE: Markings on pump bushings varies depending
on pump capacity. Markings may vary from
what is shown on art.
M91342
036 or 372
12. Note the location and markings on four bushings (I)
to ensure correct orientation at assembly.
13. Remove four bushings, drive gear (J), and idler
gear (K) from pump as an assembly.
14. Remove bushings from gears.
15. Inspect gears and bushing faces for scoring,
excessive scratching, or damage. If necessary,
replace pump.
16. Inspect input gear shaft splines. If damaged,
replace pump.
17. Measure gear shaft bearing surfaces. If not within
specifications, replace pump.
11 - 32
Note Hole
Location
038 or 374
M91350
4/6/01
GEAR PUMP ASSEMBLY
HYDRAULICS
1. Lay pump body on a clean, flat surface, and install
back bushings into bore as shown. Push bushings
to bottom of bore.
H
G
NOTE: Idler gear is symmetrical and can be placed in
pump body either end first.
J
K
M91339
4. Install O-ring (G) and formed O-ring gaskets (H).
M91351
F
2. Install drive gear (J) and idler gear (K) into pump
body and bushings.
038 or 374
M91338
036 or 372
M91356
3. Install front bushings into pump body and onto drive
gear and idler gear shafts.
5. Install two backing washers (F).
6. If not already done, install new shaft seal in front
cover using a suitable driver.
7. Install front cover over drive gear shaft and onto
pump body.
D
C
M91337
8. Turn pump over, and install O-ring (D) and formed
O-ring gaskets (D).
4/6/01
11 - 33
ROCKSHAFT ASSEMBLY
HYDRAULICS
8. Remove rockshaft hydraulic pressure tube (A).
B
B
C
M91336
M91995
9. Install two backing washers (B).
10. Install rear cover and secure with two small (M8),
and two large (M10) socket head cap screws.
Tighten M8 cap screws to 28 N•m (240 lb-in.), and
M10 cap screws to 55 N•m (40 lb-ft).
11. Install pump. (See "HYDRAULIC GEAR PUMP
REMOVAL AND INSTALLATION").
9. Remove two seat standoffs (B).
10. Disconnect SCV (if equipped) or manifold block
pressure tube (C).
ROCKSHAFT ASSEMBLY
Removal:
1. Remove seat and seat support. (See "SEAT AND
SEAT SUPPORT" in Miscellaneous section.)
2. Remove seat close out panels. (See "SEAT CLOSE
OUT PANELS" in Miscellaneous section.)
3. Remove kick plate. (See "KICK PLATE" in
Miscellaneous section.)
4. Remove three point hitch. (See "THREE POINT
HITCH" in Miscellaneous section.)
5. Remove park brake lever and linkage. (See
"PARKING BRAKE LINKAGE REMOVAL AND
INSTALLATION" in Brakes section.)
6. Disconnect lighting wiring harness on RH side of
tractor where wiring harness enters ROPS.
7. Move wiring harness clear of rockshaft housing.
D
D
M91997
11. Remove twelve cap screws (D) securing rockshaft
housing to transmission. Gently pry up around
edge of rockshaft cover to loosen.
A
M91996
11 - 34
4/6/01
ROCKSHAFT LIFT ARMS
HYDRAULICS
1. Remove snap ring (A) and washer from end of cam
plate pin. Disconnect position feedback rod (B).
2. Remove cap screw (C) from end of rockshaft.
c CAUTION
The approximate weight of the rockshaft
assembly is 39 kg (85 lb). Do not attempt to
remove rockshaft assembly without an assistant
or overhead crane.
NOTE: Two spring pins (D) retain cam plate to
rockshaft.
12. Remove rockshaft housing from final drive housing.
D
Installation:
NOTE: Installation is reverse of removal.
• Clean sealing surfaces of rockshaft and final drive
housing. Install a new bead of sealant (TY16021)
on transaxle rockshaft mounting surface.
• If lift arms have been removed they must be reset.
(See "LIFT ARMS ADJUSTMENT").
• Tighten 8.8 grade cap screws to 55 N•m (40 lb-ft).
• Tighten 10.9 grade cap screws to 80 N•m (60 lb-ft).
M91999
3. Remove cam plate.
E
ROCKSHAFT LIFT ARMS
Removal:
NOTE: Lift arms may be removed with rockshaft
assembly installed in tractor. DO NOT remove
splined cross shaft unless rockshaft is first
removed from tractor. Internal components will
fall into transmission if splined cross shaft is
removed while rockshaft is attached to
transmission.
M94640
C
4. If not already done, use center punch to mark (E)
splined cross shaft and lift arm.
5. Remove lift arm from splined cross shaft.
A
B
M91998
4/6/01
11 - 35
ROCKSHAFT LIFT ARMS
HYDRAULICS
G
F
M91364
H
6. Remove washer (F) from splined cross shaft.
7. Remove outer O-ring (G) from groove in housing.
NOTE: DO NOT remove splined cross shaft unless
rockshaft is first removed from vehicle. Internal
components will fall into transmission if splined
cross shaft is removed while rockshaft is on
transmission.
If rockshaft assembly is still installed on
transmission, remove right lift arm only.
M94642
9. If necessary, remove spring pin (H) and separate
rockshaft lever arm and piston rod. Remove lever
arm and piston rod from rockshaft housing.
NOTE: Inner O-ring may come out of bore with splined
sleeve when removed.
I
M94641
M91368
8. Remove right side lift arm and splined cross shaft
from housing as a unit.
10. Remove two splined sleeves (I) from housing.
NOTE: If right side lift arm must be removed from
splined cross shaft, use center punch to mark
shaft and lift arm for alignment.
11 - 36
NOTE: Beveled ends of the splined sleeves should
face inward.
There is an O-ring in ID of beveled end of
splined sleeve.
4/6/01
ROCKSHAFT LIFT ARMS
HYDRAULICS
G
L
J
M91365
11. Remove inner O-ring (J) from bore of rockshaft
housing.
K
M91371
5. Install new outer O-ring (G) into groove between
splined sleeve and rockshaft housing.
6. Align punch marks and assemble right side lift arm
to splined cross shaft. Secure with large washer,
and cap screw.
M91366
12. Remove O-rings (K) from bevelled end of splined
sleeves.
13. Inspect splines on ID of splined sleeves for
damage. Inspect OD for grooves or excessive
wear. Replace as required.
14. Measure OD of splined sleeves. If not in
specification, replace.
15. Measure ID of bushing (L) in housing. If not in
specification, replace.
M94644
7. Install washer onto rockshaft against right side lift
arm.
NOTE: Install shaft carefully to prevent splined cross
shaft from knocking O-ring out of groove in
bevelled end of splined sleeve.
Specifications:
Splined Sleeve Minimum OD. . . 46.5 mm (1.832 in.)
Bushing Maximum ID. . . . . . . . . 44.2 mm (1.738 in.)
8. Install right side lift arm and rockshaft into right
splined sleeve in rockshaft housing.
Installation:
E
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
1. If required, use a piloted bushing driver to install
new bushings (L) into rockshaft housing.
2. Install two new inner O-rings (J) into rockshaft
housing against bushings.
3. Install new O-rings (K) into bevelled end of two
splined sleeves.
4. Install right side splined sleeve into rockshaft
housing with bevel to the inside.
4/6/01
M91369
11 - 37
ROCKSHAFT LIFT ARMS
HYDRAULICS
9. Align punch marks on splined cross shaft and
rockshaft lever arm and install cross shaft through
lever arm and into housing.
10. Install left side splined bushing into rockshaft
housing and onto splined cross shaft.
11. Install outer O-ring (G) into groove between splined
sleeve and rockshaft housing.
14. Replace spring pins in lift arm or cam plate if
damaged.
C
A
G
F
M91998
M91364
12. Install washer (F) onto splined cross shaft.
15. Install cam plate and retain with cap screw (C).
16. Attach position feedback rod and retain with washer
and snap ring (A).
NOTE: Whenever the rockshaft feedback mechanism
has been disturbed, be sure to adjust
Rockshaft Position Feedback Linkage. (See
"ROCKSHAFT
POSITION
FEEDBACK
LINKAGE ADJUSTMENT").
E
Specifications:
Lift Arm Raise Angle (Above Horizontal) . . . . . . . 50°
Lift Arm Lower Angle (Below Horizontal) . . . . . . 20°
Total Lift Arm Range . . . . . . . . . . . . . . . . . . . . . . . 70°
Maximum Variance Between Lift Arms . . . . . . . . . 5°
M89408
13. Align punch marks (E) on lift arm and splined cross
shaft, and install left side lift arm onto shaft.
D
M91999
11 - 38
4/6/01
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
ROCKSHAFT DISASSEMBLY AND
ASSEMBLY
Disassembly:
D
H
M94669
B
3. Remove two cap screws (H).
C
A
B
M94645
I
M94647
1. Remove two lock nuts (A), four washers (B) and two
cap screws (C) that retain control lever to lever arm
(D). Remove control lever.
4. Remove shaft support tube (I).
F
G
D
E
M94648
M94646
5. Remove two remaining cap screws and rockshaft
valve cover.
2. Remove lock nut (E), lever arm(D), four belleville
washers(F), and one flat washer (G).
4/6/01
11 - 39
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
N
J
K
M94652
J
M94649
6. Remove two snap rings (J), two flat washers, and
link (K).
9. Replace three O-rings (N).
P
L
O
Q
L
M94650
R
M94653
7. Remove two washers (L).
10. Remove cotter pin (O) and washer, and disconnect
position feedback rod (P) from feedback lever (Q).
11. Remove spring pin (R), and feedback lever.
M
M94651
8. Remove three socket head cap screws (M) and
rockshaft control valve.
M94663
12. Slide limiter (S) away from rockshaft housing.
Remove woodruff key.
11 - 40
4/6/01
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
U
T
S
M94658
18. Remove plastic cap on top of cylinder head.
W
M94654
13. Remove lift control shaft (T) from rockshaft
housing. Remove limiter (S) and rubber washer
(U).
14. Remove position feedback shaft (W) from housing.
15. Replace O-rings on lift control and position
feedback shafts.
M94659
X
19. Remove plug and spring.
M94655
16. Remove relief valve (X).
M94662
20. Remove ball.
Y
M94656
M94658
17. Replace two O-rings in relief valve.
4/6/01
11 - 41
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
21. Remove two cap screws (Y) and rate of drop/stop
valve stem.
M94661
M94657
25. Place a suitable bolt in threaded hole in end of
piston. Remove piston.
22. Replace O-ring in end of valve stem.
M94667
26. Replace inner and outer piston rings.
Assembly:
M94660
23. Remove cylinder head. Replace O-rings in cylinder
head.
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
NOTE: When assembling, DO NOT lubricate belleville
washers or lift control lever friction surfaces.
1. Install a new inner and outer piston rings.
Z
IMPORTANT: Use care when installing piston into
cylinder bore to prevent damage to piston rings.
Be sure piston rings are centered in cylinder
bore and properly seated in piston ring groove
during installation.
M94668
24. Remove rate of drop/stop valve spool (Z). Replace
O-ring on spool.
11 - 42
2. Lubricate piston and rings liberally with hydraulic oil.
Using a plastic mallet, install piston into cylinder
bore.
3. Install new O-rings into cylinder head.
4. Install cylinder head into cylinder bore. Retain with
two lower cap screws. Tighten cap screws to 80
N•m (60 lb-ft).
4/6/01
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
Z
M94658
M94668
9. Install plastic cap on top of cylinder head.
5. Install a new O-ring onto rate of drop/stop valve
spool (Z). Install rate of drop/stop valve spool into
bore in cylinder head.
6. Install a new O-ring into end of rate of drop/stop
valve stem. Install rate of drop/stop valve stem
onto cylinder head and retain with two cap screws.
M94656
10. Install two new O-rings in relief valve.
X
M94662
7. Install ball.
M94655
11. Install relief valve (X). Tighten to 50 N•m (37 lb-ft).
M94659
8. Install plug and spring.
4/6/01
11 - 43
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
U
P
O
T
S
Q
R
W
M94653
M94654
12. If removed, install washers onto lift control (T) and
position feedback (W) shafts.
13. If removed, install snap rings onto lift control and
position feedback shafts.
14. Install new O-rings onto lift control and position
feedback shafts.
15. Install lift control shaft into rockshaft housing. Install
rubber washer (U) and limiter (S) onto shaft.
16. Install position feedback shaft into housing.
18. Install feedback lever (Q) onto feedback shaft.
Retain with spring pin (R).
19. Connect position feedback rod (P) to position
feedback lever. Retain with washer and cotter pin
(O).
N
M94652
S
M94663
20. Install new O-rings (N) into rockshaft control valve
and rockshaft housing at rockshaft valve mounting
surface.
17. Install woodruff key into shaft. Slide limiter over
woodruff key and against rockshaft housing.
11 - 44
4/6/01
ROCKSHAFT DISASSEMBLY AND ASSEMBLY
HYDRAULICS
M
I
M94647
M94651
21. Install rockshaft control valve and retain with three
socket head cap screws (M). Tighten cap screws
to 47 N•m (35 lb-ft).
24. Install shaft support tube (I) onto lift control shaft
and retain with two cap screws. Tighten cap
screws to 80 N•m (60 lb-ft).
IMPORTANT: Make sure that Belleville washers are
correctly installed with cupped sides of each
pair of washers facing each other.
NOTE: Lever arm should be installed so that when the
lever if in the full forward (down) position, the
lever arm is parallel to the ground.
L
F
L
M94650
22. Install two washers (L).
G
D
J
E
K
J
M94646
25. Install washer (G), four belleville washers (F), and
lever arm (D) to shaft. Retain with lock nut (E).
M94649
23. Install link (K). Retain with two flat washers, and
two snap rings (J).
4/6/01
11 - 45
SELECTIVE CONTROL VALVE REMOVAL AND INSTALLATION
HYDRAULICS
D
A
B
A
B
C
M94675
9. Remove cotter pin (A) and washer securing PTO
link (B) to PTO lever. Move link clear of SCV.
B
M94645
26. Install control lever to lever arm. Retain with two
cap screws (C), four washers (B), and two lock
nuts (A).
SELECTIVE CONTROL VALVE
REMOVAL AND INSTALLATION
NOTE: Tractor may be equipped with a manifold block
instead of an SCV. Removal and installation of
this block is basically the same as that of the
SCV.
