Case Ih SM-Maxxum

SERVICE MANUAL
MAXXUM 100 , MAXXUM 110 Multicontroller , MAXXUM 110 , MAXXUM 115

Multicontroller , MAXXUM 115 , MAXXUM 120 Multicontroller , MAXXUM 120 ,
MAXXUM 125 Multicontroller , MAXXUM 125 , MAXXUM 130 Multicontroller ,
MAXXUM 130 , MAXXUM 140 Multicontroller , MAXXUM 140
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Contents
INTRODUCTION
HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMSA
PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve . . . . A.10.B
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve . . . . . . . . . . . . . . A.10.C
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve. . . . . . A.10.D
SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A

HYDRAULIC COMMAND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.14.A
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A
ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A
ENGINE AND PTO IN .................................................................... B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
TRANSMISSION, DRIVE AND PTO OUT .........................................C

POWER COUPLING Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.10.C
TRANSMISSION Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.B
TRANSMISSION Power Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.C
TRANSMISSION Semi-Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.D
ADDITIONAL REDUCERS Creeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.30.C
ADDITIONAL REDUCERS Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.30.D

REAR PTO Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.40.C
FRONT PTO Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.42.C
AXLES, BRAKES AND STEERING..................................................D

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FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.10.A
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.12.A
2WD-4WD SYSTEM Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.14.C
STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C
SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C
PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

BRAKE CONNECTION Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.34.C
SUSPENSION Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.40.C
WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C
FRAME AND CAB ......................................................................... E

FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B
SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A
USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning. . . . . . . . . . . . . . . . . . . . E.40.D
HITCH AND WORKING TOOL ........................................................H

HITCH Front hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.10.B
HITCH Rear hitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.10.C
HITCH Electronic draft control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.10.D
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INTRODUCTION
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Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Consumables Lubrications and Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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INTRODUCTION
Foreword
Technical Information
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through CD-ROM and in paper manuals. A coding system called ICE has been
developed to link the technical information to other Product Support functions e.g. Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customers
machine. When a customer has a concern on his machine it is usually because a function or system on his machine
is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the
technical information in this manual to resolve that customers concern, you will find all the information classified using
the new ICE coding, according to the functions or systems on that machine. Once you have located the technical
information for that function or system then you will find all the mechanical, electrical or hydraulic devices, compo-
nents, assemblies and sub assemblies for that function or system. You will also find all the types of information that
have been written for that function or system, the technical data (specifications), the functional data (how it works),
the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).
By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right
piece of technical information you need to resolve that customers concern on his machine. This is made possible by
attaching 3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION - is the component or function on the machine, that the piece of technical information is going to
describe e.g. Fuel tank.
• INFORMATION TYPE - is the piece of technical information that has been written for a particular component or
function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel
held by the Fuel tank.
• PRODUCT - is the model that the piece of technical information is written for.
Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination
of those categories to find the right piece of technical information you need to resolve that customers concern on his
machine.
That information could be:

• the description of how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
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INTRODUCTION
How to Use this Manual

This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the
beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the
end of a Chapter. Page number references are included for every piece of technical information listed in the Chapter
Contents or Chapter Index.
Each Chapter is divided into four Information types:

• Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and, assemblies.
• Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and assemblies.
• Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic
devices, components and assemblies.
• Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices, com-
ponents and assemblies.
Sections
Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by
a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the
machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This
table illustrates which Sections could be included in a manual for a particular product.
SECTION
A - Distribution Systems
B - Power Production
C - Power Train
D - Travelling
E - Body and Structure
F - Frame Positioning
G - Tool Positioning
H - Working Arm
J - Tools and Couplers
K - Crop Processing
L - Field Processing
PRODUCT
Tractors X X X X X X X X
Vehicles with working arms: backhoes, X X X X X X X X X
excavators, skid steers, .....
Combines, forage harvesters, balers, .... X X X X X X X X X X
Seeding, planting, floating, spraying X X X X X X X X X
equipment, ....
Mounted equipment and tools, ..... X X X X
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INTRODUCTION
This manual contains these Sections. The contents of each Section are explained over the following pages.
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
POWER TRAIN C
TRAVELLING D
BODY AND STRUCTURE E
TOOL POSITIONING G
CROP PROCESSING K
Section Contents
SECTION A, DISTRIBUTION SYSTEMS
This Section covers the main systems that interact with most of the functions of the product. It includes the central
parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components that
are dedicated to a specific function are listed in the Chapter where all the technical information for that function is
included.
SECTION B, POWER PRODUCTION

This Section covers all the functions related to the production of power to move the machine and to drive various
devices.
SECTION C, POWER TRAIN

This Section covers all the functions related to the transmission of power from the engine to the axles and to internal
or external devices and additional Process Drive functions.
SECTION D, TRAVELLING
This Section covers all the functions related to moving the machine, including tracks, wheels, steering and braking. It
covers all the axles both driven axles and non-driven axles, including any axle suspension.
SECTION E, BODY AND STRUCTURE

This Section covers all the main functions and systems related to the structure and body of the machine. Including
the frame, the shields, the operator’s cab and the platform.
SECTION G, TOOL POSITIONING

This Section covers all the functions related to the final and/or automatic positioning of the tool once the tool is posi-
tioned using the Working Arm or the machine frame.
SECTION K, CROP PROCESSING

This Section covers all the functions related to crop processing.
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INTRODUCTION
Chapters
Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the
Section letter i.e. Chapter B.10 is inside Section B, Power Production.
CONTENTS
The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data (remove,
install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that Chapter for
that function or system on the machine.
Contents
POWER PRODUCTION
ENGINE _ 10.A
TECHNICAL DATA
ENGINE - General specification (B.10.A - D.40.A.10)
CS6050
FUNCTIONAL DATA
ENGINE - Dynamic description (B.10.A - C.30.A.10)

CS6050
SERVICE
ENGINE - Remove (B.10.A - F.10.A.10)
CS6050
DIAGNOSTIC
ENGINE - Troubleshooting (B.10.A - G.40.A.10)
CS6050
INDEX
The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been
written in that Chapter for that function or system on the machine.
Index
POWER PRODUCTION - B
ENGINE
ENGINE - Dynamic description (B.10.A - C.30.A.10)
CS6050
ENGINE - General specification (B.10.A - D.40.A.10)
CS6050
ENGINE - Remove (B.10.A - F.10.A.10)
CS6050
ENGINE - Troubleshooting (B.10.A - G.40.A.10)
CS6050
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INTRODUCTION
Information Units and Information Search

Each chapter is composed of information units. Each information unit has the ICE code shown in parentheses which
indicates the function and the type of information written in that information unit. Each information unit has a page ref-
erence within that Chapter. The information units provide a quick and easy way to find just the right piece of technical
information you are looking for.
example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)

Information Unit ICE code A 10.A 18 C 10.A.30
ICE code classification Distribution Primary Stack valve Functional Sectional view
systems hydraulic data
power
CRIL03J033E01 1
Navigate to the correct information unit you are searching for by identifying the function and information type
from the ICE code.
• (1) Function and (2) Information type.
• (A) corresponds to the sections of the repair manual.
(B) corresponds to the chapters of the repair manual.
(C) corresponds to the type of information listed in the chapter contents, Technical data, Functional Data, Diag-
nostic or Service.
(A) and (B) are also shown in the page numbering on the page footer.
THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL.
• You will find a table of contents at the beginning and end of each section and chapter.
You will find an alphabetical index at the end of each chapter.
• By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly
find the information you are looking for.
Page Header and Footer

The page header will contain the following references:
• Section and Chapter description
The page footer will contain the following references:

• Publication number for that Manual, Section or Chapter.
• Version reference for that publication.
• Publication date
• Section, chapter and page reference e.g. A.10.A / 9
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INTRODUCTION
Important information
All repair and maintenance works listed in this manual must be carried out only by staff belonging to the Case I H
Service network, strictly complying with the instructions given and using, whenever required, the special tools.
Anyone who carries out the above operations without complying with the prescriptions shall be responsible for the
subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional or
local dealers, reject any responsibility for damages due to the anomalous behaviour of parts and/or components not
approved by the manufacturer himself, including those used for the servicing or repair of the product manufactured
or marketed by the Manufacturer. In any case, no warranty is given or attributed on the product manufactured or
marketed by the Manufacturer in case of damages due to an anomalous behaviour of parts and/or components not
approved by the Manufacturer.
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INTRODUCTION
Safety rules
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by authorised work-
shops. All instructions should be carefully observed and special equipment where indicated should be used.
Anyone who carries out service operations described without carefully observing these instructions will be directly
responsible for any damage caused.
NOTES FOR EQUIPMENT

Equipment shown in this manual is:
• designed expressly for use on these tractors;
• necessary to make a reliable repair;
• accurately built and strictly tested to offer efficient and long-lasting working life.
NOTICES
The words “front”, “rear”, “right hand”, and “left hand” refer to the different parts as seen from the operator’s seat
oriented to the normal direction of movement of the tractor.
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL

This warning symbol points out important messages involving personal
safety. Carefully read the safety rules contained herein and follow advised
precautions to avoid potential hazards and safeguard your safety.
In this manual you will find this symbol together with the following
key-words:
WARNING -it gives warning about improper repair operations and potential
consequences affecting the service technician’s personal safety.
DANGER - it gives specific warning about potential dangers for personal
safety of the operator or other persons directly or indirectly involved in
the operation.
TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in workshops are due from non-observance of some essential rules
and safety precautions.
The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well
the machine in question was designed and built.
A wise and careful service technician is the best precautions against accidents.
Careful observance of this basic precaution would be enough to avoid many severe accidents.
DANGER
Never carry out any cleaning, lubrication or maintenance operations when the engine is running.
B013
SAFETY RULES
Generalities
• Carefully follow specified repair and maintenance procedures.
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INTRODUCTION
• Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as
anti-slipping footwear, gloves, safety goggles, helmets, etc.
• Wear safety glasses with side guards when cleaning parts using compressed air.
• Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing.
• Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear when-
ever welding. All persons standing in the vicinity of the welding process should wear approved eye protection.
NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.
• Never carry out any repair on the machine if someone is sitting on the operator’s seat, except if they are qualified
operators assisting in the operation to be carried out.
• Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side
of the machine when operating the fender switches.
• Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop
the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves,
etc.
• All repair and maintenance operations should be carried out with the greatest care and attention.
• Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all
equipment which should be raised.
• Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such
fluids are flammable.
• The fuel filling gun should always remain in contact with the filler neck. Maintain this contact until the fuel stops
flowing into the tank to avoid possible sparks due to static electricity build-up.
• To transfer a failed tractor, use a trailer or a low loading platform trolley if available.
• To load and unload the machine from the transportation means, select a flat area providing a firm support to the
trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the
transporter.
• Always use lifting equipment of appropriate capacity to lift or move heavy components.
• Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen.
No persons should stand near the fastening point.
• The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil.
• Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non-flammable non-toxic pro-
prietary solvents.
• Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal
container.
START UP
• Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extrac-
tion.
• Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts.
ENGINE
• Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant
should be topped up only when the engine is stopped.
• Do not fill up fuel tank when the engine is running.
• Never adjust the fuel injection pump when the tractor is moving.
• Never lubricate the tractor when the engine is running.
ELECTRICAL SYSTEMS
• If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (-) to
(-). Avoid short-circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During
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INTRODUCTION
charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery
area. Do no smoke.
• Do not charge batteries in confined spaces.
• Always disconnect the batteries before performing any type of service on the electrical system.
HYDRAULIC SYSTEMS
• Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate the skin.
For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece
of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate
medical attention may result in serious infections or dermatitis.
• Always take system pressure readings using the appropriate gauges.
WHEELS AND TYRES

• Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check for
possible damage to the rims and tyres.
• Stay at the tyre side when inflating.
• Check the pressure only when the tractor is unloaded and tyres are cold to avoid wrong readings due to over-
pressure.
• Never cut, nor weld a rim with the inflated tyre assembled.
• To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable
supports under the tractor in accordance with regulations in force.
• Deflate the tyre before removing any object caught into the tyre tread.
• Never inflate tyres using flammable gases as they may generate explosions and cause injuries to bystanders.
REMOVAL AND INSTALLATION

• Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported
by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads
to be lifted.
HEALTH AND SAFETY
CONTENT
Section Description Page
HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADHESIVES AND SEALERS - see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ANTIFREEZE - see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . 5
ARC WELDING - see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BATTERY ACIDS - see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) - see Fire. . . . . . . . . . . . . 6
BRAZING - see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHEMICAL MATERIALS - GENERAL - see Legal Aspects. . . . . . . . . . . . . . . . . 6
DO’S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DO NOTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CORROSION PROTECTION MATERIALS - see Solvents, Fire. . . . . . . . . . . . . . . 6
DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC SHOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST FUMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIBRE INSULATION - see Dusts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRE - see Welding, Foams, Legal Aspects.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FIRST AID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FOAMS - Polyurethane - see Fire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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FUELS - see Fire, Legal Aspects, Chemicals - General, Solvents.. . . . . . . . . . . . . . . . 8

GAS CYLINDERS - see Fire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL WORKSHOP TOOLS AND EQUIPMENT. . . . . . . . . . . . . . . . . . . . . 9
LEGAL ASPECTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANTS AND GREASES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PAINTS - see Solvents and Chemical Materials - General.. . . . . . . . . . . . . . . . . . . . . 10
SOLDER - see Welding.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SOLVENTS - see Chemical Materials - General Fuels (Kerosene), Fire.. . . . . . . . . .. 10
SUSPENDED LOADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WELDING - see Fire, Electric Shock, Gas Cylinders.. . . . . . . . . . . . . . . . . . . . . . . . 11
HEALTH AND SAFETY PRECAUTIONS

Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to
health. This section lists, alphabetically, some of these hazardous operations and the materials and equipment asso-
ciated with them. The precautions necessary to avoid these hazards are identified.
The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with
health and safety in mind.
ACIDS AND ALKALIS

see Battery acids, e.g. caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Causes burns.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary
protective clothing. Do not breathe mists.
Ensure access to water and soap is readily available for splashing accidents.
ADHESIVES AND SEALERS

see Fire
Highly Flammable, Flammable, combustible.
Generally should be stored in “No Smoking” areas; cleanliness and tidiness in use should be observed, e.g. dispos-
able paper covering benches; should be dispensed from applicators where possible; containers, including secondary
containers, should be labelled.
Solvent based Adhesives/Sealers

See Solvents.
Follow manufacturers instructions.
Water based Adhesives/Sealers

Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chem-
icals. Skin and eye contact should be avoided and adequate ventilation provided during use.
Resin based Adhesives/Sealers

e.g. epoxide and formaldehyde resin based.
Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic or harmful
chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions.
Anaerobic, Cyanoacrylate and other Acrylic Adhesives

Many are irritant, sensitizing or harmful to the skin. Some are eye irritants.
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Skin and eye contact should be avoided and the manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) must not contact the skin or eyes. If skin or eye tissue is bonded cover with a
clean moist pad and get medical attention. do not attempt to pull tissue apart. Use in well ventilated areas as vapours
can cause irritation of the nose and eyes.
For two-pack systems see Resin based adhesives/sealers.
Isocyanate (Polyurethane) Adhesives/ Sealers

see Resin based Adhesives.
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity
reactions can occur.
Any spraying should preferably be carried out in exhaust ventilated booths removing vapours and spray droplets from
the breathing zone. Individuals working with spray applications should wear supplied air respirators.
ANTIFREEZE
see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol.
Highly Flammable, Flammable, Combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapours given off from coolant antifreeze (glycol) arise only when heated.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical
attention must be found immediately.
ARC WELDING
see Welding.
BATTERY ACIDS
see Acids and Alkalis.
Gases released during charging are explosive.
Never use naked flames or allow sparks near charging or recently charged batteries.
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols)

see Fire.
Combustible.
Splashes to the skin and eyes are slightly irritating.
Avoid skin and eye contact as far as possible.
Inhalation of vapour hazards do not arise at ambient temperatures because of the very low vapour pressure.
BRAZING
see Welding.
CHEMICAL MATERIALS - GENERAL

see Legal Aspects.
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids,
oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful,
corrosive, irritant or highly inflammable and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life-expectancy.
DO’S
Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled
clothing and have it cleaned.
Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any
accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from
Manufacturers.
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Do organise work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapours/aerosols/
dusts/fumes; inadequate container labelling; fire and explosion hazards.
Do wash before job breaks; before eating, smoking, drinking or using toilet facilities when handling chemical materials.
Do keep work areas clean, uncluttered and free of spills.
Do store according to national and local regulations.
Do keep chemical materials out of reach of children.
DO NOTS
Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or
harmful chemicals; give off toxic or harmful fumes; be explosive when mixed together.
Do Not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are
inside a vehicle.
Do Not apply heat or flame to chemical materials except under the manufacturers’ instructions. Some are highly
inflammable and some may release toxic or harmful fumes.
Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some
fumes are heavier than air and will accumulate in confined areas, pits etc.
Do Not transfer chemical materials to unlabeled containers.
Do Not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels will dry the skin
and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities.
Do Not use emptied containers for other materials, except when they have been cleaned under supervised conditions.
Do Not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.
Clutch Fluids
see Brake and Clutch Fluids.
Clutch Linings and Pads

see Brake and Clutch Linings and Pads.
CORROSION PROTECTION MATERIALS

see Solvents, Fire.
Highly flammable, flammable.
These materials are varied and the manufacturers instructions should be followed. They may contain solvents, resins,
petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of
adequate ventilation and not in confined spaces.
Cutting
see Welding.
De-Waxing
see Solvents and Fuels (Kerosene).
DUSTS
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or
those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.
ELECTRIC SHOCK
Electric shocks can result from the use of faulty electrical equipment or from the misuse of equipment even in good
condition.
Ensure that electrical equipment is maintained in good condition and frequently tested.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.
Ensure that electric equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Use reduced voltage equipment ( 110 volt) for inspection and working lights where possible.
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Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.
Use air operated mobile equipment where possible in preference to electrical equipment.
In cases of electrocution:-
• switch off electricity before approaching victim
• if this is not possible, push or drag victim from source of electricity using dry non-conductive material
• commence resuscitation if trained to do so
• SUMMON MEDICAL ASSISTANCE
EXHAUST FUMES
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, alde-
hydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or
general ventilation and not in confined spaces.
Gasolene (Petrol) Engine

There may not be adequate warning properties of odour or irritation before immediate and delayed toxic or harmful
effects arise.
Diesel Engine
Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.
FIBRE INSULATION
see Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical
effect.
Precautions should be taken to avoid excessive skin contact through careful organisation of work practices and the
use of gloves.
FIRE
see Welding, Foams, Legal Aspects.
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or
harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equip-
ment or welding processes.
Ensure before using electrical or welding equipment but that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
FIRST AID
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in first aid proce-
dures.
Splashes in the eye should be flushed with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Inhalation affected individuals should be removed to fresh air immediately.
If swallowed or if effects persist consult a doctor with information (label) on material used.
Do not induce vomiting (unless indicated by manufacturer).
FOAMS - Polyurethane
see Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
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Individuals with chronic respiratory diseases, asthma, bronchial medical problems or histories of allergic diseases
should not work with or near uncured materials.
The components, vapours, spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapours and spray mists must not be breathed. These materials must be applied with adequate ventilation and res-
piratory protection. Do not remove respirator immediately after spraying, wait until vapour/ mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes.
Smoking, open flames or the use of electrical equipment during foaming operations and until vapours/mists have
cleared should not be allowed.
Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation (see Body
Section 44 Legal and Safety Aspects).
FUELS
see Fire, Legal Aspects, Chemicals - General, Solvents.
Used as fuels and cleaning agents.
Gasolene (Petrol).
Highly flammable.
Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, e.g. through vomiting,
is a very serious hazard.
Gasolene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye
causes severe smarting.
Motor gasolene may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentrations
of gasolene vapours must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea,
headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of conscious-
ness.
Ensure there is adequate ventilation when handling and using gasolene. Great care must be taken to avoid the serious
consequences of inhalation in the event of vapour build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasolene storage tanks.
Gasolene should not be used as a cleaning agent. It must not be siphoned by mouth.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspi-
ration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye
may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapours. Exposure to mists and vapours from
kerosene at elevated temperatures should be avoided (mists may arise in de-waxing).
Avoid skin and eye contact and ensure there is adequate ventilation.
Gas-Oil (Diesel Fuel)

see Fuels (Kerosene).
Combustible.
Gross or prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer.
GAS CYLINDERS
see Fire.
Gases such as oxygen, acetylene, carbon dioxide, argon and propane are normally stored in cylinders at pressures of
up to 140 bar( 2000 lb/in2) and great care should be taken in handling these cylinders to avoid mechanical damage to
them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel
gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
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Gases
see Gas Cylinders.
Gas Shielded Welding

see Welding.
Gas Welding
see Welding.
GENERAL WORKSHOP TOOLS AND EQUIPMENT

It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used
where required.
Never use tools or equipment for any purpose other than that for which they were designed.
Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by over-
loading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A
damaged grinding wheel can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials or using
spraying equipment.
Glues
see Adhesives and Sealers.
High Pressure Air, Lubrication and Oil Test Equipment accordance with local regulations
see Lubricants and Greases.
Always keep high pressure equipment in good condition and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle at the skin as the fluid may penetrate to the underlying tissue etc. and cause
serious injury.
LEGAL ASPECTS
Many laws and regulations make requirements relating to health and safety in the use of materials and equipment in
workshops. Always conform to the laws and regulations applicable to the country in which you are working.
Workshops should be familiar, in detail, with the associated laws and regulations. Consult the local factory inspec-
torate or appropriate authority if in any doubt.
LUBRICANTS AND GREASES

Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service
(e.g. routine service change sump oils) are more irritating and more likely to cause serious effects including skin
cancer in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil. Proprietary hand cleaners may be of value provided they can be re-
moved from the skin with water. Do not use petrol, paraffin or other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particular care
should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil.
Dry clean or launder such clothing at regular intervals. Discard oil soaked shoes.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
Used oils may only be disposed of in accordance with local regulations.
Noise Insulation Materials

see Foams, Fibre Insulation.
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PAINTS
see Solvents and Chemical Materials - General.
Highly Flammable, Flammable.
One Pack. Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should
only be carried out with adequate ventilation.
Two Pack. Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers
instructions should be followed and the section of page 5 on resin based adhesives, isocyanate containing Adhesives
and Foams should be consulted.
Spraying should preferably be carried out in exhausted ventilated booths removing vapour and spray mists from the
breathing zone. Individuals working in booths should wear respiratory protection. Those doing small scale repair work
in the open shop should wear supplied air respirators.
Paint Thinners
see Solvents.
Petrol
see Fuels (Gasolene).
Pressurised Equipment
see High Pressure Air, Lubrication and Oil Test Equipment.
Resistance Welding
see Welding.
Sealers
see Adhesives and Sealers.
SOLDER
see Welding.
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (nor-
mally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is
used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be evolved.
Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of
these should be avoided.
Removal of excess solder should be undertaken with care, to ensure that fine lead dust is not produced, which can
give toxic effects if inhaled. Respiratory protection may be necessary.
Solder spillage and filing should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid indigestion of lead or inhalation of solder dust
from clothing.
SOLVENTS
see Chemical Materials - General Fuels (Kerosene), Fire.
e.g. Acetone, white spirit, toluene, xylene, trichlorethane.
Used in cleaning materials, de-waxing, paints, plastics, resins, thinners etc.
Highly Inflammable, Flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact.
Some can be absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure to high concentrations of vapours or mists will cause eye and throat irritation, drowsiness, dizziness,
headaches and in the worst circumstances, unconsciousness.
Repeated or prolonged exposures to excessive but lower concentrations of vapours or mists, for which there might
not be adequate warning indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.
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Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapours and spray mists and keep containers tightly
sealed. Do not use in confined spaces.
When the spraying material contains solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal
respiratory protection in the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.
Sound Insulation
see Fibre Insulation, Foams.
Spot Welding
see Welding.
SUSPENDED LOADS
There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or raised
load, e.g. jacked up vehicle, suspended engine, etc.
Always ensure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the
job, in good condition and regularly maintained.
Never improvise lifting tackle.
Underseal
see Corrosion Protection.
WELDING
see Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at high velocity and the eyes and skin must be pro-
tected.
Arc Welding
This process emits a high level of ultraviolet radiation which may cause eye and skin burns to the welder and to other
persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must
be worn, and screens used to shield other people.
Metal spatter will also occur and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded and from any applied coatings
or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation should
always be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary,
particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In
extreme cases where adequate ventilation cannot be provided, supplied air respirators may be necessary.
Gas Welding
Oxy-acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of
these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright and eye protection should be used, but the ultra-violet emission is much less than that from arc
welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work,
particularly during cutting away of damaged body parts and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be evolved from the metals in the brazing rod, and a severe hazard may arise if brazing
rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert
advice may be required.
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SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS
WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.
White Spirit
see Solvents.
ECOLOGY AND THE ENVIRONMENT

Soil, air and water are vital factors of agriculture and life in general. Where legislation does not yet rule the treatment
of some of the substances which are required by advanced technology, common sense should govern the use and
disposal of products of a chemical and petrochemical nature.
The following are recommendations which may be of assistance:

• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti freeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these
substances. Agricultural consultants will, in many cases, be able to help you as well.
HELPFUL HINTS
1. Avoid filling tanks using unsuitable containers or inappropriate pressurised fuel delivery systems which may cause
considerable spillage.
2. In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which can
be harmful to your health.
3. Modern oils contain additives. Do not burn contaminated fuels and/or waste oils in ordinary heating systems.
4. Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids,
etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a
proper way to comply with local legislation and available resources.
5. Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should
not be allowed to get into the soil but should be collected and disposed of safely.
6. Do not open the air-conditioning system yourself. It contains gases which should not be released into the atmos-
phere. Your dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge
the system anyway.
7. Repair any leaks or defects in the engine cooling or hydraulic system immediately.
8. Do not increase the pressure in a pressurised circuit as this may lead to the components exploding.
9. Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, causing the loss of
oils, coolant, etc.
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INTRODUCTION
Torque
Minimum hardware tightening torques for normal assembly applications unless otherwise
stated
NOTICE: Shown below is the suggested initial torque tightening sequences for general applications, tighten in se-
quence from item 1 through to the last item of the hardware.
df5019-1 1
Imperial hardware
Nominal SAE SAE SAE SAE SAE SAE LOCK- LOCK-
Size GRADE 2 GRADE GRADE 5 GRADE GRADE GRADE NUTS NUTS
Unplated 2 plated Unplated 5 plated 8Unplated 8 plated GR.B GR.B
or Silver w/ZnCr or Silver w/ZnCr or Silver w/ZnCr w/GR5 w/GR8
plated GOLD plated GOLD plated GOLD BOLT BOLT
1/4 6.2 Nm 8.1 Nm 9.7 Nm 13 Nm 14 Nm 18 Nm 6.9 Nm 9.8 Nm
55 lb in 72 lb in 86 lb in 112 lb in 121 lb in 157 lb in 61 lb in 86 lb in
5/16 13 Nm 17 Nm 20 Nm 26 Nm 28 Nm 37 Nm 14 Nm 20 Nm
115 lb in 149 lb in 178 lb in 229 lb in 250 lb in 324 lb in 125 lb in 176 lb in
17 lb ft 22 lb ft 26 lb ft 34 lb ft 37 lb ft 48 lb ft 19 lb ft 26 lb ft
1.0 289 Nm 373 Nm 742 Nm 960 Nm 1048 Nm 1356 Nm 523 Nm 739 Nm
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INTRODUCTION
Metric hardware
Nominal CLASS 5.8 CLASS 5.8 CLASS 8.8 CLASS 8.8 CLASS 10.9 CLASS 10.9 LOCKNUT
Size UNPLATED UNPLATED UNPLATED UNPLATED UNPLATED UNPLATED CL.8
w/CL8.8
BOLT
M4 1.7 Nm 2.2 Nm 2.6 Nm 3.4 Nm 3.7 Nm 4.8 Nm 1.8 Nm
15 lb in 19 lb in 23 lb in 30 lb in 33 lb in 42 lb in 16 lb in
M6 5.8 Nm 7.6 Nm 8.9 Nm 12 Nm 13 Nm 17 Nm 6.3 Nm
M8 14 Nm 18 Nm 22 Nm 28 Nm 31 Nm 40 Nm 15 Nm
21 lb ft 27 lb ft 32 lb ft 41 lb ft 45 lb ft 58 lb ft 22 lb ft
20083680 2
Identification - Hexagon cap screw and carriage bolts classes 5.6 and onwards
1.Manufacturers identification 2. Property class
20083681 3
Identification - Hexagonal nuts and locknuts classes 05 onwards

1. Manufacturers identification 2. Property class
3. Clock marking
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INTRODUCTION
20083682 4
Identification - Cap screws and carriage bolts

1. SAE grade 2 2. SAE grade 5
3. SAE grade 8 4. Regular nuts
5. SAE grade 5 hex nuts 6. SAE grade 8 hex nuts
20083683 5
Locknuts - grade identification

Grade A : no notches Grade B : one circumferential notch
Grade C : two circumferential notches
20083684 6

Grade A : no marks Grade B : three marks
Grade C : six marks
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INTRODUCTION
20083685 7

Grade A : no marks Grade B : letter B
Grade C : letter C
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INTRODUCTION
Consumables Lubrications and Coolants

Lubrications
The correct engine oil viscosity grade is dependent upon ambient temperature. Refer to the chart when selecting oil
for your tractor engine.
SS09J076 1
NOTE: In areas where prolonged periods of extreme temperatures are encountered, local lubricant practices are
acceptable; such as the use of SAE 5W-30 in extreme low temperatures or SAE 50 in extreme high temperatures.
Biodegradable Transmission and Hydraulic Oil

A biodegradable oil has been approved for use in the transmission, 4WD front axle and hubs, and the hydraulic system
of your tractor. Although the oil is 90% biodegradable, it is important to follow safe handling and disposal practices.
Biodegradable oil should not be used in conjunction with other oils. Use the following procedure to replace standard
oil with biodegradable lubricant.
1. Operate the tractor until the oil that is being changed reaches a temperature greater than 60 °C (140 °F).
2. Stop the engine and immediately drain the oil.
3. Replace all transmission and hydraulic filters.
4. Add the biodegradable oil to the correct level and run the tractor to circulate the oil.
5. Check for oil leaks and recheck the oil level.
Sulphur in Fuel
The engine oil and filter change period are shown in the Lubrication and Maintenance in the operators manual. How-
ever, locally available fuel may have a high sulphur content, in which case the engine oil and filter change period
should be adjusted as follows:
Sulphur Content % Oil Change Period

Below 0.5 Normal
From 0.5 - 1.0 Half the normal
Above 1.0 One quarter normal
NOTE: The use of fuel with a sulphur content above 1.3% is not recommended.
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INTRODUCTION
Coolants
To reduce the amount of deposits and corrosion, the water used in the cooling system must comply with the following
values.
Total Hardness Chloride Sulphate

300 parts per million 100 parts per million 100 parts per million
Using Plain water

If you reside in a country where antifreeze is not available, use clean water premixed with 5% chemical inhibitor.
CAUTION
Inhibitor solution is irritating to eyes and skin . It contains buffered potassium hydroxide.
B084
• Avoid contact with eyes or prolonged or repeated skin contact.

• Wear protective eyewear when using.
• In case of contact with eyes, flush with water for 15 minutes and obtain medical attention.
• Wash skin with soap and water after use.
• Keep out of reach of children.
Lubrications and Coolant Specifications

CIH INTERNATIONAL
RECOMMENDED FLUIDS AND APPLICATIONS
SPECIFICATION SPECIFICATION
ENGINE OIL
AKCELA NO. 1 ENGINE OIL 15W-40 API CI-4,
MS 1121
AKCELA NO. 1 ENGINE OIL 10W-30 ACEA E7
TRANSMISSION, REAR AXLE AND HYDRAULIC
SYSTEM OIL
AKCELA NEXPLORE API GL4,
FRONT AXLE (Axle and Hubs) MAT 3525 ISO VG32/46,
AKCELA NEXPLORE M2C 134D
FRONT P.T.O GEARBOX OIL
AKCELA NEXPLORE
ENGINE RADIATOR COOLANT
AKCELA PREMIUM ANTI-FREEZE
MS 1710 Ethylene Glycol
(mixed with 50% of water)
BRAKE OIL
AKCELA LHM FLUID n/a ISO 7308
AIR CONDITIONING COMPRESSOR OIL
Low Viscosity Oil SP10 n/a PAG-E13, ISO100 Viscosity
GREASE FITTINGS AND BEARINGS
AKCELA MULTI-PURPOSE GREASE 251H EP 251H EP NLGI2, Li-Ca
Regarding filling quantity - see Capacities ()
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INTRODUCTION
Capacities
MAXXUM / MAXXUM Multicontroller
UNIT 100 110 120 130 115 125 140
176 l 250 l
FUEL TANK
(46.5 US gal) (66 US gal)
COOLING SYSTEM (with cab)
25 l (6.6 US gal)
*) only for North America
*23 l (6.1 US gal)
MAXXUM 100, 110 and 115
21 l 23 l
21 l
COOLING SYSTEM (less cab) n/a (5.5 US (6.1 US n/a
(5.5 US gal)
gal) gal)
ENGINE (including filter) 10 l (2.64 US gal) 15 l (3.96 US gal)
TRANSMISSION / REAR AXLE
58 l 58 l
(with 12x12, Light Duty axle) n/a n/a
(15.3 US gal) (15.3 US gal)
65 l 65 l
(with 12x12, Heavy Duty axle) n/a n/a
(17.2 US gal) (17.2 US gal)
58.5 l 58.5 l
(15.5 US gal) (15.5 US gal)
65.5 l 65.5 l
(with 24x24, Heavy Duty axle) n/a
(17.3 US gal) (17.3 US gal)
55.5 l 55.5 l
(14.7 US gal) (14.7 US gal)
62 l
(with 16x16, Heavy Duty axle)
(16.4 US gal)
4WD FRONT AXLE - 9l
DIFFERENTIAL (2.38 US gal)
4WD FRONT HUBS (Class 3 1.25 l
Axle - less breaks) 0.33 US gal)
4WD FRONT HUBS (Class 3 3l
Axle - with breaks) (0.79 US gal)
4WD FRONT HUBS (Class 4 3.6 l
Axle - less breaks) (0.95 US gal)
4WD FRONT HUBS (Class 4 4l
Axle - with breaks (1.06 US gal)
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INTRODUCTION
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SERVICE MANUAL
HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS

84276322A 31/05/2010
A
Contents
HYDRAULIC - PNEUMATIC - ELECTRICAL -

ELECTRONIC SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A

MAXXUM 100 , MAXXUM 110 Multicontroller , MAXXUM 110 , MAXXUM 115 Multicontroller , MAXXUM 115 , MAXXUM 120 Multicontroller
, MAXXUM 120 , MAXXUM 125 Multicontroller , MAXXUM 125 , MAXXUM 130 Multicontroller , MAXXUM 130 , MAXXUM 140
Multicontroller , MAXXUM 140
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve . . . . . . A.10.B
MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 120 , MAXXUM 125 , MAXXUM 130 , MAXXUM 140
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve . . . . . . . . . . . . . . . . A.10.C

PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve. . . . . . . . A.10.D
MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 120 , MAXXUM 125 , MAXXUM 130 , MAXXUM 140
SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A

HYDRAULIC COMMAND SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.14.A

ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

MAXXUM 100 , MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ] , MAXXUM 110 , MAXXUM 115 Multicontroller [Z7BE50001 -
Z9BE60000 ] , MAXXUM 115 , MAXXUM 120 Multicontroller [Z7BE50001 - Z9BE60000 ] , MAXXUM 120 , MAXXUM 125 Multicontroller
[Z7BE50001 - Z9BE60000 ] , MAXXUM 125 , MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ] , MAXXUM 130 , MAXXUM
140 Multicontroller [Z7BE50001 - Z9BE60000 ] , MAXXUM 140
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

MAXXUM 110 Multicontroller [Z9BE40001 - ] , MAXXUM 110 Multicontroller [Z9BE60001 - ] , MAXXUM 115 Multicontroller [Z9BE40001 - ] ,
MAXXUM 130 Multicontroller [Z9BE60001 - ] , MAXXUM 140 Multicontroller [Z9BE40001 - ] , MAXXUM 140 Multicontroller [Z9BE60001 - ]
ELECTRONIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

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PRIMARY HYDRAULIC POWER SYSTEM - 10.A

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Contents
HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC

SYSTEMS - A
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic pump
Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fixed displacement pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable displacement pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charge pump
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM
Overview - Variable Displacement Pump High Pressure Hydraulic Circuit 16 x 16 Models. . . . . . . . . . . 10
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overview - Variable Displacement Pump High Pressure Hydraulic Circuit 24 x 24 Models. . . . . . . . . . . 36
Overview - Fixed Displacement Pump Hydraulic Circuit 12 x 12 and 24 x 24 Models . . . . . . . . . . . . . . . 41
Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic schema (16x16 CCLS with Electronic Draft Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hydraulic schema (16x16 CCLS with Mechanical Draft Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
MAXXUM 100, MAXXUM 110, MAXXUM 115, MAXXUM 120, MAXXUM 125, MAXXUM 130, MAXXUM 140
Hydraulic schema (24x24 CCLS with Electronic Draft Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Hydraulic pump
Fixed displacement pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fixed displacement pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fixed displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Variable displacement pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Variable displacement pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Variable displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Variable displacement pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Variable displacement pump - Dynamic description (System description CCLS) . . . . . . . . . . . . . . . . . . . 66
Charge pump
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Compensator
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Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SERVICE
Hydraulic pump
Fixed displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fixed displacement pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fixed displacement pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Variable displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Variable displacement pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Variable displacement pump - Replace (Input shaft seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Variable displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Variable displacement pump - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Variable displacement pump - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Test (Air Ingress) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Charge pump
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Compensator
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER
SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Torque
BSE3603A 1
BRJ4969C 2
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SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Special tools

DESCRIPTION PART NUMBER
Tee adaptor 11/16 ORFS female x 380000570*
11/16 ORFS male x 7/16 UNF female
Adaptor M10 banjo x 7/16 UNF 380000572*

female
Adaptor 7/16 UNF female x M12 x 380000577*
1.5p male
Adaptor 7/16 UNF male 380000999
Adaptor M14 banjo x M14 x 1.5p 380000579*
female
Tee adaptor 7/16 UNF female x 1/4 380000580*
BSP hose tail x 1/2 hose
7/16 UNF male Quick release adaptor 380000492
Adaptor M10 x 1.0p x 7/16 UNF 380000493
female
Hand pump 380000215
Lift relief valve fitting 380000217
90 quick release fitting with adaptor 380001146.
M8 x 1.0 male
Blanking Cap 11/16 ORFS 380000599*
Pressure Gauge 0–10 bar 380000551#
Pressure Gauge 0–27 bar 3800001145
Pressure Gauge 0–40 bar (5 off) 380000552#
Pressure Gauge 0–250 bar 380000553 #
Remote valve coupling 380000554#
Quick release adaptor 380000543
Pressure gauge hose 380000545#
1/8 NPT fitting to attach hose 292246 380000544#
to gauge
T–adaptor 13/16 ORFS female x 380000842.
13/16 ORFS male x 7/16 UNF female
Adaptor M10 x 1.0p x 7/16 JIC male 380000494
(enables use of gauges with 7/16 JIC
hoses if used)
diagnostic switch 380000488
Bypass connector 380001147.
Bypass connector 380000561
Trailer brake fitting 380000550#
Open Centre Lift Pressure Regulating 380000231
Valve Adjusting Tool
Flow Meter 120 l/min)
* Part of hydraulic adaptor kit
380000464
# Part of hydraulic pressure test kit
380000240
Remote valve check valve removal 380002720
tool
Charge pump pressure test adaptor 380200015
Lift ram pressure test tee piece 13/16 380200012
ORFS
Oil cooler pressure test adaptor 380200006
Hydraulic pump pressure test adaptor 380200090
Lube pressure test adaptor 380200091
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SYSTEM
Hydraulic pump Fixed displacement pump - General specification

Filter
Type Full-flow, screw-on cartridge
Location Pump intake, on the R.H. side of the rear axle housing
PUMP
Type Gear type, with oil suction from transmission casing
Location On the R.H. side of the rear axle housing
Manufacturer BOSCH
Drive Driven by PTO input shaft
Corresponding rated output I/min 80
(US gallon/min) 21.1
Hydraulic pump Fixed displacement pump - Torque
BVE0672A 1
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SYSTEM
Hydraulic pump Variable displacement pump - General specification

Variable Displacement Piston Pump
Type
(Swash Plate Controlled)
Rotation Clockwise
Minimum Pump Speed 800 RPM
Maximum Pump Speed 2662 RPM
Pump Speed @ 2200 RPM (enginespeed) 2514 RPM
Displacement 45 cm³/rev (2.75 in³/rev)
113 l/min (24.9 UK gpm)
Output (new pump) @ 2200 RPM (enginespeed)
29.8 US gpm
23 bar +/- 1
Standby Pressure
( 334 psi +/- 14.5)
210 bar +/- 5
Maximum System Pressure
( 3045 psi +/- 72.5)
245 bar +/- 5
Spike Clipper Relief Valve
( 3553 psi +/- 72.5)
Peak Pressure 315 bar (4568 psi)
Hydraulic pump Variable displacement pump - Torque
BSE3603A 1
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SYSTEM
BRJ4969C 2
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SYSTEM
Charge pump - General specification

Type Rotor Pump
Displacement 57 cm³/rev (3.48 in³/rev)
143 l/min (31.5 UK gpm)
Output (new pump) @ 2200 RPM (enginespeed)
37.8 US gpm
Charge Pressure Filter Dump Valve Open @ 6 bar (87 psi)
Charge Pressure Limiting Valve Open @ 1.72 bar (24.9 psi)
Charge Pressure Switch (making charge pressure warning light flash) Close @ 0.55 - 0.82 bar (8 - 11.9 psi)
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SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Overview - Variable

Displacement Pump High Pressure Hydraulic Circuit 16 x 16
Models.
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SYSTEM
Variable Displacement Pump High Pressure Hydraulic Circuit 16 x 16 Models
1 To Additional Remote Control Valves 2 End Plate With Pilot Line Pressure Reducing Valve and
Load Sensing Shuttle Valve
3 Variable Displacement Hydraulic Pump 4 Low Pressure Switch
5 Mid Mounted Remote Control Valve 6 Boosted Lubrication Oil
7 Front Suspension Control Valve 8 Trailer Brake Valve
9 Power Beyond Ports 10 Subplate with Low Pressure Compensator Valve
11 Feed to Low Pressure circuit 12 Lift Cylinder
13 Electronic Draft Control Valve 14 Electro-Hydraulic Remote Control Valve
A High Pressure Circuit Oil B Steering Circuit

C Low Pressure Circuit Oil D Trapped Oil
E Return To Reservoir Oil F Suction Oil
G Charge Pump Oil H Lubrication Oil
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SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Static description

The hydraulic systems can be separated into the following circuits:-
High Pressure Circuit

Hydraulic Lift Assembly.
Remote Control Valves.
Trailer Brake (Where Fitted)
Suspended Front Axle.
Front Lift (Where fitted).
Steering Circuit
Steering Motor and Cylinders
Low Pressure Circuit

Independent Power Take Off (PTO).
Differential Lock
Front Wheel Drive engagement
Transmission clutch and synchroniser engagement
Creeper engagement (Where fitted)
Front PTO (Where fitted)
50 kph engagement (Where fitted)
Lubrication Circuit
PTO Clutch Plates
Transmission Clutch Plates.
Transmission Shaft Pressure Lube
Pump Drive Gear Bearing.
Hydraulic Lift Cross Shaft
The high pressure circuit is of the ‘Closed Centre Load Sensing’ design on all tractor model options fed by either a
Variable Displacement Pump or a Fixed Displacement Pump.
The steering, low pressure and lubrication circuits are fed by a separate fixed displacement pump via a solenoid
activated lubrication block..
Hydraulic Pump/ HPL/ Remote Valve Options

Less Hydraulic Trailer Brakes With Hydraulic Trailer Brakes Hydraulic Trailer Brake Italy
Fixed Disp. Variable Disp. Fixed Disp. Variable Disp. Fixed Disp. Variable Disp.
MDC EDC MDC EDC MDC EDC MDC EDC MDC EDC MDC EDC
Remotes 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4 2 4
12 x 12 Y Y Y Y Y Y
24 x 24 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
16 x 16 Y Y Y Y Y Y Y Y Y Y Y Y
Before commencing work on a tractor it is important to identify if the tractor has a variable displacement pump or fixed
displacement pumps and the type of transmission.
Figure 1 shows the variable displacement pump with a 16 x 16 Transmission.
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BSE3575A 1
Figure 2 shows the variable displacement pump with a 16 x 16 Transmission and ARGO hydraulic oil filter fitted to
later models..
BAIL07APH323ASA 2
Figure 3 shows the fixed displacement pump with a 24 x 24 Transmission.
BSE3665A 3
Closed centre remote valves (1) and Electronic draft control .
BSE3604B 4
Tractors installed with the electronic draft control hydraulic lift assembly use a unique operator control panel.
(1). Draft sensitivity control knob
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SYSTEM
(2). Drop rate control knob

(3). Height limit control knob
(4). Slip limit control knob
BSE2884A 5
Maxxum Models with armrest unit from Serial No. Z9BE40001- and Z9BE60001-
BRL6436B 6
The lift arm position control is unique to tractors with electronic draft control.
.
(1). Stop adjuster thumbwheel
(2). Stop
(3). Position control lever
(4). Draft loading wheel
(5). Raise/lower switch
BSE2892B 7
.
Maxxum Models with armrest unit from Serial No. Z9BE40001 and Z9BE60001
The raise and lowering functions of the electronic draft control lift system can also be operated from the rear fender
switch (1).
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BRE1483B 8
The closed centre model tractors can also have electro-hydraulic remote valves (1).
BSE3604B 9
Located below the Electronic Draft Control valve (Where fitted), is the Hydraulic Power Tapping port (Power Beyond)
block. This includes a priority valve (1) and also a low pressure regulating valve. This block also has a flange plate
which allows the addition of a trailer brake valve.
BSF3967A_430 10
Fixed Displacement high pressure hydraulic systems can be identified from the following:-
Fixed displacement pump.
BSE3572A 11
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Mechanical remote control valves
BSE3664A 12
Located below the Electronic Draft Control valve (Where fitted), is the Hydraulic Power Tapping port (Power Beyond)
block. This includes a priority valve and also a low pressure regulating valve. This block also has a flange plate which
allows the addition of a trailer brake valve.
1. Power Beyond Ports

2. Pressure Relief Valve
BSE3845A 13
The type of transmission installed can be identified by inspecting the transmission control lever.
Tractors with 16 x 16 transmission have a single control lever (1) with two shift buttons.
Closed centre hydraulic system only.
Figure [Invalid Reference] shows Semi-Powershift control lever..
BSE2889C_437 14
Maxxum Models with armrest unit from Serial No. Z9BE40001- and Z9BE60001-
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BAIL09CCM793AVA 15
Tractors installed with 24 x 24 transmission uses two control levers. The main transmission lever (1) is provided with
push buttons (2) and (3) to actuate the Dual Command function.
These tractors can use either variable displacement pump or a fixed displacement pump.
BSE3688A_438 16
Tractors installed with 12 x 12 Command transmission uses two control levers. These are the main shift lever (1) and
the range lever (2).
BSE3689A_439 17
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CLOSED CENTRE LOAD SENSING HIGH PRESSURE HYDRAULIC CIRCUIT
1b0o2004061057 18
High Pressure Circuit Components and Pipework
Tractors with Variable Flow Piston Pump
1 Remote and EDC Control Valves 2 Trailer Brake Valve

3 Load Sense Lines 4 Flow and Pressure Compensator Valve
5 Variable Flow Hydraulic Pump 6 Feed to Remote Valves
7 To Hydraulic Lift Ram 8 Feed to Electro-Hydraulic Valve Pilot Line
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The principal of operation of the closed centre load sensing high pressure hydraulic circuit with variable flow piston
pump is to supply oil flow on demand. It also enables simultaneous operation of the trailer brakes, hydraulic lift,
remote control valve assemblies and front axle suspension where fitted. The load sensing variable flow piston pump
offers significant benefits in reducing the engine power loss that occurs in open centre systems where a high volume
of oil, often far in excess of demand, is continuously pumped round the hydraulic circuit even when they are not being
operated.
A fixed displacement pump (Charge Pump) serves as an initial displacement pump for the variable displacement pump
. The variable displacement pump first of all supplies oil to the trailer brake valve (where fitted), the remote valves
and electronic draft control valve and a pilot oil supply with lower priority. The highest load pressure is indicated to
the flow and compensating valve on the pump via the load sensing line. The flow and compensator valve controls
the pump pressure in such a way that it always exceeds the highest load pressure by a pre-set difference. A priority
valve for low pressure circuit demand is located in the bottom subplate of the remote valve stack. Tractors fitted with
Electro-hydraulic remote valves also have high pressure oil supplied from the variable displacement pump to the top
plate of the remote valve stack. The oil passes through the top plate via a small filter and a pressure limiting valve (
20 - 22 Bar). The oil is then directed to the pilot oil supply of the electro-hydraulic control valve.
BSF4142A 19
Tractors with Variable Flow Piston Pump
1 End Plate 2 Load Sensing port for Mid Mount Valve

3 Electro-Hydraulic Remote Valves 4 Electronic Draft Control Valve
5 Trailer Brake Valve (Where Fitted) 6 Load Sensing Line
7 Low Pressure Circuit Distribution Manifold 8 Low Pressure Feed
9 Flow and Pressure Compensator Valve 10 Variable Displacement Pump
11 High Pressure Feed to Electro-Hydraulic Remote 12 Feed To Hydraulic Lift Cylinder
Valves
13 Feed to Italian type trailer brake solenoids 14 High Pressure Feed to Electro-Hydraulic Valve Pilot
Line
The high pressure circuit is illustrated in PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A).
Hydraulic pump assembly.
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Figure 20 shows the variable displacement pump assembly.

Integral with the high pressure variable displacement pump is the load sensing valve, containing the pressure and
flow compensating valves, the steering pump , the charge pressure and main system filters and various electrical
switches.
BSE3575A 20
Figure 21 shows the fixed displacement pump assembly.
BSE3572A_434 21
Load sensing valve assembly (1), consists of a flow compensating valve (2) and a high pressure control valve (3). The
load sensing valve receives hydraulic signals from operated components through the load sense line (4) and relays
this to the pump which will adjust to satisfy the system demands.
Figure 22 shows the load sense valve assembly.
BSE3660A 22
Steering pump,
The steering pump is a separate unit but still driven from the same drive gear as the main pump.
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BSE3662A 23
Trailer brake valve which is located beneath the cab just in front of the hydraulic lift assembly. The valve diverts oil
pressure to the trailer brakes whenever both tractor brake pedals are depressed.
BSE3599A 24
The hydraulic lift Electronic Draft Control Valve is a stack type design mounted together with the Remote Control
Valves (1) at the rear below the cab, and incorporates the safety valve for the lift cylinders
The lift cylinder safety valve protects the lift cylinder from shock loadings and limits the pressure in the cylinder to 210
- 215 bar
The hydraulic lift control valve is a proportional solenoid operated valve, controlled by a microprocessor, to raise and
lower the hydraulic lift.
BSE3604A 25
Closed centre load sensing remote control valves
There are two types of remote valves available for the closed centre system. Standard fitment are the mechanical
remote valves operated via a cable from within the cab and optional on all 16 x 16 models are electro hydraulically
operated valves, (1), Figure 26, which are operated by electrical switches and have their own in-built processor to
control oil flow via a solenoid valve.
Up to four mechanical type valves can be installed.
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BSE3604B 26
Hydraulic Lift Cylinders.
Models with mechanical draft control utilize a main lift cylinder which is located internally within the rear axle top cover
and also one or two 50 mm external cylinders depending on specification , Figure 27.
BSE3844A 27
Models with electronic draft control utilize two external cylinders, one per lift arm, anchored to the rear axle with a
bracket, Figure 28.
BSE3666A 28
Suspended front axle control valve.
Located on the right hand side of the tractor and attached to the rear axle centre housing. Receives high pressure
oil, via the trailer brake valve, if fitted, and with the use of processor controlled PWM valves controls oil to a cylinder,
attached between the front axle and front support, to provide a hydraulically controlled suspended front axle.
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BSE3668A 29
BAIL07APH357HSA 30
Front axle to front support hydraulic control cylinder (1).
BSE3769A 31
Hydraulic system filters.
Figure 32 shows the main hydraulic filter (1) for tractors fitted with 12 x 12 Transmission with mechanical draft control.
BSE3021A 32
Figure 33 shows the main hydraulic filters for tractors with fixed displacement hydraulic pump. this type of pump is
only fitted to tractors with 24 x 24 with mechanical draft control.
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BSE2928A 33
1. Intake Filter 2. Transmission Feed Pressure Filter
The main filter (3) and the charge filter (1) Figure 34 are only installed on tractors with variable displacement pump
(CCLS system).
BSE2755A 34
The main filter (1) and the charge filter (2) Figure 27 are installed on tractors with variable displacement pump (CCLS
system).
BAIS06CCM055AVA 35
1. Main Intake (Suction) Filter 2. Charge Filter
Mid-Mount Remote Valves.

Optional additional remote valves are mounted under the cab. Connected into the high pressure oil line supplied from
the hydraulic pump after the trailer brake valve and operated via a joystick control in the cab.
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BSE3576A_435 36
BAIL06CCM063ASA 37
High Pressure Hydraulic System, Fixed Displacement Pump - Electrical Switches
BSE3661A 38
1. Oil Temperature Switch 2. Intake Filter restriction (vacuum) Switch

3. Steering Pressure Switch
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High Pressure Hydraulic System, Variable Displacement Pump(CCLS) - Electrical Switches
BSE3573A 39
1. Intake Filter restriction (vacuum) Switch 2. Low Oil Temperature Switch

3. Low Charge Pressure Warning Switch
BAIL07APH325ASA 40
1. Low Charge Pressure Warning Switch 2. Intake Filter restriction (vacuum) Switch
3. Low Oil Temperature Switch
Steering Motor
All models use a fixed displacement motor.
BSD2178A 41
Steering Cylinders.
Receives high pressure oil directly from the steering motor.
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BSE2868B 42
Load Sensing Shuttle Valve.
Located in each remote valve slice, the Electronic Draft Control valve and between the trailer brake valve, front sus-
pension valve and mid-mounted valves, where fitted, is the load sensing shuttle valve (2). This allows the function
with the highest pressure demand to send sensing pressure to the load sensing valve, Figure 44, on the variable
displacement pump.
BSB0388A_436 43
1. Valve Body
2. Flow Compensating Valve
3. Pressure Compensator Valve
4. Load Sensing Line
BSE3660A 44
With Reference to PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A).

Operation of the closed centre high pressure hydraulic circuit is as follows:-
The components in the high pressure hydraulic circuit are connected by their load sensing lines to the hydraulic load
sensing valve which controls the output of the hydraulic pump.
When the trailer brakes, remote control valves, hydraulic lift or front axle suspension (where fitted) are operating, the
load sensing valve on variable flow piston pump, compares the pressure in the component load sense line with the
output pressure of the hydraulic pump.
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If pump output pressure is less than the combined pressure of the load sense line and spring force of the flow con-
trol valve, then pump output continues to increase. When circuit demand is satisfied pump pressure overcomes the
combined pressure of the load sense line and flow compensating valve spring. This moves the spool in the flow com-
pensating valve to the right, allowing control pressure oil to be directed to the variable flow swash plate servo piston,
which de-strokes the pump to adjust output to circuit demand.
For a detailed explanation on the load sensing operating principle of the variable flow piston pump refer to Hydraulic
pump Fixed displacement pump - Static description (A.10.A).
High Pressure oil is fed to a subplate at the bottom of the remote valve stack where it is directed to the Trailer Brake
valve which has priority for safety reasons. The oil is then redirected to the Electronic Draft Control Valve and the
Electro-Hydraulic Remote Valves. Within the subplate is a pressure compensating valve which diverts the oil to the
low pressure system at a pressure of 17 - 18 bar.
High Pressure oil is also fed to the top of the Remote Valve stack through an end plate which incorporates a pressure
limiting valve and this supplies oil at 20 - 22 bar to the pilot line galleries in the Electro-Hydraulic Remote Valves.
Surplus oil from the charge pump to the variable displacement pump is fed past the 0.8 bar valve and boosts the
pressure in the lubrication circuit.
Refer to PRIMARY HYDRAULIC POWER SYSTEM - Overview (A.10.A).
FIXED DISPLACEMENT HIGH PRESSURE HYDRAULIC CIRCUIT
BSE3806A 45
Tractors with Mechanical Hydraulic Lift and Fixed Displacement Hydraulic Pump
1 Remote Control Valves 2 Feed To Mechanical Draft Control Valve

3 Mechanical Draft Control Valve 4 Steering Pump (Steering Circuit)
5 High Pressure Circuit Gear Pump 6 Hose To Pressure Relief Valve
7 Feed To Lift Cylinder 8 Pressure Relief Valve( 195 - 205 Bar)
9 High Pressure Feed To Remote Valve Stack
On high pressure hydraulic systems with fixed displacement pump, all components are connected in series and pump
flow is continually circulating through the hydraulic system even when the circuits are not being operated.
The priority of operation is given to the order of components in the circuits, that is trailer brakes, remote valves and
hydraulic lift.
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The high pressure hydraulic circuits for tractors installed with mechanically controlled hydraulic lift are shown in Fig-
ures 52 and include the components shown on the following pages.
Fixed displacement hydraulic pump assembly comprising of the high pressure gear pump and steering/low pressure
gear pump .
BSE3572A_440 46
High pressure circuit relief valve (1) located on the right hand side of the top cover diverts pump flow to sump if the
system pressure reaches 190 bar ( 2755 lbf/in2).
BSF4290A 47
The trailer brake valve is located beneath the cab on top of the hydraulic lift cover. The valve diverts oil pressure to
the trailer brakes whenever the right hand tractor brake pedals is depressed. This is unlike the valve installed on the
closed centre system where both pedals have to be depressed in order for the valve to operate.
The trailer brake has absolute priority over other services in the circuit.
BSE3599A_441 48
The remote valves are available as two, three or four valves per tractor.
The valves can be double-acting with float and kick out.
Double acting convertible to single-acting with float.
Double acting convertible to single-acting.
When four remote valves are installed the optional flow divider valve (1) is available enabling simultaneous operation
of remote valve No 1 with another remote valve or hydraulic lift.
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BSE3664A_442 49
On tractors which are fitted with mechanical hydraulic lift, the lift cylinder control valve (1) assembly is located at the
front of the hydraulic lift assembly. The lift cylinder safety valve is mounted on the rear face of the control valve which
must be removed to obtain access. This safety valve will operate at between 210 - 215 Bar.
BSF3981A 50
The low pressure regulating valve is located in the top manifold situated on the lubrication services distribution block
on the left hand side of the rear axle centre housing. This valve regulates the pressure in the low pressure circuit to
17 - 18 bar ( 246 - 261 lbf/in2).
Also located in this manifold are the oil cooler by-pass valve and the lubrication relief valve ( 7.3 - 8.3 bar).
When the oil is cold and pressure differential across the oil cooler is higher than 6 bar ( 87 lbf/in2) the cooler by-pass
valve (1) located on the right hand side of the transmission will operate to ensure that adequate flow to the lubrication
circuit is maintained. This feature of diverting oil from the cooler assists in aiding a rapid warm up of oil in cold weather
conditions.
The steering pump / steering return oil is directed through the oil cooler at the front of the tractor and is limited to a
maximum pressure of 7 bar ( 101 lbf/in2) by the lubrication relief valve located in the lubrication services distribution
block on the left hand side of the rear axle centre housing.
BSE3775B 51
High Pressure Circuit for Tractors with Fixed Displacement Pump and Mechanical Hydraulic Lift
With Reference to Figure 52.

Both the high and low pressure pumps are driven by a ‘live’ drive gear train directly connected to the PTO clutch input
drive shaft and driven by the engine flywheel.
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Oil is drawn through the common intake port and filter to both the high and steering/low pressure pump assemblies.
The high pressure pump supplies constant oil flow according to engine speed, through the trailer brake and remote
valves via a subplate at the bottom of the remote valve stack. The subplate incorporates a flow control valve which
limits the maximum operating pressure.
Oil, after passing through the remote valves, enters the hydraulic lift control valve located at the front of the lift as-
sembly, which controls the raising and lowering of the lift.
All excess oil flow produced by the hydraulic pump is returned direct to the rear axle through the control valve spool
located in the hydraulic lift control valve assembly.
Also located within the assembly is the lift cylinder safety valve, which protects the lift cylinder and seals from exces-
sive peaks of pressure during operation.
For further details on operation of the mechanical hydraulic lift assembly, trailer brake valve and mechanical remote
refer to the appropriate Chapters in this Section of the Repair Manual :
HITCH Electronic draft control - Static description (H.10.D) (MECH LIFT),
Trailer brake valve - Static description (D.34.C) (TBV),
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - Static description (A.10.B)
(MECH REMOTES).
BSF4116A 52
Fixed Displacement Pump High Pressure Hydraulic Circuit Operation
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SYSTEM
Tractors With Mechanical Hydraulic Lift

Hydraulic Lift Operating
Steering System System Pressure Trapped Oil

Oil Oil
Low Pressure Return to Lubrication Oil
Circuit Oil 17 - 18 Reservoir Oil
bar ( 246 - 261
lbf/in²)
Suction Oil
1. Lift Control Valve 2. Lift Cylinder Safety Valve

3. Mechanical Hydraulic Lift Assembly 4. Steering Motor
5. Low Pressure Circuit Pressure Regulating Valve 6. Steering and Low Pressure Circuit Gear Pump
7. Fixed Displacement Pump 8. Pressure Relief Valve ( 195 - 205 Bar)
9. Subplate with Pressure Compensator 10. Trailer Brake Valve
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PRIMARY HYDRAULIC POWER SYSTEM - Overview - Variable

Displacement Pump High Pressure Hydraulic Circuit 24 x 24
Models.
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SYSTEM
Variable Displacement Pump Closed Centre Load Sensing Hydraulic Circuit 24 x 24 Models
1 To Additional Remote Control Valves 2 End Plate With Load Sensing Shuttle Valve
3 Variable Displacement Hydraulic Pump 4 Mid Mounted Remote Control Valve
5 Low Pressure Switch 6 Boosted Lubrication Oil
7 Front Suspension Control Valve 8 Trailer Brake Valve
9 Power Beyond Ports 10 Subplate with Low Pressure Compensator Valve
11 Feed to Low Pressure circuit 12 Lift Cylinder
13 Electronic Draft Control Valve 14 Remote Control Valve

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BSF4140B 1
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SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Overview - Fixed

Displacement Pump Hydraulic Circuit 12 x 12 and 24 x 24 Models
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SYSTEM
Fixed Displacement Pump Hydraulic Circuit 12 x 12 and 24 x 24 Models
1 Remote Control Valves 2 Low Pressure Services Manifold

3 Steering Motor 4 Low Pressure Warning Lamp
5 Low Pressure Switch 6 Steering Pump
7 Fixed Displacement Pump 8 Pressure Relief Valve ( 195 - 205 bar )
9 Trailer Brake Valve 10 Subplate with Low Pressure Compensator Valve
11 Mechanical Draft Control Valve

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BSF4139A 1
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PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema

Tractors with 12 x 12 Transmission with Fixed Displacement Pump and Mechanical Draft Control
1. Steering Motor 2. Oil Cooler

3. Oil Cooler Bypass Valve,Low Pressure Regulating Valve, 4. Transmission Lubrication
lube relief valve
5. Pumps Drive Lubrication 6. Mechanical Draft Control Valve
7. PTO lubrication Control Valve 8. End Plate
9. Mechanical Remote Valves 10. Sub Plate with Relief Valve and Power Beyond Tap and
ports
11. Trailer Brake Valve 12. Trailer Brake Coupling
13. Italian Version Trailer Brake coupling and Solenoid 14. Low Pressure Distribution Manifold
Assembly
15. Brake Pedals and Master Cylinder 16. Fixed Displacement Pump and Steering Pump
17. Brake Valve
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BRH3222A 1
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24 x 24 Model with Fixed Displacement Pump and Mechanical Draft control
1. Fixed Displacement Pump and Steering Pump 2. Steering Motor

3. Oil Cooler 4. Oil Cooler By-pass Valve,Lubrication Relief Valve,Low
Pressure Regulating Valve
5. Pumps drive lubrication 6. Mechanical Draft Control Valve
7. PTO lubrication control valve 8. End Plate
9. Remote control valves 10. Sub plate with relief valve and power beyond tap and
ports
11. Trailer Brake valve 12. Trailer Brake Coupling
13. Italian Trailer Brake Coupling and Solenoid assembly 14. Low Pressure Distribution Manifold
15. Brake Pedals and Master Cylinders 16. Hi Lo Lube Valve
17. Transmission Solenoids 18. Forward and Reverse Valve
19. Hi Lo Valve Assembly 20. Front Brake Valve
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BRH3220A 2
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16 x 16 Tractors with Fixed Displacement Pump and Mechanical Draft Control
1. Fixed Displacement Pump 2. Steering Motor

3. Oil Cooler 4. Oil Cooler Bypass Valve, Low Pressure Regulating Valve,
Lube Relief Valve
5. Pumps Drive Lubrication 6. Mechanical Draft Control Valve
7. PTO Lubrication Control Valve 8. End Plate
9. Mechanical Remote Control Valves 10. Sub Plate with Relief Valve and Power Beyond Tap and
ports
11. Trailer Brake Valve 12. Trailer Brake Coupling
13. Italian Version Trailer Brake Coupling and Solenoid 14. Low Pressure Distribution Manifold
Assembly
15. Brake Pedals and Master Cylinder 16. Transmission Side Covers -C1,C2,C3, and C4 solenoids
17. Top Cover PWM Valves - 1-4, 5-8, Forward and Reverse 18. Transmission Lubrication
19. Front Brake Valve
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BRH3221A 3
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PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (16x16

CCLS with Electronic Draft Control)
1 17th gear (overdrive) Engage and Dump 2 Oil Cooler
Solenoids
3 Oil Cooler By Pass Valve 4 Steering Motor
5 Charge Pump 6 Variable Flow Pump
7 Steering Pump 8 Suspension Valve
9 PTO Lubrication Control Valve 10 End Plate
11 Electronic Remote Valves 12 EDC Valve
13 Sub Plate 14 Trailer Brake Valve
15 Trailer Brake Coupler 16 Italian Version Trailer Brake Coupler
17 Low Pressure Distribution Manifold 18 Brake Pedal Master Cylinders
19 Transmission Side Cover 20 Transmission Lubrication Valve
21 Front Brake Valve
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BSF4516A 1
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CCLS with Mechanical Draft Control)
1 17th gear (overdrive) Engage and Dump 2 Oil Cooler

Solenoids
3 Oil Cooler By Pass Valve 4 Steering Motor
5 Charge Pump 6 Variable Flow Hydraulic Pump
7 Steering Pump 8 Mechanical Draft Control Valve
9 PTO Lubrication Control Valve 10 Flow Control Block
11 End Plate 12 Remote Control Valves
13 Sub Plate with Priority Valve and Power Beyond 14 Trailer Brake Valve
Ports
15 Trailer Brake Coupler 16 Italian Trailer Brake Solenoid Block and Coupler
17 Low Pressure Distribution Manifold 18 Brake Pedals and Master Cylinders
19 Pumps Drive Lubrication 20 Transmission Lubrication
21 Transmission Side Cover C1, C2, C3, and C4 22 Top Cover PWM Valves 1-4, 5-8, Forward and
Solenoids Reverse
23 Front Brake Valve
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BSF4517A 1
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CCLS with Electronic Draft Control)
1 Oil Cooler 2 Lube Relief Valve and Oil Cooler By Pass Valve
3 Steering Motor 4 Charge Pump
5 Variable Flow Pump 6 Steering Pump
7 PTO Lubrication Control Valve 8 End Plate
9 Electronic Remote Valves 10 Electronic Draft Control Valve
11 Sub Plate with Low Pressure Priority Valve 12 Trailer Brake Valve
13 Trailer Brake Coupler 14 Italian Version Trailer Brake Coupler and Solenoid
Assembly
15 Low Pressure Distribution Manifold 16 Brake Pedals and Master Cylinders
17 Pump Drive Lubrication 18 Hi Lo Lube Valve
19 C1, C2 Clutch Solenoids 20 Forward and Reverse Solenoid Valves
21 Hi Lo Valve 22 Front Brake Valve
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BSF4518A 1
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SYSTEM
Hydraulic pump Fixed displacement pump - Static description

The hydraulic pumps are a gear type and fixed displacement according to ERPM.
The hydraulic pumps are mounted on the right hand side of the rear axle housing and are driven from gears splined
directly to the PTO drive shaft. Oil is supplied to the hydraulic pumps from the rear axle housing, via a common intake
filter.
The front hydraulic pump controls hydrostatic steering, front and rear differential locks, PTO and PTO brake, and four
wheel drive engagement.
The rear hydraulic pump supplies oil for the hydraulic lift, trailer brake valve, and remote control valves.
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SYSTEM
Hydraulic pump Fixed displacement pump - Overview
BVE0673A 1
Hydraulic Pump Assembly With Fixed Displacement Closed Centre System
1 Hydraulic lift system oil pump 2 Steering / low pressure oil pump
3 Main intake filter restriction (vacuum) switch 4 Main intake filter
5 Low oil temperature switch
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SYSTEM
Hydraulic pump Fixed displacement pump - Exploded view
BSD2033A 1
Hydraulic Lift System Oil Pump Exploded View
1 Bearing Block 2 Oil Seal

3 Plastic Back-up Seal 4 O-ring Seal
5 Pump Housing 6 O-ring Seal
7 End Plate 8 Retaining Bolts
9 Drive Gears 10 Bearing Block
11 Oil Seal 12 Plastic Back-up Seal
13 End Plate
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Hydraulic pump Variable displacement pump - Static description

The variable flow closed centre load sensing hydraulic pump assembly is mounted on the right hand side of the rear
axle centre housing and contains within its body two hydraulic pumps.
• A charge pump of the gear type to supply oil at a charge pressure of 3 bar (44 psi) to a variable flow closed centre
load sensing hydraulic piston pump.
• A variable flow closed centre load sensing piston type hydraulic pump supplying oil to the high pressure circuits
for operation of:
Trailer Brake
Hydraulic Lift Assembly
Remote Control Valves
Front Axle Suspension
Front Lift
Mid Mount remote valves
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Hydraulic pump Variable displacement pump - Overview
BSE3602A 1
1 Load Sensing Valve assembly 2 Steering Pump

Supplementary Lube valve and By-pass
3 4 Main Intake Filter restriction (vacuum) Switch
Valve
5 Main Filter 6 Low Oil Temperature Switch
Variable Displacement Pump and Charge
7 8 Charge Pump Filter
Pump
9 Low Charge Pressure Warning Switch 10 Main System Relief Valve 245 bar (3553 psi)
11 Pressure Feed to Remote Valve Block
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Hydraulic pump Variable displacement pump - Exploded view
BSE3588A 1
Variable Flow Piston Pump Components
1 Rod 2 Piston
3 ‘O’ Ring 4 Plug
5 Seal 6 Bearing
7 Shim 8 Shaft
9 Bearing 10 Valve Plate
11 Snap Ring 12 Spring
13 Seal 14 Pins
15 Rotor Cylinder 16 Cone
17 Plate 18 Pistons
19 Swash Plate 20 Thrust Bearing
21 Spring
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Hydraulic pump Variable displacement pump - Dynamic description

Principal of Operation
Both pumping elements are driven by a ‘live’ drive gear train directly connected to the PTO clutch input drive shaft
and driven by the engine flywheel.
The operating principal of the fixed displacement gear pump is to provide a constant oil flow directly related to the
rotation speed of the pump
The operating principal of a variable flow piston pump is to provide oil flow on demand and minimises the engine
power absorbed in driving the hydraulic pump when the hydraulic circuits do not require maximum pump flow.
The variable flow piston pump in hydraulic systems therefore has distinct power loss advantages over fixed displace-
ment gear type pumps, which continually provide oil flow and absorb engine power even when the hydraulic circuits
do not require the total pump output.
BSD2188A 1
Variable Displacement Piston Pump - Sectional Drawing
1 Stroke control piston 2 Rod

3 Swash plate return spring 4 Driveshaft
5 Swash plate 6 Slipper (9 off)
7 Piston and barrel (9 off) 8 Inlet port
9 Shaft pre-load spring 10 Outlet port
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The major components of the variable flow piston pump with closed centre load sensing
are:
• A nine element pumping head.
• A plate mechanism (swash plate) to adjust piston stroke and corresponding pump output.
• A load sensing valve which monitors the requirements of the hydraulic circuits and signals the pump to increase
or decrease hydraulic oil flow accordingly.
The nine element pumping head is cylindrical in shape and has nine barrels, into each of which, is installed a piston.
On the end of each piston is pressed a slipper which always remains in contact with the face of the swash plate located
at the front of the pumping head.
The drive shaft, which is driven by the pump drive gear, rotates the pumping head. As the pumping head rotates, the
pistons move in and out of their barrels, following the contour of the swash plate. For every revolution of the drive
shaft each piston completes one pumping cycle.
The swash plate, which does not rotate but pivots about the front of the pumping head, is the control mechanism that
limits the stroke of each piston and works in conjunction with the pressure and flow compensating valves in the load
sensing line.
As the pumping head rotates each barrel passes over the inlet and then the outlet ports of the pump. During the inlet
cycle for each piston and barrel, oil is pumped into the barrel pushing the piston forward so that it always remains in
contact with the swash plate. The stroke of each piston and volume of oil charged into its barrel is therefore dependent
on the angle of the swash plate.
After a piston and barrel has completed the inlet stroke, further rotation of the head aligns the barrel with the outlet
port. Oil within the barrel is then forcibly ejected by the piston through the exhaust port to the hydraulic circuits.
BSE3585A 2
Variable Displacement Hydraulic Pump Installation
1 Trailer Brake Valve Assembly 2 Load Sensing Line

3 Flow and Compensator Valve 4 Steering Pump
5 Filter Restriction Vacuum Switch 6 Main Intake Filter
7 Low Oil Temperature Switch 8 Charge Pressure Filter
9 Variable Displacement Pump
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The location of the principal components in the hydraulic pump assembly are identified above. These items are shown
on the hydraulic circuit diagrams which describe the operating modes of the pump. The principal function of the valves
and switches is as follows:
Intake Filter and Restriction Switch

Oil for both the charge and steering pump is drawn from the rear axle centre housing via the intake filter. The filter
incorporates a by-pass valve, which is an integral part of the replaceable filter and it is therefore essential that the
correct filter is installed at every filter change.
When the filter is blocked the oil filter restriction vacuum switch is activated and illuminates the oil filter restriction
warning light on the instrument panel.
Because oil is more viscous (thicker) when cold and can falsely indicate that the filter requires servicing a low temper-
ature oil switch is also used in the filter restriction circuit. This switch ensures that the warning light will not operate
if the oil temperature is less than 40 °C (104 °F).
Low Charge Pressure Switch

The low charge pressure switch will cause a light to ‘Flash’ on the instrument cluster whenever the charge pressure
is less than 0.75 bar (10.9 psi).
Charge Pressure Filter Dump Valve

The charge pressure filter dump valve is a safety relief valve for relieving excess pressure on the charge pump should
the filter be restricted. This valve will start to operate if the charge pressure exceeds 6 bar (87 psi).
Charge Pressure Valve

The charge pressure valve diverts excess oil supplied by the charge pump and not required by the variable flow piston
pump to the inlet port of the steering and lubrication circuit pump.
This valve starts to operate at a pressure of 1 bar (14.5 psi)and when fully open limits the charge pressure circuit oil
to 3 bar (43.5 psi).
Flow and Pressure Compensating Valves

Output from the variable flow piston pump is determined by adjusting the angle of the swash plate in the pump. The
flow compensating valve senses the circuit operating pressure and adjusts the swash plate angle to control pump
output.
If pump output and circuit pressure rises to 205 bar (2973 psi) the pressure compensating valve overrides the flow
compensating valve and adjusts the swash plate angle to limit maximum system pressure.
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Hydraulic pump Variable displacement pump - Dynamic description

(System description CCLS)
The charge pressure pump draws oil through the charge pump inlet filter.
Oil drawn by the charge pump flows through the charge pressure filter to the variable flow piston pump and also
through the charge pressure valve to the inlet port of the steering pump.
Because output from the charge pump can exceed the combined demand of the steering and variable displacement
pumps an open gallery between the inlet side of the charge and steering pumps allows excess flow to the inlet side
of the steering.
The variable flow closed centre load sensing hydraulic pump operates progressively in 5 modes:
• Generating Low Pressure Standby pressure
• Low Pressure Standby
• High Pressure Circuit Maximum Demand
• High Pressure Circuit Low Demand
• Maximum System Pressure (High Pressure Standby)
1 Electro Hydraulic Remote (EHR) Valve 2 Low Pressure Pilot Line for EHR Control Spool
3 Load Sensing Line from EHR Valve 4 Electronic Draft Control (EDC) Valve
5 Load Sensing Line from EDC Valve 6 Lift Ram
7 Load Sensing Line from Trailer Brake Valve 8 Load Sensing Shuttle Valves
9 Flow Compensating Valve 22 bar (319 psi) 10 Pressure Compensating Valve 205 bar (2973
psi)
11 Variable Displacement Pump Assembly 12 Low Charge Pressure Warning Switch
13 Steering System Supply oil 14 Steering Pump
15 Charge Pressure Bypass Valve 3 bar (44 psi) 16 Supplementary lube valve 0.8 bar (12 psi)
17 Main Intake Filter Vacuum Switch 18 Main Intake Filter
19 Low Temperature Switch 40 °C (104 °F) 20 Charge Pump
21 Charge Pressure Filter 22 Charge Pressure Filter Dump Valve 6 bar (87
psi)
23 Main System Relief Valve 245 bar (3553 psi) 24 Trailer Brake Valve Outlet
25 Low Pressure Regulating Valve 26 Low Pressure Relief Valve 30 bar (435 psi)
27 Trailer Brake Valve 28 Low Pressure Regulating Valve Assembly
29 End Plate with Pressure Regulator Valve for 30 High Pressure Supply to Front Suspension or
Supply to EHR Pilot Line 20 - 22 bar (290 - Mid Mount Remotes, where fitted
319 psi)
31 Low pressure Supply to Transmission
clutches, Four Wheel Drive, Differential
Locks, PTO clutch and PTO Brake
A Load Sensing Line from High pressure circuit B Return to Reservoir from flow and pressure
components compensating valves.
C Gallery to Swash Plate servo piston from flow D System Pressure sensing gallery to flow and
and compensating valves pressure compensating valves
E System pressure supply to low pressure F Regulated Low pressure oil supply
regulating valve
G System pressure outlet from low pressure H Low pressure regulating valve spool sensing
regulating valve gallery
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BSF4141F 1
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Generating Low Pressure Standby

Low pressure standby is the system pressure 21 bar (305 psi), maintained by the hydraulic pump when high pressure
hydraulic circuits are not being operated.
Control of the swash plate, which regulates the output of the variable displacement piston pump, is achieved by the
flow and pressure compensating valves located on the top of the pump.
When the engine is first started, the swash plate return spring positions the swash plate for maximum output of the
pump. During engine start up, Low Standby Pressure has not yet been generated by the pump and the flow compen-
sating valve spool is held to the right by spring pressure. The position of the spool prevents oil pressure generated
by the pump, being applied through gallery D to the swash plate servo piston through gallery "C". The swash plate
consequently remains in the maximum flow position until the piston pump has developed standby pressure.
psi)
psi)
319 psi)
System Pressure 205 bar (2973 psi) Return To Reservoir
Standby Pressure 22 bar (319 psi) Steering Circuit
Control Pressure Low Pressure 17 bar (247 psi)
Charge Pressure 3 bar (44 psi) Trapped Oil
Suction Lubrication Oil
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BSF4141A 2
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Regulating Low Pressure Standby

When the pressure in the system is below 17 bar (247 psi) the Low-Pressure Priority valve is held by the spring to
give flow priority to the low-pressure systems.
As the pressure in the system increases to 17 bar (247 psi) the Low-Pressure Priority valve is moved against the
spring, by the pressure sensed through the orifice, to allow increased flow to the high pressure systems and regulates
the pressure in the low pressure system.
As system pressure continues increases to 22 bar (319 psi), known as Low Standby Pressure, the increase in pres-
sure is sensed in gallery D and applied to the end of the flow compensator spool. The spool gradually moves against
the spring allowing oil flow from gallery D to gallery C, Figure 3.
The controlled pressure rise in gallery C operates the swash plate servo piston, changing the angle of the swash plate
in relation to the pumping head. The change in angle reduces the operating stroke of the pistons and output of the
pump.
As pump output decreases and the pressure in gallery D reduces to less than 22 bar (319 psi), the spring in the flow
compensating valve gradually moves the spool to the left opening gallery C to sump through gallery B, via the spring
cavity of the pressure compensating valve. This reduces the pressure applied to the servo piston, allowing the servo
piston to retract at a controlled rate under pressure from the swash plate return spring, which re-adjusts the angle of
the swash plate to increase pump output.
This process where the flow compensating valve spool moves back and forth to control the pressure applied to the
servo piston, continues until there is a demand by the hydraulic system to increase output to operate the hydraulic lift,
remote control valves, front axle suspension (where fitted) or trailer brakes (where fitted).
psi)
psi)
319 psi)
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BSF4141B(R) 3
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High Pressure circuit High Demand

After the pump has reached standby pressure and one of the high pressure services is operated, the pressure rise in
the hydraulic circuit being operated is sensed by the load sensing line A.
The pressure in the sensing line is now applied to the spring loaded end of the flow compensator valve.
The combined pressure from the pilot line and flow compensating valve return spring causes the flow compensating
spool to move against the standby pressure in gallery D, preventing the flow of oil to the swash plate servo piston
through gallery C.
The movement of the spool opens gallery C to the return to sump gallery B, allowing the servo piston to retract under
pressure from the swash plate return spring, which re-adjusts the angle of the swash plate to increase pump output.
As the pressure in the system increases the Low Pressure Priority Valve works against the spring to regulate the low
pressure system to 17 bar (247 psi).
psi)
psi)
319 psi)
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BSF4141C 4
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High Pressure circuit Low Demand

As pump output increases so does the system pressure generated and applied to the end of the flow compensating
spool through gallery D.
When the hydraulic operating cycle nears completion, eg. the hydraulic lift is raised out of the ground and the main
spool in the electronic draft control valve gradually returns to the neutral position, the pressure in the load sensing line
similarly begins to decrease. When the pressure generated in gallery D is 22 bar (319 psi) greater than that in the
load sensing gallery A the flow compensator spool moves back against the spring to open gallery D to gallery C. The
controlled pressure rise in gallery C now operates the swash plate servo piston and changes the swash plate angle
to reduce pump output and the speed of lift.
It can now be seen that the basic principle of pump control, when operating the hydraulic high pressure circuits, is
similar to that for operation of the pump at standby pressure when there is no high pressure hydraulic demand. The
only difference is that because the pressure in the hydraulic system circuit being operated is sensed through the load
sensing line A, the pressure required to operate the flow compensating valve is higher than that for standby pressure
operation.
The Low-Pressure Priority Valve will continue to sense the changes in system pressure to regulate the low-pressure
system to 17 bar (247 psi).
psi)
psi)
319 psi)
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BSF4141D 5
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Limiting Maximum System Pressure

To limit the maximum output pressure of the piston pump under normal operating conditions, a pressure compensating
valve, located adjacent to the flow compensator valve, is incorporated in the swash plate control circuit. This valve
limits the pressure to 190 bar (2755 psi) and operates as follows:
As the pressure in gallery D increases to 205 bar (2973 psi) the pressure compensator valve spool moves against
the valve return spring and opens gallery D to gallery C. The pressure in gallery D is now applied to the servo piston
which changes the swash plate angle to reduce pump output to minimum flow. This operating mode is referred to as
high pressure standby.
If the pressure in gallery D for some reason exceeds the setting of the pressure compensating valve there is a system
safety valve set to 245 bar (3553 psi) to prevent consequential damage that may occur due to excessive pressures.
The Low-Pressure Priority Valve will continue to sense the changes in system pressure to regulate the low-pressure
system to 17 bar (247 psi).
psi)
psi)
319 psi)
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BSF4141E 6
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Charge pump - Exploded view
BSE3587A_457 1
Charge Pump Components
1 End Plate 2 Seal

3 Coupling 4 Shaft
5 Rotor Housing 6 Charge Pump Housing
7 Seal 8 Pin
9 Hub 10 Screw Plug
11 System Relief Valve ( 245 bar (3552.5 psi)) 12 Check Valve Plug
13 Seal 14 Check Valve Spool
15 Main Charge Filter 16 Pump Rotor
17 Key 18 Screws
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BAIL07APH346FSA 2
Charge Pump Components
1 End Plate 2 Seal