Removal:
1. Remove seat and seat support. (See "SEAT AND
SEAT SUPPORT") in Miscellaneous section.)
2. Disconnect electrical connector from hazard light
switch.
3. If equipped, remove mid PTO control knob.
4. Remove SCV control knob, rockshaft control knob,
and PTO control knob.
5. Remove 5 cap screws and right closeout panel from
SCV and rockshaft lift control levers.
6. Remove gear shift knob. Remove four cap screws
and left closeout panel from gear shift levers.
7. Remove two cap screws securing closeout panel at
front of seat to kick plate. Remove closeout panel.
8. Under fenders, locate front cap screw that secures
fenders to seat support angle. Remove two cap
screws and seat support angle.
11 - 46
C
M91391
NOTE: Wheel, tire, and fender removed for clarity.
10. Disconnect four tubes (C) from bottom of SCV.
4/6/01
HYDRAULICS
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY
Installation:
H
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
G
Installation is the reverse of removal.
• Tighten ends of J-shaped tube to 81 - 89 N•m
(60 - 67 lb-ft).
• Tighten SCV work port tube ends to
51 - 57 N•m (38 - 42 lb-ft).
E
F
SELECTIVE CONTROL VALVE
DISASSEMBLY, INSPECTION, &
ASSEMBLY
C
Disassembly, Inspection, and Assembly
M94676
11. Remove J-shaped tube (D) from SCV to rockshaft
housing.
12. Disconnect SCV pressure tube (E).
13. Remove two cap screws (F), two lock nuts, and four
washers. Remove rockshaft control lever (G).
NOTE: Some internal components of SCV are NOT
serviceable. If SCV internal components are
excessively worn or damaged, check for
availability of kits.
1. Remove control valve shift linkage.
NOTE: SCV control linkage may be either a single lock
model or a multi-lock model.
NOTE: On tractors equipped with mid PTO, it may be
necessary to remove mid PTO control shaft
before SCV can be removed.
14. Remove three cap screws (H) securing SCV and
PTO lever bracket to final drive housing. Remove
PTO lever bracket and SCV.
I
M94678
15. Replace two O-rings (I) between final drive housing
and SCV.
4/6/01
11 - 47
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY HYDRAULICS
Single Lock Control Removal:
Multi-Lock Control Removal:
8
8
2
10
9
7
3
1
6
5
6
7
1
4
5
1
2
3
4
1. Link Rod
5. Cotter Pin
2. Spacer
6. Pin
1. Ball Joints
6. Pin
3. Pin
7. Guide Bar
2. Washer
7. Cap Screw
4. Bellcrank
8. Lever
3. Nut
8. Lever
4. Bellcrank
9. Lock Lever
5. Cotter Pin
10. Spring
1. Remove nuts and washers securing link rods to
bellcranks.
2. Remove four cap screws retaining lever assembly to
valve body. Remove lever assembly.
1. Remove nuts and washers securing ball joints to
bellcranks.
2. Remove four cap screws retaining lever assembly to
valve body. Remove lever assembly.
11 - 48
4/6/01
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY
HYDRAULICS
SCV Disassembly:
3. O-ring
6. Small Balls
9. Detent Cap
NOTE: Use care when removing valve spool and
detent assembly from valve body. Detent cap
may come off, and balls may fall out and be
lost. Push valve spool out from lever side to
remove.
A
M91395
1. Remove four socket head cap screws (A) on end
cover. Remove end cover. Replace end cover
gasket.
3. Slide spool with detent assembly out of valve body.
4. Inspect spool and valve body for signs of wear or
damage. If worn or damaged, replace entire
selective control valve assembly.
5. Remove spacer from spool.
6. Remove seal, backing washer, and O-ring from
valve body. Replace O-ring and seal.
9
6
B
M91398
M91396
NOTE: Valve spools are similar. Center valve section
does NOT contain a detent assembly.
7. Remove detent cap (9) by inserting a suitable pin
punch into the threaded hole and pressing inward
to release spring tension on balls (6). Slide detent
cap off end of spool.
9
6
2. Hold spring slightly compressed and remove spring
retainer plug (B) and valve spring retainer.
Remove spring.
5
6
8
3
1
M91399
M91397
4
8. Remove detent cap.
9. Remove four small balls.
7
2
9
7
1. Seal
4. Spacer
7. Spring
2. Washer
5. Spool
8. Ball
4/6/01
8
M91647
11 - 49
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY HYDRAULICS
10. Remove larger ball (8), and spring (7).
Valve Spools Assembly:
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
8. Install O-ring, backing washer, and seal into valve
body.
9. Install spring, spring retainer, and valve spring
retainer plug. Tighten plug to 15 N•m (133 lb-in.).
10. Install end cover. Retain with four socket head cap
screws. Tighten cap screws to 19 N•m (14.5 lb-ft).
11. Install lever assembly. Retain with four cap screws.
Tighten cap screws to 40 N•m (30 lb-ft).
1. Install spring and ball into end of valve spool.
Load Check Valves:
Removal:
9
8
7
6
A
5
M91648
2. Apply a small amount of general purpose grease
into the holes for the small balls (6) on the valve
spool.
3. Insert four small balls into holes in valve spool.
4. Slide detent cap (9) over end of valve spool. Do not
slide over balls at this time.
1. Remove valves (A).
B
C
D
M91649
2. Replace O-ring (B).
3. Inspect spring (C) and valve poppet (D) for wear or
damage. Replace if necessary.
M91398
Installation:
Installation is the reverse of removal.
5. Using a suitable pin punch, press on the ball in the
end of the spool to slightly compress the spring.
Slide detent cap over four small balls.
NOTE: When properly installed, the four small balls will
retain the larger ball, and maintain spring
pressure on the larger ball.
6. Install spacer onto spool.
7. slide spool into valve body.
11 - 50
4/6/01
HYDRAULICS
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY
D
G
E
F
M91651
2. Replace O-rings (F) and backing washers (G).
3. Inspect valve for wear or damage. Replace if
necessary.
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
Installation:
Installation is the reverse of removal.
• Tighten check valve to 24 N•m (18 lb-ft).
IMPORTANT: Replace all O-rings and seals. Used
or damaged O-rings and seals will leak.
Relief Valve:
Removal:
• Tighten relief valve to 50 N•m (37 lb-ft).
NOTE: If replacement of relief valve was necessary, or
if relief valve setting was changed, perform
SCV pressure relief valve adjustment. (See
"SYSTEM PRESSURE ADJUSTMENT").
E
M91650
1. Remove valve (E).
4/6/01
11 - 51
SELECTIVE CONTROL VALVE DISASSEMBLY, INSPECTION, & ASSEMBLY HYDRAULICS
11 - 52
4/6/01
CONTENTS
MISCELLANEOUS
CONTENTS
Page 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT PTO SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THREE POINT HITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SEAT AND SEAT SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEAT CLOSE OUT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROLL OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
KICK PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATOR’S PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUSE PANEL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
KEY SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COWL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAB REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CAB REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WINDSHIELD WASHER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAB WATER LINE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CAB HEATER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PTO GEARBOX REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PTO INSTALLATION KIT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PTO GEARBOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PTO GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PTO GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4/6/01
12 - 1
NOTES
12- 2
MISCELLANEOUS
4/6/01
MISCELLANEOUS
SPECIFICATIONS
SPECIFICATIONS
TORQUE SPECIFICATIONS
Wheel Mounting Bolts:
Front and Rear Wheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Front wheels (Model 4200 Equipped With 4.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Front Wheels (Model 4300 Equipped With 5.0 x 15 F2 Ribbed Tires) 68 N•m (50 lb-ft)
Wheel Disc-to-Rim Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
Steering Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 49 N•m (29 - 36 lb-ft)
Center Link Bracket Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 N•m (110 lb-ft)
Center Link Spring Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 N•m (70 lb-ft)
ROPS Attaching Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 N•m (250 lb-ft)
FRONT PTO SPECIFICATIONS
Drive Shaft Greasing Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hours
Gear Box Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Hours
Front PTO Speed (At 2700 Engine RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 rpm
4/6/01
12 - 3
REPAIR
MISCELLANEOUS
REPAIR
THREE POINT HITCH
Center Lift Link Removal:
F
C
E
D
B
A
M95262
M95263
1. Disconnect center lift link from storage hook.
2. Remove lynch pin (A) from hitch pin attaching
center lift link to bracket on rockshaft.
3. Support center lift link and remove hitch pin (B).
Remove center lift link.
Installation:
Installation is the reverse of removal.
Draft Arm & Adjustable Sway Bar Removal:
12 - 4
1. Remove spring clip (C) from clevis pin on front of
adjustable sway bar. Remove clevis pin.
2. Remove spring pin (D) from hitch pin on bottom of
adjustable lift link (E).
3. Support draft arm and adjustable sway bar and
remove hitch pin and two retainers.
4. Remove lynch pin (F) from anchor pin at front of
draft arm.
5. Remove adjustable sway bar and draft arm.
Installation:
Installation is the reverse of removal.
Adjustable (RH) and Fixed (LH) Lift Link Removal:
4/6/01
SEAT AND SEAT SUPPORT
MISCELLANEOUS
SEAT CLOSE OUT PANELS
Removal:
G
A
B
H
D
M95264
C
1. Remove lynch pin (G) from rockshaft at top of lift
link (H).
2. Remove lift link.
Installation:
Installation is the reverse of removal.
SEAT AND SEAT SUPPORT
Removal:
1. Disconnect seat switch electrical connector.
2. Remove two cap screws at rear of seat support
attaching seat support to tractor frame.
3. Remove two nuts at front of seat support attaching
seat support to operators platform and standoffs.
4. Remove seat and seat support from tractor as an
assembly.
M95267
1. Remove cap on range shift knob (A) to left of seat.
Remove cap screw and knob.
2. (Collar Shift or SyncReverser Tractor) Repeat step
1 and remove gear shift knob (B).
3. If equipped, unscrew and remove 4-WD T-handle
knob.
4. Remove cap screws (C) securing shift lever gate
and remove gate.
D
E
Installation:
Installation is the reverse of removal.
F
G
M95266
5. Unscrew SCV control knob (D) and remove.
6. Remove rockshaft control knob (E).
7. Remove PTO control knob (F).
8. Remove cap screws (G) securing SCV/rockshaft
control lever gate and remove gate.
9. Remove seat. (See "SEAT AND SEAT SUPPORT").
4/6/01
12 - 5
REAR FENDERS
MISCELLANEOUS
I
D
H
M95265
B
10. Remove two cap screws (H) and seat closeout
panel (I).
C
M95269
Installation:
Installation is the reverse of removal.
NOTE: If removed, install rear wheel fenders before
installing seat platform.
REAR FENDERS
NOTE: The following procedure is for either LH or RH
fender.
If tractor is equipped with an auxiliary SCV,
disconnect two control cables at valve before
removing RH fender.
2. Remove front cap screw (B) securing fender to seat
support angle.
3. Remove cap screw (C) securing fender to ROPS.
IMPORTANT: It may be necessary for an assistant
to support the fender when removing the cap
screws securing it to the ROPS.
4. Support fender and remove nut (D) and washer
securing fender to ROPS. Remove fender.
Installation:
Removal:
Installation is the reverse of removal.
ROLL OVER PROTECTIVE
STRUCTURE (ROPS)
Removal:
A
M95268
1. Remove three lock nuts (A) and carriage bolts
securing fender to operator’s platform.
12 - 6
1. Remove rear wheels and tires. (See "REAR
WHEELS").
2. Remove seat and seat support. (See "SEAT AND
SEAT SUPPORT").
3. Remove rear fenders. (See "REAR FENDERS").
4. Remove seat close out panels. (See "SEAT CLOSE
OUT PANELS").
5. Disconnect wiring harness electrical connectors
from wiring inside roll bar (warning light
connectors, work light connectors, tail light
connectors).
4/6/01
FRONT WHEELS
MISCELLANEOUS
onto suitable stands that will support the
tractor by the frame.
c CAUTION
3. Remove lug bolts and wheel.
The approximate weight of the ROPS is 57 kg
(125 lb). Do not attempt to remove ROPS without
an assistant or overhead crane.
E
Installation:
1. Install wheel onto axle, insert lug bolts and lightly
tighten bolts.
2. Raise front of tractor, remove support stands and
lower tractor to floor.
3. Tighten lug bolts to following specification:
Specifications:
Lug Bolt Torque . . . . . . . . . . . . . . . 122 N•m (90 lb-ft)
4200 with 4.0x15 F2 Ribbed Tires . . 68 N•m (50 lb-ft)
4300 with 5.0x15 F2 Ribbed Tires . . 68 N•m (50 lb-ft)
REAR WHEELS
IMPORTANT:
If both rear wheels are to be
removed, support the tractor frame in a manner
that will prevent the frame from pivoting on the
front axle.
M94684
F
6. If equipped, remove cap screw and nut securing
ROPS to auxiliary SCV bracket.
7. Remove four cap screws (E) and nuts securing
ROPS to support plates (F) on underside of rear
axle.
8. Lift ROPS to clear tractor, and remove.
Installation:
Installation is the reverse of removal.
• Tighten hardware to specifications:
Torque Specifications:
ROPS Mounting Cap Screws to Nuts
. . . . . . . . . . . . . . . . . . . . . . . . . . 340 N•m (250 lb-ft)
Removal:
1. Loosen lug bolts slightly before raising tractor rear
axle.
2. Raise rear of tractor and lower onto support stands
so that tractor is supported by rear axle.
NOTE:
If the rear wheels are being removed to
perform work on the rear axles, lower tractor
onto suitable stands that will support the
tractor frame.
3. Remove lug bolts and wheel.
Installation:
1. Install wheel onto axle, insert lug bolts and lightly
tighten bolts.
2. Raise rear of tractor, remove support stands and
lower tractor to floor.
3. Tighten lug bolts to 88 - 108 N•m (65 - 80 lb-ft).
FRONT WHEELS
Removal:
1. Loosen lug nuts slightly before raising tractor front
axle.
2. Raise front of tractor and lower onto support stands
so that tractor is supported by front axle.
NOTE:
4/6/01
If the front wheels are being removed to
perform work on the front axles, lower tractor
12 - 7
FLOOR MAT
MISCELLANEOUS
FLOOR MAT
OPERATOR’S PLATFORM
Removal:
Removal:
1. Remove fuse panel cover. (See "FUSE PANEL
COVER").
2. Remove all plastic rivets holding rubber mat to floor
plate.
1. Remove fuse panel cover (See "FUSE PANEL
COVER").
2. Remove floor mat. (See "FLOOR MAT").
3. Remove kick plate (See "KICK PLATE").
IMPORTANT:
(HST Model) Use care when
removing floor mat from forward and reverse
pedals. It may be necessary to remove pedal
pads to prevent damage to floor mat.
3. Lift and remove floor mat.
Installation:
A
Installation is the reverse of removal.
M95268
SIDE PANELS
Removal:
1. Raise hood and support with hood prop latch.
2. Pull out side panel lock clips and turn to release top
of panel.
3. Tilt top of side panel out. Lift and remove panel from
tractor.
Installation:
1. Position the two tabs on the bottom of the side
panel on the wire loops welded to the tractor
frame.
2. Lower the side panel into position, making sure the
panel lock clips are in the correct position to go
through the slots in the top of the side panels.
3. Tilt panel into position and onto lock clips. Pull and
turn lock clips to lock panel to tractor. Fold lock
clips flat.
4. Close and latch the hood.
KICK PLATE
NOTE: Wheel and tire removed for clarity.
4. Remove six lock nuts (A) and carriage bolts
securing operator’s platform to fenders.
5. (HST Model) Remove two nuts and carriage bolts
securing forward pedal. Remove pedal. Repeat for
reverse pedal.
6. Remove six cap screws, lock nuts, and washers
from rubber isolators attaching platform to frame.
7. If equipped, remove cotter pin and washer, and
disconnect differential lock rod from pedal. Move
pedal toward rear of tractor to clear operator’s
platform.
8. Lift operator’s platform slightly, and slide rearward.
Remove operator’s platform. Inspect rubber
isolators for cracks and deterioration. Replace as
necessary.
Installation:
Installation is the reverse of removal.
Removal:
1. Remove rate of drop knob from control shaft at front
edge of seat.
2. Remove seat and seat support. (See "SEAT AND
SEAT SUPPORT").
3. Remove seat close out panels. (See "SEAT CLOSE
OUT PANELS").
4. Remove 5 cap screws through isolators attaching
kick plate to operator’s platform. Remove kick
plate.
Installation:
Installation is the reverse of removal.
12 - 8
4/6/01
STEERING WHEEL
MISCELLANEOUS
STEERING WHEEL
FUSE PANEL COVER
Removal:
1. Remove steering wheel center cap.
2. Remove lock nut.
3. Remove steering wheel. If necessary, use a suitable
puller.
Installation:
NOTE:
Lubricate the steering shaft splines with
general purpose grease before installing
steering wheel.
Removal:
1. Remove two cap screws from RH and LH side top
edge of cover.
2. Open fuse panel door. Remove two cap screws
from top edge of cover inside door.
3. Tilt top of cover towards seat.
4. Lift and remove cover.
Installation:
Installation is the reverse of removal.
GRILLE
Removal:
1. Open hood and support on hood prop latch.
2. Remove side panels. (See "SIDEPANELS").
3. Pull out 2 panel lock clips at top of grille, and turn to
release top of grille.
A
M91921
1. Remove center cap retaining ring from steering
wheel.
2. Install steering wheel and retain with nut. Tighten
steering wheel nut to 39-49 N•m (29-36 lb-ft).
3. Install plastic retaining ring to steering wheel center
cap.
4. Install center cap and retaining ring to steering
wheel.
CONTROL PANEL
Removal:
1. Disconnect negative (–) battery cable.
2. Remove steering wheel. (See "STEERING
WHEEL").
3. Remove throttle control knob.
4. Remove screws securing control panel; lift off the
panel.
5. Disconnect all wiring harness connectors to control
panel.
6. Remove control panel.
M91769
4. Tilt top of grille forward and disconnect the
headlight connectors (A).
5. Lift and remove grille from tractor.
Installation:
1. Slide the bottom of the grille under the battery tray.
Insert the locating tabs on the bottom of the grille
into the wire loops welded to the tractor frame.
2. Connect the headlights.
3. Tilt grille into position and onto lock clips. Pull and
turn lock clips to lock grille to tractor. Fold lock clips
flat.
4. Install side panels. (See "SIDE PANELS").
5. Lower the hood.
Installation:
Installation is the reverse of removal.
4/6/01
12 - 9
BATTERY
MISCELLANEOUS
BATTERY
clamps.
4. Connect positive (+) battery terminal clamp. Tighten
positive battery clamp bolt securely.
5. Connect negative (–) battery terminal clamp.
Tighten negative battery clamp bolt securely.
Removal:
c CAUTION
Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode.
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
• Antidotes:
• External: Flush with clear water for at least 15
minutes. Call a Physician Immediately.
• Internal: Drink large quantities of milk or
water. Follow with Milk of Magnesia or
Vegetable Oil. Call a Physician Immediately.
• Eyes: Force eye open and flush with clear
water for at least 15 minutes. Call a
Physician Immediately.
• Neutralize all Acid spills with a solution of 1
part baking soda to 5 parts water.
1. Remove grille. (See "GRILLE").
A
KEY SWITCH PANEL
Removal:
1. Remove steering wheel tilt locking lever knob.
2. Disconnect battery negative (–) cable.
3. Remove fuse panel cover. (See "FUSE PANEL
COVER").
4. Remove two screws attaching key switch panel to
console. Slide key switch panel down and away
from console.
5. Disconnect key switch electrical connector and
remove panel.
Installation:
Installation is the reverse of removal.
COWL PANEL
Removal:
1. Remove side panels. (See "SIDEPANELS").
1. Remove steering wheel (SEE "STEERING
WHEEL").
2. Remove control panel. (See "CONTROL PANEL").
3. Remove fuse panel cover. (See "FUSE PANEL
COVER").
4. Remove key switch panel. (See "KEY SWITCH
PANEL").
5. Raise hood and support with hood prop latch.
B
C
M95024
A
2. Disconnect negative (–) battery cable (A).
3. Disconnect positive (+) battery cable (B).
4. Loosen two cap screws (C) and battery hold downs.
5. Remove battery.
Installation:
1. Clean both battery terminals before installation.
2. Check for proper battery fluid level.
3. Install battery and secure with battery hold down
12 - 10
B
M91770
6. Remove cap screw under rear of hood at top front
of cowl panel.
7. Support panel and remove cap screw (B) from side
of panel at bottom. Remove shroud panel.
8. Repeat for other side.
4/6/01
ENGINE HOOD
MISCELLANEOUS
Installation:
Installation is the reverse of removal.
B
ENGINE HOOD
Removal:
1. Open hood and support on hood prop latch.
A
NOTE: An assistant may be required to support hood
during removal.
2. Remove four cap screws and nuts attaching hood to
LH and RH hinges.
3. Remove hood.
Installation:
D
F
Installation is the reverse of removal.
E
FUEL TANK
C
Removal:
c CAUTION
Diesel fuel is flammable! Extinguish all open
flames before working on fuel system. Do not
smoke.
1. Park tractor on level surface, shut engine off,
engage park brake.
2. Allow tractor and engine to cool before attempting
to service fuel system.
3. Remove engine side panels.
4. Remove steering wheel. (See "STEERING
WHEEL").
5. Remove control panel. (See CONTROL PANEL").
6. Remove key switch panel (See "KEY SWITCH
PANEL").
7. Remove cowl panels. (See "COWL PANEL").
8. Remove hood. (See "ENGINE HOOD").
9. Remove brake pedal shaft. (See "BRAKE PEDAL
REMOVAL AND INSTALLATION" in Brake
section.)
M95270
10. Remove four cap screws (A) and hood support
frame (B).
11. Disconnect throttle link (C) at engine by pulling rod
outward.
12. Drain fuel from tank into a suitable container.
13. Label and remove fuel lines from fuel tank.
14. Remove fuel overflow drain hose (D).
15. Remove drain cock (E) and fuel hose elbow (F)
from fuel tank.
H
G
M91317
16. Loosen screw (G) on clamp holding fuel gauge
sender wiring harness to fuel tank.Turn clamp to
release harness.
17. Remove two nuts (H) and lock washers connecting
wires to fuel gauge sender. Remove wires.
4/6/01
12 - 11
CAB REPAIR
MISCELLANEOUS
NOTE: An assistant may be required to tilt steering
support while removing fuel tank.
22. Tilt steering support toward rear of tractor and
remove tank from frame.
I
Installation:
Installation is the reverse of removal.
CAB REPAIR
M95271
CAB DOOR
18. If necessary, drain coolant overflow tank and
disconnect hose from radiator to tank.
19. Remove cap screw (I) and coolant overflow tank.
Removal:
1. Open cab door.
A
B
J
C
K
M91319
MX1746
20. Remove two cap screws (J) , washers and rubber
isolators (K) securing bottom of steering support to
frame.
N
L
2. Remove clip (A) from damper (B). Disconnect
damper from ball joint (C).
3. Close and latch door.
4. Remove plastic caps from door hinge bolts.
5. Remove hex nut and flat washer from threaded end
of each hinge bolt.
M
D
E
M91320
21. Remove two nuts (L), four washers, and two cap
screws (M) from rubber isolators (N) that secure
top of steering support to frame.
12 - 12
MX1747
4/6/01
CAB REAR
MISCELLANEOUS
6. Tap hinge bolt (D) with pin punch to remove bolt and
flat washer (E). Repeat at other hinge.
7. Hold door securely and unlatch to remove.
Installation:
Installation is the reverse of removal. Latch door closed
and align hinges before installing hinge bolts. Do not
tighten hinge bolts very tight or door will not swing
correctly.
CAB REAR
c
CAUTION
To avoid injury, have an assistant hold window
up while disconnecting dampers.
6. Insert tip of flat head screwdriver behind clip (E)
and disconnect damper (F). Repeat for other
damper.
7. Close rear window.
Removal:
G
C
D
MX1752
A
B
MX1750
1. Pry carefully with a screwdriver to unsnap and
remove cover from rear wiper motor assembly (A).
2. Disconnect wiring harness connector (B).
3. Plug end of washer fluid hose (C).
4. Disconnect hose from spray nipple (D).
5. Open rear window.
8. Support rear window on wooden blocks (G).
9. Remove plastic caps from rear window hinge bolts.
10. Remove hex nut and flat washer from threaded end
of each hinge bolt.
H
E
MX1753
F
11. Tap hinge bolt (H) with pin punch to remove bolt.
Repeat at other hinge.
12. Remove rear window from cab.
MX1751
Installation:
1. Installation is the reverse order of removal. Use an
assistant to help hold glass in place while aligning
hinges. Do not tighten hinge bolts very tight or
glass will not swing easily.
2. Snap end of dampener back onto post.
4/6/01
12 - 13
CAB
MISCELLANEOUS
CAB
Cab Removal:
1. Disconnect negative cable from battery.
2. Drain engine coolant from radiator.
3. Remove cab door panels.
4. Remove cab floor mat and all upholstery liners
except those covering the fender deck.
5. Remove engine side panels. (See “SIDE PANELS,
REMOVAL & INSTALLATION” ).
G
MX1756
A
B
10. Disconnect brn ground wire (G) from panel behind
cab seat. Cut all tie straps as needed to free the
ground wire for cab removal.
E
H
D
C
MX1748
MX1754
6. Release 60 amp fuse holder (A) from mounting clip
(B) using tip of flat head screwdriver.
7. Remove power lead (C) from starter motor terminal
(D).
8. Disconnect Red wire bullet connector (E).
11. Disconnect heater hose (H) at R.H. and L.H. sides
of tractor. Plug or cap the hoses.
M
L
F
K
J
I
MX1755
MX1749
9. Label and disconnect eight bullet connectors (F)
under rear of cab (four at each side of rockshaft).
12 - 14
12. Remove the following hardware from the two front
cab mounts:
• Lock Nut (I)
• Flat Washer (J)
• Rubber Washer (K)
• Flat Washer (L)
• Hex Bolt (M)
4/6/01
WINDSHIELD WASHER REPAIR
MISCELLANEOUS
WINDSHIELD WASHER REPAIR
NOTE: for diagnosis of windshield washer pump
electrical problems.
See drawing on next page to identify
windshield washer components and water line
routing through cab frame.
N
A
MX1757
13. Repeat for rear cab mounts (N).
MX0409
O
B
P
M63145
If front or rear washer is not working, check the
following items:
14. Remove front splash plate (O) from front of cab by
removing cap screws (P) and lock nuts from cab
frame. Repeat for other side of cab.
NOTE: Cab must be lifted with a hoist capable of
raising cab high enough for front of cab to clear
tractor fenders, (if removing from the rear), or
for front of cab to clear engine cover, (if
removing from the front.)
Have suitable stands ready to support the rear
of the cab (after it is removed) to prevent the
tail lamps from contacting the ground.
15. The cab is now free to be lifted using a overhead
crane. Route lifting straps through main frame of
cab, avoiding the fiberglass roof and overhead
console. Wrap straps around corners of frame to
prevent straps from sliding, and allowing cab to
shift while being lifted.
Alternatively, a large fork truck may be used to lift
the cab by putting the forks through the rear
window opening. Span a 4x4 beam across the
door frames inside the cab to prevent tips of forks
from contacting overhead console. Cab must be
lifted high enough for the front bottom corners of
cab to clear tractor fenders.
4/6/01
• Check vent hole on reservoir cap is clear (A), and
that reservoir is full of clean, unfrozen, windshield
washer fluid. Listen for pump operation.
• Check that front or rear spray nozzles are not
clogged by removing washer hose from nozzle and
operating front or rear washer switches. Clean the
clogged nozzle with a pin and compressed air.
• If no fluid is discharged from washer hose when
pump is operated, be sure check-valve is installed
correctly on water line. An arrow on check-valve
body indicates direction of flow. (Front check valve
is located in roof overhang above windshield. Rear
check valve is located inside cab under padding
above rear window.) Remove check valve and
operate front or rear washer switch to check for
fluid flow.