3 Coupling 4 Shaft
5 Rotor Housing 6 Charge Pump Housing
7 Seal 8 Pin
9 Hub 10 Screw Plug
11 System Relief Valve ( 245 bar (3552.5 psi)) 12 Check Valve Plug
13 Seal 14 Check Valve Spool
15 Main Charge Filter 16 Pump Rotor
17 Key 18 Screws
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Compensator - Exploded view
BSE3586A_454 1
Flow and Pressure Compensating Valves
1 Plug 2 Seal
3 Disc 4 Spring
5 Spring 6 Seat
7 Housing 8 Screw
9 Spool 10 Snap-ring
11 Plug 12 Plug
13 Seal 14 Seal
15 Damper Screw 16 Nozzle
17 Seat 18 Spring
19 Spring 20 Disc
21 Seal 22 Plug
23 Nut 24 Screw
25 Locknut
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Hydraulic pump Fixed displacement pump - Remove

Prior operation:
Remove the battery cover and disconnect the battery negative cable (refer to Battery - Disconnect (A.30.A)).
Prior operation:
Raise the rear of the tractor, place an axle stand under the right hand side final drive case and remove the right hand
side rear wheel (refer to Rear wheel - Remove (D.50.C)).
Prior operation:
Remove the drain plug and drain oil into a suitable container.
Install the drain plug after the oil has drained (refer to REAR AXLE - Drain fluid (D.12.A)).
WARNING
Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -
safety goggles, gloves and shoes.
B026
1. Using a suitable filter strap, remove the oil filter (1).
BVE0444A 1
2. Disconnect the low oil temperature switch electrical

connector (1) and the main intake filter restriction
switch electrical connector (2).
Cut the cable tie and reposition the wiring harness.
BVE0445A 2
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3. Remove the steering / low pressure oil pump oil sup-

ply pipe.
BVE0446A 3
4. Remove the hydraulic lift system oil pump oil supply

pipe.
BVE0449A 4
5. Remove the main oil supply pipe lower retaining bolt

(1).
BVE0450A 5
6. Remove the oil supply manifold retaining nuts.
BVE0451A 6
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7. Remove the oil supply manifold (1) and the main oil
supply pipe (2) as an assembly.
BVE0452A 7
8. Detach the hydraulic lift system oil pump supply pipe.
BVE0453A 8
9. Remove the hydraulic lift system oil pump.
BVE0454A 9
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Hydraulic pump Fixed displacement pump - Overhaul
WARNING
B026
1. Install new oil seals and O-rings. When installing

oil seals in the bearing block ensure that the plas-
tic back-up seal (1) is correctly positioned in the rub-
ber seal (2). Hydraulic pump Fixed displacement
pump - Exploded view (A.10.A).
TIA35012 1
2. Install the driveshaft and driven gears into the hy-

draulic pump body, ensuring that the identification
marks (1) face in the same direction.
BVE0680A 2
3. Tighten the retaining bolts to the specified torque

value.
BVE0674A 3
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Hydraulic pump Fixed displacement pump - Visual inspection

1. Wash all components using a suitable degreaser.
2. Inspect the O-ring seal groove and the shaft oil seal
recess in the mounting flange, these should be un-
damaged and free from burrs.
3. Examine the gears, shafts, and bearing blocks for
wear. The pump must be renewed if:
4. The PTFE coated bearings (1) in the bearing blocks
are worn through revealing the bronze backing.
The gear side faces are scored. This concern is often
caused by contaminated oil.
There is a distinctive wear step on the side faces of
the gears and bearing blocks.
BVE0681A 1
5. IMPORTANT: When servicing the pump gears, par-

ticular attention must be paid to the following points:
The width of each gear set must be within 0.005 mm (
0.0002 in.) of each other to ensure satisfactory pump
efficiency.
6. Journals must be within 0.013 mm ( 0.0005 in.) of
each other.
7. Gear faces must be flat. This feature may be
checked using engineers blue on the bearing face
and rotating against the gear. This check will also
reveal any sharp edges on the teeth.
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Hydraulic pump Variable displacement pump - Remove
Prior operation:
Remove the right hand rear wheel - see Rear wheel - Remove (D.50.C).
NOTE: The hydraulic pump is a heavy component and weighs 30 kg (66 lb). It is important that it is securely supported
when being removed from the tractor.
NOTE: If oil is not drained from transmission, do not remove tube from sump at sump end otherwise oil spillage will
occur.
NOTE: To prevent excessive loss of oil loosen intake filter by approximately one turn and leave for one minute to
allow oil in filter to drain into sump.
1. Drain oil into a suitable container.
2. Remove charge filter (1) by unscrewing anti-clock-
wise.
Remove the intake filter (3) by removing the retaining
bolts (2).
BSE2755A_455 1
3. Disconnect all electrical and hydraulic connections to

pump.
NOTE: Loosen the oil filter vent cap and leave for one
minute to allow oil in the filters to drain into the sump.
BAIS06CCM055AVB 2
Remove filter retaining bolts.
BAIL08CVT263AVA 3
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4. Ensure lubrication pipe banjo connector and brake

line retaining bracket are disconnected from pump
body.
5. Remove filter housing and related tubes and elbows
including the supplementary lube valve.
6. Undo pump retaining nuts and remove pump.
BSD2052A 4
Next operation:
Charge pump - Overhaul (A.10.A)
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Hydraulic pump Variable displacement pump - Overhaul

Hydraulic pump Variable displacement pump - Exploded view (A.10.A)
Prior operation:
Hydraulic pump Variable displacement pump - Remove (A.10.A)
1. Remove pressure and flow compensating valves as-

sembly.
BSD2023A 1
2. Undo the 4 retaining bolts and remove circlip from

opposite end of pump. Gently remove charge Pump
from main pump assembly.
BSD2051A 2
3. Examine valve plate (1). Check to see if it is scored,

nicked, warped or damaged by cavitation. Look for
score marks or damage around the bearing surface
area. Check the inlet and discharge port area for
signs of contamination. This contamination may
show as grooves starting in the feathering notch.
BSD2025A 3
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4. Remove bearing cone (1) and splined connector.
70-421-491 4
5. Remove preload spacer from driveshaft. Remove

pumping head and piston from housing. Using a suit-
able marker identify each piston and slipper to their
corresponding barrel in the pumping head.
TIA35167 5
Pumping Head and Slipper Assembly

6. Separate pumping head and slipper assembly and
inspect for damage. Where damage is identified the
pumping element must be replaced.
1 Pistons and Slippers

2 Cone
3 Washer
4 Pumping Head
5 Pins (3 off)
TIA35168 6
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Pumping Head Spring Assembly

7. If necessary disassemble pumping head spring as-
sembly by compressing the collar against the spring.
1 Pumping Head
2 Washer
3 Spring
4 Collar
5 Retaining Ring
NOTICE: Due to high spring pressure take care when re-
moving retaining ring.
TIA35169 7
8. Remove swash plate (1) assembly.
70-421-461 8
9. Inspect components for wear and replace if dam-

aged.
Pump Reassembly
10. Before reassembling the load sensed variable dis-
placement pump, replace all worn and damaged
parts and assemblies and all seals and O rings.
Lubricate the seals and O rings with petroleum jelly
to retain them during reassembly and provide lubri-
cation to the dust and shaft seals. Also lubricate all
part surfaces freely with clean hydraulic fluid.
Install a new input shaft bearing cup (1), and swash
plate bearings (2).
70-421-973 9
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11. Install input shaft into housing.
70-421-456 10
12. Install swash plate control spring (1) and swash plate
bearings (2).
70-421-462 11
13. Reassemble the swash plate (1), into the housing by

tilting the swash plate with the push rod socket up
slightly and installing.
NOTE: Caution must be used when installing the complete
swash plate so as not to dislodge the swash plate spring
or the saddle bearings.
70-421-461_460 12
14. Insert the push rod (1), through the stroke piston bore
and reengage the end of the tube into the swash
plate socket.
70-421-476 13
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15. Tilt the swash plate up and insert the push rod (1),
down and into the socket. Make sure the push rod is
engaged in the socket correctly.
1b0o2004061062 14
16. Install the stroke control piston (2), in the bore. Screw
the plug (1), back on.
70-421-473 15
Pumping Head and Piston Assembly

17. Install the guide pins (1), in the block splines.
70-421-972 16
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18. Lubricate and install the bearing (1), spider and pis-
ton assemblies (2), on the pivot and into the block
assembly.
70-421-468 17
19. Check bearing preload before installing the rotating

group. Install bearing (1), and spacer (2), on the
shaft.
70-421-492 18
Next operation:
Install the charge pump as described in Charge pump - Overhaul (A.10.A).
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Hydraulic pump Variable displacement pump - Replace (Input shaft

seal)
Prior operation:
1. When replacing the input shaft seal, make sure the

pump housings mounting flange is clean. Use circlip
pliers to remove the input shaft seal retaining ring.
1b0o2004061061 1
2. With the retaining ring removed, use a punch or sim-

ilar tool, and carefully pierce the top of the lip seal.
Using the punch, pry the seal from its bore.
70-421-485 2
3. Protect the inner lip of the new shaft seal (1), lubri-
cate and install the seal over the input shaft (2), and
into the pump housing.
70-421-528 3
4. Tap the shaft seal into the pump housing until it is just
slightly below flush of the counterbore face.
NOTE: Do not seat the seal this time.
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5. Use a seal driver, (1), such as a 31.8 mm (1.25 in)

ID 38.1 mm (1.5 in) OD x 63.5 mm (2.5 in) long pipe
as shown here, to press both the retaining ring and
shaft seal into the pump housing.
NOTE: Press the retaining ring in just far enough that it
snaps into the retaining ring groove machined into the
pump housing.
70-421-482_456 4
Next operation:
Hydraulic pump Variable displacement pump - Install (A.10.A)
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Hydraulic pump Variable displacement pump - Install

Prior operation:
Charge pump - Overhaul (A.10.A)
1. Install the pump and tighten the nuts.
BSD2052A 1
2. Install filter housing, related tubes and elbows includ-

ing the supplementary lube valve.
3. Ensure lubrication pipe banjo connector and brake
line retaining bracket are connected to the pump
body.
4. Connect all electrical and hydraulic connections to
pump.
5. Install the intake filter (3) by installing the retaining
bolts (2).
Install charge filter (1) by screwing clockwise.
BSE2755A_455 2
Install the filter housing and tighten the retaining bolts to 40

N·m (29.5 lb ft).
BAIL08CVT263AVA 3
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6. Connect all the relevant hoses and pipes. Ensure the

oil filter vent cap is tightened.
BAIS06CCM055AVB 4
Next operation:
Install the right hand rear wheel - see Rear wheel - Install (D.50.C).
Refill the driveline with the correct specification oil - see Consumables Lubrications and Coolants.
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Hydraulic pump Variable displacement pump - Pressure test

The following tests check operation of the hydraulic pump and associated high pressure circuits.
NOTICE: Before performing any pressure testing operate the tractor until the oil in the rear axle is at normal operating
temperature 75 °C (167 °F).
Standby Pressure
1. Remove the pressure compensating valve plug
and install the 90 ° quick release fitting adaptor
380001146 (1).
- Test port thread M8 x 1.0
BVE0153A 1
2. Attach a 0 - 40 bar (0 - 580 psi) pressure gauge

380000552, using the quick release coupler
380000543 (1) and the hose 380000545.
BVE0154A 2
3. Set the engine speed to 1500 rev/min to observe the

system operation pressure or 2200 rev/min for the
maximum system pressure.
The pressure reading should be 22 - 24 bar ( 319 -
348 lbf/in²) and is the ‘Standby Pressure‘.
NOTICE: Do Not operate the tractor brakes or any remote control valve lever, otherwise the system pressure will
increase to maximum pressure of 205 - 215 bar (2973 - 3118 psi) this will result in damage to the pressure gauge.
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4. If the pressure reading is not to the specification, ad-

just the flow compensating valve (1).
If the pressure reading is high, examine the flow com-
pensating valve (1) spool for sticking.
BVE0154B 3
Maximum Pressure
5. Remove the pressure compensating valve plug
and install the 90 ° quick release fitting adaptor
380001146 (1).
BVE0153A 4
6. Attach a 0 - 250 bar (0 - 3625 psi) pressure

gauge 380000553, using the quick release coupler
380000543 (1) and the hose 380000545.
BVE0154A 5
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7. Set the remote control valve number 1 in the ‘Extend’

position.
Set the engine speed to 1500 rev/min to observe the
The pressure reading should be 205 - 215 bar (2973
- 3118 psi) and is the ‘Maximum Pressure‘.
BVE0159C 6
8. If the pressure reading is not to specification adjust

the pressure compensating valve (2).
BVE0154B 7
Charge Pressure
9. Remove the charge pressure switch and install the
adaptor 380000572 (1) and the quick release fitting
380000492 (2).
Attach a 0 - 10 bar (0 - 145 psi) pressure gauge
380000543 and the hose 380000545.
BSE2607A 8
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SYSTEM
10. Install a 180 l/min (47.55 US gpm) flow meter be-

tween the remote control valves number 1 and num-
ber 2. Ensure the inlet hose of the flow meter is in-
stalled into the extend port of valve number 1.
Fully open the load valve on the flow meter.
Set the hydraulic oil flow to maximum.
BVE0158A 9
11. Set the remote control valve number 2 in the ‘Float’

position.
Set the remote control valve number 1 in the ‘Extend’
position.
BVE0159A 10
12. Move the remote control valve lever for the remote
control valve number 1 between the extend and neu-
tral position.
13. The following pressures should be observed:
• 6 - 8 bar (87 - 116 psi) - Neutral

• 2 bar (29 psi) - Extend
If the pressure reading is below 1.6 bar (23.2 psi),

replace the hydraulic oil filters and re-test.
If after re-test the charge pressure is still below the
specification, check the supplementary lube valve,
examine both the charge pressure filter dump valve
and the charge pressure valve before disassembling
the hydraulic oil pump to inspect for wear.
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SYSTEM
Hydraulic pump Variable displacement pump - Flow test

To flow test the variable flow piston pump it is recommended that the output is checked at the remote control valves.
1. Install the flow meter between the inlet ports of the

remote control valves number 1 and number 2.
BVE0158A 1
2. Set the hydraulic oil flow to maximum.

3. Ensure the load valve on the flow meter is fully
‘Open’.
4. Set the engine speed to 1100 rev/min.
position and the remote control valve number 1 in the
‘Extend’ position.
BVE0159A 2
6. Adjust the load on the flow meter to a pressure of 100

bar (1450 psi).
If a flow of 47 l/min (12.42 US gpm) is recorded the
hydraulic pump oil flow is within specification.
NOTE: This test is performed at half maximum rated speed and assumes that pump flow at rated speed is twice that
measured in the test.
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SYSTEM
Hydraulic pump - Test (Air Ingress)

The hydraulic oil pump aeration test should be performed whenever the operation of the hydraulic system is erratic
or the hydraulic pump is extremely noisy.
The purpose of the test is to find out if the malfunction of the system is due to internal or external air ingress.
1. Disconnect the driveline breather tube (1) from the

top of the rear axle.
BVE0398A 1
2. Attach approximately 2 m (6.56 ft) of 10 mm (0.394

in) clear plastic tube (1) to the driveline breather con-
nection (2) on top of the rear axle and position the
tubing so that it forms a ‘U’ (Similar to a manometer).
BVE0399A 2
3. Fill the tube with sufficient oil to prevent the ingress

of air through the tube.
4. Set the engine speed to 1000 rev/min and pull and
hold the remote control valve lever.
If internal air ingress is identified, oil or bubbles will
be drawn into the driveline through the clear plastic
tube.
If external air ingress is identified, oil in the clear plas-
tic tube will be pushed towards the open end by the
air being drawn into the driveline through the inlet
system of the hydraulic oil pump.
BVE0159A 3
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SYSTEM
WARNING
If the leak is excessively large it is possible for the oil to be projected out of the tube. Take care to position
the tube so not to cause injury or project oil into the work area.
B027
5. If external air ingress is identified, possible air ingress

through the hydraulic oil pump filter(s), intake tube
joints, remote control valve tube joints.
If internal air ingress is identified, possible hydraulic
oil pump shaft seal damaged or worn.
BVE0437A 4
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SYSTEM
Charge pump - Overhaul

Charge pump - Exploded view (A.10.A)
Prior operation:
1. Remove 4 bolts securing charge pump housing and

carefully separate charge pump housing from main
pump body.
BSD2051A 1
BAIL07APH345ASA 2
2. Use circlip pliers to remove the input shaft seal re-

taining ring (1).
70-421-484 3
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SYSTEM
3. Remove pump rotor, housing and rotor shaft. Inspect

for wear or damage.
NOTE: Ensure when reassembling the pump that the
punched dot markings on the rotor and rotor housing face
to the outside of the pump housing, as illustrated.
BSD2049A 4
4. Inspect seal in end cover and replace if required -

as described in Hydraulic pump Variable displace-
ment pump - Replace (Input shaft seal) (A.10.A).
5. Tighten housing retaining bolts to a torque of 50 - 62
Nm (36.9 - 45.7 lb ft).
BSD2051A 5
BAIL07APH345ASA 6
Next operation:
Hydraulic pump Variable displacement pump - Overhaul (A.10.A)
Hydraulic pump Variable displacement pump - Install (A.10.A)
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SYSTEM
Compensator - Overhaul
Compensator - Exploded view (A.10.A)
1. Disconnect load sense line connection and remove

pressure and flow compensating valve assembly.
Remove the tamper proof caps, carefully unscrew
each adjuster and remove the component parts.
NOTICE: Due to extreme spring pressure within valves DO
NOT remove rear plugs until the adjusters have been re-
moved.
BSD2023A 1
2. To ensure correct re-assembly keep the component

parts for each valve separate.
3. Re-assembly of the valves follows the removal pro-
cedure in reverse. On re-assembly observe the fol-
lowing:
Wash all components in a suitable solvent.
Examine all components for wear or damage. If the
spools are damaged it is necessary to replace the
complete valve assembly.
Lubricate all parts with clean hydraulic oil.
To aid re-assembly of pressure and flow compensat-
ing valves, the spools should be inserted into the rear
of the housing.
Tighten all plugs and locknuts to the correct torque
as detailed in Specifications.
TIA35166 2
When installing valve on pump ensure all ‘O’ ring seals are
correctly installed.
Pressure test the pump and adjust the pressure and flow
compensating valves to the correct specification as de-
scribed in Hydraulic pump Variable displacement pump
- Pressure test (A.10.A) and Hydraulic pump Variable
displacement pump - Flow test (A.10.A).
TIA35007 3
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SYSTEM
NOTE: If the damper screw (1) is removed for any reason it

should be re-installed in alignment with the three ports and
should be loctited into position. Failure to adjust this screw
correctly could reduce the efficiency of the system.
BSF4760A 4
4. Install pressure and flow compensating valve assem-

bly and connect load sense line connection.
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Index

SYSTEMS - A

PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (16x16 CCLS with Electronic Draft Control) . . . 50
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (16x16 CCLS with Mechanical Draft Control) . 52
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (24x24 CCLS with Electronic Draft Control) . . . 54
Charge pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Charge pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charge pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Compensator - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Compensator - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Hydraulic pump - Test (Air Ingress) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Hydraulic pump Fixed displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic pump Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic pump Fixed displacement pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hydraulic pump Fixed displacement pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Hydraulic pump Fixed displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hydraulic pump Fixed displacement pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hydraulic pump Fixed displacement pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic pump Fixed displacement pump - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Hydraulic pump Variable displacement pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hydraulic pump Variable displacement pump - Dynamic description (System description CCLS) . . . . . . . . . . . . . 66
Hydraulic pump Variable displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hydraulic pump Variable displacement pump - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Hydraulic pump Variable displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic pump Variable displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Hydraulic pump Variable displacement pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Hydraulic pump Variable displacement pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Hydraulic pump Variable displacement pump - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Hydraulic pump Variable displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hydraulic pump Variable displacement pump - Replace (Input shaft seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Hydraulic pump Variable displacement pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hydraulic pump Variable displacement pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRIMARY HYDRAULIC POWER SYSTEM - Overview - Fixed Displacement Pump Hydraulic Circuit 12 x 12 and
24 x 24 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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PRIMARY HYDRAULIC POWER SYSTEM - Overview - Variable Displacement Pump High Pressure Hydraulic
Circuit 16 x 16 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PRIMARY HYDRAULIC POWER SYSTEM - Overview - Variable Displacement Pump High Pressure Hydraulic
Circuit 24 x 24 Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PRIMARY HYDRAULIC POWER SYSTEM - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRIMARY HYDRAULIC POWER SYSTEM - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical

remote valve - 10.B
MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 120 , MAXXUM 125 ,
MAXXUM 130 , MAXXUM 140
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Contents

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote

valve - 10.B
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Mid-mount remote control valve

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SERVICE
Command
Configurable detent - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Configurable detent - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Remote control valve

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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SYSTEM Closed center mechanical remote valve

remote valve - Special tools
CAUTION
The operations described in this section can only be carried out with the ESSENTIAL tools indicated by an
(X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended
specific tools listed below and certain other tools, which are to be made according to the drawings included
in this manual.
B008
List of specific tools required for the various operations described in this section.
X 380000495 Lifting bracket.

remote valve - General specification
Remote Control Valve Output @ 100 bar (1450.0 psi) @ 2200 erpm 90 l/min (23.8 US gpm)
Detent Regulating Valve Pressure Pre set non adjustable

remote valve - Torque
BVE0601A 1
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Mid-mount remote control valve - Torque

BSF4582A 1
Mid-mount remote control valve - General specification

Type Parallel-Closed Centre Circuit

Maximum Flow through one valve at rated engine speed:
- Fixed Displacement Pump 80 Litres/Min
( 21.1 U.S. Gals/Min)
- Variable Flow Displacement Pump 95 Litres/Min

( 25.0 U.S. Gals/Min)
Maximum Flow through Third Mid mount Valve: 37.7 Litres/Min
( 10 U.S. Gals/Min)
Valve to Coupler Hoses 1/2 in Bore with 13/16 in ORFS
fittings both ends
Load Sense Relief Valve Setting 165.47+/- 1.7 Bar
.( 2400 +/- 25 lbf in2 )
Load Sense Differential 19.65 - 20.33 Bar.
( 285 - 295 lbf in2)
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remote valve - Dynamic description
OIL FLOW IN NEUTRAL (Refer to Figure 1)

When the remote control valves are in neutral, the main control spool is held in the central position by the centring
spring.
Oil flow from the parallel gallery (A) to the raise and lower ports is blocked by the lands of the main control spool.
Gallery (C) and load sensing gallery (D) are vented to the reservoir through galley (G).
The galleries to the raise and lower ports are blocked by the lands on the main control spool.
The pin (9) on the lock valve (8) is positioned in the waisted section of the main control spool (10) allowing the lock
valve (8) to be spring loaded into the closed position preventing an extended cylinder retracting under load, should
there be a slight leakage in the main control spool.
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Single Remote Control Valve Operation - Neutral
1. Flow Control Spool 2. Metering Land

3. Flow Control Adjuster 4. Manually Adjusted Flow Control Restriction
5. Spool Centring and Detent Mechanism 6. Lower (Cylinder Retract) Port
7. Raise (Cylinder Extend) Port 8. Lock Valve
9. Pin 10. Main Control Spool
11. Load Hold Check Valve
Trapped Oil Return To Reservoir
Pump Pressure
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BRJ5260B 1
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OIL FLOW IN RAISING (CYLINDER EXTEND) Refer to Figure 2

When the remote control valve lever is moved to the raise position, the main control spool (10) moves to the right and
the spring loaded detent balls (5) engage with the left hand groove in the detent mechanism.
Moving the main control spool (10) to the raise position causes the pin (9) on the lock valve (8) to ride up the ramp of
the main control spool and hold the lock valve in the open position.
Gallery (B) is now open to gallery (C) and gallery (E) is open to gallery (F) .
The flow from gallery (C) is blocked by the load hold check valve (11) until the pressure in the gallery is sufficient to
lift load hold check valve (11) off its seat against the back pressure in the lift port gallery (E) .
Oil can flow from :-
Gallery (C) past the load hold check valve (11) into Gallery (E) .
Across the flat on the main control spool (10) to Gallery (F) .
Through the lock valve (8).
Out through the raise port (7) of the remote control valve.
Exhaust oil from the extending cylinder returns through the lowering port (6) and gallery (H), around the land on the
main control spool (10) and back to the reservoir via the common gallery (G) .
If the load hold check valve (11) was not installed the situation could occur where pump pressure is insufficient to
support the load in the raise port (7) when the remote control valve is moved from neutral to the raise position. Under
this situation the load would momentarily drop until pump pressure was sufficient to support the load.
The rate of flow through the remote control valve is adjusted by the manual flow control adjuster (3), which manually
changes the size of restriction (4).
To maintain set flow through the remotes under all conditions with varying pump inlet pressure in parallel gallery (A)
the flow control spool senses the differential pressure across the manually adjusted flow control restriction (4) between
galleries (A) and ‘ (B) .
The differential pressure sensed on each end of the spool causes the spool to move to a new state of equilibrium and
continually regulates the flow across the spool metering lands (2) to maintain a constant flow through the manually
adjusted flow control restriction (4) irrespective of the pressure in other hydraulic circuits.
The pressure in gallery (C) is also transmitted down the load sensing gallery (D) to the flow compensating valve of
the variable flow piston pump where pump output is regulated according to the circuit demand.
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OIL FLOW IN RAISING (CYLINDER EXTEND)

Pump Pressure Return To Reservoir
Remote Valve Operating

Pressure
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BRJ5259B 2
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OIL FLOW IN LOWERING (CYLINDER RETRACT) Refer to Figure 3

When the remote control valve lever is moved to the lower position the main control spool (10) moves to the left and
the spring loaded detent balls (5) engage with the middle groove in the detent mechanism.
In a similar manner as for the raise cycle of the remote control valve the position of the spool causes the pin (9) on
the lock valve (8) to hold the lock valve in the open position.
Gallery (B) is now open to gallery (C) and gallery (E) is open to gallery (H) .
Oil from the parallel gallery (A) flows past the flow control spool (1) and the restrictor (2) into gallery (C) and the load
sensing gallery (D) .
The load hold check valve (11) remains closed until pump system pressure is sufficient to overcome the back pressure
in gallery ‘ (E). When the load hold check valve (11) lifts off the seat oil flows into gallery (H) , round the main control
spool (10) to gallery (G) and out through the lowering port (6) of the remote control valve coupling.
Exhaust oil from the retracting cylinder returns to the reservoir gallery (G) though the raise port (7) and the lock valve
(8).
Pump output and system pressure will continually react to the maximum demand of the tractor high pressure hydraulic
circuits as sensed through the load sensing lines.
Flow through the remote control valve is controlled in exactly the same manner as described above in the ‘Oil Flow
In Raising’ section by sensing differential pressure across the manually adjusted flow control restriction (4).
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Single Remote Control Valve Operation - Lowering (Cylinder Retract)

Remote Valve Operating

Pressure
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BRJ5261B 3
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OIL FLOW IN FLOAT (Refer to Figure 4)

The float position allows the free flow of oil from both the raise and lower ports of the remote control valve permitting
the cylinder to extend or retract freely. This feature is particularly useful to allow equipment such as scraper blades
to ‘float’ or follow the ground contour.
When the remote control valve lever is pushed fully forward to the float position the main control spool (10) is moved
fully to the left and the spring loaded detent balls engage with the right hand groove in the detent mechanism (5).
Oil flow from the gallery (B) to the raise and lower ports is blocked by the lands of the spool.
The position of the main control spool (10) causes the pin (9) on the lock valve (8) to hold the lock valve in the open
position.
The raise and lower ports of the remote control valve are open to the reservoir gallery (G) allowing a free flow of oil
from one port of the cylinder to the other.
Should a void occur in the circuit oil will be drawn by suction from one side of the cylinder to the other.
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Single Remote Control Valve Operation - Float

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BRJ5262B 4
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OPERATION OF DETENT PRESSURE REGULATING VALVE (Refer to Figure 5)

Under normal operating conditions excessive pressures in the remote control valve circuits are protected by the de-
tent pressure regulating valve which returns the main control spool (1) to neutral when the operating pressure of the
cylinder exceeds the factory preset value.
If the remote control valve lever is physically held by the operator to prevent the main control spool (1) returning
to neutral the maximum operating pressure is restricted to a maximum of 210 bar (3045.00 psi) by the pressure
compensating valve in the closed centre load sensing (CCLS) hydraulic pump.
Operation of the detent regulating valve is as follows :-
When the main control spool (1) is moved to the raise or lower position the detent balls (5) of the spool centering and
detent mechanism (4) are held in detents by the tapered face of the spring loaded plunger (3).
In the raise or lower condition the operating pressure of the remote control valve circuit is also sensed in the centre
drilling of the main control spool through the small radial drillings (2). As pressure increases a force is applied to the
small ball (7) in the end of the main control spool (1) which pushes the detent regulating valve piston (6) and spring
loaded plunger (3) to the left. The detent balls in the centring mechanism are no longer held in the detent by the
tapered face of the spring loaded plunger (3) and the centring spring moves the main control spool to neutral.
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Operation of Detent Pressure Regulating Valve
1. Main Control Spool 2. Radial Drillings

3.. Spring Loaded Plunger 4. Spool Centring and Detent Mechanism
5. Detent Balls 6. Detent Regulating Valve Piston
7. Ball
Remote Valve Pressure Return To Reservoir

@ . 210 bar (3045.00 psi)
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BRJ5263B 5
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OPERATION OF TWO OR MORE CONTROL VALVES SIMULTANEOUSLY (Refer to Figure 6)

Because the stack type remote valves have a common parallel input gallery and individual flow control valves it is
possible to operate two or more remotes simultaneously without loss of efficiency.
This is achieved by the flow control spools which regulate flow through each remote valve irrespective of pump system
pressure.
If these valves were not fitted and two remotes were operating simultaneously at different pressures all oil would
attempt to flow to the light load circuit.
The following details the process of operating a single remote valve and then operating an additional remote valve at
the same time.
When a single service is operated the pressure in the parallel gallery is at pump pressure.
The pressure in the load sense line to the hydraulic pump is equal to the operating pressure of the working remote
valve.
Required flow through the remote valve is set by turning the manual flow control knob. This action adjusts the size of
restriction (3).
The pressure differential across the restriction (3) is sensed on each end of the flow control valve spool and causes
the spool to move to a position of equilibrium which adjusts the flow across the spool metering lands (4).
The adjustment of flow across the metering land (4) produces a constant flow across the manually adjusted flow
control restriction (3) and through the remote valve.
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Single Remote Valve Operating
Pump Pressure Return to Reservoir
Remote Valve Operating Trapped Oil

Pressure
A. Remote Valve in Operation B. Remote Valves in Neutral

1. Parallel Gallery (Interconnecting Remote Valves 3. Manually Adjusted Flow Control Restriction
Sections) 4. Spool Metering Lands
2. Load Sense Line (Interconnecting Remote 5. Flow Control Spool
Valves Sections) 6. Load Sense Line Check Valve
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve
BAIL07APH403JSA 6
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Two Remote Valves Operating (Refer to Figure 7)

It is essential that the flow of oil through two or more remote valves operating simultaneously at different pressure is
individually controlled otherwise oil will always flow to the circuit operating at the lowest pressure.
When operating two or more hydraulic services the operating pressure in the parallel gallery is at the highest operating
pressure of the hydraulic system as sensed through the load sense line.
Check valves in the load sense line between each valve section ensure only the highest pressure is directed to the
pump flow pressure compensating valve.
In the same manner as for single remote valve operation the differential pressure across the manually adjusted flow
control restriction (3) is sensed by the flow compensating spool.
Because each remote valve is operating at a different pressures the flow control valve spools will move to different
positions to achieve a state of equilibrium.
The flow across the metering land (4) of the lower pressure operating remote valve will be different to the flow across
the metering land of the higher operating pressure remote valve.
The metering land on each flow control spool now maintains the required constant flow through the manually adjusted
flow control restriction in each remote valve irrespective of the higher pump system pressure required to operate other
hydraulic circuits.
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Two Remote Valves Operating
Pump Pressure Lower Pressure Remote

Valve Operation
High Pressure Remote Return To Reservoir
Valve Operation
A. Remote Valve Operating At High Pressure B. Remote Valve Operating At Lower Pressure
1. Parallel Gallery (Interconnecting Remote Valves 3. Manually Adjusted Flow Control Restriction
Sections) 4. Spool Metering Lands
Valves Sections) 6. Load Sense Line Check Valve
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BAIL07APH404JSA 7
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84276322A 31/05/2010
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remote valve - Static description
Hydraulic remote control valves are available to operate external hydraulic cylinders, motors etc. All models have two
valves as standard, installed at the rear of the tractor adjacent to the top link.
BSE3074C 1
The levers and their respective valves are colour coded for identification.
I Green
II Blue
III Brown
IV Black
BSE3074E 2
Each valve is controlled by a separate lever providing four operating positions.
Raise (R) - Pull a lever toward you to extend the cylinder to which it is connected.
Neutral (N) - Push the lever forward to select neutral and de-activate the connected cylinder.
Lower (L) - Push the lever forward, past neutral, to retract the cylinder.
Float (F) - Push the lever fully forward, beyond the ‘lower’ position, to select ‘float’. This will permit the cylinder to
extend or retract freely, allowing equipment such as scraper blades to ‘float’ or follow the ground contour.
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BRE1719C 3
Each control lever has a ’rolling gate’ which is used to select or lock-out individual remote valve functions. Detents
on the lever (1) will lock the ’gate’ in one of five positions.
I. - Neutral and Raise locked out: Lower and Float functional. Move the lever into float before selecting this position.
II. - Raise locked out: Neutral, Lower and Float functional.
III.- All valve functions are operative.
IV. - Float locked out: Raise, Neutral and Lower functional.
V. - Lever locked in neutral: No valve functions are available.
BRE1560B 4
On tractors with four valves, the first and second valves may be controlled by levers or by a 4-way joystick control
mounted to the right of the operator’s seat.
BRE1534B 5
Additional Oil Supply For Remote Hydraulic Services

For implements or attachments requiring continuous or high oil flows from the tractor hydraulic system, provision is
made to connect directly into the main hydraulic circuit at the rear of the tractor.
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1. Pressure Line (P) - M22 x 1.5/15.5 (ISO 6149)

2. Low Pressure Relief Valve ( 30 Bar )
3. Return Oil Line (R) - M27 x 2/19 (ISO 6149)
BSE3074B 6
The remote valves are a stack type design clamped together with the hydraulic lift Electronic Draft Control valve (1)
on the Closed Centre Load Sensing hydraulic systems.
BSE3074D 7
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BVE0602A 8
Remote Control Valve and Electronic Draft Control Valve Interconnecting Galleries
Pump Pressure Return To reservoir
Load Sensing
1 Return to Reservoir 2 Load sensing Gallery

3 Parallel Supply Gallery 4 End Cover
5 Remote Control Valve IV 6 Remote Control Valve III
7 Remote Control Valve II 8 Remote Control Valve I
9 Electronic Draft Control Valve 10 From Hydraulic Oil Pump
11 Return to Reservoir 12 Load Sense Line
All valve sections have a common parallel inlet and return to reservoir gallery.
The load sensing gallery passes through the centre of the valve stack and signals the pump to increase or decrease
output according to the demand.
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The parallel gallery and load sensing system enables two or more valves to be operated simultaneously without loss
of efficiency.
‘O’ ring seals (1) and load sense check valves (2) between each valve section ensure the highest circuit load sense
pressure is transmitted to control the output of the hydraulic oil pump.
BSB0388A 9
The principal hydraulic components within each remote control valve section are:-
Flow Control Adjuster

The flow control adjuster is manually operated and adjusts oil flow through the remote valve. Turning the adjuster
changes the size of the restriction in the path of oil flowing through the flow control spool.
Flow Control Spool

The flow control spool senses pressure differential across the restriction set by the flow control adjuster and regulates
flow through the remote valve. Because each flow control spool individually senses the pressure differential in the
remote valve being operated, two or more circuits working at different pressures can be controlled simultaneously.
Load Hold Check Valve

The load hold check valve prevents a back-flow of pressure from the remote valve circuit when the main control spool
is operated and the hydraulic oil pump system pressure is less than the back-pressure in the circuit.
This is explained by the following example:-
When a cylinder is holding a heavy load and the main control spool is moved from the neutral to the raise position, the
hydraulic system pressure may be less than the back pressure in the remote control valve circuit. When this occurs
the back pressure would cause oil in the circuit to flow backwards and the load to momentarily drop before hydraulic
system pressure has risen to hold and then raise the load further. The load hold check valve prevents this situation
from occurring.
Main Control Spool

The main control spool is spring centered to a neutral position and when moved directs oil flow to the raise or lower
ports of the remote control valve.
Lock Valve
The lock valve is located in the raise port of the remote control valve and is closed whenever the main control spool
is in neutral. The lock valve prevents leak-down of an implement should there be any leakage across the lands of the
main control spool when in the neutral position. The lock valve is automatically opened whenever the main control
spool is moved from the neutral position.
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Spool Centring and Detent Mechanism

The spool centring and detent mechanism spring loads the main control spool to the neutral position. When the main
control spool is moved to the Raise, Lower or Float positions the spool centring and detent mechanism holds the main
control spool in position using ball bearings which engage in grooves within a detent cage.
A factory set detent regulating valve in the spool centring and detent mechanism automatically releases the balls and
returns the main control spool to neutral whenever the operating pressure exceeds the preset value.
BAIL06CCM165FSA 10
Remote Control Valve Components
1 Flow Control Adjuster 2 Flow Control Spool

3 Load Hold Check Valve 4 Main Control Spool
5 Lock Valve 6 Spool Centring and Detent Mechanism
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Mid-mount remote control valve - Sectional view

BSF4598A 1
Control Valve with Detent (Boom) Components
1 Wiper Seal 2 O-Ring

3 O-Ring 4 Spacer
5 Spool Cap 6 Screw
7 Spring 8 Ball (4 Off)
9 Retaining Ring 10 Detent Sleeve
11 Boot 12 Spacer
13 Ball 14 Spool End Detent Pin
15 Spring 16 O-Ring
17 Centering Spring Seat 18 Spool Spacer Cap
19 Compensator Piston 20 Housing
21 Seal Plate 22 Screw
23 Spool
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Mid-mount remote control valve - Dynamic description

With Reference to Figure 1

When the control valve with detent (boom) (1) is in neutral, output from the pump (3) can flow uninterrupted through
the staggered centre gallery (A) and the lands on the spool (2) prevent flow to the cylinder ports (B). The lands on
the spool trap the oil between the outlet port of the valve and the cylinders. When the spool is activated (as shown
in the lower non detented (bucket) valve (6) high pressure oil is directed to the staggered centre gallery (C). The
load sense shuttle (7) in turn transmits the highest pressure to the load sense valve on the hydraulic pump (3) and
all the compensators (5) within the valve assembly. The Pump responds to the load sense signal with load sense
pressure plus pump margin or differential. It is this pressure margin or differential that overcomes the compensators
and permits flow to the staggered centre gallery and the cylinder port (D).
BSF4597A 1
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High Pressure Circuit Oil Return To Reservoir Oil
Load Sensing Pressure Oil Trapped Oil
1 Control Valve with Detent (Boom) 2 Boom Spool

3 Pump 4 Bucket Spool
5 Compensator 6 Control Valve less detent (Bucket) Valve
7 Load Sense Shuttle Valve
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Mid-mount remote control valve - Static description

BSF4392A 1
Mid Mount Valve Loader Components
1 Multi-Quick Coupler 2 Loader Support

3 Tip Hose - Blue 4 Crowd Hose - Red
5 Raise Hose - Green 6 Lower Hose - Yellow
7 Mid Mount Valve Assembly
Tractors equipped with the Mid Mount Valve option are fitted with a seat mounted joystick, a mid mount valve assem-
bly, plumbing and loader mounting brackets ready for attaching the loader arms.
The Mid Mount Valve is located underneath the cab on the right hand side. The base version has a two spool valve
for raising and lowering the boom and tipping and curling the bucket when used with a loader.
BSE3576A 2
The valves are operated by means of a joystick control (1) mounted on the right hand side of the seat.
The three position push/pull lever (2) is used to fully lock the joystick in neutral to avoid accidental operation. In the
middle position side travel of the joystick is locked.
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BRE1700B 3
European loader ready options come complete with a “Multi-Quick" coupler. This allows the couplers to be connected
and disconnected at once with the minimum of leakage.
1. Lock Button
2. Protective Cover
3. Alignment Holes
4. Clamp Handle
BRE1536B 4
A third hydraulic service (where fitted) is electrically controlled via a cable that connects to a socket (1) on the loader
subframe. This is operated by depressing a switch located on the joystick handle.
BRE1535B 5
The mid mount valves are fed high pressure oil via a hose (1) from the power beyond port of the sub plate located at
the bottom of the remote valve stack.
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BSF4561A 6
Oil from the mid mount valves is returned from the outlet port via a hose (1) and an elbow to the hydraulic pump filter
housing manifold.
BSF4571A 7
The spools are cable (1) operated by the joystick situated in the cab.
BSF4564A 8
A load sense relief valve is located on the inlet slice of the valve assembly.
BSF4578A 9
The Load sensing line (1) is connected to the front of the end plate on machines with Electronic remote valves.
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BSF4567A 10
On machines with mechanical remote valves the load sensing line (1) is connected to the left hand side of the end
plate on top of the remote valve stack.
BSF5493A 11
MID MOUNT VALVE HYDRAULIC CIRCUIT
BSF4574A 12
1 End Plate on Remote Valve Stack 2 Mid Mount Valve Slice

3 Return to Hydraulic pump Filter manifold 4 Main Hydraulic Pump
5 Sub Plate on bottom of Remote Valve Stack
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The main hydraulic pump (4) sends high pressure oil to the subplate (5) located at the base of the remote valve stack.
The high pressure oil is then taken from the power beyond port of the sub plate to the inlet port of the mid mount
valve inlet slice (2) . The return oil is directed through the exhaust gallery of the valves, out of the outlet slice, and
is returned to reservoir via an elbow connected to the suction manifold of the main pump filter housing (3). The load
sensing line is connected within the valve assembly to the end plate of the remote valve stack (1).
Third Valve Slice (Where fitted).
Description and Operation

The third hydraulic service is activated using a button located on the loader joystick. With the button depressed, oil
is diverted from the bucket circuit to a pair of couplers mounted on the loader arm. These can be used to operate a
bucket grab or similar piece of equipment.
BRE1700D 13
The two solenoids are connected to the main harness via connectors C413 and C414 which are located on the right
hand side underneath the step.
BRE1753A 14
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BSE4572A 15
BSE4572B 16
Third Valve Section
1 Solenoid 2 Port “A"

3 Port “B" 4 Solenoid
5 Spool
When both solenoids are not energised the valve is in neutral (See Figure 15). Oil from the high pressure circuit can
flow uninterrupted through the staggered open centre gallery and the lands on the spool prevent flow to the cylinder
ports “A” and “B”. When a solenoid is energised (See Figure 16) the spool is moved to the left. High pressure oil flows
past the lands of the spool and is fed to Port “B”. Return Oil allowed back to reservoir across the spool from Port “A”.
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Command Configurable detent - Install

1. Ensure the detent configuration knob is in position III

on the cap. Place the shims inside the cap making
sure they are correctly positioned.
2. Fit the cap over the detent section making sure rotary
shaft (1) of the adjustable detent fits onto the config-
uration knob.
BAIL06CCM178ASA 1
3. Place the hexagon headed screws (1) into cap and

tighten both screws evenly to a torque of 5.5 Nm
(4.06 lbft) .
BAIL06CCM176ASA 2
4. Move the spool from neutral to lower, raise, and back

to neutral to ensure smooth operation.
5. To assemble the plastic knob to the alloy knob (1)
use the screws that are supplied with the new knob.
These screws are coated with micro encapsulated
adhesive and can only be used once. Tighten to 1.5
Nm (1.11 lbft) .
BAIL06CCM179ASA 3
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Command Configurable detent - Remove

1. Before removing the detent housing ensure the re-

mote spool is in the neutral position and the detent
configuration knob (1) is in position III.
BAIL06CCM175ASA 1
2. Unscrew the two hexagon headed screws (1) which

retain the cap to the valve slice.
BAIL06CCM176ASA 2
3. Carefully remove the cap. Do not push or pull the

spool whilst removing the cap. Ensure that the ’O’
ring (1) is not damaged during the removal process.
NOTE: Inside the cap there are shims between the spring
seat and the cap. These shims are unique to the detent
unit and should be removed from the cap and kept safe for
installation.
BAIL06CCM177ASA 3
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Remote control valve - Disassemble

1. Remove the remote control valve quick release cou-

pling manifolds (1).
The couplers are serviced as an assembly and
should not be disassembled.
BVE0474A 1
2. Remove the remote control valve control cable re-

taining bracket.
BVE0483A 2
3. Remove the remote control valve end cover retaining

nuts.
Remove the remote control valve end cover.
BVE0484A 3
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4. Remove the remote control valve slices from the re-

mote control valve base manifold.
BVE0485A 4
BVE0480A_414 5
Mechanical Remote Control Valve Components
1 Flow Control Adjuster 2 Flow Control Spool

3 Load Holding Check Valve 4 Main Control Spool
5 Lock Valve 6 Spool Centering and Detent Mechanism
84276322A 31/05/2010
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5. Disassemble the remote control valve slice using the

following instructions and illustrations.
Remove the O-ring (1) and the check valve (2).
Remove the flow control adjuster knob (1) and un-
screw the flow control adjuster from the remote con-
trol valve body.
BSB0388A_415 6
6. Prior to removing the control valve spool ensure the

flats (1) on the end of the spool are in the vertical
position as shown.
Remove the remote control valve main control spool.
CAUTION
Do not rotate the main control spool or use force once
inserted into the bore, otherwise damage to the main
control spool and the lock valve pin will occur.
B004
BSB0394A 7
7. Remove the lock valve from the raise port as follows:-

Using a small screwdriver, open the two slots (1) on
the keeper (2) and turn the keeper through 90 °.
Remove the spring seat (3) from the remote control
valve housing. Remove the lock valve.
BSB0385A 8
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BSB0386A 9
Lock Valve
1 Plunger 2 Lock Valve

3 Ball 4 Spring
5 Washer 6 Spring
7 Spring Seat 8 Keeper
8.
WARNING
A large spring is positioned beneath the plug, take ex-
treme care when removing plugs.
B041
BSB0393A 10
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BSB0396B 11
Flow Control Spool and Load Hold Check Valve (Early type with ball)
1 Flow Control Spool 2 Spring

3 Spring Guide 4 Plug and ‘O’ Ring
5 Plastic Cap 6 Retainer
7 Plug 8 Backup Ring
9 ‘O’ Ring 10 Spring
11 Load Hold Check Valve Ball
84276322A 31/05/2010
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BAIL06CCM211FSA 12
Flow Control Spool and Load Hold Check Valve (Later Type with cone)
1 Flow Control Spool 2 Retainer

3 Spring 4 Spring Guide
5 Plug and ’O’ Ring 6 Plastic Cap
7 Retainer 8 Plug
9 Back-up Ring 10 ’O’ Ring
11 Spring 12 Check Valve Cone
Lift Check Valve Removal

9. Remove the plastic cap (6) and the snap ring (7) Fig-
ure 10, taking care not to scratch the bore.
10. Locate and clamp the extractor tool 380002720 onto
the retainer (1) by tightening the nut on the tool (2).
BAIL06CCM222ASA 13
11. Pull out the tool and retainer.

12. Remove the check valve and spring.
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BSB0498A 14
Main Control Spool
1 End Cap 2 ‘O’ Ring

3 Shims 4 Spool Centring Mechanism
5 Main Control Spool 6 ‘O’ Ring
7 ‘O’ Ring 8 Spacer
9 Back-Up Ring 10 Detent Release Orifice
11 Ball 12 Plunger
13 Spring 14 Spring Seat
13. Remove the main control spool (5) by removing the
spool centring mechanism (4).
NOTE: It is not recommended that the spool centering
mechanism (4) is disassembled.
14. Housed within the centre of the remote control valve
main control spool (5) is the detent release orifice
(10). This is factory preset and servicing should
be restricted to washing in an approved degreas-
ing agent without removing the orifice from within the
spool.
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Remote control valve - Assemble

BSB0498A 1
Control Valve Spool
1 End Cap 2 ‘O’ Ring

3 Shims 4 Spool Centring Mechanism
5 Spool 6 ‘O’ Ring
7 ‘O’ Ring 8 Spacer
9 Back-Up Ring 10 Detent Release Orifice
11 Ball 12 Plunger
13 Spring 14 Spring Seat
1. Prior to inserting the control valve spool into the
housing, ensure the flats (1) on the end of the spool
are in the vertical position as shown, then install the
load holding check valve, as described below.. Do
Not rotate the spool after installing the load holding
valve otherwise damage to spool and load holding
valve plunger will occur.
WARNING
Do not rotate the main control spool or use force once
inserted into the bore, otherwise damage to the main
control spool and the lock valve pin will occur.
B004
BSB0508A 2
2. Install the control valve spool. Retain by screwing on

the spool centering mechanism.
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BSB0386A 3
Load Check Valve
1 Plunger 2 Load Holding Valve

3 Ball 4 Spring
5 Washer 6 Spring
7 Spring Seat 8 Keeper
3. Load check valve installation
Dimensions:
L = Plunger Length
Z = Depth to the Plunger
Y = Depth to the Pilot Ball
B = Pilot Ball diameter ( 4 mm (0.16 in)
X = Gap between the Plunger and the Pilot Ball
NOTE: When the control valve is in the neutral position

there must be a gap (X) 0.2 - 0.3 mm (0.008 - 0.012 in)
between the plunger and the pilot ball.
BAIL06CCM194ASA 4
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Calculating Gap (X)

4. Install the shortest plunger (No rings , 15.07 mm
(0.59 in) in position with the control valve in neutral.
BAIL06CCM195ASA 5
5. Measure dimension ‘Z‘ from the top of the plunger to

the top face of the remote valve body (e.g. 36.43 mm
(1.43 in) ).
6. Remove the plunger.
7. Install the load check valve and the pilot ball. Ensure
that both are fully seated.
8. Measure dimension ‘Y‘ from the top of the ball to the
top face of the valve body (e.g. 36.43 mm (1.43 in).
BAIL06CCM196ASA 6
Load Check Valve Installation

9. Ensure that the control spool is in neutral.
10. Install the determined plunger using long nosed pli-
ers.
11. Install the lock valve, pilot ball, pilot spring, washer
and the spring (Refer to Figure 3).
12. Use a screwdriver to bend both retainer lugs (1) (fig-
ure 6) upwards, and locate the retainer to the bore.
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13. Fit the spring seat into the retainer, straighten the
lugs and turn the assembly counterclockwise 90 ° to
secure in the remote valve body.
BAIL06CCM197ASA 7
Flow Control Valve Installation

14. Install the flow control spool valve (1), together with
the spring (2), guide (3) and retaining plug (4).
Tighten the retaining plug to a torque of 67 Nm (49.42
lbft)
BAIL06CCM198ASA 8
Flow Control Regulator Installation

15. Assemble the flow control regulator (1) with ‘O‘ rings
(7), (8), and (9).
BAIL06CCM199ASA 9
16. Screw the flow control regulator into the valve body.
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17. Using a screwdriver, turn the restrictor clockwise as

far as it will go, and then turn back 60 °(minimum flow
position).
BAIL06CCM200ASA 10
18. Install the clamp, rotary knob (2), washer and the nut
to the restrictor stem. Ensure that the rotary knob lug
is located to the left of the stop pin (1).
19. Tighten the nut to a torque of 3 Nm (2.213 lbft) with-
out rotating the restrictor.
20. Install the cap with the groove facing the knob lug.
21. Check the minimum and maximum flow available
from the remote valve using a flow meter.
If the rotary knob has been installed as described
above the minimum flow should be approximately 10
l/min (2.64 US gpm) and the maximum flow should
be approximately 80 l/min (21.13 US gpm).
Lift Check Valve Installation

22. Check the bore for any rough edges and smooth if
necessary.
23. Install the check valve (1) into the remote valve body.
BAIL06CCM201ASA 11
24. Fit the back up ring (6) and the ’O’ ring (7) in the
groove in the retainer (3) and locate the spring (2)
onto the inner spigot of the retainer.
25. Locate the snap ring (4), retainer and spring assem-
bly onto the installation tool 380002720 (5). Install
the assembly into the remote valve bore and push
until the tool handle contacts the remote valve body.
26. The snap ring must be located in the groove. Ensure
that the retainer is located up against the snap ring.
Install a new plastic cap.
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Load Sense Check Valve Installation

27. Install new ’O’ Ring seal and back up ring.
NOTE: Clearance ’X’ should be approximately 0.5 mm
(0.020 in) from the flange face of the valve segment to the
top edge of the inserted check valve.
BAIL06CCM139ASA 12
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Remote control valve - Travel adjust

NOTE: Ensure the remote control valve is in neutral before proceeding.

1. Remove the remote control valve cable lock nut.
BVE0460A 1
2. Adjust the remote control valve cable adjustment nut.

Adjustment is correct when all the positions are avail-
able (eg. extend, neutral, retract, and float).
Repeat steps 1-3 for the remaining remote control
valve cable(s).
BVE0532A 2
3. Install the remote control valve cable lock nuts.
BVE0460A_413 3
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Mid-mount remote control valve - Disassemble

1. Remove the three retaining nuts from one end leav-

ing the tie rods in position to aid slice removal and
assembly.
NOTE: Prior to disassembly the valve should be thoroughly
cleaned using an approved de-greasing agent.
BSF4566A 1
2. Remove the outlet slice being careful not to dislodge

the spring (1) located in the valve slice.
Carefully separate the remaining slices.
BSF4562A 2
3. Loosen the knurled knob on the end of the solenoid.
BSF4579A 3
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4. Undo the solenoid nut.
BSF4576A 4
5. Withdraw the solenoid assembly. Repeat for the op-

posite solenoid.
BSF4575A 5
6. Carefully remove spool from the valve slice.

Inspect the spool and bore for scoring and damage.
If the spool is badly scored or worn the valve assem-
bly must be replaced.
BSF4577A 6
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Mid-mount remote control valve - Assemble

1. Lubricate spool before re-assembly.

To avoid damage to “O" ring seals on either end
of spools, insert spool into valve housing before in-
stalling “O" ring (1) and Wiper (2).
SHB35063 1
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Mid-mount remote control valve - Remove

1. Raise the steps and lock in an upright position using

the pin. Swing out the battery tray. Remove the
cover. Disconnect the battery negative cable
Disconnect the supply and return pipes from the
valve assembly.
NOTE: Drain oil from pipes into a suitable receptacle.
BVE0207A_422 1
2. Disconnect the load sensing line and the loader

hoses if fitted.
Unclip the retaining pins from the joystick control
shafts. Loosen the screws which clamp the joystick
cables in place.
Loosen and remove the three retaining bolts and
carefully remove the mid mount valve.
BSF4563A 2
3. Disconnect the solenoid wires from the harness

Disconnect the load sensing line
Disconnect the loader control hoses (where fitted)
Disconnect the inlet and outlet hoses.
Undo the retaining pins from the joystick control
shafts. Loosen the screws which clamp the joystick
cables in place.
BRE1753A 3
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4. Undo the valve assembly retaining nuts and remove

the valve assembly
Undo the tie rod nuts and remove the third valve
slice.
BSF4563A 4
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Mid-mount remote control valve - Install

1. Assemble the valve slices onto the tie rods.

When reassembling the valve slices progressively
tighten the smaller tie bar retaining nuts to a torque
of 19 Nm ( 14 lbf.ft)
BSF4566A_423 1
2. Tighten the larger tie bar nut to a torque of 45 Nm (

33 lbf.ft).
BSF4565A 2
3. Install the valve assembly on to the bracket and

torque nuts to 56 Nm ( 41 lbf.ft).
Reconnect inlet, outlet, and load sensing hoses.
Reconnect loader hoses (where fitted).
BSF4563A 3
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Mid-mount remote control valve - Overhaul

1. Clean the machine thoroughly paying particular at-

tention to the hydraulic valve area.
2. Operate lever to relieve hydraulic pressure in the cir-
cuits.
3. Remove the operating linkage from the valve spools
to be resealed.
4. Remove the two screws and the seal plate from the
spool. (Items (8) and (7) Figure 1).
5. Remove the centring spring housing from the lower
end of the valve spool by removing the two screws.
(Items (16) and (17) Figure 1).
6. Remove the screw retaining the centring spring to
the spool (Item (15)Figure 1). The spool can be pre-
vented from turning by inserting a steel rod in the link-
age hole on the upper end.
7. Remove the seal plate from the spool (Item (1) Figure
1) .
8. Remove the lip seal and wiper ring from either end
of the spool (Items (5), (6), (10) and (11) Figure 1).
It may be helpful to slide the spool to push the seals
out. Care should be taken not to damage the spool
or valve block during this operation. Be aware that
the spool will be unsupported at this point and may
slide out of the valve block. Support the spool as
necessary.
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BSF4569A 1
Control Valve less Detent (Bucket) Components
1 Seal Plate 2 Fitting

3 Valve Body 4 Spring
5 Lip Seal 6 Wiper Ring
7 Seal Plate 8 Retaining Screw
9 Spool 10 Lip Seal
11 Wiper Ring 12 Centering Spring Sea
13 Centring Spring 14 Centering Spring Seat
15 Screw 16 Retaining Screw
17 Centring Spring Cover
9. Carefully place the seal over the end of the spool and
press the seal into position between the spool and
the valve block recess. It may be helpful to lubricate
the spool slightly with hydraulic oil to facilitate this
operation. The trapped air behind the seal can be
released by slightly pushing the spool into the valve
block. This will allow the seal to locate correctly in its
housing. Do not allow the spool feathering lands or
balancing grooves to pass through the seal as dam-
age will occur.
10. Fit a new wiper ring with the lip facing outwards away
from the seal.
11. Fit the seal plate onto the valve block using the two
screws. Tighten the screws to 10 Nm.
12. Repeat this operation - steps 9 to 12 - for the spring
end of the spool.
13. Fit the centring spring with retaining bolt (Item (15)
Figure 1) into the end of the spool. Use Loctite 242
on the bolt threads before tightening to 10 Nm.
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14. Fit the spring cap and screws through the seal plate
and tighten to 10 Nm.
15. Reconnect the linkage to the spool end.
16. Both valve spools are sealed in the same way .
17. Mid-mount remote control valve - Sectional view
(A.10.B).
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Index

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote

valve - 10.B
Command Configurable detent - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Command Configurable detent - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mid-mount remote control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Mid-mount remote control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Mid-mount remote control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mid-mount remote control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mid-mount remote control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Mid-mount remote control valve - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Mid-mount remote control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Mid-mount remote control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Mid-mount remote control valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mid-mount remote control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - Dynamic description . . . . . 6
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - General specification . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - Special tools . . . . . . . . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - Static description . . . . . . 35
PRIMARY HYDRAULIC POWER SYSTEM Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . 4
Remote control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Remote control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remote control valve - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote

valve - 10.C

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Contents

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve -

10.C
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAXXUM 110 Multicontroller [Z9BE40001 - ], MAXXUM 110 Multicontroller [Z9BE60001 - ], MAXXUM 115 Multicontroller
[Z9BE40001 - ], MAXXUM 115 Multicontroller [Z9BE60001 - ], MAXXUM 120 Multicontroller [Z9BE40001 - ], MAXXUM
120 Multicontroller [Z9BE60001 - ], MAXXUM 125 Multicontroller [Z9BE40001 - ], MAXXUM 125 Multicontroller
140 Multicontroller [Z9BE40001 - ], MAXXUM 140 Multicontroller [Z9BE60001 - ]
FUNCTIONAL DATA
Remote control valve
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SERVICE
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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SYSTEM Electro-hydraulic remote valve

valve - Torque
BAIL07APH384BMA 1

valve - Special tools
DESCRIPTION PART NUMBER
Lifting Bracket 380000495
Check valve removing and refitting tool 380002720
Flowmeter 0 - 200 ltrs/min. Procure Locally

valve - General specification
Remote Valve Output 95 - 105 ltrs/min . @ 100 bar @ 2200 erpm.
Detent Regulating Valve Pressure Pre set non adjustable
84276322A 31/05/2010
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Mid-mount remote control valve - Torque

MAXXUM 110 Multicontroller [Z9BE40001 - ], MAXXUM 110 Multicontroller [Z9BE60001 - ], MAXXUM 115 Multicontroller [Z9BE40001 - ], MAXXUM 115
Multicontroller [Z9BE60001 - ], MAXXUM 120 Multicontroller [Z9BE40001 - ], MAXXUM 120 Multicontroller [Z9BE60001 - ], MAXXUM 125 Multicontroller
[Z9BE40001 - ], MAXXUM 125 Multicontroller [Z9BE60001 - ], MAXXUM 130 Multicontroller [Z9BE40001 - ], MAXXUM 130 Multicontroller [Z9BE60001
- ], MAXXUM 140 Multicontroller [Z9BE40001 - ], MAXXUM 140 Multicontroller [Z9BE60001 - ]
BAIL06CCM141ASA 1
Mid Mount Valve Assembly Torques showing tightening sequence
Refer to Mid-mount remote control valve - Assemble (A.10.C)
84276322A 31/05/2010
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valve - Dynamic description
When the remote valves are in neutral the control valve spool is held in the central position by the centering spring.
Oil flow from the parallel gallery (A) to the raise and lower ports is blocked by the lands of the main control spool.
Gallery (C) and load sensing gallery (D) are vented to reservoir through galley (G).
The galleries to the raise and lower ports are blocked by the lands on the main control spool.
The pin on the lock valve is positioned in the waisted section of the spool allowing the valve to be spring loaded into
the closed position preventing an extended cylinder retracting under load should there be a slight leakage in the main
spool.
Figure 1
Single Remote Control Valve Operation-Neutral
1. Flow Control Spool

2. Metering Land
4. Main Control Spool
5. Spool Centering Spring
6. Control Spool Operating Piston
7. Position Sensor
8. Micro Processor
9. Solenoid Valve
10. Pin
11. Lock Valve
12. Raise (Cylinder Extend) Port
13. Lower (Cylinder Retract) Port
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BAIL07APH319G 1
Single Remote Control Valve Operation-Neutral
Trapped Oil Pilot Line Pressure
OIL FLOW IN RAISING (CYLINDER EXTEND)

When the remote valve operator control switch is moved to the raise position the control spool is moved to the left via
pilot line oil from the solenoid control unit, supplied from Gallery (I).
84276322A 31/05/2010
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Moving the spool to the raise position causes the pin (6) on the lock valve to ride up the ramp of the spool and hold
the valve in the open position.
Gallery (B) is now open to gallery (C) and gallery (E) is open to gallery (F).
The flow from gallery (C) is blocked by the load hold check valve (3) until pressure in the gallery is sufficient to lift the
valve off its seat against the back pressure in the lift port gallery (E) .
Oil can flow from:-
Gallery (C) past the load hold check valve into Gallery (E) .
Across the flat on the main control spool to Gallery (F) .
Through the lock valve (7).
Out through the raise port (8) of the remote valve.
Exhaust oil from the extending cylinder returns through the lowering port and gallery (H), around the land on the main
control spool and back to reservoir via the common gallery (G) .
If the load hold check valve (3) was not installed the situation could occur where pump pressure is insufficient to
support the load in the raise port when the remote valve is moved from neutral to raise condition. Under this situation
the load would momentarily drop until pump pressure was sufficient to support the load.
The rate of flow through the remote control valve is controlled electronically by the control unit solenoid, again based
on the setting of the flow potentiometer within the cab.
To maintain set flow through the remotes under all conditions with varying pump inlet pressure in parallel gallery (A)
the flow control spool senses the pressure and the spool adjusts to provide the required flow at each operating remote.
The differential pressure sensed on each end of the spool causes the spool to move to a new state of equilibrium and
continually regulates the flow across the spool metering lands (2) to maintain a constant flow through the flow control
restriction irrespective of pressure in other hydraulic circuits.
The pressure in gallery (C) is also transmitted down the load sensing gallery (D) to the flow compensating valve of
the variable flow piston pump where pump output is regulated according to circuit demand.
Figure 2
Single Remote Control Valve Operation-Raising (Cylinder Extend)

2. Metering Land
7. Position Sensor
8. Micro Processor
9. Solenoid Valve
10. Pin
11. Lock Valve
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BAIL07APH320GSA 2
Single Remote Control Valve Operation-Raising (Cylinder Extend)
Remote Valve Operating Pilot Line Pressure

Pressure
OIL FLOW IN LOWERING (CYLINDER RETRACT)

When the remote valve operator control switch is moved to the lower position the control spool is moved to the right
via pilot line oil from the solenoid control unit, supplied from gallery (I) .
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In a similar manner as for the raise cycle of the remote valve the position of the spool causes the pin on the lock valve
to hold the valve in the open position.
Gallery (B) is now open to gallery (C) and gallery (E) is open to gallery (H) .
Oil from the parallel gallery (A) flows past the flow control valve spool and restrictor (2) into gallery (C) and the load
sensing gallery (D) .
The load hold check valve (3) remains closed until pump system pressure is sufficient to overcome the back pressure
in gallery (E) . When the load hold check valve lifts of the seat oil flows into gallery (H) , round the control valve spool
to gallery (G) and out through the lowering port of the remote valve coupling.
Exhaust oil from the Retracting cylinder returns to reservoir gallery (G) through the raising port and lock valve (7).
Pump output and system pressure will continually react to the maximum demand of the tractor high pressure hydraulic
circuits as sensed through the load sensing lines.
Flow through the remotes is controlled in exactly the same manner as described in the ‘Oil Flow In Raising’ section
by sensing differential pressure across the flow control spool.
Figure 3
Single Remote Control Valve Operation-Lowering (Cylinder Retract)

2. Metering Land
7. Position Sensor
8. Micro Processor
9. Solenoid Valve
10. Pin
11. Lock Valve
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BAIL07APH321GSA 3
Single Remote Control Valve Operation-Lowering (Cylinder Retract)
Remote Valve Operating Pilot Line Pressure

Pressure
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OIL FLOW IN FLOAT

The float position allows the free flow of oil from both the raise and lower ports of the remote valve permitting the
cylinder to extend or retract freely. This feature is particularly useful to allow equipment such as scraper blades to
‘float’ or follow the ground contour.
When the remote valve operator control switch is moved to the float position the control spool is moved fully to the
right via pilot line oil from the solenoid control unit, supplied from gallery (I) .
Oil flow from the gallery (B) to the raise and lower ports is blocked by the land of the spool end.
The position of the spool causes the pin (7) on the lock valve to hold the valve in the open position.
The raise and lower ports of the remote valve are open to reservoir gallery (G) allowing a free flow of oil from one port
of the cylinder to the other.
Should a void occur in the circuit oil will be drawn by suction from one side of the cylinder to the other.
Figure 4
Single Remote Control Valve Operation-Float

2. Metering Land
7. Position Sensor
8. Micro Processor
9. Solenoid Valve
10. Pin
11. Lock Valve
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BAIL07APH322GSA 4
Single Remote Control Valve Operation-Float
Pilot Line Pressure
OPERATION OF TWO OR MORE CONTROL VALVES SIMULTANEOUSLY

Because the stack type remote valves have a common parallel input gallery and individual flow control valves it is
possible to operate two or more remotes simultaneously without loss of efficiency.
84276322A 31/05/2010
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This is achieved by the flow control spools which regulate flow through each remote valve irrespective of pump system
pressure.
If these valves were not fitted and two remotes were operating simultaneously at different pressures all oil would
attempt to flow to the light load circuit.
The following details the process of operating a single remote valve and then operating an additional remote valve at
the same time.
When a single service is operated the pressure in the parallel gallery is at pump pressure.
The pressure in the load sense line to the hydraulic pump is equal to the operating pressure of the working remote
valve.
Required flow through the electro-hydraulic remote valve is set by turning the operator controlled potentiometer in the
cab. The flow is then determined by the control valve spool which is electrically controlled by the control unit solenoid.
The pressure differential in combination with the spring acting on the ends of the flow control spool causes the spool
to move to a position of equilibrium which adjusts the flow across the spool metering lands (3).
The adjustment of flow across the metering land (3) produces a constant flow through the remote valve.
Pump Pressure
Return to Reservoir
Remote Valve Operating Pressure
Trapped Oil
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Single Remote Valve Operating
Remote Valve Operating Trapped Oil

Pressure
A. Remote Valve in Operation B. Remote Valves in Neutral

1. Parallel Gallery (Interconnecting Remote Valves 3. Spool Metering Lands
Sections)
Valves Sections)
5. Load Sense Line Check Valve
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve
BAIL06CCM023GSA 5
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84276322A 31/05/2010
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It is essential that the flow of oil through two or more remote valves operating simultaneously at different pressures is
individually controlled otherwise oil will always flow to the circuit operating at the lowest pressure.
When operating two or more hydraulic services the operating pressure in the parallel gallery is at the highest operating
pressure of the hydraulic system as sensed through the load sense line.
Check valves in the load sense line between each valve section ensure only the highest pressure is directed to the
pump flow pressure compensating valve.
In the same manner as for single remote valve operation the differential pressure across the flow control spool is
sensed and flow adjusted accordingly.
Because each remote valve is operating at a different pressure the flow control valve spools will move to different
positions to achieve a state of equilibrium.
The flow across the metering land (3) of the lower pressure operating remote valve will be different to the flow across
the metering land of the higher operating pressure remote valve.
The metering land on each flow control spool now maintains the required constant flow through the flow control re-
striction in each remote valve irrespective of the higher pump system pressure required to operate other hydraulic
circuits.
Pump Pressure
Lower Pressure Remote Valve Operation
High Pressure Remote Valve Operation
Return To Reservoir
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Two Remote Valves Operating
Pump Pressure Lower Pressure Remote

Valve Operation
High Pressure Remote Return To Reservoir
Valve Operation
A. Remote Valve Operating At High Pressure B. Remote Valve Operating At Lower Pressure
1. Parallel Gallery (Interconnecting Remote Valves 3. Spool Metering Lands
Sections)
Valves Sections)
5. Load Sense Line Check Valve
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BAIL06CCM025GSA 6
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valve - Static description
Electro-Hydraulic type remote valves are optional on all models of tractors with electro-shift transmission.
Each remote valve has its own built in microprocessor which controls the oil flow through a solenoid activated valve,
based on inputs received from the operator controlled switches.
Each remote valve is connected into the electrical CAN BUS system to the DU control module, located behind the
drivers seat. Each remote valve can also detect system faults and send a message to the DU module which in turn
sends a signal to allow a fault code to be displayed on the instrument cluster.
A list of fault codes and the fault finding charts can be found in Control module - Fault code index (A.50.A).
BSE3604B_486 1
Control Levers
The electro-hydraulic remote valves are operated by control levers in the right-hand console. Each control lever is
coloured to correspond to the colour on the remote valve. A maximum of four electro-hydraulic remote valves may
be fitted.
BRE1713 2
1 Control lever I Green 2 Control lever II Blue

3 Control lever III Brown 4 Control lever IV Black
The remote valve control levers have four positions: neutral, extend, retract, and float.
Pull the lever back from the neutral position, to the “extend" (raise) position. From neutral, push forward to the “retract"
(lower) position. Push the lever fully forward to the float position. Float will permit the cylinder to extend or retract
allowing equipment such as scraper blades to “float" or follow the ground contour.
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BRE1710B 3
NOTICE: The hydraulic master can be used to immediately stop operation of the rear remote valves. To do this bring
the switch into the mid position.
The “float" position is also used for retracting a single-acting cylinder and for the OFF position for hydraulic motors.
The extend, (1), neutral, (2), retract, (3), and float, (4), positions are identified by symbols on the decal adjacent to
each control lever.
BRF1858B 4
Isolator Switch
The remote valves will not operate unless the system is energised using the isolator switch (1). Press and release
the lower part of the switch to activate the system, press the upper part to de-activate. When activated the amber
warning light (2) will light. Once energised, the remote valves will operate whenever the tractor engine is running.
NOTICE: The isolator switch may be used to immediately stop operation of the rear remote hydraulics by quickly
depressing the top of the switch. The isolator switch only controls the remote valves and has no effect on three point
linkage operation.
BRE1712B 5
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Manual and Programmable Lever Operation

The Enhanced keypad is used to select and programme the timed functions for each of the electro-hydraulic remote
valves. As each remote valve is selected using the remote valve key (1), a visual display of the valve functions will
appear in the Dot Matrix screen.
Depress the key once to activate the remote valve display in the DMD. Repeated operation of the key will cycle through
each valve display individually.
BRE1567B_494 6
Manual Operation
When used in manual mode, without the timer function, the electronic remote valves will operate in a similar way to
the mechanical valves previously described.
NOTICE: Care must be taken when operating in the manual mode that the remote valve lever is not left in the detented
extend or retract positions when using remote cylinders. When the cylinder has reached the end of its stroke the
control lever must be returned to the neutral position manually. Failure to observe this procedure will overheat the oil
and may lead to failure of hydraulic or driveline components.
NOTICE: Never use the neutral position from the extend or retract position to stop a hydraulic motor. Sudden hydraulic
lock up of the system may cause extensive damage to the motor.
In manual mode, oil flow through each valve is adjusted using the flow rate setting as previously described.
Timed Programme Operation

Timed programme operation is provided primarily for operation of hydraulic cylinders. This feature allows the operator
to programme a time delay between when the control levers are activated and when the oil flow to the implement is
stopped.
To operate the electronic remote valves in programmed mode, depress the appropriate side of timer control switch (1)
as shown. When the switch is depressed, the green light adjacent to the switch will start to flash. The system is now
in standby mode ready to accept a programme sequence. The light will continue to flash for twenty seconds allowing
the operator sufficient time to begin the programming sequence. If a programme is not started within this period, the
system will automatically de-activate, depress the timer control switch again to restart the sequence.
BRE1702B 7
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Programming a Double Acting Service

To programme the remote valves, first ensure the cylinder hydraulic hoses are properly connected to the appropriate
rear remote valve. Start the tractor engine and set at the normal operating speed in which the cylinder is to be oper-
ated. This is important as the programming of the control levers is based on a time interval corresponding to the time
it takes the cylinder rod to extend and retract. Any change in engine rpm will have an effect on hydraulic flow and
therefore the time taken for the cylinder to extend and retract.
The timed period for control lever operation remains the same regardless of oil flow, therefore consistent operation is
required for the system to function correctly. Using the corresponding timer switch (1) depress the switch so the light
begins to flash. While the light is flashing move control lever (2) to extend the cylinder. At this point the light ceases
to flash and will remain on.
Hold the lever until the cylinder is extended to the desired position and then return the lever to the neutral position.
When the lever is returned to the neutral position the programming light will begin to flash again indicating the retract
phase of the cycle should now be programmed.
BRE1711B 8
Operate the control lever (2) to retract the cylinder (L) and the programming light will cease to flash and remain on.
Hold the lever until the cylinder has completed the retract cycle and then return to the neutral position. After the
second phase has been programmed the light will remain on.
Timed programme operation of the remote valve is now completed for both extend and retract movements of the
cylinder.
Repeat the above sequence to programme the remaining control levers.
BRE1711C 9
Programming of the control lever can be performed in either sequence, extend/retract, retract/extend or for one move-
ment only, extend or retract. The maximum allowable time span for any timed operation is 30 seconds.
NOTE: Turning the keystart switch OFF will erase the programme.
Programming a Single Acting Service

To programme a single acting service carry out the same setup procedure as previously described for a double acting
service.
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With the programme light flashing, move the remote valve lever from neutral to the extend position (R). When the
cylinder has extended to the desired position, manually return the lever to the neutral position. The programme light
will continue to flash but this should be ignored and the lever left in the neutral position. After 10 seconds the light
will cease to flash and will remain on, thus indicating the single acting programme has been memorised.
The single acting service can be programmed in both the extend and retract modes.
NOTE: When using a timed sequence for a single acting service i.e. programmed in extend mode only, the retract
mode will not function until the programme sequence has been deleted.
If the control lever is moved to the float position no timed programme is possible and the control lever must be returned
to neutral manually.
BRE1711B_487 10
Replaying a Timed Programme

The timed sequence begins as soon as the lever is placed in the extend or retract detent position. On reaching the
end of the timed period, oil flowing through the remote valve will be halted, the remote valve lever should now be
returned to the neutral position ready for the next operation. Throughout the replay sequence, the green warning light
will remain illuminated.
Deleting Programmes
To delete a programme, depress the programme switch to de-activate timer operation. The light will extinguish and
the memorised sequence will be cleared from the programme in the memory.
Relieving System Pressure

To ease removal and installation of the couplers, relieve the pressure in the system. Securely support the implement.
Make sure no one will be injured by moving equipment when relieving pressure in the system. Move the control lever
to the float position with the engine running. This will relieve the pressure. Turn the engine off with the control lever
still in float. After the engine is shut down return the control lever to the neutral position. The couplers can now be
connected or disconnected with minimal pressure and effort.
WARNING
Before connecting or disconnecting hydraulic hoses at the remote cylinders, relieve the pressure in the circuit
by first starting the engine and then move the control levers fully forward to the “float" position. Then stop
the engine. Make sure no one will be injured by moving equipment when relieving pressure in the system.
Before disconnecting cylinders or equipment, make sure the equipment or implement is supported securely.
Never work under equipment supported by a hydraulic device because it may drop if the control is actuated
(even with the engine stopped) or in the event of hose failure, etc. always use a secure support for equipment
which must be serviced while in the raised position. Make sure that oil contained within the remote cylinders
is clean and is of the correct grade.
B064
QUICK COUPLERS
Each remote control valve has a pair of 1/2 in.
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quick-disconnect, female couplers (1) and (2). The couplers are of a self-sealing/locking design but will allow remote
cylinder hoses to pull free if the implement should become disconnected from the tractor. The raise (lift) coupler (1),
is on the left-hand side, the lower (drop) coupler (2), on the right-hand side. The couplers referred to in this picture
are for remote control valve No. I.
The flip-up covers are colour coded black, brown, blue and green to corresponding to the control levers in the cab.
BRE1565B 11
Hinged, spring-loaded dust caps are provided on each coupler. To connect a remote cylinder, lift the dust cap (1) and
insert the feed and/or return hose into the coupler, ensuring that it is correctly seated. Ensure that there is sufficient
slack in the hose(s) to allow the tractor/implement to turn in either direction.
Actuate the remote valve to supply hydraulic pressure which will complete the hydraulic coupling of the tractor and
implement.
To disconnect, grip the hose a short distance from the coupler, push the hose forward, into the coupler, then quickly
pull on the hose to ‘pop’ the coupler free
The couplers will accept standard 1/2 in SAE or ISO connectors. The couplers can be connected or disconnected
under pressure. Disconnect pressure is proportional to system pressure. Increased system pressure will require
increased force to disconnect the couplers.
BRE1574B 12
NOTE: The oil flow through remote valve number one will always take priority over the other valves. For equipment
using more than one valve, the hydraulic service requiring the highest flow should be connected to valve number one.
Relieving System Pressure

To ease removal and installation of the couplers, relieve the pressure in the system. Securely support the implement.
Make sure no one will be injured by moving equipment when relieving pressure in the system. Move the control lever
to the float position with the engine running. This will relieve the pressure. Turn the engine off with the control lever
still in float. After the engine is shut down return the control lever to the neutral position. The couplers can now be
connected or disconnected with minimal pressure and effort.
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WARNING
Before connecting or disconnecting hydraulic hoses at the remote cylinders, relieve the pressure in the circuit
by first starting the engine and then move the control levers fully forward to the “float" position. Then stop
the engine. Make sure no one will be injured by moving equipment when relieving pressure in the system.
Before disconnecting cylinders or equipment, make sure the equipment or implement is supported securely.
Never work under equipment supported by a hydraulic device because it may drop if the control is actuated
(even with the engine stopped) or in the event of hose failure, etc. always use a secure support for equipment
which must be serviced while in the raised position. Make sure that oil contained within the remote cylinders
is clean and is of the correct grade.
B064
CONNECTING SINGLE-ACTING CYLINDERS

Connect the hose from a single-acting cylinder to the left lower coupler on the remote control valve, as previously
described
.
To extend a single-acting cylinder, pull the control lever back to the “extend" position (2).
Manually return the lever to the neutral position to stop the cylinder before it is fully extended or allow the valve to
return to neutral automatically when the cylinder reaches the end of its stroke and timed operation.
To retract a single-acting cylinder, move the lever fully forward to the “float" position (F).
NOTE: In single acting timer mode the remote lever will lock in the extend position and will not automatically return
to the neutral position.
NOTICE: Always use the “float" position to lower a single-acting cylinder. The “retract" position is for double-acting
cylinders only.
BRE1710B_488 13
CONNECTING DOUBLE-ACTING CYLINDERS

Connect the feed hose from a double-acting cylinder to the left hand coupler (1) on the remote control valve and the
return hose to the right hand coupler (2), as previously described. To extend a double-acting cylinder, pull the control
lever back to the “extend" position .
To retract a double-acting cylinder, push the control lever forward past neutral to the “retract" position . Further forward
movement of the lever will select “float" which will allow the cylinder to extend or retract freely. This feature is very
helpful when carrying out work with equipment such as scraper blades and loaders.
NOTE: To prevent cylinders creeping under load, always connect the hose from the load supporting side of the cylinder
to the left hand coupler.
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BRE1538B 14
OPERATING CONTINUOUS FLOW HYDRAULIC EQUIPMENT

Continuous flow hydraulic equipment (e.g., hydraulic motors) should be connected to the 1st remote control valve
couplers with the pressure hose connected to the right retract coupler and the return hose connected to the low pres-
sure return circuit.
BRE1710B_488 15
The flow control should be adjusted to regulate the motor speed. If the flow control is open too far, the 3-point hitch
and other remote valves will slow down or stop. Using the flow control this way will ensure that the hydraulic system
will only supply the oil required by the motor.
With the remote control valve lever fully forward in the “float" (4) position, the motor will be stationary. The hydraulic
motor will operate if the lever is pulled back to the “retract" (3) position. To stop the motor, move the lever from the
retract position to the float position. In the float position the motor will be able to stop slowly, which will not damage
the motor.
NOTICE: When operating continuous flow equipment, the remote control valve lever must not be moved rearward to
the neutral or raise positions as damage to the equipment may result.
Observe the following to further protect the tractor and equipment.
- Do not open any bypass valve in the equipment or motor. Use the flow control to regulate the rate of flow or speed
of the motor.
- Do not hold the remote control valve lever to operate the equipment.
- To ensure optimum hydraulic oil cooling, operate continuous flow equipment at the highest flow setting (by use of
the flow control) and lowest engine speed that will give the required machine performance and speed.
OPERATING SEVERAL REMOTE VALVES SIMULTANEOUSLY OR REMOTE VALVES AND

HYDRAULIC LIFT SIMULTANEOUSLY
If operating two or more remote control valves simultaneously or remote valves and the hydraulic lift, all the flow
control valves (1), should be adjusted using the enhanced keypad to provide a partial flow, as previously described.
If not so adjusted, all the available flow may be directed to the full flow circuit when the pressure in that circuit is less
than that of the other circuits in use.
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BRE1457E 16
NOTE: The oil flow through remote valve number one will always take priority over the other valves. For equipment
using of more than one remote valve, the hydraulic service with the highest flow requirement should be connected to
valve number one.
BRE1570B_489 17
BLEEDING REMOTE CYLINDERS

When connecting a cylinder with trapped air, i.e., a new cylinder, one that has been out of service or one that has had
the hoses disconnected, it will be necessary to bleed the cylinder to remove the air.
With the hoses connected to the remote control valve couplers at the rear of the tractor, position the cylinder with the
hose end uppermost and extend and retract the cylinder seven or eight times using the remote control valve operating
lever.
Check the rear axle oil level before and after operating a remote cylinder.
DESCRIPTION
The remote valves are a stack type design clamped together with the hydraulic lift electronic draft control valve (1).
The stack assembly also incorporates the low pressure regulating and priority valve .
BSE3604A_490 18
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BSE3659A_491 19
Electronic Draft Control and Closed Centre Remote Control Valve Stack
1 Solenoid 2 End Plate With Pressure Limiting Valve ( 20 - 22 bar)

3 Coupler 4 Remote Control Valve No IV
5 Remote Control Valve No III 6 Remote Control Valve No II
7 Remote Control Valve No I 8 Feed To Right Hand Lift Cylinder
9 Power Beyond Feed 10 Lift Cylinder Relief Valve ( 230 bar)
11 Low Pressure Relief Valve ( 28 - 33 Bar) 12 Power Beyond Return
13 Feed To Left Hand Cylinder 14 Wire Harness for Remote Valve Solenoids
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BSF4119A 20
Remote Control Valve and EDC Control Valve Interconnecting Galleries
Load Sensing Control Valve Pilot Oil
1 Control valve pilot line return oil 2 Control valve pilot line oil
3 Return to Reservoir Gallery 4 Load sensing Gallery
5 Pump Pressure Gallery 6 End Plate with Pressure Regulating Valve
7 Remote Valve IV 8 Remote Valve III
9 Remote Valve II 10 Remote Valve I
11 Electronic Draft Control Valve 12 Feed From Hydraulic Oil Pump
13 Return to Reservoir 14 Load Sensing Line
All valve sections have a common parallel inlet and return to reservoir gallery. The electro-hydraulic remote valve
sections also have common galleries for the control valve pilot pressure and return oil.
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The load sensing gallery passes through the centre of the valve stack and signals the pump to increase or decrease
output according to demand.
The parallel gallery and load sensing system enables two or more valves to be operated simultaneously without loss
of efficiency.
’O’ ring seals (1) and load sense check valves (2) between each valve section ensure the highest circuit load sense
pressure is transmitted to control output of the hydraulic pump.
BSB0388A_492 21
The principal hydraulic components within each Electro-Hydraulic remote control valve section are:-
Solenoid Control Unit - PCC Valve (Figure 23 )

A signal to operate a solenoid activated valve is received from the operator control switches into the microprocessor
of the control unit. The spool within the solenoid valve moves according to the forces of the solenoid which allows pilot
oil pressure, regulated to 20 - 22 bar, to act on the control valve spool. The control unit is also able to accurately sense
the position of the spool and can detect errors in the system, which, via the CAN BUS electrics, can be displayed as
fault codes which have a ’4***’ number.
Flow Control Spool (1).