• Check for fluid flow from pump by removing fluid
lines (B) from pump ports and operating front or
rear washer switches. If no pump output, remove
reservoir and flush with clean water until clear.
• If fluid lines are clogged, try to clear with
compressed air. Look for pinched line at front or
rear washer nozzles. If front fluid line is clogged,
cab must be lifted up from tractor to route a new
line up cab door post frame. ()
12 - 15
CAB WATER LINE LOCATIONS
MISCELLANEOUS
CAB WATER LINE LOCATIONS
1
2
3
10
4
9
8
5
7
11
6
12
CAB HEATER REPAIR
1.
Heater Control
Valve
7.
Cab Heater Water
Return Hose/Tube
2.
Heater Core
8.
Front Washer Fluid
Hose
3.
Rear Washer
Check Valve
9.
4.
Rear Washer Fluid
Hose
10. Cab Heater Water
Supply Hose/Tube
5.
Washer Reservoir
11. Water Pump
6.
Washer Pump
12. Heater Hose Drain
Valve
12 - 16
Front Washer Check
Valve
NOTE: For blower motor electrical diagnosis, see of
Electrical Section.
1. Drain cooling system at drain valve (L) on right rear
of engine compartment.
2. Lower cab overhead console to access heater
control valve (1), heater core (2), and blower
motor.
3. Water lines running inside of cab frame are steel
tubing, with rubber hose and clamps at joints, and
require cab to be lifted from tractor to service.
4. Route hose in overhead console to prevent it from
kinking when overhead console is raised to install.
4/6/01
FRONT PTO
MISCELLANEOUS
FRONT PTO
PTO GEARBOX REMOVAL
1. Open engine cover and latch open. Remove engine
side shields.
2. Unlatch front grille fasteners. Disconnect headlamp
wiring harness and remove front grille from tractor.
3. Disconnect negative battery cable.
4. Disconnect electrical lead to Front PTO clutch, and
tie PTO harness back to tractor frame where it can
not become entangled with implements or front
axle.
6. Support Front PTO housing from bottom with floor
jack (D), and remove four mounting cap screws.
7. Lower PTO housing down out of tractor frame while
rotating top of PTO housing forward to separate
front and rear halves of PTO drive shaft.
G
F
E
A
C
E
B
A
M72600
M72598
8. Remove M10x35 allen head cap screws and lock
washers (E), holding PTO drive shaft flange (F) to
engine crankshaft pulley (G).
5. Remove four lock nuts (A) from upper and lower
front mounting cap screws holding Front PTO
mounting brackets (B) to tractor frame (C).
D
M72599
4/6/01
12 - 17
PTO INSTALLATION KIT PARTS
MISCELLANEOUS
PTO INSTALLATION KIT PARTS
1
2
3
4
5
8
6
7
3
2
6
M72587
12 - 18
Item
Qty.
Description
1
1
Adapter Flange
2
8
Lock Washer
3
8
Cap Screw–M5x12
4
1
Driveshaft
5
1
PTO Gearbox
6
2
Mounting Bracket
7
3
Cap Screw–M10x25
8
3
Lock Washer–M10
4/6/01
PTO GEARBOX INSTALLATION
MISCELLANEOUS
PTO GEARBOX INSTALLATION
Procedure:
NOTE: PTO Gearbox is not filled with oil at the factory,
and must be filled before operating for the first
time.
1. Park tractor. Raise engine cover and latch open.
Remove engine side covers. Unlatch front grille,
disconnect headlamp electrical connectors and
remove front grille from tractor.
2. Disconnect negative battery cable.
6. Assemble rear half of PTO shaft (H) to adapter
flange (I) using four M5x12 allen head cap screws
and lock washers (J).
7. Install M10x25 allen head cap screws and lock
washers (K) into adapter flange (I) to match bolt
pattern on engine crankshaft pulley (L). (Three cap
screws are used on models 4300 & 4400; four are
used on model 4200.)
8. Slide rear half of PTO shaft into tractor frame (under
radiator) as shown. Do not attach drive shaft to
engine crankshaft pulley at this time.
E
F
M
A
D
G
C
B
M72599
A
D
C
M72601
B
3. Install mounting brackets (A) onto PTO gearbox
housing using four M12x40 cap screws (B), lock
washers (C), and flat washers (D).
4. Fill PTO gearbox at dipstick tube with 80W-90 gear
oil.
5. Install front half of PTO drive shaft (E) onto gearbox
input flange using four M5x12 allen head cap
screws (F) and lock washers (G).
9. Place PTO gearbox housing (M) onto a small floor
jack and roll under front of Front Hitch Kit.
P
O
N
J
M72602
M72603
4/6/01
L
I
K
H
10. Begin to lift the PTO gearbox (N) up into tractor
frame with floor jack, while directing the splines of
the two halves of the PTO drive shaft together.
Align the grease fitting (O) on the front half, with
12 - 19
PTO GEARBOX DISASSEMBLY
MISCELLANEOUS
the alignment mark (P) on the face of the rear half.
Join splines together while lifting PTO gearbox up
into tractor frame.
PTO GEARBOX DISASSEMBLY
R
B
A
Q
M72617
M72598
11. Install one M12x65 cap screw (Q) through bottomfront mounting hole on left and right side of tractor.
Secure with lock washers and hex nuts.
12. Install one M12x60 cap screw (R) through top-front
mounting hole on left and right side of tractor.
Secure with lock washers and hex nuts.
13. Tighten all eight cap screws to 95 N•m (70 lb-ft).
U
1. Using a drain pan and a 8 mm allen wrench (A),
drain gear oil by removing drain plug (B) on bottom
of PTO gearbox.
PTO Clutch Removal:
C
T
S
D
C
M72618
C
M72600
14. Install three M10x35 allen head cap screws and
lock washers (S) through PTO drive shaft flange
(T) and into engine crankshaft pulley (U).
12 - 20
2. Remove three cap screws (C) holding PTO shaft
shield (D) to clutch shield. Remove shield from
gearbox.
4/6/01
PTO GEARBOX DISASSEMBLY
MISCELLANEOUS
E
L
K
MX0402
F
G
M72619
E
3. Remove three cap screws (E) holding clutch shield
(F) to gearbox housing. Remove clutch shield,
washers and spacers (G).
6. Loosen lock-nut (K) on EMC anti-rotation cap screw
(L). Remove cap screw from gearbox housing.
7. Pull EMC off of gearbox input shaft.
Splitting Gearbox Case:
H
I
K
L
MX0403
MX0401
4. Remove three allen head cap screws (H) from PTO
spline shaft flange (I). Remove spline shaft flange
by tapping on side of flange with a soft-faced
hammer to break it free from electromechanical
clutch (EMC) (J).
5. Using a strap wrench to hold outside of EMC from
turning, remove cap screw (K) and flat washer (L)
from center of EMC.
4/6/01
1. Loosen each of the eight gearbox housing cap
screws 4 turns.
12 - 21
PTO GEARBOX DISASSEMBLY
MISCELLANEOUS
P
Q
R
M
MX0405
M
MX0404
2. Place wooden blocks under cast ears (M) of
gearbox so that rear half of gearbox housing is free
to drop down onto bench.
3. Tap on heads of cap screws to break gasket seal
between halves of gearbox. Loosen cap screws
and separate gearbox halves. If gearbox did not
separate completely, use a punch or drift in bottom
of holes that cap screws were removed from; Do
not pry gearbox apart at sealing surface.
3. Remove retaining rings (P) from first reduction shaft
(Q), and second reduction shaft (R).
4. Remove, count, and label shims under retaining
rings on each reduction shaft.
5. Mark the face of the first and second reduction
gears with a felt tip marker to insure they will be
installed in the same direction as removed.
Removing Gears:
S
MX0412
O
N
6. Use a puller to remove the first reduction gear (S)
from it’s shaft.
7. Remove, count, and label the shims under the first
reduction gear.
MX0405
1. Note that there are shims on the input shaft (N) and
on output shaft (O). These may be on the shafts,
or stuck to the bearings. Do not allow these to be
lost. Count, label, and set shims aside.
2. Clean gearbox of old gasket material and oil.
12 - 22
4/6/01
PTO GEARBOX DISASSEMBLY
MISCELLANEOUS
T
U
MX0414
8. Use a puller to remove the second reduction gear
(T) from it’s shaft.
9. Remove, count, and label the shims under the
second reduction gear.
MX0416
10. Roller bearings inside of reduction gears are
pressed in against an internal snap ring, which is
not accessible and will not allow bearings to be
pressed out. If roller bearings need replacement,
cut inner race of one of the bearings with an air
chisel, and remove inner race, ball cage, and ball
bearings. This will allow access to internal snap
ring, allowing it to be removed.
11. Press out remaining bearing and outer race on a
arbor press.
MX0413
12. Remove retaining ring and shims from input shaft.
Count, label, and set shims aside.
13. Mark the face of the input shaft gear (U) with a felt
tip marker to insure it will be installed in the same
direction as it was removed.
14. Use a puller to remove input shaft gear, being
careful not to catch hooks of puller on shims under
input gear. Do not use arbor press to press output
shaft from gear, or damage to shims will result.
15. Remove key from key slot on input shaft by holding
key with locking pliers and tapping on pliers until
key is pulled free from slot.
16. Remove, count, and label shims under input shaft
gear.
17. Tap on input shaft with a soft faced hammer to
remove shaft from bearing and seal.
18. Input shaft seal can only be removed from the
outside of the gear case. Pry out seal using a large
screwdriver under edge of seal.
19. Input shaft bearing can only be removed by
pressing bearing towards inside of gear case. Use
an arbor press to remove bearing from case.
V
X
W
MX0415
20. Remove external snap ring and shims from output
shaft (V). Count, label, and set shims aside.
4/6/01
12 - 23
PTO GEARBOX ASSEMBLY
MISCELLANEOUS
21. Mark the face of the output shaft gear (W) with a felt
tip marker to insure it will be installed in the same
direction as it was removed.
22. Use a puller to remove output shaft gear, being
careful not to catch hooks of puller on shims under
output gear.
23. Remove key (X) from keyway on output shaft by
holding key with locking pliers and tapping on
pliers until key is pulled free from slot.
24. Remove, count, and label shims from input shaft.
PTO GEARBOX ASSEMBLY
Output Shaft Assembly And Installation:
A
B
Y
MX0419
MX0417
25. Remove key (Y) from keyway on outside of output
shaft by holding key with locking pliers and tapping
on pliers until key is pulled free from slot.
26. Place the PTO gearbox in an arbor press to drive
out the output shaft and bearing from the gearbox
housing.
27. Use the arbor press to remove the output shaft
bearing from the shaft.
1. Assemble five shims (A) onto output shaft. Install
key (B) into keyway on shaft.
D
C
MX0420
2. Place output shaft gear (21T) into arbor press with
assembly mark facing down, and keyway (C)
facing forward.
3. Align key on output shaft (D) with keyway on gear,
and press shaft into gear until shims bottom out
against gear face.
12 - 24
4/6/01
PTO GEARBOX ASSEMBLY
MISCELLANEOUS
Intermediate Gear Assembly And Installation
E
F
H
G
A
MX0416
MX0421
4. Install three shims (E) onto output shaft and secure
with external snap ring (F).
5. Place bearing (G) onto arbor press with inner race
supported. Press output shaft into bearing until
bearing contacts shims (H).
1. If bearings (A) were removed from first or second
intermediate gears, install internal snap ring in
groove in center of gear, and press a new bearing
in from each side of the gear until bearings contact
snap ring.
I
C
K
B
J
MX0418
6. Install new seal (I) into front half of gear case,
pressing seal down until it contacts machined
flange face (J).
7. Install output shaft assembly (K) into front half of
gear case, pressing bearing into case with arbor
press until bearing is seated on machined flange
face (J).
MX0423
2. Place two shims (B) on each intermediate gear
shaft. Press gear onto shaft using a large diameter
driver (C) and an arbor press. Repeat for other
intermediate gear.
4/6/01
12 - 25
PTO GEARBOX ASSEMBLY
MISCELLANEOUS
1
2
3
4
5
5
6
7
1
1
8
1
9
5
10
14
11
12
1
22
8
13
1
15
38
16 11
37
12
13
17
18
36
35
34
33
26
32
31
19
30
20
29
28
21
27
26
21
22
25
23
24
MX0422
1. Ball Bearing (6)
11. Cap Screw–M8x16 (8)
21. Dowel Pin–M8x50 (2)
31. Snap Ring–M30
2. Shim–M25x35x1 (5)
12. Lock Washer–M8 (8)
22. Key–M8x7x28 (2)
32. Shim–M30x42x1 (1)
3. Input Shaft Gear–16T
13. Axle Stub (2)
23. Output Shaft (1)
33. Gasket (1)
4. Shim–M25x35x1 (2)
14. Shim–M25x35x1 (3)
24. Gear Case–Front (1)
34. Drain Plug (1)
5. Snap Ring–M25 (3)
15. 2nd Reduction Gear–36T 25. Seal–Output Shaft (1)
35. Seal Washer (1)
6. Shim–M25x35x1 (2)
16. Shim–M25x35x1 (2)
26. Ball Bearing (2)
36. Gear Case–Rear (1)
7. Shim–M25x35x1 (3)
17. Dipstick (1)
27. Shim–M30x42x1 (5)
37. Seal–Input Shaft (1)
8. Snap Ring–M47 (2)
18. Vent (1)
28. Output Shaft Gear–21T 38. Input Shaft (1)
9. 1st Reduction Gear–27T 19. Lock Washer–M10 (8)
10. Shim–M25x35x1 (2)
12 - 26
20. Cap Screw–M10x55 (8)
29. Shim–M30x42x1 (2)
30. Shim–M30x42x0.5 (1)
4/6/01
PTO GEARBOX ASSEMBLY
MISCELLANEOUS
Input Shaft Installation:
Gear Case Assembly:
C
D
C
B
E
H
A
A
C
B
F
G
I
MX0424
J
MX0405
1. Install input shaft bearing (A) to inside of gear case.
Press bearing in until seated on machined flange
(B) in bore of case.
2. Install input shaft seal (C) from outside of gear
case, pressing in until seated flush with outside of
case.
3. Remove input shaft key (D) (if installed) from input
shaft (E).
4. Install input shaft through seal and bearing, tapping
lightly with a soft faced hammer.