Ensures that if more than one remote valve is operated that the available oil flow is proportionally distributed amongst
the valves being operated depending on demand. The flow control valve spool senses the differential pressure within
the valve and regulates the flow accordingly. Because each flow control spool individually senses the pressure in the
remote valve being operated, two or more circuits working at different pressures can be controlled simultaneously.
Load Hold Check Valve (2).

The check valve prevents a back flow of pressure from the remote valve circuit when the control spool is operated
and pump system pressure is less than the back pressure in the circuit.
This is explained by the following example:-

When a cylinder is holding a heavy load and the control valve spool is moved from the neutral to raise position, the
pump system pressure may be less than the back pressure in the remote valve circuit.
When this occurs the back pressure would cause oil in the circuit to flow backwards and the load to momentarily drop
before pump system pressure has risen to hold and then raise the load further. The load hold check valve prevents
this situation from occurring.
Lock Valve (5).

The lock valve is located in the raise port of the remote valve and is closed whenever the remote valve is in neutral.
The lock valve prevents leak down of an implement should there be any leakage across the lands of the spool when
in the neutral position. The lock valve is automatically opened whenever the control spool is moved from the neutral
position.
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Control Valve Spool (4).

The control valve spool is spring centred to a neutral position and when moved by the regulated pilot pressure, via
the solenoid control unit, directs oil flow to the raise or lower ports of the control valve.
Spool Centering Spring (3).

The spool centering mechanism spring loads the control valve spool to the neutral position.
BAIL07APH318ASA 22
Closed Centre Remote Control Valve Components
1 Flow Control Spool 2 Check Valve

3 Spring 4 Control Valve Spool
5 Load Holding Check Valve
BSD2037A 23
Control Unit Assembly
1 Solenoid Valve 2 Control Valve Spool

3 Centering Spring 4 Control Piston and Seal
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5 Position Sensor 6 Control Micro Processor
High pressure oil is supplied direct from the pump to the electro-hydraulic control via the end plate on top of the valve
stack (1). This oil is directed to the pilot oil supply in the control valve and is regulated to 20 - 22 bar by a pressure
reducing valve located in the end plate.
BSE3678A_493 24
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Remote control valve - Sectional view
BAIL06CCM034FSA 1
1 Micro processor unit 2 Solenoid valve

3 Load holding check valve 4 Control valve spool
5 Flow control spool 6 Lift check valve
7 Centering spring guide
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Mid-mount remote control valve - Static description

BRL6530B 1
1. Remote valve assembly 2. Return Hose

3. Loader Hose Pressure Ports 4. Loader Hose Return Ports
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BRL6531B 2
1. High Pressure Supply Hose 2. Pilot Return Line

3. Load Sensing Hose 4. Pilot Line Pressure Hose
5. Return Hose
Tractors equipped with the Mid Mount Valve option are fitted with an armrest mounted joystick, a mid mount valve
assembly, plumbing and loader mounting brackets ready for attaching the loader arms.
The Mid Mount Valve assembly is located underneath the cab on the right hand side. The base version has a two
spool valve for raising and lowering the boom and tipping and curling the bucket when used with a loader. Three and
four valve options are also available.
The valves are operated by means of a joystick control mounted on the right hand armrest of the seat. For front loader
operation an electronic joystick is utilised with a push button switch (1) mounted on the top side of the handle and a
proportional paddle switch (2) mounted on the side of the handle for EHR control.
BAIL08CVT039ASA 3
For front hitch operation a three button electronic joystick is used to control the mid mount valves.
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BAIL08CVT038ASA 4
The valves can also be operated by the remote levers also mounted on the armrest.
BAIL08CVT030ASA 5
On tractors equipped with both mid and rear mounted valves, the joystick can be used to control either valve pack. A
selector switch on the armrest console allows the operator to switch joystick control between the rear and mid-mount
remote valves. At key-on, the joystick indicator lamps will not illuminate and the joystick remains disabled. To activate
the joystick, momentarily depress the button Figure 6. The mid-mount valve indicator lamp will illuminate to confirm
activation. .
BAIL08CVT027ASA 6
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BRE1536B 7
1. Lock Button 2. Protective Cover

3. Alignment Holes 4. Clamp Handle
The mid mount valves are fed high pressure oil from the variable displacement pump located on the rear axle housing
on the right hand side.
The high pressure oil is fed into the inlet manifold through hose (1) .
BAIL08CVT037ASA 8
Return oil is fed back to tank via hose (1) to the suction filter
BAIL08CVT033ASA 9
Pilot line pressure is fed from the ‘T‘ connector on top of the transmission accumulator.
Pilot line return oil is fed back to tank by a hose connected to the transmission side cover.
Load sensing oil is fed from a hose connected by a ‘T‘ connector on top of the rear axle housing.
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Mid-mount remote control valve - Exploded view

BAIL06CCM125FSA 1
Mid Mount Valve Components
1. Spool Control Unit 2. Valve slice

3. Plug 4. Spool Valve
5. Load Sensing Valve 6. Check Valve
7. End Cap 8. Connection port
9. ’O’ Ring 10. Nut
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valve - Calibrate
NOTE: The calibration procedure is controlled by the electronic management system. To prevent inadvertent move-
ment of the tractor, firmly apply the parking brake and block the wheels, front and rear.
1. Install the diagnostic connector 380000843 into the
diagnostic socket (1).
BAIL06CCM213AVA 1
2. Disconnect all implements from the rear remotes.

3. Make sure all EHR program switches are switched
OFF.
4. Use the "up", "down" and "menu" keys on the ICU3 to
navigate the HH menu’s to H1 on the RP controller.
BAIL09HHP259FVB 2
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5. Select the rear EHR sub-menu using the "menu" key,

the top section of the display will display "CAL".
BAIL09HHP257AVB 3
6. Press and hold the program switch (1), for lever No.1
for at least 2 seconds until the display changes.
BAIL08CVT318 4
7. The calibration will proceed, the program lamp for

EHR 1 will be illuminated and the top section of the
display will show "1".
When the neutral position has been acquired and
stored, the program lamp is turned off and the top
section of the display will show "2".
BAIL09HHP260AVA 5
8. While "2" is displayed, move the lever to the raise

position, the program light will illuminate.
When movement is detected the program lamp for
EHR 1 is turned off. After the raise position is es-
tablished the top section of the display will change to
"3", the program light will switch off.
BAIL09HHP272AVB 6
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9. While "3" is displayed, move the lever to the full flow

lower position, the program light will illuminate.
When a stable value for the full flow lower position of
the lever is seen it is recorded with the minimum flow
rate value, the top section of the display will change
to "4", the program light will switch off.
BAIL09HHP273AVA 7
10. While "4" is displayed move the lever to the float po-
sition, the program light will illuminate.
When a stable value for the float position of the lever
is seen and recorded the top section of the display
will change to "CAL" to indicate the calibration pro-
cedure is complete.
BAIL09HHP274AVA 8
11. To calibrate the remaining EHR levers (2 to 4), repeat

the steps 6 to 10.
12. Key OFF to store the calibration values.
NOTE: If a lever is not calibrated the program lamp is
switched on regardless of the program switch state.
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Mid-mount remote control valve - Disassemble

Prior operation:
Mid-mount remote control valve - Remove (A.10.C)
BAIL06CCM092FSA 1
1. Inlet Manifold 2. Electronic Remote Valves

3. Tie Rod Nuts 4. End Plate
5. Tie Rod
1. Loosen and remove the tie rod nuts (3) from the end
plate (4) .
2. Remove the end plate .
3. Remove the remote valve slices (2) taking care not to
dislodge the load sensing valves and ’O’ rings seated
in the valve face.
4. Unscrew the tie rod bolts from inlet manifold
5. Refer to Mid-mount remote control valve - Ex-
ploded view (A.10.C) to view valve components
and Mid-mount remote control valve - Assemble
(A.10.C) for reassembly.
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Mid-mount remote control valve - Assemble

BAIL06CCM092FSA 1
1.Inlet Manifold 2.Electronic Remote Valves

3.Tie Rod Nuts 4.End Plate
5.Tie Rod
1. Insert the tie rods into the inlet manifold and screw in
by hand as far as they will go.
BAIL06CCM128ASA 2
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2. Push a shim onto the tie rods if any adhesive shims

have been used previously.
BAIL06CCM129ASA 3
3. Insert load sensing shuttle valve along with the ’O’

ring and support ring as shown in Figure 4 in port ’Y’.
Figure 5
NOTE: Clearance X should be approximately 0.5 mm from
the flange face of the valve segment to the top edge of the
inserted shuttle valve.
BAIL06CCM139ASA 4
4. Insert new ’O’ Rings (3) into the pressure and return
ports and also the load sense ’O Ring and support
ring (4).
BAIL06CCM131ASA 5
5. Insert new ’O’ Rings (5) into pilot line oil holes
BAIL06CCM132ASA 6
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6. Place the first valve slice onto the tie rods and insert
new ’O’ rings (6) into the relevant ports.
BAILCCM133ASA 7
7. If the flange face has corrugations that have been

smoothed with a dressing stone, one spacer (7) must
be threaded onto each tie rod. Insert the load sense
valve (8) and support ring as shown.
NOTE: Clearance X should be approximately 0.5 mm from

the flange face of the valve segment to the top edge of the
inserted shuttle valve.
BAIL06CCM134ASA 8
8. Insert the ’O’ rings (9) into the control oil holes.
BAIL06CCM135ASA 9
9. Push the last slice (10) onto the tie rods and insert
the ’O’ rings.
BAIL06CCM136ASA 10
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10. Fit the end plate (12).
BAIL06CCM138ASA 11
11. Push the end plate onto the tie rods and screw on
the nuts (13) by hand
BAIL06CCM140ASA 12
12. Place the now assembled valve stack onto a level

surface to correctly align the sections.
13. Tighten the nuts in the specified order and to the
correct torque. See figure 13
BAIL06CCM141ASA 13
Next operation:
Mid-mount remote control valve - Install (A.10.C)
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Mid-mount remote control valve - Remove

NOTICE: This procedure should be performed with the cab removed

1. Disconnect the negative cable from the battery and
insulate. Refer to Battery - Disconnect (A.30.A)
2. Disconnect the hoses and pipes from the remote
valve assembly
3. Disconnect the pilot line pressure hose (1) and the
load sensing hose (2)
NOTE: Drain all hoses into a suitable receptacle
BAIL06CCM062ASA 1
4. Disconnect the electrical connectors (1) .
BAIL06CCM063ASA 2
5. Undo the mid mount valve stack retaining bolts. (1) .

Remove valve stack from support.
WARNING
The remote valve assembly is heavy and must be re-
moved under the complete control of the technician to
prevent bodily injury.
M484
BAIL06CCM064ASA 3
Next operation:
Mid-mount remote control valve - Disassemble (A.10.C)
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Mid-mount remote control valve - Install

Prior operation:
Mid-mount remote control valve - Remove (A.10.C) Mid-mount remote control valve - Disassemble (A.10.C)
1. Place the remote valve assembly onto the support.
WARNING
The valve stack is very heavy DO NOT attempt to install
without the use of lifting equipment.
B037
2. Tighten retaining bolts (1) to 24 Nm 18 Foot pounds.
BAIL06CCM064ASA 1
3. Connect the harness connectors (1) to the remote

valve solenoids.
BAIL06CCM063ASA 2
4. Reconnect hoses and pipes..

5. If a new valve slice has been replaced or added it will
be necessary to reprogram the number of the valves
within the valve assembly. See Control module -
Configure (A.50.A) ..
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Index

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve -

10.C
Mid-mount remote control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
[Z9BE40001 - ], MAXXUM 115 Multicontroller [Z9BE60001 - ], MAXXUM 120 Multicontroller [Z9BE40001 - ], MAXXUM 120
Multicontroller [Z9BE60001 - ], MAXXUM 125 Multicontroller [Z9BE40001 - ], MAXXUM 125 Multicontroller [Z9BE60001 - ], MAXXUM
130 Multicontroller [Z9BE40001 - ], MAXXUM 130 Multicontroller [Z9BE60001 - ], MAXXUM 140 Multicontroller [Z9BE40001 - ],
MAXXUM 140 Multicontroller [Z9BE60001 - ]
Mid-mount remote control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mid-mount remote control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mid-mount remote control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Mid-mount remote control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mid-mount remote control valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Mid-mount remote control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - Calibrate . . . . . . . . . . . . . . . . . . . . . . 43
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - Dynamic description . . . . . . . . . . . . . 6
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - General specification . . . . . . . . . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - Special tools . . . . . . . . . . . . . . . . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - Static description . . . . . . . . . . . . . . 23
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PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remote control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical

remote valve - 10.D
MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 120 , MAXXUM 125 ,
MAXXUM 130 , MAXXUM 140
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Contents

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote

valve - 10.D
FUNCTIONAL DATA
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAXXUM 100, MAXXUM 110, MAXXUM 115, MAXXUM 125
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SYSTEM Open center mechanical remote valve

remote valve - Sectional view
BRH3316B 1
Single/double-acting auxiliary control valve with automatic detent release
1. Single/double-acting switching valve 2. Valve retaining plug

3. Seal 4. Seal
5. Seal 6. Check valve seat
7. Non-return valve 8. Seal
9. Seal 10. Control support
11. Control valve stem 12. Tapered needle
13. Spring 14. Seal
15. Detent balls 16. Seal
17. Seal 18. Internal plunger
19. Spring 20. Cover
21. Detent release pressure adjuster screw 22. Control valve stem return spring
23. Cup 24. Seal
25. Detent notch body 26. Detent ball support
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remote valve - Dynamic description
LIFTING - By pulling back the control lever (located in the cab) the control valve stem (2) shifts to connect the cylinder
bottom chamber with the delivery line (E) by way of the check valve (3) and line (G) and also the cylinder top chamber
with the exhaust line (L) by way of line (H), intercepting the supply of oil to the lift control valve. Keep the lever pulled
back, to extend the cylinder to its full stroke; on releasing the lever it will automatically return to the neutral position
under the action of the return spring, and the entire flow from the pump will be conveyed to the lift control valve by
way of lines (M).
MJS140208 1
Pressurised Oil
Suction Oil
Static Oil
LOWERING - To lower the implement, push the control lever (located in the cab). The control valve stem (2) will shift
to the position indicated in fig. 8 thus allowing the oil in the lower cylinder chamber to flow to the exhaust (L) through
the line (G), while the upper chamber is connected to the delivery line (E) through line (H) and check valve (3).
BRK5519B 2
LIFTING - By pulling back the control lever (located in the cab) the control valve stem (2) shifts to connect the cylinder
with the delivery line (E) by way of the check valve (3) and line (G). Line (H), for the control of double-acting cylinders,
is not used at this stage as it is permanently connected to the exhaust (L) by the open position of the switching valve
(1).
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A.10.D / 4
BRK5520B 3
LOWERING By pushing back the control lever (located in the cab) the stem (2) will shift to the position indicated in
fig. 10. The oil contained in the cylinder, pressurised by the weight of the lifted implement, will flow to the exhaust (L)
by way of line (G), while the entire flow from the pump is also conveyed to the exhaust (L) through the check valve
(3) and line (H).
BRK5510B 4
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OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SIN-

GLE/DOUBLE-ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT PO-
SITION
BRK5508B 5
LIFTING
By pulling back the control lever (located in the cab), the control valve stem (2) shifts and the detent balls (26) engage
the left hand groove, where they are held in place by the support (28) and spring (24). The movement of the stem
(2) (connects: delivery line (E) with the lower chamber of the cylinder, by way of the check valve (3) and the line (G),
and also the upper cylinder chamber with the exhaust line (L) by way of line (H), intercepting the supply of oil to the
hydraulic lift control valve. On completion of the lifting movement, the oil pressure increases to 170 - 175 bar (2465.0
- 2537.5 psi), acting through the port (Y), it overcomes the resistance of the spring of the tapered cap (23). Inside
chamber (T) the oil pressure increases and, acting on the support (28), it overcomes the resistance of the spring, thus
moving the support (28). In this condition the two detent balls (26) drop onto the support (28), releasing the stem (2)
which, under the action of the spring (6), returns to the neutral position, and consequently the entire flow from the
pump is conveyed to the lift control valve through lines (M).
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BRK5509B 6
LOWERING
To lower the implement, push forward the control lever (in the cab). The control valve stem (2) shifts and the detent
balls (26) engage in the central groove where they are held in position by the support (28) and the spring (24). In this
condition the oil contained in the lower chamber of the cylinder can flow to the exhaust (L) by way of line (G), while
the upper chamber is connected with the delivery (E) by way of line (H) and check valve (3) . On completion of the
lowering operation, the detent will be automatically released in the manner described previously.
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OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SIN-

GLE/DOUBLE-ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT PO-
SITION
BRK5507B 7
FLOAT OPERATION
For float operation push forward the control lever (in the cab). The control valve stem (2) shifts and the balls (26)
enter the right-hand groove, held in place by the support and spring (24) . In this position the stem (2) connects: the
two lines (M) providing the lift control valve with the entire pump flow and the two exhaust lines (L), by way of lines
(H) and (G) respectively with the upper and lower chambers of the cylinder. In this condition the only force exerted
on the implement will be that created by its own weight, thus allowing the implement to follow the profile of the terrain
and permitting the hydraulic lift to be used. With float operation the automatic detent release function is excluded, as
there will be insufficient pressure in the auxiliary control valve.
NOTE: To govern a double-acting cylinder you need to fully screw in the screw (1); to govern a single-acting cylinder
you need to unscrew it
BRK5511B 8
Single/double-acting switching valve
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A.10.D / 8
1. Single/double-acting switching valve 2. Seal

3. Valve retaining plug 4. Seal
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A.10.D / 9

remote valve - Static description
Two or three mechanical remote valves can be fitted with simple lever control. Implements can be connected and
disconnected under pressure. Non leak down valves are provided to ensure a raised implement will stay at a preset
height.
Figure 1 shows the trailer brake valve (1) which is bolted to the sub plate (4). The end plate (2) has an outlet pipe to
the hydraulic lift valve. The remote valves (3) are sandwiched between the sub plate (4) and the end plate (2).
BRH3303B 1
The rear auxiliary control valves are operated by the hand levers located on the right-hand side of the driving position
BRE1719C 2
Converting Remote Valves to Single or Double Acting Operation
Each remote valve is equipped with a screw (1) which converts the valve from double to single acting operation. See
Figure 3.
Single Acting: Unscrew the adjusting screw (1) fully outwards (anti-clockwise) until it stops. Do not overtighten.
Double Acting: Screw the adjusting screw (1) fully inwards (clockwise). Do not overtighten.
BRH3262B 3
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Index

SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote

valve - 10.D
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve - Dynamic description . . . . . . 4
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve - Sectional view . . . . . . . . . . . 3
PRIMARY HYDRAULIC POWER SYSTEM Open center mechanical remote valve - Static description . . . . . . . . 10
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SECONDARY HYDRAULIC POWER SYSTEM - 12.A

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Contents

SYSTEMS - A
TECHNICAL DATA
Hydraulic pump
General specification (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Hydraulic pump
Exploded view (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Regulator and lubrication valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic pump
Remove (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Visual inspection (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure test (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - SECONDARY HYDRAULIC POWER
SYSTEM
Hydraulic pump - General specification (Steering / Low Pressure)

Type fixed displacement gear type pump
38.5 l/min (8.5 UK gpm)
Minimum Output (new pump) @ 2200 RPM (engine)
10.2 US gpm
22 - 28 l/min (4.8 - 6.2 UK gpm)
Flow to steering motor
5.8 - 7.4 US gpm
Steering Pressure (maximum) 186 bar (2697 psi)
Regulated Low Pressure 17 - 19 bar (247 - 276 psi)
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SYSTEM
Hydraulic pump - Exploded view (Steering / Low Pressure)
BSD2033A 1
1 Bearing Block 2 Oil Seal

3 Plastic Backup Seal 4 O-ring Seal
5 Pump Housing 6 O-ring Seal
7 End Plate 8 Retaining Bolts
9 Drive Gears 10 Bearing Block
11 Oil Seal 12 Plastic Backup Seal
13 End Plate
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SYSTEM
Regulator and lubrication valve - Pressure test

The following test checks the operation of the cooler by–pass valve and lubrication valve and should be performed if
insufficient lubrication pressure is suspected.
NOTICE: Before performing any pressure or flow testing operate the tractor until the oil in the rear axle is at normal
operating temperature. 75 °C (167.0 °F).
1. Install the T-adaptor 380000580 (2) and the quick
release fitting 380000492 (1) into the oil cooler line.
380001145 (3), using the quick release coupler
380000543 and the hose 380000545.
BVE0170A 1
2. The following pressures should be observed at the

different engine rev/min.
5 bar (73 psi) @ 1000 RPM
6 bar (87 psi) @ 1500 RPM
9 bar (131 psi) @ 2000 RPM
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SYSTEM
Hydraulic pump - Remove (Steering / Low Pressure)

Prior operation:
Disconnect the battery cable - see Battery - Disconnect (A.30.A).
Drain the driveline oil - see REAR AXLE - Drain fluid (D.12.A).
WARNING
B026
1. Raise the rear of the tractor, place an axle stand (1)

under the right hand side final drive case and remove
the right hand side rear wheel.
24327 1
2. Using a suitable filter strap, remove the oil filter (1).
BVE0444A 2
3. Remove the steering / low pressure oil pump oil sup-

ply pipe.
BVE0446A 3
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SYSTEM
4. Disconnect the oil supply pipe from the steering / low

pressure oil pump.
BVE0447A 4
5. Remove the steering / low pressure oil pump.
BVE0448A 5
Next operation:
Hydraulic pump - Overhaul (Steering / Low Pressure) (A.12.A)
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SYSTEM
Hydraulic pump - Overhaul (Steering / Low Pressure)

Hydraulic pump - Exploded view (Steering / Low Pressure) (A.12.A)
Prior operation:
Hydraulic pump - Remove (Steering / Low Pressure) (A.12.A)
WARNING
B026
1. Disassembly the steering / low pressure oil pump and

view for partial damage or wear as described in Hy-
draulic pump - Visual inspection (Steering / Low
Pressure) (A.12.A).
2. Install new oil seals and O-rings. When installing
oil seals in the bearing block ensure that the plastic
back-up seal (1) is correctly positioned in the rubber
seal (2).
TIA35012 1
3. Install the driveshaft and driven gears into the hy-

draulic pump body, ensuring that the identification
marks (1) face in the same direction.
BVE0680A 2
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A.12.A / 8
SYSTEM

value.
BVE0675A 3
Next operation:
Hydraulic pump - Install (Steering / Low Pressure) (A.12.A)
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A.12.A / 9
SYSTEM
Hydraulic pump - Visual inspection (Steering / Low Pressure)

1. Wash all components using a suitable degreaser.
2. Inspect the O-ring seal groove and the shaft oil seal
recess in the mounting flange, these should be un-
damaged and free from burrs.
3. Examine the gears, shafts, and bearing blocks for
wear. The pump must be renewed if:
• The PTFE coated bearings (1) in the bearing blocks are

worn through revealing the bronze backing.
• The gear side faces are scored. This concern is often
caused by contaminated oil.
• There is a distinctive wear step on the side faces of the
gears and bearing blocks.
BVE0681A 1
NOTICE: When servicing the pump gears, particular attention must be paid to the following points:
• The width of each gear set must be within 0.005 mm
(0.0002 in) of each other to ensure satisfactory pump effi-
ciency.
• Journals must be within 0.013 mm (0.00051 in) of each
other.
• Gear faces must be flat. This feature may be checked us-
ing engineers blue on the bearing face and rotating against
the gear. This check will also reveal any sharp edges on
the teeth.
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SYSTEM
Hydraulic pump - Install (Steering / Low Pressure)

Prior operation:
Hydraulic pump - Overhaul (Steering / Low Pressure) (A.12.A)
WARNING
B026
1. Install the steering / low pressure oil pump. Tighten

the retaining bolts to the specified torque value.
BVE0448B 1
2. Connect the oil supply pipe to the steering / low pres-

sure oil pump. Tighten the retaining bolts to the spec-
ified torque value.
BVE0447B 2
3. Install the steering / low pressure oil pump oil sup-

ply pipe. Tighten the retaining bolts to the specified
torque value.
BVE0446B 3
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SYSTEM
4. Install a new oil filter (1).
BVE0444A 4
5. Install the right-hand rear wheel and remove the axle

stand (1) from under the right-hand final drive case.
For the tighten torque - see Rear wheel - Torque
(D.50.C).
24327 5
Next operation:
Connect the battery cable - see Battery - Connect (A.30.A).
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SYSTEM
Hydraulic pump - Pressure test (Steering / Low Pressure)

There is no pressure relief valve in the steering hydraulic pump. The following practical test will determine if the
steering hydraulic pump output is sufficient to allow satisfactory operation of the steering system.
Steering Test
1. Set the engine speed to 1100 RPM.
2. Quickly turn the steering from lock to lock.
If the steering is operating correctly the reaction
should be immediate with no time delay between
turning the steering wheel and the movement of the
wheels.
3. At full lock the relief valve in the steering motor
should be heard to blow and the engine speed drop
to approximately 970 RPM.
If on the 12x12 / 24x24 with fixed displacement pump
the transmission / steering low pressure warning
symbol is displayed when the steering is held on full
lock, this is an indication that the hydraulic pump has
developed an internal leak. Check the torque of the
hydraulic pump mounting bolts and if tight, examine
the hydraulic pump for leaking seals or wear.
BVE0400A 1
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Index

SYSTEMS - A

Hydraulic pump - Exploded view (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic pump - General specification (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic pump - Install (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic pump - Overhaul (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic pump - Pressure test (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic pump - Remove (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic pump - Visual inspection (Steering / Low Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Regulator and lubrication valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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HYDRAULIC COMMAND SYSTEM - 14.A

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Contents

SYSTEMS - A
TECHNICAL DATA
HYDRAULIC COMMAND SYSTEM
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic schema (Low Pressure Hydraulic Circuit - 12x12 Transmission) . . . . . . . . . . . . . . . . . . . . . . . . 14

Restrictor valve
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE
Leakage test Low Pressure Component (Variable Displacement Pump Systems) . . . . . . . . . . . . . . . . . . 23
Priority valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - HYDRAULIC COMMAND SYSTEM
HYDRAULIC COMMAND SYSTEM - Special tools
CAUTION
in this manual.
B008
Pressure Test Tools

Tool No. Description Alternative
previous No.
380000492 7/16" UNF male Quick release adaptor 297240
380000493 Adaptor M10 x 1.0p x 7/16 UNF female 297404
380000543 Quick release coupler 291924
X 380000545 Hose 292246
X 380000552 Pressure Gauge 0 - 40 bar (0 - 580 psi) 293242
380000572 Adaptor M10 banjo x 7/16 UNF female 297602
380000577 Adaptor 7/16 UNF female M12x1.5 male 297607
380001146 90° Quick Relaese fitting with adaptor M8 x 1.0 male 297241
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HYDRAULIC COMMAND SYSTEM - Static description

LOW PRESSURE HYDRAULIC CIRCUITS WITH 16x16 TRANSMISSION
With Reference to HYDRAULIC COMMAND SYSTEM - Hydraulic schema (Low Pressure Hydraulic Circuit -
16x16 Transmission) (A.14.A).
The function of the principal components in the circuit are described as follows:
High pressure oil from the variable displacement pump, via the trailer brake valve if fitted, is supplied to a flow dividing
and low pressure regulating valve, located in the lower slice of the remote valves and EDC assembly.
The oil is divided in the valve, depending on system demands and the oil destined for the low pressure system is
regulated to 17 - 18 bar (246.5 - 261 psi). High pressure oil is also fed to the end plate on top of the remote valves.
This oil is the pilot line supply for the Electro-Hydraulic remotes, excess oil is returned to sump.
BSE3604A_490 1
The low pressure distributor valve block is located under the cab on the left of the rear axle centre housing. The block
is fed oil directly from low pressure regulating valve line. Located in the valve block are the solenoid valves for the
4WD, creeper, differential lock, P.T.O and P.T.O. brake.
BSF3978A 2
1 Creeper Solenoid 2 Differential Lock Solenoid

3 PTO Clutch (PWM) 4 Four Wheel Drive Solenoid
5 PTO Brake Solenoid
NOTE: The four wheel drive is spring applied and the solenoid is energised whenever disengagement of the drive is
required.
The transmission top cover contains the transmission control solenoids for one to four and five to eight range engage-
ment and forward and reverse engagement.
The low pressure oil is again supplied direct from the regulating valve outlet and is distributed by galleries within the
top cover.
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Solenoid Function
SS09K026 3
1 5 - 8 Range Synchro Solenoid 2 1 - 4 Range Synchro Solenoid

3 Reverse Solenoid Clutch 4 Forward Solenoid Clutch
SS09K027 4
5 C4 Valve 6 C3 Valve
7 C2 Valve 8 C1 Valve
Transmission Creeper
The creeper actuating solenoid valve (1) is located in the low pressure distribution block on the left hand side of the
rear axle centre housing.
BSE3775A 5
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Lubrication Oil
Lubrication oil can be supplied from two sources. Lubrication oil is supplied from the return side of the steering motor
and from the charge pressure circuit via a supplementary lube valve.
The supplementary lube valve (1) is located in a three way elbow in the inlet tube to the steering pump.
The valve is rated at 0.8 bar (11.6 psi). When the pressure differential between the charge pump and the variable
displacement pump is more than 0.8 bar (11.6 psi), the surplus oil is directed pass the valve and into the lubrication
circuit.
BSE3589B 6
The steering pump / steering return oil is directed through the oil cooler at the front of the tractor and is limited to
a maximum pressure of 7 bar (101.5 psi) by the lubrication relief valve (1) located in the transmission side cover.
Components lubricated by this oil are the transmission shafts and clutches.
BSF4045A 7
When the oil is cold and pressure differential across the oil cooler is higher than 6 bar (87 psi) the cooler by-pass
valve (1) located on the right hand side of the transmission will operate to ensure that adequate flow to the lubrication
circuit is maintained.
This feature of diverting oil from the cooler assists in aiding a rapid warm up of oil in cold weather conditions.
BSE3773A 8
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BSF4044A 9
16 x 16 Transmission Top Cover
1 5-8 Solenoid 2 1-4 Solenoid

3 1-4/5-8 Synchroniser Position Potentiometer 4 Forward/Reverse Synchroniser Position
Potentiometer
5 Low Pressure Feed 6 Reverse Solenoid
7 Forward Solenoid
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BSF4042C 10
16 x 16 Transmission Top Cover
1 Reverse Solenoid 2 Forward/Reverse Rail

3 Forward/Reverse Shift Fork 4 Forward/Reverse Detent Assembly
5 Forward/Reverse Synchroniser Position 6 1-4/5-8 Synchroniser Position Potentiometer
Potentiometer
7 1-4/5-8 Shift Rail 8 1-4/5-8 Shift Fork
9 1-4/5-8 Detent Assembly 10 Piston
11 5-8 Solenoid 12 1-4 Solenoid
13 Piston 14 Forward Solenoid
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12x12 Transmission) (A.14.A). The function of the principal components in the circuit are described as follows:
Oil is drawn through the steering and low pressure circuit pump to the steering motor.
The flow of low pressure oil is diverted in one direction through the low pressure regulating valve and oil by pass
cooler valve and on to the services distribution block which diverts oil when needed to the Diff lock, PTO, and PTO
brake. The flow is also diverted through the services distribution block and returns to reservoir.
BSE3662A_448 11
The low pressure regulating valve in the top manifold (1) of the lubrication distribution block limits the pressure in this
circuit to 17 - 18 bar (246.5 - 261 psi) and the excess flow passes into the lubrication circuit.
Low pressure circuit oil is directed through the oil cooler at the front of the tractor and is limited to a maximum pressure
of 7 bar (101.5 psi) by the lubrication valve (2) which is also located in the manifold on top of the lubrication distribution
valve. Components lubricated by this oil are transmission shafts , hydraulic pump drive gear, hydraulic lift cross shaft
and PTO clutch lubrication.
When the oil is cold and pressure differential across the oil cooler is higher than 6 bar (87 psi) the cooler by-pass
valve (3) also located in the manifold on top of the lubrication distribution valve will operate to ensure that adequate
flow to the lubrication circuit is maintained. This feature of diverting oil from the cooler assists in aiding a rapid warm
up of oil in cold weather conditions.
SS09K028 12
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24x24 Transmission) (A.14.A). Oil is drawn through the steering and low pressure circuit pump to the steering motor
which feeds oil to the low pressure services manifold . The top section of the manifold houses the Oil Cooler by-pass
valve, low pressure regulating valve, and the lubrication relief valve.
BSE3662A_448 13
The low pressure regulating valve (1) mounted above the low pressure services block limits the pressure in this circuit
to 17 - 18 bar (246.5 - 261 psi) and the excess flow passes into the lubrication circuit.
SS09K029 14
The solenoids in the in the low pressure services block, are energised to divert flow and engage the creeper (where
fitted), differential lock, PTO clutch and brake and disengage four wheel drive.
NOTE: The four wheel drive is spring applied and the solenoid is energised whenever disengagement of the drive is
required.
BSE3745A 15
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Solenoid Function
BSF3978A 16
1 Creeper (Where fitted) 2 Diff lock

3 PTO 4 Four Wheel Drive
5 PTO Brake
The pulse width modulated solenoids in the transmission top cover are used to progressively engage/disengage the
transmission forward/reverse synchroniser.
BSE3770A 17
1 Reverse Synchroniser 2 Forward Synchroniser

3 Forward/Reverse Potentiometer
The dump solenoid (1) in the transmission side cover is a safety solenoid controlled by the pressure switches in the
A and B clutch circuits.
In the unlikely event that both these clutches are pressurised at the same time the dump solenoid is energised allowing
pressure in the circuit to be diverted to sump preventing ‘lock up’ of the transmission.
BSE3777A 18
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Low pressure circuit oil is directed through the oil cooler at the front of the tractor and limited to a maximum pressure
of 7 bar (101.5 psi) by the lubrication valve (2) located in the manifold on top of the lubrication distribution block on
the left hand side of the rear axle centre housing. Components lubricated by this oil are transmission clutches and
shafts, hydraulic pump drive gear, hydraulic lift cross shaft and PTO clutch lubrication.
When the oil is cold and pressure differential across the oil cooler is higher than 6 bar (87 psi), the cooler by-pass
valve (3) which is also located in the manifold on top of the lubrication distribution block on the left hand side of the
rear axle centre housing will operate to ensure that an adequate oil flow to the lubrication circuit is maintained. This
feature of diverting oil from the cooler assists in aiding a rapid warm up of oil in cold weather conditions.
SS09K012 19
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HYDRAULIC COMMAND SYSTEM - Hydraulic schema (Low

Pressure Hydraulic Circuit - 12x12 Transmission)
1 Steering Motor 2 Lubrication Relief Valve

3 Low Pressure Regulating Valve 4 Oil Cooler Bypass Valve
5 Low Pressure Services Manifold 6 Low Pressure Switch
7 Steering Pump 8 Filter
9 PTO Brake 10 PTO Clutch
11 Differential Lock 12 4WD Clutch

C Lubrication Oil D Low Pressure Oil
E Return To Reservoir F Suction Oil
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BSF4162B_ 1
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1 Steering Motor 2 Oil Cooler By-Pass Valve
3 Lubrication Control Valve Assembly 4 Transmission Control Solenoid Assembly
5 Variable Displacement Pump 6 Low Pressure Switch
7 Steering Pump 8 Subplate with Low Pressure Compensator Valve
11 Low Pressure oil distribution Manifold 12 Rear Differential Lock
13 Four Wheel Drive Clutch 14 Transmission Top Cover Solenoids
A High Pressure Circuit oil B Steering Circuit

C Lubrication Oil D Low pressure Circuit Oil
E Return To Reservoir F Suction Oil
G Charge Pump Oil
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BSF4150A_ 1
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1 Transmission Control Valve Assembly 2 Steering Motor
3 Pressure Switch 4 Lubrication Relief Valve
5 Low Pressure Regulating Valve 6 Oil Cooler By-pass Valve
7 Low Pressure Services Manifold 8 Low Pressure Switch
9 Steering Pump 10 Filter
13 Differential Lock 14 Four Wheel Drive Clutch
15 Forward and Reverse Solenoids 16 Lubrication Valve
A High Pressure Circuit Oil B Steering Circuit Oil

C Lubrication Circuit Oil D Low Pressure Circuit Oil
E Trapped Oil F Return To Reservoir
G Suction Oil
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BSF4162A_ 1
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Restrictor valve - Dynamic description

Operation of Low Pressure Regulating Valve
The regulated flow of oil discharged from the variable displacement piston pump is directed to the low and high pres-
sure hydraulic circuits via the trailer brake valve (where fitted) and the pressure regulating valve.
Because pump output is initially directed through the trailer brake valve, where fitted, the system ensures that the
trailer brakes have priority over other hydraulic circuits.
The pressure regulating valve, located in the bottom section of the remote valve and EDC block, controls the maximum
pressure of oil in the low pressure hydraulic circuit while at the same time directing high pressure system oil to the
hydraulic power lift and remote control valves.
he low pressure hydraulic circuit, which is at a pressure of 17 bar (246.50 psi) operates the electronic remote valve
spools (where fitted), P.T.O, differential lock, four wheel drive engagement system and transmission control circuits.
With reference to Figures 1, 2 and 3, operation of the pressure regulating valve is as follows:
When the pressure in the system is below 17 bar (246.50 psi) the Low-Pressure regulating valve is held to the left
by the spring allowing system pressure oil from the variable displacement piston pump to flow from gallery (E) to the
low pressure hydraulic circuits through gallery (F) to give flow priority to the low-pressure systems, Figure 1.
The resulting pressure in gallery (F) is sensed in the pressure sensing gallery (H) drilled through the centre of the
spool. As the pressure in gallery (F) increases, the spool moves against the spring restricting the flow of oil into gallery
(F) to maintain the pressure of oil in the low pressure hydraulic circuit at 17 bar (246.50 psi), while at the same time
allowing system pressure oil to flow into gallery (G).
When the high pressure hydraulic circuits are not in operation the variable displacement piston pump is on minimal
delivery and the pressure regulating valve spool directs most of the flow from gallery (E) to gallery (F), in order to
maintain the low pressure hydraulic circuit pressure of 17 bar (246.50 psi), Figure 2.
When the high pressure hydraulic circuits are in operation and the variable displacement piston pump has increased
delivery to satisfy demand, the spool moves almost totally against the spring in order to regulate the pressure of oil in
the low pressure hydraulic circuit, Figure 3.
It can now be seen that the spool moves back and forth to maintain the low pressure circuit oil at 17 bar (246.50 psi),
while at the same time allowing system pressure oil to be directed to the high pressure hydraulic circuit for operation
of the hydraulic lift and remote control valves.
To prevent any damage occurring due to excessive pressures in the low pressure hydraulic circuit, the low pressure
circuit safety valve will operate whenever the pressure increases to 30 bar (435.00 psi). Should this occur the safety
valve poppet will lift off its seat and vent the circuit to reservoir.
(A) Load Sensing Line from High pressure circuit (B) Return to Reservoir from flow and pressure
components. compensating valves.
(C) Gallery to Swash Plate servo piston from flow (D) System Pressure sensing gallery to flow and
and compensating valves pressure compensating valves
(E) System pressure supply to low pressure (F) Regulated Low pressure oil supply
regulating valve
(G) System pressure outlet from low pressure (H) Low pressure regulating valve spool sensing
regulating valve gallery
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System Pressure @ 205 bar

Return to Reservoir
(2972.5 psi)
Standby Pressure @ 22 bar
Low Pressure System
(319.00 psi)
Control Pressure
System pressure less than low standby pressure.
BSF4062C 1
System pressure at low standby, no high pressure demand.
BSF4062B 2
System pressure at high standby, high pressure demand.
BSF4062A 3
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Restrictor valve - Exploded view
BSE3807A 1
Power Beyond and Pressure Regulating Valve Manifold
1 Low Pressure Feed Connector 2 Seal

3 Seat 4 Valve
5 Seat 6 Spring
7 Shims 8 Manifold Body
9 High Pressure Inlet Feed Connector 10 Pressure Regulating Valve Spool
11 Seat 12 Spring
13 Shims 14 End Cap
15 Plug 16 Power Beyond Connector
17 Poppet Valve 18 Shims
19 Plug 20 Spring
21 Power Beyond Connector 22 Plug
23 Seat 24 Load Sensing Line Connector
25 Seat 26 Washer
27 Washer 28 Spring
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HYDRAULIC COMMAND SYSTEM - Leakage test Low Pressure

Component (Variable Displacement Pump Systems)
This test is performed to confirm that the suspected low pressure component has a pressure leak.
1. Install the flow meter between the inlet ports of the

remote control valves number 1 and number 2.
Set the hydraulic oil flow to maximum.
BVE0158A 1
2. Ensure the load valve on the flow meter is fully

‘Open’.
position and the remote control valve number 1 in the
‘Extend’ position.
5. Adjust the load on the flow meter to a pressure of
14.5 bar (210 psi).
6. Operate the suspected low pressure component, i.e.
four wheel drive, transmission clutches, differential
lock.
7. Observe the flow on the flow meter. The flow will
decrease to supply the component being operated
and should rise back to the original flow. If the flow
remains decreased, this indicates a pressure leak in
the low pressure components circuit being tested.
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Priority valve - Pressure test

The low pressure circuit can be checked on all models by removing the low pressure warning switch, located in the
low pressure distribution block on the left hand side of the rear axle.
Prior operation:
Apply the parking brake.
Remove the four wheel driveshaft - see Shaft - Remove (Standard axle) (D.14.C).
Models with suspended front axle:
Release the circlip and drift the sleeve backwards - as described in FRONT AXLE - Remove (Suspended Axle)
(D.10.A).
Raise the left hand rear wheel and place a suitable support under the axle casing. Remove the left hand rear wheel.
1. Install the adaptor 380000577 (1), 7/16 - 20 JIC male

x 7/16 - 20 UNF male (2) and the 90 ° quick release
fitting 380001146 (3).
380000543 and the hose 380000545.
Set the engine speed to 1500 RPM to observe the
system operation pressure or 2200 RPM for the max-
imum system pressure.
The pressure reading should be 17 - 19 bar (247 -
276 psi).
BVE0162A 1
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Low Pressure Component Tests

2. The components of the low pressure system, ie, the
PTO, PTO brake, Four Wheel Drive, Differential lock
and the Creeper can be tested from the test ports
located in the low pressure distribution block.
BVE0163A 2
Pressure Test Ports, Pressure Switches and Solenoid Valve Identification
A Side on view of manifold body B Below view of manifold body
1 Differential lock pressure switch 2 Differential lock test port

3 Low pressure warning switch 4 Four Wheel Drive test port
5 Four Wheel Drive pressure switch 6 PTO brake solenoid valve
7 Four Wheel Drive solenoid valve 8 PTO PWM solenoid valve
9 Differential lock solenoid valve 10 Creeper solenoid valve
11 PTO test port 12 PTO brake test port
13 Creeper test port
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3. Remove the fuel tank rear securing strap (1) from the
fuel tank support and pull the fuel tank out. This will
improve the access to the low pressure distribution
block.
BVE0164A 3
4. Remove the test port plug and install the adaptor

380000493 (1), 7/16 - 20 JIC male x 7/16 - 20 UNF
male (3) and the 90 ° quick release fitting 380001146
(2).
Install the adaptor 380000572 and the quick release
fitting 380000492 for the PTO brake pressure test.
• Test port thread M10 x 1.0
NOTE: Adaptor is shown in the Four Wheel Drive test port.
BVE0165A 4

380000543 (2) and the hose 380000545.
Set the engine speed to 1500 RPM to observe the
Operate the component to be tested, the pressure
reading should be 17 - 19 bar (247 - 276 psi).
NOTE: Pressure is only present at the four wheel drive
pressure test port when four wheel drive is disengaged.
Pressure is not present when four wheel drive is engaged
or the parking brake is applied.
BVE0166A 5
6. If there is no change in pressure when the compo-

nent is operated, but the low pressure system test
pressures are within specification. The fault could be
either with the solenoid or the wiring. Check for volt-
age at the respective connector. If +12 v is available
suspect the solenoid, if no voltage is seen suspect
the wiring.
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17th gear Clutch Pressure Test

7. Remove the test port plug and install the adap-
tor 380000493 (1) and the quick release adaptor
380000492 (2).
• Test port thread M10 x 1.0
BVE0619A 6

380000543 (2) and the hose 380000545.
Drive the tractor and change from gear 16 to gear
17. The pressure reading should be 17 - 19 bar (247
- 276 psi), when gear 17 is engaged.
CAUTION
Ensure the pressure hose does not touch any moving
part.
B005
BVE0620A 7
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Index

SYSTEMS - A

HYDRAULIC COMMAND SYSTEM - Hydraulic schema (Low Pressure Hydraulic Circuit - 12x12 Transmission) 14
HYDRAULIC COMMAND SYSTEM - Leakage test Low Pressure Component (Variable Displacement Pump Sys-
tems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
HYDRAULIC COMMAND SYSTEM - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC COMMAND SYSTEM - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Priority valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Restrictor valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Restrictor valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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ELECTRICAL POWER SYSTEM - 30.A
MAXXUM 100 , MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ] ,

MAXXUM 140
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Contents

SYSTEMS - A
TECHNICAL DATA
ELECTRICAL POWER SYSTEM
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 115 Multicontroller [Z7BE50001 - Z9BE60000 ],
Fuse and relay box

Alternator
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Battery
FUNCTIONAL DATA
Static description PROTECTING THE ELECTRONIC AND ELECTRICAL SYSTEMS DURING BATTERY
CHARGING OR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuse and relay box

Alternator
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Battery
Connector
Component Diagram 00 Connectors 00-09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Component diagram 01 Connectors 10-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54







Component diagram 08 Connectors 80-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Component diagram 09 Connectors 90-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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Component diagram 10 Connectors 100-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Component diagram 11 Connectors 110-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124











Component diagram 23 Connectors230-239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ]








Wiring harness
Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Electrical schematic frame 01 Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

MAXXUM 110 4v W/Cab 16x16, MAXXUM 115 4v W/Cab 16x16, MAXXUM 120 4v W/Cab 16x16, MAXXUM 125 4v
W/Cab 16x16, MAXXUM 130 4v W/Cab 16x16, MAXXUM 140 4v W/Cab 16x16
Electrical schematic frame 02 Engine 1 - Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

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Electrical schematic frame 03 Engine 1 - North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Electrical schematic frame 04 Engine 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396




Electrical schematic frame 08 Transmission 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404



Electrical schematic frame 11 EDC HYDRAULICS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410



Electrical schematic frame 14 EHR HYDRAULICS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418


Electrical schematic frame 16 FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

Electrical schematic frame 17 Power Take Off 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424


Electrical schematic frame 19 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

Electrical schematic frame 20 FAST STEER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Electrical schematic frame 21 Cab Accessory 1 - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Electrical schematic frame 22 Cab Accessory 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

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Electrical schematic frame 23 Cab Accessories 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

Electrical schematic frame 25 Main Lamps / Indicators 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440


Electrical schematic frame 27 Main Lamps/Indicators 3 - ISO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Electrical schematic frame 28 Main Lamps / Indicators 3 - NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Electrical schematic frame 29 Main Lamps / Indicators 3 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

Electrical schematic frame 30 Work Lamps - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Electrical schematic frame 31 Work Lamps - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452

Electrical schematic frame 32 Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

Electrical schematic frame 33 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456

Electrical schematic frame 34 Wipers - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

Electrical schematic frame 35 Wipers - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

Electrical schematic frame 36 Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

Electrical schematic frame 37 Processors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466


Electrical schematic frame 39 Air Con - Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470

Electrical schematic frame 40 Air Con Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472

Electrical schematic frame 41 Air Con Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474


W/Cab 16x16, MAXXUM 140 2v W/Cab 16x16
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Electrical schematic frame 27 Main Lamps / Indicators 3 - ISO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528














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MAXXUM 100 2v L/Cab 16x16, MAXXUM 110 2v L/Cab 16x16, MAXXUM 115 2v L/Cab 16x16, MAXXUM 125 2v
L/Cab 16x16, MAXXUM 140 2v L/Cab 16x16


















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MAXXUM 100 2v L/ Cab 24x24, MAXXUM 110 2v L/ Cab 24x24, MAXXUM 115 2v L/ Cab 24x24, MAXXUM 125 2v L/
Cab 24x24, MAXXUM 140 2v L/ Cab 24x24

















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W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12
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W/Cab 12x12

W/Cab 12x12

W/Cab 12x12
W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12
W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12


W/Cab 12x12
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W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

W/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12
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L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12
L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12
L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12
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L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12

L/Cab 12x12
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 972
Overview Earth points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 988

MAXXUM 110 Multicontroller, MAXXUM 115 Multicontroller, MAXXUM 120 Multicontroller, MAXXUM 125 Multicontroller,
MAXXUM 130 Multicontroller, MAXXUM 140 Multicontroller

MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 115 Multicontroller [Z7BE50001 -
Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 120 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 125
Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v
W/Cab 16x16, MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16
Electrical schematic frame 02 Starting and Charging - Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 992

Electrical schematic frame 03 Starting and Charging - Electrical Main Switch . . . . . . . . . . . . . . . . . . . . . 994


Electrical schematic frame 06 Engine 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000

Electrical schematic frame 07 Transmission 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002


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Electrical schematic frame 10 EDC Hydraulics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008

Electrical schematic frame 11 EDC Hydraulics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010



Electrical schematic frame 14 Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016

Electrical schematic frame 15 Power Take Off 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018

Electrical schematic frame 16 Power Take Off 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020

Electrical schematic frame 17 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1022

Electrical schematic frame 18 Cab Accessory 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024

Electrical schematic frame 19 Cab Accessory 1 - Electrical Main Switch . . . . . . . . . . . . . . . . . . . . . . . 1026

Electrical schematic frame 20 Cab Accessory 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1028

Electrical schematic frame 21 Cab Accessory 1 - LP Roof, Electrical Main Switch . . . . . . . . . . . . . . . 1030
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Electrical schematic frame 22 Cab Accessory 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032
Electrical schematic frame 23 Cab Accessory 2 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034

Electrical schematic frame 24 Main Lamps / Indicators 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036

Electrical schematic frame 25 Main Lamps / Indicators 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . 1038



Electrical schematic frame 28 Main Lamps / Indicators 3 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . 1044

Electrical schematic frame 29 Work Lamps 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1046

Electrical schematic frame 30 Work Lamps 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048

Electrical schematic frame 31 Work Lamps 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050

Electrical schematic frame 32 Work Lamps 2 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052

Electrical schematic frame 33 Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1054

Electrical schematic frame 34 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056

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Electrical schematic frame 35 Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
Electrical schematic frame 36 Wipers - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060

Electrical schematic frame 37 Mirror Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1062

Electrical schematic frame 38 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1064

Electrical schematic frame 39 Processors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066

Electrical schematic frame 40 Processors 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068

Electrical schematic frame 41 Air Con 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1070

Electrical schematic frame 42 Air Con 2 - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1072

Electrical schematic frame 43 Air Con 2 - Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074

Electrical schematic frame 44 Electronic Hydraulic Remotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1076

Electrical schematic frame 45 Armrest Control Unit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078



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Electrical schematic frame 48 Engine Harness Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
Electrical schematic frame 49 Electronic Front Hitch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086

Electrical schematic frame 50 Electronic Front Hitch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088

Electrical schematic frame 51 Turn Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1090

Electrical schematic frame 52 Electrical Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1092

SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1094
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1096
Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1098

Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100

Battery
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1107
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1109
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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111
DIAGNOSTIC
Battery
Testing Heavy Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
Testing Charging Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113

Testing Open Circuit Voltage Test - State of Charge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114

Testing Specific Gravity - State of charge test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114

Testing Flat or discharged battery suspected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115

Testing Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115

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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM
ELECTRICAL POWER SYSTEM - General specification

MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 115 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 120 Multicontroller
[Z7BE50001 - Z9BE60000 ], MAXXUM 125 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ],
MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 100, MAXXUM 110, MAXXUM 115, MAXXUM 120, MAXXUM 125, MAXXUM 130,
MAXXUM 140
Description All Models

Alternator ISKRA, 12 V, 120 A (optional 150 A)
Battery Minimum maintenance 12 V 176 Ah (1300 cca)
Starting motor Positive engagement, solenoid operated

4.2 kW - geared reduction
Cold starting aid Optional inlet manifold grid heater ( 80 A) and fuel heater
Bulb rating and type

- headlights 60/55 W - H4
- parking lights (front) 5 W - R5 W
- parking lights (rear) 5 W - P 21/5 W
- work lights (hi-mount rear, on C-pillar and grabrail) 12 V 55 W - H3
- turn indicators (front) 21 W - PY21 W
- turn indicators (rear) 21 W - R21 W or PY21 W
- stop lights 21 W - P 21/5 W
- licence plate lights 5 W - R5 W
- rotating beacon 55 W - H1
- interior / step light 12 V R 10 W
- HID Xenon work lights rear roof HID DIS 12 V 35 W
- work lights hood 12 V 50 W - GE886
- SMV (slow moving vehicle) lights (N. America only) 21 W-P21 W
and extremity lights
- roof front work lights 12.8 V 50 W - GE885
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Fuse and relay box - General specification

MAXXUM 140
Description of the relays

Relay Function
R1/R2 (K1/K2) Front windscreen wiper module and rear window wiper module
R3 (K3) Ignition Relay
R4 (K4) Side tail lights and illumination
R5 (K5) Starter
R6 (K6) Blower Motor
R7 (K7) Dipped beam headlamps
R8 (K8) Stoplamps
R9 (K9) Main beam headlamps
R10 (K10) Pneumatic trailer brake supply
R11 (K11) Hydraulic trailer brake supply
R12 (K12) Stoplamps switch feed and trailer brake pneumatic
R13 (K13) Supply EDC Control Unit, Vistronic Fuel / Grid Heater Relay
R14 (K14) Fuel shut off relay (only mechanical engine)
BRI4190C 1
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Relays 15 to 20 Function
R15 (K15) Worklamps Engine (Hood)
R16 (K16) Worklamps C- pillar rear
R17 (K17) Electronic supply
R18 (K18) Electronic battery isolator
R19 (K19) Air conditioner compressor clutch
R20 (K20) Electronic remote valve power ( not used for MAXXUM Multicontroller)
SS09K022 2
MAXXUM
SS09K023 3
MAXXUM Multicontroller
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Relays outside of the relay box

Relay Function
R21 (K21) Heated Mirror Timer Relay
R22 (K22) European Loader Relay 1
R23 (K23) European Loader Relay 2
K24 Fuel Heater Relay
K25 Grid Heater Relay
K26 Grabrail Worklamps LP Roof
K27 Rear Worklamps LP Roof
K28 Beacon LP Roof
K31 D+ Cut off front loader (only for MAXXUM Multicontroller)
SS09K008 4 SS09K011 5
MAXXUM MAXXUM Multicontroller
SS09K004 6 SS09K010 7
SS09K009 8
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Fuses
No. Amps Circuit
1 10 Interior light left / Puddle Lamp left and right / Handbrake
2 25 Cigar lighter / power studs
3 10 Air conditioning compressor Clutch
4 10 Accessory sockets
5 30 Blower motor
6 10 Radio / Worklamp ECU
7 20 Potential 30 / Main Light Switch / Hazard Switch
8 20 Potential 30 / Starter Switch
9 25 Supply Loader Option
10 - not used
11 10 Windshield Wiper, Front / Rear
12 10 Front and Rear Windshield Washer / Rear Wiper
13 15 Brake lights / Brake light relay K8
14 15 Potential 15 / Main Light Switch / Flasher Unit
15 20 Stoplamp Switch left - right / pneumatic relay K12 and pedal latch / Battery Isolator
16 15 Ital. Hydraulic and pneumatic trailer brake relay
17 25 Potential 15 / power socket 3-pin right rear cab
18 15 Potential 15 / blower relay air cushion electric seat
19 7,5 Potential 15 / Heated Mirrors
20 10 Potential 15 / Standartsignal Socket / Radar / ADIC Keypad
21 15 Brake Fluid Level Switch / Water in Fuel Sensor
22 15 Side Lamps RH / Spot light right
23 15 Side Lamps LH / licence plate lights / 7-pin trailer socket
24 10 Control panel right - switch illumination
25 15 Dip Beam Headlamps
26 15 Main Beam Headlamps
27 15 Engine Hood
28 15 Worklamp ECU, Roof Rear
29 30 Worklamps ECU, Roof Front, Grabrail
30 15 Worklamps Relay C-Pillar
31 15 Rotating Beacon
32 30 Potential 30 / Flasher Unit
33 25 Diagnostic Connector / Turn Assist
34 10 Potential 30 / ADIC Battery Positive
35 10 XCM Zentral - XCM Auxiliary Control Unit / Small Controller
36 10 Potential 15 / Instrument Cluster
37 15 Transmission Ignition
38 10 MAXXUM: Rear PTO Switch / Rear PTO Warning Light / HPL / Small Control
Module / Ground Speed PTO / Transmission Display
MAXXUM Multicontroller: Rear PTO Switch / Rear PTO Warning Light / HPL / PTO
Speed / Transmission Display / Armrest / Allwheel Drive Switch
39 10 MAXXUM: HPL / Armrest / Hand Trottle / EHR Levers
MAXXUM Multicontroller: Supply Hydraulicmaster

40 10 Potential 15 / Radio
41 15 Front PTO
42 10 Front Suspension / HPL
43 10 Engine ECU Activate
43 10 Supply Fuel shut Off Relay, Cigar Lighter, ADIC (only mechanical engine)
44 25 Potential 30 / Socket for-mounted equipment DIA
45 25 Potential 15 / 8AMP 2-pin mobil phone socket
46 15 Electronic engine ECU
47 10 Electronic engine ECU
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No. Amps Circuit

48 - not used
49 15 Supply K24/K25 Vistronic Fan
50 - not used
51 5 Turn assist steering system
52 15 Potential 15 / Relay K25/K24 Vistronic Fan (only for MAXXUM Multicontroller)
53 15 Potential 15 / Processor EDC (only for MAXXUM Multicontroller)
54 10 Potential 15 / Processor EDC (only for MAXXUM Multicontroller)
55 - not used
56 - not used
57 - not used
58 - not used
59 - not used
60 10 Battery isolator control
SS09K022 9
MAXXUM
SS09K023 10
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Maxi Fuses
No. Amps Fused components
MF1 80 Feeds F9, F11, F12, F13, F14, F15, F16, F17, F18, F19, F20, F21, F45, F51
MF2 80 Feeds F6, F7, F8
MF3 80 MAXXUM: Feeds F29, F30, F33, F34, F35
MAXXUM Multicontroller: Feeds F29, F30, F33, F34, F35, F52, F53, F54, F60
MF4 80 Feeds F27, F28, 3-Pin Power Socket Right Rear
MF5 80 Feeds F25, F26, F31, F32
MF6 80 MAXXUM: Feeds F1, F2, F3, F5, F44
MAXXUM Multicontroller: Feeds F1, F2, F3, F4, F5, F44, F49
SS09K022 11
MAXXUM
SS09K023 12
All Models
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Power Fuses
Fuse No. Amps Protected Supply
PF1 250 Main Supply
PF2 30 Electronics Supply
PF3 10 Electrical Battery Main Switch
SS09J070 13
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Alternator - Torque
MAXXUM 140
Value
Pulley Retaining Nut 80 Nm (59.0 lb ft)
Terminal Nut - B+ 12 Nm (8.9 lb ft)
Terminal Nut - D+ 3.5 Nm (2.6 lb ft)
Mounting Bolts 25 Nm (18.4 lb ft)
Alternator - General specification

MAXXUM 140
Polarity Negative Ground

Nominal Voltage 14.0 V
Maximum Rev/Min. - Permanent/Intermittent 15,000/18,000
Nominal Output 120 A / 150 A
Regulator Controlled Voltage 14.1 V +/- 0.15
Rotor Field Winding Resistance 2.7 Ω +/- 0.27 @ 23 °C (73.4 °F) ± 5 °C (41.0 °F)
(at 120 A / 150 A)
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Battery - General specification

MAXXUM 140
Description Battery Specification

Capacity (Ampere hour at 20 hour rate) 107 / 132
Cold Cranking Ampere Rating 800 / 960
Voltage 12
Cells 6
Ground Terminal Negative
Temperature Efficiency of a Fully Charged Battery

25 °C ( 77 °F) 100 %
-4.5 °C ( 23.9 °F) 82 %
-24.0 °C ( -11.2 °F) 64 %
-27.5 °C ( -17.5 °F) 58 %
-31.0 °C ( -23.8 °F) 50 %
-34.5 °C ( -30.1 °F) 40 %
-37.5 °C ( -35.5 °F) 33 %
107 Ah ( 800 cca) 132 Ah ( 960 cca)

Slow Charge Programs 25 hours at 5 A 30 hours at 5 A
12.5 hours at 10 A 15 hours at 10 A
Fast charge Program (emergencies only) 7 hours at 18 A 8.5 hours at 18 A
Use the following table to determine the state of charge

State of Charge Corrected Specific Gravity Corrected Specific Gravity Average Battery Next Testing Steps
@ 15 °C (59 °F) @ 25 °C (77 °F) Voltage
100 % 1.295 1.287 12.60 Proceed to Heavy
load test - see
Battery - Testing
(A.30.A).
75 % 1.253 1.246 12.40 Proceed to Heavy
load test Battery
- see Battery -
Testing (A.30.A).
50 % 1.217 1.210 12.20 Fully recharge
the battery before
performing heavy
load test.
25 % 1.177 1.170 12.00 Fully recharge
the battery before
performing heavy
load test. Refer to
table below.
Discharged 1.137 1.130 11.80 Battery discharged.
Slow recharge will
be required.
Specific Gravity Fast charge up to :

1.150 SG or less 60 minutes
1.151 - 1.175 SG 45 minutes
1.176 - 1.200 SG 30 minutes
1.201 - 1.225 SG 15 minutes
(Slow charge only)
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FAMM Battery Recharge Procedure (Voltage of a charged battery : 12.65 - 12.85 V)

Battery Voltage Recharge Current Recharge Time Recharge Voltage
V A h V
12.2 - 12.6 V 10 % of Nominal Ah 4 15.9 - 16.2 V
< 12.2 V 10 % of Nominal Ah 8 15.9 - 16.2 V
EXIDE Battery Recharge Procedure (Voltage of a charged battery : 12.65 - 12.85 V)

V A h V
12.45 - 12.65 V 10 % of Nominal Ah 6 14.7 - 14.8 V
12.2 - 12.44 V 10 % of Nominal Ah 8 14.7 - 14.8 V
< 12.2 V Sulphate crystals have been produced on electrodes - this requires the following
two separate charge sequences
First recharge sequence 1 24 14.7 - 14.8 V
Second recharge sequence 10 % of Nominal Ah 8 14.7 - 14.8 V
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ELECTRICAL POWER SYSTEM - Static description PROTECTING

THE ELECTRONIC AND ELECTRICAL SYSTEMS DURING BATTERY
CHARGING OR WELDING
MAXXUM 140
Precautions
To avoid damage to the electronic/electrical systems, always observe the following:
1. Never make or break any of the charging circuit connections, including the battery connections, when the engine
is running.
2. Never short any of the charging components to earth.
3. Do not use a slave battery of higher than 12 V nominal voltage.
4. Always observe correct polarity when installing the batteries or using a slave battery to jump start the engine.
Follow the instructions in the operator’s manual when jump starting the tractor. Connect positive to positive and
negative to negative.
5. Always disconnect the earth cable from the batteries before carrying out arc welding on the tractor or on any
implement attached to the tractor.
6. Position the welder earth cable clamp as close to the welding area as possible.
7. If welding is to be carried out in close proximity to a computer module, then the module should be removed from
the tractor. It is recommended that this procedure be carried out by an authorised dealer.
8. Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding
is in progress.
9. Always disconnect the negative cable from the batteries when charging the batteries in the tractor with a battery
charger.
WARNING
Batteries contain sulphuric acid. In case of contact with skin, flush the affected area with water for five min-
utes. Seek medical attention immediately. Avoid contact with the skin, eyes or clothing. Wear eye protection
when working near batteries.
B040
NOTICE: Failure to disconnect the two earth cable connections at the battery prior to charging the batteries or welding
on the tractor or attached implement will result in damage to the electronic and electrical systems.
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Fuse and relay box - Static description

MAXXUM 140
Fuses and Relays

NOTICE: Do not replace a blown fuse with another of a different rating.
The fuse box is located behind a panel on the top of the right hand control console.
To check or change fuses, remove the two screws securing the panel to the console.
In addition to the main fuses there are additional ’Maxi’ fuses which are provided to protect the main fuses and elec-
trical circuit.
BSE2778A 1
There is provision for 60 fuses although they may not all be fitted, depending on the specification of the tractor. The
fuses are numbered and colour coded
Refer to Fuse and relay box - General specification (A.30.A) for fuse positions and descriptions.
More relays are located behind the front of the right hand control console.
Refer to Fuse and relay box - General specification (A.30.A) for relay functions.
SS09K003 2
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The flasher relay unit (1), is located behind the right hand trim under the transmission control levers and ’Heated
Mirrors’ (2) relays.
INA 3 SS09K007 4
MAXXUM MAXXUM Multicontroller
Grid Heater relay, (1), located to the rear of the left hand side of the engine.
SS09K005 5
Grid Heater Fuse ( 125 Amp), (1), located on the right hand side of the engine near the starter motor.
BRI4561B 6
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In addition to the fuses in the internal fuse box, there are also extra fuses located on the battery tray. A 250 Amp
’MEGA’ fuse (1) which protects the main electrical system and one 30 Amp fuse (2) which protect the electronics
system supply and one 10 Amp fuse (3) witch protect the electrical battery main switch (where fitted).
SS09K002 7
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Alternator - Static description

MAXXUM 140
ISKRA 120 A (optional 150 A) alternators are fitted to all models. They incorporate internal cooling fans and integral
regulators. The alternator is mounted at the front on the right hand side of the engine and is driven from a crankshaft
pulley via a ‘poly vee’ drive belt.
BSE2983A 1
Alternator Operation
Refer to Wiring harness - Electrical schematic frame 01 (A.30.A) for charging circuit schematic.
When the key start switch is turned on a small current flows from the battery through the rotor field wiring. The circuit
is made via the charge indicator warning lamp, alternator terminal ‘D+’ the rotor field winding, the alternator regulator
and ground.
At this stage the warning light is illuminated and the rotor partially magnetised.
When the engine is started and the partially magnetised rotor revolves within the stator windings a 3-phase alternating
current is generated. A constant portion of the generated current is converted to direct current by the three field diodes
incorporated in the rectifier pack.
This direct current is fed back to supplement the current flowing through the rotor field winding.
This action results in an ever increasing magnetic influence of the rotor along with an associated rapid rise in gener-
ated output current and voltage.
During the rise in generated output voltage (reflected at the ‘D+’ terminal) the brilliance of the warning lamp is re-
duced and when the voltage at the ‘D+’ terminal equates to that at the battery side of the warning light the lamp is
extinguished.
The voltage continues to rise until the predetermined regulated voltage level is reached.
In the event of drive belt breakage the voltage will not build up within the alternator and so the charge indicator light
will remain on to indicate failure.
SS09G224 2
Alternator
1 Output Connection (B+ Terminal) 2 Warning Lamp (D+ terminal)
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Battery - Static description

MAXXUM 140
All models use a single “low maintenance - hybrid" battery with negative ground of six cell construction and is located
on the right hand side of the tractor behind the cab steps.
NOTE: "Low maintenance" means that under normal charging conditions the battery may lose a small amount of
water from the electrolyte. Conditions that may cause water loss include prolonged charging above 14.4 volts where
gassing occurs as it approaches full charge. This can be caused by a faulty charging system or boost/recovery charg-
ing equipment.
The battery has four major functions:
• To provide a source of current for starting, lighting and instrumentation.

• To help control the voltage in the electrical system.
• To furnish current when the electrical demands exceed the alternator output.
• To support quiescent loads from radio and micro processor memory.
The battery is constructed in such a manner that each cell contains positive and negative plates placed alternatively
next to each other. Each positive plate is separated from a negative plate by a non-conducting porous envelope
separator. If any of the positive plates should make contact with negative plates within a cell, the cell will short circuit
and suffer irreparable damage. All of the positive plates are welded to a bus-bar, forming a positive terminal and all
of the negative plates are welded to a similar bus-bar forming a negative terminal.
Each positive plate is composed of a lead grid with lead peroxide pasted into the grid openings. The negative plates
are composed of a lead grid with spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.
Battery Identification
Two manufacturers of batteries (FAAM and EXIDE), are used in production and it is important before servicing the
battery that the manufacturer is identified to ensure the correct testing and charging procedures are followed.
The batteries can be identified by their unique part number, which is stamped into the casing or by the positioning of
the manufacturers date code.
FAAM Battery Identification
SS09J041 1 SS09J039 2
• 14L 9 203 (14L x yyy) Date Code

• 14L - Production plant
• x - Year
• yyy - Day progressive number
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EXIDE Battery Identification
SS09J035 3 SS09J040 4
• 9J CW33 (xy - zzzz) Date Code

• x - Year
• y- Month (B-Jan, C-Feb, D-Mar, E-Apr, F-May, G-Jun, H-Jul, J-Aug, K-Sep, L-Oct, M-Nov, A-Dec)
• zzzz - Production plant
Part number identification

Manufacturer Part Number
FAAM 87303728
FAAM Option 87319423
EXIDE 82027433
EXIDE Option 5199958
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Connector - Component Diagram 00 Connectors 00-09

MAXXUM 140
C001 ENGINE TO CAB MAIN HARNESS CONNECTOR- E1
MAXXUM
POS. WIRE NUMBER CIRCUIT REFERENCE
1 5400D (Y) CAN H
2 5420D (G) CAN L
10 2556 (N) FRONT HITCH SWITCH COMMON RAIL
11 6305 (N) REVERSIBLE FAN OPTION - MOTOR FEED
13 6407 (O) ENGINE SHUTDOWN SIGNAL (EDC16)
14 6408D (G) FUSED B+ TO ECU (1)
15 6408A (G) FUSED B+ TO ECU (1)
16 6408B (G) FUSED B+ TO ECU (1)
17 6408C (G) FUSED B+ TO ECU (1)
18 1135 (G) THERMOSTART WARNING LAMP
19 650 (TQ) COOLANT LEVEL SWITCH
20 6418 (K) ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO K
22 2040 (LG) WATER IN FUEL SENSOR
23 6310 (N) FAN SOLENOID
24 3016 (S) BRAKE FLUID LEVEL SIGNAL
25 10G / 10J (G) IGNITION SUPPLY
26 1030B (U) HEADLAMP DIP BEAM
27 1030A (U) HEADLAMP DIP BEAM
28 6325 (N) REVERSIBLE FAN OPTION - RELAY FEED
29 1073A (L) WORKLAMP FRONT FEED
30 376 (L) HORN FEED
31 57AH (B) EARTH (ALL)
32 57AJ (B) EARTH (ALL)
33 57AK (B) EARTH (ALL)
34 39B (G) TEMPERATURE GAUGE SIGNAL
35 57AM (B) EARTH (ALL)
36 1027B (U) HEADLAMP MAIN BEAM
37 1027A (U) HEADLAMP MAIN BEAM
38 2095 / 2095A (G) INSTRUMENT SIGNAL GROUND
39 31 (Y) ENGINE OIL PRESSURE SENDER SIGNAL
40 2014 (G) ENGINE OIL PRESSURE SENDER (+5 VOLT)
41 1006 / 1006A (N) ALTERNATOR WARNING LAMP
42 1035 (W) ENGINE OIL PRESSURE WARNING LAMP
43 71C (W) IGNITION SWITCHED FEEDS (UNFUSED)
44 1005 (S) AIR CLEANER WARNING LAMP
45 1001S (W) STARTER SOLENOID FEED
46 1001T (W) STARTER SOLENOID FEED
47 2050AF (G) PTO SUPPLY / DOG SUPPLY
48 6300 (N) FAN SPEED
49 5020H (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
50 2019 (K) ENGINE RPM (TACHO MODULE TO TPM)
MAXXUM - Multicontroller
1 5400D (Y) CAN H
2 5420D (G) CAN L
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14 6408D (O) / 6408D (G) FUSED B+ TO ECU (1)
25 10G (G) IGNITION SUPPLY
26 1030Y (U) / 1030B (U) HEADLAMP DIP BEAM
27 1030Z (U) / 1030A (U) HEADLAMP DIP BEAM
28 39 (G) / - TEMPERATURE GAUGE SIGNAL
29 1073A (P) WORKLAMP FRONT FEED
30 376 (P) HORN FEED
31 57AH (B) EARTH (ALL)
32 57AJ (B) EARTH (ALL)
35 57AM (B) EARTH (ALL)
36 1027Y (U) / 1027B (U) HEADLAMP MAIN BEAM
37 1027Z (U) / 1027A (U) HEADLAMP MAIN BEAM
38 2095A (G) / 2095 (G) INSTRUMENT SIGNAL GROUND
39 31 (Y) / - ENGINE OIL PRESSURE SENDER SIGNAL
41 1006A (N) / 1006 (N) ALTERNATOR WARNING LAMP
42 1035 (W) / - ENGINE OIL PRESSURE WARNING LAMP
43 71D (W) / 71C (W) IGNITION SWITCHED FEEDS (UNFUSED)
50 2019 (K) / - ENGINE RPM (TACHO MODULE TO TPM)
NOTE: For the wiring color code refer to, Wiring harness - Overview (A.30.A).
MAXXUM
BRI4400B 1 BRI4400B-01 2
RIGHT HAND SIDE FRONT CAB FLOOR
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SS08F114 3 BRI4400B-01 4
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C004 OIL PRESSURE LIGHT SWITCH

C004VBRK5703A 5 SS08K527 6
LEFT HAND SIDE ENGINE - MECHANICAL ENGINES ONLY
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C006 STARTER SOLENOID

1 150B (B) BATTERY FEED (UNFUSED)(ALL)
1 1001 (W) STARTER SOLENOID FEED
BRI4401B 8
C006V-BRI4401E 7
RIGHT HAND SIDE REAR ENGINE
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C007 BRAKE FLUID RESERVOIR LEVEL SWITCH
MAXXUM
1 10H (G) IGNITION SUPPLY
MAXXUM
C007V-BRI4402E 9 BRI4445B-03 10
TOP OF ENGINE
SS08F105 11 SS08F092 12
TOP OF ENGINE
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C009 AIR CLEANER VACUUM SWITCH

1 57JB (B) EARTH (ALL)
C009V-BRI4523E 13 BRI4445B-03 14
RIGHT HAND SIDE ENGINE
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Connector - Component diagram 01 Connectors 10-19

MAXXUM 140
C010 AIR CONDITIONING COMPRESSOR

1 1018 (G) AIR CONDITIONER CLUTCH
2 57JC (B) VEHICLE EARTH (ALL)
SS08F106 1 SS08K508 2
LEFT HAND SIDE ENGINE
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C011 AIR CONDITIONING PRESSURE SWITCH
1 2006A (U) DE-ICING SWITCH - AIR CONDITIONER
2 2006B (U) DE-ICING SWITCH - AIR CONDITIONER
3 2007 (Y) AIR CONDITIONER LOW PRESSURE
4 5200 (N) EDC VALVE SUPPLY
MAXXUM
A 2006A (U) DE-ICING SWITCH - AIR CONDITIONER
B 2006B (U) DE-ICING SWITCH - AIR CONDITIONER
C011V BRI4524E 3 SS08F107 4
RIGHT HAND SIDE FRONT TOP ENGINE
MAXXUM
INA 5 SS08M001 6
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C012 COOLANT TEMPERATURE SENDER

A 39A (G) TEMPERATURE GAUGE SIGNAL
B 39B (G) TEMPERATURE GAUGE SIGNAL
C 57FN (Y) EARTH (ALL)
C012VBRF1865A 7 C003C-BRK5702B 8
FRONT OF ENGINE - MECHANICAL ENGINES ONLY
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C013 ALTERNATOR

1 1006 (N) ALTERNATOR WARNING LAMP
1 150 (N) BATTERY FEED (ALL)
MAXXUM
C013-BRI4528A 9 BRI4430B 10
RIGHT HAND SIDE FRONT ENGINE
SS08F240 11 SS08F115 12
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C014 STEERING ANGLE SENSOR
MAXXUM
1 3100 (G) STEERING SENSOR +5v
2 3120 (K) STEERING SENSOR SIGNAL
3 3140 (LG) STEERING SENSOR GROUND
4 2095 (G) INSTRUMENT SIGNAL GROUND
MAXXUM
C014-BRI4526A 13 SS08F108 14
RIGHT HAND SIDE BOTTOM FRONT ENGINE
SS08F109 15 SS08F108 16
RIGHT HAND SIDE BOTTOM FRONT ENGINE
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C015 ELECTRICAL SHUT OFF SOLENOID

1 (B)
NOTE: For the wiring color code refer to, . Wiring harness - Overview (A.30.A).
SS09D354 17 SS09D353 18
LEFT HAND SIDE ENGINE - MECHANICAL ENGINE ONLY
C017 WATER IN FUEL SENSOR

1 2040 (G) WATER IN FUEL SENSOR
2 57JE (B) EARTH (ALL)
3 10J (G) IGNITION SUPPLY
C017V-BRI4443E 19 SS08F069 20
BOTTOM LEFT HAND SIDE REAR ENGINE
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C019 EXTENSION HARNESS CONNECTOR T1 (ELECTRONIC)
MAXXUM
1 3024 (Y) / 3024 (Y/K) 2WD SOLENOID
2 7005 (U) / 7005 (U/L/B) TRANS CREEPER GR SOL
3 7080 (LG) / 7080B (LG) DIFF-LOCK SOLENOID FEED
4 2130 (N) / 2130 (B/N/S) PTO BRAKE SOLENOID
5 2051 (O) / 2051 (TQ) PTO SOLENOID RETURN (-)
6 2042 (O) / 2042 (O/S) PTO SOLENOID-REAR
7 2140 (O) / 2140 (B/O/S PTO SPEED SENSOR
8 2062 (W) / 2062 (W/LG/S) PTO TWIST SENSOR
9 2016A (Y) / 2016A (Y/G) REAR AXLE SPEED SENSOR-SIGNAL
10 6000 (K) / 6000 (K/LG/S) ENGINE SPEED SIGNAL
11 7321 (L) / 7321 (L/Y/B) SOLENOID 2 18x9 RETURN
12 7320 (W) / 7320 (W/N/B) SOLENOID 2 18x9 TRANSMISSION
13 7301 (Y) / 7301 (Y/LN/B) SOLENOID 1 18x9 RETURN
14 7300 (W) / 7300 (W/LG/B) SOLENOID 1 18x9 TRANSMISSION
15 7815 (K) / 7815 (K/O/B) TRANS PWM SOLENOID C1 RETURN
16 7810 (K) / 7810 (K/N/B) TRANS PWM SOLENOID C1
17 7820 (K) / 7825 (K) / 7825 TRANS PWM SOLENOID C2 / TRANS PWM SOLENOID C2 RETURN
(K/R/B)
18 7820 (K) / 7820 (K/L/B) / 7825 TRANS PWM SOLENOID C2 / TRANS PWM SOLENOID C2 RETURN
(K)
19 7835 (K) / 7835 (K/U/B) TRANS PWM SOLENOID C3 RETURN
20 7830 (K) / 7830 (K/S/B) TRANS PWM SOLENOID C3
21 9036 (LN) / 9036 (LN/L/Y) 50KPH DUMP SOLENOID RETURN
22 7840 (K) / 7840 (K/W/B) TRANS PWM SOLENOID C4
23 8045 (L) / 8045 (L/LN/S) TRANS REV SOL RET
24 8040 (LG) / 8040 (LG/L/S) TRANS REV SOLENOID
25 8035 (L) / 8035 (L/LG/S) TRANS FWD SOL RET
26 8030 (LG) / 8030 (LG/O/S) TRANS FWD SOLENOID
27 7581 (O) / 7581 (O/L/B) CREEPER POSITION SIGNAL
28 7670 (R) / 7670 (R/S/Y) TRANS FRONT SYNCHRO POSITION
29 9035 (LN) / 9035 (LN/W/B) 50KPH DUMP SOLENOID
30 7960 (L) / 7960 (L/K/B) TRANS SLOW/FAST
31 7500 (G) / 7500 (B/G) TRANS OIL TEMP. SENSOR
32 5097 (K) / 5097 (K/G/B) EDC VALVE DOWN RETURN
33 5090 (K) / 5090 (K/R) EDC VALVE DOWN
34 5087 (K) / 5087 (K/U/B) EDC VALVE UP RETURN
35 5085 (K) / 5085 (K/U) EDC VALVE UP
36 5070 (LN) / 5070 (LN/LG) EDC LEFT PIN
37 5075 (K) EDC VOLTAGE TO PINS
38 5065 (LN) / 5065 (LN/L) EDC RIGHT PIN
39 9033 (LN) / 9033 (LN/R) 50KPH SOLENOID+
40 9034 (LN) / 9034 (LN/B) 50KPH SOLENOID-
41 7000J (U) / 7000J (U/R/B) TRANS CONTROL SUPPLY
42 7220 (S) / 7220 (S/N/B) TRANSMISSION HIGH RANGE
43 7230 (S) / 7230 (S/O/B) TRANSMISSION LOW RANGE
44 7525B (G) / 7525B (G/B/S) TRANS SENSOR SUPPLY 5v
45 60A (B/W) SENSOR GROUND
46 5080 (K) / 5080 (K/N) EDC ROCKSHAFT
47 5020A (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
49 3500 (W) / 3500 (W/B/S) POWER STEERING PRESSURE SIGNAL
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1 3024 (Y) 2WD SOLENOID
2 7005 (U) TRANS CREEPER GR SOL
3 7080 (G) DIFF-LOCK SOLENOID FEED
4 2130 (N) PTO BRAKE SOLENOID
5 2051 (O) PTO SOLENOID RETURN (-)
6 2042 (O) PTO SOLENOID-REAR
7 2140 (O) PTO SPEED SENSOR
8 2062 (W) PTO TWIST SENSOR
9 2016A (Y) REAR AXLE SPEED SENSOR-SIGNAL
10 6000 (K) ENGINE SPEED SIGNAL
11 7321 (P) SOLENOID 2 18x9 RETURN
12 7320 (W) SOLENOID 2 18x9 TRANSMISSION
13 7301 (Y) SOLENOID 1 18x9 RETURN
15 7815 (K) TRANS PWM SOLENOID C1 RETURN
16 7810 (K) TRANS PWM SOLENOID C1
21 9036 (N) 50KPH DUMP SOLENOID RETURN
23 8045 (P) TRANS REV SOL RET
24 8040 (G) TRANS REV SOLENOID
25 8035 (P) TRANS FWD SOL RET
26 8030 (G) TRANS FWD SOLENOID
27 7581 (O) CREEPER POSITION SIGNAL
28 7670 (R) TRANS FRONT SYNCHRO POSITION
29 9035 (N) 50KPH DUMP SOLENOID
30 7960 (P) TRANS SLOW/FAST
31 7500 (G) TRANS OIL TEMP. SENSOR
32 5097 (K) EDC VALVE DOWN RETURN
33 5090 (K) EDC VALVE DOWN
34 5087 (K) EDC VALVE UP RETURN
35 5085 (K) EDC VALVE UP
36 5070 (N) EDC LEFT PIN
38 5065 (N) EDC RIGHT PIN
39 9033 (N) 50KPH SOLENOID+
40 9034 (N) 50KPH SOLENOID-
41 7000J (U) TRANS CONTROL SUPPLY
42 7220 (S) TRANSMISSION HIGH RANGE
43 7230 (S) TRANSMISSION LOW RANGE
44 7525B (G) TRANS SENSOR SUPPLY 5v
46 5080 (K) EDC ROCKSHAFT
47 5020A (N) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
49 3500 (W) POWER STEERING PRESSURE SIGNAL
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MAXXUM
C019-BRI4405A 21 BRI4400B-02 22
SS08F117 23 BRI4400B-02 24
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MAXXUM 140
C020 EXTENSION HARNESS CONNECTOR T2 (CAB)
MAXXUM
1 29 (G) /29 (G/B) MAIN FUEL SENDER SIGNAL
2 1013D (R) RIGHT HAND LAMPS
3 1014E (R/B) / 1014E (R) LEFT HAND LAMPS
4 810A (G/L) / 810A (G) STOPLAMPS
5 349 (LN) / 349 (LN/R/B) TRAILER TURN LAMPS RH
6 350 (LN) / 350 (LN/W/B) TRAILER TURN LAMPS LH
7 7845 (K) / 7845 (K/Y/B) TRANS PWM SOLENOID C4 RETURN
8 3286 (LN) / 3286 (LN/K/Y) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
9 7160 (R) / 7160 (R/N/B) HYD LOW CHARGE WARNING
10 3281 (LN) / 3281 (LN/B/Y) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
12 2095B (G) / 2095B (G/W/B) INSTRUMENT SIGNAL GROUND
13 1000A (W) / 1000D (W/Y) / 3270 SAFETY START SWITCH SUPPLY / LOWER SOLENOID RET
(O) / 3270 (O/L/S)
14 1001 (W) / 1001 (W/R) / 3250 STARTER SOLENOID FEED / RAISE SOLENOID RET
(O) / 3250 (O/G/S)
15 7126 (LG) / 7126 (LG/O/U) DIFF LOCK PRESSURE SWITCH
16 3240 (O) / 3240 (O/B/S) RAISE SOLENOID PWR
17 3045 (Y) / 3045 (Y/U/S) FOUR WHEEL DRIVE WARNING LAMP
18 3260 (O) / 3260 (O/N/S) LOWER SOLENOID PWR
19 7581A (O) / 7582 (U) / 7582 CREEPER POSITION SIGNAL / CREEPER RAIL SWITCH NOT
(U/S/Y)
20 8010A (LN) / 8010A (LN/W/B) TRAILER BRAKE PRESSURE
21 8000A (N) / 8000A (N/TQ/B) TRAILER BRAKE SOLENOID
22 8000X (N) / 8000X (N/TQ/B) TRAILER BRAKE SOLENOID
23 3024 (Y/K) / 3025A (Y) / 3280 2WD SOLENOID / FOUR WHEEL DRIVE SOLENOID (MANUAL) /
(O) / 3280 (O/U/S) SUSPENSION LOCKOUT SOLENOID UPPER
24 8010 (LN) / 8010 (LN/W/B) TRAILER BRAKE PRESSURE
25 57BK (B) EARTH (ALL)
26 8020 (LN) / 8020 (LN/K/B) TRAILER BRAKE PRESSURE
27 8060D (U) / 8060D (U/B/S) TRAILER BRAKE SUPPLY
28 2012 (Y) / 2012 (Y/O) TRANS OIL PRESSURE WARNING LAMP
29 7080 (LG) / 7080 (B/LG) / 3285 DIFF-LOCK SOLENOID FEED / SUSPENSION LOCKOUT SOLENOID
(LN) / 3285 (LN/G/Y) LOWER
30 5515 (S) EHR +12V IGN.
31 5500 (R) EHR CAN HIGH
32 5510 (U) / 2050M (G) EHR CAN LOW / PTO SUPPLY / DOG SUPPLY
33 6000B (K) ENGINE SPEED SIGNAL
39 4022 (S) / 4022 (S/B) BACK-UP ALARM FEED
40 57AA (B) EARTH (ALL)
41 60 (B/W) / 60A (B/W) SENSOR GROUND
42 7500 (G) / 7500 (B/S) TRANS OIL TEMP. SENSOR
43 2050 (G) / 2050L (G) / 2050M PTO SUPPLY / DOG SUPPLY
(G)
44 2140 (O) / 2140 (B/O/S) PTO SPEED SENSOR
45 2042 (O) / 2042 (O/S) PTO SOLENOID-REAR
46 2051 (O) /2051 (O/TQ) PTO SOLENOID RETURN (-)
47 2130 (N) / 2130 (B/N/S) PTO BRAKE SOLENOID
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48 7130 (B/N) / 7130A (N) HYD FILTER WNG LP
50 2016 (Y) / 2016 (Y/G) / 2016 REAR AXLE SPEED SENSOR-SIGNAL
(B/N/S)
51 7000T (U) / 7000P (U/R/B) TRANS CONTROL SUPPLY
1 29 (G) / 29 (G/B) MAIN FUEL SENDER SIGNAL
3 1014E (R) LEFT HAND LAMPS
4 810A (G) STOPLAMPS
5 349 (N) TRAILER TURN LAMPS RH
6 350 (N) TRAILER TURN LAMPS LH
8 3286 (N) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
9 7160 (R) HYD LOW CHARGE WARNING
10 3281 (N) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
11 2055A (W) / 2055 (W) PTO SYNCHRO GROUND SPEED ENGAGED
12 2095B (G) INSTRUMENT SIGNAL GROUND
13 3270 (O) LOWER SOLENOID RET
14 3250 (O) RAISE SOLENOID RET
15 7126 (G) DIFF LOCK PRESSURE SWITCH
16 3240 (O) RAISE SOLENOID PWR
17 3045 (Y) FOUR WHEEL DRIVE WARNING LAMP
18 3260 (O) LOWER SOLENOID PWR
19 7582 (U) CREEPER RAIL SWITCH NOT
20 8010A (N) / 8010A (LN) TRAILER BRAKE PRESSURE
21 8000A (N) TRAILER BRAKE SOLENOID
22 8000X (N) TRAILER BRAKE SOLENOID
23 3280 (O) SUSPENSION LOCKOUT SOLENOID UPPER
24 8010 (N) TRAILER BRAKE PRESSURE
25 57BK (B) EARTH (ALL)
27 8060D (U) TRAILER BRAKE SUPPLY
28 2012 (Y) TRANS OIL PRESSURE WARNING LAMP
29 3285 (N) SUSPENSION LOCKOUT SOLENOID LOWER
30 5265B (S) / 5515 (S) HYDRAULIC MASTER SW #2 / EHR +12V IGN
31 5500 (R) EHR CAN HIGH
32 5510 (U) EHR CAN LOW
37 9000 (LN/S/B) / 9000 (N) DIVERTER VALVE
39 - / 4022 (S) BACK-UP ALARM FEED
43 2050L (G) / 2050 (G) PTO SUPPLY / DOG SUPPLY
48 7130 (N) / 7130A (N) HYD FILTER WNG LP
49 8070 (P) TRAILER PARK BRAKE SOLENOID
51 7000P (U) / - TRANS CONTROL SUPPLY
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MAXXUM
C020-BRI4413A 1 BRI4400B-03 2
SS08F119 3 BRI4400B-03 4
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C022 FUEL TANK SENDER

1 29 (G/B) MAIN FUEL SENDER SIGNAL
2 2095D (G) INSTRUMENT SIGNAL GROUND
C022VBRE1639A 5 SS08K528 6
LEFT HAND SIDE BEHIND CAB STEPS
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C023 TRANSMISSION OIL TEMPERATURE SENSOR

A 7500 (G) TRANSMISSION OIL TEMP. SENSOR
B 60AD (B/W) EARTH SENSOR
MAXXUM 12x12
C023V-BRK5711A 7 SS08M018 8
LEFT HAND SIDE TRANSMISSION - VIEW SHOWN 12x12
MAXXUM 24x24
C023V-BRK5716A 9 SS08M018 10
RIGHT HAND SIDE TRANSMISSION - VIEW SHOWN 24x24
MAXXUM 16x16 and MAXXUM - Multicontroller
C023VBRE1636A 11 SS08M018 12
RIGHT HAND SIDE TRANSMISSION - VIEW SHOWN 16x16

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C025 C4 VALVE / RANGE C4 CLUTCH SOLENOID

C025V-BRK5717A 13 SS08K508 14
RIGHT HAND SIDE TRANSMISSION
C026 C3 VALVE / RANGE C3 LUTCH SOLENOID

C026V-BRK5718A 15 SS08K508 16
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C027V-BRK5719A 17 SS08K508 18

C028V-BRK5720A 19 SS08K508 20
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MAXXUM 140
C033 PTO BRAKE SOLENOID

1 2130 (N) SOLENOID VALVE PTO BRAKE
2 57ET (B) VEHICLE EARTH (ALL)
MAXXUM
C033V-BRK5723A 1 SS08K508 2
LEFT HAND SIDE REAR TRANSMISSION
MAXXUM - Mulitcontroller
SS08F121 3 SS08K508 4
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C034 FOUR WHEEL DRIVE SOLENOID

1 3024 (Y) (3025A (Y)) 2WD SOLENOID / FOUR WHEEL DRIVE SOLENOID (MANUAL)
2 57EX (B) VEHICLE EARTH (ALL)
MAXXUM
C034V-BRK5713A 5 SS08K508 6
SS08F122 7 SS08K508 8
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C035 FOUR WHEEL DRIVE SWITCH

1 57EN (B) EARTH (ALL)
MAXXUM
C035V-BRK5724A 9 BRE1625B 10
LEFT HAND SIDE TRANSMISSION IN FRONT OF REAR AXLE
SS08F123 11 SS08F100 12
LEFT HAND SIDE TRANSMISSION IN FRONT OF REAR AXLE
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C036 TRANSMISSION OIL PRESSURE SWITCH

1 57EM (B) EARTH (ALL)
MAXXUM
C036V-BRK5721A 13 BRE1625B 14
LEFT HAND SIDE TRANSMISSION
SS08F124 15 SS08F100 16
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MAXXUM 140
C041 PTO SOLENOID

MAXXUM
C041V-BRK5722A 1 SS08K508 2
SS08F125 3 SS08K508 4
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C042 DIFFERENTIAL LOCK SOLENOID

1 7080 (LG) DIFF-LOCK SOLENOID FEED
2 57ES (B) EARTH (ALL)
MAXXUM
C042V-BRK5714A 5 SS08K508 6
SS08F126 7 SS08K508 8
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C043 DIFFERENTIAL LOCK OPERATION SWITCH

1 7000T (U) TRANS CONTROL SUPPLY
MAXXUM
C043V-BRK5715A 9 BRE1625B 10
SS08F127 11 SS08F100 12
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C044 GROUND SPEED PTO SWITCH

1 2050AD (G) PTO SUPPLY / DOG SUPPLY
2 2055 (B/W/S) PTO SYNCHRO GROUND SPEED ENGAGED
SS08F128 13 SS08K508 14
RIGHT HAND SIDE TOP OF TRANSMISSION
C046 AXLE SPEED SENSOR

2 60AB (B/W) SENSOR GROUND
SS08F129 15 SS08K508 16
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C047 LEFT HAND DRAFT SENSING PIN

1 60AF (B/W) SENSOR GROUND
2 5070 (LN) EDC LEFT PIN
3 5075B (K) EDC VOLTAGE TO PINS
C047V-BRK5734A 17 SS08F069 18
REAR LEFT HAND SIDE TRANSMISSION
C048 RIGHT HAND DRAFT SENSING PIN

1 60AE (B/W) SENSOR GROUND
2 5065 (LN) EDC RIGHT PIN
3 5075A (K) EDC VOLTAGE TO PINS
SS08F130 19 SS08F069 20
REAR RIGHT HAND SIDE TRANSMISSION
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MAXXUM 140
C050 TRAILER BRAKES - HYDRAULIC

1 8000A (N) / 8000 (N) TRAILER BRAKE SOLENOID
2 8010A (LN) TRAILER BRAKE PRESSURE
3 8020A (N) / 8020 (N) TRAILER BRAKE PRESSURE
4 57FB (B) / 57 (B) EARTH (ALL)
SS08F132 1 SS08F131 2
C052 ROCKSHAFT POTENTIOMETER
POS: WIRE NUMBER CIRCUIT REFERENCE

1 60AG (B/W) SENSOR GROUND
3 5020A (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
C052V-BRK5733A 3 SS08F072 4
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C054 PTO SPEED SENSOR

1 60AA (B/W) SENSOR GROUND
BRE1666A 5 SS08F062 6
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C055 TRAILER SOCKET

1 1013D (R) / 1013 (U) RIGHT HAND LAMPS
2 810A (G) / 810 (R) STOPLAMPS
3 1014E (R) / 1014 (N) LEFT HAND LAMPS
4 349 (LN) / 49 (G) TRAILER TURN LAMPS RH / RIGHT HAND TURN SIGNAL
5 57EG (B) / 57 (B) EARTH (ALL)
6 350 (LN) / 50 (Y) TRAILER TURN LAMPS LH / LEFT HAND TURN SIGNAL
MAXXUM
C055V-BRE1650A 7 SS07E067 8
REAR TRANSMISSION
SS08F133 9 SS07E067 10
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C056 ENGINE TO LIGHTING HARNESS SOCKET / FRONT LAMPS
MAXXUM
1 57A (B) / 57JF (B) EARTH (ALL)
2 376 (L) HORN FEED
6 57JG (B) / 57B (B) EARTH (ALL)
7 1030A (U) / 1030 (U) HEADLAMP DIP BEAM
8 1027A (U) / 1027 (U) HEADLAMP MAIN BEAM
1 57JF (B) / 57 (B) EARTH (ALL)
2 376 (L) / 376 (L/N) HORN FEED
3 1030B (U) / 1030B (U/R) HEADLAMP DIP BEAM
4 1027B (U) / 1027B (U/W) HEADLAMP MAIN BEAM
5 1073A (L) / 1097 (R/S) WORKLAMP FRONT FEED / FEED FRONT WORKLAMP OUTER
6 57JG (B) / 57D (B) EARTH (ALL)
7 1030A (U) / - HEADLAMP DIP BEAM
8 1027A (U) / - HEADLAMP MAIN BEAM
MAXXUM
C056V-BRJ4642E 11 SS08F134 12
TOP REAR ENGINE
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SS08F135 13 SS08F134 14
TOP REAR ENGINE
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C057 HORN

1 57C (B) EARTH (ALL)
1 376 (L/N) HORN FEED
SS08F137 15 BRI4445B 16
FRONT HOOD
C058 LEFT HAND WORKLAMP

A 1097A (R) FEED FRONT WORKLAMP OUTER
B 57E (B) EARTH (ALL)
SS08F338 17 SS08K538 18
FRONT HOOD
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C059 RIGHT HAND HEADLAMP

1 57B (B) EARTH (ALL)
2 1030D (U) HEADLAMP DIP BEAM
3 1027D (U) HEADLAMP MAIN BEAM
SS08F337 19 SS08F141 20
FRONT HOOD
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MAXXUM 140
C060 LEFT HAND HEADLAMP

1 57A (B) EARTH (ALL)
2 1030C (U) HEADLAMP DIP BEAM
3 1027C (U) HEADLAMP MAIN BEAM
SS08F339 1 SS08F141 2
FRONT HOOD
C061 RIGHT HAND WORKLAMP

A 1097B (R) FEED FRONT WORKLAMP OUTER
B 57F (B) EARTH (ALL)
SS08F340 3 SS08K538 4
FRONT HOOD
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C062 RIGHT HAND STOP LAMP
MAXXUM
1 10C (G) IGNITION SUPPLY
2 10D (G) IGNITION SUPPLY
3 840 (G) R & L STOPLAMP SIGNAL
4 830 (R) STOPLAMP SWITCH RH
4 3026 (Y) BRAKE PEDAL SWITCH - RIGHT
C062-BRI4407 5 SS08F146 6
BEHIND STEERING CONSOLE
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C063 LEFT HAND STOP LAMP
MAXXUM
1 10B (G) IGNITION SUPPLY
2 10A (G) IGNITION SUPPLY
3 840A (G) R & L STOPLAMP SIGNAL
4 820 (R) STOP LAMP SWITCH LH
4 3025 (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
C063-BRI4408 7 SS08F146 8
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C064 RIGHT HAND GRABRAIL WORKLAMP

2 1097B (R) FEED FRONT WORKLAMP OUTER
4 57L (B) (57V (B)) EARTH (ALL)
SS08K504 9 SS08F147 10
RIGHT HAND SIDE CAB ROOF
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C065 LEFT HAND GRABRAIL WORKLAMP

2 1097A (R) (R/S) FEED FRONT WORKLAMP OUTER
4 57V (B) (57L (B)) (57DV (B)) EARTH (ALL)
SS08K505 11 SS08F147 12
LEFT HAND SIDE CAB ROOF
Low profile roof
SS08K535 13 SS08F147 14
LEFT HAND SIDE CAB ROOF - VIEW SHOWN LOW PROFILE CAB
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C066 RIGHT HAND GRABRAIL SIDELAMP

1 249 (LTG) SMV LAMPS RH
2 1013 (R) RIGHT HAND LAMPS
SS08K506 15 SS08F147 16
C067 LEFT HAND GRABRAIL SIDELAMP

1 250 (LTG) SMV LAMPS LH
2 1014C (R) LEFT HAND LAMPS
4 57E (B) EARTH (ALL)
SS08K507 17 SS08F147 18
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C068 RADAR GUN

1 2028B (G) RADAR ASSEMBLY (GUN) SIGNAL
2 57JD (B) EARTH (ALL)
3 2027 (R) RADAR ASSEMBLY (GUN) POWER
4 2031 (Y) RADAR PRESENT
MAXXUM
C068V-BRI4406E 19 SS08F150 20
REAR RIGHT HAND SIDE ENGINE
SS08F151 21 SS08F150 22
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MAXXUM 140
C072 STARTER (KEY) SWITCH

1 150A (N) BATTERY FEED (UNFUSED) (ALL)
2 137 (W) RADIO FEED
3 71 (W) IGNITION SWITCHED FEEDS (UNFUSED)
4 1010 (G) IGNITION RELAY (COIL)
6 1000 (W) SAFETY START SWITCH SUPPLY
C072-BRI4409A-1 1 SS08F160 2
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C073 WIPER SWITCH

1 1038A (LN) (N) WINDSHIELD WIPER FEED-REAR
3 587 (LG) (G) WINDSHIELD WIPER INTERMITTENT DELAY
5 58 (R) WIPER MOTOR-LOW
6 56 (W) WIPER MOTOR-HIGH
7 1121 (G) RR WINDSHIELD WASH
8 1119 (G) RR WINDSHIELD WIPER
9 97 (LG) (G) WINDSHIELD WASHER FEED
10 63 (U) WIPER MOTOR-PARK FEED
C073-BRI4410A 3 BRI4410B 4
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C074 TURN SWITCH

1 150AA (N/G) (N) BATTERY FEED (UNFUSED) (ALL)
2 1024 (R) RIGHT & LEFT HAND SIDELAMP FEED
3 1027D (U/W) (U) HEADLAMP MAIN BEAM
4 1030C (U/R) (U) HEADLAMP DIP BEAM
5 3000 (G/LG) (G) FLASHER UNIT SUPPLY (TERMINAL 49)
6 376 (L/N) (L) HORN FEED
7 3001 (G/R) (G) LEFT HAND FLASHER CIRCUIT
8 3002 (G/W) (G) RIGHT HAND FLASHER CIRCUIT
BRF1880A 5 SS08F161 6
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C075 SHUTTLE SWITCH
MAXXUM
1 7525C (G) TRANS SENSOR SUPPLY 5v
2 7250 (S) TRANSMISSION FORWARD SIGNAL
3 7260 (S) TRANSMISSION REVERSE SIGNAL
4 7730 (LN) NOT IN PARKLOCK
5 7000B (U) TRANS CONTROL SUPPLY
6 1001X (W) STARTER SOLENOID FEED
7 7420A (Y) TCM TO CLUTCH POSITION SWITCH
8 57SS (B) EARTH (ALL)
4 7420 (Y) TCM TO CLUTCH POSITION SWITCH
6 7245 (N) DEADMAN
MAXXUM
C075-BRI4411A 7 BRI4411B 8
C075-BRI4411A 9 SS08F162 10

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C076 CLUTCH SWITCH
MAXXUM
1 7420B (Y) TCM TO CLUTCH POSITION SWITCH
2 7420C (Y) TCM TO CLUTCH POSITION SWITCH
3 7660 (R) TRANS CLUTCH DISCONNECT
2 7000R (U) TRANS CONTROL SUPPLY
C076-BRI4415A 11 SS08F146 12
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C077 CLUTCH POTENTIOMETER

1 7525A (G) TRANS SENSOR SUPPLY 5v
2 7430 (Y) CLUTCH POSITION SIGNAL
3 60B (B/W) SENSOR GROUND
C077-BRI4414A 13 SS08F163 14
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C079 INSTRUMENT CLUSTER ’A’
MAXXUM
5 3005 (G) LEFT HAND TURN SIGNAL WARNING LAMP
6 3004 (G) RIGHT HAND TURN SIGNAL WARNING LAMP
7 9027 (W) CAL/ SEL INPUT ADIC
8 7640Z (LN) DIAGNOSTIC PLUG RS232 IN
9 7650Z (W) DIAGNOSTIC PLUG RS232 OUT
12 7130 (N) HYD FILTER WNG LP
13 2040 (LG) WATER IN FUEL SENSOR
14 1052 (Y) GET U HOME LIGHTS RELAY
15 1012E (R) ILLUMINATION
16 1001P (W) STARTER SOLENOID FEED
21 2020 (Y) ENGINE SHUT DOWN (TACHO MODULE TO TPM)
23 57BE (B) EARTH (ALL)
24 160R (Y) BATTERY SUPPLY ELECTRONICS
25 1006A (N) ALTERNATOR WARNING LAMP
26 9031A (L) ADIC MEMORY B+
20 2087A (O) EXHAUST BRAKE SOLENOID
26 9031 (L) ADIC MEMORY B+
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C079-BRI4416A 15 BRI4416B-01 16
BEHIND INSTRUMENT CLUSTER
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MAXXUM 140
C080 INSTRUMENT CLUSTER ’B’
MAXXUM
11 3062 (L) IMPLEMENT SOCKET SWITCH
14 2330 (L) PTO SPEED ISO11876 SKT.PIN#3
15 2320 (L) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
16 2300 (L) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
17 2310 (L) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
14 2330 (L) PTO SPEED ISO11876 SKT.PIN#3
15 2320 (L) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
16 2300 (L) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
17 2310 (L) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
25 2028C (G) RADAR ASSEMBLY (GUN) SIGNAL
C080-BRI4417A 1 BRI4416B-01 2
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C081 INSTRUMENT CLUSTER ’C’
MAXXUM
1 5190 (R) HPL INTERLOCK / LIFT-O-MATIC
6 8020 (LN) TRAILER BRAKE PRESSURE
7 3014A (R) HANDBRAKE WARNING LAMP SIGNAL
8 1056 (O) -
10 1055 (U) -
11 3052 (L) DOME LAMP TO DOOR SWITCH
13 1034 (LG) TURN SIGNAL WARNING LAMP (TERM C3)
14 29 (G) MAIN FUEL SENDER SIGNAL
18 1026 (U) HIGH BEAM INDICATOR LAMP
19 2200Z (G) SERVICE MODE INITIATE
25 5420G (G) CAN L
26 5400G (Y) CAN H
12 2012A (Y) TRANS OIL PRESSURE WARNING LAMP
13 1034 (G) TURN SIGNAL WARNING LAMP (TERM C3)
16 1033 (G) TURN SIGNAL WARNING LAMP (TERM C2)
20 39 (G) TEMPERATURE GAUGE SIGNAL
25 5420G (G) CAN L
26 5400G (Y) CAN H
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C081-BRI4418A 3 BRI4416B-01 4
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C083 HAZARD SWITCH

2 1021 (L) HAZARD SWITCH SUPPLY (BATTERY)
3 1020A (G/W) HAZARD SWITCH SUPPLY
7 57BF (B) EARTH (ALL)
8 1020 (G/S) HAZARD SWITCH SUPPLY
SS08F164 5 SS08F094 6
STEERING COLUMN CONSOLE
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C084 LEFT HAND UPPER FRONT WORKLAMP

A 1098A (W) FRONT WORKLAMP RELAY GROUND
B 57AB (B) EARTH (ALL)
C084-BRI4458A 7 SS08F166 8
LEFT HAND SIDE FRONT CAB ROOF
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C085 RIGHT HAND UPPER FRONT WORKLAMP

A 1098B (W) FRONT WORKLAMP RELAY GROUND
B 57AA (B) EARTH (ALL)
C085-BRI4457A 9 SS08F166 10
RIGHT HAND SIDE FRONT CAB ROOF
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C088 FRONT WIPER MOTOR

1 28 (Y) (Y/LG) WIPER MOTOR (PARK RETURN)
2 57M (B) (57DL (B)) EARTH (ALL)
3 58 (R) (R/LG) WIPER MOTOR-LOW
4 1019 (G) (1019A (G)) WINDSHIELD WIPER FEED
6 56 (W) (W/LG) WIPER MOTOR-HIGH
C088-BRI4446A 11 SS08F162 12
FRONT CAB ROOF
Low profile roof
SS08F169 13 SS08F162 14
FRONT CAB ROOF - VIEW SHOWN LOW PROFILE CAB
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MAXXUM 140
C090 LEFT HAND DOOR SWITCH

1 3052B (L) (L/W) DOME LAMP TO DOOR SWITCH
C090-BRI4444A 1 BRI4437B 2
REAR TOP LEFT HAND SIDE CAB DOOR
C091 RIGHT HAND DOOR SWITCH

1 3052A (L) (L/W) DOME LAMP TO DOOR SWITCH
C091-BRI4445A 3 BRI4437B 4
REAR TOP RIGHT HAND SIDE CAB DOOR
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C092 LEFT HAND CONSOLE LAMP

1 57W (B) EARTH (ALL)
2 1014 / 1014D (R) LEFT HAND LAMPS
C092-BRI4561A 5 BRI4459B-01 6
C093 LEFT HAND STOP/TAIL LIGHT

1 57AX (B) EARTH (ALL)
2 3004 (G/W) RIGHT HAND TURN SIGNAL WARNING LAMP
3 1013A (R) RIGHT HAND LAMPS
4 810 (G/L) STOPLAMPS
SS08F171 7 SS08F170 8
LEFT HAND SIDE REAR FENDER
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C094 RIGHT HAND STOP/TAIL LIGHT

2 3004 (G/W) RIGHT HAND TURN SIGNAL WARNING LAMP
4 810 (G/L) STOPLAMPS
SS08F172 9 SS08F170 10
RIGHT HAND SIDE REAR FENDER
C095 LEFT HAND REAR LICENCE PLATE WORKLAMP

1 1014B (R) LEFT HAND LAMPS
2 978B (W) LICENCE PLATE LAMP
C095-BRI4566A 11 SS08K508 12
LEFT HAND SIDE REAR CAB ROOF
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C096 RIGHT HAND REAR LICENCE PLATE /WORKLAMP

1 1014A (R) LEFT HAND LAMPS
2 978A (W) LICENCE PLATE LAMP
C096-BRI4567A 13 SS08K508 14
RIGHT HAND SIDE REAR CAB ROOF
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C097 LEFT HAND ROTATING BEACON

1 4012A (L) (L/R) ROTATING BEACON FEED
2 57Z (B) (57DN (B)) EARTH (ALL)
C097-BRI4571A 15 SS08F177 16
Low profile roof
C097V-BRK5744A 17 SS08F177 18
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C098 RIGHT HAND ROTATING BEACON

1 4012B (L) (L/R) ROTATING BEACON FEED
2 57Y (B) (57DM (B)) EARTH (ALL)
C098-BRI4562A 19 SS08F177 20
Low profile roof
C098V-BRK5745A 21 SS08F177 22
RIGHT HAND SIDE CAB ROOF - VIEW SHOWN LOW PROFILE CAB
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C099 INTERIOR LAMP

1 3052A (L) DOME LAMP TO DOOR SWITCH
3052B (L)
2 57R (B) EARTH (ALL)
1 3057 (L) PUDDLE LAMP RETURN
3057A (L)
1 666A (L) DOMELAMP SWITCH FEED
SS08K510 23 SS08F178 24
INTERIOR CAB ROOF
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MAXXUM 140
C100 TCM - TRANSMISSION CONTROL MODULE (CN1a)
MAXXUM
1 7000C (U) TRANS CONTROL SUPPLY
2 7000D (U) TRANS CONTROL SUPPLY
3 7000E (U) TRANS CONTROL SUPPLY
4 7431 (TQ) SUPPLY
6 7920 (TQ) CLUTCH ’C’ SIGNAL
7 7930 (TQ) CLUTCH ’D’ SIGNAL
10 9033 (LN) 50KPH SOLENOID+
11 7910 (TQ) CLUTCH ’B’ SIGNAL
13 7980 (K) TRANS MED. RANGE
14 5000A (L) EDC MEMORY POWER
15 5400T (Y) CAN H
16 5420T (G) CAN L
19 61 (O) CASE GROUND
20 5200A (N) EDC VALVE SUPPLY
21 5500H (R) EHR CAN HIGH
22 5510H (U) EHR CAN LOW
23 60 (B/W) SENSOR GROUND
25 57Y (B) EARTH (ALL)
26 57Z (B) EARTH (ALL)
14 5000A (P) EDC MEMORY POWER
15 5400 (Y) CAN H
16 5420 (G) CAN L
19 61 (B) CASE GROUND
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C100-BRI4419A 1 BRI4416B-01 2
REAR OF CAB BEHIND OPERATOR’S SEAT
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C101 TCM - TRANSMISSION CONTROL MODULE (CN1b)
MAXXUM
1 6402 (G) ECU TO THROTTLE POT. VAR
3 5050 (LN) EDC QUADRANT
4 5045 (LN) EDC DROP RATE
5 5120 (K) EDC HEIGHT LIMIT SIGNAL
6 5040 (LN) EDC DRAFT POSITION
7 5145 (TQ) EDC SLIP LIMIT POT
8 5155 (U) EDC LOWER LIMIT POT
9 5065 (LN) EDC RIGHT PIN
10 5070 (LN) EDC LEFT PIN
11 2050K (G) PTO SUPPLY / DOG SUPPLY
16 5020 (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
17 7525 (G) TRANS SENSOR SUPPLY 5v
18 5130 (TQ) EDC WORK SIGNAL - RAISE WORK SWITCH
20 5125 (TQ) EDC RAISE SIGNAL - RAISE WORK SWITCH
22 820B (R) STOPLAMP SWITCH LH
23 830B (R) STOPLAMP SWITCH RH
27 7420D (Y) TCM TO CLUTCH POSITION SWITCH
29 5100 (K) EDC EXTERNAL SWITCH UP
30 5095 (K) EDC EXTERNAL SWITCH DOWN
3 5050 (N) EDC QUADRANT
4 5045 (N) EDC DROP RATE
5 5120 (K) EDC HEIGHT LIMIT SIGNAL
6 5040 (N) EDC DRAFT POSITION
7 5145 (TQ) EDC SLIP LIMIT POT
8 5155 (U) EDC LOWER LIMIT POT
9 5065 (N) EDC RIGHT PIN
10 5070 (N) EDC LEFT PIN
11 7000F (U) TRANS CONTROL SUPPLY
16 5020 (N) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
18 5130 (TQ) EDC WORK SIGNAL - RAISE WORK SWITCH
20 5125 (TQ) EDC RAISE SIGNAL - RAISE WORK SWITCH
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21 1001N (W) STARTER SOLENOID FEED
22 5132 (TQ) EDC FLOAT
23 7420 (Y) TCM TO CLUTCH POSITION SWITCH
33 2028 (G) RADAR ASSEMBLY (GUN) SIGNAL
C101-BRI4420A 3 BRI4420B 4
REAR OF CAB BEHIND OPERATOR’S SEAT
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C103 GEARSHIFT LEVER

1 7525D (G) TRANS SENSOR SUPPLY 5v
2 7210A (S) TRANSMISSION SHIFT UP
3 7200A (S) TRANSMISSION SHIFT DOWN
4 7525E (G) TRANS SENSOR SUPPLY 5v
5 4101A (TQ) TRANS RANGE ENABLE
C103-BRJ4688A 5 BRI4478B 6
BOTTOM RIGHT HAND CONSOLE
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C104 GEAR SHIFT INDICATOR- DOG CONNECTOR
MAXXUM
A1 2050D (G) PTO SUPPLY / DOG SUPPLY
A2 1013 (R) RIGHT HAND LAMPS
C1 57AB (B) EARTH (ALL)
C3 5400F (Y) CAN H
C4 5420F (G) CAN L
A1 (K) PTO SUPPLY / DOG SUPPLY
A2 (S) RIGHT HAND LAMPS
C1 (N) EARTH (ALL)
C3 (Y) CAN H
C4 (G) CAN L
MAXXUM
C104-BRI4428A 7 BRI4428B 8
RIGHT HAND CONSOLE
SS08F212 9 BRI4428B 10
RIGHT HAND CONSOLE
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C105 WORKLAMP ECU

B1 4011 (L) ROTATING BEACON SWITCH SUPPLY
B2 138B (L) RADIO KAM
B3 57X (B) EARTH (ALL)
B4 1098A (W) FRONT WORKLAMP RELAY GROUND
B5 1098B (W) FRONT WORKLAMP RELAY GROUND
B6 1090 (R) REAR WORKLAMP RELAY SIGNAL
B7 1097A (R) FEED FRONT WORKLAMP OUTER
B8 1097B (R) FEED FRONT WORKLAMP OUTER
C1 997 (G) WORK LAMP-REAR FEED (OUTER)
C2 4012 (L) ROTATING BEACON FEED
C3 998A (G) WORK LAMP-REAR FEED (INNER)
C4 998B (G) WORK LAMP-REAR FEED (INNER)
C5 1013AH (R) RIGHT HAND LAMPS
C6 1092 (R) FRONT WORKLAMP RELAY SIGNAL
C7 1071A (L) WORKLAMP FRONT FEED
C8 1071B (L) WORKLAMP FRONT FEED
C105-BRI4453A 11 SS08K548 12
INTERIOR CAB ROOF
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C106 RADIO CONNECTOR A

4 3077 (Y) RADIO +12VB
6 3078 (O) RADIO +12V ILLUMINATION
7 3079A (R) RADIO +12V IGNITION
8 57 (B) EARTH (ALL)
C106-BRI4454A 13 SS08F180 14
INTERIOR CAB ROOF
C107 RADIO CONNECTOR B

3 3091 (L) SPEAKER RR-RHS +
4 3092 (L) SPEAKER RR-RHS -
5 3097 (G) SPEAKER RR-LHS +
6 3098 (G) SPEAKER RR-LHS -
C107-BRI4455A 15 SS08F180 16
INTERIOR CAB ROOF
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C109 REAR WIPER MOTOR

1 1120 (G) (G/O/B) RR WINDSHIELD WIPER PARK RETURN
2 57D (B) (57DE (B)) EARTH (ALL)
3 1038 (LN) (1038B (LN/B/S)) WINDSHIELD WIPER FEED-REAR
C109-BRI4456A 17 SS08F181 18
REAR CAB ROOF
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MAXXUM 140
C110 RIGHT FRONT SPEAKER
Low profile roof

1 3093 (S) SPEAKER FRT-RHS +
2 3094 (S/B) SPEAKER FRT-RHS -
Low profile roof
SS08K536 1 SS08F177 2
RIGHT HAND SIDE CAB ROOF - VIEW SHOWN LOW PROFILE CAB
C111 LEFT FRONT SPEAKER
Low profile roof

1 3095 (W) SPEAKER FRT-LHS +
2 3096 (W/B) SPEAKER FRT-LHS -
Low profile roof
SS08K537 3 SS08F177 4
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C113 FRONT HITCH POTENTIOMETER

1 60A (N) SENSOR GROUND
2 2510 (G) FRONT HITCH POSITION SIGNAL
3 2530 (O) FRONT HITCH V REF
SS08K542 5 SS08F072 6
RIGHT HAND SIDE FRONT HITCH
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C114 FRONT PTO LAMP

1 2250E (K) PTO FRONT - SUPPLY
2 2270 (O) PTO FRONT - WARNING LAMP
C114-BRI4429C 7 SS08F185 8
RIGHT HAND CONSOLE
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C115 FRONT PTO SWITCH

1 2250D (K) PTO FRONT - SUPPLY
2 2248 (K) PTO FRONT - SWITCH (VCCS)
3 2245 (K) PTO FRONT - SWITCH TO MODULE (MOM)
C115-BRI4424C 9 SS08F072 10
RIGHT HAND CONSOLE
C116 REAR PTO SWITCH

1 2050H (G) PTO SUPPLY / DOG SUPPLY
2 2045 (O) PTO SWITCH TO MODULE
3 2046 (O) PTO SWITCH (VCC)
C116-BRI4425C 11 SS08F072 12
RIGHT HAND CONSOLE
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C117 REAR PTO LAMP

1 2050G (G) PTO SUPPLY / DOG SUPPLY
2 2065A (N) PTO ENGAGED
C117-BRI4430C 13 SS08F185 14
RIGHT HAND CONSOLE
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C118 REAR PTO BRAKE SWITCH
MAXXUM
1 2120A (LN) PTO BRAKE SIGNAL
2 2050J (G) PTO SUPPLY / DOG SUPPLY
6 2065 (N) PTO ENGAGED
1 2120 (N) PTO BRAKE SIGNAL
6 2068 (U) PTO SOFT START
7 57DJ (B) EARTH (ALL)
8 1013Y (R) RIGHT HAND LAMPS
9 57YZ (B) EARTH (ALL)
10 1013YZ (R) RIGHT HAND LAMPS
MAXXUM
C118-BRI4475C 15 SS08F094 16
RIGHT HAND CONSOLE
SS08F186 17 SS08F094 18
RIGHT HAND CONSOLE
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C119 BLOWER UNIT
MANUAL
3 9211 (G/Y) AC-BLOWER SPEED LOW (1)
4 9212 (K) / (G/K) AC-BLOWER SPEED MED.1 (2)
5 9213 (K/O) AC-BLOWER SPEED MED.2 (3)
8 9214 (G/S) AC-BLOWER SPEED HIGH.2 (2)
ATC
1 982F (R) BLOWER MOTOR FEED
3 57CD (B) EARTH (ALL)
4 9225 (U/R) AC-BLOWER SPEED
6 9224 (O/B) AC-SIGNAL AMBIENT TEMPERATURE SENSOR
7 9223 (R/B) AC-SIGNAL CAB TEMPERATURE SENSOR
8 57ZC (B) EARTH (ALL)
MANUAL
SS08K543 19 SS08M003 20
LEFT HAND SIDE REAR CAB
ATC
SS07E288 21 SS08M003 22
LEFT HAND SIDE REAR CAB
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MAXXUM 140
C120 EDC CONTROL PANEL 1
OPERATOR CONTROL ARMREST
C121 EDC CONTROL PANEL 2
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C127 TCM - TRANSMISSION CONTROL MODULE (CN3a)
MAXXUM
1 6440 (S) HAND THROTTLE POSITION 1
2 7970 (L) TRANS MED/REV
3 2059 (W) FENDER PTO SWITCH INPUT
4 6530 (N) CONSTANT ERPM INCREASE
5 6540 (N) CONSTANT ERPM DECREASE
6 5133 (TQ) EDC STOP
7 5240 (O) EDC RAISE SIGNAL-RAISE WORK SWITCH No.2
8 7040 (N) TRANS CREEPER SWITCH
10 7210 (S) TRANSMISSION SHIFT UP
11 7200 (S) TRANSMISSION SHIFT DOWN
15 1039 (LG) NASO LIGHTS INPUT
16 5595 (S) EHR MASTER STOP SWITCH
17 6460A (U) HAND THROTTLE SWITCH (NOT IDLE)
18 2056 (W) PTO FENDER PTO SWITCH ON
19 7126 (LG) DIFF LOCK PRESSURE SWITCH
21 5610 (R) HTS PROGRAM
22 5630 (R) HTS MANUAL SWITCH
23 5620 (R) HTS ON/OFF SWITCH
24 3027 (Y) FOUR WHEEL DRIVE SOLENOID (AUTO)
25 3025 (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL) / TRANS CONTROL
SUPPLY
26 5250 (O) EDC WORK SIGNAL-RAISE WORK SWITCH No.2
3 7960 (R) TRANS SLOW/FAST
6 5133 (TQ) EDC STOP
8 7040 (R) TRANS CREEPER SWITCH
10 3025A (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
11 3026A (Y) BRAKE PEDAL SWITCH - RIGHT
16 2069 (O) PTO MANAGEMENT ON
19 3014 (R) HANDBRAKE WARNING LAMP SIGNAL
20 5600 (N) HTS LIVE SIGNAL
22 6620 (N) ECU COOLANT TEMP. SIGNAL
23 7425 (N) DRIVE SIGNAL
25 3025B (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
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C127-BRI4422A 1 BRI4416B-03 2
BEHIND OPERATOR’S SEAT
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C128 TCM - TRANSMISSION CONTROL MODULE (CN3b)
MAXXUM
1 7945 (L) TCM CLUTCH E RETURN
2 7580 (U) CREEPER SOLENOID MONITOR
3 7235 (Y) TRANS LOW RANGE SOL - RET
4 8045 (L) TRANS REV SOL RET
6 9035 (LN) 50KPH DUMP SOLENOID
7 7985 (G) TRANS REVERSE RANGE
10 9036 (LN) 50KPH DUMP SOLENOID RETURN
11 6510 (N) CONSTANT ERPM SET 1
12 7586 (U) PARKLOCK SOLENOID
13 7940 (TQ) CLUTCH ’E’ SIGNAL
19 7411 (Y) TRANS HYDROSTAT INPUT SPEED SENSOR (CVT)
20 7400 (Y) TRANS RPM SPEED SENSOR TO TCM INPUT
22 7760 (W) TORQUE SENSOR
24 2120 (LN) PTO BRAKE SIGNAL
28 7120 (Y) DIFF-LOCK WNG LP (MAUAL)
29 7125 (LG) DIFF-LOCK WNG LP (AUTO)
30 7175 (Y) DIFF LOCK SWITCH (MANUAL ON)
31 7170 (W) DIFF LOCK SWITCH (AUTO ON)
32 6404 (G) THROTTLE POT. TO LOW IDLE SWITCH
33 2055A (W) PTO SYNCHRO GROUND SPEED ENGAGED
34 7000K (U) TRANS CONTROL SUPPLY
4 2056A (W) PTO FENDER PTO SWITCH ON
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23 2068 (U) PTO SOFT START
24 2120A (N) PTO BRAKE SIGNAL
25 2050B (G) PTO SUPPLY / DOG SUPPLY
28 7120 (Y) DIFF-LOCK WNG LP (MANUAL)
29 7125 (G) DIFF-LOCK WNG LP (AUTO)
34 2050C (G) PTO SUPPLY / DOG SUPPLY
C128-BRI4423A 3 BRI4420B 4
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C129 RIGHT HAND WORKLAMP

2 998 (G/LN/B) (998 (G)) WORK LAMP-REAR FEED (INNER)
4 57AP (B) EARTH (ALL)
SS08F187 5 SS08F147 6
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MAXXUM 140
C130 LEFT HAND WORKLAMP

2 998 (G) (998 (G/LN/B)) WORK LAMP-REAR FEED (INNER)
SS08F188 1 SS08F147 2
C131 LICENCE PLATE LAMP 1

1 1013B (R) RIGHT HAND LAMPS
1 57AW (B) EARTH (ALL)
SS08F189 3 BRI4449B 4
REAR FENDERS
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C134 RIGHT HAND HPL SWITCH

1 5100 (K/W) EDC EXTERNAL SWITCH UP
2 5200 (N/R/B) EDC VALVE SUPPLY
3 5095 (K/G) EDC EXTERNAL SWITCH DOWN
SS08K521 5 SS08F072 6
C135 LEFT HAND HPL SWITCH

1 5100 (K/W) EDC EXTERNAL SWITCH UP
2 5200 (N/R/B) EDC VALVE SUPPLY
3 5095 (K/G) EDC EXTERNAL SWITCH DOWN
SS08K520 7 SS08F072 8
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C136 HANDBRAKE

1 57BL (B) EARTH (ALL)
2 3014B (R) HANDBRAKE WARNING LAMP SIGNAL
3 666B (L) DOMELAMP SWITCH FEED
4 3150 (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
C136-BRI4469A 9 SS08F192 10
LEFT HAND SIDE OF OPERATOR’S SEAT
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C138 SEAT AIR PUMP

1 181L (G) BLOWER MOTOR FEED
3 181K (G) BLOWER MOTOR FEED
4 57CN (B) EARTH (ALL)
MAXXUM
C138-BRJ4667A 11 SS08F193 12
RIGHT HAND SIDE OF OPERATOR’S SEAT
SS08F213 13 SS08F193 14
RIGHT HAND SIDE OF OPERATOR’S SEAT
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C139 FRONT WASHER MOTOR

1 97 (G) WINDSHIELD WASHER FEED
2 57F (B) EARTH (ALL)
C139-BRI4481A 15 SS08F222 16
REAR OF TRACTOR UNDERNEATH CAB
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MAXXUM 140
C140 REAR WASHER MOTOR

1 1121A (G) RR WINDSHIELD WASH
2 57G (B) EARTH (ALL)
C140-BRI4482A 1 SS08F222 2
C143 REAR IMPLEMENT SOCKET

1 3070e (L) ’B’ PILLAR SKT SUPPLY
2 150BF (N) BATTERY FEED (UNFUSED)(ALL)
4 57CR (B) EARTH (ALL)
C143-BRJ4660B 3 BRI4452B 4
OUTSIDE REAR CAB
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C144 TRAILER BRAKES - AIR

1 2095C (G) INSTRUMENT SIGNAL GROUND
5 57EH (B) EARTH (ALL)
6 8070 (P/W/S) / 8070 (L) TRAILER PARK BRAKE SOLENOID
8 8060F (U) TRAILER BRAKE SUPPLY
MAXXUM
C144V-BRE1650A 5 SS08F134 6
REAR OF TRANSMISSION BEHIND REMOTE VALVE STACK
SS08F194 7 SS08F134 8
REAR OF TRANSMISSION BEHIND REMOTE VALVE STACK
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C146 LIFT-O-MATIC SWITCH

1 2050N (G) PTO SUPPLY / DOG SUPPLY
2 5190 (R) HPL INTERLOCK / LIFT-O-MATIC
C146-BRI4487A 9 BRI4487B 10
BOTTOM OF RIGHT HAND CONSOLE
C148 DIVERTER VALVE CONNECTOR

1 57FJ (B) EARTH (ALL)
2 9000 (N) DIVERTER VALVE
INA 11 SS08K508 12
TRANSMISSION
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MAXXUM 140
C156 REVERSE SYNCHRO SOLENOID

2 8045 (L) TRANS REV SOL RET
C156V-BRK5746A 1 SS08K508 2
TOP OF TRANSMISSION
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C157 FORWARD SYNCHRO SOLENOID

2 8035 (L) TRANS FWD SOL RET
C157V-BRK5747A 3 SS08K508 4
TOP OF TRANSMISSION
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C158 SYNCHRO POSITION POTENTIOMETER

1 7525B (G) (7525E (G)) TRANS SENSOR SUPPLY 5v
3 60AC (B/W) SENSOR GROUND
MAXXUM
C158V-BRK5748A 5 SS08F072 6
TOP OF TRANSMISSION
SS08F214 7 SS08F072 8
TOP OF TRANSMISSION
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MAXXUM 140
C161 LOW PWM SOLENOID

C161V-BRK5749B 1 SS08K508 2
RIGHT HAND SIDE FRONT OF TRANSMISSION - 24x24 ONLY
C162 HIGH PWM SOLENOID

C162V-BRK5750B 3 SS08K508 4
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C163 DUMP SOLENOID

C163V-BRK5751A 5 SS08K508 6
C166 LOW RANGE SWITCH

A 7000L (U) TRANS CONTROL SUPPLY
B 7230 (S) TRANSMISSION LOW RANGE
C166V-BRK5752A 7 SS08M018 8
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C167 HIGH RANGE SWITCH

A 7000K (U) TRANS CONTROL SUPPLY
B 7220 (S) TRANSMISSION HIGH RANGE
C167V-BRK5753A 9 SS08M018 10
C168 FRONT HPL SOLENOID VALVE

1 2570 (N/B/S) FRONT HITCH RAISE SOLENOID
2 57JT (B) EARTH (ALL)
INA 11 SS08F267 12
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C169 FRONT PTO SOLENOID VALVE

1 2043 (K) (L) PTO SOLENOID FRONT
2 2044 (K) (L) PTO SOLENOID FRONT RETURN (-)
SS08F112 13 SS08K508 14
FRONT OF ENGINE UNDER THE COOLER
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MAXXUM 140
C170 FRONT HPL LIMIT POTENTIOMETER

2 2520 (N) FRONT HITCH SET POSITION SIGNAL
3 2530A (N) FRONT HITCH V REF
4 2540E (N) FRONT HITCH +12v IGN
5 2540X (N) FRONT HITCH +12v IGN
MAXXUM
BRE1786A 1 SS08F131 2
BEHIND RIGHT HAND CONSOLE
SS08F184 3 SS08F131 4
BEHIND RIGHT HAND CONSOLE
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C173 LOW HYDRAULIC CHARGE SWITCH

MAXXUM 24x24
INA 5 SS08K527 6
TOP OF TRANSMISSION - ONLY 24x24
SS08F196 7 SS08K527 8
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C174 PAS PRESSURE SWITCH

1 3500 (W/B/S) POWER STEERING PRESSURE SIGNAL
1 57FC (B) EARTH (ALL)
MAXXUM 24x24
INA 9 BRE1625B 10
SS08F215 11 BRE1625B 12
RIGHT HAND SIDE TRANSMISSION - ONLY 16x16
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C175 HPL FILTER BLOCKED SWITCH

A 57EP (B) EARTH (ALL)
B 7130 (N) HYD FILTER WNG LP
MAXXUM 24x24
INA 13 SS08M018 14
C175-BRJ4639A 15 SS08M018 16
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C176 TRANSMISSION OIL TEMPERATURE SENDER

2 7130A (N) HYD FILTER WNG LP
MAXXUM 24x24
INA 17 SS08K508 18
C176-BRJ4640A 19 SS08K508 20
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MAXXUM 140
C182 AUTO FOUR WHEEL DRIVE SWITCH
MAXXUM
1 3025 (Y) / 57EN (B) FOUR WHEEL DRIVE SOLENOID (MANUAL) / EARTH (ALL)
1 3025 (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
8 1012B (R) ILLUMINATION
10 1012C (R) ILLUMINATION
MAXXUM
INA 1 SS08F094 2
RIGHT HAND CONSOLE SWITCH PANEL
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SS08F198 3 SS08F094 4
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C183 AUTO DIFF LOCK SWITCH

2 7000A (U) TRANS CONTROL SUPPLY
7 7125 (G) DIFF-LOCK WNG LP (AUTO)
8 7000M (U) TRANS CONTROL SUPPLY
9 7120 (Y) DIFF-LOCK WNG LP (MANUAL)
10 7000L (U) TRANS CONTROL SUPPLY
MAXXUM
INA 5 SS08F094 6
SS08F199 7 SS08F094 8
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C184 TRANS/EDC CONNECTOR C2

1 2320 (L/K/Y) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2 2300 (L/B/Y) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
3 2330 (L/G/Y) PTO SPEED ISO11876 SKT.PIN#3
4 2310 (L/G/Y) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
5 5190B (R/W/B) IMPLEMENT SOCKET SWITCH / HPL INTERLOCK / LIFT-O-MATIC
6 1050 (G/W) ACCESSORY FEED
INA 9 SS08K544 10
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C189 FRONT WORKLAMP SWITCH

2 1092 (R)) FRONT WORKLAMP RELAY SIGNAL
7 57M (B) EARTH (ALL)
INA 11 BRI4438A 12
ONLY 12x12
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MAXXUM 140
C191 REAR WORKLAMP SWITCH

2 1090 (R) REAR WORKLAMP RELAY SIGNAL
7 57N (B) EARTH (ALL)
INA 1 BRI4438A 2
ONLY 12x12
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C192 CREEPER GEAR SWITCH
MAXXUM
2 2050A (G) PTO SUPPLY / DOG SUPPLY
7 57H (B) EARTH (ALL)
2 2050A (G) PTO SUPPLY / DOG SUPPLY
8 1012A (R) ILLUMINATION
MAXXUM
INA 3 SS08F094 4
SS08F201 5 SS08F094 6
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C193 CIGAR LIGHTER (ILLUMINATION)

1 3070B (L) ’B’ PILLAR SKT SUPPLY
2 57CV (B) EARTH (ALL)
1 1012G (R) ILLUMINATION
MAXXUM
C193-BRJ4650A 7 SS08F221 8
LEFT HAND C PILLAR REAR
SS08F202 9 SS08F221 10
LEFT HAND C PILLAR REAR
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C197 HIGH/MEDIUM RANGE SWITCH

A 7230 (S) TRANSMISSION LOW RANGE
B 7000S (U) TRANS CONTROL SUPPLY
C197V-BRK5755A 11 SS08K508 12
RIGHT HAND SIDE TRANSMISSION - 24x24 ONLY
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MAXXUM 140
C217 EDC RAISE VALVE

C217V-BRK5756A 1 SS08F062 2
REAR OF TRACTOR EDC VALVE
C218 EDC LOWER VALVE

C218V-BRK5757A 3 SS08F062 4
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MAXXUM 140
C222 CREEPER GEAR SOLENOID

2 57ER (B) EARTH (ALL)
MAXXUM
C222V-BRK5727A 1 SS08K508 2
SS08F203 3 SS08K508 4
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C229 THERMO COLD ADVANCE CONNECTOR

1 6414 (G) FUSED IGN.+ TO ECU
SS09D359 5 SS08K527 6
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Connector - Component diagram 23 Connectors230-239

MAXXUM 140
C230 THERMO COLD ADVANCE CONNECTOR

1 (B) -
2 (B) -
SS09E003 1 SS08K508 2
C232 REVERSE ALARM

1 57EJ (B) EARTH (ALL)
2 4022 (S) BACK-UP ALARM FEED
INA 3 SS08K508 4
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C235 30AMP POWER SOCKET AND STUDS
MAXXUM
1 3070C (L) ’B’ PILLAR SKT SUPPLY
2 9032A (Y) EARTH (ALL)
3 57CW (B) EARTH (ALL)
1 3070C (L) / 150BF (N) ’B’ PILLAR SKT SUPPLY
2 9032A (Y) / 9032B (Y) IGN.+ TO POWER SKT.
MAXXUM
INA 5 BRI4455B 6
RIGHT HAND CONSOLE
SS09A056 7 SS08F110 8
RIGHT HAND SIDE UNDER CONSOLE
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C239 TCM TRANSMISSION CONTROL MODULE (CN2)
MAXXUM
1 7915 (L) TCM CLUTCH B RETURN
2 7225 (W) TRANS HI RANGE SOL - RET
3 7935 (L) TCM CLUTCH D RETURN
6 7925 (L) TCM CLUTCH C RETURN
7 7982 (W) TRANS MED. RANGE RET
8 7900 (TQ) CLUTCH ’A’ SIGNAL
11 5220 (Y) EDC RAISE LAMP
13 9034 (LN) 50KPH SOLENOID-
16 3168 (O) AUTO GUIDANCE DUMP SOLENOID FEED (HSD)
19 5180 (TQ) EDC SLIP INDICATOR LAMP
22 5596 (S) EHR MASTER STOP LAMP
23 6355 (R) +5V LOW POWER REFERENCE
24 5110 (K) EDC LAMP SIGNAL
25 5230 (Y) EDC LOWER LAMP
26 57X (B) EARTH (ALL)
11 5220 (Y) EDC RAISE LAMP
19 5110 (K) EDC LAMP SIGNAL
24 5180 (TQ) EDC SLIP INDICATOR LAMP
25 5230 (Y) EDC LOWER LAMP
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C239-BRI4421A 9 BRI4416B-01 10
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MAXXUM 140
C240 EDC MOUSE CONNECTOR
C242 ENGINE E.C.U.

4 57FE (B) EARTH (ALL)
5 6408F (G) FUSED B+ TO ECU (1)
6 57FD (B) EARTH (ALL)
24 6320 (N) FAN 5V REF
53 6305 (O) REVERSIBLE FAN OPTION - MOTOR FEED
61 5420D (G) CAN L
62 5400D (Y) CAN H
68 6570 (G) ECU TO FUEL FILTER HEATER RETURN
79 2040A (LG) WATER IN FUEL SENSOR
93 6586 (L) ECU TO GRID HEATER RELAY RETURN
C242V-BRJ5060E 1 SS08F204 2
TOP OF ENGINE
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C247 SUSPENSION LOCK SWITCH

2 7000F (U) TRANS CONTROL SUPPLY
3 3210 (U) SUSPENSION SWITCH RETURN
7 3290 (O) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
8 7000G (U) TRANS CONTROL SUPPLY
MAXXUM
INA 3 SS08F094 4
SS08F205 5 SS08F094 6
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C248 SFA VALVES

2 3250 (O) / 3250 (O/G/S) RAISE SOLENOID RET
4 3270 (O) / 3270 (O/P/S) LOWER SOLENOID RET
5 3280 (O) / 3280 (O/U/S) SUSPENSION LOCKOUT SOLENOID UPPER
6 3281 (LN) / 3290 (D/Y/S) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-) /
SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
7 3285 (LN) / 3300 (O) SUSPENSION LOCKOUT SOLENOID LOWER / SENSE LINE
CONTROL SOLENOID
8 3286 (LN) / 3310 (O) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-) / RAISE
LOCKOUT SOLENOID
MAXXUM
C248V-BRI4614E 7 SS07K176 8
TOP OF TRANSMISSION
SS08F206 9 SS07K176 10
TOP OF TRANSMISSION
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C249 SUSPENSION LOWER SOLENOID

1 3260 (O/N/S) LOWER SOLENOID VALVE POWER SUPPLY
2 3270 (O/L/S) LOWER SOLENOID VALVE RETURN SIGNAL
SS08F216 11 SS08K508 12
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MAXXUM 140
C250 SUSPENSION LOWER LOCKOUT SOLENOID

1 3300 (O) SENSE LINE CONTROL SOLENOID
2 3310 (O) RAISE LOCKOUT SOLENOID
SS08F217 1 SS08K508 2
C251 SUSPENSION RAISE SOLENOID

1 3240 (O/B/S) RAISE SOLENOID VALVE POWER SUPPLY
2 3250 (O/G/S RAISE SOLENOID VALVE RETURN SIGNAL
SS08F218 3 SS08K508 4
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C252 SUSPENSION RAISE LOCKOUT SOLENOID

1 3280 (O/U/S) SUSPENSION LOCKOUT SOLENOID UPPER
2 3290 (O/Y/S) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
SS08F219 5 SS08K508 6
C253 FRONT AXLE SELF LEVEL

1 5220 (G) / 3220 (O) EDC RAISE LAMP / AXLE HEIGHT SENSOR 5V REF
2 3230 (U) / 3230 (O) AXLE HEIGHT SENSOR POSITION
SS08F208 7 SS08F207 8
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C254 FRONT HITCH / FRONT PTO CONNECTOR

1 2044 (O) / 2044 (K) (L) PTO SOLENOID-FRONT RETURN(-)
2 2043 (O) / 2043 (K) (L) PTO SOLENOID-FRONT
3 2260 (O) / - PTO FRONT - SPEED SIGNAL
4 60AE (B/W) / 60A (N) SENSOR GROUND
5 2570 (R) / 2570 (W) FRONT HITCH RAISE SOLENOID
6 2530 (S) / 2530 (O) FRONT HITCH V REF
7 2510 (N) / 2510 (G) FRONT HITCH POSITION SIGNAL
With EFH
1 2044 (O) / 57G (B) PTO SOLENOID-FRONT RETURN(-) / EARTH (ALL)
2 2043 (O) / 376 (W) PTO SOLENOID-FRONT / HORN FEED
3 2260 (O) / - PTO FRONT - SPEED SIGNAL
4 60AE (B/W) / - SENSOR GROUND
5 2570 (R) / - FRONT HITCH RAISE SOLENOID
6 2530 (S) / - FRONT HITCH V REF
7 2510 (N) / - FRONT HITCH POSITION SIGNAL
8 57JT (B) / - EARTH (ALL)
FZ........ ---->
C254V-BRI4532E 9 SS07K176 10
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----> FZ........
SS08F209 11 SS08F134 12
With EFH
C254V-BRI4532E 13 SS07K176 14
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C255 ENGINE SPEED SENSOR

1 2095C (G) INSTRUMENT SIGNAL GROUND
SS08K553 15 SS09D357 16
C256 FOOT THROTTLE MECHANICAL

1 2014 (G/K) ENGINE OIL PRESSURE SENDER (+5 VOLT)
2 6402A (G/K/Y) ECU TO THROTTLE POT. VAR
3 2095C (G/W/B) INSTRUMENT SIGNAL GROUND
C256V_BRE1647E 17 SS08F072 18
BASE OF STEERING CONSOLE
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C257 LEFT HAND PTO SWITCH

1 2050 (G/R) PTO SUPPLY / DOG SUPPLY
2 2059 (W/U) FENDER PTO SWITCH INPUT
3 2056 (W/R/Y) PTO FENDER PTO SWITCH ON
SS08F210 19 SS08F072 20
C258 RIGHT HAND PTO SWITCH

1 2050 (G/R) PTO SUPPLY / DOG SUPPLY
2 2059 (W/U) FENDER PTO SWITCH INPUT
3 2056 (W/R/Y) PTO FENDER PTO SWITCH ON
SS08F211 21 SS08F072 22
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MAXXUM 140
C260 FLASHER ECU
MAXXUM
A1 3009A (G) FLASHER UNIT SUPPLY B+
A2 249 (LG) SMV LAMPS RH
A3 349 (LN) TRAILER TURN LAMPS RH
A4 250 (LG) SMV LAMPS LH
A5 350 (LN) TRAILER TURN LAMPS LH
A6 1020 (G) HAZARD SWITCH SUPPLY
A7 1034 (LG) TURN SIGNAL WARNING LAMP (TERM C3)
A8 3000B (G) FLASHER UNIT SUPPLY (TERMINAL 49)
B1 3009B (G) FLASHER UNIT SUPPLY B+
B2 3002 (G) RIGHT HAND FLASHER CIRCUIT
B3 3001 (G) LEFT HAND FLASHER CIRCUIT
B4 1020A (G) HAZARD SWITCH SUPPLY
B5 1033 (LG) TURN SIGNAL WARNING LAMP (TERM C2)
B6 50 (G) LEFT HAND TURN SIGNAL
B7 49 (G) RIGHT HAND TURN SIGNAL
B8 57BG (B) EARTH (ALL)
C1 49A (G) RIGHT HAND TURN SIGNAL
C2 50A (G) LEFT HAND TURN SIGNAL
C3 1039 (LG) NASO LIGHTS INPUT
A2 249 (G) SMV LAMPS RH
A3 349 (N) TRAILER TURN LAMPS RH
A4 250 (G) SMV LAMPS LH
A5 350 (N) TRAILER TURN LAMPS LH
A7 1034 (G) TURN SIGNAL WARNING LAMP (TERM C3)
B5 1033 (G) TURN SIGNAL WARNING LAMP (TERM C2)
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MAXXUM
C260-BRJ4665A 1 SS08F179 2
RIGHT HAND CONSOLE
SS08F223 3 SS08F179 4
RIGHT HAND CONSOLE
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C262 AUTO TRANS SWITCH & CAL/SEL

1 7475 (R) TRANS AUTO OFF
3 7476 (R) TRANS AUTO ON
C262-BRI4581C 5 SS08F094 6
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C269 CAB TO ENGINE MAIN CONNECTOR E2
MAXXUM
1 3272 (O) LOADER VALVE #1 OUT
2 3273 (O) LOADER VALVE #1 RETURN
3 3235 (O) ACCELEROMETER SIGNAL
4 2590 (LN) EXTERNAL SWITCH FHPL UP
5 2591 (LN) EXTERNAL SWITCH FHPL DOWN
14 2044 (O) PTO SOLENOID-FRONT RETURN(-)
19 2570 (R) FRONT HITCH RAISE SOLENOID
21 2510 (N) FRONT HITCH POSITION SIGNAL
22 2530 (S) / 2530B (N) FRONT HITCH V REF
25 3230 (U) AXLE HEIGHT SENSOR POSITION
26 5520 / 5520A (LG) EHR 5V Ref.
31 2043 (O) PTO SOLENOID-FRONT
32 2260 (O) PTO FRONT - SPEED SIGNAL
33 57JY (B) EARTH (ALL)
34 1010 / 1010C (G) IGNITION RELAY (COIL)
35 3274 (R) LOADER VALVE #2 OUT
36 3275 (R) LOADER VALVE #2 RETURN
37 57JZ (B) EARTH (ALL)
38 1018 (LG) AIR CONDITIONER CLUTCH
42 5200 / 5200A (N) EDC VALVE SUPPLY
46 2250 / 2250L (K) PTO FRONT - SUPPLY
47 3070D (L) ’B’ PILLAR SKT SUPPLY
48 9032B (Y) IGN+ TO POWER SKT.
49 172A (W) BATTERY ISOLATOR RELAY COIL (OFF)
50 171B (W) BATTERY ISOLATOR RELAY COIL
2 3273 (O) / 57RO (B) LOADER VALVE #1 RETURN / EARTH (ALL)
4 2590 (N) EXTERNAL SWITCH FHPL UP
5 2591 (N) EXTERNAL SWITCH FHPL DOWN
6 2592 (N) EFH VALVE DOWN +
7 2593 (N) EFH VALVE DOWN -
8 2598 (S) EFH ACCUMULATOR 14 BAR
9 2599 (N) EFH ACCUMULATOR 40 BAR
15 2597 (N) EFH PRESSURE SENSOR SIGNAL
16 2587 (N) EFH EXTERNAL SWITCH +
17 2588 (P) EFH EXTERNAL SWITCH UP
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18 2589 (R) EFH EXTERNAL SWITCH DOWN
19 2570 (R) / 2570Z (R) FRONT HITCH RAISE SOLENOID
22 2530 (S) / 2530B (N) FRONT HITCH V REF
26 5520 (O) / 3220 (O) EHR 5V Ref. / AXLE HEIGHT SENSOR 5V REF
27 2596 (R) EFH POSITION SENSOR -
28 2595 (P) EFH POSITION SENSOR SIGNAL
29 2594 (Y) / 2594 (O) EFH POSITION SENSOR +
33 57HA (B) EARTH (ALL)
34 1010 (G) / 1010C (G) IGNITION RELAY (COIL)
36 3275 (R) / 57RE (B) LOADER VALVE #2 RETURN / EARTH (ALL)
38 1018 (G) AIR CONDITIONER CLUTCH
41 - / 2087 (O) EXHAUST BRAKE SOLENOID
42 5200 (N) / - EDC VALVE SUPPLY
44 2007 (Y) / - AIR CONDITIONER LOW PRESSURE
47 - / 3070D (P) ’B’ PILLAR SKT SUPPLY
50 - / 171A (W) BATTERY ISOLATOR RELAY COIL
C269-BRI4403A 7 BRI4400B-04 8
RIGHT HAND SIDE CAB FLOOR
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MAXXUM 140
C275 VISCOTRONIC FAN INTO HARNESS

3 6408G (G) FUSED B+ TO ECU (1)
5 6320 (N) FAN 5V REF.
C275-BRI4531A 1 SS08F162 2
TOP OF ENGINE
C276 VISCOTRONIC FAN

3 6408G (G) PROTECTED BY FUSE B+ TO CONTROL UNIT (1)
4 6310 (N) FAN SOLENOID VALVE
5 6320 (N) VENTILATOR 5V REF
C276-BRJ4668A 3 SS08N086 4
FRONT OF ENGINE
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C278 CABIN DIAGNOSTIC CONNECTOR

A 57AL (B) EARTH (ALL)
B 6408E (G) FUSED B+ TO ECU (1)
C 5400O (Y) CAN H
D 5420O (G) CAN L
E 6418 (K) ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO K
G 2200Z (G) SERVICE MODE INITIATE
SS08F226 5 SS08F224 6
RIGHT HAND SIDE C PILLAR
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C279 EHR VALVE CONNECTOR 1

1 5515A (S) EHR +12V IGN.
2 5510A (U) EHR CAN LOW
3 5500A (R) EHR CAN HIGH
C279V-BRE1641A 7 SS08F107 8
REAR OF TRACTOR - 16x16 ONLY
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MAXXUM 140

1 5515B (S) EHR +12V IGN.
2 5510C (U) EHR CAN LOW
3 5500C (R) EHR CAN HIGH
C280V-BRE1641C 1 SS08F107 2

1 5515C (S) EHR +12V IGN.
2 5510E (U) EHR CAN LOW
3 5500E (R) EHR CAN HIGH
4 57FF (B) EARTH (ALL)
C281V-BRE1642A 3 SS08F107 4
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1 5515D (S) EHR +12V IGN.
2 5510G (U) EHR CAN LOW
3 5500G (R) EHR CAN HIGH
4 57FG (B) EARTH (ALL)
C282V-BRE1642C 5 SS08F107 6
C287 FLYWHEEL TORQUE SENSOR

1 2050AB (G) PTO SUPPLY / DOG SUPPLY
3 60AJ (B/W) SENSOR GROUND
SS08F220 7 SS08F069 8
RIGHT HAND SIDE OF TRANSMISSION
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C288 PTO TWIST SENSOR

1 2050AA (G) PTO SUPPLY / DOG SUPPLY
3 60AK (B/W) EARTH (ALL)
C288V-BRE1652A 9 SS08F069 10
TOP OF TRANSMISSION
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C289 50 KPH / 17TH GEAR DUMP SOLENOID

1 9035 (LN) 50KPH DUMP SOLENOID
2 9036 (LN) 50KPH DUMP SOLENOID RETURN
MAXXUM
C289V-BRK5725A 11 SS08K508 12
TOP OF TRANSMISSION
SS08F227 13 SS08K508 14
TOP OF TRANSMISSION
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MAXXUM 140
C290 50KPH / 17TH GEAR SOLENOID

MAXXUM
C290V-BRK5726A 1 SS08K508 2
TOP OF TRANSMISSION
SS08F228 3 SS08K508 4
TOP OF TRANSMISSION
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C292 CAN BUS TERMINATOR

1 5400D (Y) CAN H
2 5420D (G) CAN L
C292V-BRE1802E 5 SS08K508 6
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C293 RIGHT HAND FENDER 1

1 1013C (R) / 1013 (R) RIGHT HAND LAMPS
2 810C (G) / 810 (G/L) STOPLAMPS
3 3004B (G) / 3004 (G/W) RIGHT HAND TURN SIGNAL WARNING LAMP
4 57AV (B) EARTH (ALL)
5 998B (G) / 998 (G/LN/B) WORK LAMP-REAR FEED (INNER)
SS08F229 7 SS07E067 8
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C294 RIGHT HAND FENDER 2

1 5100B (K) / 5100 (K/W) EDC EXTERNAL SWITCH UP
2 5200B (N) / 5200 (N/R/B) EDC VALVE SUPPLY
3 5095A (K) / 5095 (K/G) EDC EXTERNAL SWITCH DOWN
4 2057 (W) / 2059 (W/U) PTO FENDER SWITCH LH - RH LINK / FENDER PTO SWITCH INPUT
5 2050E (G) / 2050 (G/R) PTO SUPPLY / DOG SUPPLY
6 2056 (W) / 2056 (W/R/Y) PTO FENDER PTO SWITCH ON
SS08F230 9 SS07E067 10
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C295 LEFT HAND FENDER 1

1 1014C (R) / 1013 (R) LEFT HAND LAMPS / RIGHT HAND LAMPS
2 810B (G) / 810 (G/L) STOPLAMPS
3 3005B (G) / 3004 (G/W) LEFT HAND TURN SIGNAL WARNING LAMP / RIGHT HAND TURN
SIGNAL WARNING LAMP
4 57AW (B) / 57AV (B) EARTH (ALL)
5 998A (G) / 998 (G/LN/B) WORK LAMP-REAR FEED (INNER)
6 57AN (B) / 57AP (B) EARTH (ALL)
SS08F231 11 SS07E067 12
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C296 LEFT HAND FENDER 2

1 5100A (K) / 5100 (K/W) EDC EXTERNAL SWITCH UP
2 5200C (N) / 5200 (N/R/B) EDC VALVE SUPPLY
3 5095B (K) / 5095 (K/G) EDC EXTERNAL SWITCH DOWN
4 2059 (W) / 2059 (W/U) FENDER PTO SWITCH INPUT
5 2057 (W) / 2050 (G/R) PTO FENDER SWITCH LH - RH LINK / PTO SUPPLY / DOG SUPPLY
6 2056B (W) / 2056 (W/R/Y) PTO FENDER PTO SWITCH ON
SS08F232 13 SS07E067 14
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MAXXUM 140
C301 CONSTANT ERPM +/- SWITCH
MAXXUM
7 57J (B) EARTH (ALL)
9 57K (B) EARTH (ALL)
10 1012H (R) ILLUMINATION
MAXXUM
INA 1 SS08F094 2
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SS08F233 3 SS08F094 4
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C302 HTS SWITCH
MAXXUM
2 7000H (U) TRANS CONTROL SUPPLY
2 7000H (U) TRANS CONTROL SUPPLY
3 5600 (R) HTS LIVE SIGNAL
8 1012D (R) ILLUMINATION
MAXXUM
INA 5 SS08F094 6
SS08F234 7 SS08F094 8
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C309 CONSTANT ERPM SWITCH

3 6500 (N) CONSTANT ERPM ON/OFF
7 6550 (N) CONSTANT ERPM SET LAMP
INA 9 SS08F094 10
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MAXXUM 140
C313 HYDRALIC STOP (EHR STOP SWITCH)
MAXXUM
1 5597 (S) EHR MASTER ENABLE
5 5200J (N) EDC VALVE SUPPLY
6 5835 (S) HYDRAULIC MASTER SWITCH HIGH FLOW PUMP LINK
1 5265 (N) HYDRAULIC MASTER SW #2
2 5200E (N) EDC VALVE SUPPLY
3 5265D (N) HYDRAULIC MASTER SW #2
4 5260 (N) HYDRAULIC MASTER SW #1
7 57DG (B) EARTH (ALL)
8 1013V (R) RIGHT HAND LAMPS
9 57FA (B) EARTH (ALL)
10 1013P (R) RIGHT HAND LAMPS
MAXXUM
C313-BRI4577A 1 SS08F094 2
RIGHT HAND C PILLAR
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SS08F236 3 SS08F094 4
RIGHT HAND C PILLAR
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C314 HAND THROTTLE

1 5200F (N) EDC VALVE SUPPLY
2 6440A (S) HAND THROTTLE POSITION 1
4 6460A (S) HAND THROTTLE SWITCH (NOT IDLE)
5 5020D (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
6 60J (B/W) SENSOR GROUND
C314-BRJ4675A 5 SS07E067 6
RIGHT HAND CONSOLE
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C315 ENGINE E.C.U. A

1 Y/G *(N/G)
2 B/U *(N/B)
3 W/G
8 P/W *(W/B)
9 N/B
11 G
12 W
13 R/B *(O/U)
16 S/Y
17 S/B *(W/U)
18 N/B
19 G
20 W
21 R
22 Y/G
23 Y
27 R
28 S/B
31 O/W *(S/R)
32 O/U
33 B/P *(S/Q)
36 K/B
40 U/B
41 W/Y
43 R/G
46 U/R *(S/B)
47 N/W
48 S/R
49 O
50 R
51 O/B
52 W/U
53 S/W *(W/R)
54 Y/R
58 P/B *(O/G)
* With 4 cylinders.
C315V-BRJ5060E 7 SS08F239 8
TOP OF ENGINE
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MAXXUM 140
C321 DIA IN LINE

1 57HB (B) VEHICLE EARTH (ALL)
2 1010 (G) IGNITION RELAY (MAGNETIC COIL)
MAXXUM
C321-BRK5736A 1 SS08K508 2
BOTTOM RIGHT HAND SIDE ENGINE
SS08F237 3 SS08K508 4
BOTTOM RIGHT HAND SIDE ENGINE
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C324 O.C.M. CONNECTOR CN1-A
MAXXUM
1 2540S (N) FRONT HITCH +12v IGN
2 2540T (N) FRONT HITCH +12v IGN
3 2540W (N) FRONT HITCH +12v IGN
7 3285 (LN) SUSPENSION LOCKOUT SOLENOID LOWER
8 2250K (K) PTO FRONT - SUPPLY
14 5000B (L) EDC MEMORY POWER
15 5400S (Y) CAN H
16 5420S (G) CAN L
19 61G (B) CASE GROUND
20 5200M (N) EDC VALVE SUPPLY
25 57BR (B) EARTH (ALL)
26 57BS (B) EARTH (ALL)
7 3285 (N) SUSPENSION LOCKOUT SOLENOID LOWER
8 2540R (N) FRONT HITCH +12v IGN
12 2570Z (R) FRONT HITCH RAISE SOLENOID
14 5000B (P) EDC MEMORY POWER
15 5400A (Y) CAN H
16 5420A (G) CAN L
20 2250A (K) PTO FRONT - SUPPLY
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C324-BRI4462A 5 BRI4416B-05 6
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C325 O.C.M. CONNECTOR CN1-B
MAXXUM
16 2530 (N) FRONT HITCH V REF
17 5520 (LG) EHR 5V Ref.
18 2550 (N) FRONT HITCH OVERIDE SWITCH
19 2591 (LN) EXTERNAL SWITCH FHPL DOWN
21 1001Z (W) STARTER SOLENOID FEED
23 3295 (O) FRONT SUSPENSION PRESSURE SWITCH SIGNAL
26 2590 (LN) EXTERNAL SWITCH FHPL UP
30 5561 (O) EHR TIMED FLOW SWITCH #1
17 3220 (O) AXLE HEIGHT SENSOR 5V REF
18 2540X (N) FRONT HITCH +12v IGN
21 1001M (W) STARTER SOLENOID FEED
C325-BRI4461A 7 BRI4420B 8
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C326 A.C.U. CONNECTOR CN2
MAXXUM
3 3286 (LN) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
6 3281 (LN) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
21 57BN (B) EARTH (ALL)
26 57BP (B) EARTH (ALL)
6 3281 (N) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
13 3286 (N) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
C326-BRI4463A 9 BRI4416B-07 10
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C327 O.C.M. CONNECTOR CN3-A

1 5551 (O) EHR POTENTIOMETER SIGNAL VALVE#1
3 5552 (U) EHR POTENTIOMETER SIGNAL VALVE#2
5 5553 (W) EHR POTENTIOMETER SIGNAL VALVE#3
8 2067 (R) -
14 5572 (L) FENDER 3RD EHR SWITCH (RES)
15 5564 (L) EHR TIMED FLOW SWITCH #4
16 5521 (LG) EHR MOTOR #1
20 5570 (L) FENDER 3RD EHR SWITCH (RES)
22 4051 (W) LINK LEVEL SWITCH - LOWER
24 4052 (W) LINK LEVEL SWITCH SIDE EXTEND
25 4053 (W) LINK LEVEL SWITCH SIDE RETRACT
C327-BRI4465A 11 BRI4416B-08 12
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C328 O.C.M. CONNECTOR CN3-B
MAXXUM
5 4054 (W) LINK LEVEL DUMP SOLENOID
6 4056 (W) LINK LEVEL TOP LINK RETRACT SOLENOID
7 4058 (W) LINK LEVEL RIGHT LINK LOWER SOLENOID
11 4060 (W) HYDRAULIC SELECT FRONT
14 4055 (W) LINK LEVEL TOP LINK EXTEND SOLENOID
15 4057 (W) LINK LEVEL RIGHT LINK RAISE SOLENOID
25 2250C (K) PTO FRONT - SUPPLY
26 5591 (L) EHR WARNING LAMP#1
31 4061 (W) HYDRAULIC SELECT REAR
33 4050 (W) LINK LEVEL SWITCH - RAISE
34 2250B (K) PTO FRONT - SUPPLY
28 2575 (W) STEYR EFH TRANSPORT SIGNAL – BOSCH EFH MODULE
29 2576 (W) STEYR EFH WORK SIGNAL – BOSCH EFH MODULE
30 2578 (G) STEYR EFH TRANSPORT SWITCH – ELOBAU ARMREST
31 2579 (N) STEYR EFH WORK SWITCH – ELOBAU ARMREST
32 2577 (P) STEYR EFH DIAGNOSTIC LAMP – BOSCH EFH MODULE
C328-BRI4466A 13 BRI4420B 14
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C329 O.C.M. CONNECTOR CN4
MAXXUM
1 4101 (TQ) TRANS RANGE ENABLE
2 5580 (U) JOYSTICK REAR LAMP (MC)
3 5585 (Y) JOYSTICK FRONT LAMP (MC)
5 5640 (R) HTS AUTO SWITCH
6 3169 (O) AUTO GUIDANCE DUMP SOLENOID RETURN (CURSEN)
10 3014C (R) HANDBRAKE WARNING LAMP SIGNAL
11 7770 (U) TRANS FORWARD PRESSURE SWITCH
12 6620 (R) ECU COOLANT TEMP. SIGNAL
14 7960 (W) TRANS SLOW/FAST
16 7730 (LN) NOT IN PARKLOCK
17 8050 (R) TRANS REV PRESSURE
21 5830 (R) HIGH FLOW PUMP LINK
23 7476 (R) TRANS AUTO ON
25 5840 (W) FRONT HITCH DETECT INPUT
10 5265C (N) HYDRAULIC MASTER SW #2
C329-BRI4464A 15 BRI4416B-10 16
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MAXXUM 140
C339 SMALL CONTROL MODULE (SCM)

2 2050 (G) / 2050B (G) PTO SUPPLY / DOG SUPPLY
3 2050C (G) / 2050C (G/W) PTO SUPPLY / DOG SUPPLY
4 5000 (L/R) EDC MEMORY POWER
5 2051 (O/TQ) PTO SOLENOID RETURN (-)
6 7125 (LG/B/Y) DIFF-LOCK WNG LP (AUTO)
7 2200 (G/N/B) SERVICE MODE INITIATE
8 7500 (B/G) TRANS OIL TEMP. SENSOR
9 2065 (N/G/B) PTO ENGAGED
10 7080 (B/LG) DIFF-LOCK SOLENOID FEED
12 5400 (Y) CAN H
13 5420 (G) CAN L
14 5300 (K/W/B) ECU FLASH PROGRAM SIGNAL
15 3025A (Y/U) FOUR WHEEL DRIVE SOLENOID (MANUAL)
16 2055 (B/W/S) PTO SYNCHRO GROUND SPEED ENGAGED
17 7175 (Y/B) DIFF LOCK SWITCH (MANUAL ON)
18 2130 (B/N/S) PTO BRAKE SOLENOID
19 7650 (W/LN) DIAGNOSTIC PLUG RS232 OUT
20 7640 (B/LN) DIAGNOSTIC PLUG RS232 IN
21 2140 (B/O/S) PTO SPEED SENSOR
22 2045 (O/G) PTO SWITCH TO MODULE
23 3026A (Y/R) BRAKE PEDAL SWITCH - RIGHT
24 7170 (B/W) DIFF LOCK SWITCH (AUTO ON)
26 2042 (O/S) PTO SOLENOID-REAR
27 2065A (N/G/B) PTO ENGAGED
28 7120 (N/R/Y) DIFF-LOCK WNG LP (MAUAL)
30 3024 (Y/K) 2WD SOLENOID
31 2046 (O/LG) PTO SWITCH (VCC)
32 5190 (R/W/B) HPL INTERLOCK / LIFT-O-MATIC
33 2120 (B/LN/S) PTO BRAKE SIGNAL
34 3025B (Y/U) FOUR WHEEL DRIVE SOLENOID (MANUAL)
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INA 1 BRI4420B 2
ONLY 12x12
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MAXXUM 140
C341 COLD START DEVICE

1 (B) -
NOTE: For the wiring colour code refer to, Wiring harness - Overview (A.30.A).
SS09E004 1 SS09D353 2
C344 EHR CAN TERMINATOR

C344V-BRE1757A 3 SS08K508 4
BEHIND REMOTE VALVE STACK - 16x16 ONLY
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C348 NEUTRAL SWITCH 3/4 RAIL

A 7220B (S) TRANSMISSION HIGH RANGE
B 7000R (U) TRANS CONTROL SUPPLY
C348V-BRE1797A 5 SS08K508 6
RIGHT HAND SIDE TRANSMISSION - 24x24 ONLY
C349 NEUTRAL SWITCH 1/2

A 7220A (S) TRANSMISSION HIGH RANGE
B 7000P (U) TRANS CONTROL SUPPLY
C349V-BRK5712A 7 SS08K508 8
FRONT RIGHT HAND SIDE TRANSMISSION - 24x24 ONLY
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MAXXUM 140
C350 POWER B+

1 1 (R) BATTERY SUPPLY
C350-BRI4431A 1 SS07K143 2
C351 ELECTRONIC POWER

1 160 (U) BATTERY SUPPLY ELECTRONICS
2 1C (R) BATTERY SUPPLY
C351-BRI4432A 3 SS07K144 4
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C352 POWER B-

1 57 (B) VEHICLE EARTH (ALL)
C352-BRI4433A 5 SS07K143 6
C353 DE-GAS BOTTLE

1 650 (TQ) COOLANT GAUGE SENSOR
2 57JA (B) VEHICLE EARTH (ALL)
C353-BRI4489A 7 SS08K508 8
TOP ENGINE
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C354 GRID HEATER RELAY

1 6586 (L) ECU TO GRID HEATER RELAY RETURN
2 6408H (G) FUSED B+ TO ECU (1)
C354V-BRI4477E 9 SS08K508 10
LEFT HAND SIDE REAR ENGINE
C357 STARTER INHIBITOR SWITCH