5. Install five M25x35x1 shims (F) onto end of input
shaft.
6. Install M8x7x28 key (D) into key on input shaft.
7. Press input shaft gear (G) onto shaft using arbor
press. Press gear onto input shaft until groove (H)
on shaft is exposed enough to install two
M25x35x1 shims (I), and snap ring (J) on shaft.
8. After shims and snap ring are installed on shaft,
press input shaft back out of gear case until shims
(I & F) are compressed between snap ring &
bearing (J & A). This will cause the input shaft to
extend out of the gear case to it’s maximum length.
1. Clean both front and rear gear case halves and
install new gasket.
2. Install one shim on output shaft bearing (A), and
two shims on input shaft (B).
3. Place front half of gear case on top of rear half,
aligning pins (C) with holes on rear case.Tap on
gear case
4. Install eight M10x55 cap screws and lock washers
and torque to 55 N•m (40 lb-ft), drawing gear case
halves together.
PTO Clutch Installation:
1. Install key into keyway on output shaft.
A
B
MX0425
C
2. Install EMC clutch (A) onto output shaft, lining up
key in shaft with keyway in clutch housing.
3. Align hole in PTO clutch (B) with tapped hole in
gear case (C).
4/6/01
12 - 27
PTO GEARBOX ASSEMBLY
MISCELLANEOUS
N
F
G
D
E
L
M
H
M72619
MX0401
N
4. Install M10x40 cap screw (D), M10 flat washer, and
lock washer (E) into output shaft. Hold input shaft
flange of gear box in soft faced vice while
tightening cap screw on output shaft.
5. Install PTO spline shaft flange (F) onto EMC clutch,
lining up cap screws (G) with holes in clutch (H).
Tighten cap screws evenly until flange is drawn
down onto step of clutch.
7. Install clutch shield (L) over EMC clutch. Install two
spacers (M) and three M8 cap screws (N).
C
O
J
C
K
I
MX0402
6. Place M10 hex nut (I) on threaded hole in case.
Screw M10x55 cap screw (J) through clutch
flange, hex nut, and into threads of gear case until
there is a 2–5 mm gap between head of screw and
clutch bracket (K). Tighten hex nut (I).
12 - 28
M72618
8. Install PTO shaft shield (O) to clutch shield. Secure
with three cap screws (P), lock washers and flat
washers.
4/6/01
INDEX
Numerics
2-Speed PTO
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-82
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 8-78
Switch Test and Adjustment . . . . . . . . . . . . 4-95
4-Speed Transmission
SRT
Assembly/Installation . . . . . . . . . . . . . . 7-37
Disassembly . . . . . . . . . . . . . . . . . . . . . 7-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-29
4-WD
Differential Removal & Disassembly . . . . . 8-29
Drive Shaft Removal & Installation . . . . . . . 8-25
Final Drive Cover
Installation . . . . . . . . . . . . . . . . . . . . . . 8-26
Removal & Inspection . . . . . . . . . . . . . 8-25
Final Drive Housing
Assembly . . . . . . . . . . . . . . . . . . . . . . . 8-28
Installation . . . . . . . . . . . . . . . . . . . . . . 8-29
Final Drive Housing Disassembly . . . . . . . . 8-28
Output Shaft
Removal and Installation . . . . . . . . . . . 8-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Spindle Shaft
Assembly and Installation . . . . . . . . . . 8-28
Removal and Disassembly . . . . .8-27, 8-29
A
Brake Lights Operation-European . . . . . . . . . 4-170
Alternator
40 Amp - Amperage Output Test . . . . . . . . 4-83
Components . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Removal and Installation . . . . . . . . . . . . . . 3-76
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Amperage Tests
Regulated . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Motor Draw . . . . . . . . . . . . . . . . . .
Starting Motor No-Load . . . . . . . . . . . . . . .
Unregulated - 40 Amp Alternator . . . . . . . .
4-83
4-85
4-86
4-83
Axle (4-WD) Components . . . . . . . . . . . . . . . . . 8-14
B
Back Plate
Component Location . . . . . . . . . . . . . . . . . . 6-9
Ball Joint Removal and Installation (2-WD) . . . 9-14
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Removal and Installation . . . . . . . . . . . . . 12-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4/6/01
Brake
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Component Location . . . . . . . . . . . . . . .8-6, 8-8
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Disassembly and Inspection . . . . . . . . . . . 10-19
Housing Component Location . . . . . . . . . . 10-4
Parking
Adjustment . . . . . . . . . . . . . . . . . . . . . 10-18
Component Location (Console Mount) 10-8
Component Location (Side Mount) . . . 10-5
Linkage Removal and Installation . . . 10-26
Pedal
Adjustment . . . . . . . . . . . . . . . . . . . . . 10-17
Removal and Installation
CST or SRT . . . . . . . . . . . . . . . . . 10-24
HST . . . . . . . . . . . . . . . . . . . . . . . 10-21
Pedals and Linkage Component Location
CST and SRT (Exploded View) . . . . . 10-12
CST and SRT (Overall View) . . . . . . . 10-13
HST (Exploded View) . . . . . . . . . . . . . 10-10
HST (Overall View) . . . . . . . . . . . . . . 10-11
PTO
Component Location . . . . . . . . . . . . . . 8-60
Disassembly and Assembly . . . . . . . . . 8-88
Removal and Installation . . . . . . . . . . . 8-86
Specifications . . . . . . . . . . . . . . . . . . . . . . . 10-3
Theory of Operation . . . . . . . . . . . . . . . . . 10-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . 10-15
Brake Switch Test . . . . . . . . . . . . . . . . . . . . . . . 4-98
Break-In Engine Oil . . . . . . . . . . . . . . . . . . . . . . 2-20
Bulb Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
C
Cab Door Removal & Installation . . . . . . . . . . 12-12
Cab Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
Cab Heater Repair . . . . . . . . . . . . . . . . . . . . . 12-16
Cab Removal & Installation . . . . . . . . . . . . . . . 12-14
Cab Water Line Location . . . . . . . . . . . . . . . . 12-16
Cab Wiring Harness . . . . . . . . . . . . . . . . . . . . 4-190
Cam Followers . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Camshaft
End Play Check . . . . . . . . . . . . . . . . . . . . . 3-21
Removal and Installation . . . . . . . . . . . . . . 3-51
Charge Pump Pressure Test (HST) . . . . . . . . . 6-19
Charging Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
Electrical Schematic . . . . . . . . . . . . . . . . . 4-151
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-150
INDEX - 1
INDEX
Clutch & Forward/Reverse Shafts
SyncReverser (SRT)
Installation . . . . . . . . . . . . . . . . . . . . . . 7-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Hydrostatic Transmission . . . . . . . . . . . . . . . 6-7
Hydrostatic Transmission Back Plate . . . . . . 6-9
Parking Brake (Console Mount) . . . . . . . . . 10-8
Parking Brake (Side Mount) . . . . . . . . . . . . 10-5
PTO
2-Speed . . . . . . . . . . . . . . . . . . . . . . . . 8-64
PTO (Mid) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-65
PTO (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Range Shift . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Rocker Arm Components . . . . . . . . . . . . . . 3-32
Selective Control Valve (SCV) . . . . . . . . . 11-13
SRT
4 Speed Transmission . . . . . . . . . . . . . . 7-5
Clutch Pedal and Linkage . . . . . . . . . . . 7-6
Clutches and Cover . . . . . . . . . . . . . . . . 7-4
Forward/ Reverse Lever and Linkage . . 7-7
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Timing Gear Cover . . . . . . . . . . . . . . . . . . . 3-55
Water Pump and Thermostat . . . . . . . . . . . 3-59
Clutch Shaft
Collar Shift (CST)
Removal & Installation . . . . . . . . . . . . . 5-27
Connecting Rod
Bearing Clearance Check . . . . . . . . . . . . . . 3-19
Side Play Check . . . . . . . . . . . . . . . . . . . . . 3-18
Common Circuit Tests . . . . . . . . . . . . . . . . . . . . 4-7
Control Panel Gauges-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-156
Electrical Schematic . . . . . . . . . . . . . . . . . 4-155
Charging Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-53
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Clutch
CST
Disassembly . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . .
Shimming Procedure . . . . . . . . . . . . . .
CST and SST
Installation . . . . . . . . . . . . . . . . . . . . . .
PTO
Components . . . . . . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . .
Removal and Installation . . . . . . . . . . .
5-18
5-17
5-23
5-20
8-62
8-88
8-86
Component Location
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Axle (4-WD) . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Axle Shaft and Brake
Left Hand . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Right Hand . . . . . . . . . . . . . . . . . . . . . . . 8-8
Back Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Brake (PTO) . . . . . . . . . . . . . . . . . . . . . . . . 8-60
Brake Housing . . . . . . . . . . . . . . . . . . . . . . 10-4
Brake Pedals and Linkage
CST and SRT (Exploded View) . . . . . 10-12
CST and SRT (Overall View) . . . . . . . 10-13
HST (Exploded View) . . . . . . . . . . . . . 10-10
HST (Overall View) . . . . . . . . . . . . . . 10-11
Clutch (PTO) . . . . . . . . . . . . . . . . . . . . . . . . 8-62
Crankshaft and Main Bearings . . . . . . . . . . 3-48
Differential (4-WD) . . . . . . . . . . . . . . . . . . . 8-17
Differential Lock . . . . . . . . . . . . . . . . . . . . . 8-12
Drive Shaft (4-WD) . . . . . . . . . . . . . . . . . . . 8-13
Drive Shaft (Mid PTO) . . . . . . . . . . . . . . . . 8-66
Engine Valves . . . . . . . . . . . . . . . . . . . . . . . 3-32
Final Drive (4-WD) . . . . . . . . . . . . . . . . . . . 8-16
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Gear Pump (Front) . . . . . . . . . . . . . . . . . . 11-14
Gear Pump (Rear) . . . . . . . . . . . . . . . . . . 11-15
Hydraulic System . . . . . . . . . . . . . . . . . . . . 11-6
Hydrostatic Control Linkage . . . . . . . . . . . . 6-10
Hydrostatic Hoses and Lines . . . . . . . . . . . . 6-6
Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . 6-9
Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . 6-8
INDEX - 2
Control Panel Gauges-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-57
Control Panel Indicator
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-61
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Control Panel Removal and Installation . . . . . . 12-9
Cooling System Pressure Test . . . . . . . . . . . . . 3-27
Cowl Panel Removal and Installation . . . . . . . 12-10
Cranking Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
Electrical Schematic . . . . . . . . . . . . . . . . . 4-133
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
Cranking Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-35
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Crankshaft
End Play Check . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing Clearance Check . . . . . . . . .
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . .
3-20
3-48
3-20
3-47
Cruise Control Diagnosis
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-184
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4/6/01
INDEX
Cruise Control Magnet Test . . . . . . . . . . . . . . . 4-97
Cruise Control Switch Test . . . . . . . . . . . . . . . . 4-97
Cylinder Bore Inspection . . . . . . . . . . . . . . . . . . 3-46
Cylinder Compression Test . . . . . . . . . . . . . . . . 3-16
Cylinder Head
Disassembly and Assembly . . . . . . . . . . . . 3-35
Removal and Installation . . . . . . . . . . . . . . 3-34
D
Diagnosis
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Hydrostatic Power Train (HST) . . . . . . . . . . 6-15
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Diesel Fuel
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Differential
Assembly and Installation . . . . . . . . . . . . . .
Backlash Adjustment . . . . . . . . . . . . . . . . .
Lock Fork Removal & Installation . . . . . . . .
Removal & Disassembly . . . . . . . . . . . . . . .
8-57
8-22
8-58
8-55
Differential (4-WD) Components . . . . . . . . . . . . 8-17
Differential Lock Components . . . . . . . . . . . . . . 8-12
Diode Block Test . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Drive Shaft (4-WD) Components . . . . . . . . . . . 8-13
Drive Shaft (Mid PTO) Components . . . . . . . . . 8-66
E
Electrical
2-Speed PTO
Indicator Lights . . . . . . . . . . . . . . . . . . 4-158
Switch Test and Adjustment . . . . . . . . 4-95
Alternator
Components . . . . . . . . . . . . . . . . . . . . . 3-79
Removal and Installation . . . . . . . . . . . 3-76
Amperage Tests
Regulated . . . . . . . . . . . . . . . . . . . . . . . 4-83
Starting Motor Draw . . . . . . . . . . . . . . . 4-85
Starting Motor No-Load . . . . . . . . . . . . 4-86
Unregulated - 40 Amp Alternator . . . . . 4-83
Battery
Charge . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Load Test . . . . . . . . . . . . . . . . . . . . . . . 4-82
Removal and Installation . . . . . . . . . . 12-10
Specifications . . . . . . . . . . . . . . . . . . . . . 4-8
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Brake Lights Operation-European . . . . . . 4-170
Brake Switch Test . . . . . . . . . . . . . . . . . . . . 4-98
Bulb Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-186
4/6/01
Cab Troubleshooting Chart . . . . . . . . . . . 4-192
Cab Turn Signal Wiring Harness . . . . . . . 4-191
Charging Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . 4-152
Operation . . . . . . . . . . . . . . . . . . . . . . 4-150
Charging Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-54
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-52
Control Panel Gauges-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . 4-156
Control Panel Gauges-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-58
Control Panel Indicator
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-62
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Cranking Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . 4-134
Operation . . . . . . . . . . . . . . . . . . . . . . 4-132
Cranking Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-36
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-34
Cruise Control Diagnosis
European . . . . . . . . . . . . . . . . . . . . . . 4-184
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Cruise Control Magnet Test . . . . . . . . . . . . 4-97
Cruise Control Switch Test . . . . . . . . . . . . . 4-97
Diagnostic Information . . . . . . . . . . . . . . . . . 4-6
Diode Block Test . . . . . . . . . . . . . . . . . . . . 4-89
Electrical Schematics
Cab-European . . . . . . . . . . . . . . . . . . 4-189
Engine Coolant Temperature Gauge
European . . . . . . . . . . . . . . . . . . . . . . 4-154
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Engine Coolant Temperature Sensor Test . 4-87
Engine Oil Pressure Indicator Light
European . . . . . . . . . . . . . . . . . . . . . . 4-154
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Engine Oil Pressure Switch Test . . . . . . . . 4-88
Front PTO
Indicator Light Operation . . . . . . . . . . 4-166
Solenoid Operation . . . . . . . . . . . . . . 4-166
Solenoid Test . . . . . . . . . . . . . . . . . . . . 4-96
Switch Test . . . . . . . . . . . . . . . . . . . . . . 4-96
Fuel Gauge
European . . . . . . . . . . . . . . . . . . . . . . 4-154
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Sensor Test . . . . . . . . . . . . . . . . . . . . . 4-99
Fuel Shutoff Solenoid Tests . . . . . . . . . . . . 4-99
Fuel Supply-European
Diagnosis . . . . . . . . . . . . . . . . . .4-44, 4-142
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-40
Fuel Supply-N.A.