A 1001 (W) STARTER SOLENOID FEED
B 1000A (W) SAFETY START SWITCH SUPPLY
C357V-BRF1873A 11 SS08M018 12
TOP OF TRANSMISSION - 12x12 ONLY
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C358 REAR CREEPING SENSING SWITCH

1 7000N (U) TRANS CONTROL SUPPLY
C358V-BRE1665A 13 SS08K508 14
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C359 4/5 SYNCHRO SOLENOID

2 7960 (L) TRANS SLOW/FAST
3 60AH (B/W) SENSOR GROUND
C359V-BRE1653A 15 SS08F072 16
TRANSMISSION TOP COVER - 16x16 ONLY
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MAXXUM 140
C360 5-8 SYNCHRO SOLENOID

2 7321 (L) SOLENOID 2 18x9 RETURN
C360V-BRE1617A 1 SS08K508 2
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C361 1-4 SYNCHRO SOLENOID

C361V-BRE1617C 3 SS08K508 4
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C362 BLOWER SWITCH
MANUAL
A 9211 (G/Y) AC-BLOWER SPEED LOW (1)
B 9212 (K) AC-BLOWER SPEED MED.1 (2)
C 9213 (K/O) AC-BLOWER SPEED MED.2 (3)
D 9214 (G/S) AC-BLOWER SPEED HIGH.2 (2)
E 982A (R) BLOWER MOTOR FEED
F 9210 (G) AC-SWITCH POWER
ATC
A 9228 (G/S) AC-AUTOMATIC BLOWER SPEED
B 9211 (G/Y) AC-BLOWER SPEED LOW (1)
C 9212 (K/G) AC-BLOWER SPEED MED.1 (2)
D 9213 (K/O) AC-BLOWER SPEED MED.2 (3)
E 9227 (B/W) AC-BLOWER SWITCH SUPPLY
MANUAL
C362-BRJ4661A 5 SS08F238 6
LEFT HAND C-PILLAR
ATC
SS09E005 7 SS08F238 8
LEFT HAND C-PILLAR
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C365 8 AMP SOCKET

1 9032C (Y) STARTER SWITCH+ TO SOCKET
2 57CT (B) VEHICLE EARTH (ALL)
C365-BRJ4651A 9 SS08F177 10
LEFT-HAND C-PILLAR
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C366 RADAR SOCKET

1 2320 (L) / 2320 (L/K/Y) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2 2300 (L) / 2300 (L/B/Y) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
3 2330 (L) / 2330 (L/LG/Y) PTO SPEED ISO11876 SKT.PIN#3
4 2310 (L) / 2310 (L/G/Y) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
6 1050A (G) / 1050 (G/W) ACCESSORY FEED
7 61B (B) / 61 (B) CASE GROUND
MAXXUM
C366V-BRK5730A 11 SS08K549 12
RIGHT HAND SIDE CONSOLE
SS08F200 13 SS08K549 14
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C367 GRID HEATER CONNECTOR

3 6580B (K) ECU TO GRID HEATER RELAY#1
4 1006B (N) ALTERNATOR WARNING LAMP
5 1001Y (W) STARTER SOLENOID FEED
6 6580A (K) ECU TO GRID HEATER RELAY#1
7 10K (G) IGNITION SUPPLY
8 57HC (B) EARTH (ALL)
INA 15 SS08K551 16
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C368 DIODE CONNECTOR 1 & 2
MAXXUM
1 820A (R) STOPLAMP SWITCH LH
2 825A (Y) PNEUMATIC TRAILER SOLENOID +12V
1 830A (R) STOPLAMP SWITCH RH
2 825B (Y) PNEUMATIC TRAILER SOLENOID +12V
1 820 (R) STOPLAMP SWITCH LH
2 820A (R) STOPLAMP SWITCH LH
1 830 (U) STOPLAMP SWITCH RH
2 830A (U) STOPLAMP SWITCH RH
MAXXUM
C368-BRI4474A 17 SS08F092 18
RIGHT HAND CONSOLE
SS08K547 19 SS08F092 20
RIGHT HAND CONSOLE
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C369 JOYSTICK

1 5200H (N) EDC VALVE SUPPLY.
4 57JS (B) EARTH (ALL)
5 5580 (U) JOYSTICK REAR LAMP (MC)
6 5585 (Y) JOYSTICK FRONT LAMP (MC)
INA 21 BRI4451B 22
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MAXXUM 140
C370 COMMAND ARM
MAXXUM
A1 6440B (S) HAND THROTTLE POSITION 1
A2 5125 (TQ) EDC RAISE SIGNAL-RAISE WORK SWITCH
A3 5130 (TQ) EDC WORK SIGNAL-RAISE WORK SWITCH
A4 5200E (N) EDC VALVE SUPPLY
A5 5020C (LN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
A6 5050 (LN) EDC QUADRANT
A7 5155 (U) EDC LOWER LIMIT POT
A8 7200B (S) TRANSMISSION SHIFT DOWN
B1 7210B (S) TRANSMISSION SHIFT UP
B2 5120 (K) EDC HEIGHT LIMIT SIGNAL
B3 5145 (TQ) EDC SLIP LIMIT POT
B4 5045 (LN) EDC DROP RATE
B5 5040 (LN) EDC DRAFT POSITION
B6 60D (B/W) SENSOR GROUND
B7 4101B (TQ) TRANS RANGE ENABLE
B8 7525F (G) TRANS SENSOR SUPPLY 5v
C1 5240 (O) EDC RAISE SIGNAL-RAISE WORK SWITCH No.2
C2 5220 (Y) EDC RAISE LAMP
C3 5230 (Y) EDC LOWER LAMP
C4 5110 (K) EDC LAMP SIGNAL
C5 5180 (TQ) EDC SLIP INDICATOR LAMP
C6 5620 (R) HTS ON/OFF SWITCH
C7 5133 (TQ) EDC STOP
C8 5250 (O) EDC WORK SIGNAL-RAISE WORK SWITCH No.2
A2 5125 (TQ) / (W) EDC RAISE SIGNAL-RAISE WORK SWITCH
A3 5130 (TQ) / (W) EDC WORK SIGNAL-RAISE WORK SWITCH
A4 2582 (G) / (B) STEYR - EXT SWITCHES UP
A5 2583 (N) / (B) STEYR - EXT SWITCHES DOWN
A6 5132 (TQ) / (W) EDC FLOAT
A7 5133 (TQ) / (W) EDC STOP
B1 3278 (O) / - LOADER VALVE #3 RELAY
B2 2578 (G) / (W) STEYR EFH TRANSPORT SWITCH – ELOBAU ARMREST
B3 2584 (W) / (W) OILMOTOR MODE
B4 2560A (N) / (Y) FRONT HITCH 0v REF
B5 2579 (N) / (W) STEYR EFH WORK SWITCH – ELOBAU ARMREST
B6 5400N (Y) / (Y) CAN H
B7 5420N (G) / (G) CAN L
B8 2050P (G) / (L) PTO SUPPLY / DOG SUPPLY
C1 57BZ (B) / (B) EARTH (ALL)
C2 3277 (O) / (W) LOADER VALVE #3 COIL
C3 2585 (N) / (W) EFH RAISE SWITCH
C4 2586 (N) / (W) EFH WORK SWITCH
C5 5520 (G) / (O) EHR 5V Ref.
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C6 5400C (Y) / (Y) CAN H
C7 5420C (G) / (G) CAN L
C8 1013W (R) / (S) RIGHT HAND LAMPS
MAXXUM
C370-BRJ4666A 1 SS08F314 2
RIGHT HAND SIDE CAB FLOOR NEAR OPERATOR'S SEAT
SS08F241 3 SS08F314 4
RIGHT HAND SIDE CAB FLOOR NEAR OPERATOR'S SEAT
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C373 KEYPAD

1 1050F (G) ACCESSORY FEED
2 5420H (G) CAN L
3 5400H (Y) CAN H
4 61H (B) CASE GROUND
C373-BRI4471A 5 SS08F193 6
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C374 HAZARD SWITCH HARNESS CONNECTOR

1 1021 (L) HAZARD SWITCH SUPPLY (BATTERY)
2 1020A (G) / 1020A (G/W) HAZARD SWITCH SUPPLY
4 1020 (G) / 1020 (G/S) HAZARD SWITCH SUPPLY
C374V-BRI4412E 7 SS07K215 8
BEHIND THE STEERING WHEEL
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C375 ADIC DIAGNOSTICS

1 7650Z (W) DIAGNOSTICS PLUG RS232 OUT
2 7640Z (LN) DIAGNOSTICS PLUG RS232 IN
3 57BT (B) VEHICLE EARTH (ALL)
C375-BRI4485A 9 BRI4485B 10
RIGHT HAND CONSOLE
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C376 FOOT THROTTLE (ELECTRONIC)
MAXXUM
4 6355B (R) +5V LOW POWER REFERENCE
7 60BL (B/W) SENSOR GROUND
8 60BM (B/W) SENSOR GROUND
3 7000BG (U) TRANS CONTROL SUPPLY
SS08F243 11 SS08F242 12
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C377 DIODE

1 978 (W) LICENCE PLATE LIGHT
2 997C (G) WORK LAMP - POWER SUPPLY REAR (OUTER)
C377-BRI4568A 13 SS08F092 14
RIGHT HAND SIDE REAR CAB ROOF
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C378 SWITCH PANEL
MAXXUM
A1 7000 (U) / 7000A (U) TRANS CONTROL SUPPLY
A2 5640 (R) HTS AUTO SWITCH
A3 7476 (R) TRANS AUTO ON
A4 3025 (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
A5 3027 (Y) FOUR WHEEL DRIVE SOLENOID (AUTO)
A6 7120 (Y) DIFF-LOCK WNG LP (MAUAL)
A7 7125 (LG) / 7125 (G) DIFF-LOCK WNG LP (AUTO)
A8 7170 (W) DIFF LOCK SWITCH (AUTO ON)
B1 7175 (Y) DIFF LOCK SWITCH (MANUAL ON)
B2 5630 (R) HTS MANUAL SWITCH
B3 6620 (N) ECU COOLANT TEMP. SIGNAL
B4 6530 (N) CONSTANT ERPM INCREASE
B5 6540 (N) CONSTANT ERPM DECREASE
B6 7040 (N) TRANS CREEPER SWITCH
B7 2067 (R) / 2069 (U) / PTO MANAGEMENT ON
B8 57AD (B) / 57 (B) EARTH (ALL)
C1 2050A (G) / 2050 (G) PTO SUPPLY / DOG SUPPLY
C2 3210 (U) SUSPENSION SWITCH RETURN
C3 3290 (O) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
C5 5610 (R) HTS PROGRAM
C7 6510 (N) CONSTANT ERPM SET 1
C8 9027 (W) CAL/ SEL INPUT ADIC
A1 7000A (U) / 7000 (U) TRANS CONTROL SUPPLY
A2 9000 (LN/S/B) / - DIVERTER VALVE
A4 3025B (Y) / 3025 (Y) FOUR WHEEL DRIVE SOLENOID (MANUAL)
A5 3027 (Y) FOUR WHEEL DRIVE SOLENOID (AUTO)
A6 7120 (Y) DIFF-LOCK WNG LP (MANUAL)
A7 7125 (G) DIFF-LOCK WNG LP (AUTO)
A8 7170 (W) DIFF LOCK SWITCH (AUTO ON)
B1 7175 (Y) DIFF LOCK SWITCH (MANUAL ON)
B3 6620 (N) ECU COOLANT TEMP. SIGNAL
B4 6530 (N) CONSTANT ERPM INCREASE
B5 6540 (N) CONSTANT ERPM DECREASE
B6 7040 (R) / 7040 (N) TRANS CREEPER SWITCH
B7 1012F (R) / 1012 (R) ILLUMINATION
C1 2050A (G) / 2050 (G) PTO SUPPLY / DOG SUPPLY
C2 3010 (U) FOGLAMP FEED
C3 3290 (O) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
C4 5600 (N) / 5600 (R) HTS LIVE SIGNAL
C5 5610 (R) HTS PROGRAM
C7 6510 (N) CONSTANT ERPM SET 1
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MAXXUM
C378-BRI4468A 15 SS08F244 16
RIGHT HAND CONSOLE
SS08F245 17 SS08F244 18
RIGHT HAND CONSOLE
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C379 LEFT HAND FRONT SMV LAMP

1 250A (LTG) SMV LIGHTS LEFT
2 57T (B) EARTH (ALL)
C379-BRI4452A 19 SS08K508 20
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MAXXUM 140
C380 LEFT HAND REAR SMV LAMP

1 250B (LTG) SMV LIGHTS LEFT
2 57Q (B) EARTH (ALL)
C380-BRI4572A 1 SS08K508 2
REAR LEFT HAND SIDE CAB ROOF
C381 RIGHT HAND FRONT SMV LAMP

1 249A (LTG) SMV LIGHTS RH
C381-BRI4459A 3 SS08K508 4
FRONT RIGHT HAND SIDE CAB ROOF
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C382 RIGHT HAND REAR SMV LAMP

1 249B (LTG) SMV LIGHTS RH
C382-BRI4563A 5 SS08K508 6
REAR RIGHT HAND SIDE CAB ROOF
C383 LEFT HAND REAR WORKLAMP

2 997A (G) WORK LAMP-REAR FEED (OUTER)
4 57P (B) EARTH (ALL)
C383-BRI4565A 7 SS08F147 8
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C384 RIGHT HAND REAR WORKLAMP

2 997B (G) WORK LAMP-REAR FEED (OUTER)
C384-BRI4569A 9 SS08F147 10
C385 RIGHT HAND REAR RADIO SPEAKER

SS08F249 11 SS08F177 12
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C386 LEFT HAND REAR RADIO SPEAKER

SS08F248 13 SS08F177 14
C387 RIGHT HAND CONSOLE LAMP

1 57H / 57DH (B) EARTH (ALL)
2 1013B (R) / 1013G (R) RIGHT HAND LAMPS
C387-BRI4459A 15 SS08F250 16
RIGHT HAND SIDE INTERIOR CAB ROOF
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C388 LEFT HAND PUDDLE LAMP

1 3057A (L) PUDDLE LAMP RETURN
2 666C (L) DOMELAMP SWITCH FEED
SS08K514 17 SS08K508 18
C389 RIGHT HAND PUDDLE LAMP

1 3057 (L) PUDDLE LAMP RETURN
2 666B (L) DOMELAMP SWITCH FEED
SS08K515 19 SS08K508 20
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MAXXUM 140
C390 EHR LEVER 1/2

1 5521 (LG) EHR Motor #1
2 5520A (G) EHR 5V Ref.
3 5520B (G) EHR 5V Ref.
6 5522 (G) EHR Motor #2
8 5520G (G) EHR 5V Ref.
9 5520H (G) EHR 5V Ref.
11 60C (B/W) SENSOR GROUND
C390-BRI4495C 1 BRI4411B-01 2
RIGHT HAND CONSOLE EHR PANEL
C391 LAMP 1

1 5591 (LG) EHR WARNING LAMP#1
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C391-BRI4497C 3 BRI4445B-02 4
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C392 EHR TO MAIN REAR CONNECTOR 1

A1 5520 (G) / 5520B (LG) EHR 5V Ref.
A2 5521 (LG) EHR Motor #1
A3 5522 (G) / 5522 (LG) EHR Motor #2
A6 5591 (LG) / 5591 (L) EHR WARNING LAMP#1
A7 5551 (O) EHR POTENTIOMETER SIGNAL VALVE#1
A8 5552 (U) EHR POTENTIOMETER SIGNAL VALVE#2
B1 5553 (O) / 5553 (W) EHR POTENTIOMETER SIGNAL VALVE#3
B2 5554 (O) / 5554 (U) EHR POTENTIOMETER SIGNAL VALVE#4
B3 5570 (L) FENDER 3RD EHR SWITCH (RES)
B4 5572 (L) FENDER 3RD EHR SWITCH (RES)
B5 5592 (L) EHR WARNING LAMP#2
B8 5200 / 5200P (N) EDC VALVE SUPPLY
C1 5561 (O) EHR TIMED FLOW SWITCH #1
C4 5564 (L) EHR TIMED FLOW SWITCH #4
C5 5596 (L) / 5596 (S) EHR MASTER STOP LAMP
C6 60 / 60AE (B/W) SENSOR GROUND
C392-BRI4494A 5 SS08F244 6
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C393 EHR TO MAIN REAR CONNECTOR 2

1 5591 (L/R/Y) EHR WARNING LAMP#1.
2 5592 (L/S/Y) EHR WARNING LAMP#2
3 5593 (L/U/Y) EHR WARNING LAMP#3
4 5594 (L/W/Y) EHR WARNING LAMP#4
5 5597 (S/W/Y) EHR MASTER ENABLE
6 2250G (K/O/S) / 2250 (K/O/S) PTO FRONT - SUPPLY
7 5200J (N/R/B) / 5200 (N/R/B) EDC VALVE SUPPLY
8 5561 (O/S/Y) EHR TIMED FLOW SWITCH #1
9 5562 (O/U/Y) EHR TIMED FLOW SWITCH #2
10 5563 (O/W/Y) EHR TIMED FLOW SWITCH #3
11 5564 (L/N/Y) EHR TIMED FLOW SWITCH #4
INA 7 SS08F244 8
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C394 EHR SWITCH 1/2 TIME FLOW

5 5520C (G) EHR 5V Ref.
C394-BRI4498C 9 BRI4438A 10
C395 EHR SWITCH 3/4 TIME FLOW

4 5563 (O) SWITCH TIME-CONTROLLED OIL FLOW ELECTROHYDR. REMOTE
VALVE 3
5 5520D (G) ELECTROHYDR. REMOTE VALVE 5V Ref.
6 5564 (L) SWITCH TIME-CONTROLLED OIL FLOW ELECTROHYDR. REMOTE
VALVE 4
C395-BRI4520C 11 BRI4438A 12
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C396 LAMP 2

2 5200 (B) EDC VALVE SUPPLY
C396-BRI4496C 13 BRI4445B-02 14
C397 LAMP 3

2 5200C (N) EDC VALVE SUPPLY
C397-BRI4521C 15 BRI4445B-02 16
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C398 LAMP 4

1 5200D (N) EDC VALVE SUPPLY
C398-BRI4522C 17 BRI4445B-02 18
C399 MASTER LAMP

1 5596 (L) EHR MASTER STOP LAMP
2 5200E (N) EDC VALVE SUPPLY
C399-BRI4492C 19 BRI4445B-02 20
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MAXXUM 140
C400 EHR LEVER 3/4

2 5520E (G) EHR 5V Ref.
3 5520F (G) EHR 5V Ref.
8 5520J (G) EHR 5V Ref.
9 5520K (G) EHR 5V Ref.
11 60D (B/W) SENSOR GROUND
C400-BRI4490C 1 BRI4411B-01 2
RIGHT HAND CONSOLE LEVER CONTROL UNIT
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C401 CERPM SET SWITCH
MAXXUM
5 7000AE (U) TRANS CONTROL SUPPLY
8 1012D (R) ILLUMINATION
10 1012K (R) ILLUMINATION
MAXXUM
INA 3 SS08F094 4
RIGHT HAND CONSOLE KEY PAD
SS08F257 5 SS08F094 6
RIGHT HAND CONSOLE KEY PAD
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C406 TRAILER BRAKE SOLENOID - AIR

2 57EK (B) EARTH (ALL)
SS08F258 7 SS07K217 8
REAR OF TRACTOR BEHIND CAB
C407 AIR BRAKE PRESSURE SENDER

2 8020B (LN) TRAILER BRAKE PRESSURE
SS08F259 9 SS08F072 10
RIGHT HAND BY REAR AXLE
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C408 TRAILER BRAKE SOLENOID - HYDRAULIC

1 8000C (N) TRAILER BRAKE SOLENOID
1 8000B (N) TRAILER BRAKE SOLENOID
INA 11 BRI4452B 12
C409 ITALIAN TRAILER BRAKE - LOW PUMP PRESSURE SWITCH

1 8060E (U) TRAILER BRAKE SUPPLY
INA 13 BRI4490D 14
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MAXXUM 140
C410 ITALIAN TRAILER BRAKE - LINE PRESSURE SWITCH

INA 1 BRI4490D 2
C411 FRONT SUSPENSION POTENTIOMETER

2 3230 (O) AXLE HEIGHT SENSOR POSITION
SS08F261 3 SS08F072 4
RIGHT HAND SIDE FRONT AXLE
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C413 LOADER VALVE 1

1 3272 (O) FRONT LOADER CONTROL VALVE 1 OUTPUT
2 3273 (O) FRONT LOADER CONTROL VALVE 1 RETURN SIGNAL
C414 LOADER VALVE 2

1 3274 (R) FRONT LOADER CONTROL VALVE 2 OUTPUT
2 3275 (R) FRONT LOADER CONTROL VALVE 2 RETURN SIGNAL
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C416 20 AMP MULTI SOCKET

A 3070C (L) POWER SUPPLY SOCKET ON THE B-PILLAR
B 57CW (B) VEHICLE EARTH (ALL)
C 9032A (Y) STARTER SWITCH+ TO SOCKET
INA 5 BRI4475B 6
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C417 8A RING TERMINALS (2 OFF)

1 3070 (L/W) ’B’ PILLAR SKT SUPPLY
MAXXUM
INA 7 SS08F265 8
REAR RIGHT HAND SIDE CONSOLE PANEL
SS08F266 9 SS08F265 10
REAR RIGHT HAND SIDE CONSOLE PANEL
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C418 FRONT CREEPING SENSING SWITCH

C418V-BRE1665C 11 SS08K508 12
C419 DOWN SHIFT

2 7200 (S/K/B) TRANSMISSION SHIFT DOWN
4 7000 (U/R/B) TRANS CONTROL SUPPLY
SS09D360 13 SS08F147 14
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MAXXUM 140
C420 UP SHIFT

2 7210 (S/LG/B) TRANSMISSION SHIFT UP
SS09D361 1 SS08F147 2
RIGHT HAND CONSOLE
C421 RANGE SHIFT

2 7009 (W/G/S) TRANS RANGE DISABLE SWITCH
SS09D362 3 SS08F147 4
RIGHT HAND CONSOLE
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C422 PTO MANAGEMENT

2 2050C (G) POWER SUPPLY PTO / SHIFTING CLAW
3 2069 (U) PTO MANAGEMENT ON
C422V-BRJ5075E 5 SS08F094 6
C423 BRAKE PEDAL LATCHED

1 10L (G) IGNITION SUPPLY
2 7996 (R) BRAKE PEDALS UNLATCHED SIGNAL
C423V-BRF1886A 7 SS08F275 8
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C424 LOADER POWER
MAXXUM
1 3271 (R) / 3271A (O) LOADER RELAY FEED
2 57FP (B) EARTH (ALL)
1 3271A (O) / 3271 (R) LOADER RELAY FEED
2 1006D (N) / 1006 (U) ALTERNATOR WARNING LAMP
C424V-BRI4485E 9 SS08F267 10
BOTTOM RIGHT-HAND CONSOLE
C425 AUXILIARY HEADLAMP SWITCH

1 1030A (U) / 1027A (U) HEADLAMP DIP BEAM / MAIN BEAM HEADLIGHT
C425-BRI4480A 11 BRI4445B 12
RIGHT HAND SIDE C-PILLAR
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C427 BOOST PRESSURE / TEMPERATURE SENSOR (EDC 16)

1 (Y)
2 (S/W) *(W/R)
3 (R/B) *(O/U)
4 (U/B)
* With 4 cylinders.
SS08F269 13 SS08F268 14
C428 OIL PRESSURE/TEMPERATURE SENSOR (EDC 16)

1 (Y/G)
2 (K/B)
3 (N/B)
4 (Y/R)
C428-BRI4536A 15 SS08F268 16
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C429 RAIL PRESSURE SENSOR (EDC 16)

1 (P/W) *(W/R)
2 (R/G)
3 (S/B)
* With 4 cylinders.
C429-BRI4540A 17 SS08F270 18
TOP LEFT HAND SIDE ENGINE
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MAXXUM 140
C430 COOLANT TEMPERATURE SENSOR (EDC 16)

1 (P/B) *(O/G)
2 (W/Y)
* With 4 cylinders.
C430V-BRJ5028E 1 SS08F271 2
FRONT RIGHT HAND SIDE ENGINE
C431 FUEL TEMPERATURE SENSOR (EDC 16)

1 (W/U)
2 (O/B)
C431-BRI4538A 3 SS08F271 4
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C432 CRANKSHAFT SPEED SENSOR (EDC 16)

1 (W)
2 (R)
3 (G)
MAXXUM
C432-BRI4615A 5 SS08F270 6
SS08F272 7 SS08F270 8
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C433 CAMSHAFT SPEED SENSOR (EDC 16)

1 (W)
2 (R)
3 (R)
SS08F273 9 SS08F270 10
REAR LEFT HAND SIDE ENGINE
C434 CYLINDER INJECTOR 1 AND 2 (EDC 16)

1 (N/B)
2 (S/R)
3 (S/Y)
4 (N/W)
C434-BRI4542A 11 SS08F274 12
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1 (W/G) *(S/Q)
2 (O/U) *(W/U)
3 (S/B)
4 (B/P) *(N/G)
* With 4 cylinders.
C436-BRI4543A 13 SS08F274 14

1 (U/B)
2 (O/W)
3 (U/R)
4 (Y/B)
C438-BRI4545A 15 SS08F274 16
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MAXXUM 140
C440 FUEL METERING UNIT (EDC 16)

1 (G)
2 (O)
C440-BRI4539A 1 SS08F271 2
REAR LEFT HAND SIDE ENGINE
C441 LOADER VALVE 1

INA 3 SS08M031 4
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C442 LOADER VALVE 2

INA 5 SS08M031 6
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C443 E.H.R. CAN

1 5500B (R) EHR CAN HIGH
2 5510B (U) EHR CAN LOW
MAXXUM
C443-BRJ4680A 7 SS08F275 8
RIGHT HAND CONSOLE
SS08F277 9 SS08F275 10
RIGHT HAND CONSOLE
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C444 TRANS CAN

1 5400E (Y) CAN H
2 5420E (G) CAN L
MAXXUM
C444-BRJ4681A 11 SS08F275 12
RIGHT HAND CONSOLE
SS08F279 13 SS08F275 14
RIGHT HAND CONSOLE
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C445 CAN DIAGNOSTIC SELECT

1 5400O (Y) CAN H
2 5420O (G) CAN L
MAXXUM
C445-BRJ4682A 15 SS08F280 16
RIGHT HAND CONSOLE
SS08F282 17 SS08F280 18
RIGHT HAND CONSOLE
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MAXXUM 140
C455 OIL MOTOR OPERATIONS SWITCH

2 2050M (G) PTO SUPPLY / DOG SUPPLY
3 2584 (W) OILMOTOR MODE
7 57DE (B) EARTH (ALL)
8 1013U (R) RIGHT HAND LAMPS
SS08F286 1 SS08F094 2
RIGHT HAND C PILLAR
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MAXXUM 140
C492 EFH RAISE CONTROL BUTTON

1 (W) EFH - WORK
2 (O) EFH 9,5V
3 (W) EFH - RAISE
4 (W) EFH - WORK HEADLAND TURN SEQUENCES
5 (P) EFH SUPPLY 12V
6 (W) EFH - RAISE HEADLAND TURN SEQUENCES
7 (B) EARTH (ALL)
8 (S) ILLUMINATION
9 (B) EARTH (ALL)
10 (S) ILLUMINATION
SS08F288 1 SS08F094 2
ARMREST
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MAXXUM 140
C500 BATTERY ISOLATOR DASH HARNESS

1 1H (R) BATTERY SUPPLY
2 10P (G) / 170A (N) BATTERY ISOLATOR CONTROL SWITCH / IGNITION SUPPLY
3 171 (W) / 171A (N) BATTERY ISOLATOR RELAY COIL
4 10W (G) / 170B (N) BATTERY ISOLATOR CONTROL SWITCH / IGNITION SUPPLY
5 172 (W) / 172 (Y) BATTERY ISOLATOR RELAY COIL (OFF)
6 - / 666E (L) DOMELAMP SWITCH FEED
MAXXUM
C500-BRI4560A-1 1 SS08F131 2
SS08F290 3 SS08F131 4
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C503 ISOLATOR ROCKER SWITCH (ISOLATOR CONTROL)
MAXXUM
2 1H (R) BATTERY POWER SUPPLY
3 170 (K/N/B) ACTUATING SWITCH BATTERY ISOLATOR
4 171A (W/TQ/B) RELAY COIL BATTERY ISOLATOR
1 171A (N) BATTERY ISOLATOR RELAY COIL
2 1H (R) BATTERY SUPPLY
3 172 (Y) BATTERY ISOLATOR RELAY COIL (OFF)
7 170 (K) BATTERY ISOLATOR CONTROL SWITCH
8 666E (L) DOMELAMP SWITCH FEED
MAXXUM
SS09E017 5 SS08F094 6
SS08F292 7 SS08F094 8
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C504 DIODE (ISOLATOR CONTROL)

1 1001AD (W) STARTER SOLENOID FEED
2 171C (W) BATTERY ISOLATOR RELAY COIL
MAXXUM
SS09E018 9 SS08F092 10
SS09E013 11 SS08F092 12
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MAXXUM 140
C511 TURN ASSIST - LVDT COILS

1 3179 (N) TURN ASSIST - POSITION SENSOR SECONDARY NEGATIVE
2 3175 (W) TURN ASSIST - POSITION SENSOR PRIMARY POSITIVE
3 3177 (U) TURN ASSIST - POSITION SENSOR SECONDARY COMMON
4 3176 (B) TURN ASSIST - POSITION SENSOR PRIMARY NEGATIVE
5 3178 (G/Y) TURN ASSIST - POSITION SENSOR SECONDARY POSITIVE
SS08F295 1 SS08F294 2
REAR OF ENGINE
C512 TURN ASSIST SOLENOID VALVE

1 3173 (R) TURN ASSIST – HYDRAULIC VALVE HIGH SIDE DRIVER
2 3174 (G) TURN ASSIST – HYDRAULIC VALVE LOW SIDE DRIVER
SS08F297 3 SS08F296 4
REAR OF ENGINE
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C513 PROXIMITY SENSOR

2 3172 (L) / 3172 (U) TURN ASSIST – STEERING PROXIMITY SENSOR POSITION
3 10C (G) / 10C (N) IGNITION SUPPLY
SS08F299 5 SS08F298 6
STEERING CONSOLE
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C514 CONTROL SWITCH

3 3170 (O) FSS – ENABLE
4 3180 (B) FSS – SAFETY SWITCH
7 3171 (O) FSS – LAMP
8 10E (G) IGNITION SUPPLY
MAXXUM
INA 7 SS08F094 8
SS09E008 9 SS08F094 10
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C515 CONTROL MODULE (CENTRALINA)

A1 3170 (O) FSS – ENABLE
A2 3173 (R) FSS – HYDRAULIC VALVE HIGH SIDE DRIVER
A4 5400 (Y) CAN H
A5 5420 (G) CAN L
A6 3174 (G) FSS – HYDRAULIC VALVE LOW SIDE DRIVER
A7 57C (B) EARTH (ALL)
A8 57B (B) EARTH (ALL)
B1 3171 (O) FSS – LAMP
B4 3172 (L) FSS – STEERING PROXIMITY SENSOR POSITION
B5 3178 (G/Y) FSS – POSITION SENSOR SECONDARY POSITIVE
B6 3179 (N) FSS – POSITION SENSOR SECONDARY NEGATIVE
B8 160 (U) BATTERY SUPPLY ELECTRONICS
C1 3175 (W) FSS – POSITION SENSOR PRIMARY POSITIVE
C2 3176 (B) FSS – POSITION SENSOR PRIMARY NEGATIVE
C3 3177 (U) FSS – POSITION SENSOR SECONDARY COMMON
C4 3180 (B) FSS – SAFETY SWITCH
C8 10D (G) IGNITION SUPPLY
MAXXUM
C515-BRI4486A 11 SS08K548 12
SS08F302 13 SS08K548 14
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C517 GRABRAIL WORKLAMPS RELAY
Low profile roof

2 57MD (B) EARTH (ALL)
3 1091 (R) FRONT WORKLAMP LOWER RELAY SIGNAL
4 1097G (R/S) FEED FRONT WORKLAMP OUTER
Low profile roof
SS08F304 15 SS08F303 16
RIGHT HAND SIDE ROOF - VIEW SHOWN LOW PROFILE CAB
C518 BEACON RELAY
Low profile roof

1 4011A (L/G) ROTATING BEACON SWITCH SUPPLY
2 57MF (B) EARTH (ALL)
3 4120 (L/Y) BEACON RELAY COIL
4 4012 (L/R) ROTATING BEACON FEED
Low profile roof
SS08F305 17 SS08F303 18
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C519 RIGHT HAND GRABRAIL SIDELAMP
Low profile roof

1 249C (LG/W/S) SMV LAMPS RH
2 1013H (R) RIGHT HAND LAMPS
4 57DD (B) EARTH (ALL)
Low profile roof
SS08M005 19 SS08F147 20
CAB ROOF - VIEW SHOWN LOW PROFILE CAB
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MAXXUM 140
C520 RIGHT HAND FRONT SMV LAMP
Low profile roof

2 249A (LG/W/S) SMV LAMPS RH
4 57K (XB) EARTH (ALL)
Low profile roof
SS08M025 1 SS08F147 2
C521 BEACON SWITCH
Low profile roof

2 4011B (L/G) ROTATING BEACON SWITCH SUPPLY
3 4120 (L/Y) BEACON RELAY COIL
7 57MA (B) EARTH (ALL)
Low profile roof
SS08F307 3 SS08F094 4
RIGHT HAND SIDE C PILLAR - VIEW SHOWN LOW PROFILE CAB
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C522 FENDER WORKLAMP SWITCH
Low profile roof

2 1013AD (R) RIGHT HAND LAMPS
3 1090 (R) REAR WORKLAMP RELAY SIGNAL
7 57MC (B) EARTH (ALL)
Low profile roof
SS08F308 5 SS08F094 6
C523 FRONT WORKLAMP SWITCH
Low profile roof

2 1013AC (R) RIGHT HAND LAMPS
3 1092 (R) FRONT WORKLAMP RELAY SIGNAL
7 57MB (B) EARTH (ALL)
Low profile roof
SS08F309 7 SS08F094 8
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C524 GRABRAIL WORKLAMP SWITCH
Low profile roof

2 1013AB (R) RIGHT HAND LAMPS
3 1091 (R) FRONT WORKLAMP LOWER RELAY SIGNAL
7 57ME (B) EARTH (ALL)
Low profile roof
SS08F310 9 SS08F094 10
C525 RIGHT HAND REAR SMV LAMP
Low profile roof

2 249B (LG/W/S) SMV LAMPS RH
4 57DG (B) EARTH (ALL)
Low profile roof
SS08M027 11 SS08F147 12
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C526 LEFT HAND REAR SMV LAMP
Low profile roof

2 250B (LG/R/S) SMV LAMPS LH
4 57DS (B) EARTH (ALL)
Low profile roof
SS08M026 13 SS08F147 14
C527 INTERIOR LAMP
Low profile roof

1 666A (L/W) DOMELAMP SWITCH FEED
1 3052B (L/W) / 3052A (L/W) DOME LAMP TO DOOR SWITCH
2 57DT (B) EARTH (ALL)
Low profile roof
C527V-BRH3388A 15 SS08F311 16
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C528 LEFT HAND GRABRAIL SIDELAMP
Low profile roof

1 250C (LG/R/S) SMV LAMPS LH
2 1014D (R/B) LEFT HAND LAMPS
4 57DP (B) EARTH (ALL)
Low profile roof
SS08M028 17 SS08F147 18
C529 LEFT HAND FRONT SMV LAMP
Low profile roof

2 250A (LG/R/S) SMV LAMPS LH
4 57DU (B) EARTH (ALL)
Low profile roof
SS08M029 19 SS08F147 20
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MAXXUM 140
C530 RADIO CONNECTOR A
Low profile roof

4 138 (L/TQ) RADIO KAM
7 3079 (R) RADIO +12V IGNITION
8 57DA (B) EARTH (ALL)
Low profile roof
C530-BRK5741A 1 SS08F313 2
C531 RADIO CONNECTOR B
Low profile roof

3 3093 (S) SPEAKER FRT-RHS +
4 3094 (S/B) SPEAKER FRT-RHS -
5 3095 (W) SPEAKER FRT-LHS +
6 3096 (W/B) SPEAKER FRT-LHS -
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Low profile roof
C531-BRK5742A 3 SS08F313 4
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C532 ROOF TO CAB HARNESS CONNECTOR
MAXXUM
A1 998D (G/LN) WORK LAMP-REAR FEED (INNER)
A2 28 (Y/LG) WIPER MOTOR (PARK RETURN)
A3 56 (W/LG) WIPER MOTOR - HIGH
A4 58 (R/LG) WIPER MOTOR - LOW
A5 1019 (G) / 1019A (G) WINDSHIELD WIPER FEED
A6 1038B (LN/B/S) / 1038 (LN/B/S) WINDSHIELD WIPER FEED-REAR
A7 1120 (G/O/B) RR WINDSHIELD WIPER PARK RETURN
A8 4011 (L/G) ROTATING BEACON SWITCH SUPPLY
B1 1013 (R) / 1013B (R) RIGHT HAND LAMPS
B2 249 (LG/W/S) SMV LAMPS RH
B3 666 (L/W) / 666A (L/W) DOMELAMP SWITCH FEED
B4 1090 (R/TQ) REAR WORKLAMP RELAY SIGNAL
B5 1092 (R/N) FRONT WORKLAMP RELAY SIGNAL
B7 1071B (L) WORKLAMP FRONT FEED
B8 1071A (L) WORKLAMP FRONT FEED
C1 1014 (R/B) / 1014D (R/B) LEFT HAND LAMPS
C2 250 (LG/R/S) SMV LAMPS LH
C3 138 (L/TQ) / 138A (L/TQ) RADIO KAM
C4 3079 (R/K) RADIO +12V IGNITION
A1 998D (G/LN) / 998 (G) WORK LAMP-REAR FEED (INNER)
A2 28 (Y/LG) / 28 (Y) WIPER MOTOR (PARK RETURN)
A3 56 (W/LG) / 56 (W) WIPER MOTOR - HIGH
A4 58 (R/LG) / 58 (R) WIPER MOTOR - LOW
A5 1019A (G) / 1019 (G) WINDSHIELD WIPER FEED
A6 1038B (LN/B/S) / 1038 (LN) WINDSHIELD WIPER FEED-REAR
A7 1120 (G/O/B) / 1120 (G) RR WINDSHIELD WIPER PARK RETURN
A8 4011 (L/G) / 4011 (L) ROTATING BEACON SWITCH SUPPLY
B1 1013B (R) / 1013 (R) RIGHT HAND LAMPS
B2 249 (LG/W/S) / 249 (LTG) SMV LAMPS RH
B3 666A (L/W) / 666 (L) DOMELAMP SWITCH FEED
B4 1090 (R/TQ) / 1090 (R) REAR WORKLAMP RELAY SIGNAL
B5 1092 (R/N) / 1092 (R) FRONT WORKLAMP RELAY SIGNAL
B6 1925C (R) / 1925 (R) MIRROR CONTROL +12V
B7 1071B (L) WORKLAMP FRONT FEED
B8 1071A (L) WORKLAMP FRONT FEED
C1 1014D (R/B) / 1014 (R) LEFT HAND LAMPS
C2 250 (LG/R/S) / 250 (LTG) SMV LAMPS LH
C3 138A (L/Y) / 138 (L) RADIO KAM
C4 3079 (R/K) / 3079 (R) RADIO +12V IGNITION
C5 1927A (R) / 1927 (R) MIRROR ILLUMINATION
C7 1013E (R) / 1013AH (R) RIGHT HAND LAMPS
Low profile roof

A1 998D (G/LN) / 998D (G) WORK LAMP-REAR FEED (INNER)
A2 28 (Y/LG) WIPER MOTOR (PARK RETURN)
A3 56 (W/LG) WIPER MOTOR - HIGH
A4 58 (R/LG) WIPER MOTOR - LOW
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A5 1019A (G) WINDSHIELD WIPER FEED
A6 1038B (LN/B/S) WINDSHIELD WIPER FEED-REAR
A7 1120 (G/O/B) RR WINDSHIELD WIPER PARK RETURN
A8 4011 (L/G) ROTATING BEACON SWITCH SUPPLY
B1 1013B (R) RIGHT HAND LAMPS
B2 249 (LG/W/S) SMV LAMPS RH
B3 666A (L/W) DOMELAMP SWITCH FEED
B4 1090 (R/TQ) / 1090 (R) REAR WORKLAMP RELAY SIGNAL
B5 1092 (R/N) FRONT WORKLAMP RELAY SIGNAL
B7 1071B (L) / 1071A (L) WORKLAMP FRONT FEED
C1 1014D (R/B) LEFT HAND LAMPS
C2 250 (LG/R/S) SMV LAMPS LH
C3 138A (L/Y) / 138 (L) RADIO KAM
C4 3079 (R/K) RADIO +12V IGNITION
C7 1013E (R) / 1013AH (R) RIGHT HAND LAMPS
MAXXUM
C532-BRI4476A 5 SS08F314 6
SS08F316 7 SS08F314 8
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C539 TURN ASSIST INPUT CONNECTOR
MAXXUM
1 5000D (L) EDC MEMORY POWER
2 5200AB (N) EDC VALVE SUPPLY
3 57CZ (B) EARTH (ALL)
4 5400X / 5400V (Y) CAN H
5 5420X / 5420V (G) CAN L
6 1001AC (W) STARTER SOLENOID FEED
1 6408F (G) / 160 (U) FUSED B+ TO ECU (1) / BATTERY SUPPLY ELECTRONICS
2 1011G (Y/W) / 10A (G) SUPPLY TO FUSES / IGNITION SUPPLY
3 57HN (B) / 57A (B) EARTH (ALL)
4 5400M (Y) / 5400 (Y) CAN H
5 5420M (G) / 5420 (G) CAN L
MAXXUM
C539-BRI4691A 9 SS08F317 10
FRONT RIGHT HAND CAB FLOOR
SS08F318 11 SS08F317 12
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MAXXUM 140
C542 AIR CONDITIONING THERMOSTAT

1 9215 (U/K) / (U) AC-SWITCH ON
2 2006A (L) / (U/R) DE-ICING SWITCH - AIR CONDITIONER
SS08F101 1 SS08F100 2
UNDER THE SEAT
C543 AIR CONDITIONING LOW PRESSURE SWITCH

A 2006 (U/K) DE-ICING SWITCH - AIR CONDITIONER
B 9215 (U/K) AC-SWITCH ON
SS08F104 3 SS08F026 4
UNDER THE SEAT
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MAXXUM 140
C550 DIVERTOR SWITCH

1 5200K (N) POWER SUPPLY EPC CONTROL VALVE
2 9000 (LN) OIL FLOW DIVIDER
INA 1 SS08F092 2
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C551 HEATED MIRROR SWITCH

2 1925A (R) MIRROR CONTROL +12V
3 1928 (R) HEATED MIRROR RELAY COIL +12V FROM SW
7 57MS (B) EARTH (ALL)
8 1927B (R) MIRROR ILLUMINATION
MAXXUM
C551-BRI4574A 3 SS08F094 4
SS08M032 5 SS08F094 6
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C557 AIR CONDITIONING CONTROL
MANUAL
1 5420M (G) / - CAN L
2 5400M (Y) / - CAN H
4 2006A (U) / (L) DE-ICING SWITCH - AIR CONDITIONING
5 2006B (U) / (W/U) DE-ICING SWITCH - AIR CONDITIONING
6 2005 (O) / (W/U) CLUTCH RELAY AIR CONDITIONING SYSTEM
ATC
1 5420P (G) / (G) CAN L
2 5400P (Y) / (Y) CAN H
3 - / 9229 (O/R) AC-DEFOG
4 2006A (U) / (W) DE-ICING SWITCH - AIR CONDITIONING
5 2006B (U) / (W/U) DE-ICING SWITCH - AIR CONDITIONING
6 2005 (O) / (L/R) CLUTCH RELAY AIR CONDITIONING SYSTEM
MANUAL
SS08M030 7 SS07F063 8
LEFT HAND SIDE BEHIND OPERATOR'S SEAT
ATC
SS07F062 9 SS07F063 10
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C559 AIR CONDITIONING POWER

1 982B (G) / (R) POWER SUPPLY BLOWER MOTOR
2 982C (G) / (R) POWER SUPPLY BLOWER MOTOR
3 57NZ (B) EARTH (ALL)
4 57PA (B) EARTH (ALL)
SS08F320 11 SS07F064 12
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MAXXUM 140
C576 BRAKE DE-ICER

2 57FN (B) EARTH (ALL)
SS08F321 1 SS07K214 2
LEFT HAND SIDE REAR AXLE
C577 PARK BRAKE SOLENOID

1 8070 (L) TRAILER PARK BRAKE SOLENOID
2 57EL (B) EARTH (ALL)
SS08F322 3 SS07K220 4
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C579 BATTERY SWITCH SOLENOID

1 171B (W/TQ/B) BATTERY ISOLATOR RELAY COIL
2 57NN (B) EARTH (ALL)
3 57NP (B) EARTH (ALL)
4 172A (W/TQ/Y) BATTERY ISOLATOR RELAY COIL (OFF)
SS08F324 5 SS08F323 6
RIGHT HAND BEHIND STEPS
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MAXXUM 140
C580 BATTERY ISOLATOR TO ENGINE HARNESS CONNECTOR

1 171B (W) / 171B (W/TQ/B) BATTERY ISOLATOR RELAY COIL
2 57HA (B) EARTH (ALL)
3 172A (W) / 172A (W/TQ/Y) BATTERY ISOLATOR RELAY COIL (OFF)
SS08F289 1 SS08F207 2
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MAXXUM 140
C604 BUS TERMINATING RESISTOR
C607 ELECTRICAL MIRROR LEFT HAND

1 1922A (G) MIRROR CONTROL COMMON
2 1920 (O) LH MIRROR CONTROL SIDE-SIDE
3 1921 (Y) LH MIRROR CONTROL UP-DOWN
4 1927A (R) MIRROR ILLUMINATION
5 57AC (B) EARTH (ALL)
SS08K516 1 SS08F325 2
FRONT LEFT-HAND SIDE CAB ROOF
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C608 ELECTRICAL MIRROR RIGHT HAND

1 1922B (G) MIRROR CONTROL COMMON
2 1923 (O) RH MIRROR CONTROL SIDE-SIDE
3 1924 (Y) RH MIRROR CONTROL UP-DOWN
5 57AD (B) EARTH (ALL)
SS08K517 3 SS08F325 4
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C609 MIRROR CONTROL

4 57AE (B) EARTH (ALL)
7 1922 (G) MIRROR CONTROL COMMON
8 1925 (R) MIRROR CONTROL +12V
MAXXUM
C609-BRI4572A 5 BRI4457B 6
INTERIOR CAB ROOF
SS08F327 7 SS08F326 8
INTERIOR CAB ROOF
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MAXXUM 140
C619 MEMORY +

1 150AG (N) BATTERY FEED (ALL)
1 150AM (N) BATTERY FEED (ALL)
1 1D (R) STOPLAMP SWITCH FEED
SS08F084 1 SS08F082 2
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MAXXUM 140
C625 FUEL HEATER RELAY

2 6408J (G) FUSED B+ TO ECU (1)
SS08F329 1 SS08F092 2
C626 FUEL HEATER CONNECTOR

C626V-BRJ4656E 3 SS08F092 4
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C627 TEMPERATURE CONTROL POTENTIOMETER
MANUAL
1 9215 (U) / (U/K) AC-SWITCH ON
2 2006 (L) / (U/R) DE-ICING SWITCH - AIR CONDITIONER
ATC
A 9216 (LG/R) AC-TEMPERATURE POTENTIOMETER CAB
B 57ZN (B) EARTH (ALL)
MANUAL
C627V-BRK5738A 5 SS08M031 6
LEFT-HAND SIDE C PILLAR
ATC
SS08K555 7 SS08M001 8
LEFT-HAND SIDE C PILLAR
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C628 H.V.A.C. ECU

1 (G) CAN L
2 (Y) CAN H
3 9226 (Y/R) AC-SIGNAL WATER VALVE
4 982G (W/R) BLOWER MOTOR FEED
5 9225 (U/R) AC-BLOWER SPEED
6 982 (U/R) BLOWER MOTOR FEED
15 2005 (L/R) AIR CON CLUTCH RELAY
16 (O/R) DEHUMIDIFIED OUTPUT
17 982J (R) BLOWER MOTOR FEED
18 57ZE (B) VEHICLE EARTH (ALL)
21 9223 (R/B) AC-SIGNAL CAB TEMPERATURE SENSOR
22 9222 (Y/B) AC-SIGNAL OUTLET TEMPERATURE SENSOR
23 9221 (L/B) AC-EVAPORATOR TEMPERATURE SENSOR
24 9224 (O/B) AC-SIGNAL AMBIENT TEMPERATURE SENSOR
25 9217 (N/R) AC-SWITCH MAX DEFROST
26 9218 (S/R) AC-SWITCH ECONOMY
27 9228 (G/S) AC-AUTOMATIC BLOWER SPEED
28 9211 (G/Y) AC-BLOWER SPEED LOW (1)
29 9216 (LG/R) AC-TEMPERATURE POTENTIOMETER CAB
30 9212 (K/G) AC-BLOWER SPEED MED.1 (2)
31 9213 (K/O) AC-BLOWER SPEED MED.2 (3)
33 2006A (W) DE-ICING SWITCH - AIR CONDITIONER
34 2006B (W/U) DE-ICING SWITCH - AIR CONDITIONER
35 9220 (U) AC-LOW PRESSURE SWITCH INPUT
36 9219 (U/W) AC-LOW PRESSURE SWITCH OUTPUT
SS07F068 9 SS07F067 10
LEFT-HAND SIDE BEHIND OPERATOR'S SEAT
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C629 AIR CONDITIONING SWITCH
MANUAL
2 9210 (G) AC-SWITCH POWER
3 9215 (U) AC-SWITCH ON
ATC
1 9217 (N/R) AC-SWITCH MAX DEFROST
2 982E (R) BLOWER MOTOR FEED
3 9218 (S/R) AC-SWITCH ECONOMY
7 57ZM (B) EARTH (ALL)
9 57ZL (B) EARTH (ALL)
MANUAL
C629-BRJ4662A 11 SS08F094 12
LEFT HAND SIDE C PILLAR
ATC
SS08M033 13 SS08F094 14
LEFT HAND SIDE C PILLAR
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MAXXUM 140
C630 H.V.A.C. UNIT

A 9222 (Y) / (Y/B) AC-SIGNAL OUTLET TEMPERATURE SENSOR
B 9221 (Y) / (L/B) AC-EVAPORATOR TEMPERATURE SENSOR
C 9220 (R) / (U) AC-LOW PRESSURE SWITCH INPUT
D 57ZH (B) EARTH (ALL)
E 982D (R) BLOWER MOTOR FEED
F 9226 (Y) / (Y/R) AC-SIGNAL WATER VALVE
G 9219 (B/W) / (U/W) AC-LOW PRESSURE SWITCH OUTPUT
SS07E286 1 SS08M002 2
LEFT HAND SIDE CAB
C635 REAR PTO BRAKE SWITCH JUMPER

2 2120A (N) PTO BRAKE SIGNAL
4 2120 (N) PTO BRAKE SIGNAL
SS08F331 3 SS08F330 4
RIGHT HAND SIDE UNDER THE CONSOLE
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C636 POWER STUD

1 3070A (L) / 3070 (L/W) ’B’ PILLAR SKT SUPPLY
2 57CX (B) / 57 (B) EARTH (ALL)
MAXXUM
C636V-BRJ4676E 5 SS08F110 6
RIGHT HAND CONSOLE
SS08F264 7 SS08F110 8
RIGHT HAND CONSOLE
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C638 WORKLAMPS REAR RELAY
Low profile roof

1 998D (G) WORK LAMP-REAR FEED (INNER)
2 57PR (B) EARTH (ALL)
3 1090B (R) REAR WORKLAMP RELAY SIGNAL
4 998Z (G) WORK LAMP-REAR FEED (INNER)
Low profile roof
SS08F332 9 SS08F303 10
C639 LEFT HAND LOW ROOF WORKLAMPS
Low profile roof

2 1097H (R) FEED FRONT WORKLAMP OUTER
4 57PL (B) EARTH (ALL)
Low profile roof
INA 11 SS08F147 12
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MAXXUM 140
C640 LOW ROOF WORKLAMPS
Low profile roof

1 1013AH (R) RIGHT HAND LAMPS
1 1013AG (R) RIGHT HAND LAMPS
1 1013AJ (R) RIGHT HAND LAMPS
Low profile roof
INA 1 SS08F082 2
C647 LOADER SOLENOID VALVE 1

SS08F262 3 SS08K508 4
RIGHT HAND SIDE BEHIND STEPS
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C648 LOADER SOLENOID VALVE 2

SS08F263 5 SS08K508 6
RIGHT HAND SIDE BEHIND STEPS
C649 GROUND SPEED PTO LINK CONNECTOR

1 (W)
2 (W)
INA 7 SS08M031 8
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MAXXUM 140
C650 WORKLAMP
Low profile roof

2 1097B (R/S) FEED FRONT WORKLAMP OUTER
4 57DK (B) EARTH (ALL)
Low profile roof
SS08K531 1 SS08F147 2
C652 RIGHT HAND REAR WORKLAMP
Low profile roof

2 998AB (G) WORK LAMP-REAR FEED (INNER)
4 57DF (B) EARTH (ALL)
Low profile roof
INA 3 SS08F147 4
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C653 RIGHT HAND FRONT WORKLAMP
Low profile roof

2 1097J (R) FEED FRONT WORKLAMP OUTER
4 57PK (B) EARTH (ALL)
Low profile roof
SS08K532 5 SS08F147 6
C655 LEFT HAND REAR WORKLAMP
Low profile roof

2 998AA (G) WORK LAMP-REAR FEED (INNER)
4 57DR (B) EARTH (ALL)
Low profile roof
INA 7 SS08F147 8
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C656 LEFT HAND FRONT WORKLAMP
Low profile roof

2 1097H (R) FEED FRONT WORKLAMP OUTER
4 57PL (B) EARTH (ALL)
Low profile roof
SS08K533 9 SS08F147 10
LEFT HAND SIDE ROOF - VIEW SHOWN LOW PROFILE CAB
C658 DIFF LOCK ACTIVATED CONNECTOR

1 7126B (G) DIFF LOCK PRESSURE SWITCH
2 7000Z (U) TRANS CONTROL SUPPLY
INA 11 SS08M031 12
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C659 DIFF LOCK ACTIVATED SWITCH
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MAXXUM 140
C660 BRAKE PAD LATCH IN-LINE CONNECTOR

1 1050 (G) ACCESSORY FEED
2 5420 (G) CAN L
3 5400 (Y) CAN H
4 61 (B/O) CASE GROUND
INA 1 SS09E020 2
C661 BRAKE PAD LATCH IN-LINE CONNECTOR

1 1050 (G) ACCESSORY FEED
2 5420 (G) CAN L
3 5400 (Y) CAN H
4 61 (B/O) CASE GROUND
INA 3 SS08F193 4
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C662 DELTA P SWITCH

1 7130B (N) HYD FILTER WNG LP
2 57EW (B) EARTH (ALL)
INA 5 SS08K508 6
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C663 FIXED DISPLACEMENT PUMP CONNECTOR

1 57EP (B) EARTH (ALL)
4 3500 (W/B/S) POWER STEERING PRESSURE SIGNAL
SS08F333 7 SS08F131 8
TOP OF TRANSMISSION
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C669 EUROPEAN LOADER RELAY 1

30 3271 (B) LOADER RELAY FEED
86 3277 (O) LOADER VALVE #3 COIL
SS08K540 9 SS08K539 10
RIGHT HAND SIDE UNDER THE FUSE BOX
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MAXXUM 140
C670 EUROPEAN LOADER RELAY 2

30 3271 (O) LOADER RELAY FEED
86 3278 (O) LOADER VALVE #3 RELAY
SS08K541 1 SS08K539 2
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MAXXUM 140
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MAXXUM 140
C902 AUTOMATIC AIR CONDITIONING BLOWER MODULE

3 9225 (Y) AC-BLOWER SPEED
4 982 (R) BLOWER MOTOR FEED
SS08F017 1 SS08F016 2
IN CAB BEHIND OPERATOR’S SEAT
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C903 CONNECTOR BLOWER MOTOR

1 (R) SUPPLY
2 (B) EARTH (ALL)
SS08F019 3 SS08F018 4
C904 HVAC UNIT

A 982D (R) BLOWER MOTOR FEED
C 9226 (Y) AC-SIGNAL WATER VALVE
INA 5 SS08F020 6
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C905 OUTSIDE TEMPERATURE SENSOR

1 9224 (Y) AC-SIGNAL AMBIENT TEMPERATURE SENSOR
2 57ZC (B/W) EARTH (ALL)
SS08F022 7 SS08F021 8
C906 CAB TEMPERATURE SENSOR

A 9223 (Y) AC-SIGNAL CAB TEMPERATURE SENSOR
B 57ZC (B/W) EARTH (ALL)
INA 9 SS08F023 10
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C907 OUTLET TEMPERATURE SENSOR

1 9222 (Y) AC-SIGNAL OUTLET TEMPERATURE SENSOR
2 57ZH (B) EARTH (ALL)
SS08F024 11 SS08F021 12
UNDER THE SEAT
C908 EVAP EVAPORATOR TEMPERATURE SENSOR

1 9221 (Y) AC-EVAPORATOR TEMPERATURE SENSOR
2 57ZH (B) EARTH (ALL)
SS08F025 13 SS08F021 14
UNDER THE SEAT
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C909 AIR CONDITIONING AUTOMATIC LOW PRESSURE SWITCH

A 9219 (B/W) AC-LOW PRESSURE SWITCH OUTPUT
B 9220 (R) AC-LOW PRESSURE SWITCH INPUT
SS08F027 15 SS08F026 16
UNDER THE SEAT
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MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ]
C910 EDC LED CHECKS AND SWITCH

1 5200H (N) / 5200 (O) EDC VALVE SUPPLY
3 5100C (K) / 5100 (W) EDC EXTERNAL SWITCH UP
4 5095C (K) / 5095 (W) EDC EXTERNAL SWITCH DOWN
5 5110 (K) / Status (W) EDC LAMP SIGNAL
6 5180 (TQ) / Slip (W) EDC SLIP INDICATOR LAMP
7 5220 (Y) / Raise (W) EDC RAISE LAMP
8 5230 (Y) / Lower (W) EDC LOWER LAMP
11 1012H (R) / 1012 (S) ILLUMINATION
12 57BY (B) / 57AY (B) EARTH (ALL)
SS07E063 1 SS07E065 2
RIGHT-HAND SIDE CONSOLE
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C911 EDC POTENTIOMETER PANEL

1 60K (B/W) / 60K (N) SENSOR GROUND
2 5020F (N) / 5020F (O) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
3 5155 (U) / 5155 (G) EDC LOWER LIMIT POTENTIOMETER
4 5120 (K) / 5120 (G) EDC HEIGHT LIMIT SIGNAL
5 5045 (N) / 5045 (G) EDC DROP RATE
6 5040 (N) / 5040 (G) EDC DRAFT POSITION
7 5145 (TQ) / 5145 (G) EDC SLIP LIMIT POTENTIOMETER
11 1012C (R) / 1012C (S) ILLUMINATION
SS07E064 3 SS07E065 4
C912 EDC POSITION POTENTIOMETER

1 5020G (N) / 699 (O) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
2 60L (B/W) / 697 (N) SENSOR GROUND
3 5050 (N) / 698 (G) EDC QUADRANT
5 1012D (R) / 700 (S) ILLUMINATION
6 57AX (B) / 701 (B) EARTH (ALL)
SS07E066 5 SS07E067 6
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C913 EFH EXTERNAL BUTTON FOR FRONT POWER LIFT

1 2587 (N) / 57ZZ (B) / 2587 (O) EFH EXTERNAL SWITCH + / EARTH (ALL)
2 2588 (L) / 2582 (G) / 2588 (K) EFH EXTERNAL SWITCH UP / STEYR - EXT SWITCHES
3 2589 (R) / 2583 (N) / 2589 (K) EFH EXTERNAL SWITCH DOWN / STEYR - EXT SWITCHES
SS07E061 7 SS07E068 8
C914 EXTERNAL BUTTON FOR FRONT POWER LIFT

1 2587 (N) / 2587A (O) EFH EXTERNAL SWITCH +
2 2588 (L) / 2588 (K) EFH EXTERNAL SWITCH UP
3 2589 (R) / 2589 (K) EFH EXTERNAL SWITCH DOWN
SS08F034 9 SS07E068 10
FRONT TOP OF TRANSMISSION
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C915 EFH CONNECTOR FOR INTERFACE (ENGINE)

1 2590 (N) / 2590 (K) EXTERNAL SWITCH FHPL UP
3 2592 (N) / 2592 (K) EFH VALVE DOWN +
5 2598 (S) / 2598 (K) EFH ACCUMULATOR 40 BAR
6 2599 (N) / 2599 (K) EFH ACCUMULATOR 14 BAR
7 2597 (N) / 2597 (G) EFH PRESSURE SENSOR SIGNAL
8 2596 (R) / 2596A (N) EFH POSITION SENSOR -
9 2595 (L) / 2595 (G) EFH POSITION SENSOR SIGNAL
10 2594 (Y) / 5580A (O) EFH POSITION SENSOR +
11 57GJ (B) / 57GJ (N) EARTH (ALL)
SS08F035 11 SS07E065 12
FRONT TOP OF TRANSMISSION
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C916 EFH CONTROL PANEL (POTENTIOMETER UNIT) CONTROL

1 631A (K) DIAGNOSTIC
2 57DD (B) EARTH (ALL)
3 5265B (Y) HYDRAULIC MASTER SW #2
4 1013RC (S) RIGHT HAND LAMPS
5 615 (G) SIGNAL 14 BAR
7 2598 (O) EFH ACCUMULATOR 40 BAR
8 2599 (O) EFH ACCUMULATOR 14 BAR
9 620 (N) EARTH (ALL)
10 621 (K) SIGNAL MULTI CONTROLLER RAISE/WORK
11 602 (O) SUPPLY STAB. 9.5V
12 612 (G) PRESSURE CONTROL
13 671 (K) EFH MODUS
14 669 (K) EFH MODUS
15 622 (G) SIGNAL SET POINT
16 603 (G) SIGNAL POTENTIOMETER STROKE LIMITATION
17 623 (G) SIGNAL LOWERING SPEED
18 604 (G) SIGNAL POTENTIOMETER MIX
19 5520 (O) EHR 5V REF
20 2586 (K) EFH WORK SWITCH
SS08F037 13 SS08F036 14
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C917 EFH ELECTRONIC MODULE

2 602 (O) SUPPLY STAB. 9.5V
3 603 (G) SIGNAL POTENTIOMETER STROKE LIMITATION
4 604 (G) SIGNAL POTENTIOMETER MIX
5 2575 (W) SIGNAL RAISE
8 2597 (G) EFH PRESSURE SENSOR SIGNAL
9 2587A (O) EFH EXTERNAL SWITCH +
12 612 (G) PRESSURE CONTROL
13 1006A (U) ALTERNATOR WARNING LAMP
14 2576 (W) SIGNAL LOWERING
17 2588A (K) EFH EXTERNAL SWITCH UP
19 2592 (O) EFH VALVE DOWN +
20 620 (N) EARTH (ALL)
21 621 (K) SIGNAL MULTI CONTROLLER RAISE/WORK
22 622 (G) SIGNAL SET POINT
23 623 (G) SIGNAL LOWERING SPEED
24 5265A (Y) HYDRAULIC MASTER SW #2
25 2595 (G) EFH POSITION SENSOR SIGNAL
28 57DF (N) EARTH (ALL)
29 2582B (R) STEYR - EXT SWITCHES
31 631 (K) DIAGNOSTIC
36 2589A (K) EFH EXTERNAL SWITCH DOWN
37 2590 (O) EXTERNAL SWITCH FHPL UP
38 2596 (N) EFH POSITION SENSOR -
39 2594 (O) EFH POSITION SENSOR +
46 570G (N) SUPPLY EARTH
47 2582C (R) STEYR - EXT SWITCHES
SS08F039 15 SS08F038 16
RIGHT HAND SIDE BESIDE FUSE BOX
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C918 EFH INTERFACE (SUPPLY)

1 2582A (G) / 2582A (R) STEYR - EXT SWITCHES
2 5260C (N) / 5265 (Y) HYDRAULIC MASTER SW #2
3 57DA (B) / 57 (B) EARTH (ALL)
4 1006C (N) / 1006A (U) ALTERNATOR WARNING LAMP
5 1013R (R) / 1013R (S) RIGHT HAND LAMPS
6 2585 (N) / 2585 (K) EFH RAISE SWITCH
7 2586 (N) / 2586 (K) EFH WORK SWITCH
8 5520 (G) / 5520 (O) EHR 5V REF
9 2576 (W) SIGNAL LOWERING
10 2575 (W) SIGNAL RAISE
11 2577 (L) DIAGNOSTIC
SS08F040 17 SS07E065 18
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C919 EFH INTERFACE TO ENGINE CABLE

1 2590 (N) / 2590 (O) EXTERNAL SWITCH FHPL UP
3 2592 (N) / 2592 (O) EFH VALVE DOWN +
5 2596 (R) / 2596 (N) EFH POSITION SENSOR -
6 2594 (O) EFH POSITION SENSOR +
7 2597 (N) / 2597 (G) EFH PRESSURE SENSOR SIGNAL
8 2598 (S) / 2598 (O) EFH ACCUMULATOR 40 BAR
9 2599 (N) / 2599 (O) EFH ACCUMULATOR 14 BAR
10 2595 (L) / 2595 (G) EFH POSITION SENSOR SIGNAL
SS08F041 19 SS07E065 20
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C920 ARU CAN DOG X20

1 (K) / (L) POWER SUPPLY POTENTIAL +15
2 (S) LIGHTING
3 (N) / (B) EARTH
4 (Y) CAN H
5 (G) CAN L
SS08F042 1 SS07E069 2
ARMREST
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C921 SUPPLY X1

1 (S) LIGHTING
2 (B) EXTERNAL FHPL RAISE
3 (B) EXTERNAL FHPL LOWER
4 (W) EDC-RAISE
5 (W) SIGNAL SHIFT
7 (Y) 12 V EDC
8 (B) EARTH
9 (L) +12 V
11 (W) SIGNAL FRONT LOADER
12 (W) EDC CONTROL - TRANSPORT
13 (W) EDC-STOP
14 (W) OIL MOTOR
SS08F043 3 SS07E071 4
ARMREST
C922 CAN BUS X7

3 (Y) CAN H
4 (G) CAN L
SS08F044 5 SS07E276 6
ARMREST
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C924 EDC STOP BUTTON X14

1 (U) EDC-STOP
2 (U) EDC-STOP
SS08F045 7 SS07E070 8
ARMREST
C925 ARU BUTTON RAPID RETRACT X2

1 (B) 12 V EDC
2 (B) SIGNAL EDC-FLOAT / RAPID RETRACT
SS08F046 9 SS07E070 10
ARMREST
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C926 MULTICONTROLLER II X11

1 (R) POWER SUPPLY 5V STAB.
2 (LG) LIGHTING
3 (U) SIGNAL FORWARDS / REVERSE
4 (S/K) SIGNAL SPEED NEGATIVE
5 (S) SIGNAL HEADLAND MANAGEMENT CONTROL
6 (N/G) SIGNAL EHS RAISE
7 (W/LN) SIGNAL EDC CONTROL - TRANSPORT
9 (B) EARTH
10 (Y) SIGNAL SHIFT
11 (R/U) SIGNAL AUTO TRANS ON/OFF
12 (W/G) SIGNAL SPEED POSITIVE
13 (N) SIGNAL EHS LOWER
14 (K) SIGNAL EDC-RAISE
15 (W) SUPPLY EDC 12V
16 (L) POWER SUPPLY 12V HYDRAULIC MASTER
SS08F048 11 SS08F047 12
ARMREST
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C927 MULTICONTROLLER II X21

2 (B) EARTH
3 (W) SUPPLY EDC 12V
4 (N) SIGNAL EDC CONTROL - TRANSPORT
5 (S) SIGNAL EDC RAISE
6 (S/K) SIGNAL SHIFT
7 (N) SIGNAL EHS LOWER
8 (N/G) SIGNAL EHS RAISE
9 (W/LN) SIGNAL SPEED NEGATIVE
10 (R/U) SIGNAL SPEED POSITIVE
11 (W/G) SIGNAL AUTO TRANS ON/OFF
12 (K) SIGNAL HEADLAND MANAGEMENT CONTROLLER
13 (W) SIGNAL FORWARDS / REVERSE
14 (LG) LIGHTING
SS08F049 13 SS07E074 14
ARMREST
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C928 MULTICONTROLLER PRINT X4

1 (L) SUPPLY EDC 12V
SS08F050 15 SS07E075 16
ARMREST
C929 HAND THROTTLE SLIDER X3

2 (W) SIGNAL
4 (N) EARTH
SS08F051 17 SS07E276 18
ARMREST
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C930 AUX CONTROL LEVER X4

1 (R) SUPPLY 5V
2 (W) SIGNAL
4 (N) EARTH
SS08F052 1 SS07E276 2
ARMREST
C931 AUX JOYSTICK X5

1 (R) SUPPLY 5V
2 (W) SIGNAL
3 (N) EARTH
4 (B) SUPPLY 5V
5 (R) SUPPLY 5V
6 (W) SIGNAL
7 (N) EARTH
8 (B) SIGNAL
SS08F053 3 SS07E278 4
ARMREST
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C933 POTENTIOMETER AUX 3 AND 4 X15

1 (R) SUPPLY 5V
2 (W) SIGNAL
3 (N) EARTH
4 (R) SUPPLY 5V
5 (W) SIGNAL
6 (N) EARTH
SS08F054 5 SS07E081 6
ARMREST
C934 POTENTIOMETER AUX 1 AND 2 X16

1 (R) SUPPLY 5V
2 (W) SIGNAL
3 (N) EARTH
4 (R) SUPPLY 5V
5 (W) SIGNAL
6 (N) EARTH
SS08F055 7 SS07E081 8
ARMREST
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C935 EFH SWITCH ILLUMINATION RAISE CONTROL CONNECTOR X9

1 (S) LIGHTING
2 (B) EARTH
SS08F056 9 SS07E070 10
ARMREST
C936 SHIFT BUTTON MULTICONTROLLER PRINT X30/19

1 (B) SIGNAL
2 (B) POWER SUPPLY 5V STAB.
SS08F057 11 SS07E075 12
ARMREST
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C937 JOYSTICK FRONT LOADER BUTTON 2 X21

1 (W) SIGNAL
2 (L) SUPPLY 12V
SS08F059 13 SS08F058 14
ARMREST
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C940 EFH SOLENOID 14 BAR MEMORY

1 2599 (K) EFH ACCUMULATOR 14 BAR
2 5594B (N) EHR WARNING LAMP #4
SS08F063 1 SS08F062 2
RIGHT HAND SIDE REAR AXLE
C941 EFH SOLENOID VALVE 40 BAR ACCUMULATOR

1 2598 (K) EFH ACCUMULATOR 40 BAR
2 5594C (N) EHR WARNING LAMP #4
SS08F064 3 SS08F062 4
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C942 EFH SWITCH TRANSPORT RAISE

1 669 (K) EFH MODUS
2 2585 (K) EFH RAISE SWITCH
3 671 (K) EFH MODUS
7 57DB (B) EARTH (ALL)
8 1013RA (S) RIGHT HAND LAMPS
9 57DH (B) EARTH (ALL)
10 1013RD (S) RIGHT HAND LAMPS
SS08F066 5 SS08F094 6
C943 EFH SOLENOID LOWER

1 2592 (K) EFH VALVE DOWN +
SS08F067 7 SS08F062 8
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C944 EFH SOLENOID RAISE

1 2590 (K) EXTERNAL SWITCH FHPL UP
SS08F068 9 SS08F062 10
C945 EFH PRESSURE SENSOR

1 2596B (N) EFH POSITION SENSOR -
2 2597 (G) EFH PRESSURE SENSOR SIGNAL
3 5580B (O) EFH PRESSURE SENSOR+
SS08F070 11 SS08F069 12
RIGHT HAND SIDE FRONT HITCH
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C946 EFH ANGLE OF ROTATION SENSOR

1 2596C (N) EFH POSITION SENSOR -
2 2595 (G) EFH POSITION SENSOR SIGNAL
3 5580C (O) EFH POSITION SENSOR+
SS08F071 13 SS08F069 14
LEFT HAND SIDE FRONT HITCH
C947 EFH INTERNALLY OPERATED FRONT POWER LIFT BUTTON RAISE/LOWER

1 2589B (K) EFH EXTERNAL SWITCH DOWN
2 2587B (O) EFH EXTERNAL SWITCH +
3 2588B (K) EFH EXTERNAL SWITCH UP
7 57DC (B) EARTH (ALL)
8 1013RB (S) RIGHT HAND LAMPS
9 57DJ (B) EARTH (ALL)
10 1013RE (S) RIGHT HAND LAMPS
SS08F065 15 SS08F094 16
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C948 EFH EXTERNAL BUTTON FOR RAISE/LOWER

1 2588 (K) EFH EXTERNAL SWITCH UP
2 2587A (O) EFH EXTERNAL SWITCH +
3 2589 (K) EFH EXTERNAL SWITCH DOWN
INA 17 SS08F072 18
LEFT HAND SIDE FRONT HITCH
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C950 EDC SLIP CONTROL

1 SLIP (W) EPC SIGNAL EARTH
1 SLIP+ (O) EPC SUPPLY POTENTIAL +15
SS07E265 1 SS07E058 2
C951 EDC LOWERING CONTROL

1 LOWER (W) EPC SIGNAL EARTH
1 LOWER+ (O) EPC SUPPLY POTENTIAL +15
SS07E266 3 SS07E058 4
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C952 EDC RAISE CONTROL

1 RAISE (W) EPC SIGNAL EARTH
1 RAISE+ (O) EPC SUPPLY POTENTIAL +15
SS07E267 5 SS07E058 6
C953 EDC DIAGNOSIS

1 STATUS (W) EPC SIGNAL EARTH
1 STATUS+ (O) EPC SUPPLY POTENTIAL +15
SS07E268 7 SS07E058 8
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C954 EDC INTERNALLY ACTIVATED POWER LIFT BUTTON

1 5100 (W) EDC EXTERNAL SWITCH UP
2 EXTERNAL+ (O) EDC SUPPLY POTENTIAL +15
3 5095 (W) EDC EXTERNAL SWITCH DOWN
7 57BY (B) EARTH (ALL)
8 1012HA (S) ILLUMINATION
9 57CY (B) EARTH (ALL)
10 1012HB (S) ILLUMINATION
SS07E269 9 SS08F094 10
C957 POWER SOCKET POWER SUPPLY REAR

1 150BF (N) BATTERY FEED (ALL)
2 9032B (Y) IGN.+ TO POWER SKT.
SS08F073 11 SS08F110 12
IN CAB RIGHT HAND BEHIND OPERATOR’S SEAT
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C958 POWER SOCKET GROUND

SS08F074 13 SS08F111 14
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C960 30A POWER SOCKET / GROUND

1 57CY (B) / 57CR (B) EARTH (ALL)
SS08F076 1 SS08F111 2
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MAXXUM 140
C971 ENGINE EXHAUST BRAKE

1 2087B (O) EXHAUST BRAKE SOLENOID
1 3000C (G) FLASHER UNIT SUPPLY (TERMINAL 49)
SS08F085 1 BRI4445B 2
STEERING CONSOLE
C974 AUTOMATIC AIR CONDITIONING SYSTEM BLOWER MODULE

1 982 (R) BLOWER MOTOR FEED
3 9225 (Y) AC-BLOWER SPEED
SS08F087 3 SS08F086 4
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C984 ARU EFH BUTTON RAISE CONTROL X8

2 (L) SUPPLY 12V
SS08F060 1 SS07E081 2
ARMREST
C988 FRONT LOADER VALVES

1 3277 (O) SIGNAL FRONT LOADER RELAY #1
2 3278 (O) SIGNAL FRONT LOADER RELAY #2
3 3274 (R) / 3274 (O) LOADER VALVE #2 OUT
SS07E261 3 SS07E054 4
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MAXXUM 140
C993 AIR CONDITIONING MECH. BLOWER RESISTANCE

1 (K/O) SPEED 3
2 (W) SPEED 2
3 (G/Y) SPEED 1
SS08F089 1 SS08M034 2
C994 AIR CONDITIONING MECH. BLOWER RESISTANCE

1 (G/K) 2ND SPEED
SS08F091 3 SS08F090 4
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Wiring harness - Electrical schema index

PROCESSORS, MODULES AND PANELS

Code Description Frame
A001 Gearshift Indicator Wiring harness - Electrical schematic frame 09 (A.30.A)
A002 EDC Control Panel Wiring harness - Electrical schematic frame 12 (A.30.A)
A003 EDC Mouse Wiring harness - Electrical schematic frame 12 (A.30.A)
A004 EDC Status Lamp Panel Wiring harness - Electrical schematic frame 12 (A.30.A)
A005 Radio Wiring harness - Electrical schematic frame 21 (A.30.A)
Wiring harness - Electrical schematic frame 22 (A.30.A)
A006 Instrument Cluster Keypad Wiring harness - Electrical schematic frame 24 (A.30.A)
A007 Flasher Unit Wiring harness - Electrical schematic frame 27 (A.30.A)
A008 Worklamp ECU Wiring harness - Electrical schematic frame 30 (A.30.A)
A009 XCM Central Control Unit (CN1-A) Wiring harness - Electrical schematic frame 37 (A.30.A)
A010 XCM Auxiliary Controller (CN1-A) Wiring harness - Electrical schematic frame 37 (A.30.A)
A011 Instrument Panel Wiring harness - Electrical schematic frame 37 (A.30.A)
A012 Instrument Panel C Wiring harness - Electrical schematic frame 38 (A.30.A)
A013 EMU Connector Wiring harness - Electrical schematic frame 38 (A.30.A)
A014 XCM Auxiliary Controller (CN4) Wiring harness - Electrical schematic frame 38 (A.30.A)
A015 XCM Auxiliary Controller (CN3-B) Wiring harness - Electrical schematic frame 38 (A.30.A)
A017 XCM Auxiliary Controller (CN2) Wiring harness - Electrical schematic frame 38 (A.30.A)
A018 Processor EDC Wiring harness - Electrical schematic frame 38 (A.30.A)
A019 XCM Central Control Unit (CN2) Wiring harness - Electrical schematic frame 38 (A.30.A)
A020 Heater/Air Con Connector Wiring harness - Electrical schematic frame 40 (A.30.A)
A021 Auto Temp Control Wiring harness - Electrical schematic frame 40 (A.30.A)
A022 Grid Heater Controller Wiring harness - Electrical schematic frame 04 (A.30.A)
A023 SCM Vistronic Fan Module Wiring harness - Electrical schematic frame 37 (A.30.A)
SENSORS, POTENTIOMETERS
B1 Flywheel torque sensor Wiring harness - Electrical schematic frame 04 (A.30.A)
B2 Throttle Potentiometer (mechanical engine) Wiring harness - Electrical schematic frame 05 (A.30.A)
B3 Hand Throttle Wiring harness - Electrical schematic frame 05 (A.30.A)
B4 Water in Fuel Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B5 Boost Pressure/Temperature Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B6 Oil Pressure/Temperature Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B7 Fuel Rail Pressure Sensor Wiring harness - Electrical schematic frame 07 (A.30.A)
B8 Coolant Temperature Sensor Wiring harness - Electrical schematic frame 07 (A.30.A)
B9 Fuel Temperature Sensor Wiring harness - Electrical schematic frame 07 (A.30.A)
B10 Crankshaft Speed Sensor Wiring harness - Electrical schematic frame 07 (A.30.A)
B11 Camshaft Speed Sensor Wiring harness - Electrical schematic frame 07 (A.30.A)
B12 Fuel Metering Unit Wiring harness - Electrical schematic frame 07 (A.30.A)
B13 Clutch Potentiometer Wiring harness - Electrical schematic frame 09 (A.30.A)
B14 4-5 Synchro Potentiometer Wiring harness - Electrical schematic frame 08 (A.30.A)
B15 Synchro Position Potentiometer Wiring harness - Electrical schematic frame 08 (A.30.A)
B16 Axle Speed Sensor Wiring harness - Electrical schematic frame 09 (A.30.A)
B17 LH Draft Pin Wiring harness - Electrical schematic frame 11 (A.30.A)
B18 Rockshaft Potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B19 RH Draft Pin Wiring harness - Electrical schematic frame 11 (A.30.A)
B20 Front Hitch Position Potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B21 Rear PTO Speed Sensor Wiring harness - Electrical schematic frame 18 (A.30.A)
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B22 PTO Shaft Twist Sensor Wiring harness - Electrical schematic frame 18 (A.30.A)
B23 Front Suspension Potentiometer Wiring harness - Electrical schematic frame 19 (A.30.A)
B24 Turn Assist - LVDT Coils Wiring harness - Electrical schematic frame 20 (A.30.A)
B25 Turn Assist Steering Wheel Sensor Wiring harness - Electrical schematic frame 20 (A.30.A)
B26 Speaker R/H Rear Wiring harness - Electrical schematic frame 21 (A.30.A)
B27 Speaker R/H Front Wiring harness - Electrical schematic frame 21 (A.30.A)
B28 Speaker L/H Rear Wiring harness - Electrical schematic frame 21 (A.30.A)
B29 Speaker L/H Front Wiring harness - Electrical schematic frame 21 (A.30.A)
B30 Horn Wiring harness - Electrical schematic frame 30 (A.30.A)
B31 Fuel Tank Sender Wiring harness - Electrical schematic frame 33 (A.30.A)
B32 Radar gun Wiring harness - Electrical schematic frame 33 (A.30.A)
B33 Steering Angle Sensor Wiring harness - Electrical schematic frame 33 (A.30.A)
B34 Outside temperature sensor Wiring harness - Electrical schematic frame 40 (A.30.A)
B35 Cab temperature sensor Wiring harness - Electrical schematic frame 40 (A.30.A)
B36 Outlet temperature sensor clime Wiring harness - Electrical schematic frame 40 (A.30.A)
B37 EVAP evaporator temperature sensor Wiring harness - Electrical schematic frame 40 (A.30.A)
B38 Temperature potentiometer air conditioning Wiring harness - Electrical schematic frame 40 (A.30.A)
B39 Coolant Temperature Sender Wiring harness - Electrical schematic frame 05 (A.30.A)
B40 Engine Speed Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
DIODES
D1 Diode Main Battery Switch Wiring harness - Electrical schematic frame 01 (A.30.A)
D2 Diode brake light left Wiring harness - Electrical schematic frame 24 (A.30.A)
D3 Diode brake light right Wiring harness - Electrical schematic frame 24 (A.30.A)
D4 Diode licence plate light Wiring harness - Electrical schematic frame 25 (A.30.A)
MISCELLANEOUS
E1 Vistronic Fan Wiring harness - Electrical schematic frame 06 (A.30.A)
E2 Rotating Beacon L/H Wiring harness - Electrical schematic frame 30 (A.30.A)
E3 Rotating Beacon R/H Wiring harness - Electrical schematic frame 30 (A.30.A)
E4 Air Con Compressor Wiring harness - Electrical schematic frame 39 (A.30.A)
FUSES (PF - POWER FUSES, MF - MAXI FUSES, F - MINI FUSES)