Operation . . . . . . . . . . . . . . . . . . . . . . 4-138
Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Ground Circuit Test . . . . . . . . . . . . . . . . . . 4-80
INDEX - 3
INDEX
Hazard Switch
Operation . . . . . . . . . . . . . . . . . . . . . . 4-172
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Key Switch Test . . . . . . . . . . . . . . . . . . . . . 4-91
Light Switch Operation
European . . . . . . . . . . . . . . . . . . . . . . 4-170
N.A. . . . . . . . . . . . . . . . . . . . . . . .4-64, 4-70
N.A. (New) . . . . . . . . . . . . . . . . . . . . . . 4-70
N.A. (Old) . . . . . . . . . . . . . . . . . . . . . . . 4-64
Light Switch Test . . . . . . . . . . . . . . . . . . . . 4-92
Lights Diagnosis
European . . . . . . . . . . . . . . . . . . . . . . 4-174
North American . . . . . . . . . . . . . .4-66, 4-72
Main Electrical Schematic
European (New) . . . . . . . . . . . . . . . . . 4-112
European (Old) . . . . . . . . . . . . . . . . . 4-108
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
N.A. (New) . . . . . . . . . . . . . . . . . . . . . . 4-19
Manifold Heater Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . 4-136
Theory of Operation . . . . . . . . . . . . . . 4-132
Manifold Heater Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-38
Theory of Operation . . . . . . . . . . . . . . . 4-34
Manifold Heater Test . . . . . . . . . . . . . . . . . 4-88
Mid PTO Indicator Light . . . . . . . . . . . . . . 4-166
Mid PTO Switch Test . . . . . . . . . . . . . . . . . 4-95
Park Brake Indicator Light . . . . . . . . . . . . . 4-60
Park Brake Switch Test . . . . . . . . . . . . . . . 4-98
Power Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . 4-124
Operation . . . . . . . . . . . . . . . . . . . . . . 4-120
Power Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4-28
Operation . . . . . . . . . . . . . . . . . . . . . . . 4-24
PTO (Front)
Indicator Light - European . . . . . . . . . 4-166
Indicator Light - N.A. . . . . . . . . . . . . . . 4-60
PTO (Mid) Indicator Light . . . . . . . . . . . . . 4-166
PTO (Rear)
Circuit Diagnosis - European . . . . . . . 4-160
Indicator Lights - European . . . . . . . . 4-158
Reading Electrical Schematics . . . . . . . . . . . 4-5
Rear PTO Indicator Light
European . . . . . . . . . . . . . . . . . . . . . . 4-158
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Schematics
Cab-European . . . . . . . . . . . . . . . . . . 4-189
Charging Circuit-European . . . . . . . . 4-151
Charging Circuit-N.A. . . . . . . . . . . . . . . 4-53
Control Panel Gauges-European . . . . 4-155
Control Panel Gauges-N.A. . . . . . . . . . 4-57
Control Panel Indicator Lights . . . . . . . 4-61
Cranking Circuit-European . . . . . . . . . 4-133
Cranking Circuit-N.A. . . . . . . . . . . . . . . 4-35
Engine Shutoff Circuit-European . . . . 4-145
INDEX - 4
Engine Shutoff Circuit-N.A. . . . . . . . . . 4-47
Fuel Supply-European . . . . . . . . . . . . 4-139
Fuel Supply-N.A. . . . . . . . . . . . . . . . . . 4-41
Lights-European . . . . . . . . . . . .4-171, 4-173
Power Circuit-European . . . . . . . . . . . 4-121
Power Circuit-N.A. . . . . . . . . . . . . . . . . 4-25
PTO-European . . . . . . . . . . . . . . . . . . 4-159
Schematics and Wiring Harness Legend
Cab-European . . . . . . . . . . . . . . . . . . 4-188
European . . . . . . . . . . . . . . . . . . . . . . 4-101
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Seat Switch Test . . . . . . . . . . . . . . . . . . . . . 4-92
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Amp Draw Test . . . . . . . . . . . . . . . . . . 4-85
No-Load Amp Draw and RPM Tests . . 4-86
Solenoid Test . . . . . . . . . . . . . . . . . . . . 4-84
Theory and Diagnosis-European . . . . . . . 4-121
Theory and Diagnosis-N.A. . . . . . . . . . . . . 4-25
Theory and Diagnostic Information . . . . . . . . 4-6
Theory of Operation Information . . . . . . . . . . 4-6
Transmission Neutral Switch Test - CST . . 4-93
Transmission Neutral Switch Test - HST . . 4-93
Troubleshooting-European . . . . . . . . . . . . 4-119
Troubleshooting-N.A. . . . . . . . . . . . . . . . . . 4-23
Turn Signal Switch Operation
European . . . . . . . . . . . . . . . . . . . . . . 4-172
N.A. . . . . . . . . . . . . . . . . . . . . . . .4-64, 4-70
Turn Signal Switch Test . . . . . . . . . . . . . . . 4-94
Voltage Tests - Regulated . . . . . . . . . . . . . 4-83
W1 Main Wiring Harness
European (New) . . . . . . . . . . . . . . . . . 4-114
European (Old) . . . . . . . . . . . . . . . . . . 4-110
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
N.A. (New) . . . . . . . . . . . . . . . . . . . . . . 4-20
W2 Fuel Solenoid Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . 4-115
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W3 Neutral Start Wiring Harness
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W3Neutral Start Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . 4-115
W4 Cruise Control Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . 4-116
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W5 Cruise Control Magnet Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . 4-116
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W6 Trailer Connector Wiring Harness . . . 4-117
W7 2-Speed PTO Wiring Harness . . . . . . 4-118
W8 Front PTO Wiring Harness . . . . . . . . . 4-118
Washer Pump Diagnosis . . . . . . . . . . . . . 4-198
Wiper Diagnosis . . . . . . . . . . . . . . . . . . . . 4-196
Wire Color Abbreviation Chart . . . . . . . . . . . 4-6
4/6/01
INDEX
Electrical Schematics
Charging Circuit-European . . . . . . . . . . . . 4-151
Charging Circuit-N.A. . . . . . . . . . . . . . . . . . 4-53
Control Panel Gauges-European . . . . . . . 4-155
Control Panel Gauges-N.A. . . . . . . . . . . . . 4-57
Control Panel Indicator Lights . . . . . . . . . . 4-61
Cranking Circuit-European . . . . . . . . . . . . 4-133
Cranking Circuit-N.A. . . . . . . . . . . . . . . . . . 4-35
Engine Shutoff Circuit-European . . . . . . . 4-145
Engine Shutoff Circuit-N.A. . . . . . . . . . . . . . 4-47
Fuel Supply-European . . . . . . . . . . . . . . . 4-139
Fuel Supply-N.A. . . . . . . . . . . . . . . . . . . . . 4-41
Lights-European . . . . . . . . . . . . . . .4-171, 4-173
Lights-N.A. . . . . . . . . . . . . . . . . . . . . .4-65, 4-71
Main Electrical Schematic
-European (New) . . . . . . . . . . . . . . . . 4-112
-European (Old) . . . . . . . . . . . . . . . . . 4-108
Main Electrical Schematic-N.A. . . . . . . . . . 4-17
Main Electrical Schematic-N.A. (New) . . . . 4-19
Power Circuit-European . . . . . . . . . . . . . . 4-121
Power Circuit-N.A. . . . . . . . . . . . . . . . . . . . 4-25
PTO-European . . . . . . . . . . . . . . . . . . . . . 4-159
Engine
Alternator
Components . . . . . . . . . . . . . . . . . . . . . 3-79
Removal and Installation . . . . . . . . . . . 3-76
Cam Followers . . . . . . . . . . . . . . . . . . . . . . 3-54
Camshaft
End Play Check . . . . . . . . . . . . . . . . . . 3-21
Removal and Installation . . . . . . . . . . . 3-51
Checks, Tests & Adjustments . . . . . . . . . . . . 3-8
Connecting Rod
Bearing Clearance Check . . . . . . . . . . 3-19
Side Play Check . . . . . . . . . . . . . . . . . . 3-18
Coolant Temperature Sensor Test . . . . . . . 4-87
Cooling System Pressure Test . . . . . . . . . . 3-27
Crankshaft
End Play Check . . . . . . . . . . . . . . . . . . 3-20
Front Oil Seal . . . . . . . . . . . . . . . . . . . . 3-48
Main Bearing Clearance Check . . . . . . 3-20
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . 3-47
Cylinder Bore Inspection . . . . . . . . . . . . . . 3-46
Cylinder Compression Test . . . . . . . . . . . . 3-16
Cylinder Head
Head & Valves Disassembly/Assembly 3-35
Head & Valves Removal/Installation . . 3-34
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . 3-38
Fan/Alternator Belt Adjustment . . . . . . . . . . 3-26
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . 3-60
Fuel Injection Nozzles . . . . . . . . . . . . . . . . 3-66
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
4/6/01
Fuel Injection Pump
Static Timing Adjustment (EPA) . . . . . . 3-26
Static Timing Adjustment (Non-EPA) . . 3-24
Fuel Injection Pump (EPA) . . . . . . . . . . . . . 3-64
Fuel Injection Pump (Non-EPA) . . . . . . . . . 3-63
Fuel Supply Pressure Test . . . . . . . . . . . . . 3-29
Fuel System
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Components . . . . . . . . . . . . . . . . . . . . . 3-61
Idle Adjustments
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . 3-16
Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . 3-38
Manifold Heater Test . . . . . . . . . . . . . . . . . 4-88
Oil Pressure Switch Test . . . . . . . . . . . . . . 4-88
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . 3-28
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Piston and Connecting Rod . . . . . . . . . . . . 3-40
Piston to Cylinder Head Clearance . . . . . . 3-39
Radiator Bubble Test . . . . . . . . . . . . . . . . . 3-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Rocker
Arm Assembly . . . . . . . . . . . . . . . . . . . 3-32
Arm Component Location . . . . . . . . . . 3-32
Cover Removal/Installation . . . . . . . . . 3-31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting Motor
Disassembly and Assembly . . . . . . . . . 3-70
Gear Train . . . . . . . . . . . . . . . . . . . . . . 3-73
Inspection/Test . . . . . . . . . . . . . . . . . . . 3-72
Removal and Installation . . . . . . . . . . . 3-69
Theory of Operation . . . . . . . . . . . . . . . . . . 3-10
Thermostat & Water Pump . . . . . . . . . . . . . 3-59
Thermostat Opening Test . . . . . . . . . . . . . . 3-24
Timing Gear
Backlash Check . . . . . . . . . . . . . . . . . . 3-22
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Cover Plate . . . . . . . . . . . . . . . . . . . . . 3-57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 3-13
Valve Clearance Adjustment . . . . . . . . . . . 3-17
Valve Lapping . . . . . . . . . . . . . . . . . . . . . . . 3-39
Valve Lift Check . . . . . . . . . . . . . . . . . . . . . 3-21
Valve Seat Grinding . . . . . . . . . . . . . . . . . . 3-39
Valve Seats Inspection . . . . . . . . . . . . . . . . 3-36
Valves Guides . . . . . . . . . . . . . . . . . . . . . . 3-37
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Drain Interval . . . . . . . . . . . . . . . . . . . . . . . 2-23
Engine Coolant Temperature Gauge
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-154
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
INDEX - 5
INDEX
Engine Shutoff Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-146
Electrical Schematic . . . . . . . . . . . . . . . . . 4-145
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
Engine Shutoff Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-47
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . 3-38
F
Fuel Gauge Sensor Test . . . . . . . . . . . . . . . . . . 4-99
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . 3-66
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Fuel Injection Pump
Static Timing Adjustment (EPA) . . . . . . . . . 3-26
Static Timing Adjustment (Non-EPA) . . . . . 3-24
Fuel Injection Pump (EPA) . . . . . . . . . . . . . . . . 3-64
Fuel Injection Pump (Non-EPA) . . . . . . . . . . . . 3-63
Fuel Shutoff Solenoid Tests . . . . . . . . . . . . . . . 4-99
Fuel Supply Pump Pressure Test . . . . . . . . . . . 3-29
Face Seal Fittings
Inch Studs Ends Torque . . . . . . . . . . . . . . . 2-16
Metric Studs Ends Torque . . . . . . . . . . . . . 2-17
Fuel Supply-European
Electrical Operation . . . . . . . . . . . . . . . . . . 4-40
Electrical Schematic . . . . . . . . . . . . . . . . . 4-139
Fenders (Rear)
Removal and Installation . . . . . . . . . . . . . . 12-6
Fuel Supply-N.A.
Electrical Diagnosis . . . . . . . . . . . . .4-44, 4-142
Electrical Operation . . . . . . . . . . . . . . . . . 4-138
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-41
Final Drive
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly, Inspection and Assembly . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . .
8-21
8-54
8-51
8-48
8-20
Fuel System
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Component Location . . . . . . . . . . . . . . . . . 3-61
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 3-29
Final Drive (4-WD) Components . . . . . . . . . . . . 8-16
Fuel Tank Removal and Installation . . . . . . . . 12-11
Floor Mat Removal and Installation . . . . . . . . . 12-8
Fuse Panel Cover Removal & Installation . . . . 12-9
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Front Axle
4-WD
Drive Shaft Removal & Installation . . . 8-25
Final Drive Cover Installation . . . . . . . . 8-26
Final Drive Housing Assembly . . . . . . . 8-28
Final Drive Housing Disassembly . . . . 8-28
Final Drive Housing Installation . . . . . . 8-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Spindle Housing Removal and Disassembly
8-29
Spindle Shaft Assembly and Installation 8-28
Spindle Shaft Removal and Disassembly 8-27
Final Drive Cover Removal & Inspection . . 8-25
Front Axle (4-WD)
Differential Removal & Disassembly . . . . . 8-29
G
Gear Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Component Location (Front) . . . . . . . . . . .