F1 Interior light left / Puddle lamp left + right / Wiring harness - Electrical schematic frame 21 (A.30.A)
Handbrake 10 A Wiring harness - Electrical schematic frame 22 (A.30.A)
F2 Cigar lighter / Power Studs 25 A Wiring harness - Electrical schematic frame 21 (A.30.A)
F3 A/C Clutch 10 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F4 Accessory Sockets 10 A Wiring harness - Electrical schematic frame 21 (A.30.A)
F5 Blower Motor 30 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F6 Radio / Worklamp ECU 10 A Wiring harness - Electrical schematic frame 21 (A.30.A)
F7 Potential 30 / Main Light Switch / Hazard Wiring harness - Electrical schematic frame 26 (A.30.A)
Switch 20 A
F8 Potential 30 / Starter Switch 20 A Wiring harness - Electrical schematic frame 01 (A.30.A)
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F9 Supply Loader Option 25 A Wiring harness - Electrical schematic frame 02 (A.30.A)
F11 Windshield Wiper, front/rear 10 A Wiring harness - Electrical schematic frame 34 (A.30.A)
F12 Front + Rear Windshield Washer / Rear Wiring harness - Electrical schematic frame 34 (A.30.A)
Wiper 10 A Wiring harness - Electrical schematic frame 35 (A.30.A)
F13 Brake lights / Brake light relay K8 15 A Wiring harness - Electrical schematic frame 26 (A.30.A)
F14 Potential 15 / Main Light Switch / Flasher Wiring harness - Electrical schematic frame 26 (A.30.A)
Unit 15 A
F15 Stoplamp Switch left/right / pneumatic relay Wiring harness - Electrical schematic frame 16 (A.30.A)
K12 / Battery Isolator 20 A
F16 Italian Hydraulic & Pneumatic trailer brake Wiring harness - Electrical schematic frame 32 (A.30.A)
relay 15 A
F17 Potential 15 / power socket 3-pin right rear Wiring harness - Electrical schematic frame 21 (A.30.A)
cab 25 A Wiring harness - Electrical schematic frame 22 (A.30.A)
F18 Potential 15 / blower relay air cushion Wiring harness - Electrical schematic frame 39 (A.30.A)
electric seat 15 A
F19 Potential 15 / Heated mirrors 7.5 A Wiring harness - Electrical schematic frame 23 (A.30.A)
F20 Potential 15 / Standardsignal Socket / Radar Wiring harness - Electrical schematic frame 24 (A.30.A)
/ ADIC Keypad 10 A
F21 Brake Fluid Level Switch / Water in Fuel Wiring harness - Electrical schematic frame 06 (A.30.A)
Sensor 15 A
F22 Side Lamps R/H / Spot light right 15 A Wiring harness - Electrical schematic frame 25 (A.30.A)
F23 Side Lamps L/H / licence plate lights / 7-pin Wiring harness - Electrical schematic frame 25 (A.30.A)
trailer socket 15 A
F24 Control panel right - switch illumination 10 A Wiring harness - Electrical schematic frame 25 (A.30.A)
F25 Dip Beam Headlamps 15 A Wiring harness - Electrical schematic frame 26 (A.30.A)
F26 Main Beam Headlamps 15 A Wiring harness - Electrical schematic frame 26 (A.30.A)
F27 Worklamps Engine Hood 15 A Wiring harness - Electrical schematic frame 30 (A.30.A)
F28 ISO and NASO Roof: ISO and NASO Roof:
Worklamps ECU, Roof rear 15 A Wiring harness - Electrical schematic frame 30 (A.30.A)
LP Roof: LP Roof:
Worklamps, low roof rear K27 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
Worklamps ECU, Roof front, Grabrail 30 A Wiring harness - Electrical schematic frame 30 (A.30.A)
LP Roof: LP Roof:
Worklamps, low roof front, Grabrail K26 30 Wiring harness - Electrical schematic frame 31 (A.30.A)
A
F30 Worklamps Relay C-pillar 15 A Wiring harness - Electrical schematic frame 30 (A.30.A)
Rotating Beacons 15 A Wiring harness - Electrical schematic frame 30 (A.30.A)
LP Roof: LP Roof:
Low roof Rotating Beacons K28 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
F32 Potential 30 / Flasher Unit 30 A Wiring harness - Electrical schematic frame 30 (A.30.A)
F33 Diagnostics Connector / Turn Assist 25 A Wiring harness - Electrical schematic frame 36 (A.30.A)
F34 Potential 30 / ADIC Battery Positive 10 A Wiring harness - Electrical schematic frame 37 (A.30.A)
F35 XCM Central - XCM Auxiliary Control Unit / Wiring harness - Electrical schematic frame 37 (A.30.A)
Small Controller 10 A
F36 Potential 15 / Instrument Cluster 10 A Wiring harness - Electrical schematic frame 37 (A.30.A)
F37 Transmission Ignition 15 A Wiring harness - Electrical schematic frame 37 (A.30.A)
F38 Rear PTO Switch / Rear PTO Warning Light Wiring harness - Electrical schematic frame 37 (A.30.A)
/ HPL / Small Control Module / Ground
Speed PTO / Transmission Display 10 A
F39 HPL / Armrest / Hand Trottle / EHR Levers Wiring harness - Electrical schematic frame 12 (A.30.A)
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F40 Potential 15 / Radio 10 A Wiring harness - Electrical schematic frame 21 (A.30.A)
F41 Front PTO 15 A Wiring harness - Electrical schematic frame 37 (A.30.A)
F42 Front Suspension / HPL 10 A Wiring harness - Electrical schematic frame 11 (A.30.A)
F43 Engine ECU Activate (electronic engine) 10 Wiring harness - Electrical schematic frame 01 (A.30.A)
A
F43 Supply Fuel shut Off Relay, Cigar Lighter, Wiring harness - Electrical schematic frame 01 (A.30.A)
ADIC (mechanical engine) 10 A
F44 Potential 30 / Socket for mounted equipment Wiring harness - Electrical schematic frame 39 (A.30.A)
DIA 25 A
F45 Potential 15 / 8AMP 2-pin mobil phone Wiring harness - Electrical schematic frame 24 (A.30.A)
socket 25 A
F46 Supply Engine ECU (electronical engine) Wiring harness - Electrical schematic frame 06 (A.30.A)
15 A
F47 Supply Engine ECU (electronical engine) Wiring harness - Electrical schematic frame 06 (A.30.A)
10 A
F49 Supply K24/K25 Vistronic Fan (electronical Wiring harness - Electrical schematic frame 06 (A.30.A)
engine) 15 A
F51 Turn Assist rapid steering system 5 A Wiring harness - Electrical schematic frame 20 (A.30.A)
F60 Battery Isolator Control 10 A Wiring harness - Electrical schematic frame 01 (A.30.A)
MF1 80 A Feeds F9, F11, F12, F13, F14, F15, Wiring harness - Electrical schematic frame 01 (A.30.A)
F16, F17, F18, F19, F20, F21, F45, F51
MF2 80 A Feeds F6, F7, F8 Wiring harness - Electrical schematic frame 01 (A.30.A)
MF3 80 A Feeds F29, F30, F33, F34, F35 Wiring harness - Electrical schematic frame 37 (A.30.A)
MF4 80 A Feeds F27, F28, 3-pin Power Socket Wiring harness - Electrical schematic frame 24 (A.30.A)
Right Rear
MF5 80 A Feeds F25, F26, F31, F32 Wiring harness - Electrical schematic frame 30 (A.30.A)
MF6 80 A Feeds F1, F2, F3, F5, F44 Wiring harness - Electrical schematic frame 21 (A.30.A)
PF1 Main Supply 250 A Wiring harness - Electrical schematic frame 01 (A.30.A)
PF2 Electronics Supply 30 A Wiring harness - Electrical schematic frame 01 (A.30.A)
PF3 Electrical Battery Main Switch 10 A Wiring harness - Electrical schematic frame 01 (A.30.A)
CHARGING / POWER SUPPLY

G1 Battery Wiring harness - Electrical schematic frame 01 (A.30.A)
G2 Alternator Wiring harness - Electrical schematic frame 01 (A.30.A)
LIGHTS AND LAMPS

H1 Rear PTO Engage Lamp Wiring harness - Electrical schematic frame 17 (A.30.A)
H2 Front PTO Engage Lamp Wiring harness - Electrical schematic frame 17 (A.30.A)
H3 Console Lamp R/H Wiring harness - Electrical schematic frame 21 (A.30.A)
H4 Puddle Lamp L/H Wiring harness - Electrical schematic frame 21 (A.30.A)
H5 Puddle Lamp R/H Wiring harness - Electrical schematic frame 21 (A.30.A)
H6 Interior Lamp - High Roof Wiring harness - Electrical schematic frame 21 (A.30.A)
H7 Interior Lamp - Low Roof Wiring harness - Electrical schematic frame 22 (A.30.A)
H8 Console Lamp Wiring harness - Electrical schematic frame 23 (A.30.A)
H9 Lamp 1 Wiring harness - Electrical schematic frame 15 (A.30.A)
H13 Master Lamp Wiring harness - Electrical schematic frame 15 (A.30.A)
H14 Turn signal / side marker light, right Wiring harness - Electrical schematic frame 25 (A.30.A)
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H15 Licence Plate Lamp Right Wiring harness - Electrical schematic frame 25 (A.30.A)
H16 Licence Plate Lamp Left Wiring harness - Electrical schematic frame 25 (A.30.A)
H17 Licence Plate Lamp, Roof Left Wiring harness - Electrical schematic frame 25 (A.30.A)
H18 Licence Plate Lamp, Roof Right Wiring harness - Electrical schematic frame 25 (A.30.A)
H19 R/H Worklamp on C-Pillar Wiring harness - Electrical schematic frame 25 (A.30.A)
H20 L/H Worklamp on C-Pillar Wiring harness - Electrical schematic frame 25 (A.30.A)
H21 R/H Side Lamp Front Wiring harness - Electrical schematic frame 27 (A.30.A)
H22 L/H Side Lamp Front Wiring harness - Electrical schematic frame 27 (A.30.A)
H23 SMV Lamp - Front L/H Roof Wiring harness - Electrical schematic frame 28 (A.30.A)
H24 SMV Lamp - Rear L/H Roof ISO Roof:
NASO Roof:
H25 SMV Lamp - Front R/H Roof Wiring harness - Electrical schematic frame 28 (A.30.A)
H26 SMV Lamp - Rear R/H Roof ISO Roof:
NASO Roof:
H29 Grabrail Side Lamp R/H - Roof ISO Roof:
LP Roof:
H30 SMV Lamp - Rear R/H - Roof Wiring harness - Electrical schematic frame 29 (A.30.A)
H31 SMV Lamp - Front R/H - Roof Wiring harness - Electrical schematic frame 29 (A.30.A)
H32 Grabrail Side Lamp L/H - Roof ISO Roof:
LP Roof:
H33 SMV Lamp - Rear L/H - Roof Wiring harness - Electrical schematic frame 29 (A.30.A)
H34 SMV Lamp - Front L/H - Roof Wiring harness - Electrical schematic frame 29 (A.30.A)
H35 Worklamp Upper L/H Front Wiring harness - Electrical schematic frame 30 (A.30.A)
H36 Worklamp Upper R/H Front Wiring harness - Electrical schematic frame 30 (A.30.A)
H37 Worklamp L/H Rear Wiring harness - Electrical schematic frame 30 (A.30.A)
H38 Worklamp R/H Rear Wiring harness - Electrical schematic frame 30 (A.30.A)
H39 Worklamp R/H Front Grabrail Wiring harness - Electrical schematic frame 30 (A.30.A)
H40 Worklamp L/H Front Grabrail Low and High Wiring harness - Electrical schematic frame 30 (A.30.A)
Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H41 Worklamp L/H Engine Hood Wiring harness - Electrical schematic frame 30 (A.30.A)
H42 Worklamp R/H Engine Hood Wiring harness - Electrical schematic frame 30 (A.30.A)
H43 Headlamp R/H Wiring harness - Electrical schematic frame 30 (A.30.A)
H44 Headlamp L/H Wiring harness - Electrical schematic frame 30 (A.30.A)
H45 Worklamp R/H Front Grabrail Low Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H46 Worklamp R/H Front Low Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H47 Worklamp L/H Front Low Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H48 Worklamp R/H Rear Low Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H49 Worklamp L/H Rear Low Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
H54 Licence Plate Lamp Wiring harness - Electrical schematic frame 25 (A.30.A)
H55 Turn Signal / side marker light, left Wiring harness - Electrical schematic frame 25 (A.30.A)
RELAYS
K1 Windshield Wiper module front and rear Wiring harness - Electrical schematic frame 34 (A.30.A)
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K3 Ignition Relay Wiring harness - Electrical schematic frame 01 (A.30.A)
K4 Side Light/Illumination Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K5 Starter Relay Wiring harness - Electrical schematic frame 01 (A.30.A)
K6 Blower Motor Relay Wiring harness - Electrical schematic frame 39 (A.30.A)
K7 Headlight Dip Beam Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K8 Stoplamp Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K9 Headlight Main Beam Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K10 Pneumatic Trailer Brake Supply Relay Wiring harness - Electrical schematic frame 32 (A.30.A)
K11 Hydraulic Trailer Brake Supply Relay Wiring harness - Electrical schematic frame 32 (A.30.A)
K12 Stoplamp Switch Left-Right / Air Brake Wiring harness - Electrical schematic frame 16 (A.30.A)
Relay
K13 Supply EDC Control Unit, Vistronic, Wiring harness - Electrical schematic frame 02 (A.30.A)
Fuel/Grid Heater Relay Wiring harness - Electrical schematic frame 03 (A.30.A)
K14 Fuel Shut Off Relay mechanical Motor Wiring harness - Electrical schematic frame 01 (A.30.A)
K15 Worklamp Engine Hood Relay Wiring harness - Electrical schematic frame 30 (A.30.A)
K16 Worklamp C-pillar Rear Relay Wiring harness - Electrical schematic frame 30 (A.30.A)
K17 Electronics Supply Wiring harness - Electrical schematic frame 37 (A.30.A)
K18 Battery Isolator Wiring harness - Electrical schematic frame 01 (A.30.A)
K19 Air Conditioning Compressor Coupling Wiring harness - Electrical schematic frame 39 (A.30.A)
Relay
K20 EHR Power Relay Wiring harness - Electrical schematic frame 15 (A.30.A)
K21 Heated Mirrors Timerelay Wiring harness - Electrical schematic frame 23 (A.30.A)
K22 European Loader Relay Solenoid 1 Wiring harness - Electrical schematic frame 02 (A.30.A)
K24 Fuel Heater Relay Wiring harness - Electrical schematic frame 06 (A.30.A)
K25 Grid Heater Relay Wiring harness - Electrical schematic frame 06 (A.30.A)
K26 Worklamp Grabrail - Low Roof Relay Wiring harness - Electrical schematic frame 31 (A.30.A)
K27 Worklamps Rear - Low Roof Relay Wiring harness - Electrical schematic frame 31 (A.30.A)
K28 Low Roof Beacon Relay Wiring harness - Electrical schematic frame 31 (A.30.A)
MOTORS
M1 Starter Motor and Solenoid Wiring harness - Electrical schematic frame 01 (A.30.A)
M2 Electric Mirror L/H Wiring harness - Electrical schematic frame 23 (A.30.A)
M3 Electric Mirror R/H Wiring harness - Electrical schematic frame 23 (A.30.A)
M4 Seat pump Wiring harness - Electrical schematic frame 24 (A.30.A)
M5 Front Wiper Motor Wiring harness - Electrical schematic frame 34 (A.30.A)
M6 Rear Washer Motor Wiring harness - Electrical schematic frame 34 (A.30.A)
M7 Front Washer Motor Wiring harness - Electrical schematic frame 34 (A.30.A)
M8 Rear Wiper Motor Wiring harness - Electrical schematic frame 34 (A.30.A)
M9 Heater / Air Con Automatic, Blower Motor Wiring harness - Electrical schematic frame 40 (A.30.A)
M10 Heater / Air Con Blower Motor Wiring harness - Electrical schematic frame 41 (A.30.A)
RESISTORS
R1 Terminating Resistor 1 A Wiring harness - Electrical schematic frame 15 (A.30.A)
R2 Cigar Lighter Wiring harness - Electrical schematic frame 21 (A.30.A)
R3 Terminating Resistor mechanical Motor Wiring harness - Electrical schematic frame 36 (A.30.A)
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R4 Grid Heater Wiring harness - Electrical schematic frame 06 (A.30.A)
R5 Bus Terminating Resistor Wiring harness - Electrical schematic frame 15 (A.30.A)
SWITCHES
S1 Battery Isolator Control Relay Switch Wiring harness - Electrical schematic frame 01 (A.30.A)
S2 Starter Switch Wiring harness - Electrical schematic frame 01 (A.30.A)
S3 Foot Throttle (Electronic Engine) Wiring harness - Electrical schematic frame 02 (A.30.A)
S4 Constant Engine Speed Program Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S5 Engine Inc/Dec Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S6 De-Gas Bottle Wiring harness - Electrical schematic frame 05 (A.30.A)
S7 Vacuum Switch Wiring harness - Electrical schematic frame 05 (A.30.A)
S8 Shuttle Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S9 Clutch Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S10 Duplicate Transmission Control - Upshift Wiring harness - Electrical schematic frame 08 (A.30.A)
S11 Gearshift Connector Wiring harness - Electrical schematic frame 08 (A.30.A)
S12 Duplicate Transmission Control - Downshift Wiring harness - Electrical schematic frame 08 (A.30.A)
S13 Duplicate Transmission Control - Rangeshift Wiring harness - Electrical schematic frame 08 (A.30.A)
S14 High Range Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S15 Creeper Gear Detection Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S16 Normal Gear Detection Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S17 Low Range Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S18 Creeper Gear Switch Wiring harness - Electrical schematic frame 09 (A.30.A)
S19 Transmission Oil Pressure Switch Wiring harness - Electrical schematic frame 09 (A.30.A)
S20 Transmission Auto Function Switch Wiring harness - Electrical schematic frame 09 (A.30.A)
S21 Transmission Oil Temperature Sensor Wiring harness - Electrical schematic frame 11 (A.30.A)
S22 HPL External Switch L/H Wiring harness - Electrical schematic frame 12 (A.30.A)
S23 HPL External Switch R/H Wiring harness - Electrical schematic frame 12 (A.30.A)
S24 HTS Record Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S25 Lift-o-Matic Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S26 Delta P Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S27 Low Charge Pressure Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S28 Hydraulic Temperature Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S29 Hydraulic Blocked Filter Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S30 PAS Pressure Switch Wiring harness - Electrical schematic frame 13 (A.30.A)
S31 4WD Activated Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S32 Differential Lock Option Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S33 Brake Pedal Latch Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S34 Stoplamp Switch R/H Wiring harness - Electrical schematic frame 16 (A.30.A)
S35 Stoplamp Switch L/H Wiring harness - Electrical schematic frame 16 (A.30.A)
S36 4WD Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S37 Ground Speed PTO Engaged Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S38 Rear PTO Brake Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S39 Rear PTO Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S40 Front PTO Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S41 PTO Management Switch Wiring harness - Electrical schematic frame 18 (A.30.A)
S42 Front Suspension Switch Wiring harness - Electrical schematic frame 19 (A.30.A)
S43 Turn Assist Steering Wheel Switch Wiring harness - Electrical schematic frame 20 (A.30.A)
S44 Door Switch L/H Wiring harness - Electrical schematic frame 21 (A.30.A)
S45 Door Switch R/H Wiring harness - Electrical schematic frame 21 (A.30.A)
S46 Mirror Control Wiring harness - Electrical schematic frame 23 (A.30.A)
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S47 Heated Mirror Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S48 Seat Switch Wiring harness - Electrical schematic frame 24 (A.30.A)
S49 Auxiliary Headlamp Switch Wiring harness - Electrical schematic frame 25 (A.30.A)
S50 L/H Fender PTO Switch Wiring harness - Electrical schematic frame 25 (A.30.A)
S51 R/H Fender PTO Switch Wiring harness - Electrical schematic frame 25 (A.30.A)
S52 Turn Switch Wiring harness - Electrical schematic frame 26 (A.30.A)
S53 Hazard Switch Wiring harness - Electrical schematic frame 26 (A.30.A)
S54 Grabrail Worklamp Switch - Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
S55 C-pillar Worklamp Switch - Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
S56 Beacon Switch - Roof Wiring harness - Electrical schematic frame 31 (A.30.A)
S57 Engine Roof Worklamp Switch Wiring harness - Electrical schematic frame 31 (A.30.A)
S58 Handbrake Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S59 Italian Trailer Brake - Line Pressure Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S60 Italian Trailer Brake - Pump Pressure Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S61 Air Brake Pressure Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S62 Brake Fluid Reservoir Switch Wiring harness - Electrical schematic frame 33 (A.30.A)
S63 Windshield Wiper Switch Front and Rear Wiring harness - Electrical schematic frame 34 (A.30.A)
S64 Air Con Pressure Switch High / Low Wiring harness - Electrical schematic frame 39 (A.30.A)
S65 Air Conditioning Low Pressure Switch Wiring harness - Electrical schematic frame 40 (A.30.A)
S66 Heater Blower Switch Wiring harness - Electrical schematic frame 40 (A.30.A)
S67 Air Conditioning Switch Wiring harness - Electrical schematic frame 40 (A.30.A)
S68 Air Conditioning Manual Temperature Wiring harness - Electrical schematic frame 41 (A.30.A)
Control Switch
S69 Temperature Control Wiring harness - Electrical schematic frame 41 (A.30.A)
S72 Oil Pressure Switch Wiring harness - Electrical schematic frame 05 (A.30.A)
S73 Neutral Switch 3-4 Rail Wiring harness - Electrical schematic frame 08 (A.30.A)
S74 Neutral Switch 1-2 Rail Wiring harness - Electrical schematic frame 08 (A.30.A)
S75 Hi-Med Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S76 Cold Advance Switch Wiring harness - Electrical schematic frame 01 (A.30.A)
S77 CERPM Cruise Auto Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S78 Front Upper Worklamp Switch Wiring harness - Electrical schematic frame 30 (A.30.A)
S79 Main Lamps Rear Switch Wiring harness - Electrical schematic frame 30 (A.30.A)
S80 Start Inhibitor Switch Wiring harness - Electrical schematic frame 06 (A.30.A)
S81 Differential Lock Activated Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S83 EHR Switch 3/4 Time Flow Wiring harness - Electrical schematic frame 14 (A.30.A)
S84 EHR 3-4 Lever Assy Wiring harness - Electrical schematic frame 14 (A.30.A)
S85 EHR 1-2 Lever Assy Wiring harness - Electrical schematic frame 14 (A.30.A)
S86 EHR Switch 1/2 Time Flow Wiring harness - Electrical schematic frame 14 (A.30.A)
S87 Hydraulic Master Switch (EHR Stop Switch) Wiring harness - Electrical schematic frame 15 (A.30.A)
POWER SOCKETS / CONNECTORS

X1 Loader 2 Control Socket Wiring harness - Electrical schematic frame 03 (A.30.A)
X2 Loader 1 Control Socket Wiring harness - Electrical schematic frame 03 (A.30.A)
X3 Loader Control Joystick Wiring harness - Electrical schematic frame 02 (A.30.A)
X4 Trans Can Wiring harness - Electrical schematic frame 09 (A.30.A)
X5 Fixed Displacement Pump Wiring harness - Electrical schematic frame 13 (A.30.A)
X6 Brake Pad Latch In-Line Connector Wiring harness - Electrical schematic frame 16 (A.30.A)
X7 Brake Pad Latch Keypad Connector Wiring harness - Electrical schematic frame 16 (A.30.A)
X8 Ground Speed PTO Link Connector Wiring harness - Electrical schematic frame 17 (A.30.A)
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X9 Rear PTO Brake Switch Jumper Wiring harness - Electrical schematic frame 17 (A.30.A)
X10 Front Hitch / PTO Extension Connector Wiring harness - Electrical schematic frame 18 (A.30.A)
X11 8 A Ring Terminals Black/Red Cable Right Wiring harness - Electrical schematic frame 21 (A.30.A)
Rear Wiring harness - Electrical schematic frame 22 (A.30.A)
X12 Power Socket, 3-Pin Cable Right Rear Wiring harness - Electrical schematic frame 21 (A.30.A)
X13 Seat Pump Wiring harness - Electrical schematic frame 24 (A.30.A)
X14 Power Socket, 3-Pin Right Rear Wiring harness - Electrical schematic frame 24 (A.30.A)
X15 8 A Socket, Cable Left C-Pillar Wiring harness - Electrical schematic frame 24 (A.30.A)
X16 2-Pin Socket, Engine Compartment DIA Wiring harness - Electrical schematic frame 24 (A.30.A)
X17 Trailer Brake Connector Wiring harness - Electrical schematic frame 32 (A.30.A)
X18 Trailer Socket Wiring harness - Electrical schematic frame 32 (A.30.A)
X19 Air Brake Connector Wiring harness - Electrical schematic frame 32 (A.30.A)
X20 Standard Signal Socket Wiring harness - Electrical schematic frame 33 (A.30.A)
X21 EST Diagnostic Connector Wiring harness - Electrical schematic frame 36 (A.30.A)
X22 Select CAN Diag Wiring harness - Electrical schematic frame 36 (A.30.A)
X23 CAN Select Wiring harness - Electrical schematic frame 36 (A.30.A)
SOLENOID VALVES
Y1 Battery Switch Solenoid Wiring harness - Electrical schematic frame 01 (A.30.A)
Y2 Loader Valve 2 Wiring harness - Electrical schematic frame 02 (A.30.A)
Y4 Injector 1 - EDC 16 Wiring harness - Electrical schematic frame 07 (A.30.A)
Y10 5-8 Synchro Solenoid Wiring harness - Electrical schematic frame 09 (A.30.A)
Y11 Clutch C1 Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y12 Reverse Synchro Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y13 Forward Synchro Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y16 Creeper Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y17 17th Gear Dump Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y18 17th Gear Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y21 Diverter Switch Wiring harness - Electrical schematic frame 12 (A.30.A)
Y22 Diverter Valve Wiring harness - Electrical schematic frame 12 (A.30.A)
Y23 EDC Down Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y24 EDC Up Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y25 EHR Valve-1 Wiring harness - Electrical schematic frame 15 (A.30.A)
Y29 Differential Lock Solenoid Wiring harness - Electrical schematic frame 16 (A.30.A)
Y30 4WD Solenoid Wiring harness - Electrical schematic frame 16 (A.30.A)
Y31 Rear PTO Brake Solenoid Wiring harness - Electrical schematic frame 18 (A.30.A)
Y32 Rear PTO Solenoid Wiring harness - Electrical schematic frame 18 (A.30.A)
Y33 Suspension Lower Solenoid Wiring harness - Electrical schematic frame 19 (A.30.A)
Y34 Suspension Lower Lockout Solenoid Wiring harness - Electrical schematic frame 19 (A.30.A)
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Y35 Suspension Raise Solenoid Wiring harness - Electrical schematic frame 19 (A.30.A)
Y36 Suspension Raise Lockout Solenoid Wiring harness - Electrical schematic frame 19 (A.30.A)
Y37 Turn Assist Solenoid Valve Wiring harness - Electrical schematic frame 20 (A.30.A)
Y38 Italian Trailer Brake Solenoid 1 Wiring harness - Electrical schematic frame 32 (A.30.A)
Y40 Air Brake Solenoid Wiring harness - Electrical schematic frame 32 (A.30.A)
Y41 Brake De-Icer - Trailer Brakes Wiring harness - Electrical schematic frame 32 (A.30.A)
Y42 Park Brake Solenoid - Trailer Brakes Wiring harness - Electrical schematic frame 32 (A.30.A)
Y43 Heating Valve ATC Wiring harness - Electrical schematic frame 40 (A.30.A)
Y45 Clutch - Low PWM Wiring harness - Electrical schematic frame 10 (A.30.A)
Y46 Clutch - High PWM Wiring harness - Electrical schematic frame 10 (A.30.A)
Y47 Transmission Dump Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
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A001 Gearshift Indicator Wiring harness - Electrical schematic frame 45 (A.30.A)
A002 Not used -
A003 Not used -
A004 Not used -
A006 Instrument Cluster Keypad Wiring harness - Electrical schematic frame 22 (A.30.A)
A008 Worklamp ECU Wiring harness - Electrical schematic frame 31 (A.30.A)
A009 XCM Central Control Unit (CN1-A) Wiring harness - Electrical schematic frame 39 (A.30.A)
A011 Instrument Panel Wiring harness - Electrical schematic frame 40 (A.30.A)
A018 Processor EDC Wiring harness - Electrical schematic frame 40 (A.30.A)
A020 Heater/Air Con Connector Wiring harness - Electrical schematic frame 43 (A.30.A)
A021 Auto Temp Control Wiring harness - Electrical schematic frame 43 (A.30.A)
A022 Not used -
A030 Print ARU Wiring harness - Electrical schematic frame 45 (A.30.A)
A031 Turn Assist Control Unit, KA processor Wiring harness - Electrical schematic frame 51 (A.30.A)
A043 Multi Controller III Wiring harness - Electrical schematic frame 46 (A.30.A)
A044 EFH Control Panel Wiring harness - Electrical schematic frame 49 (A.30.A)
SENSORS, POTENTIOMETERS
B1 Flywheel torque sensor Wiring harness - Electrical schematic frame 04 (A.30.A)
B2 Not used -
B3 Not used -
B4 Water in Fuel Sensor Wiring harness - Electrical schematic frame 05 (A.30.A)
B5 Boost Pressure/Temperature Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B6 Oil Pressure/Temperature Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B7 Fuel Rail Pressure Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B10 Crankshaft Speed Sensor Wiring harness - Electrical schematic frame 06 (A.30.A)
B12 Fuel Metering Unit Wiring harness - Electrical schematic frame 06 (A.30.A)
B13 Clutch Potentiometer Wiring harness - Electrical schematic frame 07 (A.30.A)
B14 4-5 Synchro Potentiometer Wiring harness - Electrical schematic frame 07 (A.30.A)
B15 Synchro Position Potentiometer Wiring harness - Electrical schematic frame 07 (A.30.A)
B16 Axle Speed Sensor Wiring harness - Electrical schematic frame 08 (A.30.A)
B17 LH Draft Pin Wiring harness - Electrical schematic frame 10 (A.30.A)
B18 Rockshaft Potentiometer Wiring harness - Electrical schematic frame 10 (A.30.A)
B19 RH Draft Pin Wiring harness - Electrical schematic frame 10 (A.30.A)
B20 Front Hitch Position Potentiometer Wiring harness - Electrical schematic frame 10 (A.30.A)
B21 Rear PTO Speed Sensor Wiring harness - Electrical schematic frame 16 (A.30.A)
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B22 PTO Shaft Twist Sensor Wiring harness - Electrical schematic frame 15 (A.30.A)
B23 Front Suspension Potentiometer Wiring harness - Electrical schematic frame 17 (A.30.A)
B24 Turn Assist - LVDT Coils Wiring harness - Electrical schematic frame 51 (A.30.A)
B25 Turn Assist Steering Wheel Sensor Wiring harness - Electrical schematic frame 51 (A.30.A)
B26 Speaker R/H Rear Wiring harness - Electrical schematic frame 18 (A.30.A)
B27 Speaker R/H Front Wiring harness - Electrical schematic frame 18 (A.30.A)
B28 Speaker L/H Rear Wiring harness - Electrical schematic frame 18 (A.30.A)
B29 Speaker L/H Front Wiring harness - Electrical schematic frame 18 (A.30.A)
B30 Horn Wiring harness - Electrical schematic frame 22 (A.30.A)
B31 Fuel Tank Sender Wiring harness - Electrical schematic frame 34 (A.30.A)
B32 Radar gun Wiring harness - Electrical schematic frame 34 (A.30.A)
B34 Outside temperature sensor Wiring harness - Electrical schematic frame 43 (A.30.A)
B35 Cab temperature sensor Wiring harness - Electrical schematic frame 43 (A.30.A)
B36 Outlet temperature sensor clime Wiring harness - Electrical schematic frame 43 (A.30.A)
B37 EVAP evaporator temperature sensor Wiring harness - Electrical schematic frame 43 (A.30.A)
B38 Temperature potentiometer air conditioning Wiring harness - Electrical schematic frame 43 (A.30.A)
B39 Not used -
B40 Not used -
B41 Draught potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B42 EDC position potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B43 EHR potentiometer throughflow volume Wiring harness - Electrical schematic frame 47 (A.30.A)
additional control unit 1
B48 EHR control sensor joystick Wiring harness - Electrical schematic frame 47 (A.30.A)
B49 EHR control sensor joystick Wiring harness - Electrical schematic frame 47 (A.30.A)
B50 EHR control sensor shift lever additional Wiring harness - Electrical schematic frame 47 (A.30.A)
control unit
B51 EFH lift limitation potentiometer Wiring harness - Electrical schematic frame 49 (A.30.A)
B52 EFH lowering speed potentiometer Wiring harness - Electrical schematic frame 49 (A.30.A)
B53 EFH pressure mix position control Wiring harness - Electrical schematic frame 49 (A.30.A)
potentiometer
B54 EFH nominal value potentiometer Wiring harness - Electrical schematic frame 49 (A.30.A)
B55 EFH rotary angle sensor Wiring harness - Electrical schematic frame 50 (A.30.A)
B56 EFH pressure sensor Wiring harness - Electrical schematic frame 50 (A.30.A)
B68 Slip limitation potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B69 EDC draught sensitivity potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B70 Lowering speed potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B71 Lift limitation potentiometer Wiring harness - Electrical schematic frame 11 (A.30.A)
B72 Rotary angle sensor, front power lift Wiring harness - Electrical schematic frame 16 (A.30.A)
B73 Hand Throttle Slider Wiring harness - Electrical schematic frame 46 (A.30.A)
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DIODES
D1 Diode Main Battery Switch Wiring harness - Electrical schematic frame 52 (A.30.A)
D2 Diode brake light left Wiring harness - Electrical schematic frame 22 (A.30.A)
D3 Diode brake light right Wiring harness - Electrical schematic frame 22 (A.30.A)
D4 Diode licence plate light Wiring harness - Electrical schematic frame 29 (A.30.A)
D5 Not used -
MISCELLANEOUS
E2 Rotating Beacon L/H Wiring harness - Electrical schematic frame 31 (A.30.A)
E3 Rotating Beacon R/H Wiring harness - Electrical schematic frame 31 (A.30.A)
E4 Air Con Compressor Wiring harness - Electrical schematic frame 41 (A.30.A)
FUSES (PF - POWER FUSES, MF - MAXI FUSES, F - MINI FUSES)

F1 Interior light left / Puddle lamp left + right / Wiring harness - Electrical schematic frame 18 (A.30.A)
Handbrake 10 A Wiring harness - Electrical schematic frame 19 (A.30.A)
F2 Cigar lighter / Power Studs 25 A Wiring harness - Electrical schematic frame 18 (A.30.A)
F3 A/C Clutch 10 A Wiring harness - Electrical schematic frame 41 (A.30.A)
F4 Accessory Sockets 10 A Wiring harness - Electrical schematic frame 18 (A.30.A)
F5 Blower Motor 30 A Wiring harness - Electrical schematic frame 41 (A.30.A)
F6 Radio / Worklamp ECU 10 A Wiring harness - Electrical schematic frame 18 (A.30.A)
F7 Potential 30 / Main Light Switch / Hazard Wiring harness - Electrical schematic frame 26 (A.30.A)
Switch 20 A
F8 Potential 30 / Starter Switch 20 A Wiring harness - Electrical schematic frame 01 (A.30.A)
F9 Supply Loader Option 25 A Wiring harness - Electrical schematic frame 48 (A.30.A)
F11 Windshield Wiper, front/rear 10 A Wiring harness - Electrical schematic frame 35 (A.30.A)
F12 Front + Rear Windshield Washer / Rear Wiring harness - Electrical schematic frame 35 (A.30.A)
Wiper 10 A Wiring harness - Electrical schematic frame 36 (A.30.A)
F13 Brake lights / Brake light relay K8 15 A Wiring harness - Electrical schematic frame 14 (A.30.A)
F14 Potential 15 / Main Light Switch / Flasher Wiring harness - Electrical schematic frame 26 (A.30.A)
Unit 15 A
F15 Stoplamp Switch left/right / pneumatic relay Wiring harness - Electrical schematic frame 14 (A.30.A)
K12 / Battery Isolator 20 A
F16 Italian Hydraulic & Pneumatic trailer brake Wiring harness - Electrical schematic frame 33 (A.30.A)
relay 15 A
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F17 Potential 15 / power socket 3-pin right rear Wiring harness - Electrical schematic frame 18 (A.30.A)
cab 25 A Wiring harness - Electrical schematic frame 19 (A.30.A)
F18 Potential 15 / blower relay air cushion Wiring harness - Electrical schematic frame 41 (A.30.A)
electric seat 15 A
F19 Potential 15 / Heated mirrors 7.5 A Wiring harness - Electrical schematic frame 37 (A.30.A)
F20 Potential 15 / Standardsignal Socket / Radar Wiring harness - Electrical schematic frame 22 (A.30.A)
/ ADIC Keypad 10 A Wiring harness - Electrical schematic frame 23 (A.30.A)
F21 Brake Fluid Level Switch / Water in Fuel Wiring harness - Electrical schematic frame 05 (A.30.A)
Sensor 15 A
F22 Side Lamps R/H / Spot light right 15 A Wiring harness - Electrical schematic frame 24 (A.30.A)
F23 Side Lamps L/H / licence plate lights / 7-pin Wiring harness - Electrical schematic frame 24 (A.30.A)
trailer socket 15 A Wiring harness - Electrical schematic frame 25 (A.30.A)
F24 Control panel right - switch illumination 10 A Wiring harness - Electrical schematic frame 24 (A.30.A)
F25 Dip Beam Headlamps 15 A Wiring harness - Electrical schematic frame 26 (A.30.A)
F26 Main Beam Headlamps 15 A Wiring harness - Electrical schematic frame 26 (A.30.A)
F27 Worklamps Engine Hood 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
F28 Worklamps ECU, Roof rear 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
LP Roof: LP Roof:
Worklamps, low roof rear K27 15 A Wiring harness - Electrical schematic frame 32 (A.30.A)
F29 Worklamps ECU, Roof front, Grabrail 30 A Wiring harness - Electrical schematic frame 31 (A.30.A)
LP Roof: LP Roof:
Worklamps, low roof front, Grabrail K26 30 Wiring harness - Electrical schematic frame 32 (A.30.A)
A
F30 Worklamps Relay C-pillar 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
LP Roof:
F31 Rotating Beacons 15 A Wiring harness - Electrical schematic frame 31 (A.30.A)
LP Roof: LP Roof:
Low Roof Rotating Beacons K28 15 A Wiring harness - Electrical schematic frame 32 (A.30.A)
F32 Potential 30 / Flasher Unit 30 A Wiring harness - Electrical schematic frame 27 (A.30.A)
F33 Diagnostics Connector / Turn Assist 25 A Wiring harness - Electrical schematic frame 38 (A.30.A)
F34 Potential 30 / ADIC Battery Positive 10 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F35 XCM Central - XCM Auxiliary Control Unit / Wiring harness - Electrical schematic frame 39 (A.30.A)
Small Controller 10 A
F36 Potential 15 / Instrument Cluster 10 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F37 Transmission Ignition 15 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F38 Rear PTO Switch / Rear PTO Warning Light Wiring harness - Electrical schematic frame 39 (A.30.A)
/ HPL / PTO Speed / Transmission Display /
Armrest / Allwheel Drive Switch 10 A
F39 Supply Hydraulicmaster 10 A Wiring harness - Electrical schematic frame 12 (A.30.A)
F40 Potential 15 / Radio 10 A Wiring harness - Electrical schematic frame 18 (A.30.A)
F41 Front PTO 15 A Wiring harness - Electrical schematic frame 39 (A.30.A)
F42 Front Suspension / HPL 10 A Wiring harness - Electrical schematic frame 10 (A.30.A)
F43 Engine ECU Activate 10 A Wiring harness - Electrical schematic frame 01 (A.30.A)
F44 Potential 30 / Socket for mounted equipment Wiring harness - Electrical schematic frame 41 (A.30.A)
DIA 25 A
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F45 Potential 15 / 8AMP 2-pin mobil phone Wiring harness - Electrical schematic frame 22 (A.30.A)
socket 25 A Wiring harness - Electrical schematic frame 23 (A.30.A)
F46 Not used -
F47 Not used -
F48 Not used -
F49 Potential 30 / EFH Electronic front hitch 7.5 Wiring harness - Electrical schematic frame 49 (A.30.A)
A
F51 Turn Assist rapid steering system 5 A Wiring harness - Electrical schematic frame 38 (A.30.A)
F52 Potential 15 / Relay K25/K24 Vistronic Fan Wiring harness - Electrical schematic frame 40 (A.30.A)
F53 Potential 15 / Processor EDC Wiring harness - Electrical schematic frame 40 (A.30.A)
F54 Potential 15 / Processor EDC Wiring harness - Electrical schematic frame 40 (A.30.A)
F60 Battery Isolator Control 10 A Wiring harness - Electrical schematic frame 52 (A.30.A)
GF1 Fuse Supply Grid Heater Relay 125 A Wiring harness - Electrical schematic frame 01 (A.30.A)
F16, F17, F18, F19, F20, F21, F45, F51 Wiring harness - Electrical schematic frame 02 (A.30.A)
MF2 80 A Feeds F6, F7, F8 Wiring harness - Electrical schematic frame 01 (A.30.A)
F53, F54, F60
MF4 80 A Feeds F27, F28, 3-pin Power Socket Wiring harness - Electrical schematic frame 22 (A.30.A)
Right Rear Wiring harness - Electrical schematic frame 23 (A.30.A)
MF5 80 A Feeds F25, F26, F31, F32 Wiring harness - Electrical schematic frame 31 (A.30.A)
MF6 80 A Feeds F1, F2, F3, F4, F5, F44, F49 Wiring harness - Electrical schematic frame 41 (A.30.A)
PF1 Main Supply 250 A Wiring harness - Electrical schematic frame 01 (A.30.A)
PF2 Electronics Supply 30 A Wiring harness - Electrical schematic frame 01 (A.30.A)
PF3 Not used -

G1 Battery Wiring harness - Electrical schematic frame 01 (A.30.A)
LIGHTS AND LAMPS

H1 Rear PTO Engage Lamp Wiring harness - Electrical schematic frame 15 (A.30.A)
H2 Front PTO Engage Lamp Wiring harness - Electrical schematic frame 15 (A.30.A)
H3 Console Lamp R/H Wiring harness - Electrical schematic frame 18 (A.30.A)
H4 Puddle Lamp L/H Wiring harness - Electrical schematic frame 18 (A.30.A)
H5 Puddle Lamp R/H Wiring harness - Electrical schematic frame 18 (A.30.A)
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H6 Interior Lamp - High Roof Wiring harness - Electrical schematic frame 18 (A.30.A)
H7 Interior Lamp - Low Roof Wiring harness - Electrical schematic frame 20 (A.30.A)
H14 Turn signal / side marker light, right Wiring harness - Electrical schematic frame 24 (A.30.A)
H15 Licence Plate Lamp Right Wiring harness - Electrical schematic frame 24 (A.30.A)
H16 Licence Plate Lamp Left Wiring harness - Electrical schematic frame 24 (A.30.A)
H17 Licence Plate Lamp, Roof Left Wiring harness - Electrical schematic frame 24 (A.30.A)
H18 Licence Plate Lamp, Roof Right Wiring harness - Electrical schematic frame 24 (A.30.A)
H19 R/H Worklamp on C-Pillar Wiring harness - Electrical schematic frame 31 (A.30.A)
H20 L/H Worklamp on C-Pillar Wiring harness - Electrical schematic frame 31 (A.30.A)
H21 R/H Side Lamp Front Wiring harness - Electrical schematic frame 27 (A.30.A)
H22 L/H Side Lamp Front Wiring harness - Electrical schematic frame 27 (A.30.A)
H35 Worklamp Upper L/H Front Wiring harness - Electrical schematic frame 29 (A.30.A)
H36 Worklamp Upper R/H Front Wiring harness - Electrical schematic frame 29 (A.30.A)
H37 Worklamp L/H Rear Wiring harness - Electrical schematic frame 29 (A.30.A)
H38 Worklamp R/H Rear Wiring harness - Electrical schematic frame 29 (A.30.A)
H39 Worklamp R/H Front Grabrail Wiring harness - Electrical schematic frame 31 (A.30.A)
H40 Worklamp L/H Front Grabrail Low and High Wiring harness - Electrical schematic frame 31 (A.30.A)
Roof Wiring harness - Electrical schematic frame 32 (A.30.A)
H41 Worklamp L/H Engine Hood Wiring harness - Electrical schematic frame 31 (A.30.A)
H42 Worklamp R/H Engine Hood Wiring harness - Electrical schematic frame 31 (A.30.A)
H43 Headlamp R/H Wiring harness - Electrical schematic frame 26 (A.30.A)
H44 Headlamp L/H Wiring harness - Electrical schematic frame 26 (A.30.A)
H45 Worklamp R/H Front Grabrail Low Roof Wiring harness - Electrical schematic frame 32 (A.30.A)
H46 Worklamp R/H Front Low Roof Wiring harness - Electrical schematic frame 30 (A.30.A)
H47 Worklamp L/H Front Low Roof Wiring harness - Electrical schematic frame 30 (A.30.A)
H48 Worklamp R/H Rear Low Roof Wiring harness - Electrical schematic frame 30 (A.30.A)
H49 Worklamp L/H Rear Low Roof Wiring harness - Electrical schematic frame 30 (A.30.A)
H55 Turn Signal / side marker light, left Wiring harness - Electrical schematic frame 24 (A.30.A)
H56 EDC slip control Wiring harness - Electrical schematic frame 12 (A.30.A)
H57 EDC lowering control Wiring harness - Electrical schematic frame 12 (A.30.A)
H58 EDC raising control Wiring harness - Electrical schematic frame 12 (A.30.A)
H59 EDC diagnosis Wiring harness - Electrical schematic frame 12 (A.30.A)
H60 Not used -
H61 Not used -
H62 Not used -
H63 Not used -
H64 EFH monitor green Wiring harness - Electrical schematic frame 49 (A.30.A)
H65 EFH diagnosis red Wiring harness - Electrical schematic frame 49 (A.30.A)
RELAYS
K1 Windshield Wiper module front and rear Wiring harness - Electrical schematic frame 35 (A.30.A)
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K4 Side Light/Illumination Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K5 Starter Relay Wiring harness - Electrical schematic frame 01 (A.30.A)
K6 Blower Motor Relay Wiring harness - Electrical schematic frame 41 (A.30.A)
K7 Headlight Dip Beam Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K8 Stoplamp Relay Wiring harness - Electrical schematic frame 14 (A.30.A)
K9 Headlight Main Beam Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K10 Pneumatic Trailer Brake Supply Relay Wiring harness - Electrical schematic frame 33 (A.30.A)
K11 Hydraulic Trailer Brake Supply Relay Wiring harness - Electrical schematic frame 33 (A.30.A)
K12 Stoplamp Switch Left-Right / Air Brake Wiring harness - Electrical schematic frame 14 (A.30.A)
Relay
K13 Supply EDC Control Unit, Vistronic, Wiring harness - Electrical schematic frame 39 (A.30.A)
Fuel/Grid Heater Relay
K14 Not used -
K15 Worklamp Engine Hood Relay Wiring harness - Electrical schematic frame 31 (A.30.A)
K16 Worklamp C-pillar Rear Relay Wiring harness - Electrical schematic frame 31 (A.30.A)
K17 Electronics Supply Wiring harness - Electrical schematic frame 39 (A.30.A)
K18 Battery Isolator Wiring harness - Electrical schematic frame 52 (A.30.A)
K19 Air Conditioning Compressor Coupling Wiring harness - Electrical schematic frame 41 (A.30.A)
Relay
K21 Heated Mirrors Timerelay Wiring harness - Electrical schematic frame 37 (A.30.A)
K26 Worklamp Grabrail - Low Roof Relay Wiring harness - Electrical schematic frame 32 (A.30.A)
K27 Worklamps Rear - Low Roof Relay Wiring harness - Electrical schematic frame 30 (A.30.A)
K28 Low Roof Beacon Relay Wiring harness - Electrical schematic frame 32 (A.30.A)
K31 D+ cut-off Frontloader Wiring harness - Electrical schematic frame 48 (A.30.A)
K43 Not used -
K44 Not used -
K45 Not used -
K46 Not used -
K47 Not used -
MOTORS
M1 Starter Motor and Solenoid Wiring harness - Electrical schematic frame 01 (A.30.A)
M2 Electric Mirror L/H Wiring harness - Electrical schematic frame 37 (A.30.A)
M3 Electric Mirror R/H Wiring harness - Electrical schematic frame 37 (A.30.A)
M4 Seat pump Wiring harness - Electrical schematic frame 22 (A.30.A)
M5 Front Wiper Motor Wiring harness - Electrical schematic frame 35 (A.30.A)
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M6 Rear Washer Motor Wiring harness - Electrical schematic frame 35 (A.30.A)
M7 Front Washer Motor Wiring harness - Electrical schematic frame 35 (A.30.A)
M8 Rear Wiper Motor Wiring harness - Electrical schematic frame 35 (A.30.A)
M9 Heater / Air Con Automatic, Blower Motor Wiring harness - Electrical schematic frame 43 (A.30.A)
M10 Heater / Air Con Blower Motor Wiring harness - Electrical schematic frame 42 (A.30.A)
RESISTORS
R1 Terminating Resistor 1 A Wiring harness - Electrical schematic frame 44 (A.30.A)
R2 Cigar Lighter Wiring harness - Electrical schematic frame 18 (A.30.A)
R3 Not used -
R7 Fuel Heater Wiring harness - Electrical schematic frame 01 (A.30.A)
SWITCHES
S1 Battery Isolator Control Relay Switch Wiring harness - Electrical schematic frame 52 (A.30.A)
S3 Foot Throttle (Electronic Engine) Wiring harness - Electrical schematic frame 04 (A.30.A)
S4 Constant Engine Speed Program Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S5 Engine Inc/Dec Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S7 Vacuum Switch Wiring harness - Electrical schematic frame 04 (A.30.A)
S8 Shuttle Switch Wiring harness - Electrical schematic frame 07 (A.30.A)
S10 Not used -
S11 Not used -
S12 Not used -
S13 Not used -
S15 Creeper Gear Detection Switch Wiring harness - Electrical schematic frame 07 (A.30.A)
S16 Normal Gear Detection Switch Wiring harness - Electrical schematic frame 07 (A.30.A)
S18 Creeper Gear Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S19 Transmission Oil Pressure Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S20 Transmission Auto Function Switch Wiring harness - Electrical schematic frame 46 (A.30.A)
S21 Transmission Oil Temperature Sensor Wiring harness - Electrical schematic frame 10 (A.30.A)
S22 HPL External Switch L/H Wiring harness - Electrical schematic frame 12 (A.30.A)
S23 HPL External Switch R/H Wiring harness - Electrical schematic frame 12 (A.30.A)
S24 HTS Record Switch Wiring harness - Electrical schematic frame 10 (A.30.A)
S26 Not used -
S27 Low Charge Pressure Switch Wiring harness - Electrical schematic frame 12 (A.30.A)
S28 Hydraulic Temperature Switch Wiring harness - Electrical schematic frame 12 (A.30.A)
S29 Hydraulic Blocked Filter Switch Wiring harness - Electrical schematic frame 12 (A.30.A)
S30 PAS Pressure Switch Wiring harness - Electrical schematic frame 12 (A.30.A)
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S31 4WD Activated Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S34 Stoplamp Switch R/H Wiring harness - Electrical schematic frame 14 (A.30.A)
S35 Stoplamp Switch L/H Wiring harness - Electrical schematic frame 14 (A.30.A)
S36 4WD Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S42 Front Suspension Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S43 Turn Assist Steering Wheel Switch Wiring harness - Electrical schematic frame 51 (A.30.A)
S44 Door Switch L/H Wiring harness - Electrical schematic frame 18 (A.30.A)
S45 Door Switch R/H Wiring harness - Electrical schematic frame 18 (A.30.A)
S46 Mirror Control Wiring harness - Electrical schematic frame 37 (A.30.A)
S48 Seat Switch Wiring harness - Electrical schematic frame 22 (A.30.A)
S50 L/H Fender PTO Switch Wiring harness - Electrical schematic frame 24 (A.30.A)
S51 R/H Fender PTO Switch Wiring harness - Electrical schematic frame 24 (A.30.A)
S52 Turn Switch Wiring harness - Electrical schematic frame 26 (A.30.A)
S54 Grabrail Worklamp Switch - Roof Wiring harness - Electrical schematic frame 32 (A.30.A)
S55 C-pillar Worklamp Switch - Roof Wiring harness - Electrical schematic frame 32 (A.30.A)
S56 Beacon Switch - Roof Wiring harness - Electrical schematic frame 32 (A.30.A)
S57 Engine Roof Worklamp Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S59 Italian Trailer Brake - Line Pressure Switch Wiring harness - Electrical schematic frame 33 (A.30.A)
S60 Italian Trailer Brake - Pump Pressure Switch Wiring harness - Electrical schematic frame 33 (A.30.A)
S61 Air Brake Pressure Switch Wiring harness - Electrical schematic frame 33 (A.30.A)
S62 Brake Fluid Reservoir Switch Wiring harness - Electrical schematic frame 34 (A.30.A)
S63 Windshield Wiper Switch Front and Rear Wiring harness - Electrical schematic frame 35 (A.30.A)
S64 Air Con Pressure Switch High / Low Wiring harness - Electrical schematic frame 41 (A.30.A)
S65 Air Conditioning Low Pressure Switch Wiring harness - Electrical schematic frame 42 (A.30.A)
S66 Heater Blower Switch Wiring harness - Electrical schematic frame 42 (A.30.A)
S67 Air Conditioning Switch Wiring harness - Electrical schematic frame 42 (A.30.A)
S68 Air Conditioning Manual Temperature Wiring harness - Electrical schematic frame 42 (A.30.A)
Control Switch
S70 Not used -
S71 Not used -
S72 Not used -
S73 Not used -
S74 Not used -
S75 Not used -
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S77 Not used -
S78 Not used -
S81 Not used -
S87 Hydraulic Master Switch (EHR Stop Switch) Wiring harness - Electrical schematic frame 13 (A.30.A)
S88 F/R Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S90 Headland Management Control Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S91 Speed+ Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S92 Speed- Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S93 EHR Raise Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S94 EHR Lower Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S95 EDC Control Transport Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S106 Front Loader Button Joystick Solenoid 2 Wiring harness - Electrical schematic frame 46 (A.30.A)
S107 Internally Operated Front Power Lift Button Wiring harness - Electrical schematic frame 12 (A.30.A)
S108 EFH Raise Control Button Wiring harness - Electrical schematic frame 45 (A.30.A)
S109 EDC Stop Button Wiring harness - Electrical schematic frame 45 (A.30.A)
S110 EDC Rapid Retract Button (Float Position) Wiring harness - Electrical schematic frame 45 (A.30.A)
S111 Front Loader Button Joystick Solenoid 1 Wiring harness - Electrical schematic frame 47 (A.30.A)
S112 Engine Back Pressure Brakes Switch Wiring harness - Electrical schematic frame 48 (A.30.A)
S114 External Button, EFH Raise/Lower Wiring harness - Electrical schematic frame 50 (A.30.A)
S115 EFH Switch Transport Raise Wiring harness - Electrical schematic frame 49 (A.30.A)
S116 Internally Operated Front Power Lift Button Wiring harness - Electrical schematic frame 50 (A.30.A)
S117 Shift Button Wiring harness - Electrical schematic frame 46 (A.30.A)
S118 Mechanical Battery Main Switch Wiring harness - Electrical schematic frame 02 (A.30.A)
S119 Oil Motor Mode Switch Wiring harness - Electrical schematic frame 48 (A.30.A)
S120 Not used -
S121 Not used -
S122 Not used -

X4 Trans Can Wiring harness - Electrical schematic frame 38 (A.30.A)
X5 Fixed Displacement Pump Wiring harness - Electrical schematic frame 12 (A.30.A)
X8 Ground Speed PTO Link Connector Wiring harness - Electrical schematic frame 15 (A.30.A)
X9 Rear PTO Brake Switch Jumper Wiring harness - Electrical schematic frame 16 (A.30.A)
X10 Front Hitch / PTO Extension Connector Wiring harness - Electrical schematic frame 16 (A.30.A)
X11 8 A Ring Terminals Black/Red Cable Right Wiring harness - Electrical schematic frame 18 (A.30.A)
Rear Wiring harness - Electrical schematic frame 19 (A.30.A)
X12 Power Socket, 3-Pin Cable Right Rear Wiring harness - Electrical schematic frame 18 (A.30.A)
X13 Seat Pump Wiring harness - Electrical schematic frame 22 (A.30.A)
X14 Power Socket, 3-Pin Right Rear Wiring harness - Electrical schematic frame 22 (A.30.A)
X15 8 A Socket, Cable Left C-Pillar Wiring harness - Electrical schematic frame 22 (A.30.A)
X16 2-Pin Socket, Engine Compartment DIA Wiring harness - Electrical schematic frame 22 (A.30.A)
X17 Trailer Brake Connector Wiring harness - Electrical schematic frame 33 (A.30.A)
X18 Trailer Socket Wiring harness - Electrical schematic frame 33 (A.30.A)
X19 Air Brake Connector Wiring harness - Electrical schematic frame 33 (A.30.A)
X20 Standard Signal Socket Wiring harness - Electrical schematic frame 34 (A.30.A)
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X21 EST Diagnostic Connector Wiring harness - Electrical schematic frame 38 (A.30.A)
X22 Select CAN Diag Wiring harness - Electrical schematic frame 38 (A.30.A)
X23 CAN Select Wiring harness - Electrical schematic frame 38 (A.30.A)
SOLENOID VALVES
Y1 Battery Switch Solenoid Wiring harness - Electrical schematic frame 52 (A.30.A)
Y17 17th Gear Dump Solenoid Wiring harness - Electrical schematic frame 09 (A.30.A)
Y22 Not used -
Y23 EDC Down Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y24 EDC Up Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y29 Differential Lock Solenoid Wiring harness - Electrical schematic frame 14 (A.30.A)
Y34 Suspension Lower Lockout Solenoid Wiring harness - Electrical schematic frame 17 (A.30.A)
Y36 Suspension Raise Lockout Solenoid Wiring harness - Electrical schematic frame 17 (A.30.A)
Y37 Turn Assist Solenoid Valve Wiring harness - Electrical schematic frame 51 (A.30.A)
Y40 Air Brake Solenoid Wiring harness - Electrical schematic frame 33 (A.30.A)
Y41 Brake De-Icer - Trailer Brakes Wiring harness - Electrical schematic frame 33 (A.30.A)
Y42 Park Brake Solenoid - Trailer Brakes Wiring harness - Electrical schematic frame 33 (A.30.A)
Y43 Heating Valve ATC Wiring harness - Electrical schematic frame 43 (A.30.A)
Y45 Not used -
Y46 Not used -
Y47 Not used -
Y60 Front PTO Solenoid Wiring harness - Electrical schematic frame 16 (A.30.A)
Y61 EFH-Solenoid 40 bar (580 psi) Accumulator Wiring harness - Electrical schematic frame 49 (A.30.A)
Y62 EFH-Solenoid 14 bar (203 psi) Accumulator Wiring harness - Electrical schematic frame 49 (A.30.A)
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Y63 EFH-Solenoid Raise Wiring harness - Electrical schematic frame 50 (A.30.A)
Y64 EFH-Solenoid Lower Wiring harness - Electrical schematic frame 50 (A.30.A)
Y65 Not used -
Y66 Not used -
Y67 Not used -
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Wiring harness - Electrical schematic frame 01 Starting and

Charging
MAXXUM 110 4v W/Cab 16x16, MAXXUM 115 4v W/Cab 16x16, MAXXUM 120 4v W/Cab 16x16, MAXXUM 125 4v W/Cab 16x16, MAXXUM 130 4v
Compo- Connector Description

nent
D1 C504 Diode
F8 Starter Switch Fuse 20 A
F43 Engine ECU Fuse 10 A
F60 Battery Isolator Control Fuse 10 A
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
K5 Starter Crank Relay
K14 Fuel Shut Off Relay
K18 Battery Isolator Relay
M1 C006 Start Solenoid
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
PF1 Electronics Supply Power Fuse 250 A
PF2 Main Supply Power Fuse 30 A
PF3 Implement Socket Front Power Fuse 10 A
S1 C503 ISO Control Relay Switch
S2 C072 Starter Switch
Y1 C579 Battery Switch Solenoid
Additional Connectors:
C001 C079 C101 C242 C269 C325 C350 C351 C352 C500 C580
Wire Colour Codes

B Black R Red LG Light K Pink
Green
N Brown O Orange U Blue W White
LN Light Y Yellow TQ Turquoise
Brown
S Slate G Green L Lilac
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16W-CABEHR-1 1
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Wiring harness - Electrical schematic frame 02 Engine 1 - Europe


nent
F9 Loader Option Fuse 25 A
K13 Cold Advance Relay
K22 C669 European Loader Relay 1
S3 C376 Foot Throttle - Electronic engine
X3 C369 Loader Control Joystick
Y2 C414 Loader Valve 2
C001 C127 C128 C242 C269 C424 C441 C442 C647 C648
Wire Colour Codes

Green
Brown
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16W-CABEHR-2 1
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Wiring harness - Electrical schematic frame 03 Engine 1 - North

America

nent
F9 Supply D+ Relay Front Loader Fuse 25 A
K13 Supply EDC Control Unit Relay
X1 C648 Loader 2 Solenoid Connector
C001 C127 C128 C242 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
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SS09D200 1
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Wiring harness - Electrical schematic frame 04 Engine 2


nent
B1 C287 Crankshaft Speed Sensor
S4 C401 Constant Engine Speed Programme Switch
S5 C301 Engine Inc/Dec Switch
C001 C019 C020 C079 C127 C128 C378
Wire Colour Codes

Green
Brown
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16W-CABEHR-3 1
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nent
B2 C256 Throttle Pot
B3 C314 Hand Throttle
S6 C353 De-Gas Bottle
S7 Vacuum Switch
S72 C009 Oil Pressure Switch
C001 C019 C020 C079 C081 C100 C101 C127 C269
Wire Colour Codes

Green
Brown
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16W-CABEHR-4 1
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A.30.A / 399


nent
B4 C017 Water in Fuel Sensor
B5 C427 Boost Pressure / Temp Sensor
B6 C428 Oil Pressure / Temp Sensor
E1 C276 Visctronic Fan
F21 Grid Heater / WIF Sensor / Brake Fluid Level Fuse 15 A
F46 Engine ECU Supply Fuse 15 A
K24 C625 Fuel Heater Relay
K25 C354 Grid Heater Relay
C001 C079 C242 C269 C275 C315
Wire Colour Codes

Green
Brown
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A.30.A / 400
16W-CABEHR-5 1
84276322A 31/05/2010
A.30.A / 401


nent
B7 C429 Fuel Rail Pressure Sensor
B8 C430 Coolant Temperature Sensor
B9 C431 Fuel Temperature Sensor
B11 C433 Camshaft Speed Sensor
B12 C440 Fuel Metering Unit
Y4 C434 Injector 1
Y5 C434 Injector 2
Y6 C436 Injector 3
Y7 C436 Injector 4
Y8 C438 Injector 5
Y9 C438 Injector 6
C315
Wire Colour Codes

Green
Brown
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SS09D201 1
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Wiring harness - Electrical schematic frame 08 Transmission 1


nent
B14 C359 4-5 Synchro Solenoid
B15 C158 Synchro Position Potentiometer
S8 C075 Shuttle Switch
S9 C076 Clutch Switch
S10 C420 Duplicate Control Switch - Upshift
S11 C103 Gearshift Connector
S12 C419 Duplicate Control Switch - Downshift
S13 C421 Duplicate Control Switch - Rangeshift
S14 C167 High Range Switch
S15 C358 Creeper Sensor Switch
S16 C418 Creeper Sensor Forward Switch
S17 C166 Low Range Switch
C019 C020 C100 C101 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 404
16W-CABEHR-7 1
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A.30.A / 405


nent
A001 C104 Gearshift Indicator
B13 C077 Clutch Potentiometer
B16 C046 Axle Speed Sensor
S18 C192 Creeper Gear Switch
S19 C036 Trans Oil Pressure Switch
S20 C262 Trans Auto Function Switch
X4 C444 Trans Can
Y10 C360 5-8 Synchro Solenoid
C019 C020 C079 C081 C101 C127 C128 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 406
16W-CABEHR-8 1
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A.30.A / 407


nent
Y11 C028 Clutch C1 Solenoid
Y12 C156 Reverse Synchro Solenoid
Y13 C157 Forward Synchro Solenoid
Y16 C222 Creeper Solenoid
Y17 C289 19th Gear Dump Solenoid
Y18 C290 19th Gear Solenoid
C019 C020 C100 C128 C239
Wire Colour Codes

Green
Brown
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A.30.A / 408
16W-CABEHR-9 1
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Wiring harness - Electrical schematic frame 11 EDC HYDRAULICS 1


nent
B17 C047 LH Draft Pin
B18 C052 Rockshaft Potentiometer
B19 C048 RH Draft Pin
B20 C170 Front Hitch Position Potentiometer
F42 Front Suspension / HPL Fuse 10 A
S21 C023 Trans Oil Temperature Sender
C019 C101 C269 C324 C325 C392
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 410
16W-CABEHR-10 1
84276322A 31/05/2010
A.30.A / 411


nent
A002 C121 EDC Control Panel
A003 C240 EDC Mouse Connector
A004 C120 EDC Status Lamp Panel
F39 EDC Valves Fuse 10 A
S22 C135 HPL External Switch L.H.
S23 C134 HPL External Switch R.H.
Y21 C550 Diverter Switch
Y22 C148 Diverter Valve
C020 C100 C101 C127 C239 C294 C296 C370
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 412
16W-CABEHR-11 1
84276322A 31/05/2010
A.30.A / 413

Fixed Displacement Pump

nent
S24 C302 HTS Record Switch
S25 C146 Lift-O-Matic Switch
S26 C662 Delta P Switch
S28 C176 Hydraulic Temp Switch
S29 C175 Hydraulic Blocked Filter Switch
X5 C663 Fixed Displacement Pump Connector
Y23 C218 EDC Down Solenoid
Y24 C217 EDC Up Solenoid
C019 C020 C079 C081 C100 C127 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 414
SS09D203 1
84276322A 31/05/2010
A.30.A / 415
Variable Displacement Pump

nent
S27 C173 Low Charge Pressure Switch
S30 C174 PAS Pressure Switch
C019 C020 C079 C081 C100 C127 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 416
SS09D202 2
84276322A 31/05/2010
A.30.A / 417
Wiring harness - Electrical schematic frame 14 EHR HYDRAULICS 1


nent
S83 C395 EHR Switch 3-4 Time/Flow
S84 C400 EHR 3-4 Lever Assy
S86 C394 EHR Switch 1-2 Time/Flow
C325 C327 C328 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 418
16W-CABEHR-13 1
84276322A 31/05/2010
A.30.A / 419


nent
H9 C391 Lamp 1
H10 C396 Lamp 2
H11 C397 Lamp 3
H12 C398 Lamp 4
H13 C399 Master Lamp
K20 EHR Power Relay
R1 C344 Terminating Resistor 1 A
R5 C604 Bus Terminating Resistor
S87 C313 EHR Hydraulic Stop Switch
Y25 C279 EHR Valve Connector 1
C020 C326 C327 C328 C329 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 420
16W-CABEHR-14 1
84276322A 31/05/2010
A.30.A / 421
Wiring harness - Electrical schematic frame 16 FWD


nent
F15 Stoplamp Switch / Pedals Latched Fuse 20 A
K12 Stoplamps / Air Brake Relay
S31 C035 4WD Activated Switch
S32 C183 Diff Lock Op Switch
S33 C423 Brake Pedal Latch Switch
S34 C062 R.H. Stoplamp Switch
S35 C063 L.H. Stoplamp Switch
S36 C182 4WD Switch
S81 C659 Diff Lock Activated Switch
X6 C660 Brake Pad Latch In-line Connector
X7 C661 Brake Pad Latch Keypad Connector
Y29 C042 Diff Lock Solenoid
Y30 C034 4WD Solenoid
C019 C020 C081 C127 C128 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 422
16W-CABEHR-15 1
84276322A 31/05/2010
A.30.A / 423
Wiring harness - Electrical schematic frame 17 Power Take Off 1


nent
H1 C117 Rear PTO Engage Lamp
H2 C114 Front PTO Engage Lamp
S37 C044 Ground Speed PTO Engaged
S38 C118 Rear PTO Brake Switch & Lamp
S39 C116 Rear PTO Switch
S40 C115 Front PTO Switch
X8 C649 Ground Speed PTO Link Connector
X9 C635 Rear PTO Brake Switch Jumper
C020 C127 C128 C324 C325 C326 C328
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 424
16W-CABEHR-16 1
84276322A 31/05/2010
A.30.A / 425


nent
B21 C054 PTO Speed Sensor
B22 C288 PTO Shaft Twist Sensor
S41 C422 PTO Management Switch
X10 C254 Front Hitch / PTO Extension Connector
Y31 C033 PTO Brake
Y32 C041 PTO Solenoid
C001 C019 C128 C239 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 426
16W-CABEHR-17 1
84276322A 31/05/2010
A.30.A / 427
Wiring harness - Electrical schematic frame 19 Front Suspension


nent
B23 C411 Front Suspension Potentiometer
S42 C247 Front Suspension Switch
Y33 C249 Suspension Lower Solenoid
Y34 C250 Suspension Lower Lockout Solenoid
Y35 C251 Suspension Raise Solenoid
Y36 C252 Suspension Raise Lockout Solenoid
C020 C248 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 428
16W-CABEHR-18 1
84276322A 31/05/2010
A.30.A / 429
Wiring harness - Electrical schematic frame 20 FAST STEER

SYSTEM

nent
B24 C511 Fast Steer LVDT Coils
B25 C513 Fast Steer Steering Wheel Sensor
F51 Fast Steer Fuse 5 A
S43 C514 Fast Steer Steering Wheel Switch
Y37 C512 Fast Steer Solenoid Valve
C515 C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 430
16W-CABEHR-19 1
84276322A 31/05/2010
A.30.A / 431
Wiring harness - Electrical schematic frame 21 Cab Accessory 1 -

ISO & NASO Roof

nent
A005 C106 / C107 Radio A & Radio B
B26 C385 Speaker Rear L.H.
B27 C110 Speaker Front R.H.
B28 C386 Speaker Rear R.H.
B29 C111 Speaker Front L.H.
F1 Interior & Puddle Lights / Park Brake Status Fuse 10 A
F2 Cigar Lighter / Power Studs Fuse 25 A
F4 Accessory Sockets Fuse 10 A
F6 Radio Memory / Worklamp ECU Fuse 10 A
F40 Radio Supply Fuse 10 A
H3 C387 Console Lamp R.H.
H4 C388 Puddle Lamp L.H.
H5 C389 Puddle Lamp R.H.
H6 C099 Interior Lamp
MF6 Maxi Fuse 80 A
R2 C193 Cigar Lighter
S44 C090 L.H. Door Switch
S45 C091 R.H. Door Switch
X11 C417 8 A Ring Terminals - 2 off
X12 C416 8 A Stud Connector
C079 C235 C532 C636
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 432
16W-CABEHR-20 1
84276322A 31/05/2010
A.30.A / 433

LP Roof

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636 C640
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 434
16W-CABEHR-20C 1
84276322A 31/05/2010
A.30.A / 435
Wiring harness - Electrical schematic frame 23 Cab Accessories 2


nent
F19 Heated Mirrors Fuse 15 A
H8 C092 Console Lamp
K21 Heated Mirrors Relay
M2 C607 Electric Mirror L.H.
M3 C608 Electric Mirror R.H.
S46 C609 Mirror Control
S47 C551 Heated Mirror Switch
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 436
16W-CABEHR-21 1
84276322A 31/05/2010
A.30.A / 437


nent
A006 C373 Instrument Cluster Keypad
D2 C368 Diode
D3 C368 Diode
F20 Radar Socket / ADIC Keypad Fuse 10 A
F45 Font Implement Socket IGN+ Fuse 25 A
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
X14 C143 Implement Socket
X15 C365 8 A Socket
X16 C321 DIA Headlamp
C127 C128 C269
84276322A 31/05/2010
A.30.A / 438
16W-CABEHR-22 1
84276322A 31/05/2010
A.30.A / 439
Wiring harness - Electrical schematic frame 25 Main Lamps /

Indicators 1

nent
D4 C377 Diode
F22 Sidelamps R.H. Fuse 15 A
F23 Sidelamps L.H. Fuse 15 A
F24 Illumination Fuse 10 A
H14 C094 NASO Rear Flasher R.H.
H15 C131 Licence Plate Lamp - may or may not be fitted.
H17 C095 Rear Licence worklamp L.H.- may or may not be fitted.
H18 C096 Rear Licence worklamp R.H. - may or may not be fitted.
H19 C129 Fender Worklamp R.H.
H20 C130 Fender Worklamp L.H.
H55 C093 NASO Rear Flasher L.H.
S49 C425 Aux Headlamp Switch
S50 C257 Fender PTO Switch L.H.
S51 C258 Fender PTO Switch R.H.
C001 C020 C056 C128 C293 C294 C295 C296 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 440
16W-CABEHR-23 1
84276322A 31/05/2010
A.30.A / 441

Indicators 2

nent
F7 Potential 30 / Main Light Switch & Hazard Switch Fuse 20 A
F13 Brake Lights / Brake Light Relay K8 Fuse 15 A
F14 Potential 15 / Main Light Switch / Flasher Unit Fuse 15 A
F25 Headlamps Dipped Beam Fuse 15 A
F26 Headlamps Main Beam Fuse 15 A
K4 Side & Illumination Lights Relay
K7 Headlamps Dipped Beam Relay
K8 Stoplamps Relay
K9 Headlamps Main Beam Relay
S52 C074 Turn Switch
S53 C083 Hazard Switch
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 442
SS09D204 1
84276322A 31/05/2010
A.30.A / 443
Wiring harness - Electrical schematic frame 27 Main

Lamps/Indicators 3 - ISO Roof

nent
A007 C260 Indicator Flasher Unit Connector
H21 C066 Side Lamp R.H.
H22 C067 Side Lamp L.H.
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 444
16W-CABEHR-25 1
84276322A 31/05/2010
A.30.A / 445

Indicators 3 - NASO Roof

nent
H23 C379 SMV Lamp L.H. Front - Roof
H24 C380 SMV Lamp L.H. Rear - Roof
H25 C381 SMV Lamp R.H. Front - Roof
H26 C382 SMV Lamp R.H. Rear - Roof
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 446
SS09D205 1
84276322A 31/05/2010
A.30.A / 447

Indicators 3 - LP Roof

nent
H29 C519 Grabrail Sidelamp R.H. - Roof
H32 C528 Grabrail Sidelamp L.H. - Roof
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 448
16W-CABEHR-25C 1
84276322A 31/05/2010
A.30.A / 449
Wiring harness - Electrical schematic frame 30 Work Lamps - ISO

& NASO Roof

nent
A008 C105 EMU Connector
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
F27 Worklamps - Hood Fuse 15 A
F28 Worklamps - Rear - ECU Fuse 15 A
F29 Worklamps - Front - ECU Fuse 30 A
F30 Worklamps - Rear - Fender Fuse 15 A
F31 Rotating Beacons Fuse - 15 A
F32 Flasher Unit Fuse - 30 A
H35 C084 Worklamp Upper L.H. Front
H36 C085 Worklamp Upper R.H. Front
H37 C383 Worklamp L.H. Rear
H38 C384 Worklamp R.H. Rear
H39 C064 Worklamp Lower R.H. Front
H40 C065 Worklamp Lower L.H. Front
H41 C058 Worklamp L.H.
H42 C061 Worklamp R.H.
H43 C059 Headlamp R.H.
H44 C060 Headlamp L.H.
K15 Worklamp Lower Front Relay
K16 Worklamp Lower Rear Relay
MF5 Maxi Fuse 100 A
C001 C056 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 450
16W-CABEHR-26 1
84276322A 31/05/2010
A.30.A / 451
Wiring harness - Electrical schematic frame 31 Work Lamps - LP

Roof

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
H45 C650 Worklamp
H46 C653 Worklamp R.H. Front
H47 C656 Worklamp L.H. Front
K26 C517 Grabrail Worklamp Lower Front Relay
K27 C638 Worklamps Rear Relay
K28 C518 Roof Beacon Relay
MF5 Maxi Fuse 100 A
S54 C524 Grabrail Worklamp Switch -- Roof
S55 C522 Fender Worklamp Switch -- Roof
S56 C521 Beacon Switch -- Roof
S57 C523 Front Worklamp Switch -- Roof
C001 C056 C532 C639
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 452
16W-CABEHR-26C 1
84276322A 31/05/2010
A.30.A / 453
Wiring harness - Electrical schematic frame 32 Trailer Brakes


nent
F16 Trailer Brakes Fuse 15 A
K10 Trailer Brake Supply (Pneumatic) Relay
K11 Trailer Brake Supply (Hydraulic) Relay
S58 C136 Handbrake Switch
S59 C410 Italian Trailer Brake - Line Pressure Switch
S60 C409 Italian Trailer Brake - Pump Pressure Switch
S61 C407 Air Brake Pressure Switch
X17 C050 Trailer Brake Connector
X18 Trailer Socket
X19 C144 Air Brake Connector
Y38 C408 Italian Trailer Brake Solenoid 1
Y40 C406 Air Brake Solenoid
Y41 C576 Brake De-icer - Trailer Brakes
Y42 C577 Park Brake Solenoid - Trailer Brakes
C020 C055 C081 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 454
SS09D206 1
84276322A 31/05/2010
A.30.A / 455
Wiring harness - Electrical schematic frame 33 Sensors


nent
B31 C022 Fuel Tank Sender
B32 C068 Radar
B33 C014 Steering Sensor
S62 C007 Brake Fluid Reservoir Switch
X20 C184 Trans / EDC Connector C2
C001 C020 C079 C080 C081 C269 C366
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 456
16W-CABEHR-28 1
84276322A 31/05/2010
A.30.A / 457
Wiring harness - Electrical schematic frame 34 Wipers - ISO &

NASO Roof

nent
F11 Front Wipers Fuse 10 A
F12 Front & Rear Washer / Rear Wiper fuse 10 A
K1 Front Windshield Wiper Module Relay
M5 C088 Front Wiper Motor
M6 C140 Rear Washer Motor
M7 C139 Front Washer Motor
M8 C109 Rear Wiper Motor
S63 C073 Windshield Wiper Switch
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 458
16W-CABEHR--29 1
84276322A 31/05/2010
A.30.A / 459
Wiring harness - Electrical schematic frame 35 Wipers - LP Roof


nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 460
16W-CABEHR-29C 1
84276322A 31/05/2010
A.30.A / 461
Wiring harness - Electrical schematic frame 36 Diagnostics 1

With EHR

nent
F33 Diagnostic Socket / Engine ECU Fuse 25 A
X21 C375 EST Diagnostic Connector
X22 C445 Select Can Diag
X23 C443 CAN Select
C001 C080 C081 C100 C101 C242 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 462
SS09D207 1
84276322A 31/05/2010
A.30.A / 463
Less EHR

nent
C001 C080 C081 C100 C101 C242 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 464
SS09D208 2
84276322A 31/05/2010
A.30.A / 465
Wiring harness - Electrical schematic frame 37 Processors 1


nent
A009 C100 XCM Central Control Unit (CN1-A)
A010 C324 XCM Auxiliary Controller (CN1-A)
A011 C079 Instrument Panel A
F34 ADIC Battery Pos. Fuse 10 A
F35 EDC Memory / SCM / ACM Fuse 10 A
F36 Instrument Cluster Ignition Fuse 10 A
F37 Transmission Ignition Fuse 15 A
F38 Rear PTO Ignition / Rear PTO Switch & Lamp / HPL Fuse 10 A
F41 Front PTO Fuse 15 A
K17 Electronics Supply Relay
MF3 Maxi Fuse 80 A
C001 C619
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 466
16W-CABEHR-31 1
84276322A 31/05/2010
A.30.A / 467


nent
A012 C081 Instrument Panel C
A013 C101 Worklamp ECU
A014 C329 XCM Auxiliary Controller (CN4)
A015 C328 XCM Auxiliary Controller (CN3-B)
A018 C242 Processor EDC
A019 C239 XCM Central Control Unit (CN2)
C001 C370 C392
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 468
16W-CABEHR-32 1
84276322A 31/05/2010
A.30.A / 469
Wiring harness - Electrical schematic frame 39 Air Con - Common


nent
E4 C010 Air Con Compressor
F3 Air Con Clutch Fuse 10 A
F5 Blower Motor Fuse 30 A
F18 Electric Seat Fuse 15 A
F44 Front Implement Socket B+ Fuse 25 A
K6 Blower Motor Relay
K19 Compressor Clutch Feed Relay
S64 C011 Air Con Pressure Switch
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 470
16W-CABEHR-33 1
84276322A 31/05/2010
A.30.A / 471
Wiring harness - Electrical schematic frame 40 Air Con Auto


nent
A020 Heater / Air Con Connector
A021 C628 Auto Temp Control
B34 Heater Air Con Connector
B36 HVAC Unit
B37 HVAC Unit
B38 Temp Control
M9 Heater / Air Con Connector
S65 HVAC Unit
S66 Heater Blower Switch
S67 Air Con Switch
Y43 HVAC Unit
C119 C362 C557 C559 C627 C629 C630
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 472
16W-CABEHR-34 1
84276322A 31/05/2010
A.30.A / 473
Wiring harness - Electrical schematic frame 41 Air Con Manual


nent
M10 C119 Heater / Air Con Connector
S67 Air Con Switch
S68 Temp Control
S69 Temp Control
C362 C557 C559 C627 C629
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 474
16W-CABEHR-34B 1
84276322A 31/05/2010
A.30.A / 475

Charging
MAXXUM 100 2v W/Cab 16x16, MAXXUM 110 2v W/Cab 16x16, MAXXUM 115 2v W/Cab 16x16, MAXXUM 125 2v W/Cab 16x16, MAXXUM 140
2v W/Cab 16x16

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
S76 C230 Cold Advance Switch
C001 C079 C101 C269 C325 C350 C351 C352
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 476
16WCABMECH-1 1
84276322A 31/05/2010
A.30.A / 477

2v W/Cab 16x16

nent
C001 C127 C128 C269 C424 C441 C442 C647 C648
84276322A 31/05/2010
A.30.A / 478
16WCABMECH-2 1
84276322A 31/05/2010
A.30.A / 479

America
2v W/Cab 16x16

nent
C001 C127 C128 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 480
16WCABMECH-2B 1
84276322A 31/05/2010
A.30.A / 481

2v W/Cab 16x16

nent
A022 C367 Grid Heater Controller
C001 C019 C020 C079 C127 C128 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 482
16WCABMECH-3 1
84276322A 31/05/2010
A.30.A / 483

2v W/Cab 16x16

nent
B39 C012 Coolant Temp Sender
S7 C009 Vacuum Switch
C001 C019 C020 C079 C081 C100 C101 C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 484
16WCABMECH-4 1
84276322A 31/05/2010
A.30.A / 485

2v W/Cab 16x16

nent
B40 C255 Engine Speed Sensor
R4 C626 Fuel Heater
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 486
16WCABMECH-5 1
84276322A 31/05/2010
A.30.A / 487

2v W/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 488
16WCABMECH-6 1
84276322A 31/05/2010
A.30.A / 489

2v W/Cab 16x16

nent
C019 C020 C100 C101 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 490
16WCABMECH-7 1
84276322A 31/05/2010
A.30.A / 491

2v W/Cab 16x16

nent
X4 C444 Trans Can
C019 C020 C079 C081 C101 C127 C128 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 492
16WCABMECH-8 1
84276322A 31/05/2010
A.30.A / 493

2v W/Cab 16x16

nent
C019 C020 C100 C128 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 494
16WCABMECH-9 1
84276322A 31/05/2010
A.30.A / 495

2v W/Cab 16x16

nent
S21 C023 Trans Oil Temperature Sensor
C019 C101 C269 C324 C325 C392
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 496
SS09D192 1
84276322A 31/05/2010
A.30.A / 497

2v W/Cab 16x16

nent
F39 Supply Hydraulicmaster Fuse 10 A
C020 C100 C101 C127 C239 C294 C296 C370
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 498
SS09D193 1
84276322A 31/05/2010
A.30.A / 499

2v W/Cab 16x16

nent
C019 C020 C079 C081 C100 C127 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 500
16WCABMECH-12 1
84276322A 31/05/2010
A.30.A / 501

2v W/Cab 16x16

nent
S83 C395 EHR Switch 3/4 Time Flow
C325 C327 C328 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 502
SS09D194 1
84276322A 31/05/2010
A.30.A / 503

2v W/Cab 16x16

nent
H9 C391 Lamp 1
H10 C396 Lamp 2
H11 C397 Lamp 3
H12 C398 Lamp 4
K20 EHR Power Relay
R1 C344 Terminating Resistor - 1 A
S87 C313 Hydraulic Master Switch (EHR Stop Switch)
Y25 C279 EHR Valve 1
C020 C326 C327 C328 C329 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 504
SS09D195 1
84276322A 31/05/2010
A.30.A / 505

2v W/Cab 16x16

nent
S36 C182 4WD Switch
X6 C660 Brake Pad Latch In--line Connector
C019 C020 C081 C127 C128 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 506
16WCABMECH-15 1
84276322A 31/05/2010
A.30.A / 507

2v W/Cab 16x16

nent
C020 C127 C128 C324 C325 C326 C328
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 508
SS09D196 1
84276322A 31/05/2010
A.30.A / 509

2v W/Cab 16x16

nent
Y31 C033 PTO Brake
C019 C128 C239 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 510
16WCABMECH-17 1
84276322A 31/05/2010
A.30.A / 511

2v W/Cab 16x16

nent
C020 C248 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 512
SS09D197 1
84276322A 31/05/2010
A.30.A / 513

SYSTEM
2v W/Cab 16x16

nent
C515 C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 514
16WCABMECH-19 1
84276322A 31/05/2010
A.30.A / 515

ISO & NASO Roof
2v W/Cab 16x16

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 516
16WCABMECH-20 1
84276322A 31/05/2010
A.30.A / 517

LP Roof
2v W/Cab 16x16

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636 C640
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 518
16WCABMECH-20C 1
84276322A 31/05/2010
A.30.A / 519

2v W/Cab 16x16

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 520
16WCABMECH--21 1
84276322A 31/05/2010
A.30.A / 521

2v W/Cab 16x16

nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
X15 C365 8 A Socket
C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 522
16WCABMECH-22 1
84276322A 31/05/2010
A.30.A / 523

Indicators 1
2v W/Cab 16x16

nent
D4 C377 Diode
C001 C020 C056 C128 C293 C294 C295 C296 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 524
16WCABMECH-23 1
84276322A 31/05/2010
A.30.A / 525

Indicators 2
2v W/Cab 16x16

nent
F7 Main Light Switch & Hazard Switch Fuse 20 A
F13 Stoplamps Fuse 15 A
F14 Main Light Switch / Flasher Unit Fuse 15 A
K8 Stoplamps Relay
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 526
16WCABMECH-24 1
84276322A 31/05/2010
A.30.A / 527

Indicators 3 - ISO Roof
2v W/Cab 16x16

nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 528
16WCABMECH-25 1
84276322A 31/05/2010
A.30.A / 529

2v W/Cab 16x16

nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 530
16WCABMECH-25B 1
84276322A 31/05/2010
A.30.A / 531

2v W/Cab 16x16

nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 532
16WCABMECH-25C 1
84276322A 31/05/2010
A.30.A / 533

& NASO Roof
2v W/Cab 16x16

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
MF5 Maxi Fuse 100 A
C001 C056 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 534
16WCABMECH-26 1
84276322A 31/05/2010
A.30.A / 535

Roof
2v W/Cab 16x16

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
H45 C650 Worklamp
MF5 Maxi Fuse 100 A
S54 C524 Grabrail Worklamp Switch - Roof
S55 C522 Fender Worklamp Switch - Roof
S56 C521 Beacon Switch - Roof
S57 C523 Front Worklamp Switch - Roof
C001 C056 C532 C639
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 536
16WCABMECH-26C 1
84276322A 31/05/2010
A.30.A / 537

2v W/Cab 16x16

nent
K10 Trailer brake Supply (Pneumatic) Relay
X18 Trailer Socket
Y38 C408 Italian Trailer Brake Solenoid
Y41 C576 Brake De--icer - Trailer Brakes
C020 C055 C081 C127
84276322A 31/05/2010
A.30.A / 538
16WCABMECH-27 1
84276322A 31/05/2010
A.30.A / 539

2v W/Cab 16x16

nent
B32 C068 Radar
C001 C020 C079 C080 C081 C269 C366
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 540
16WCABMECH-28 1
84276322A 31/05/2010
A.30.A / 541

NASO Roof
2v W/Cab 16x16

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 542
16WCABMECH-29 1
84276322A 31/05/2010
A.30.A / 543

2v W/Cab 16x16

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 544
16WCABMECH-29C 1
84276322A 31/05/2010
A.30.A / 545

2v W/Cab 16x16
With EHR

nent
R3 C292 Terminating Resistor Connector
X23 C443 CAN Select
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 546
SS09D198 1
84276322A 31/05/2010
A.30.A / 547
Less EHR

nent
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 548
SS09D199 2
84276322A 31/05/2010
A.30.A / 549

2v W/Cab 16x16

nent
MF3 Maxi Fuse 80 A
C619
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 550
16WCABMECH-31 1
84276322A 31/05/2010
A.30.A / 551

2v W/Cab 16x16

nent
C001 C370
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 552
16WCABMECH-32 1
84276322A 31/05/2010
A.30.A / 553

2v W/Cab 16x16

nent
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 554
16WCABMECH-33 1
84276322A 31/05/2010
A.30.A / 555

2v W/Cab 16x16

nent
B36 HVAC Unit
B37 HVAC Unit
B38 Temp Control
S65 HVAC Unit
S67 Air Con Switch
Y43 HVAC Unit
C119 C362 C557 C559 C627 C629 C630
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 556
16WCABMECH-34 1
84276322A 31/05/2010
A.30.A / 557

2v W/Cab 16x16

nent
S67 Air Con Switch
S68 Temp Control
S69 Temp Contro
C362 C557 C559 C627 C629
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 558
16WCABMECH-34B 1
84276322A 31/05/2010
A.30.A / 559

Charging
2v W/Cab 24x24

nent
G1 C352 Battery
G2 C013 Alternator
K3 Ignition Relay
M1 Start Solenoid
MF1 C006 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
C001 C079 C101 C269 C325 C350 C351
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 560
24-WCABMECH-1 1
84276322A 31/05/2010
A.30.A / 561

2v W/Cab 24x24

nent
C001 C127 C128 C269 C424 C441 C442 C647 C648
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 562
24-WCABMECH-2 1
84276322A 31/05/2010
A.30.A / 563

America
2v W/Cab 24x24

nent
C001 C127 C128 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 564
24-WCABMECH-2B 1
84276322A 31/05/2010
A.30.A / 565

2v W/Cab 24x24

nent
C001 C019 C020 C079 C127 C128 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 566
24-WCABMECH-3 1
84276322A 31/05/2010
A.30.A / 567

2v W/Cab 24x24

nent
C001 C019 C020 C079 C081 C100 C101 C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 568
24-WCABMECH-4 1
84276322A 31/05/2010
A.30.A / 569

2v W/Cab 24x24

nent
R4 C626 Fuel Heater
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 570
24-WCABMECH-5 1
84276322A 31/05/2010
A.30.A / 571

2v W/Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 572
24-WCABMECH-6 1
84276322A 31/05/2010
A.30.A / 573

2v W/Cab 24x24

nent
S73 C348 Neutral Switch 3/4 Rail
S75 C197 Hi / Med Switch
C019 C020 C100 C101 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 574
24-WCABMECH-7 1
84276322A 31/05/2010
A.30.A / 575

2v W/Cab 24x24

nent
X4 C444 Trans Can
C019 C020 C079 C081 C101 C127 C128 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 576
24-WCABMECH-8 1
84276322A 31/05/2010
A.30.A / 577

2v W/Cab 24x24

nent
Y45 C161 Clutch C1 - Low PWM
Y46 C162 Clutch C2 - High PWM
Y47 C163 Transmission Dump Solenoid
C019 C020 C100 C128 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 578
24-WCABMECH-9 1
84276322A 31/05/2010
A.30.A / 579

2v W/Cab 24x24

nent
S21 C023 Trans Oil Temperature Sensor
C019 C101 C269 C324 C325 C392
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 580
SS09D191 1
84276322A 31/05/2010
A.30.A / 581

2v W/Cab 24x24

nent
C020 C100 C101 C127 C239 C294 C296 C370
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 582
SS09D193 1
84276322A 31/05/2010
A.30.A / 583

2v W/Cab 24x24

nent
C019 C020 C079 C081 C100 C127 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 584
24-WCABMECH-12 1
84276322A 31/05/2010
A.30.A / 585

2v W/Cab 24x24

nent
C325 C327 C328 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 586
SS09D194 1
84276322A 31/05/2010
A.30.A / 587

2v W/Cab 24x24

nent
H9 C391 Lamp 1
H10 C396 Lamp 2
H11 C397 Lamp 3
H12 C398 Lamp 4
K20 EHR Power Relay
R1 C344 Terminating Resistor - 1 A
C020 C326 C327 C328 C329 C392 C393
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 588
SS09D195 1
84276322A 31/05/2010
A.30.A / 589

2v W/Cab 24x24

nent
S36 C182 4WD Switch
C019 C020 C081 C127 C128 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 590
24-WCABMECH-15 1
84276322A 31/05/2010
A.30.A / 591

2v W/Cab 24x24

nent
C020 C127 C128 C324 C325 C326 C328
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 592
SS09D196 1
84276322A 31/05/2010
A.30.A / 593

2v W/Cab 24x24

nent
Y31 C033 PTO Brake
C019 C128 C239 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 594
24-WCABMECH-17 1
84276322A 31/05/2010
A.30.A / 595

2v W/Cab 24x24

nent
C020 C248 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 596
SS09D197 1
84276322A 31/05/2010
A.30.A / 597

SYSTEM
2v W/Cab 24x24

nent
C515 C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 598
24-WCABMECH-19 1
84276322A 31/05/2010
A.30.A / 599

ISO & NASO Roof
2v W/Cab 24x24

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 600
24-WCABMECH-20 1
84276322A 31/05/2010
A.30.A / 601

LP Roof
2v W/Cab 24x24

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636 C640
84276322A 31/05/2010
A.30.A / 602
24-WCABMECH-20C 1
84276322A 31/05/2010
A.30.A / 603

2v W/Cab 24x24

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 604
24-WCABMECH-21 1
84276322A 31/05/2010
A.30.A / 605

2v W/Cab 24x24

nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
X15 C365 8 A Socket
C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 606
24-WCABMECH-22 1
84276322A 31/05/2010
A.30.A / 607

Indicators 1
2v W/Cab 24x24

nent
D4 C377 Diode
C001 C020 C056 C128 C293 C294 C295 C296 C532
84276322A 31/05/2010
A.30.A / 608
24-WCABMECH-23 1
84276322A 31/05/2010
A.30.A / 609

Indicators 2
2v W/Cab 24x24

nent
K8 Stoplamps Relay
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 610
24-WCABMECH-24 1
84276322A 31/05/2010
A.30.A / 611

2v W/Cab 24x24

nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 612
24-WCABMECH-25 1
84276322A 31/05/2010
A.30.A / 613

2v W/Cab 24x24

nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 614
24-WCABMECH-25B 1
84276322A 31/05/2010
A.30.A / 615

2v W/Cab 24x24

nent
C020 C079 C081 C532
84276322A 31/05/2010
A.30.A / 616
24-WCABMECH-25C 1
84276322A 31/05/2010
A.30.A / 617

& NASO Roof
2v W/Cab 24x24

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
MF5 Maxi Fuse 100 A
C001 C056 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 618
24-WCABMECH-26 1
84276322A 31/05/2010
A.30.A / 619

Roof
2v W/Cab 24x24

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
H40 Worklamp Lower L.H. Front
H45 C060 Worklamp
K15 C655 Worklamp Lower Front Relay
MF5 Maxi Fuse 100 A
S55 C522 Fender Worklamp Switch - Roof
S57 C523 Front Worklamp Switch - Roof
C001 C056 C532 C639
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 620
24-WCABMECH-26C 1
84276322A 31/05/2010
A.30.A / 621

2v W/Cab 24x24

nent
X18 Trailer Socket
C020 C055 C081 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 622
24-WCABMECH-27 1
84276322A 31/05/2010
A.30.A / 623

2v W/Cab 24x24

nent
B32 C068 Radar
C001 C020 C079 C080 C081 C269 C366
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 624
24-WCABMECH-28 1
84276322A 31/05/2010
A.30.A / 625

NASO Roof
2v W/Cab 24x24

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 626
24-WCABMECH-29 1
84276322A 31/05/2010
A.30.A / 627

2v W/Cab 24x24

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 628
24-WCABMECH-29C 1
84276322A 31/05/2010
A.30.A / 629

2v W/Cab 24x24
With EHR

nent
X23 C443 CAN Select
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 630
SS09D198 1
84276322A 31/05/2010
A.30.A / 631
Less EHR

nent
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 632
SS09D199 2
84276322A 31/05/2010
A.30.A / 633

2v W/Cab 24x24

nent
MF3 Maxi Fuse 80 A
C619
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 634
24-WCABMECH-31 1
84276322A 31/05/2010
A.30.A / 635

2v W/Cab 24x24

nent
C001 C370
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 636
24-WCABMECH-32 1
84276322A 31/05/2010
A.30.A / 637

2v W/Cab 24x24

nent
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 638
24-WCABMECH-33 1
84276322A 31/05/2010
A.30.A / 639

2v W/Cab 24x24

nent
B36 HVAC Unit
B37 HVAC Unit
B38 Temp Control
S65 HVAC Unit
S67 Air Con Switch
Y43 HVAC Unit
C119 C362 C557 C559 C627 C629 C630
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 640
24-WCABMECH-34 1
84276322A 31/05/2010
A.30.A / 641

2v W/Cab 24x24

nent
S67 Air Con Switch
S68 Temp Control
S69 Temp Control
C362 C557 C559 C627 C629
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 642
24-WCABMECH-34B 1
84276322A 31/05/2010
A.30.A / 643

Charging
MAXXUM 100 2v L/Cab 16x16, MAXXUM 110 2v L/Cab 16x16, MAXXUM 115 2v L/Cab 16x16, MAXXUM 125 2v L/Cab 16x16, MAXXUM 140
2v L/Cab 16x16

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
C001 C079 C101 C269 C325 C350 C351 C352
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 644
16LCABMECH-1 1
84276322A 31/05/2010
A.30.A / 645

2v L/Cab 16x16

nent
C127 C128 C269 C424 C441 C442 C647 C648
84276322A 31/05/2010
A.30.A / 646
16LCABMECH-2 1
84276322A 31/05/2010
A.30.A / 647

America
2v L/Cab 16x16

nent
C127 C128 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 648
16LCABMECH-2B 1
84276322A 31/05/2010
A.30.A / 649

2v L/Cab 16x16

nent
S77 C309 CERPM Cruise Auto Switch
C001 C019 C020 C079 C127 C128 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 650
16LCABMECH-3 1
84276322A 31/05/2010
A.30.A / 651

2v L/Cab 16x16

nent
C001 C019 C020 C079 C081 C100 C101 C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 652
16LCABMECH-4 1
84276322A 31/05/2010
A.30.A / 653

2v L/Cab 16x16

nent
R4 C626 Fuel Heater
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 654
16LCABMECH-5 1
84276322A 31/05/2010
A.30.A / 655

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 656
16LCABMECH-6 1
84276322A 31/05/2010
A.30.A / 657

2v L/Cab 16x16

nent
B14 C359 4--5 Synchro Solenoid
S14 C167 High Range SwitchZ
C019 C020 C100 C101 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 658
16LCABMECH-7 1
84276322A 31/05/2010
A.30.A / 659

2v L/Cab 16x16

nent
Y10 C360 5--8 Synchro Solenoid
C019 C020 C079 C081 C101 C127 C128 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 660
16LCABMECH-8 1
84276322A 31/05/2010
A.30.A / 661

2v L/Cab 16x16

nent
Y20 C361 1- 4 Synchro Solenoid
C019 C020 C100 C128 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 662
16LCABMECH-9 1
84276322A 31/05/2010
A.30.A / 663

2v L/Cab 16x16

nent
C019 C101 C269 C324 C325
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 664
16LCABMECH-10 1
84276322A 31/05/2010
A.30.A / 665

2v L/Cab 16x16

nent
C020 C100
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 666
16LCABMECH-11 1
84276322A 31/05/2010
A.30.A / 667

2v L/Cab 16x16

nent
S25 C146 Lift--O--Matic Switch
S30 PAS Pressure Switch
C019 C020 C079 C081 C100 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 668
16LCABMECH-12 1
84276322A 31/05/2010
A.30.A / 669

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 670
16LCABMECH-13 1
84276322A 31/05/2010
A.30.A / 671

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 672
16LCABMECH-14 1
84276322A 31/05/2010
A.30.A / 673

2v L/Cab 16x16

nent
S36 C182 4WD Switch
C019 C020 C081 C127 C128 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 674
16LCABMECH-15 1
84276322A 31/05/2010
A.30.A / 675

2v L/Cab 16x16

nent
C020 C127 C128 C324 C325 C326 C328 C649
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 676
16LCABMECH-16 1
84276322A 31/05/2010
A.30.A / 677

2v L/Cab 16x16

nent
Y31 C033 PTO Brake
C019 C128 C239 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 678
16LCABMECH-17 1
84276322A 31/05/2010
A.30.A / 679

2v L/Cab 16x16

nent
C020 C248 C253 C269 C324 C325 C326
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 680
16LCABMECH-18 1
84276322A 31/05/2010
A.30.A / 681

SYSTEM
2v L/Cab 16x16

nent
C515 C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 682
16LCABMECH-19 1
84276322A 31/05/2010
A.30.A / 683

ISO & NASO Roof
2v L/Cab 16x16

nent
F1 Park Brake Status Fuse 10 A
MF6 Maxi Fuse 80 A
84276322A 31/05/2010
A.30.A / 684
16LCABMECH-20 1
84276322A 31/05/2010
A.30.A / 685

LP Roof
2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 686
16LCABMECH-20C 1
84276322A 31/05/2010
A.30.A / 687

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 688
16LCABMECH-21 1
84276322A 31/05/2010
A.30.A / 689

2v L/Cab 16x16

nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
C127 C269
84276322A 31/05/2010
A.30.A / 690
16LCABMECH-22 1
84276322A 31/05/2010
A.30.A / 691

Indicators 1
2v L/Cab 16x16

nent
C020 C079 C293 C295
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 692
16LCABMECH-23 1
84276322A 31/05/2010
A.30.A / 693

Indicators 2
2v L/Cab 16x16

nent
K8 Stoplamps Relay
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 694
16LCABMECH-24 1
84276322A 31/05/2010
A.30.A / 695

2v L/Cab 16x16

nent
H24 C380 SMV Lamp L.H. Rear
H26 C382 SMV Lamp R.H. Rear
H29 C519 Grabrail Sidelamp R.H.
H32 C528 Grabrail Sidelamp L.H.
C020 C079 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 696
16LCABMECH-25 1
84276322A 31/05/2010
A.30.A / 697

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 698
16LCABMECH-25B 1
84276322A 31/05/2010
A.30.A / 699

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 700
16LCABMECH-25C 1
84276322A 31/05/2010
A.30.A / 701

& NASO Roof
2v L/Cab 16x16

nent
B30 C057 Horn
MF5 Maxi Fuse 100 A
S78 C189 Worklamps Upper Front Switch
S79 C191 Main Lamps Rear Switch
C001 C056 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 702
16LCABMECH-26 1
84276322A 31/05/2010
A.30.A / 703

Roof
2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 704
16LCABMECH-26C 1
84276322A 31/05/2010
A.30.A / 705

2v L/Cab 16x16

nent
X18 Trailer Socket
C020 C055 C081 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 706
16LCABMECH-27 1
84276322A 31/05/2010
A.30.A / 707

2v L/Cab 16x16

nent
B32 C068 Radar
C001 C020 C079 C080 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 708
16LCABMECH-28 1
84276322A 31/05/2010
A.30.A / 709

NASO Roof
2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 710
16LCABMECH-29 1
84276322A 31/05/2010
A.30.A / 711

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 712
16LCABMECH-29C 1
84276322A 31/05/2010
A.30.A / 713

2v L/Cab 16x16

nent
X21 C375 ADIC Diagnostic Connector
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 714
16LCABMECH-30 1
84276322A 31/05/2010
A.30.A / 715

2v L/Cab 16x16

nent
MF3 Maxi Fuse 80 A
Wire Colour Codes
Green
Brown
84276322A 31/05/2010
A.30.A / 716
16LCABMECH-31 1
84276322A 31/05/2010
A.30.A / 717

2v L/Cab 16x16

nent
C001
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 718
16LCABMECH-32 1
84276322A 31/05/2010
A.30.A / 719

2v L/Cab 16x16

nent
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 720
16LCABMECH-33 1
84276322A 31/05/2010
A.30.A / 721

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 722
16LCABMECH-34 1
84276322A 31/05/2010
A.30.A / 723

2v L/Cab 16x16

nent
84276322A 31/05/2010
A.30.A / 724
16LCABMECH-34B 1
84276322A 31/05/2010
A.30.A / 725

Charging
MAXXUM 100 2v L/ Cab 24x24, MAXXUM 110 2v L/ Cab 24x24, MAXXUM 115 2v L/ Cab 24x24, MAXXUM 125 2v L/ Cab 24x24, MAXXUM 140
2v L/ Cab 24x24

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
C001 C079 C101 C269 C325 C350 C351 C352
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 726
24LCABMECH-1 1
84276322A 31/05/2010
A.30.A / 727

2v L/ Cab 24x24

nent
C127 C128 C269 C424 C441 C442 C647 C648
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 728
24LCABMECH-2 1
84276322A 31/05/2010
A.30.A / 729

America
2v L/ Cab 24x24

nent
C127 C128 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 730
24LCABMECH-2B 1
84276322A 31/05/2010
A.30.A / 731

2v L/ Cab 24x24

nent
C001 C019 C020 C079 C127 C128 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 732
24LCABMECH-3 1
84276322A 31/05/2010
A.30.A / 733

2v L/ Cab 24x24

nent
C001 C019 C020 C079 C081 C100 C101 C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 734
24LCABMECH-4 1
84276322A 31/05/2010
A.30.A / 735

2v L/ Cab 24x24

nent
R4 C626 Fuel Heater
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 736
24LCABMECH-5 1
84276322A 31/05/2010
A.30.A / 737

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 738
24LCABMECH-6 1
84276322A 31/05/2010
A.30.A / 739

2v L/ Cab 24x24

nent
S75 C197 Hi / Med Switch
C019 C020 C100 C101 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 740
24LCABMECH-7 1
84276322A 31/05/2010
A.30.A / 741

2v L/ Cab 24x24

nent
C019 C020 C079 C081 C101 C127 C128 C239 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 742
24LCABMECH-8 1
84276322A 31/05/2010
A.30.A / 743

2v L/ Cab 24x24

nent
Y45 C161 Clutch C1 - Low PWM
Y46 C162 Clutch C2 - High PWM
Y47 C163 Transmission Dump Solenoid
C019 C020 C100 C128 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 744
24LCABMECH-9 1
84276322A 31/05/2010
A.30.A / 745

2v L/ Cab 24x24

nent
C019 C101 C269 C324 C325
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 746
24LCABMECH-10 1
84276322A 31/05/2010
A.30.A / 747

2v L/ Cab 24x24

nent
C020 C100
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 748
24LCABMECH-11 1
84276322A 31/05/2010
A.30.A / 749

2v L/ Cab 24x24

nent
C019 C020 C079 C081 C100 C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 750
24LCABMECH-12 1
84276322A 31/05/2010
A.30.A / 751

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 752
24LCABMECH-13 1
84276322A 31/05/2010
A.30.A / 753

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 754
24LCABMECH-14 1
84276322A 31/05/2010
A.30.A / 755

2v L/ Cab 24x24

nent
S36 C182 4WD Switch
C019 C020 C081 C127 C128 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 756
24LCABMECH-15 1
84276322A 31/05/2010
A.30.A / 757

2v L/ Cab 24x24

nent
C020 C127 C128 C324 C325 C326 C328
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 758
24LCABMECH-16 1
84276322A 31/05/2010
A.30.A / 759

2v L/ Cab 24x24

nent
Y31 C033 PTO Brake
C019 C128 C239 C253 C269 C324 C325 C326 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 760
24LCABMECH-17 1
84276322A 31/05/2010
A.30.A / 761

2v L/ Cab 24x24

nent
C020 C248 C253 C269 C324 C325 C326
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 762
24LCABMECH-18 1
84276322A 31/05/2010
A.30.A / 763

SYSTEM
2v L/ Cab 24x24

nent
C515 C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 764
24LCABMECH-19 1
84276322A 31/05/2010
A.30.A / 765

ISO & NASO Roof
2v L/ Cab 24x24

nent
MF6 Maxi Fuse 80 A
84276322A 31/05/2010
A.30.A / 766
24LCABMECH-20 1
84276322A 31/05/2010
A.30.A / 767

LP Roof
2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 768
24LCABMECH-20C 1
84276322A 31/05/2010
A.30.A / 769

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 770
24LCABMECH-21 1
84276322A 31/05/2010
A.30.A / 771

2v L/ Cab 24x24

nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
C127 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 772
24LCABMECH-22 1
84276322A 31/05/2010
A.30.A / 773

Indicators 1
2v L/ Cab 24x24

nent
C020 C079 C293 C295
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 774
24LCABMECH-23 1
84276322A 31/05/2010
A.30.A / 775

Indicators 2
2v L/ Cab 24x24

nent
K8 Stoplamps Relay
C001 C020 C056 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 776
24LCABMECH-24 1
84276322A 31/05/2010
A.30.A / 777

2v L/ Cab 24x24

nent
H29 C519 Grabrail Sidelamp R.H.
H32 C528 Grabrail Sidelamp L.H.
C020 C079 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 778
24LCABMECH-25 1
84276322A 31/05/2010
A.30.A / 779

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 780
24LCABMECH-25B 1
84276322A 31/05/2010
A.30.A / 781

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 782
24LCABMECH-25C 1
84276322A 31/05/2010
A.30.A / 783

& NASO Roof
2v L/ Cab 24x24

nent
B30 C057 Horn
MF5 Maxi Fuse 100 A
C001 C056 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 784
24LCABMECH-26 1
84276322A 31/05/2010
A.30.A / 785

Roof
2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 786
24LCABMECH-26C 1
84276322A 31/05/2010
A.30.A / 787

2v L/ Cab 24x24

nent
X18 Trailer Socket
C020 C055 C081 C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 788
24LCABMECH-27 1
84276322A 31/05/2010
A.30.A / 789

2v L/ Cab 24x24

nent
B32 C068 Radar
C001 C020 C079 C080 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 790
24LCABMECH-28 1
84276322A 31/05/2010
A.30.A / 791

NASO Roof
2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 792
24LCABMECH-29 1
84276322A 31/05/2010
A.30.A / 793

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 794
24LCABMECH-29C 1
84276322A 31/05/2010
A.30.A / 795

2v L/ Cab 24x24

nent
C001 C080 C081 C100 C101 C269 C324
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 796
24LCABMECH-30 1
84276322A 31/05/2010
A.30.A / 797

2v L/ Cab 24x24

nent
MF3 Maxi Fuse 80 A
Wire Colour Codes
Green
Brown
84276322A 31/05/2010
A.30.A / 798
24LCABMECH-31 1
84276322A 31/05/2010
A.30.A / 799

2v L/ Cab 24x24

nent
C001
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 800
24LCABMECH-32 1
84276322A 31/05/2010
A.30.A / 801

2v L/ Cab 24x24

nent
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 802
24LCABMECH-33 1
84276322A 31/05/2010
A.30.A / 803

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 804
24LCABMECH-34 1
84276322A 31/05/2010
A.30.A / 805

2v L/ Cab 24x24

nent
84276322A 31/05/2010
A.30.A / 806
24LCABMECH-34B 1
84276322A 31/05/2010
A.30.A / 807

Charging
MAXXUM 100 2v W/Cab 12x12, MAXXUM 110 2v W/Cab 12x12, MAXXUM 115 2v W/Cab 12x12, MAXXUM 125 2v W/Cab 12x12

nent
D1 Diode
F8 C504 Starter Switch Fuse 20 A
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
K18 Battery Isolator Relay
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
PF3 Implement Socket Front Power Fuse 10 A
S1 C503 ISO Control Relay Switch
C001 C020 C079 C269 C350 C351 C352 C500 C580
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 808
12WCABMECH-1 1
84276322A 31/05/2010
A.30.A / 809


nent
C001 C269 C424 C441 C442 C647 C648
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 810
12WCABMECH-2 1
84276322A 31/05/2010
A.30.A / 811

America

nent
X1 Loader 2 Solenoid Connector
X2 Loader 1 Solenoid Connector
C001 C269 C327 C424 C441 C442
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 812
12WCABMECH-2B 1
84276322A 31/05/2010
A.30.A / 813


nent
C001 C079 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 814
12WCABMECH-3 1
84276322A 31/05/2010
A.30.A / 815


nent
C001 C020 C079 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 816
12WCABMECH-4 1
84276322A 31/05/2010
A.30.A / 817


nent
S80 C357 Start Inhibitor Switch
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 818
12WCABMECH-5 1
84276322A 31/05/2010
A.30.A / 819


nent
84276322A 31/05/2010
A.30.A / 820
12WCABMECH-6 1
84276322A 31/05/2010
A.30.A / 821


nent
84276322A 31/05/2010
A.30.A / 822
12WCABMECH-7 1
84276322A 31/05/2010
A.30.A / 823


nent
C020 C079 C081 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 824
12WCABMECH-8 1
84276322A 31/05/2010
A.30.A / 825


nent
84276322A 31/05/2010
A.30.A / 826
12WCABMECH-9 1
84276322A 31/05/2010
A.30.A / 827


nent
C020 C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 828
12WCABMECH-10 1
84276322A 31/05/2010
A.30.A / 829


nent
C020 C294 C296
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 830
12WCABMECH-11 1
84276322A 31/05/2010
A.30.A / 831


nent
C020 C079 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 832
12WCABMECH-12 1
84276322A 31/05/2010
A.30.A / 833


nent
84276322A 31/05/2010
A.30.A / 834
12WCABMECH-13 1
84276322A 31/05/2010
A.30.A / 835


nent
84276322A 31/05/2010
A.30.A / 836
12WCABMECH-14 1
84276322A 31/05/2010
A.30.A / 837


nent
S36 C182 4WD Switch
C020 C081 C339 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 838
12WCABMECH-15 1
84276322A 31/05/2010
A.30.A / 839


nent
C020 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 840
12WCABMECH-16 1
84276322A 31/05/2010
A.30.A / 841


nent
Y31 C033 PTO Brake
C020 C253 C269 C339 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 842
12WCABMECH-17 1
84276322A 31/05/2010
A.30.A / 843


nent
C253 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 844
12WCABMECH-18 1
84276322A 31/05/2010
A.30.A / 845

SYSTEM

nent
84276322A 31/05/2010
A.30.A / 846
12WCABMECH-19 1
84276322A 31/05/2010
A.30.A / 847

ISO & NASO Roof

nent
MF6 Maxi Fuse 80 A
C079 C235 C532 C636
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 848
12WCABMECH-20 1
84276322A 31/05/2010
A.30.A / 849

LP Roof

nent
F2 C193 Cigar Lighter / Power Studs Fuse 25 A
MF6 Maxi Fuse 80 A
R2 Cigar Lighter
C079 C235 C532 C636 C640
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 850
12WCABMECH-20C 1
84276322A 31/05/2010
A.30.A / 851


nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 852
12WCABMECH-21 1
84276322A 31/05/2010
A.30.A / 853


nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
X15 C365 8 A Socket
C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 854
12WCABMECH-22 1
84276322A 31/05/2010
A.30.A / 855

Indicators 1

nent
D4 C377 Diode
H18 C096 Rear Licence worklamp R.H.- may or may not be fitted.
C001 C020 C056 C293 C294 C295 C296 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 856
12WCABMECH-23 1
84276322A 31/05/2010
A.30.A / 857

Indicators 2

nent
K8 Stoplamps Relay
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 858
12WCABMECH-24 1
84276322A 31/05/2010
A.30.A / 859


nent
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 860
12WCABMECH-25 1
84276322A 31/05/2010
A.30.A / 861


nent
H23 C379 SMV Lamp L.H. Front -- Roof
H24 C380 SMV Lamp L.H. Rear -- Roof
H25 C381 SMV Lamp R.H. Front -- Roof
H26 C382 SMV Lamp R.H. Rear -- Roof
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 862
12WCABMECH-25B 1
84276322A 31/05/2010
A.30.A / 863


nent
H29 C519 Grabrail Sidelamp R.H. -- Roof
H30 C525 SMV Lamp R.H. Rear -- Roof
H31 C520 SMV Lamp R.H. Front -- Roof
H32 C528 Grabrail Sidelamp L.H. -- Roof
H33 C526 SMV Lamp L.H. Rear -- Roof
H34 C529 SMV Lamp L.H. Front -- Roof
C020 C079 C081 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 864
12WCABMECH-25C 1
84276322A 31/05/2010
A.30.A / 865

& NASO Roof

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
MF5 Maxi Fuse 100 A
C001 C056 C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 866
12WCABMECH-26 1
84276322A 31/05/2010
A.30.A / 867

Roof

nent
B30 C057 Horn
E2 C097 Beacon L.H.
E3 C098 Beacon R.H.
H45 C650 Worklamp
MF5 Maxi Fuse 100 A
S54 C524 Grabrail Worklamp Switch -- Roof
S55 C522 Fender Worklamp Switch -- Roof
S56 C521 Beacon Switch -- Roof
S57 C523 Front Worklamp Switch -- Roof.
C001 C056 C532 C639
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 868
12WCABMECH-26C 1
84276322A 31/05/2010
A.30.A / 869


nent
X18 Trailer Socket
C020 C055 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 870
12WCABMECH-27 1
84276322A 31/05/2010
A.30.A / 871


nent
B32 C065 Radar
C001 C020 C079 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 872
12WCABMECH-28 1
84276322A 31/05/2010
A.30.A / 873

NASO Roof

nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 874
12WCABMECH-29 1
84276322A 31/05/2010
A.30.A / 875


nent
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 876
12WCABMECH-29C 1
84276322A 31/05/2010
A.30.A / 877

2v W/Cab 12x12

nent
C001 C081 C100 C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 878
12WCABMECH-30 1
84276322A 31/05/2010
A.30.A / 879


nent
A023 C339 SCM Visctronic Fan Module
MF3 Maxi Fuse 80 A
C001 C619
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 880
12WCABMECH-31 1
84276322A 31/05/2010
A.30.A / 881


nent
84276322A 31/05/2010
A.30.A / 882
12WCABMECH-32 1
84276322A 31/05/2010
A.30.A / 883


nent
C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 884
12WCABMECH-33 1
84276322A 31/05/2010
A.30.A / 885


nent
A020 C628 Heater / Air Con Connector
A021 Auto Temp Control
B36 HVAC Unit
B37 HVAC Unit
B38 Temp Control
S65 HVAC Unit
S67 Air Con Switch
Y43 HVAC Unit
C119 C362 C557 C559 C629 C630
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 886
12WCABMECH-34 1
84276322A 31/05/2010
A.30.A / 887


nent
S67 Air Con Switch
S68 Temp Control
S69 Temp Control
C362 C557 C559 C627 C629
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 888
12WCABMECH-34B 1
84276322A 31/05/2010
A.30.A / 889

Charging
MAXXUM 100 2v L/Cab 12x12, MAXXUM 110 2v L/Cab 12x12, MAXXUM 115 2v L/Cab 12x12, MAXXUM 125 2v L/Cab 12x12

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
MF1 Maxi Fuse 80 A
MF2 Maxi Fuse 30 A
C001 C020 C079 C269 C350 C351 C352
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 890
12L-CABMECH-1 1
84276322A 31/05/2010
A.30.A / 891


nent
C001 C269 C647 C648
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 892
12L-CABMECH-2 1
84276322A 31/05/2010
A.30.A / 893

America

nent
84276322A 31/05/2010
A.30.A / 894
12L-CABMECH-2B 1
84276322A 31/05/2010
A.30.A / 895


nent
C001 C079 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 896
12L-CABMECH-3 1
84276322A 31/05/2010
A.30.A / 897


nent
C001 C020 C079 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 898
12L-CABMECH-4 1
84276322A 31/05/2010
A.30.A / 899


nent
R4 C626 Fuel Heater
S80 C357 Start Inhibitor Switch
C001 C079 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 900
12L-CABMECH-5 1
84276322A 31/05/2010
A.30.A / 901


nent
84276322A 31/05/2010
A.30.A / 902
12L-CABMECH-6 1
84276322A 31/05/2010
A.30.A / 903


nent
C020
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 904
12L-CABMECH-7 1
84276322A 31/05/2010
A.30.A / 905


nent
C020 C079 C081 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 906
12L-CABMECH-8 1
84276322A 31/05/2010
A.30.A / 907


nent
84276322A 31/05/2010
A.30.A / 908
12L-CABMECH-9 1
84276322A 31/05/2010
A.30.A / 909


nent
C020 C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 910
12L-CABMECH-10 1
84276322A 31/05/2010
A.30.A / 911


nent
C020 C294 C296
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 912
12L-CABMECH-11 1
84276322A 31/05/2010
A.30.A / 913


nent
C020 C079 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 914
12L-CABMECH-12 1
84276322A 31/05/2010
A.30.A / 915


nent
84276322A 31/05/2010
A.30.A / 916
12L-CABMECH-13 1
84276322A 31/05/2010
A.30.A / 917


nent
84276322A 31/05/2010
A.30.A / 918
12L-CABMECH-14 1
84276322A 31/05/2010
A.30.A / 919


nent
S36 C182 4WD Switch
C020 C081 C339 C378 C658
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 920
12L-CABMECH-15 1
84276322A 31/05/2010
A.30.A / 921


nent
C020 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 922
12L-CABMECH-16 1
84276322A 31/05/2010
A.30.A / 923


nent
Y31 C033 PTO Brake
C020 C253 C269 C339 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 924
12L-CABMECH-17 1
84276322A 31/05/2010
A.30.A / 925


nent
C253 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 926
12L-CABMECH-18 1
84276322A 31/05/2010
A.30.A / 927

SYSTEM

nent
84276322A 31/05/2010
A.30.A / 928
12L-CABMECH-19 1
84276322A 31/05/2010
A.30.A / 929

ISO & NASO Roof

nent
MF6 Maxi Fuse 80 A
84276322A 31/05/2010
A.30.A / 930
12L-CABMECH-20 1
84276322A 31/05/2010
A.30.A / 931

LP Roof

nent
84276322A 31/05/2010
A.30.A / 932
12L-CABMECH-20C 1
84276322A 31/05/2010
A.30.A / 933


nent
84276322A 31/05/2010
A.30.A / 934
12L-CABMECH-21 1
84276322A 31/05/2010
A.30.A / 935


nent
D2 C368 Diode
D3 C368 Diode
M4 Seat Pump
MF4 Maxi Fuse 40 A
S48 Seat Pump
X13 C138 Seat Pump
C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 936
12L-CABMECH-22 1
84276322A 31/05/2010
A.30.A / 937

Indicators 1

nent
H14 NASO Rear Flasher R.H.
H54 C131 Licence Plate lamp - may or may not be fitted.
C020 C079 C293 C295
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 938
12L-CABMECH-23 1
84276322A 31/05/2010
A.30.A / 939

Indicators 2

nent
K8 Stoplamps Relay
C001 C020 C056 C081 C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 940
12L-CABMECH-24 1
84276322A 31/05/2010
A.30.A / 941


nent
C020 C079 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 942
12L-CABMECH-25 1
84276322A 31/05/2010
A.30.A / 943


nent
84276322A 31/05/2010
A.30.A / 944
12L-CABMECH-25B 1
84276322A 31/05/2010
A.30.A / 945


nent
84276322A 31/05/2010
A.30.A / 946
12L-CABMECH-25C 1
84276322A 31/05/2010
A.30.A / 947

& NASO Roof

nent
B30 C057 Horn
MF5 Maxi Fuse 100 A
C001 C056 C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 948
12L-CABMECH-26 1
84276322A 31/05/2010
A.30.A / 949

Roof

nent
84276322A 31/05/2010
A.30.A / 950
12L-CABMECH-26C 1
84276322A 31/05/2010
A.30.A / 951


nent
X18 Trailer Socket
C020 C055 C081
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 952
12L-CABMECH-27 1
84276322A 31/05/2010
A.30.A / 953


nent
B32 C068 Radar
C001 C020 C079 C081 C269
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 954
12L-CABMECH-28 1
84276322A 31/05/2010
A.30.A / 955

NASO Roof

nent
84276322A 31/05/2010
A.30.A / 956
12L-CABMECH-29 1
84276322A 31/05/2010
A.30.A / 957


nent
84276322A 31/05/2010
A.30.A / 958
12L-CABMECH-29C 1
84276322A 31/05/2010
A.30.A / 959


nent
C001 C081 C100 C269 C339
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 960
12L-CABMECH-30 1
84276322A 31/05/2010
A.30.A / 961


nent
A023 C339 SCM Visctronic Fan Module
MF3 Maxi Fuse 80 A
C001
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 962
12L-CABMECH-31 1
84276322A 31/05/2010
A.30.A / 963


nent
84276322A 31/05/2010
A.30.A / 964
12L-CABMECH-32 1
84276322A 31/05/2010
A.30.A / 965


nent
84276322A 31/05/2010
A.30.A / 966
12L-CABMECH-33 1
84276322A 31/05/2010
A.30.A / 967


nent
84276322A 31/05/2010
A.30.A / 968
12L-CABMECH-34 1
84276322A 31/05/2010
A.30.A / 969


nent
84276322A 31/05/2010
A.30.A / 970
12L-CABMECH-34B 1
84276322A 31/05/2010
A.30.A / 971
Wiring harness - Overview

MAXXUM 140
Wire Colour Codes

B Black S Slate (Grey) G Green P Purple
N Brown R Red LG Light K Pink
Green
LN Light O Orange U Blue W White
Brown
L Lilac Y Yellow TQ Turquoise
Wire Code References

CIRC COLOUR DESCRIPTION
1 R BATTERY SUPPLY
10 G IGNITION SUPPLY
11 G IGNITION SUPPLY (2ND)
12 U MAIN BEAM HEADLAMP FUSE SUPPLY
13 U DIP BEAM HEADLAMP FUSE SUPPLY
15 U LIGHTING SWITCH SUPPLY
28 Y WIPER MOTOR (PARK RETURN)
29 G MAIN FUEL SENDER SIGNAL
31 Y ENGINE OIL PRESSURE SENDER SIGNAL
39 G TEMPERATURE GAUGE SIGNAL
44 L FLASHER UNIT (49A)
49 G RIGHT HAND TURN SIGNAL
50 G LEFT HAND TURN SIGNAL
56 W WIPER MOTOR-HIGH
57 B EARTH (ALL)
58 R WIPER MOTOR-LOW
60 B/W SENSOR GROUND
61 B CASE GROUND
63 U WIPER MOTOR-PARK FEED
65 W DUAL POWER/4 WHEEL DRIVE SWITCH FEED
71 W IGNITION SWITCHED FEEDS (UNFUSED)
84 G WINDSHIELD WASHER SWITCH FEED
90 G DUAL POWER / FOUR WHEEL DRIVE SWITCH
97 LG WINDSHIELD WASHER FEED
137 W RADIO FEED
138 P RADIO KAM
150 N BATTERY FEED (ALL)
155 G BATTERY FEED (FUSED)
160 U BATTERY SUPPLY ELECTRONICS
170 K/N/B BATTERY ISOLATOR CONTROL SWITCH
171 W/TQ/B BATTERY ISOLATOR RELAY COIL
172 W/TQ/Y BATTERY ISOLATOR RELAY COIL (OFF)
173 W BATTERY ISOLATOR RELAY COIL +12V
181 G BLOWER MOTOR FEED
182 P THERMOSTATIC SWITCH FEED
249 LG SMV LAMPS RH
250 LG SMV LAMPS LH
252 N ALTERNATOR FIELD
349 LN TRAILER TURN LAMPS RH
350 LN TRAILER TURN LAMPS LH
84276322A 31/05/2010
A.30.A / 972

365 G LOW FUEL WARNING LAMP (DELAY ON)
366 O LOW FUEL WARNING LAMP (DELAY SWITCH)
376 P HORN FEED
587 LG WINDSHIELD WIPER INTERMITTENT DELAY
649 O COOLANT TEMPERATURE SWITCH
650 TQ COOLANT LEVEL SWITCH
666 P DOMELAMP SWITCH FEED
787 G AUXILIARY FUEL PUMP SUPPLY
810 G STOPLAMPS
820 R STOPLAMP SWITCH LH
825 Y PNEUMATIC TRAILER SOLENOID +12V
830 U STOPLAMP SWITCH RH
840 G R & L STOPLAMP SIGNAL
976 W/N/B LICENCE PLATE LAMP / WORKLAMP DIODE
978 W LICENCE PLATE LAMP
979 S BLOWER MOTOR HIGH SPEED (4th)
980 N THERMOSTAT SWITCH SUPPLY
981 G A/C CLUTCH RELAY FEED
984 P TEMPERATURE CONTROL POT. INPUT
986 P TEMPERATURE CONTROL POT. OUTPUT
989 P BLOWER MOTOR MEDIUM SPEED (2nd)
996 P BLOWER MOTOR HIGH SPEED (3RD)
997 G WORK LAMP-REAR FEED (OUTER)
998 G WORK LAMP-REAR FEED (INNER)
999 G BLOWER MOTOR LOW SPEED (1st)
1000 W SAFETY START SWITCH SUPPLY
1001 W STARTER SOLENOID FEED
1002 P IMPLEMENT LAMP SWITCH SUPPLY
1003 G SUPPLY TO GAUGES
1004 G SUPPLY TO HORN AND HEADLAMP FLASH
1005 S AIR CLEANER WARNING LAMP
1006 N ALTERNATOR WARNING LAMP
1007 W ETHER START BUTTON SUPPLY
1008 N ETHER START SOLENOID SUPPLY
1010 G IGNITION RELAY (COIL)
1011 Y SUPPLY TO FUSES
1012 R ILLUMINATION
1013 R RIGHT HAND LAMPS
1014 R LEFT HAND LAMPS
1015 P DOME LAMP SWITCH FEED
1016 P HORN FEED
1017 LG AIR CON. THERMOSTATIC SWITCH FEED
1018 LG AIR CONDITIONER CLUTCH
1019 G WINDSHIELD WIPER FEED
1020 G HAZARD SWITCH SUPPLY
1021 P HAZARD SWITCH SUPPLY (BATTERY)
1022 N THERMOSTART
1023 N LIGHT SWITCH FEED
1024 R RIGHT & LEFT HAND SIDELAMP FEED
1025 G HZD SWITCH IGN FEED
1026 U HIGH BEAM INDICATOR LAMP
1027 U HEADLAMP MAIN BEAM
1028 U HEADLAMP MAIN BEAM FUSE
1029 U HEADLAMP DIP BEAM FUSE
84276322A 31/05/2010
A.30.A / 973

1030 U HEADLAMP DIP BEAM
1031 R INSTRUMENT ILLUMINATION
1032 LG TURN SIGNAL WARNING LAMP (TERM C)
1033 LG TURN SIGNAL WARNING LAMP (TERM C2)
1035 W ENGINE OIL PRESSURE WARNING LAMP
1036 N IGNITION SWITCH (BATTERY)
1037 LG FLASHER UNIT (TERM 49A)
1038 LN WINDSHIELD WIPER FEED-REAR
1039 LTG NASO LIGHTS INPUT
1040 LG FLASHER SWITCH TO RELAY-RHS CUT OUT
1041 LG FLASHER SWITCH TO RELAY-LHS CUT OUT
1042 U RELAY FEED ELECTRONICS
1043 U RELAY FEED TO FUSES
1044 W/U/S GRID HEATER FEEDBACK
1050 G ACCESSORY FEED
1051 Y SIDE LIGHTS RELAY COIL FEED
1052 Y GET YOU HOME LIGHTS RELAY
1070 R FRONT WORKLAMP SWITCH FEED
1071 P WORKLAMP FRONT FEED
1072 P WORKLAMP FRONT RELAY SUPPLY
1080 R FRONT SCREEN HEATER
1082 Y REAR SCREEN HEATER
1085 N FRONT SCREEN HEATER RELAY CONTROL
1086 N REAR SCREEN HEATER RELAY CONTROL
1090 R REAR WORKLAMP RELAY SIGNAL
1091 R FRONT WORKLAMP LOWER RELAY SIGNAL
1092 R FRONT WORKLAMP RELAY SIGNAL
1093 R FENDER WORKLAMP RELAY SIGNAL
1096 R WORKLAMP FENDER MOUNTED
1097 R FEED FRONT WORKLAMP OUTER
1098 W FRONT WORKLAMP RELAY GROUND
1099 R FEED FRONT WORKLAMP INNER
1119 G RR WINDSHIELD WIPER
1120 G RR WINDSHIELD WIPER PARK RETURN
1121 G RR WINDSHIELD WASH
1130 N ENGINE HEATER CONTROL TO IGN SWITCH
1135 G THERMOSTART WARNING LAMP
1140 K THERMOSTART INITIATE SIGNAL TO RELAY
1141 N GRID HEATER +
1142 N GRID HEATER FUSE TO PWR. RELAY
1143 N POWER RELAY TO GRID HEATER
1150 N CAL/SEL SWITCH
1160 R REVERSE ALARM
1900 LG/B/S HEATED FRONT WINDSCREEN SW SIGNAL
1901 LN/LG/S HEATED FRONT WINDSCREEN POWER
1902 O/LN/S HEATED FRONT WINDSCREEN WARNING LAMP
1903 P/B/S HEATED REAR SCREEN SW SIGNAL
1904 Y/B/S HEATED REAR SCREEN POWER
1905 U/W/S HEATED REAR SCREEN WARNING LAMP
1920 O LH MIRROR CONTROL SIDE-SIDE
1921 Y LH MIRROR CONTROL UP-DOWN
1922 G MIRROR CONTROL COMMON
1923 O RH MIRROR CONTROL SIDE-SIDE
1924 Y RH MIRROR CONTROL UP-DOWN
1925 R MIRROR CONTROL +12V
84276322A 31/05/2010
A.30.A / 974

1927 R MIRROR ILLUMINATION
1928 R HEATED MIRROR RELAY COIL +12V FROM SW
2001 N BATTERY TEMPERATURE SENSOR
2002 N BATTERY TEMP SENSOR (ALT OUTPUT)
2005 O/U AIR CON CLUTCH RELAY
2006 U DE-ICING SWITCH - AIR CONDITIONER
2007 Y/U AIR CONDITIONER LOW PRESSURE
2008 N/TQ LIFT PUMP SUPPLY
2009 G FUEL PUMP SUPPLY
2010 LG AIRCON PLUG TO DE-ICING SWITCH
2011 P HORN RETURN
2012 Y TRANS OIL PRESSURE WARNING LAMP
2013 Y PTO OVERSPEED WARNING LAMP
2014 G ENGINE OIL PRESSURE SENDER (+5 VOLT)
2015 W TACHOMETER SENSOR-SIGNAL
2016 Y REAR AXLE SPEED SENSOR-SIGNAL
2017 B BULB TEST (EIC)
2018 B RADAR PRESENT
2019 B ENGINE RPM (TACHO MODULE TO TPM)
2020 Y ENGINE SHUT DOWN (TACHO MODULE TO TPM)
2021 Y AXLE GROUND SPEED (TACHO MODULE TO TPM)
2022 B PTO 540/1000 RPM (TACHO MODULE TO TPM)
2023 S TPM TO EIC (AXLE SPEED DRIVE)
2024 S RADAR SIGNAL DRIVE
2025 S AUDIO ALARM CONTROL
2026 S IMPLEMENT SWITCH SIGNAL
2027 R RADAR ASSEMBLY (GUN) POWER
2028 G RADAR ASSEMBLY (GUN) SIGNAL
2029 P INSTRUMENT MEMORY SUPPLY
2030 N ELECTRONIC DRAFT CONTROL
2031 Y RADAR PRESENT
2040 LG WATER IN FUEL SENSOR
2041 P FUEL SHUT OFF
2042 O PTO SOLENOID-REAR
2043 O PTO SOLENOID-FRONT
2044 O PTO SOLENOID-FRONT RETURN(-)
2045 O PTO SWITCH TO MODULE
2046 O PTO SWITCH (VCC)
2047 O PTO SWITCH (VCCO)
2048 O PTO SWITCH (VCCS)
2049 O PTO SWITCH 1000RPM WARNING LAMP
2050 G PTO SUPPLY / DOG SUPPLY
2051 O PTO SOLENOID RETURN (-)
2052 W PTO LUBE SOL
2053 P PTO LUBE SOL RETURN
2055 W PTO SYNCHRO GROUND SPEED ENGAGED
2056 W PTO FENDER PTO SWITCH ON
2057 W PTO FENDER SWITCH LH - RH LINK
2059 W FENDER PTO SWITCH INPUT
2060 O PTO 540/1000 SWITCH
2062 W PTO TWIST SENSOR
2065 N PTO ENGAGED
2068 N PTO SOFT START
2069 U PTO MANAGEMENT ON
2070 O ENGINE SHUT OFF RELAY +12V
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2080 O ENGINE SHUT OFF RELAY
2087 O EXHAUST BRAKE SOLENOID
2090 W/U STARTER RELAY TO START INHIBIT SWITCH
2095 G INSTRUMENT SIGNAL GROUND
2100 G A/C CONDENSER MOTOR FEED
2120 LN PTO BRAKE SIGNAL
2130 N PTO BRAKE SOLENOID
2140 O PTO SPEED SENSOR
2150 P PTO EXT. SWITCH OFF
2151 K EPTO DRIVE RELAY UPPER SPEED
2152 K ESPTO DRIVE RELAY LOWER SPEED
2153 R ESPTO ACTUATOR UPPER SPEED
2154 N ESPTO ACTUATOR LOWER SPEED
2155 N ESPTO ACTUATOR POWER +12V
2156 N ESPTO ACTUATOR POS SIGNAL
2157 U ESPTO NEUTRAL
2158 N ESPTO LOWER SPEED
2159 U ESPTO UPPER SPEED
2200 G SERVICE MODE INITIATE
2245 K PTO FRONT - SWITCH TO MODULE (MOM)
2248 K PTO FRONT - SWITCH (VCCS)
2250 K PTO FRONT - SUPPLY
2260 O PTO FRONT - SPEED SIGNAL
2270 O PTO FRONT - WARNING LAMP
2300 P THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
2310 P IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
2320 P TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2330 P PTO SPEED ISO11876 SKT.PIN#3
2500 N FRONT HITCH SOLENOID
2510 N FRONT HITCH POSITION SIGNAL
2520 N FRONT HITCH SET POSITION SIGNAL
2530 N FRONT HITCH V REF
2540 N FRONT HITCH +12v IGN
2550 N FRONT HITCH OVERIDE SWITCH
2556 N/Y/S FRONT HITCH SWITCH COMMON RAIL
2560 N FRONT HITCH 0v REF
2570 R FRONT HITCH RAISE SOLENOID
2571 S FRONT HITCH RAISE SOLENOID RETURN(-)
2575 W STEYR EFH TRANSPORT SIGNAL – BOSCH EFH MODULE
2576 W STEYR EFH WORK SIGNAL – BOSCH EFH MODULE
2577 P STEYR EFH DIAGNOSTIC LAMP – BOSCH EFH MODULE
2578 G STEYR EFH TRANSPORT SWITCH – EOLBAU ARMREST
2579 N STEYR EFH WORK SWITCH – EOLBAU ARMREST
2580 R FRONT HITCH LOWER SOLENOID
2581 S FRONT HITCH LOWER SOLENOID RETURN (-)
2582 LG STEYR - EXT SWITCHES
2583 LN STEYR - EXT SWITCHES
2584 W OILMOTOR MODE
2585 LN EFH RAISE SWITCH
2586 LN EFH WORK SWITCH
2587 N EFH EXTERNAL SWITCH +
2588 P EFH EXTERNAL SWITCH UP
2589 R EFH EXTERNAL SWITCH DOWN
2590 LN EXTERNAL SWITCH FHPL UP
2591 LN EXTERNAL SWITCH FHPL DOWN
2592 N EFH VALVE DOWN +
2593 N EFH VALVE DOWN -
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2594 O EFH POSITION SENSOR +
2595 P EFH POSITION SENSOR SIGNAL
2596 R EFH POSITION SENSOR -
2597 LN EFH PRESSURE SENSOR SIGNAL
2598 S EFH ACCUMULATOR 14 BAR
2599 N EFH ACCUMULATOR 40 BAR
2600 Y REAR AXLE SPEED MONITOR
3000 G FLASHER UNIT SUPPLY (TERMINAL 49)
3001 G LEFT HAND FLASHER CIRCUIT
3002 G RIGHT HAND FLASHER CIRCUIT
3003 W RADIO FEED
3004 G RIGHT HAND TURN SIGNAL WARNING LAMP
3005 G LEFT HAND TURN SIGNAL WARNING LAMP
3006 G AUXILIARY FUEL TANK SENDER
3007 G FUEL GAUGE FEED
3008 U WORKLAMP WARNING LIGHT
3009 G FLASHER UNIT SUPPLY B+
3010 R FOGLAMP FEED
3011 R FOGLAMP FEED
3012 G HANDBRAKE WARNING FEED
3013 LG AUXILIARY FUEL TANK SIGNAL
3014 R HANDBRAKE WARNING LAMP SIGNAL
3015 P ACCESSORY SOCKET (POWER)
3016 S BRAKE FLUID LEVEL SIGNAL
3017 G EPB SYSTEM FAILURE WARNING LIGHT
3018 G FLASHER UNIT BUZZER FEED
3019 G EPB SYSTEM OPERATION STATUS LIGHT
3020 Y DUAL POWER SOLENOID SUPPLY
3022 Y DUAL POWER (HIGH) WARNING LAMP
3023 P EPB SYSTEM BATTERY ISOLATOR INTERLOCK
3024 Y 2WD SOLENOID
3025 Y FOUR WHEEL DRIVE SOLENOID (MANUAL)
3026 Y BRAKE PEDAL SWITCH - RIGHT
3027 Y FOUR WHEEL DRIVE SOLENOID (AUTO)
3028 Y/G BRAKE PEDAL SWITCH - LEFT
3029 LN EPB +5V REFERENCE
3030 W ACCESSORY RELAY SIGNAL
3031 N EPB +12 HOT
3032 G EPB +12 IGNITION
3033 O EPB MOTOR SUPPLY “A”
3034 Y EPB POSITION SIGNAL
3035 O EPB MOTOR SUPPLY “B”
3036 O EPB SHUTTLE PARK SWITCH INPUT
3037 Y EPB PROPORTIONAL BRAKE SIGNAL
3038 Y EPB HAND THROTTLE SWITCH
3039 O EPB SHUTTLE PARK SWITCH OUTPUT
3045 Y FOUR WHEEL DRIVE WARNING LAMP
3050 P AUXILIARY FEED CONNECTOR SUPPLY
3051 P CIGAR LIGHTER SUPPLY
3052 P DOME LAMP TO DOOR SWITCH
3053 S SPEAKER RIGHT HAND
3054 S SPEAKER NEGATIVE RH
3055 S SPEAKER LEFT HAND
3056 N SPEAKER NEGATIVE LH
3057 P PUDDLE LAMP RETURN
3060 P IMPLEMENT SOCKET RELAY
3061 P IMPLEMENT SOCKET
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3062 P IMPLEMENT SOCKET SWITCH
3070 P ’B’ PILLAR SKT SUPPLY
3073 W MICROPHONE
3074 B SCREEN FOR 3073
3075 O TRAILER SOCKET (ACCESSORY FEED)
3076 O ACCESSORY SWITCH FEED
3077 Y RADIO +12VB
3078 O RADIO +12V ILLUMINATION
3079 R RADIO +12V IGNITION
3080 P CONSOLE LAMP
3081 Y TELEPHONE OUT
3082 O TELEPHONE OUT 1
3083 N TELEPHONE MUTE
3084 V AUXILIARY INPUT COMMON RAIL
3085 W AUXILIARY INPUT (LEFT CHANNEL)
3086 R AUXILIARY INPUT (RIGHT CHANNEL)
3087 S BUTTONS COMMON
3088 G BUTTONS ‘TELEPHONE’
3089 U BUTTONS ‘VOICE’
3090 Y SEAT PUMP SUPPLY
3091 P SPEAKER RR-RHS +
3092 P SPEAKER RR-RHS -
3093 S SPEAKER FRT-RHS +
3094 S SPEAKER FRT-RHS -
3095 W SPEAKER FRT-LHS +
3096 S SPEAKER FRT-LHS -
3097 G SPEAKER RR-LHS +
3098 G/B SPEAKER RR-LHS -
3100 G STEERING SENSOR +5v
3120 K STEERING SENSOR SIGNAL
3140 LG STEERING SENSOR GROUND
3150 W HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
3155 W HANDBRAKE TRANS INTERLOCK
3160 O/G/Y AUTO GUIDANCE STEERING PRESS SENSOR SIGNAL
3161 O/G/B AUTO GUIDANCE STEERING PRESS SENSOR RETURN
3163 O/W AUTO GUIDANCE STEERING SOLENOID VLV R FEED
3164 O/W/B AUTO GUIDANCE STEERING SOLENOID VLV R RETURN
3165 O/R AUTO GUIDANCE STEERING SOLENOID VLV L FEED
3166 O/R/B AUTO GUIDANCE STEERING SOLENOID VLV L RETURN
3167 O/N AUTO GUIDANCE STEERING PRESSURE SENSOR +5V REF
3168 O/K AUTO GUIDANCE DUMP SOLENOID FEED (HSD)
3169 O/S AUTO GUIDANCE DUMP SOLENOID RETURN (CURSEN)
3170 O FAST STEER SYSTEM (FSS)- ENABLE
3171 O/R FSS - LAMP
3172 L FSS - STEERING PROXIMITY SENSOR POSITION
3173 R/G FSS - HYD. VALVE HIGH SIDE DRIVER
3174 G/B FSS - HYD. VALVE LOW SIDE DRIVER
3175 W FSS - POSITION SENSOR PRIMARY POSITIVE
3176 B FSS - POSITION SENSOR PRIMARY NEGATIVE
3177 U FSS - POSITION SENSOR SECONDARY COMMON
3178 G/Y FSS - POSITION SENSOR SECONDARY POSITIVE
3179 N FSS - POSITION SENSOR SECONDARY NEGATIVE
3180 B FSS - SAFETY SWITCH
3181 S/O AUTO GUIDANCE PPS SIGNAL INPUT TO GPS
3185 N/R/Y AUTO GUIDANCE REMOTE ENGAGE
3186 S CERES PPS IN
3187 N/O/Y AUTO GUIDANCE ROADING SELECT
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3200 O SUSPENSION SWITCH FEED
3210 U SUSPENSION SWITCH RETURN
3215 U SUSPENSION LAMP
3220 O AXLE HEIGHT SENSOR 5V REF
3230 U AXLE HEIGHT SENSOR POSITION
3235 O/R/S ACCELEROMETER SIGNAL
3240 O RAISE SOLENOID PWR
3250 O RAISE SOLENOID RET
3260 O LOWER SOLENOID PWR
3270 O LOWER SOLENOID RET
3271 U LOADER RELAY FEED
3272 O LOADER VALVE #1 OUT
3273 O LOADER VALVE #1 RETURN
3274 R LOADER VALVE #2 OUT
3275 R LOADER VALVE #2 RETURN
3276 G LOADER VALVE
3277 U LOADER VALVE #3 COIL
3278 U LOADER VALVE #3 RELAY
3280 O SUSPENSION LOCKOUT SOLENOID UPPER
3281 LN SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
3285 LN SUSPENSION LOCKOUT SOLENOID LOWER
3286 LN SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
3290 O SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
3295 LN/U/Y FRONT SUSPENSION PRESSURE SWITCH SIGNAL
3300 O SENSE LINE CONTROL SOLENOID
3310 U RAISE LOCKOUT SOLENOID
3500 W POWER STEERING PRESSURE SIGNAL
4001 R TRANSMISSION OIL WARNING LAMP (TEMP)
4002 R TRANSMISSION OIL WARNING LAMP SWITCH
4010 N RETURN TO DIG
4011 P ROTATING BEACON SWITCH SUPPLY
4012 P ROTATING BEACON FEED
4013 U TRANS CONTROL FEED
4014 U FORWARD CLUTCH SOLENOID FEED
4015 U REVERSE CLUTCH SOLENOID FEED
4016 U TORQUE CONVERTOR LOCK-UP RELAY FEED
4017 U TORQUE CONVERTOR LOCK-UP LAMP
4018 S TORQUE CONVERTOR LOCK-UP SOLENOID FEED
4019 S HYDRAULIC FILTER BY-PASS SWITCH FEED
4020 S HYDRAULIC FILTER BY-PASS LAMP
4021 S BACK-UP ALARM RELAY FEED
4022 S BACK-UP ALARM FEED
4025 Y 4 IN 1 BUCKET FEED
4040 G LINK LEVEL SWITCH SUPPLY
4050 W LINK LEVEL RAISE
4051 W LINK LEVEL LOWER
4052 W LINK LEVEL EXTEND SIDE
4053 W LINK LEVEL RETRACT SIDE
4054 W LINK LEVEL SAFETY VALVE (DUMP)
4055 W LINK LEVEL TOP LINK EXTEND SOLENOID
4056 W LINK LEVEL TOP LINK RETRACT SOLENOID
4057 W LINK LEVEL RIGHT LINK RAISE SOLENOID
4058 W LINK LEVEL RIGHT LINK LOWER SOLENOID
4060 W/G/Y HYDRAULIC SELECT FRONT
4061 W/R/Y HYDRAULIC SELECT REAR
4100 TQ TRANS RANGE ENABLE SWITCH SUPPLY
4101 TQ TRANS RANGE ENABLE
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4120 P/R BEACON RELAY COIL
5000 P EDC MEMORY POWER
5005 N EDC KEY SWITCH FEED
5010 B/W EDC EARTH
5011 B EDC EARTH CASE RFI
5015 R EDC CONTROLS BACKLIGHTING
5020 LN EDC PROC +5V REF VOLTAGE DROP POSN/RATE
5021 K EDC PROCESSOR REF VOLT (+5V) ROCKSHAFT
5022 K EDC PROCESSOR REF VOLT +5V QUADRANT
5023 K EDC PROCESSOR REF VOLT +5V HEIGHT LIMIT
5025 LN EDC LOWER SIGNAL
5030 LN EDC RAISE SIGNAL
5035 LN EDC RETURN REF. VOLTAGE EARTH
5040 LN EDC DRAFT POSITION
5045 LN EDC DROP RATE
5050 LN EDC QUADRANT
5055 LN EDC CLOCK LINE TO DISPLAY
5060 LN SERIAL DATA TO CLUSTER
5065 LN EDC RIGHT PIN
5070 LN EDC LEFT PIN
5075 K EDC VOLTAGE TO PINS
5080 K EDC ROCKSHAFT
5085 K/U EDC VALVE UP
5087 K EDC VALVE UP RETURN
5090 K EDC VALVE DOWN
5095 K EDC EXTERNAL SWITCH DOWN
5097 K EDC VALVE DOWN RETURN
5100 K EDC EXTERNAL SWITCH UP
5105 S EDC IMPLEMENT STATUS SWITCH
5110 K EDC LAMP SIGNAL
5115 K EDC SLIP SIGNAL
5120 K EDC HEIGHT LIMIT SIGNAL
5125 TQ EDC RAISE SIGNAL-RAISE WORK SWITCH
5130 TQ EDC WORK SIGNAL-RAISE WORK SWITCH
5132 TQ EDC FLOAT
5133 TQ EDC STOP
5135 TQ EDC +WHEEL SPEED SIGNAL
5140 TQ EDC -WHEEL SPEED SIGNAL
5145 TQ EDC SLIP LIMIT POT
5150 G EDC EXTERNAL SWITCH SUPPLY
5155 U EDC LOWER LIMIT POT
5160 TQ EDC HEIGHT LIMIT POT FEED
5170 LN SERIAL DATA FROM CLUSTER
5175 R ADIC KEY PAD DISABLE
5180 TQ EDC SLIP INDICATOR LAMP
5190 R HPL INTERLOCK / LIFT-O-MATIC
5200 N EDC VALVE SUPPLY
5205 N INTERNAL FENDER HITCH SWITCH - UP
5210 N EDC VALVE ENABLE
5215 N INTERNAL FENDER HITCH SWITCH - DOWN
5220 Y EDC RAISE LAMP
5230 Y EDC LOWER LAMP
5240 O EDC RAISE SIGNAL-RAISE WORK SWITCH No.2
5250 O EDC WORK SIGNAL-RAISE WORK SWITCH No.2
5260 LN HYDRAULIC MASTER SW #1
5270 N JOYSTICK LED – FRONT
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5300 K ECU FLASH PROGRAM SIGNAL
5400 Y CAN H
5420 G CAN L
5500 Y EHR CAN HIGH
5510 G EHR CAN LOW
5515 S EHR +12V IGN.
5520 LG EHR 5V Ref
5521 LG EHR Motor #1
5531 LG EHR NEUTRAL SWITCH VALVE #1
5532 G EHR NEUTRAL SWITCH VALVE #2
5533 K EHR NEUTRAL SWITCH VALVE #3
5535 LG EHR FLOAT SWITCH VALVE#1
5536 LN EHR FLOAT SWITCH VALVE#2
5537 N EHR FLOAT SWITCH VALVE#3
5538 O EHR FLOAT SWITCH VALVE#4
5541 O EHR MAX.FLOW SWITCH VALVE #1
5542 B EHR MAX.FLOW SWITCH VALVE #2
5543 S EHR MAX.FLOW SWITCH VALVE #3
5544 TQ EHR MAX.FLOW SWITCH VALVE #4
5551 O EHR POTENTIOMETER SIGNAL VALVE#1
5552 U EHR POTENTIOMETER SIGNAL VALVE#2
5553 W EHR POTENTIOMETER SIGNAL VALVE#3
5561 O EHR TIMED FLOW SWITCH #1
5564 P EHR TIMED FLOW SWITCH #4
5570 P FENDER 3RD EHR SWITCH (RES)
5574 P FENDER 3RD EHR SWITCH – UP
5576 P FENDER 3RD EHR SWITCH – DOWN
5580 TQ JOYSTICK REAR LAMP (MC)
5585 TQ JOYSTICK FRONT LAMP (MC)
5591 P EHR WARNING LAMP#1
5595 S EHR MASTER STOP SWITCH
5596 S EHR MASTER STOP LAMP
5597 S EHR MASTER ENABLE
5600 R HTS LIVE SIGNAL
5610 R HTS PROGRAM
5620 R HTS ON/OFF SWITCH
5625 R LIFT-O-MATIC SWITCH
5630 R/U/Y HTS MANUAL SWITCH
5640 R/S/Y HTS AUTO SWITCH
5700 W EHR J-STICK X+
5710 W EHR J-STICK X ACTIVE SWITCH
5720 W EHR J-STICK X FULL FLOW SWITCH
5730 W EHR J-STICK X FLOAT SWITCH
5740 W EHR J-STICK Y+
5750 W EHR J-STICK Y ACTIVE SWITCH
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5760 W EHR J-STICK Y FULL FLOW SWITCH
5770 W EHR J-STICK Y FLOAT SWITCH
5820 S EDC ROCKSHAFT POT
5830 S/R/Y HIGH FLOW PUMP LINK
5835 S/U/Y HYDRAULIC MASTER SWITCH HIGH FLOW PUMP LINK
5840 W FRONT HITCH DETECT INPUT
5900 G ISO BUS CAN SIGNAL LOW
5910 Y ISO BUS CAN SIGNAL HIGH
5915 B ISO BUS CAN SUPPLY GROUND
5920 R ISO BUS CAN SUPPLY POSITIVE
5930 LN ROTARY ENCODER SUPPLY
5935 O ROTARY ENCODER SIGNAL - "HOME"
5940 O ROTARY ENCODER SIGNAL - "ESC"
5945 TQ ROTARY ENCODER SIGNAL - "P1"
5955 B/LN RS232 INPUT T.E.C.U.
5960 W/LN RS232 OUTPUT T.E.C.U.
5962 R USB + 5V REF.
5964 W USB DATA -
5966 G USB DATA +
5968 B USB GROUND
5970 O ISO BUS ECU SIGNAL
5975 O ISO RELAY 2 POWER OUT
5980 U ISO BUS IMPLEMENT SIGNAL
5985 U ISO RELAY 1 POWER OUT
5990 O ROTARY ENCODER SIGNAL - "ENTER"
6000 K ENGINE SPEED SIGNAL
6001 B ENGINE ECU RESISTOR #1
6002 W ENGINE ECU RESISTOR #2
6003 R ENGINE ECU RESISTOR #3
6004 G ENGINE ECU RESISTOR #4
6057 TQ ENGINE STARTER RELAY GROUND
6010 Y THROTTLE POSITION SWITCH
6100 U ENGINE COLD ADVANCE CONTROL
6200 R MANIFOLD (GRID) HEATER SUPPLY
6300 N FAN SPEED
6305 N REVERSIBLE FAN OPTION - MOTOR FEED
6310 N FAN SOLENOID
6315 N REVERSIBLE FAN OPTION - RELAY CONTROL
6320 N FAN SPEED SENSOR 5V REF.
6325 N REVERSIBLE FAN OPTION - RELAY FEED
6327 R REVERSIBLE FAN RELAY POWER OUT
6330 N VISTRONIC FAN INPUT
6331 O FAN SPEED SENSOR GROUND
6355 N +5V LOW POWER REFERENCE
6400 LN ECU BATTERY SUPPLY
6401 G ECU TO THROTTLE POT.+5V
6402 G ECU TO THROTTLE POT. VAR
6403 G ECU TO THROTTLE POT.-
6404 G THROTTLE POT. TO LOW IDLE SWITCH
6405 G ECU TO THROTTLE POT. SWITCH
6407 O/Y/B ENGINE SHUTDOWN SIGNAL (EDC16)
6408 G FUSED B+ TO ECU (1)
6413 O ENGINE SHUTDOWN RELAY SUPPLY
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6414 G FUSED IGN.+ TO ECU
6415 G ECU TO J1939 INTERFACE CAN#1 CONN.(HI)
6416 G ECU TO J1939 INTERFACE CAN#1 CONN.(LO)
6417 N/A SCREEN BRAID FOR 6415 & 6416
6418 K ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO K
6419 K ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO L
6420 K ECU SINK DRIVER#6 TO DIAGNOSTIC LAMP
6422 K ENGINE MOUNTED B- TO ECU (1)
6427 K ECU TO MULTIPLE STATE SWITCH (PASS.INPUT#06)
6431 K ECU TO DIAGNOSTIC REQUEST SWITCH (DIG 15)
6432 K ECU SWITCHED BATTERY OUTPUT TO DIAGNOSTIC REQUEST
SWITCH
6440 S HAND THROTTLE POSITION 1
6460 S HAND THROTTLE SWITCH (NOT IDLE)
6500 N CONSTANT ERPM ON/OFF
6510 N CONSTANT ERPM SET 1
6530 N CONSTANT ERPM INCREASE
6540 N CONSTANT ERPM DECREASE
6550 N CONSTANT ERPM SET LAMP
6560 U ECU TO FUEL FILTER HEATER
6570 G ECU TO FUEL FILTER HEATER RETURN
6580 K ECU TO GRID HEATER RELAY#1
6585 O ECU TO GRID HEATER RELAY#2
6586 P ECU TO GRID HEATER RELAY RETURN
6590 LG ECU DIGITAL GROUND
6610 N ECU IGNITION SUPPLY
6620 O ECU COOLANT TEMP. SIGNAL
6630 O ECU COOLANT TEMP. GROUND
6640 O ECU AC PRESSURE NOT HIGH SWITCH
6650 O ECU BOOST GROUND
6660 O ECU BOOST TEMP.
6670 O ECU 5V BOOST
6680 O ECU BOOST PRESSURE
6690 O ECU SOLENOID VALVE SHUT OFF
6700 O ECU CRANK SHAFT OUTPUT SHAFT
6710 O ECU ENGINE SPEED
7000 U TRANS CONTROL SUPPLY
7001 U TRANS DISPLAY ILLUMINATION
7002 U TRANS MAIN CLUTCH SOL (C3/C4)
7003 U TRANS DUMP SOL
7004 U TRANS FRONT CLUTCH SOL (C1/C2)
7005 U TRANS CREEPER GR SOL
7007 R TRANS DUAL POWER PRESSURE SWITCH HIGH
7008 R TRANS DUAL POWER PRESSURE SWITCH LOW
7009 W TRANS RANGE DISABLE SWITCH
7010 U TRANS RANGE INDICATOR SWITCH (GR 1-4)
7022 S REVERSE ALARM GROUND SIGNAL
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7025 R/TQ/Y TRANS DISPLAY ENABLE
7030 U TRANS RANGE INDICATOR SWITCH COMMON
7035 N TRANS DUMP SOLENOID FEED
7040 N TRANS CREEPER SWITCH
7050 R TRANS RELAY SUPPLY - RUN
7060 R TRANS RELAY SUPPLY - START
7068 U TRANS CVT POWER SUPPLY (CVT)
7070 R TRANS FEED (IGN +)
7071 N FEED HYD FILTER RESTRICTION IND LAMP
7080 LG DIFF-LOCK SOLENOID FEED
7090 LG DIFF-LOCK SWITCH TO BRAKE SWITCH
7100 N DIFF-LOCK RELAY TO BRAKE SWITCH
7110 R PTO INHIBITOR SWITCH TO TRANS
7120 Y DIFF-LOCK WNG LP (MANUAL)
7125 LG DIFF-LOCK WNG LP (AUTO)
7126 LG DIFF LOCK PRESSURE SWITCH
7130 N HYD FILTER WNG LP
7135 N HYD FILTER PRESSURE SWITCH
7140 O DIFF-LOCK OFF SOLENOID
7150 S LOW OIL PRESSURE WRN FEED
7155 U VANE PUMP PRESSURE SENSOR SIGNAL
7160 R HYD LOW CHARGE WARNING
7170 W DIFF LOCK SWITCH (AUTO ON)
7175 Y DIFF LOCK SWITCH (MANUAL ON)
7180 U CREEPER SWITCH MOM SIGNAL
7190 K TRANS SOLENOID VALVE SUPPLY
7195 K TRANS SOLENOID VALVE RETURN
7196 Y TRANS FR/REV LOW SIDE RETURN (CVT)
7197 Y TRANS RANGE LOW SIDE RETURN (CVT)
7198 U TRANS HYDROSTATIC LOW SIDE RETURN (CVT)
7200 S TRANSMISSION SHIFT DOWN
7210 S TRANSMISSION SHIFT UP
7220 S TRANSMISSION HIGH RANGE
7225 W TRANS HI RANGE SOL - RET
7230 S TRANSMISSION LOW RANGE
7235 Y TRANS LOW RANGE SOL - RET
7240 S TRANSMISSION DISPLAY SWITCH
7245 LN DEADMAN
7250 S TRANSMISSION FORWARD SIGNAL
7260 S TRANSMISSION REVERSE SIGNAL
7265 K TRANS NEUTRAL SWITCH TO PROCESSOR (GR.SW 1)
7267 LG TRANS NEUTRAL SWITCH 2 TO PROCESSOR
7270 R TCM SERIAL DATA IN-DISPLAY DATA OUT
7275 W TCM SERIAL DATA OUT-DISPLAY DATA IN
7280 W LIMP HOME SWITCH 18x18 TRANS.
7290 W DIRECTIONAL INTERRUPT RELAY TO SOLENOID
7295 W DRIVE DISABLE SIGNAL
7300 W SOLENOID 1 18x9 TRANSMISSION
7301 Y SOLENOID 1 18x9 RETURN
7321 P SOLENOID 2 18x9 RETURN
7340 W SOLENOID F1 18x9 TRANSMISSION
7341 Y SOLENOID F1 18x9 RETURN
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7351 S SOLENOID F2 18x9 RETURN
7355 S SOLENOID R 18x9 TRANSMISSION
7356 U SOLENOID R 18x9 RETURN
7360 W SOLENOID A 18x9 TRANSMISSION
7361 P SOLENOID A 18x9 RETURN
7370 Y SOLENOID B 18x9 TRANSMISSION
7371 P SOLENOID B 18x9 RETURN
7380 Y SOLENOID C 18x9 TRANSMISSION
7381 P SOLENOID C 18x9 RETURN
7390 Y SOLENOID PMW (F1) 18x9 TRANSMISSION
7391 P SOLENOID PWM (F1) 18x9 RETURN
7392 O SOLENOID PWM (F2) 18x9 TRANSMISSION
7393 O SOLENOID PWM (F2) 18x9 RETURN
7395 P SOLENOID CREEP 18x9 TRANSMISSION
7396 P SOLENOID CREEP 18x9 RETURN
7400 Y TRANS RPM SPEED SENSOR TO TCM INPUT
7401 P TRANS RPM SPEED SENSOR
7402 Y TRANS WHLSP FORWARD (CVT)
7403 Y TRANS WHLSP REVERSE (CVT)
7404 Y TRANS HYDROSTAT FORWARD (CVT)
7405 Y TRANS HYDROSTAT REVERSE (CVT)
7406 LG TRANS BI-DI SPEED SENSOR RET (CVT)
7407 K HYDROSTAT 1 SOLENOID +
7408 L HYDROSTAT 1 SOLENOID GND
7410 Y TRANS RPM SPEED SENSOR TO TCM OUTPUT
7411 Y/K/B TRANS HYDROSTAT INPUT SPEED SENSOR (CVT)
7420 Y TCM TO CLUTCH POSITION SWITCH
7425 Y DRIVE SIGNAL
7430 Y CLUTCH POSITION SIGNAL
7431 TQ CLUTCH ’A’ SUPPLY
7440 Y TCM TO TRACTOR EIC-AXLE OUTPUT
7450 W TRANS CREEPER INTERLOCK SUPPLY
7460 W TRANS CREEPER CLUTCH ENGAGED
7470 S TRANS CREEPER CLUTCH DISENGAGED
7475 R TRANS AUTO OFF
7476 R TRANS AUTO ON
7480 G TRANS AUTO FUNCTION 1
7482 G TRANS AUTO ON/INCREASE
7485 K TRANS AUTO FUNCTION LAMP 1
7492 G TRANS AUTO OFF/DECREASE
7500 G TRANS OIL TEMP. SENSOR
7520 G TRANS SENSOR SUPPLY 8v
7560 G TRANS WARNING LAMP
7570 B/W SIGNAL GROUND
7579 U PARKLOCK SWITCH
7580 U CREEPER SOLENOID MONITOR
7581 O CREEPER POSITION SIGNAL
7582 U CREEPER RAIL SWITCH NOT
7583 U PARKLOCK SWITCH #2
7584 U PARKLOCK SENSOR SWITCH SIGNAL
7585 U PARKLOCK SOLENOID #2
7586 U/G/Y PARKLOCK SOLENOID
7587 U PARKLOCK OVERRIDE SWITCH
84276322A 31/05/2010
A.30.A / 985

7588 U PARKLOCK POSITION SIGNAL
7589 U BRAKE PRESSURE SIGNAL
7590 O TRANS CREEPER GEAR STATUS LAMP
7600 N TRANS FEATHERING SOLENOID
7620 N TRANS FEATHERING SOL. MONITOR
7630 N TRANS MAIN CLUTCH PRESSURE SWITCH
7640 LN DIAGNOSTIC PLUG RS232 IN
7650 W DIAGNOSTIC PLUG RS232 OUT
7655 Y/LN RS232 GROUND
7660 R TRANS CLUTCH DISCONNECT
7670 R TRANS FRONT SYNCHRO POSITION
7700 LN TRANS SHUTTLE DUMP SWITCH
7710 LN TRANS OIL TEMPERATURE SWITCH
7730 TN NOT IN PARKLOCK
7735 LN TRANS MID SPEED SIGNAL +
7740 LN TRANS MID SPEED SIGNAL -
7750 R TCM TO DOG 30/40 KPH SELECT
7755 P/G/S DOG ENABLE
7760 W TORQUE SENSOR
7770 U TRANS FORWARD PRESSURE SWITCH
7775 K B CLUTCH PRESSURE SIGNAL
7785 O A CLUTCH PRESSURE SIGNAL
7790 TQ TRANS RANGE INPUT DIGITAL FEEDBACK (CVT)
7800 TQ TRANS FR / REV INPUT DIGITAL FEEDBACK (CVT)
7810 K TRANS PWM SOLENOID C1
7815 K TRANS PWM SOLENOID C1 RETURN
7846 TQ TRANS BRAKE SOLENOID (CVT)
7847 TQ TRANS HYDROSTATIC - POSITIVE SOLENOID (CVT)
7848 TQ TRANS HYDROSTATIC - NEGATIVE SOLENOID (CVT)
7850 G TRANS DIAGNOSTIC PROGRAM VOLTAGE
7855 G TRANS DIAGNOSTIC EA
7860 G TRANS DIAGNOSTIC RCV
7865 G TRANS DIAGNOSTIC XMT
7870 G TRANS DIAGNOSTIC RTS
7875 K TRANS DIAGNOSTIC CTS
7880 B/W T C M SIGNAL GROUND
7890 TQ TRANS L-LINE DIAGNOSTIC (CVT)
7900 TQ CLUTCH ’A’ SIGNAL
7910 TQ CLUTCH ’B’ SIGNAL
7915 P TCM CLUTCH B RETURN
7920 TQ CLUTCH ’C’ SIGNAL
7925 P TCM CLUTCH C RETURN
7930 TQ CLUTCH ’D’ SIGNAL
7935 P TCM CLUTCH D RETURN
7940 TQ CLUTCH ’E’ SIGNAL
7945 P TCM CLUTCH E RETURN
7950 TQ CLUTCH SUPPLY
7960 P TRANS SLOW/FAST
7965 P HI/LO SYNCHRO SIGNAL
7970 P TRANS MED/REV
84276322A 31/05/2010
A.30.A / 986

7980 K TRANS MED RANGE
7982 W TRANS MED RANGE RET
7985 G TRANS REVERSE RANGE
7990 K TRANS BRAKE
7995 K BRAKE FLUID LEVEL
7996 R BRAKE PEDALS UNLATCHED SIGNAL
8000 N TRAILER BRAKE SOLENOID
8010 LN TRAILER BRAKE PRESSURE
8030 LG TRANS FWD SOLENOID
8035 P TRANS FWD SOL RET
8040 LG TRANS REV SOLENOID
8045 P TRANS REV SOL RET
8050 R TRANS REV PRESSURE
8060 U TRAILER BRAKE SUPPLY
8070 P/W/S TRAILER PARK BRAKE SOLENOID
9000 LN DIVERTER VALVE
9010 LN DIVERTER VALVE SUPPLY
9020 LN HYDRAULIC REMOTE VALVE SOL
9025 LN HYDRAULIC REMOTE VALVE SWITCH
9027 W CAL/ SEL INPUT ADIC
9028 W ADIC MEMORY B+
9031 P ADIC MEMORY B+
9032 Y IGN.+ TO POWER SKT.
9033 LN 50KPH SOLENOID+
9034 LN 50KPH SOLENOID-
9035 LN 50KPH DUMP SOLENOID
9036 LN 50KPH DUMP SOLENOID RETURN
84276322A 31/05/2010
A.30.A / 987
Wiring harness - Overview Earth points