Component Location (Rear) . . . . . . . . . . .
Disassembly and Inspection . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . .
11-32
11-14
11-15
11-31
11-30
Grill Removal and Installation . . . . . . . . . . . . . . 12-9
Ground Circuit Test . . . . . . . . . . . . . . . . . . . . . . 4-80
H
Hazard Switch
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-172
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Front PTO
Electrical Operation . . . . . . . . . . . . . . . . . 4-166
Heater Repair . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Front PTO Gearbox Assembly . . . . . . . . . . . . 12-24
Hood Removal and Installation . . . . . . . . . . . . 12-11
Front PTO Gearbox Disassembly . . . . . . . . . . 12-20
Hydraulic System
Bleed Procedure . . . . . . . . . . . . . . . .6-20, 11-25
Front PTO Gearbox Removal . . . . . . . . . . . . . 12-17
Front PTO Installation . . . . . . . . . . . . . . . . . . . 12-18
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . 3-60
Fuel Gauge
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-154
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
INDEX - 6
Hydraulics
Component Location
Gear Pump (Front) . . . . . . . . . . . . . . . 11-14
Gear Pump (Rear) . . . . . . . . . . . . . . . 11-15
General . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Selective Control Valve (SCV) . . . . . . 11-13
4/6/01
INDEX
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
Rate of Drop/Stop Valve Adjustment . . . . 11-25
Rockshaft
Leakage Test . . . . . . . . . . . . . . . . . . . 11-29
Lift Cycle Test . . . . . . . . . . . . . . . . . . 11-28
Position Feedback Adjustment . . . . . 11-29
Schematics
1 Spool SCV and Manifold Block . . . . 11-21
Hydrostatic Transmission . . . . . . . . . . 11-24
PTO and 3 Spool SCV . . . . . . . . . . . . 11-20
Rockshaft . . . . . . . . . . . . . . . . . . . . . . 11-22
Steering . . . . . . . . . . . . . . . . . . . . . . . 11-23
Selective Control Valve (SCV)
Disassembly and Assembly . . . . . . . . 11-47
Removal and Installation . . . . . . . . . . 11-46
Specifications
General . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Tests and Adjustments
Lift Arms Adjustment . . . . . . . . . . . . . 11-26
Rockshaft
Leakage Test . . . . . . . . . . . . . . . . 11-29
Lift Cycle Test . . . . . . . . . . . . . . . 11-28
Position Feedback Adjustment . . 11-29
Steering Pressure Adjustment . . . . . . 11-27
System Pressure Adjustment . . . . . . . 11-27
System Pressure/Flow Test . . . . . . . . 11-26
Theory Of Operation
Hydraulics (Rockshaft) . . . . . . . . . . . . 11-18
Troubleshooting . . . . . . . . . . . . . . . . . . . . 11-16
Hydrostatic Control Linkage
Component Location . . . . . . . . . . . . . . . . . 6-10
Removal and Installation . . . . . . . . . . . . . . 6-45
Hydrostatic Motor
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Component Location . . . . . . . . . . . . . . . . . . 6-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Hydrostatic Neutral Adjustment . . . . . . . . . . . . 6-17
Hydrostatic Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Component Location . . . . . . . . . . . . . . . . . . 6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 6-17
Hydrostatic System
Charge Pump Pressure Test . . . . . . . . . . . 6-19
Component Location . . . . . . . . . . . . . . . . . . 6-6
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Neutral Adjustment . . . . . . . . . . . . . . . . . . . 6-17
Pump Pressure Test . . . . . . . . . . . . . . . . . . 6-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-3
4/6/01
Theory of Operation . . . . . . . . . . . . . . . . . . 6-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-14
Hydrostatic Transmission
Component Location . . . . . . . . . . . . . . . . . . 6-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Removal and Installation . . . . . . . . . . . . . . 6-26
Tractor Splitting (Front) . . . . . . . . . . . . . . . . 6-21
I
Idle Adjustments
Slow Engine Idle . . . . . . . . . . . . . . . . . . . . . 3-16
Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
K
Key Switch Panel Removal and Installation . . 12-10
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Kick Plate Removal and Installation . . . . . . . . . 12-8
L
Light Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Lighting Specifications . . . . . . . . . . . . . . . . . . . . 4-8
Lights-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-174
Electrical Schematic . . . . . . . . . . . .4-171, 4-173
Light Switch Operation . . . . . . . . . . . . . . . 4-170
Lights-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . .4-66, 4-72
Electrical Schematic . . . . . . . . . . . . . .4-65, 4-71
Light Switch Operation . . . . . . . . . . . .4-64, 4-70
Lubricants
Alternative Lubricants . . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mixing of Lubricants . . . . . . . . . . . . . . . . . .
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Synthetic Lubricants . . . . . . . . . . . . . . . . . .
2-22
2-21
2-22
2-22
2-22
2-22
M
Manifold Heater Circuit-European
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
Theory of Operation . . . . . . . . . . . . . . . . . 4-132
Manifold Heater Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Theory of Operation . . . . . . . . . . . . . . . . . . 4-34
Manifold Heater Test . . . . . . . . . . . . . . . . . . . . . 4-88
Mid PTO
Disassembly and Assembly . . . . . . . . . . . . 8-95
Removal and Installation . . . . . . . . . . . . . . 8-94
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
INDEX - 7
INDEX
Miscellaneous Repair Specifications . . . . . . . . 12-3
O
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 3-28
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Operator’s Platform Removal and Installation . 12-8
O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Face Seal Fittings . . . . . . . . . . . . . . . . . . . . 2-18
P
Parking Brake
Linkage Removal and Installation . . . . . . . 10-26
Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Parking Brake - Console Mount
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Theory of Operation
2-Speed . . . . . . . . . . . . . . . . . . . . . . . .
Clutch and Brake . . . . . . . . . . . . . . . . .
Mid . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . .
8-69
8-67
8-70
8-71
PTO (Front)
Electrical Solenoid Tests . . . . . . . . . . . . . . 4-96
Electrical Switch Test . . . . . . . . . . . . . . . . . 4-96
Indicator Light - European . . . . . . . . . . . . 4-166
PTO (Mid)
Components . . . . . . . . . . . . . . . . . . . . . . . . 8-65
Indicator Light . . . . . . . . . . . . . . . . . . . . . . 4-166
PTO (Rear)
Components . . . . . . . . . . . . . . . . . . . . . . . . 8-63
Electrical Circuit Diagnosis-European . . . 4-160
Indicator Lights - European . . . . . . . . . . . 4-158
PTO Electrical Schematic-European . . . . . . . 4-159
Parking Brake - Side Mount
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-18
PTO Gearbox Assembly, Front . . . . . . . . . . . . 12-24
Piston and Connecting Rod . . . . . . . . . . . . . . . 3-40
PTO Removal, Front . . . . . . . . . . . . . . . . . . . . 12-17
Piston to Cylinder Head Clearance . . . . . . . . . . 3-39
Pump (Gear)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Component Location (Front) . . . . . . . . . . .
Component Location (Rear) . . . . . . . . . . .
Disassembly and Inspection . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . .
Power Circuit-European
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . .
4-193
4-124
4-121
4-120
Power Circuit-N.A.
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Electrical Schematic . . . . . . . . . . . . . . . . . . 4-25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Power Train
Final Power Train Specifications . . . . . . . . . 8-3
Hydrostatic (HST) Specifications . . . . . . . . . 6-3
PTO
2-Speed
Components . . . . . . . . . . . . . . . . . . . . . 8-64
Shafts & Gears Assembly . . . . . . . . . . 8-82
Shafts & Gears Disassembly . . . . . . . . 8-78
Clutch & Brake
Disassembly and Assembly . . . . . . . . . 8-88
Removal and Installation . . . . . . . . . . . 8-86
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Mid
Disassembly and Assembly . . . . . . . . . 8-95
Removal and Installation . . . . . . . . . . . 8-94
Rear
Shafts & Gears
Disassembly & Assembly . . . . . . . 8-74
Removal & Installation . . . . . . . . . . 8-72
Specifications
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
INDEX - 8
11-32
11-14
11-15
11-31
11-30
R
Radiator Bubble Test . . . . . . . . . . . . . . . . . . . . 3-27
Radiator Cap Pressure Test . . . . . . . . . . . . . . . 3-27
Range Shift Components . . . . . . . . . . . . . . . . . 8-10
Rear Fenders
Removal and Installation . . . . . . . . . . . . . . 12-6
Rear PTO
Disassembly and Assembly . . . . . . . . . . . . 8-74
Removal and Installation . . . . . . . . . . . . . . 8-72
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Repair
4-WD
Drive Shaft Removal & Installation . . . . 8-25
Final Drive Cover Installation . . . . . . . . 8-26
Final Drive Cover Removal & Inspection 8-25
Final Drive Housing Assembly . . . . . . . 8-28
Final Drive Housing Disassembly . . . . 8-28
Final Drive Housing Installation . . . . . . 8-29
Output Shaft Removal and Installation . 8-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Spindle Housing Removal and Disassembly
8-29
Spindle Shaft Assembly and Installation 8-28
Spindle Shaft Removal and Disassembly 8-27
Battery Removal and Installation . . . . . . . 12-10
4/6/01
INDEX
Brake Assembly . . . . . . . . . . . . . . . . . . . . 10-20
Brake Disassembly and Inspection . . . . . 10-19
Brake Pedal Removal and Installation
CST or SRT . . . . . . . . . . . . . . . . . . . . 10-24
HST . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Collar Shift (CST)
Clutch Shaft
Removal & Installation . . . . . . . . . . 5-27
Input Shaft Disassembly . . . . . . . . . . . 5-20
Snubber Shimming Procedure . . . . . . . 5-25
Traction Clutch
Disassembly . . . . . . . . . . . . . . . . . 5-18
Removal . . . . . . . . . . . . . . . . . . . . 5-17
Shimming Procedure . . . . . . . . . . . 5-23
Collar Shift (CST and SST)
Traction Clutch
Installation . . . . . . . . . . . . . . . . . . . 5-20
Control Panel Removal and Installation . . . 12-9
Cowl Panel Removal and Installation . . . . 12-10
Differential
Assembly and Installation . . . . . . . . . . 8-57
Lock Fork Removal & Installation . . . . 8-58
Removal & Disassembly . . . . . . . . . . . 8-55
Final Drive
Disassembly, Inspection and Assembly 8-54
Installation . . . . . . . . . . . . . . . . . . . . . . 8-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Floor Mat Removal and Installation . . . . . . 12-8
Front Wheel Removal and Installation . . . . 12-7
Fuel Tank Removal and Installation . . . . . 12-11
Fuse Panel Cover Removal & Installation . 12-9
Gear Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-32
Disassembly and Inspection . . . . . . . 11-31
Removal and Installation . . . . . . . . . . 11-30
Grill Removal and Installation . . . . . . . . . . . 12-9
Hood Removal and Installation . . . . . . . . . 12-11
Hydrostatic System . . . . . . . . . . . . . . . . . . . 6-21
Key Switch Panel Removal and Installation 12-10
Kick Plate Removal and Installation . . . . . . 12-8
Mid PTO
Disassembly and Assembly . . . . . . . . . 8-95
Removal and Installation . . . . . . . . . . . 8-94
Operator’s Platform
Removal and Installation . . . . . . . . . . . 12-8
Parking Brake Linkage Removal and Installation
10-26
PTO
2-Speed
Shafts & Gears Assembly . . . . . . . 8-82
Shafts & Gears Disassembly . . . . . 8-78
Clutch & Brake
Removal and Installation . . . . . . . . 8-86
Rear Shafts & Gears
Disassembly & Assembly . . . . . . . 8-74
Removal and Installation . . . . . . . . 8-72
4/6/01
Rear Fenders Removal and Installation . . . 12-6
Rear Wheel Removal and Installation . . . . 12-7
Rockshaft
Installation . . . . . . . . . . . . . . . . . . . . . 11-35
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-34
Roll Over Protective Structure (ROPS)
Removal and Installation . . . . . . . . . . . 12-6
Selective Control Valve (SCV)
Disassembly and Assembly . . . . . . . . 11-47
Removal and Installation . . . . . . . . . . 11-46
Side Panel Removal & Installation . . . . . . . 12-8
SRT
Clutch Shimming Procedure . . . . . . . . 7-22
Clutch Snubber Shimming Procedure . 7-25
Input Shaft Disassembly . . . . . . . . . . . 7-20
Repair Specifications . . . . . . . . . . . . . . . 7-3
Special Tools . . . . . . . . . . . . . . . . . . . . . 7-3
Traction Clutch Disassembly . . . . . . . . 7-18
Traction Clutch Installation . . . . . . . . . . 7-20
Traction Clutch Removal . . . . . . . . . . . 7-17
Steering Control Unit (SCU) Removal . . . . 9-13
Steering Cylinder
Installation (2-WD) . . . . . . . . . . . . . . . . 9-12
Installation (4-WD) . . . . . . . . . . . . . . . . 9-11
Removal (2-WD) . . . . . . . . . . . . . . . . . 9-12
Removal (4-WD) . . . . . . . . . . . . . . . . . 9-11
Steering Wheel
Removal and Installation . . . . . . .9-12, 12-9
SyncReverser (SRT)
4-Speed Transmission
Assembly/Installation . . . . . . . . . . . 7-37
Disassembly . . . . . . . . . . . . . . . . . 7-31
Removal . . . . . . . . . . . . . . . . . . . . 7-29
Clutch & Forward/Reverse Shafts
Installation . . . . . . . . . . . . . . . . . . . 7-29
Removal . . . . . . . . . . . . . . . . . . . . 7-27
Three Point Hitch
Removal and Installation . . . . . . . . . . . 12-4
Tie Rod
Disassembly and Assembly (2-WD) . . . 9-15
Removal and Installation (2-WD) . . . . . 9-14
Removal and Installation (4-WD) . . . . . 9-14
Tilt Steering Removal & Installation . . . . . . 9-13
Tractor Splitting
Front
Collar Shift (CST) . . . . . . . . . . . . . 5-11
Hydrostatic (HST) . . . . . . . . . . . . . 6-21
SyncReverser (SRT) . . . . . . . . . . . 7-12
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Rocker
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . 3-32
Arm Component Location . . . . . . . . . . . . . . 3-32
Cover Removal . . . . . . . . . . . . . . . . . . . . . . 3-31
INDEX - 9
INDEX
Rockshaft
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cycle Test . . . . . . . . . . . . . . . . . . . . . .
Rate of Drop/Stop Valve Adjustment . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
11-19
11-35
11-28
11-25
11-34
ROPS Removal and Installation . . . . . . . . . . . . 12-6
S
Schematics - Hydraulic
Hydrostatic System . . . . . . . . . . . . . . . . . . . 6-12
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
SCV (Selective Control Valve)
Component Location . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . .
11-13
11-47
11-46
11-17
Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Selective Control Valve (SCV)
Component Location . . . . . . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . . .
Removal and Installation . . . . . . . . . . . . .
Theory of Operation . . . . . . . . . . . . . . . . .
11-13
11-47
11-46
11-17
Serial Number Location
Chassis Identification Number . . . . . . . . . . 2-23
Side Panels Removal & Installation . . . . . . . . . 12-8
Snubber Shimming Procedure
Collar Shift (CST) . . . . . . . . . . . . . . . . . . . . 5-25
Solenoid Test
Front PTO . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Fuel Shutoff . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . 4-84
Special Tools
Final Power Train . . . . . . . . . . . . . . . . . . . . . 8-4
Specifications
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Break-In Engine Oil . . . . . . . . . . . . . . . . . . 2-20
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Diesel Fuel Lubricity . . . . . . . . . . . . . . . . . . 2-19
Diesel Fuel Storage . . . . . . . . . . . . . . . . . . 2-19
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . 2-22
Drain Interval . . . . . . . . . . . . . . . . . . . . 2-23
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
General
Power Train
Hydrostatic . . . . . . . . . . . . . . . . . . . . 6-3
General Vehicle - 4200 . . . . . . . . . . . . . . . . . 2-3
3-Point Hitch . . . . . . . . . . . . . . . . . . . . . 2-4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
INDEX - 10
Drive Train . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . 2-4
Ground Speeds . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic System . . . . . . . . . . . . . . . . . . 2-5
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General Vehicle - 4300 . . . . . . . . . . . . . . . . . 2-6
3-Point Hitch . . . . . . . . . . . . . . . . . . . . . . 2-7
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Drive Train . . . . . . . . . . . . . . . . . . . . . . . 2-7
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fuel System . . . . . . . . . . . . . . . . . . . . . . 2-7
Ground Speeds . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic System . . . . . . . . . . . . . . . . . . 2-8
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Vehicle - 4400 . . . . . . . . . . . . . . . . 2-10
3-Point Hitch . . . . . . . . . . . . . . . . . . . . . 2-11
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Drive Train . . . . . . . . . . . . . . . . . . . . . . 2-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Fuel System . . . . . . . . . . . . . . . . . . . . . 2-11
Ground Speeds . . . . . . . . . . . . . . . . . . 2-12
Hydraulic System . . . . . . . . . . . . . . . . . 2-12
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulics
General . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Lubricants
Alternative Lubricants . . . . . . . . . . . . . . 2-22
Chassis Grease . . . . . . . . . . . . . . . . . . 2-21
Mixing of Lubricants . . . . . . . . . . . . . . . 2-22
Oil Filters . . . . . . . . . . . . . . . . . . . . . . . 2-22
Storage . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Synthetic Lubricants . . . . . . . . . . . . . . . 2-22
Miscellaneous Repair . . . . . . . . . . . . . . . . . 12-3
O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . 2-18
Face Seal Fittings . . . . . . . . . . . . . . . . 2-18
O-Ring Seal
Face Seal Fittings
Inch Stud Ends Torque . . . . . . . . . 2-16
Metric Stud Ends Torque . . . . . . . . 2-17
Other Materials, Engine . . . . . . . . . . . . . . . . 3-9
Product Identification Locations . . . . . . . . . 2-23
Special Tools, Engine . . . . . . . . . . . . . . . . . . 3-9
SRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Torque
Hydraulics . . . . . . . . . . . . . . . . . . . . . . 11-4
Torque Values, Inch Fastener . . . . . . . . . . 2-14
Torque Values, Metric Fastener . . . . . . . . . 2-15
4/6/01
INDEX
Splitting the Tractor
Front
Collar Shift (CST) . . . . . . . . . . . . . . . . .
Hydrostatic (HST) . . . . . . . . . . . . . . . .
SyncReverser (SRT) . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11
6-21
7-12
8-32
SRT
Theory of Operation . . . . . . . . . . . . . . . . . . . 7-8
Tractor Splitting (Front) . . . . . . . . . . . . . . . . 7-12
Starting Motor
Amp Draw Test . . . . . . . . . . . . . . . . . . . . . . 4-85
Disassembly and Assembly . . . . . . . . . . . . 3-70
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . 3-72
No-Load Amperage Draw and RPM Tests . 4-86
Removal and Installation . . . . . . . . . . . . . . 3-69
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . 4-84
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Steering
Component Location . . . . . . . . . . . . . . . . . . 9-4
Control Unit (SCU) Removal . . . . . . . . . . . 9-13
Cylinder Installation (2-WD) . . . . . . . . . . . . 9-12
Cylinder Installation (4-WD) . . . . . . . . . . . . 9-11
Cylinder Removal (2-WD) . . . . . . . . . . . . . . 9-12
Cylinder Removal (4-WD) . . . . . . . . . . . . . . 9-11
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Steering Control Unit (SCU) Test . . . . . . . . . 9-9
Steering Cylinder Test . . . . . . . . . . . . . . . . . 9-9
Steering Wheel Removal and Installation . . 9-12
Theory of Operation . . . . . . . . . . . . . . . . . . . 9-5
Tie Rod
Disassembly and Assembly (2-WD) . . 9-15
Removal and Installation (2-WD) . . . . . 9-14
Removal and Installation (4-WD) . . . . . 9-14
Tilt Mechanism Removal & Installation . . . . 9-13
Toe-In Adjustment (2-WD) . . . . . . . . . . . . . 9-10
Toe-In Adjustment (4-WD) . . . . . . . . . . . . . . 9-9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9-6
Steering Wheel Removal and Installation . . . . . 12-9
T
Test and Adjustments
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . 3-29
Tests and Adjustments
Brake Pedal Adjustment . . . . . . . . . . . . . . 10-17
Camshaft End Play Check . . . . . . . . . . . . . 3-21
Charge Pump Pressure Test . . . . . . . . . . . 6-19
Connecting Rod
Bearing Clearance . . . . . . . . . . . . . . . . 3-19
Side Play Check . . . . . . . . . . . . . . . . . . 3-18
Cooling System Pressure Test . . . . . . . . . . 3-27
4/6/01
Crankshaft
End Play Check . . . . . . . . . . . . . . . . . . 3-20
Main Bearing Clearance . . . . . . . . . . . . 3-20
Cylinder Compression Test . . . . . . . . . . . . 3-16
Differential
Backlash Adjustment . . . . . . . . . . . . . . 8-22
Engine Idle (Slow) . . . . . . . . . . . . . . . . . . . 3-16
Fan/Alternator Belt Adjustment . . . . . . . . . . 3-26
Fuel
Injection Nozzle Test . . . . . . . . . . . . . . 3-22
Injection Pump Static Timing (EPA) . . . 3-26
Injection Pump Static Timing (Non-EPA) 3-24
Supply Pump Pressure Test . . . . . . . . 3-29
System Leakage Test . . . . . . . . . . . . . 3-29
Hydraulic Steering Pressure Adjustment . 11-27
Hydraulic System
Pressure Adjustment . . . . . . . . . . . . . 11-27
Pressure/Flow Test . . . . . . . . . . . . . . 11-26
Hydrostatic Neutral Adjustment . . . . . . . . . 6-17
Hydrostatic Pump Pressure Test . . . . . . . . 6-17
Lift Arms Adjustment . . . . . . . . . . . . . . . . 11-26
Neutral Adjustment (HST) . . . . . . . . . . . . . 6-17
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . 3-28
Parking Brake Adjustment
Console Mount . . . . . . . . . . . . . . . . . . 10-18
Side Mount . . . . . . . . . . . . . . . . . . . . . 10-18
Radiator Bubble Test . . . . . . . . . . . . . . . . . 3-27
Radiator Cap Pressure Test . . . . . . . . . . . . 3-27
Rate of Drop/Stop Valve Adjustment . . . . 11-25
Rockshaft
Leakage Test . . . . . . . . . . . . . . . . . . . 11-29
Lift Cycle Test . . . . . . . . . . . . . . . . . . 11-28
Position Feedback Adjustment . . . . . . 11-29
SRT
Clutch Linkage Adjustment . . . . . . . . . . 7-9
Shift Linkage Adjustment . . . . . . . . . . . 7-10
Starting Motor . . . . . . . . . . . . . . . . . . . . . . . 3-72
Steering Control Unit (SCU) Test . . . . . . . . . 9-9
Steering Cylinder Test . . . . . . . . . . . . . . . . . 9-9
Thermostat Opening Test . . . . . . . . . . . . . . 3-24
Timing Gear
Backlash Check . . . . . . . . . . . . . . . . . . 3-22
Toe-In Adjustment (2-WD) . . . . . . . . . . . . . 9-10
Toe-In Adjustment (4-WD) . . . . . . . . . . . . . . 9-9
Valve Clearance . . . . . . . . . . . . . . . . . . . . . 3-17
Valve Lift Check . . . . . . . . . . . . . . . . . . . . . 3-21
Theory of Operation
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Draft Sensing . . . . . . . . . . . . . . . . . . . . . . 11-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Engine Lubrication System . . . . . . . . . . . . . 3-12
Fuel and Air System . . . . . . . . . . . . . . . . . . 3-10
Hydrostatic System . . . . . . . . . . . . . . . . . . . 6-16
PTO
INDEX - 11
INDEX
2-Speed . . . . . . . . . . . . . . . . . . . . . . . . 8-69
Clutch and Brake . . . . . . . . . . . . . . . . . 8-67
Mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-70
Rockshaft Hydraulics . . . . . . . . . . . . . . . . 11-17
SCV (Selective Control Valve) . . . . . . . . . 11-17
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Transmission Power Flow
PRT 4-Speed . . . . . . . . . . . . . . . . . . . . . 7-9
V
Valve Clearance Adjustment . . . . . . . . . . . . . . . 3-17
Valve Guides Inspection/Replacement . . . . . . . 3-37
Valve Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Valve Lift Check . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Valve Seat Grinding . . . . . . . . . . . . . . . . . . . . . 3-39
Thermostat and Water Pump . . . . . . . . . . . . . . 3-59
Valve Seats Inspection . . . . . . . . . . . . . . . . . . . 3-36
Three Point Hitch
Removal and Installation . . . . . . . . . . . . . . 12-4
Voltage Tests - Regulated . . . . . . . . . . . . . . . . 4-83
Tie Rod
Disassembly and Assembly (2-WD) . . . . . . 9-15
Removal and Installation (2-WD) . . . . . . . . 9-14
Removal and Installation (4-WD) . . . . . . . . 9-14
Tilt Steering Removal and Installation . . . . . . . 9-13
Timing Gear
Backlash Check . . . . . . . . . . . . . . . . . . . . . 3-22
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Toe-In Adjustment (2-WD) . . . . . . . . . . . . . . . . 9-10
Toe-In Adjustment (4-WD) . . . . . . . . . . . . . . . . . 9-9
W
W1 Main Wiring Harness
European (New) . . . . . . . . . . . . . . . . . . . . 4-114
European (Old) . . . . . . . . . . . . . . . . . . . . . 4-110
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
N.A. (New) . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
W2 Fuel Solenoid Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W3 Neutral Start Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Torque Specifications
Final Power Train . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Hydrostatic Power Train (HST) . . . . . . . . . . . 6-3
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
SRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
W4 Cruise Control Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Torque Values
Face Seal Fittings with Inch Stud Ends . . .
Face Seal Fittings with Metric Stud Ends . .
Inch Fastener . . . . . . . . . . . . . . . . . . . . . . .
Metric Fastener . . . . . . . . . . . . . . . . . . . . . .
W6 Trailer Connector Wiring Harness . . . . . . 4-117
Tractor Splitting
Front
Collar Shift (CST) . . . . . . . . . . . . . . . . .
Hydrostatic (HST) . . . . . . . . . . . . . . . .
SyncReverser (SRT) . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16
2-17
2-14
2-15
5-11
6-21
7-12
8-32
W5 Cruise Control Magnet Wiring Harness
European . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
N.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
W7 2-Speed PTO Wiring Harness . . . . . . . . . 4-118
W8 Front PTO Wiring Harness . . . . . . . . . . . . 4-118
Washer Pump Diagnosis . . . . . . . . . . . . . . . . 4-198
Wheels
Front Wheels Removal and Installation . . . 12-7
Rear Wheels Removal and Installation . . . 12-7
Windshield Washer Repair . . . . . . . . . . . . . . . 12-15
Wiper Electrical Diagnosis . . . . . . . . . . . . . . . 4-196
Transmission Neutral Switch Test - CST . . . . . 4-93
Transmission Neutral Switch Test - HST . . . . . 4-93
Troubleshooting
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Engine Troubleshooting Chart . . . . . . . . . . 3-13
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Hydraulic System . . . . . . . . . . . . . . . . . . . 11-16
Hydrostatic System . . . . . . . . . . . . . . . . . . . 6-14
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-71
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Turn Signal Switch Test . . . . . . . . . . . . . . . . . . 4-94
INDEX - 12
4/6/01
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : No Create Date : 1998:11:30 07:33:37Z Modify Date : 2002:03:07 13:41:58-06:00 Page Count : 742 Page Mode : UseOutlines Creation Date : 1998:11:30 07:33:37Z Producer : Acrobat Distiller 3.01 for Windows Mod Date : 2002:03:07 13:41:58-06:00 Metadata Date : 2002:03:07 13:41:58-06:00EXIF Metadata provided by EXIF.tools