MAXXUM 110 Multicontroller, MAXXUM 115 Multicontroller, MAXXUM 120 Multicontroller, MAXXUM 125 Multicontroller, MAXXUM 130 Multicontroller,
MAXXUM 140 Multicontroller
Screwed earth points

Earth point (1) cab
(in the cab on the right-hand wheel case)
SS08E037 1
Earth point (2) cab

(in the cab on the rear right-hand wheel case)
SS08E038 2
Earth point (3) engine

(on the left-hand engine block)
SS08E039 3
84276322A 31/05/2010
A.30.A / 988
Earth point (5) roof

(on the right-hand C-pillar)
SS08E040 4
Overview of welding points (earth)

Welding Sequence of the earth - welding points in the circuit diagram / paths Screwed earth
point points
5 6640 (5)
43 2525 (1)
53 6590 (2)
57A 6640 (5)
57B 5660 (5)
101 7500 (1)
102 130 (1)
104 2850 (2)
105 4440 (2)
106 7650 (2)
114 5890 (5)
124 5560 (5)
131 7990 (3)
320B 8265, 8310 (2)
324 9650 (1)
84276322A 31/05/2010
A.30.A / 989

Charging
MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 115 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16,
MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16

nent
F8 Potential 30 / Starter Switch Fuse 20 A
F43 Engine ECU Activate Fuse 10 A
G1 Battery
G2 C013 Alternator
GF1 Fuse Supply Grid Heater Relay 250 A
K3 Ignition Relay
K5 Starter Relay
M1 C006 Starter Motor and Solenoid
MF1 Maxi Fuse 80 A Feeds F9, F11, F12, F13, F14, F15, F16, F17, F18, F19, F20,
F21, F45, F51
MF2 Maxi Fuse 80 A Feeds F6, F7, F8, F46, F47, F48
PF-1 Electronics Supply Fuse 250 A
PF-2 Main Supply Fuse 30 A
R4 Grid Heater
R7 Fuel Heater Resistor
C001, C079, C101, C242, C269, C325, C350, C351, C352, C626
Wire Colour Codes

B Black S Slate G Green P Purple
Green
Brown
84276322A 31/05/2010
A.30.A / 990
SS09D065 1
84276322A 31/05/2010
A.30.A / 991

Charging - Main Switch

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
K5 Starter Relay
F21, F45, F51
PF-3 Electrical Battery Main Switch Fuse 10 A
R4 Grid Heater
S118 Mechanical Battery Main Switch
C001, C079, C101, C242, C269, C325, C350, C351, C352, C626
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 992
SS09D067 1
84276322A 31/05/2010
A.30.A / 993

Charging - Electrical Main Switch

nent
G1 Battery
G2 C013 Alternator
K3 Ignition Relay
K5 Starter Relay
F21, F45, F51
PF-3 Electrical Battery Main Switch Fuse 10 A
R4 Grid Heater
C001, C079, C101, C242, C269, C325, C350, C351, C352, C626
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 994
SS09D069 1
84276322A 31/05/2010
A.30.A / 995


nent
B1 C287 Flywheel Torque Sensor
S3 C376 Foot Throttle (Electronic Engine)
S4 C401 Constant Engine Speed Program Switch
S5 C301 Engine Inc / Dec Switch
C001, C019, C020, C079, C127, C128, C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 996
SS09D070 1
84276322A 31/05/2010
A.30.A / 997


nent
F21 Brake Fluid Level Switch / Water in Fuel Sensor Fuse 15 A
Y4 Injector 1 - EDC 16
C001, C019, C020, C079, C100, C242, C269, C315, C353, C434
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 998
SS08D169 1
84276322A 31/05/2010
A.30.A / 999


nent
B5 C427 Boost Pressure / Temperature Sensor
B6 C428 Oil Pressure / Temperature Sensor
B7 C429 Fuel Rail Pressure Sensor
B8 C430 Coolant Temperature Sensor
B9 C431 Fuel Temperature Sensor
B11 C433 Camshaft Speed Sensor
B12 C440 Fuel Metering Unit
C315, C436, C438
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1000
SS08K496 1
84276322A 31/05/2010
A.30.A / 1001


nent
S15 C358 Creeper Gear Detection Switch
S16 C418 Normal Gear Detection Switch
C019, C020, C100, C101, C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1002
SS08D171 1
84276322A 31/05/2010
A.30.A / 1003


nent
S19 C036 Transmission Oil Pressure Switch
C019, C020, C081, C101, C127, C128, C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1004
SS09D072 1
84276322A 31/05/2010
A.30.A / 1005


nent
C019, C020, C100, C128, C239
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1006
SS08D173 1
84276322A 31/05/2010
A.30.A / 1007
Wiring harness - Electrical schematic frame 10 EDC Hydraulics 1


nent
S21 C023 Transmission Oil Temperature Sensor
C019, C101, C127, C269, C324, C325, C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1008
SS09D074 1
84276322A 31/05/2010
A.30.A / 1009


nent
B41 Draught Potentiometer
B42 EDC Position Potentiometer
B68 Slip Limitation Potentiometer
B69 EDC Draught Sensitivity Potentiometer
B70 Lowering Speed Potentiometer
B71 Lift Limitation Potentiometer
C101, C911, C912
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1010
SS08E018 1
84276322A 31/05/2010
A.30.A / 1011


nent
H56 C950 EDC Slip Control
H57 C951 EDC Lowering Control
H58 C952 EDC Raising Control
H59 C953 EDC Diagnosis
S22 C135 HPL External Switch LH
S23 C134 HPL External Switch RH
S27 C173 Low Charge Pressure Switch
S30 C174 PAS Pressure Switch
S107 C954 Internally Operated Front Power Lift Button
X5 C663 Fixed Displacement Pump
C020, C079, C081, C100, C101, C239, C294, C296, C910
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1012
SS08D176 1
84276322A 31/05/2010
A.30.A / 1013


nent
C019, C100, C239, C329
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1014
SS08F010 1
84276322A 31/05/2010
A.30.A / 1015
Wiring harness - Electrical schematic frame 14 Four Wheel Drive


nent
F13 Brake Lights / Brake Light Relay K8 Fuse 15 A
F15 Stoplamp Switch Left-Right / Pneumatic Relay K12 Fuse 20 A
K8 Stoplamp Relay
K12 Stoplamp Switch Left-Right / Air Brake Relay
S34 C062 Stoplamp Switch RH
S35 C063 Stoplamp Switch LH
S36 C182 4WD Switch
C019, C020, C081, C127, C128, C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1016
SS09D076 1
84276322A 31/05/2010
A.30.A / 1017


nent
H1 Rear PTO Engage Lamp
H2 Front PTO Engage Lamp
S37 C044 Ground Speed PTO Engaged Switch
C019, C020, C114, C117, C127, C128, C324, C325, C326, C328
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1018
SS08F033 1
84276322A 31/05/2010
A.30.A / 1019


nent
B21 C054 Rear PTO Speed Sensor
B72 C113 Rotary Angle Sensor, Front Power Lift
S38 C118 Rear PTO Brake Switch / Management
Y31 C033 Rear PTO Brake Solenoid
Y32 C041 Rear PTO Solenoid
Y60 C169 Front PTO Solenoid
C019, C128, C168, C239, C253, C269, C324, C325, C326
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1020
SS08K497 1
84276322A 31/05/2010
A.30.A / 1021


nent
C020, C248, C253, C269, C324, C325, C326, C378
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1022
SS08D181 1
84276322A 31/05/2010
A.30.A / 1023
Wiring harness - Electrical schematic frame 18 Cab Accessory 1


nent
A005 C106 Radio
C107
B26 C385 Speaker RH Rear
B27 C110 Speaker RH Front
B28 C386 Speaker LH Rear
B29 C111 Speaker LH Front
F1 Interior Light Left / Puddle Lamp Left + Right / Handbrake Fuse 10 A
F6 Radio / Worklamp ECU Fuse 10 A
F17 Potential 15 / Power Socket 3-pin Right Rear Cab Fuse 25 A
F40 Potential 15 Ignition Switch Radio Fuse 10 A
H3 C387 Console Lamp RH
H4 C388 Puddle Lamp LH
H5 C389 Puddle Lamp RH
H6 C099 Interior Lamp - High Roof
S44 C090 Door Switch LH
S45 C091 Door Switch RH
X11 C417 8 A Ring Terminals Black/Red Cable Right Rear
X12 Power Socket, 3-Pin Cable Right Rear
C079, C235, C378, C532, C636, C960
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1024
SS09D078 1
84276322A 31/05/2010
A.30.A / 1025

- Electrical Main Switch

nent
A005 C106 Radio
C107
B26 C385 Speaker RH Rear
B28 C386 Speaker LH Rear
H4 C388 Puddle Lamp LH
H5 C389 Puddle Lamp RH
H6 C099 Interior Lamp - High Roof
C079, C235, C378, C532, C636, C960
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1026
SS09D080 1
84276322A 31/05/2010
A.30.A / 1027

LP Roof

nent
A005 C530 Radio
C531
H7 C527 Interior Lamp - Low Roof
C079, C235, C378, C532, C636, C640, C960
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1028
SS09D209 1
84276322A 31/05/2010
A.30.A / 1029

LP Roof, Electrical Main Switch

nent
A005 C530 Radio
C531
H7 C527 Interior Lamp - Low Roof
C079, C235, C378, C532, C636, C640, C960
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1030
SS09D082 1
84276322A 31/05/2010
A.30.A / 1031


nent
B30 C057 Horn
D2 C368 Diode Brake Light Left
D3 C368 Diode Brake Light Right
F20 Potential 15 / Radar Sensor / ADIC Supply Keypad Fuse 10 A
F45 Potential 15 / 8 A 2-pin Mobile Phone Socket Fuse 25 A
M4 Seat Pump
MF4 Maxi Fuse 80 A Feeds F27, F28, 3-Pin Power Socket Right Rear
S48 Seat Switch
X13 C138 Seat Pump
X14 C143 Power Socket, 3-Pin Right Rear
X15 C365 8 A Socket, Cable Left C-Pillar
X16 C321 2-Pin Socket, Engine Compartment DIA
C001, C056, C127, C269, C957, C958
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1032
SS09D083 1
84276322A 31/05/2010
A.30.A / 1033

LP Roof

nent
B30 C057 Horn
D2 C368 Diode Brake Light Left
D3 C368 Diode Brake Light Right
F20 Potential 15 / Radar Sensor / ADIC Supply Keypad Fuse 10 A
F45 Potential 15 / 8 A 2-pin Mobile Phone Socket Fuse 25 A
M4 Seat Pump
MF4 Maxi Fuse 80 A Feeds F27, F28, 3-Pin Power Socket Right Rear
S48 Seat Switch
X13 C138 Seat Pump
X14 C143 Power Socket, 3-Pin Right Rear
X15 C365 8 A Socket, Cable Left C-Pillar
X16 C321 2-Pin Socket, Engine Compartment DIA
C001, C056, C127, C269, C957, C958
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1034
SS08D187 1
84276322A 31/05/2010
A.30.A / 1035

Indicators 1

nent
F22 Side Lamps RH / Spot Light Right Fuse 15 A
F23 Side Lamps LH / Licence Plate Lights / 7-pin Trailer Socket Fuse 15 A
F24 Control Panel Right - Switch Illumination Fuse 10 A
H14 C094 Turn Signal / Side Marker Light, Right
H15 Licence Plate Lamp Right
H16 Licence Plate Lamp Left
H17 C095 Licence Plate Lamp, Roof Left
H18 C096 Licence Plate Lamp, Roof Right
H55 C093 Turn Signal / Side Marker Light, Left
S50 C257 LH Fender PTO Switch
S51 C258 RH Fender PTO Switch
C020, C128, C131, C293, C294, C295, C296, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1036
SS08F032 1
84276322A 31/05/2010
A.30.A / 1037


nent
F22 Side Lamps RH / Spot Light Right Fuse 15 A
F23 Side Lamps LH / Licence Plate Lights / 7-pin Trailer Socket Fuse 15 A
F24 Control Panel Right - Switch Illumination Fuse 10 A
H14 C094 Turn Signal / Side Marker Light, Right
H16 Licence Plate Lamp Left
H55 C093 Turn Signal / Side Marker Light, Left
S50 C257 LH Fender PTO Switch
S51 C258 RH Fender PTO Switch
C020, C128, C131, C293, C294, C295, C296, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1038
SS08F031 1
84276322A 31/05/2010
A.30.A / 1039

Indicators 2

nent
F7 Potential 30 / Main Light Switch / Hazard Switch Fuse 20 A
F14 Potential 15 / Main Light Switch / Flasher Unit Fuse 15 A
F25 Dip Beam Headlamps Fuse 15 A
F26 Main Beam Headlamps Fuse 15 A
H43 C059 RH Headlamp
H44 C060 LH Headlamp
K4 Side Light / Illumination Relay
K7 Dip Beam Headlight Relay
K9 Main Beam Headlight Relay
C001, C056, C081, C374
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1040
SS09D085 1
84276322A 31/05/2010
A.30.A / 1041

Indicators 3

nent
A007 C260 Flasher Unit
F32 Potential 30 / Flasher Unit Fuse 30 A
H21 RH Side Lamp Front
H22 LH Side Lamp Front
C020, C056, C066, C067, C079, C081, C374, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1042
SS09D087 1
84276322A 31/05/2010
A.30.A / 1043


nent
A007 C260 Flasher Unit
F32 Potential 30 / Flasher Unit Fuse 30 A
H21 RH Side Lamp Front
H22 LH Side Lamp Front
C020, C056, C079, C081, C374, C519, C528, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1044
SS09D088 1
84276322A 31/05/2010
A.30.A / 1045
Wiring harness - Electrical schematic frame 29 Work Lamps 1


nent
D4 Diode Licence Plate Light
H35 C084 LH Front Upper Worklamp
H36 C085 RH Front Upper Worklamp
H37 LH Rear Worklamp
H38 RH Rear Worklamp
C377, C383, C384
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1046
SS09D089 1
84276322A 31/05/2010
A.30.A / 1047
Wiring harness - Electrical schematic frame 30 Work Lamps 1 -

LP Roof

nent
H46 RH Front Worklamp LP Roof
H47 LH Front Worklamp LP Roof
H48 RH Rear Worklamp LP Roof
H49 LH Rear Worklamp LP Roof
K27 C638 Relay Rear Worklamps LP Roof
C652, C653, C655, C656
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1048
SS08D194 1
84276322A 31/05/2010
A.30.A / 1049
Wiring harness - Electrical schematic frame 31 Work Lamps 2


nent
E2 Rotating Beacon LH
E3 Rotating Beacon RH
F27 Worklamps Engine Hood Fuse 15 A
F28 Worklamps ECU, Roof Rear Fuse 15 A
F29 Worklamps ECU, Roof Front, Grabrail Fuse 30 A
F30 Worklamps Relay C-Pillar Fuse 15 A
F31 Rotating Beacons Fuse 15 A
H19 RH Worklamp on C-Pillar
H20 LH Worklamp on C-Pillar
H39 RH Front Grabrail Worklamp
H40 LH Front Grabrail Worklamp LP and High Roof
H41 C058 LH Worklamp Engine Roof
H42 C061 RH Worklamp Engine Roof
K15 Worklamp Engine Hood Relay
K16 Worklamp C-Pillar Rear Relay
MF5 Maxi Fuse 80 A Feeds F25, F26, F31, F32
C001, C056, C064, C065, C097, C098, C129, C130, C293, C295, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1050
SS09D092 1
84276322A 31/05/2010
A.30.A / 1051
Wiring harness - Electrical schematic frame 32 Work Lamps 2 -

LP Roof

nent
E2 Rotating Beacon LH
E3 Rotating Beacon RH
F27 Worklamps Engine Hood Fuse 15 A
F28 Worklamps ECU, Roof Rear Fuse 15 A
F29 Worklamps ECU, Roof Front, Grabrail Fuse 30 A
F30 Worklamps Relay C-Pillar Fuse 15 A
F31 Rotating Beacons Fuse 15 A
H19 RH Worklamp on C-Pillar
H20 LH Worklamp on C-Pillar
H40 LH Front Grabrail Worklamp LP and High Roof
H41 C058 LH Worklamp Engine Roof
H42 C061 RH Worklamp Engine Roof
H45 RH Front Grabrail Worklamp LP Roof
K15 Worklamp Engine Hood Relay
K16 Worklamp C-Pillar Rear Relay
K26 C517 Grabrail Worklamp - LP Roof Relay
K28 C518 LP Roof Beacon Relay
MF5 Maxi Fuse 80 A Feeds F25, F26, F31, F32
S55 C522 C-Pillar Worklamp Switch - Roof
S57 C523 Engine Roof Worklamp Switch
C001, C056, C065, C097, C098, C129, C130, C293, C295, C532, C650
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1052
SS09D093 1
84276322A 31/05/2010
A.30.A / 1053


nent
F16 Italian Hydraulic & Pneumatic Trailer Brake Relay Fuse 15 A
K10 Pneumatic Trailer Brake Supply Relay
K11 Hydraulic Trailer Brake Supply Relay
X18 Trailer Socket
Y41 C576 Brake De-Icer - Trailer Brakes
C020, C055, C081, C127
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1054
SS09D094 1
84276322A 31/05/2010
A.30.A / 1055


nent
B32 C068 Radar Gun
B33 Steering Angle Sensor
X20 Standard Signal Socket
C001, C014, C020, C079, C080, C081, C101, C269, C366
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1056
SS09D096 1
84276322A 31/05/2010
A.30.A / 1057
Wiring harness - Electrical schematic frame 35 Wipers


nent
F11 Windshield Wiper, Front/Rear Fuse 10 A
F12 Front + Rear Windshield Washer / Rear Wiper Fuse 10 A
K1 Windshield Wiper Module Front and Rear
M5 Front Wiper Motor
M8 Rear Wiper Motor
S63 C073 Windshield Wiper Switch Front and Rear
C088, C109, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1058
SS09D097 1
84276322A 31/05/2010
A.30.A / 1059


nent
F11 Windshield Wiper, Front/Rear Fuse 10 A
F12 Front + Rear Windshield Washer / Rear Wiper Fuse 10 A
K1 Windshield Wiper Module Front and Rear
M5 Front Wiper Motor
M8 Rear Wiper Motor
S63 C073 Windshield Wiper Switch Front and Rear
C088, C109, C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1060
SS09D099 1
84276322A 31/05/2010
A.30.A / 1061
Wiring harness - Electrical schematic frame 37 Mirror Heating


nent
F19 Potential 15 / Heated Mirrors Fuse 7.5 A
K21 Heated Mirrors Timerelay
M2 C607 Electric Mirror LH
M3 C608 Electric Mirror RH
C532
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1062
SS09D100 1
84276322A 31/05/2010
A.30.A / 1063
Wiring harness - Electrical schematic frame 38 Diagnostics


nent
F33 Diagnostics Connector / Turn Assist Fuse 25 A
F51 Turn Assist Rapid Steering System Fuse 5 A
X4 C444 Trans Can
X22 C445 Select Can Diagnostic
X23 C443 CAN Select
C001, C081, C100, C242, C324, C329, C539
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1064
SS09D101 1
84276322A 31/05/2010
A.30.A / 1065


nent
A009 C100 XCM Central Control Unit DT
C239
A010 C324 XCM Auxiliary Controller DV
C326
F34 Potential 30 / ADIC Battery Pos Fuse 10 A
F35 XCM Central - XCM Auxiliary Control Unit Fuse 10 A
F36 Potential 15 / K17 Instrument Cluster Fuse 10 A
F38 Rear PTO Switch / Rear PTO Warning Light / HPL / PTO Speed / Transmission
Display / Armrest / Allwheel Drive Switch Fuse 10 A
K13 Supply EDC Control Unit Relay
K17 Electronics Supply
MF3 Maxi Fuse 80 A Feeds F29, F30, F33, F34, F35, F52, F53, F54, F60
C001, C242, C619
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1066
SS08E024 1
84276322A 31/05/2010
A.30.A / 1067


nent
A011 C079 Instrument Panel
C081
A018 C242 Processor EDC
F52 Potential 15 / Relay K25 Fuse 15 A
F53 Potential 15 / Processor EDC Fuse 15 A
F54 Potential 15 / Processor EDC Fuse 10 A
C001, C275, C625
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1068
SS08D204 1
84276322A 31/05/2010
A.30.A / 1069
Wiring harness - Electrical schematic frame 41 Air Con 1


nent
F3 A/C Clutch Fuse 10 A
F18 Potential 15 / Blower Relay Air Cushion Electric Seat Fuse 15 A
F44 Potential 30 / Socket for Mounted Equipment DIA Fuse 25 A
K19 Air Conditioning Compressor Coupling Relay
MF6 Maxi Fuse 80 A Feeds F1, F2, F3, F4, F5, F44, F49
S64 C011 Air Con Pressure Switch High
C269, C559
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1070
SS09D102 1
84276322A 31/05/2010
A.30.A / 1071
Wiring harness - Electrical schematic frame 42 Air Con 2 - Manual


nent
M10 C993 Heater / Air Con Blower Motor
C994
S65 C543 Air Con Manual Pressure Switch Low
S66 C362 Heater Blower Switch
S67 C629 Air Con Switch
S68 C542 Air Con Manual Temperature Control Switch
C119, C557, C559, C627
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1072
SS08N145 1
84276322A 31/05/2010
A.30.A / 1073
Wiring harness - Electrical schematic frame 43 Air Con 2 - Auto


nent
A020 C902 Heater/Air Con Connector
B34 C905 Outside Temperature Sensor
B35 C906 Cab Temperature Sensor
B36 C907 Outlet Temperature Sensor Clime
B37 C908 EVAP Evaporator Temperature Sensor
B38 C627 Temperature Potentiometer Air Conditioning
M9 C903 Heater / Air Con Automatic, Blower Motor
S65 C909 HVAC Unit / Pressure Switch Low
S66 C362 Heater Blower Switch
S67 C629 Air Con Switch
Y43 C904 Heating Valve ATC
C119, C557, C559, C630, C974
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1074
SS08N146 1
84276322A 31/05/2010
A.30.A / 1075
Wiring harness - Electrical schematic frame 44 Electronic Hydraulic

Remotes

nent
R1 Terminating Resistor - 1 A
Y25 C279 EHR Valve-1
C020, C344
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1076
SS08K502 1
84276322A 31/05/2010
A.30.A / 1077
Wiring harness - Electrical schematic frame 45 Armrest Control

Unit 1

nent
A001 C104 Gear Shift Indicator
A030 C921 Print ARU
C922
C924
C925
C935
C984
S108 C492 EFH Raise Control Button
S109 EDC Stop Button
S110 EDC Rapid Retract Button (Float Position)
C101, C127, C328, C370, C920
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1078
SS08D209 1
84276322A 31/05/2010
A.30.A / 1079

Unit 2

nent
A030 C921 Print ARU
C926
C929
A043 C927 Multi Controller III
C928
C936
B73 Hand Throttle Slider
S106 Front Loader Button Joystick Solenoid 2
S117 Shift Button
C101, C370, C937
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1080
SS09D103 1
84276322A 31/05/2010
A.30.A / 1081

Unit 3

nent
A030 C930 Print ARU
C931
C933
C934
B43 EHR Potentiometer Throughflow Volume Additional Control Unit 1
B48 EHR Control Sensor Joystick
B49 EHR Control Sensor Joystick
B50 EHR Control Sensor Shift Lever Additional Control Unit
S111 Front Loader Button Joystick Solenoid 1
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1082
SS08D211 1
84276322A 31/05/2010
A.30.A / 1083
Wiring harness - Electrical schematic frame 48 Engine Harness

Accessories

nent
F9 Supply D+ Relay Front Loader Fuse 25 A
K22 C669 European Loader Relay Solenoid 1
K23 C670 European Loader Relay Solenoid 2
K31 D+ Cut-off Front Loader
S112 C971 Engine Back Pressure Brakes Switch
S119 C455 Oil Motor Mode Switch
C079, C269, C424, C647, C648, C913, C914, C988
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1084
SS09D104 1
84276322A 31/05/2010
A.30.A / 1085
Wiring harness - Electrical schematic frame 49 Electronic Front

Hitch 1

nent
A044 C916 EFH Control Panel
F49 Potential 30 / EFH Electronic Front Hitch Fuse 7.5 A
S115 C942 EFH Switch Transport Raise
Y61 C941 EFH-Solenoid 40 bar Accumulator
Y62 C940 EFH-Solenoid 14 bar Accumulator
C269, C915, C917, C918, C919
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1086
SS08D213 1
84276322A 31/05/2010
A.30.A / 1087
Wiring harness - Electrical schematic frame 50 Electronic Front

Hitch 2

nent
B55 C946 EFH Rotary Angle Sensor
B56 C945 EFH Pressure Sensor
S114 C948 External Button, EFH Raise/Lower
S116 C947 Internally Operated Front Power Lift Button
Y63 C944 EFH-Solenoid Raise
Y64 C943 EFH-Solenoid Lower
C269, C296, C328, C913, C914, C915, C917, C918, C919
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1088
SS08F014 1
84276322A 31/05/2010
A.30.A / 1089
Wiring harness - Electrical schematic frame 51 Turn Assist


nent
A031 C515 Turn Assist Control Unit, KA Processor
B24 C511 Turn Assist - LVDT Coils
B25 Turn Assist Steering Wheel Sensor
S43 C514 Turn Assist Steering Wheel Switch
Y37 Turn Assist Solenoid Valve
C512, C513
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1090
SS09D190 1
84276322A 31/05/2010
A.30.A / 1091
Wiring harness - Electrical schematic frame 52 Electrical Main

Switch

nent
D1 C504 Diode Main Battery Switch
K18 Battery Isolator
S1 C503 Iso Control Relay Switch
C269, C500, C580
Wire Colour Codes

Green
Brown
84276322A 31/05/2010
A.30.A / 1092
SS08D216 1
84276322A 31/05/2010
A.30.A / 1093
Alternator - Remove
MAXXUM 140
Prior operation:
1. Remove the right hand belt guard.
SS09J020 1
2. Using a suitable 1/2 inch drive bar, rotate the acces-

sory drive belt tensioner clockwise (1) and detach the
accessory drive belt from the alternator pulley (2).
BAIL07APH050AVA 2
3. Disconnect the alternator electrical connectors and

reposition the wiring loom to one side.
SS09J018 3
84276322A 31/05/2010
A.30.A / 1094
4. Remove the alternator retaining bolts, and remove

the alternator.
BAIS09APH327AVA 4
Next operation:
Alternator - Install (A.30.A)
84276322A 31/05/2010
A.30.A / 1095
Alternator - Install
MAXXUM 140
Prior operation:
Alternator - Remove (A.30.A)
NOTE: Ensure the battery ground (negative) cable is disconnected from the battery when installing the alternator.
1. Install the alternator to the engine mounting bracket
and tighten the bolts to the specified torque of, 25
Nm (18 lbft).
BAIS09APH327AVA 1
2. Connect the alternator electrical connectors.
SS09J018 2

sory drive belt tensioner clockwise (1) and install the
accessory drive belt onto the alternator pulley (2).
BAIL07APH050AVA 3
84276322A 31/05/2010
A.30.A / 1096
4. Install the belt guard.
SS09J020 4
Next operation:
Reconnect the battery cable - see Battery - Connect (A.30.A).
84276322A 31/05/2010
A.30.A / 1097
Alternator - Preliminary test

MAXXUM 140
CAUTION - Service Precautions

1. To avoid damage to the components of the alterna-
tor charging system, service precautions must be ob-
served as follows:
- NEVER make or break any of the charging circuit
connections, including the battery, when the engine
is running.
- NEVER short any of the charging components to
ground.
- ALWAYS disconnect the battery ground cable (neg-
ative) when charging the battery on the tractor using
a battery charger.
- ALWAYS observe correct polarity when installing
the battery or using a slave battery to start the en-
gine.
NOTICE: ALWAYS CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE
Preliminary Checks
2. Prior to electrical testing thoroughly inspect the
charging and electrical system.
Check all leads and connections for continuity and
tightness.
1. Check the battery state of charge.

Using a hydrometer check the individual battery
cells. The battery should be at least 70 % charged
and in good condition.
2. Check the drive belt

Inspect the alternator drive belt and pulley, ensuring
that both are clean, free from oil and grease and in
good condition.
The alternator drive belt is automatically tensioned
by a spring tensioner mounted at the front of the
engine, refer to Alternator - Static description
(A.30.A). If the belt tension is suspect, check the
tensioner assembly as follows:
Remove the fan belt, for further information refer to

Fan and drive Belt - Remove (B.50.A).
BSE2983A 1
84276322A 31/05/2010
A.30.A / 1098
Inspection and Repair

3. Checking of the tensioner assembly operation should
be carried out, with the tensioner assembly still at-
tached to the front of the engine. To check the spring
load, place a “breakback" torque bar preset to, 52 -
63 lbf.ft ( 70 - 85 Nm) ( 7.1 - 8.7 kgf.m), onto the pul-
ley arm 15 mm socket. Raise the lever up through
an arc of 20 ° maximum. If the torque bar does not
“break" within the range, install a new fan belt ten-
sioner. For further information refer to Fan and drive
Belt tensioner - Remove (B.50.A)
Ensure the tensioner pulley rotates freely by hand.
If it does not rotate freely by hand, install a new fan
belt tensioner. For further information refer to Fan
and drive Belt tensioner - Remove (B.50.A)
4. Re-Assembly
To install the fan belt tensioner, refer to Fan and

drive Belt tensioner - Install (B.50.A).
Install the fan belt. For further information, refer to
Fan and drive Belt - Install (B.50.A)
Check the Alternator Charge Warning Lamp

5. Turn on the key start switch and check that the warn-
ing lamp is fully illuminated.
If the warning lamp is not fully illuminated check the
bulb. If the bulb is not the cause of the fault carry
out the Alternator wiring connections test as detailed
under ‘initial tests’ in this section.
If the warning lamp is illuminated start the engine and
run above idling speed. The lamp should go out.
If the lamp does not go out, stop the engine and re-
move the wire from the D+ terminal. If the lamp now
goes out a faulty alternator component is indicated.
If the warning lamp remains illuminated, check for a
short circuit to earth (ground) between the ‘D+’ cable
end and the warning lamp.
INITIAL TESTS
6. The initial tests may be performed without removing
any of the charging circuit components from the trac-
tor and enable the following items to be checked:
- Alternator wire connections
- Alternator charging current and controlled voltage
- Alternator charging circuit volt drops
- Alternator maximum output performance
Test equipment required:

7. - Voltmeter ( 0 - 30 volts moving coil type
- Millivoltmeter ( 0 - 1 volt)
- Ammeter ( 0 - 200 Amperes moving coil type)
- 1.5 Ohm 200 Amperes variable load resistor
NOTE: Most commercial test equipment incorporates sev-
eral testing devices within a single unit . Use such equip-
ment in accordance with the manufacturers instructions.
8. For further information refer to Alternator - Electri-
cal test (A.30.A) for testing procedures.
84276322A 31/05/2010
A.30.A / 1099
Alternator - Electrical test

MAXXUM 140
Alternator Wiring Connections Test

1. With reference to 1
1. Disconnect the battery

2. Disconnect the D+ (2) and B+ (3) terminals from
the alternator.
3. Reconnect the battery and turn the key start on
but do not start the engine. Connect a voltmeter (4)
between each terminal and earth (ground), (1). Bat-
tery voltage should be registered.
If battery voltage is not registered a continuity fault in

the external cable circuitry must be traced and reme-
died, refer to the circuit diagram (refer to Wiring har-
ness - Electrical schematic frame 01 (A.30.A)). BAIS06CCM694AVA 1
4. Connect the D+ terminal, warning lamp (thin

brown) wire, to earth (ground). The warning lamp
should illuminate.
5. Disconnect the battery and reconnect the re-
moved alternator cable connections to the alternator.
NOTE: If the warning lamp fails to illuminate when the cable
is reconnected to the alternator, a fault is indicated in the
alternator regulator or rotor circuits. Ensure that the D+
terminal is clean.
84276322A 31/05/2010
A.30.A / 1100
Charging Current And Controlled Voltage Tests

2. With reference to Figure 2
The following test should be performed at 20 °C, a
lower temperature will create a higher voltage and a
higher temperature will create a lower voltage.
1. Ensure all tractor electrical components are
switched off and the key start switch is in the ‘off’
position.
2. Disconnect the battery negative terminal and dis-
connect the B+ terminal (4) of the alternator.
3. Connect an ammeter (1), between the removed
(thick brown) cable (3) and the B+ alternator terminal.
4. Connect a voltmeter (2) between the alternator B+
terminal and earth (ground)
5. Reconnect the battery. Start and run the engine BAIS06CCM695AVA 2
at 2000 rev/min. and observe the ammeter and volt-
meter readings.
The voltmeter should register in excess of battery

voltage and when the ammeter reading falls to 5 Am-
peres the voltmeter reading should stabilise at 14.1
V +/- 0.15.
If the voltmeter reading exceeds the above value the

alternator regulator is faulty.
If the voltmeter reading is below the specified value a
faulty alternator component or a high resistance fault
in the external connections of the charging system is
indicated.
If the ammeter registers zero amperes a faulty alter-

nator component is indicated.
Charging Circuit Volt Drop Tests
84276322A 31/05/2010
A.30.A / 1101
(a) Insulated-Side Volt Drop Tests

Ensure the key start switch is in the ‘off’ position.

1. Disconnect the battery negative cable and discon-
nect the B+ cable (1) from the alternator
2. Connect a millivoltmeter (4) between the battery
positive terminal and the B+ cable (5). (Positive side
to cable).
3. Securely connect an ammeter (2) between the B+
terminal of the alternator and the B+ cable (negative
side to cable)
4. Reconnect the battery negative cable and connect
a variable load resistor (3), with the slider in the min-
imum current draw position (maximum resistance), BAIS06CCM696AVA 3
across the battery terminals.
5. Start the engine and increase the speed to 2000
rev/min.
6. Slowly increase the current loading of the resis-
tor (decrease resistance) until the ammeter registers
120 Amperes.
7. Observe the millivoltmeter reading which should
not exceed 400 millivolts.
If the reading is in excess of 400 millivolts, a high

resistance fault is indicated in the external circuitry.
If the required alternator output cannot be achieved

and the millivoltmeter reading is less than 400 milli-
volts, then a faulty alternator component is indicated.
.
8. Stop the engine.
84276322A 31/05/2010
A.30.A / 1102
(b) Ground-Side Volt Drop Test

1. Ensure the key start switch is in the ‘off’ position.

2. The circuit is the same as that used in the pre-
vious test except for the millivoltmeter (4) which is
now connected between the battery negative termi-
nal and the alternator frame (negative side to frame).
rev/min.
4. Slowly increase the current loading of the resistor
(decrease resistance) until the ammeter (2) registers
120 Amperes
5. Observe the voltmeter reading which should not
exceed 200 millivolts. BAIS06CCM697AVA 4
If the reading is in excess of 200 millivolts a high


volts then a faulty alternator component is indicated.
.
6. Stop the engine.

NOTE: Ensure the variable load resistor (3) is in the mini-
mum current draw position (maximum resistance).
Alternator Maximum Output Performance Test

5. With reference to 5.

nect the B+ cable (5) from the alternator.
3. Securely connect an ammeter (2) between the
B+ terminal (1) of the alternator and the B+ cable
(negative side to cable).
terminal and earth (ground).
5. Reconnect the battery, start and increase the en-
gine speed to 2000 rev/min.
6. Slowly increase the current loading of the resistor BAIS06CCM698AVA 5
(3) (decrease resistance) until the ammeter registers
120 Amperes.
fall below 13 volts.
If the reading falls below 13 volts a faulty alternator

component is indicated..
Regulator and rotor field circuit test

6. Test equipment required:
- 12 volt battery
- Multimeter
- 2.2 Watt Test Lamp
NOTICE: Prior to removal of the alternator cables from the
alternator ensure that the key start switch is in the ‘off’ po-
sition and the battery negative cable is disconnected.
84276322A 31/05/2010
A.30.A / 1103
1. Disconnect all of the alternator cables.

2. Connect a 12 volt battery and a 2.2 Watt test lamp
(2) in series between the D+ (1) and the alternator
frame (negative side to frame).
3. The test lamp should illuminate.
If the test lamp is not illuminated a fault is indicated

in the rotor circuit. Check brushes, slip rings and
continuity of rotor field windings.
If examination indicates these parts to be satisfactory

the regulator may be suspect. BAIS06CCM699AVA 6
84276322A 31/05/2010
A.30.A / 1104
Battery - Disconnect
MAXXUM 140
1. Remove the clevis draw bar/hook (1) from the spare

storage holder.
Remove the securing pins (2).
SS09J019 1
2. Raise the cab steps and using a suitable cable tie,

secure the cab steps to the cab hand rail.
BAIL08APH002AVA 2
3. Remove the battery cover.
BAIL08APH003AVA 3
84276322A 31/05/2010
A.30.A / 1105
4. Disconnect the battery negative cable (1).
BAIL08APH004AVA 4
Next operation:
Battery - Connect (A.30.A)
84276322A 31/05/2010
A.30.A / 1106
Battery - Connect
MAXXUM 140
Prior operation:
Battery - Disconnect (A.30.A)
1. Connect the battery negative cable (1).
BAIL08APH004AVA 1
2. Install the battery cover.
BAIL08APH003AVA 2
3. While supporting the cab steps, cut the cable tie and
lower the cab steps.
BAIL08APH002AVA 3
84276322A 31/05/2010
A.30.A / 1107
4. Install the clevis draw bar/hook into the spare storage

holder (1) and install the cab steps with the securing
pins (2).
SS09J019 4
84276322A 31/05/2010
A.30.A / 1108
Battery - Remove
MAXXUM 140
WARNING
B026

storage holder.
SS09J019 1
2. Raise the cab steps and using a suitable cable tie.

Secure the cab steps to the cab hand rail.
BAIL08APH002AVA 2
BAIL08APH003AVA 3
84276322A 31/05/2010
A.30.A / 1109

Disconnect the battery positive cable (2).
Remove the battery clamp (3).
Remove the battery (4).
BAIL08APH005AVA 4
Next operation:
Battery - Install (A.30.A)
84276322A 31/05/2010
A.30.A / 1110
Battery - Install
MAXXUM 140
Prior operation:
Battery - Remove (A.30.A)
WARNING
B026
NOTE: Before installing the battery check the following:

• Make sure the battery is clean and dry and the
vent caps are properly installed.
• Smear the terminals with petroleum jelly, do
not use conventional lubricating greases as
these can promote electrolytic corrosion.
• Make sure the battery tray and clamps are
clean and free from stones or small objects
which may puncture the battery casing.
• Make sure the battery terminal polarity is cor-
rect and that the terminal connections are suf-
ficiently tight, but not overtightened.
1. Install the battery (1).
Install the battery clamp (2).
Connect the battery positive cable (3).
Connect the battery negative cable (4).
BAIL08APH005AVB 1
BAIL08APH003AVA 2
84276322A 31/05/2010
A.30.A / 1111
BAIL08APH002AVA 3

pins (2).
SS09J019 4
84276322A 31/05/2010
A.30.A / 1112
Battery - Testing Heavy Load Discharge Test

MAXXUM 140
N° Test Point Expected Result Other Result (Possible Cause)

1 Check Result Action
Confirm that the battery state of refer to Battery - Testing (A.30.A) or
charge is at least 75 % (> 12.4 V). Battery - Testing (A.30.A).
Determine the capacity rating of the
battery as stated on the battery label
(should be 800 CCA (107 Ah) or 960
CCA (132 Ah). Connect the heavy
load tester across the battery termi-
nals, observing the correct polarity.
Load the battery at a rate equal to
three times the Amp-hour (Ah) rating
or half the cold cranking amps (CCA)
rating.
To remove the surface charge, apply
the heavy load tester to the battery
for 15 seconds at the specified dis-
charge current then disconnect and
leave for 5 minutes.
Apply the load for no more than 15 Voltage greater than 9.6 V. The bat- The voltage is less than 9.6 V. The
seconds and note the voltage read- tery has an acceptable output capac- battery has an unacceptable output
ing. Is the voltage less than 9.6 V? ity and will accept a normal charge if capacity and should be test charged
required or can be returned to ser- before attempting a full recharge and
vice. then retesting.
Battery - Testing Charging Overview

MAXXUM 140

Before charging the battery ensure Battery clean and serviceable Cleaning reveals battery damage,
the electrolyte is at an acceptable replace battery as necessary.
level. Clean the battery casing and
cell covers with sodium bicarbonate
(baking soda) and hot water and
clean the battery terminals if neces-
sary.
84276322A 31/05/2010
A.30.A / 1113

If the battery has failed the Heavy
load test, conduct the charge accep-
tance test to determine whether the
battery will accept a charge.
Charge the battery using either After charging, to ensure the battery
the standard charge procedure or is suitable for service conduct the
slow charge procedure for deeply heavy load discharge test, Battery -
discharged /sulphated batteries. Testing (A.30.A).
Refer to correct battery manufac-
turers charging procedure detailed
in Battery - General specification
(A.30.A).
Battery - Testing Open Circuit Voltage Test - State of Charge Test

MAXXUM 140

To remove any surface charge from Refer to the voltages in the specific
the battery, operate the vehicle on gravity test table in Battery - Gen-
full beam for one minute then turn off eral specification (A.30.A).
and leave the vehicle for 5 minutes.
Measure the open circuit voltage by
connecting a digital voltmeter across
the battery terminals.
Battery - Testing Specific Gravity - State of charge test

MAXXUM 140
NOTE: State of charge tests are used to determine if there is sufficient charge in the battery to perform a heavy load
test, but does NOT verify the ability of a battery to crank the engine.
Check the electrolyte level. If nec-
essary add distilled water to the rec-
ommended level of 17mm above the
plates. Recharge for 2 hours then
leave for 15 minutes before testing.
(refer to ’charging overview’).
Shake the battery to mix the elec-
trolyte. Remove the vent caps and
extract electrolyte using a hydrome-
ter. Note the specific gravity reading
(SG) for each cell, beginning with the
cell closest to the positive terminal.
Adjust the hydrometer readings for
any temperature variations (±0.004
SG for every ±5.5°C from which the
hydrometer is calibrated.
84276322A 31/05/2010
A.30.A / 1114

Record the SG readings for each A variance of no more than 0.025 A variance greater than 0.025 be-
cell. between any two cells. Proceed to tween any two cells indicates a de-
step 4 fective cell and the battery should be
replaced.
Refer to the SG table in Battery -
General specification (A.30.A)
Battery - Testing Flat or discharged battery suspected

MAXXUM 140

Perform Visual check of Battery and Battery has no external defects Clean, repair or replace battery as
cables. Refer to Battery - Testing Action required.
(A.30.A). Proceed to step 2
Perform a state of charge test Bat- The battery must be fully charged
Refer to Battery - General specifi-
tery - Testing (A.30.A) before proceeding to step 3 (Heavy
cation (A.30.A). If battery is above
75% charge proceed to step 3.load test, Battery - Testing
(A.30.A)).
Perform a heavy load test (refer to Is the reading below 9.6 V ? If result is below 9.6 V the battery
Battery - Testing (A.30.A)). Action has an unacceptable output capacity
If NO the battery has an acceptable and should be test charged before
ouput capacity and will accept a nor- attempting a full recharge.
mal charge
Battery - Testing Visual check

MAXXUM 140

Remove the battery cover. Visually No cracking evident and no damage A cracked case or broken posts may
check the battery, (correctly identify to posts, proceed to step 2 lead to electrolyte leakage, the bat-
battery manufacturer, refer to Bat- tery should be replaced.
tery - Static description (A.30.A)).
Is the battery case cracked or the
battery posts broken?
Are the cables and connections Cables in good condition, clean and Clean, tighten, repair or replace ca-
damaged, dirty of loose? tight on posts, proceed to step 3. bles as required and then proceed to
step 3.
Is there corrosion around the battery No corrosion, proceed to step 4 Clean the terminals using water and
terminals? sodium bicarbonate (baking soda).
A wire brush may be required to re-
move heavy corrosion. Dry the bat-
tery and proceed to step 4
Is the battery strap or clamp loose? Battery secure, proceed to step 5. Tighten as necessary and proceed to
step 5.
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Check the electrolyte fluid level. The Electrolyte at correct level, proceed Electrolyte level low, top up using
electrolyte should be around 17mm to step 6. distilled or de-mineralised water. Do
above the plates. Is the electrolyte not use tap or rain water. Proceed to
level low in any of the cells? step 6.
Using a hydrometer, Is the elec- Electrolyte is clear, proceed to ’state Cloudy or discoloured electrolyte
trolyte excessively cloudy or dis- of charge test’, refer to Battery - may be caused by overcharging or
coloured ? Testing (A.30.A). vibration. This can cause a high self
discharge of the battery. Correct the
cause then replace the battery.
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Index

SYSTEMS - A

Alternator - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100
MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 115 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 120
Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 125 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 130 Multicontroller
[Z7BE50001 - Z9BE60000 ], MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ], MAXXUM 100, MAXXUM 110, MAXXUM
115, MAXXUM 120, MAXXUM 125, MAXXUM 130, MAXXUM 140
Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1096
Alternator - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1098
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1094
Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1107
Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1105
Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111
Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1109
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Battery - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Battery - Testing Charging Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
Battery - Testing Flat or discharged battery suspected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115
Battery - Testing Heavy Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113
Battery - Testing Open Circuit Voltage Test - State of Charge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114
Battery - Testing Specific Gravity - State of charge test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114
Battery - Testing Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115
Connector - Component Diagram 00 Connectors 00-09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connector - Component diagram 01 Connectors 10-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Connector - Component diagram 08 Connectors 80-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Connector - Component diagram 09 Connectors 90-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Connector - Component diagram 10 Connectors 100-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Connector - Component diagram 11 Connectors 110-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Connector - Component diagram 23 Connectors230-239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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[Z7BE50001 - Z9BE60000 ], MAXXUM 140 Multicontroller [Z7BE50001 - Z9BE60000 ]
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ELECTRICAL POWER SYSTEM - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ELECTRICAL POWER SYSTEM - Static description PROTECTING THE ELECTRONIC AND ELECTRICAL SYS-
TEMS DURING BATTERY CHARGING OR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuse and relay box - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuse and relay box - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring harness - Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Wiring harness - Electrical schematic frame 01 Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
MAXXUM 110 4v W/Cab 16x16, MAXXUM 115 4v W/Cab 16x16, MAXXUM 120 4v W/Cab 16x16, MAXXUM 125 4v W/Cab 16x16,
MAXXUM 130 4v W/Cab 16x16, MAXXUM 140 4v W/Cab 16x16
MAXXUM 100 2v W/Cab 16x16, MAXXUM 110 2v W/Cab 16x16, MAXXUM 115 2v W/Cab 16x16, MAXXUM 125 2v W/Cab
16x16, MAXXUM 140 2v W/Cab 16x16
MAXXUM 100 2v L/Cab 16x16, MAXXUM 110 2v L/Cab 16x16, MAXXUM 115 2v L/Cab 16x16, MAXXUM 125 2v L/Cab 16x16,
MAXXUM 140 2v L/Cab 16x16
MAXXUM 100 2v L/ Cab 24x24, MAXXUM 110 2v L/ Cab 24x24, MAXXUM 115 2v L/ Cab 24x24, MAXXUM 125 2v L/ Cab 24x24,
MAXXUM 140 2v L/ Cab 24x24
MAXXUM 110 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 115 Multicontroller [Z7BE50001 - Z9BE60000
] 4v W/Cab 16x16, MAXXUM 120 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 125 Multicontroller
[Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM 130 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16, MAXXUM
140 Multicontroller [Z7BE50001 - Z9BE60000 ] 4v W/Cab 16x16
Wiring harness - Electrical schematic frame 02 Engine 1 - Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
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Wiring harness - Electrical schematic frame 02 Starting and Charging - Main Switch . . . . . . . . . . . . . . . . . . . . . . 992
Wiring harness - Electrical schematic frame 03 Engine 1 - North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Wiring harness - Electrical schematic frame 03 Starting and Charging - Electrical Main Switch . . . . . . . . . . . . . 994
Wiring harness - Electrical schematic frame 04 Engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 996
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Wiring harness - Electrical schematic frame 06 Engine 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Wiring harness - Electrical schematic frame 07 Transmission 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
Wiring harness - Electrical schematic frame 08 Transmission 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
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Wiring harness - Electrical schematic frame 10 EDC Hydraulics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008
Wiring harness - Electrical schematic frame 11 EDC HYDRAULICS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
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Wiring harness - Electrical schematic frame 11 EDC Hydraulics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
Wiring harness - Electrical schematic frame 14 EHR HYDRAULICS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Wiring harness - Electrical schematic frame 14 Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
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Wiring harness - Electrical schematic frame 15 Power Take Off 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1018
Wiring harness - Electrical schematic frame 16 FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Wiring harness - Electrical schematic frame 16 Power Take Off 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020
Wiring harness - Electrical schematic frame 17 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1022
Wiring harness - Electrical schematic frame 17 Power Take Off 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Wiring harness - Electrical schematic frame 18 Cab Accessory 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1024
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Wiring harness - Electrical schematic frame 19 Cab Accessory 1 - Electrical Main Switch . . . . . . . . . . . . . . . . 1026
Wiring harness - Electrical schematic frame 19 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Wiring harness - Electrical schematic frame 20 Cab Accessory 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1028
Wiring harness - Electrical schematic frame 20 FAST STEER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Wiring harness - Electrical schematic frame 21 Cab Accessory 1 - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . 432
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Wiring harness - Electrical schematic frame 21 Cab Accessory 1 - LP Roof, Electrical Main Switch . . . . . . . 1030
Wiring harness - Electrical schematic frame 22 Cab Accessory 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Wiring harness - Electrical schematic frame 22 Cab Accessory 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1032
Wiring harness - Electrical schematic frame 23 Cab Accessories 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Wiring harness - Electrical schematic frame 23 Cab Accessory 2 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034
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Wiring harness - Electrical schematic frame 24 Main Lamps / Indicators 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1036
Wiring harness - Electrical schematic frame 25 Main Lamps / Indicators 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Wiring harness - Electrical schematic frame 25 Main Lamps / Indicators 1 - LP Roof . . . . . . . . . . . . . . . . . . . . 1038
Wiring harness - Electrical schematic frame 27 Main Lamps / Indicators 3 - ISO Roof . . . . . . . . . . . . . . . . . . . . . 528
Wiring harness - Electrical schematic frame 27 Main Lamps/Indicators 3 - ISO Roof . . . . . . . . . . . . . . . . . . . . . . 444
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Wiring harness - Electrical schematic frame 28 Main Lamps / Indicators 3 - LP Roof . . . . . . . . . . . . . . . . . . . . 1044
Wiring harness - Electrical schematic frame 28 Main Lamps / Indicators 3 - NASO Roof . . . . . . . . . . . . . . . . . . . 446
Wiring harness - Electrical schematic frame 29 Main Lamps / Indicators 3 - LP Roof . . . . . . . . . . . . . . . . . . . . . . 448
Wiring harness - Electrical schematic frame 29 Work Lamps 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1046
Wiring harness - Electrical schematic frame 30 Work Lamps - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . 450
Wiring harness - Electrical schematic frame 30 Work Lamps 1 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048
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Wiring harness - Electrical schematic frame 31 Work Lamps - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Wiring harness - Electrical schematic frame 31 Work Lamps 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050
Wiring harness - Electrical schematic frame 32 Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Wiring harness - Electrical schematic frame 32 Work Lamps 2 - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052
Wiring harness - Electrical schematic frame 33 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Wiring harness - Electrical schematic frame 33 Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1054
Wiring harness - Electrical schematic frame 34 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1056
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Wiring harness - Electrical schematic frame 34 Wipers - ISO & NASO Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Wiring harness - Electrical schematic frame 35 Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058
Wiring harness - Electrical schematic frame 35 Wipers - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Wiring harness - Electrical schematic frame 36 Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Wiring harness - Electrical schematic frame 36 Wipers - LP Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060
Wiring harness - Electrical schematic frame 37 Mirror Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1062
Wiring harness - Electrical schematic frame 37 Processors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
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Wiring harness - Electrical schematic frame 38 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1064
Wiring harness - Electrical schematic frame 39 Air Con - Common . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Wiring harness - Electrical schematic frame 39 Processors 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066
Wiring harness - Electrical schematic frame 40 Air Con Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
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Wiring harness - Electrical schematic frame 40 Processors 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068
Wiring harness - Electrical schematic frame 41 Air Con 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1070
Wiring harness - Electrical schematic frame 41 Air Con Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Wiring harness - Electrical schematic frame 42 Air Con 2 - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1072
Wiring harness - Electrical schematic frame 43 Air Con 2 - Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1074
Wiring harness - Electrical schematic frame 44 Electronic Hydraulic Remotes . . . . . . . . . . . . . . . . . . . . . . . . . . 1076
Wiring harness - Electrical schematic frame 45 Armrest Control Unit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078
Wiring harness - Electrical schematic frame 48 Engine Harness Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 1084
Wiring harness - Electrical schematic frame 49 Electronic Front Hitch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1086
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Wiring harness - Electrical schematic frame 50 Electronic Front Hitch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088
Wiring harness - Electrical schematic frame 51 Turn Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1090
Wiring harness - Electrical schematic frame 52 Electrical Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1092
Wiring harness - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 972
Wiring harness - Overview Earth points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 988
MAXXUM 110 Multicontroller, MAXXUM 115 Multicontroller, MAXXUM 120 Multicontroller, MAXXUM 125 Multicontroller, MAXXUM
130 Multicontroller, MAXXUM 140 Multicontroller
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MAXXUM 110 Multicontroller [Z9BE40001 - ] , MAXXUM 110 Multicontroller

[Z9BE60001 - ] , MAXXUM 115 Multicontroller [Z9BE40001 - ] , MAXXUM 115
Multicontroller [Z9BE60001 - ] , MAXXUM 120 Multicontroller [Z9BE40001 - ] ,
[Z9BE40001 - ] , MAXXUM 125 Multicontroller [Z9BE60001 - ] , MAXXUM 130
Multicontroller [Z9BE40001 - ] , MAXXUM 130 Multicontroller [Z9BE60001 - ] ,
[Z9BE60001 - ]
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Contents

SYSTEMS - A
TECHNICAL DATA
Fuse and relay box

Alternator
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery
FUNCTIONAL DATA
Static description PROTECTING THE ELECTRONIC AND ELECTRICAL SYSTEMS DURING BATTERY
CHARGING OR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuse and relay box
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Alternator
Battery
Connector
Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102




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Wiring harness
Electrical symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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Electrical schematic frame 01 Power Distribution (Maxifuses 1 - 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Electrical schematic frame 02 Power Distribution (Fuses 1 - 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Electrical schematic frame 03 Power Distribution (Fuses 15 - 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322





Electrical schematic frame 08 Start / Charging (Starting & Charging W/Isolator) . . . . . . . . . . . . . . . . . . 332
Electrical schematic frame 09 Start / Charging (Starting & Charging without Isolator) . . . . . . . . . . . . . . 334
Electrical schematic frame 10 Engine Control Unit (Engine ECU 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

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Electrical schematic frame 11 Engine Control Unit (Engine ECU 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Electrical schematic frame 12 Power Distribution (Power Earthing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Electrical schematic frame 13 Transmission Controller (Transmission 1) . . . . . . . . . . . . . . . . . . . . . . . . . 342

Electrical schematic frame 14 Transmission Controller (Transmission 2) . . . . . . . . . . . . . . . . . . . . . . . . . 344

Electrical schematic frame 15 Transmission Controller (Electronic Draft Control) . . . . . . . . . . . . . . . . . . 346

Electrical schematic frame 16 Transmission Controller (5V Supply, Sensor Ground, Seat) . . . . . . . . . 348
Electrical schematic frame 17 Transmission Controller (Power Take Off) . . . . . . . . . . . . . . . . . . . . . . . . . 350

Electrical schematic frame 18 Auxiliary Control Unit (Suspention Front Axle, EHR’S, Link Levelling) . 352
Electrical schematic frame 19 Auxiliary Control Unit (Front Hitch, PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Electrical schematic frame 20 Fast Steer (Steering Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Electrical schematic frame 21 Lighting (Instrument Cluster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

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Electrical schematic frame 22 Instruments (Instrument Cluster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Electrical schematic frame 23 Electronic Control Unit 1 (Arm Rest) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Electrical schematic frame 24 Electronic Control Unit 2 (Arm Rest) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

Electrical schematic frame 25 Steering (Auto Guidance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Electrical schematic frame 26 Electronic Hydraulic Remotes (Power System) . . . . . . . . . . . . . . . . . . . . 368

Electrical schematic frame 27 Heating (Climate Control - Auto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Electrical schematic frame 28 Heating (Climate Control - Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Electrical schematic frame 29 Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Electrical schematic frame 30 Heating (Heated Screens) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

Electrical schematic frame 31 Cab Accessory (Implement Sockets, Cigar Lighter) . . . . . . . . . . . . . . . . 378
Electrical schematic frame 32 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

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Electrical schematic frame 33 Lighting Auxiliary (Worklamps/Beacons) . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Electrical schematic frame 34 Lighting (Side, Console & Licence Plate Lamps) . . . . . . . . . . . . . . . . . . . 384
Electrical schematic frame 37 Lighting (Headlamps/Worklamps Hood) . . . . . . . . . . . . . . . . . . . . . . . . . . 386

Electrical schematic frame 38 Lighting (Trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

Electrical schematic frame 39 Lighting (Interior Lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Electrical schematic frame 40 Lighting (Stop / Tail Lamps & Worklamps) . . . . . . . . . . . . . . . . . . . . . . . . . 392
Electrical schematic frame 41 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

Electrical schematic frame 42 Washers & Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

Electrical schematic frame 43 Colour Display (Instruments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Electrical schematic frame 44 Braking (Trailer Brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Electrical schematic frame 45 Braking (Electronic Park Lock Less) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

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Electrical schematic frame 46 Front Loader (Power System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Electrical schematic frame 47 Isobus (Isobus Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

Electrical schematic frame 48 Diagnostics (Sockets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Electrical schematic frame 49 CAN Bus 1 (Vehicle Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

Electrical schematic frame 50 EHR CAN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

Electrical schematic frame 51 EHR CAN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

Electrical schematic frame 52 CAN Bus 1 (Vehicle Bus - Mid Mounts) . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Electrical schematic frame 53 Can System (ISOBUS CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
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Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Battery
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
DIAGNOSTIC
Battery
Testing Charging Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Testing Open Circuit Voltage Test - State of Charge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Testing Specific Gravity - State of charge test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440

Testing Flat or discharged battery suspected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441

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Testing Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Testing Heavy Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442

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ELECTRICAL POWER SYSTEM - General specification

Description All Models

Alternator ISKRA, 12 V, 120 A (optional 150 A)
Battery Minimum maintenance 12 V 176 Ah (1300 cca)
Starting motor Positive engagement, solenoid operated

4.2 kW - geared reduction
Cold starting aid Optional inlet manifold grid heater ( 80 A) and fuel heater
Bulb rating and type

- headlights 60/55 W - H4
- parking lights (front) 5 W - R5 W
- parking lights (rear) 5 W - P 21/5 W
- work lights (hi-mount rear, on C-pillar and grabrail) 12 V 55 W - H3
- turn indicators (front) 21 W - PY21 W
- turn indicators (rear) 21 W - R21 W or PY21 W
- stop lights 21 W - P 21/5 W
- licence plate lights 5 W - R5 W
- rotating beacon 55 W - H1
- interior / step light 12 V R 10 W
- HID Xenon work lights rear roof HID DIS 12 V 35 W
- work lights hood 12 V 50 W - GE886
- SMV (slow moving vehicle) lights (N. America only) 21 W-P21 W
and extremity lights
- roof front work lights 12.8 V 50 W - GE885
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Fuse and relay box - General specification


Relay Function
K001 / K002 Wiper Module Front & Rear
K003 Ignition Relay
K004 Lights Relay
K005 Starter Motor On
K006 Blower motor
K007 Dipped Beam Headlamps
K008 Stop Lamps Relay
K009 Main Beam Headlamps
K010 Hydraulic Trailer Brake
K011 Electronic Park Brake
K012 Pneumatic Trailer Brake
K013 Engine Shutdown
K014 Get U Home
K015 Front Worklamps Hood
K016 Rear Worklamps C Pillar Relay
K017 Power Supply ECU
K018 EL.Battery Isolator
K019 Air Condition Clutch Relay
K020 El.Hydraulic Remote Lock Relay
K021 Timer Relay Battery Isolator
K022 Heated Mirror Timer Relay
Fuses
No. Amps Circuit
F001 10 Interior and step lighting and relay mirror heating
F002 25 Cigar lighter and power socket, cab (potential 30)
F003 10 Coupling of the A/C compressor
F004 10 Screw terminal red (potential 30)
F005 30 Blower motor
F006 10 Station memory and work lamp control unit
F007 20 Switch - Main headlights and hazard light switch
F008 20 Starter switch
F009 25 Front loader power
F010 30 Rear power socket (potential 15)
F011 15 Front windscreen wiper
F012 10 Rear windscreen wiper / switch, windscreen washing system, front/rear
F013 15 Relay, brake lights
F014 15 Headlight switch and flasher
F015 20 Brake light switch and pedal lock
F016 15 Trailer brake
F017 25 Power socket, cab (potential 15)
F018 15 Air blower motor relay and driver’s seat / Armrest adjust
F019 15 Heated mirrors
F020 10 Radar sensor, normal signal socket / keypad
F021 15 Water sensor for the fuel filter, brake fluid level switch
F022 15 Side marker lights, right
F023 15 Side marker lights, left / licence plate lights
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No. Amps Circuit

F024 10 Illumination - Lighting / cigar lighter - ICU - VT - heated mirror switch - EHR-lock
switch
F025 15 Dipped beam headlights relay, get you home
F026 15 Main beam headlights
F027 30 Front work lamp (bonnet)
F028 15 Work lamp control unit / Roof rear worklamps
F029 30 Work lamp control unit / Roof front worklamps + grabrail
F030 15 Work lamp (C-pillar)
F031 15 Rotating beacon (via work lamp control unit)
F032 15 Flasher unit
F033 25 Diagnostics plug 1/2
F034 10 ICU 3 and hand brake switch
F035 10 Potential 30 for electronics
F039 Not used
F040 10 Radio memory
F041 Not used
F042 Not used
F043 10 Engine electronics (potential 15)
F044 25 Front-mounted equipment socket (B+)
F045 25 Power supply - 8 A socket (potential 15) C-pillar left
F046 15 Engine controller B+ supply
F047 10 Engine controller B+ supply
F048 Not Used
F049 15 Viscotronic fan, relay heater grid, relay fuel filter heater, exhaust brake
F050 15 Reversible fan
F051 25 Electronic park brake
F052 10 ICU 3 supply
F053 15 Transmission control supply (potential 15)
F054 10 PTO rear
F055 10 Supply Ignition Fast Steer / GARU / A/C pressure switch / ACU / CCU
F056 15 PTO front
F057 15 Supply Ignition / ACU - Front hitch
F058 Not Used
F059 Not Used
F060 10 Timer relay battery isolator - battery isolator control switch
F061 10 Battery Isolator
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Maxi Fuses
No. Amps Fused components
MF1 80 Supply to F009, F013, F018, F021, F045, F050
MF3 80 Supply to V019, F030, K005, K013
MF4 80 Supply to F027, K015
MF5 80 Supply to F026, F031, F051
Diode
Diode Function
V001 Get you home
V002 Get you home
V003 Get you home
V004 Dipped Beam Headlamps Diode
V005 Brake Light Diode
V006 Brake Light Diode
V007 El. Battery Isolator Diode
SS09J050 1
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Relays outside of the relay box

K023 Grid Heater Relay
K024 Fuel Heater Relay
K040 ISO Relay 1 Rear
K041 ISO Relay 2 Rear
K042 ISO Relay 1 Front
K043 ISO Relay 2 Front
K047 Less EPL
K050 Relay Base Crank Isolate
K051 Relay Base Solenoid B
K052 Relay Base Solenoid A
K055 Front Loader 1
K056 Front Loader 2
SS09J054 2 SS09E024 3
SS09E031 4 SS09J053 5
Fuses for the electrical supply

Fuse No. Amps Fuse-protected power supply
PF1 250 Power Fuse, Main power supply B+ ( 250 A)
PF2 30 Power Fuse, Power Supply CCU
PF9 30 Power Fuse, Reserve
F70 10 Supply Memory
F71 10 Reserve
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SS09J051 6
Main current fuses for the ISO BUS power supply (if installed)
Fuse No. Amps Fuse-protected power supply
PF4 30 Power Fuse, ISO Bus Rear
PF5 30 Power Fuse, ISO Bus Rear
PF6 30 Power Fuse, ISO Bus Front
PF7 30 Power Fuse, ISO Bus Front
SS09J065 7
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Alternator - Torque
Value
Pulley Retaining Nut 80 Nm (59.0 lb ft)
Terminal Nut - B+ 12 Nm (8.9 lb ft)
Terminal Nut - D+ 3.5 Nm (2.6 lb ft)
Mounting Bolts 25 Nm (18.4 lb ft)
Alternator - General specification

Polarity Negative Ground

Nominal Voltage 14.0 V
Maximum Rev/Min. - Permanent/Intermittent 15,000/18,000
Nominal Output 120 A / 150 A
Regulator Controlled Voltage 14.1 V +/- 0.15
Rotor Field Winding Resistance 2.7 Ω +/- 0.27 @ 23 °C (73.4 °F) ± 5 °C (41.0 °F)
(at 120 A / 150 A)
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Battery - General specification

Description Battery Specification

Capacity (Ampere hour at 20 hour rate) 107 / 132
Cold Cranking Ampere Rating 800 / 960
Voltage 12
Cells 6
Ground Terminal Negative
Temperature Efficiency of a Fully Charged Battery

25 °C ( 77 °F) 100 %
-4.5 °C ( 23.9 °F) 82 %
-24.0 °C ( -11.2 °F) 64 %
-27.5 °C ( -17.5 °F) 58 %
-31.0 °C ( -23.8 °F) 50 %
-34.5 °C ( -30.1 °F) 40 %
-37.5 °C ( -35.5 °F) 33 %
107 Ah ( 800 cca) 132 Ah ( 960 cca)

Slow Charge Programs 25 hours at 5 A 30 hours at 5 A
12.5 hours at 10 A 15 hours at 10 A
Fast charge Program (emergencies only) 7 hours at 18 A 8.5 hours at 18 A
Use the following table to determine the state of charge

State of Charge Corrected Specific Gravity Corrected Specific Gravity Average Battery Next Testing Steps
@ 15 °C (59 °F) @ 25 °C (77 °F) Voltage
100 % 1.295 1.287 12.60 Proceed to Heavy
load test - see
Battery - Testing
(A.30.A).
75 % 1.253 1.246 12.40 Proceed to Heavy
load test Battery
- see Battery -
Testing (A.30.A).
50 % 1.217 1.210 12.20 Fully recharge
the battery before
performing heavy
load test.
25 % 1.177 1.170 12.00 Fully recharge
the battery before
performing heavy
load test. Refer to
table below.
Discharged 1.137 1.130 11.80 Battery discharged.
Slow recharge will
be required.
Specific Gravity Fast charge up to :

1.150 SG or less 60 minutes
1.151 - 1.175 SG 45 minutes
1.176 - 1.200 SG 30 minutes
1.201 - 1.225 SG 15 minutes
(Slow charge only)
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FAMM Battery Recharge Procedure (Voltage of a charged battery : 12.65 - 12.85 V)

V A h V
12.2 - 12.6 V 10 % of Nominal Ah 4 15.9 - 16.2 V
< 12.2 V 10 % of Nominal Ah 8 15.9 - 16.2 V
EXIDE Battery Recharge Procedure (Voltage of a charged battery : 12.65 - 12.85 V)

V A h V
12.45 - 12.65 V 10 % of Nominal Ah 6 14.7 - 14.8 V
12.2 - 12.44 V 10 % of Nominal Ah 8 14.7 - 14.8 V
< 12.2 V Sulphate crystals have been produced on electrodes - this requires the following
two separate charge sequences
First recharge sequence 1 24 14.7 - 14.8 V
Second recharge sequence 10 % of Nominal Ah 8 14.7 - 14.8 V
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ELECTRICAL POWER SYSTEM - Static description PROTECTING

THE ELECTRONIC AND ELECTRICAL SYSTEMS DURING BATTERY
CHARGING OR WELDING
Precautions
To avoid damage to the electronic/electrical systems, always observe the following:
1. Never make or break any of the charging circuit connections, including the battery connections, when the engine
is running.
2. Never short any of the charging components to earth.
3. Do not use a slave battery of higher than 12 V nominal voltage.
4. Always observe correct polarity when installing the batteries or using a slave battery to jump start the engine.
Follow the instructions in the operator’s manual when jump starting the tractor. Connect positive to positive and
negative to negative.
5. Always disconnect the earth cable from the batteries before carrying out arc welding on the tractor or on any
implement attached to the tractor.
6. Position the welder earth cable clamp as close to the welding area as possible.
7. If welding is to be carried out in close proximity to a computer module, then the module should be removed from
the tractor. It is recommended that this procedure be carried out by an authorised dealer.
8. Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding
is in progress.
9. Always disconnect the negative cable from the batteries when charging the batteries in the tractor with a battery
charger.
WARNING
Batteries contain sulphuric acid. In case of contact with skin, flush the affected area with water for five min-
utes. Seek medical attention immediately. Avoid contact with the skin, eyes or clothing. Wear eye protection
when working near batteries.
B040
NOTICE: Failure to disconnect the two earth cable connections at the battery prior to charging the batteries or welding
on the tractor or attached implement will result in damage to the electronic and electrical systems.
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Fuse and relay box - Static description

Fuses and Relays

NOTICE: Do not replace a blown fuse with another of a different rating.
The fuse box and relay box is located behind a panel at the right-hand side.
To check or change fuses or relays, remove the two screws securing the panel to the console.
In addition to the main fuses there are additional ’Maxi’ fuses which are provided to protect the main fuses and elec-
trical circuit.
There is provision for 60 fuses although they may not all be fitted, depending on the specification of the tractor. The
fuses are numbered and colour coded.
Refer to Fuse and relay box - General specification (A.30.A) for fuse positions and descriptions and for relay func-
tions.
SS09J050 1
The flasher relay unit (1), is located behind the right hand trim on the top of the fuse and relay box.
SS08H096 2
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Grid Heater relay (1), located to the rear of the left hand side of the engine.
BSE3115A 3
Grid Heater Fuse ( 125 A) (1), located on the right hand side of the engine near the starter motor.
BRI4561B 4
In addition to the fuses in the internal fuse box, there are also extra fuses located on the starter motor. A 250 A ’MEGA’
fuse (1) which protects the main electrical system and one 30 A fuse (2) which protect the front lift electrical system,
supply to the electronics system and implement ISO BUS circuit and battery isolator circuit (where fitted).
SS09J055 5
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Alternator - Static description

ISKRA 120 A (optional 150 A) alternators are fitted to all models. They incorporate internal cooling fans and integral
regulators. The alternator is mounted at the front on the right hand side of the engine and is driven from a crankshaft
pulley via a ‘poly vee’ drive belt.
BSE2983A 1
Alternator Operation
Refer to Wiring harness - Electrical schematic frame 08 Start / Charging (Starting & Charging W/Isolator)
(A.30.A) for charging circuit schematic.
When the key start switch is turned on a small current flows from the battery through the rotor field wiring. The circuit
is made via the charge indicator warning lamp, alternator terminal ‘D+’ the rotor field winding, the alternator regulator
and ground.
At this stage the warning light is illuminated and the rotor partially magnetised.
When the engine is started and the partially magnetised rotor revolves within the stator windings a 3-phase alternating
current is generated. A constant portion of the generated current is converted to direct current by the three field diodes
incorporated in the rectifier pack.
This direct current is fed back to supplement the current flowing through the rotor field winding.
This action results in an ever increasing magnetic influence of the rotor along with an associated rapid rise in gener-
ated output current and voltage.
During the rise in generated output voltage (reflected at the ‘D+’ terminal) the brilliance of the warning lamp is re-
duced and when the voltage at the ‘D+’ terminal equates to that at the battery side of the warning light the lamp is
extinguished.
The voltage continues to rise until the predetermined regulated voltage level is reached.
In the event of drive belt breakage the voltage will not build up within the alternator and so the charge indicator light
will remain on to indicate failure.
SS09G224 2
Alternator
1 Output Connection (B+ Terminal) 2 Warning Lamp (D+ terminal)
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Battery - Static description

All models use a single “low maintenance - hybrid" battery with negative ground of six cell construction and is located
on the right hand side of the tractor behind the cab steps.
NOTE: "Low maintenance" means that under normal charging conditions the battery may lose a small amount of
water from the electrolyte. Conditions that may cause water loss include prolonged charging above 14.4 volts where
gassing occurs as it approaches full charge. This can be caused by a faulty charging system or boost/recovery charg-
ing equipment.
The battery has four major functions:
• To provide a source of current for starting, lighting and instrumentation.

• To help control the voltage in the electrical system.
• To furnish current when the electrical demands exceed the alternator output.
• To support quiescent loads from radio and micro processor memory.
The battery is constructed in such a manner that each cell contains positive and negative plates placed alternatively
next to each other. Each positive plate is separated from a negative plate by a non-conducting porous envelope
separator. If any of the positive plates should make contact with negative plates within a cell, the cell will short circuit
and suffer irreparable damage. All of the positive plates are welded to a bus-bar, forming a positive terminal and all
of the negative plates are welded to a similar bus-bar forming a negative terminal.
Each positive plate is composed of a lead grid with lead peroxide pasted into the grid openings. The negative plates
are composed of a lead grid with spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.
Battery Identification
Two manufacturers of batteries (FAAM and EXIDE), are used in production and it is important before servicing the
battery that the manufacturer is identified to ensure the correct testing and charging procedures are followed.
The batteries can be identified by their unique part number, which is stamped into the casing or by the positioning of
the manufacturers date code.
FAAM Battery Identification
SS09J041 1 SS09J039 2
• 14L 9 203 (14L x yyy) Date Code

• 14L - Production plant
• x - Year
• yyy - Day progressive number
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EXIDE Battery Identification
SS09J035 3 SS09J040 4
• 9J CW33 (xy - zzzz) Date Code

• x - Year
• y- Month (B-Jan, C-Feb, D-Mar, E-Apr, F-May, G-Jun, H-Jul, J-Aug, K-Sep, L-Oct, M-Nov, A-Dec)
• zzzz - Production plant
Part number identification

Manufacturer Part Number
FAAM 87303728
FAAM Option 87319423
EXIDE 82027433
EXIDE Option 5199958
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Connector - Component Diagram 00

X001 CLUTCH SWITCH

1 1001AH (W) STARTER SOLENOID FEED
2 7425 (Y) DRIVE SIGNAL
4 1000B (W) SAFETY START SWITCH SUPPLY
SS08K077 1 SS08F146 2
STEERING CONSOLE
X002 CLUTCH POTENTIOMETER

1 7525A (G) TRANS SENSOR SUPPLY 5v
SS08K078 3 SS08F163 4
STEERING CONSOLE
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X003 STARTER SWITCH

1 150AE (N) BATTERY FEED (UNFUSED)(ALL)
2 137 (W) RADIO FEED
3 71 (W) IGNITION SWITCHED FEEDS (UNFUSED)
SS08K079 5 SS08F160 6
STEERING CONSOLE
X004 MAIN LIGHT SWITCH

1 150AA (N) BATTERY FEED (UNFUSED)(ALL)
2 1024 (R) RIGHT & LEFT HAND SIDELAMP FEED
3 1027D (U) HEADLAMP MAIN BEAM
4 1030C (U) HEADLAMP DIP BEAM
5 3000 (G) FLASHER UNIT SUPPLY (TERMINAL 49)
6 376 (P) HORN FEED
7 3001 (G) LEFT HAND FLASHER CIRCUIT
8 3002 (G) RIGHT HAND FLASHER CIRCUIT
SS08K080 7 SS08F161 8
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X005 INSTRUMENT CLUSTER UNIT CN1

1 3017 (G) EPB SYSTEM FAILURE WARNING LIGHT
8 7640Z (TN) DIAGNOSTIC PLUG RS232 IN
14 1052 (Y) GET U HOME LIGHTS RELAY
19 2014A (G) ENGINE OIL PRESSURE SENDER (+5 VOLT)
26 9031A (L) ADIC MEMORY B+
SS08K081 9 BRI4416B-02 10
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11 3062 (P) IMPLEMENT SOCKET SWITCH
14 2330 (P) PTO SPEED ISO11876 SKT.PIN#3
15 2320 (P) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
16 2300 (P) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
17 2310 (P) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
SS08K083 11 BRI4416B-03 12
X007 HAZARD SWITCH HARNESS

1 1021 (P) HAZARD SWITCH SUPPLY (BATTERY)
2 1020A (G) / 1020A (G/W) HAZARD SWITCH SUPPLY
4 1020 (G) / 1020 (G/S) HAZARD SWITCH SUPPLY
SS08K085 13 SS07K215 14
STEERING CONSOLE
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X008 KEY PAD

1 1050F (G) ACCESSORY FEED
2 5420H (G) CAN L
3 5400H (Y) CAN H
4 61H (B/O) CASE GROUND
SS08K086 15 SS08F193 16
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6 8020 (TN) TRAILER BRAKE PRESSURE
9 2087 (O) EXHAUST BRAKE SOLENOID
11 3052 (P) DOME LAMP TO DOOR SWITCH
21 7155 (U) VANE PUMP PRESSURE SENSOR SIGNAL
25 5420G (G) CAN L
26 5400G (Y) CAN H
SS08K087 17 BRI4416B-02 18
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Connector - Component diagram 01

X011 FRONT AND REAR WIPER SWITCH

1 1038A (TN) WINDSHIELD WIPER FEED-REAR
3 587 (LG) WINDSHIELD WIPER INTERMITTENT DELAY
7 1121 (G) RR WINDSHIELD WASH
9 97 (LG) WINDSHIELD WASHER FEED
SS08K089 1 BRI4410B 2
STEERING CONSOLE
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X012 SHUTTLE LEVER

4 7295 (W) DRIVE DISABLE SIGNAL
7 7425 (Y) DRIVE SIGNAL
8 57SS (B) EARTH (ALL)
9 3036 (O) EPB SHUTTLE PARK SWITCH INPUT
10 3039 (U) EPB SHUTTLE PARK SWITCH OUTPUT
11 7730 (TN) NOT IN PARKLOCK
13 1001AH (W) STARTER SOLENOID FEED
SS08K090 3 BRI4411B 4
STEERING CONSOLE
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X013 STOP LAMP SWITCH LEFT

4 820 (R) STOPLAMP SWITCH LH
SS08K091 5 SS08F146 6
X014 STOP LAMP SWITCH RIGHT

4 830 (R) STOPLAMP SWITCH RH
SS08K092 7 SS08F146 8
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X015 FOOT THROTTLE

4 6355B (R) +5V LOW POWER REFERENCE
SS08K093 9 SS08F242 10
BASE STEERING CONSOLE
X016 BRAKE PEDALS LATCHED SWITCH

1 10L (G) IGNITION SUPPLY
SS08K094 11 SS08H117 12
STEERING CONSOLE
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X018 REVERSE ALARM

1 57EJ (B) EARTH (ALL)
2 4022 (S) BACK-UP ALARM FEED
INA 13 SS08K508 14
STEERING CONSOLE
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X020 EXTENSION HARNESS CONNECTOR 2 (CAB)

1 29 (G) / 29 (GB) MAIN FUEL SENDER SIGNAL
3 1014E (R) LEFT HAND LAMPS
5 349 (TN) / 349 (G) TRAILER TURN LAMPS RH
6 350 (TN) / 350 (Y) TRAILER TURN LAMPS LH
7 7925 (P) / 8045 (P) TRANS REV SOL RET
8 3286 (TN) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
10 3281 (TN) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
11 2055 (W) PTO SYNCHRO GROUND SPEED ENGAGED
12 2095B (G) INSTRUMENT SIGNAL GROUND
15 7407 (K) / 8030 (LG) TRANS FWD SOLENIOD
17 9051 (P) / 9033 (N) 50KPH SOLENOID+
19 7408 (W) / 8035 (P) TRANS FWD SOL RET
20 8010A (TN) TRAILER BRAKE PRESSURE
28 3500 (W) / - POWER STEERING PRESSURE SIGNAL
29 3285 (TN) SUSPENSION LOCKOUT SOLENOID LOWER
30 5515 (S) EHR +12V IGN.
31 5500V (R) / 5500 (R) EHR CAN HIGH
32 5510V (U) / 5510 (U) EHR CAN LOW
33 4055 (W) / - LINK LEVEL TOP LINK EXTEND SOLENOID
34 4056 (W) / - LINK LEVEL TOP LINK RETRACT SOLENOID
35 4057 (W) / - LINK LEVEL RIGHT LINK RAISE SOLENOID
36 4058 (W) / - LINK LEVEL RIGHT LINK LOWER SOLENOID
37 9050 (P) / 9034 (N) 50KPH SOLENOID-
38 4054 (W) / - LINK LEVEL DUMP SOLENOID
39 5830 (R) / - HIGH FLOW PUMP LINK
40 8050 (R) / 7230 (S) TRANSMISSION LOW RANGE
41 7770 (U) / 7220 (S) TRANSMISSION HIGH RANGE
42 7022 (S) / 4022 (S) BACK-UP ALARM FEED
44 8000B (N) / - TRAILER BRAKE SOLENOID
45 7582 (U) / - CREEPER RAIL SWITCH NOT
46 7411 (Y) / 2016A (Y) REAR AXLE SPEED SENSOR-SIGNAL
47 7970 (P) / 7960 (P) TRANS SLOW/FAST
49 8070 (L) / 8070 (P) TRAILER PARK BRAKE SOLENOID
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50 2250N (K) / - TRANS OIL PRESSURE WARNING LAMP
SS08K095 1 BRI4400B-03 2
X021 MAIN POWER (FUSE) 1 POWER B+

SS08K096 3 SS07K143 4
X022 EXTENSION HARNESS CONNECTOR 1 (ELECTRONIC)

2 7584 (U / 7581 (O)) CREEPER POSITION SIGNAL
9 7910 (TQ) / 7840 (K) TRANS PWM SOLENOID C4
10 7935 (P) / 7301 (Y) SOLENOID 1 18x9 RETURN
11 7401 (P) TRANS RPM SPEED SENSOR
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12 7400 (Y) / - TRANS RPM SPEED SENSOR TO TCM INPUT
13 7155 (U) / - VANE PUMP PRESSURE SENSOR SIGNAL
14 7930 (TQ) / 7300 (W) SOLENOID 1 18x9 TRANSMISSION
15 7940 (TQ) / 7320 (W) SOLENOID 2 18x9 TRANSMISSION
16 7960 (W) / 7670 (R) TRANS FRONT SYNCHRO POSITION
17 7431 (TQ) / 7830 (K) TRANS PWM SOLENOID C3
18 7915 (P) / 7845 (K) TRANS PWM SOLENOID C4 RETURN
19 7000P (U) / 7000J (U) TRANS CONTROL SUPPLY
20 7945 (P) / 7321 (P) SOLENOID 2 18x9 RETURN
21 9036 (TN) / 7006 (R) 50KPH DUMP SOLENOID RETURN
22 7225 (W) / 7815 (K) TRANS PWM SOLENOID C1 RETURN
23 8045 (P) / 7825 (K) TRANS PWM SOLENOID C2 RETURN
24 7985 (G) / 7820 (K) TRANS PWM SOLENOID C2
25 3295 (O) / - FRONT SUSPENSION PRESSURE SWITCH SIGNAL
26 7235 (Y) / - TRANS LOW RANGE SOL - RET
27 7785 (O) / - CREEPER POSITION SIGNAL
28 7760 (W) / 6000 (K) ENGINE SPEED SIGNAL
29 9035 (TN) / 7005 (U) TRANS CREEPER GR SOL
30 7586 (U) / - BRAKE LUBRICATION SOLENOID
36 5070 (TN) EDC LEFT PIN
38 5065 (TN) EDC RIGHT PIN
39 9033 (TN) / 9035 (N) 50KPH DUMP SOLENOID
40 9034 (TN) / 9036 (N) 50KPH DUMP SOLENOID RETURN
41 2014B (G) / - ENGINE OIL PRESSURE SENDER (+5 VOLT)
42 7220 (S) / 7810 (K) TRANS PWM SOLENOID C1
43 7230 (S) / - TRANSMISSION LOW RANGE
44 7900 (TQ) / 7835 (K) TRANS PWM SOLENOID C3 RETURN
45 7775 (K) / - B CLUTCH PRESSURE SIGNAL
47 5020A (TN) / 7525B (G) TRANS SENSOR SUPPLY 5v
48 7920 (TQ) / 8040 (G) TRANS REV SOLENIOD
49 2050L (G) / 2050 (G) PTO SUPPLY / DOG SUPPLY
50 9000 (N) / - DIVERTER VALVE
51 7589 (U) / - BRAKE PRESSURE SIGNAL
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SS08K097 5 BRI4400B-03 6
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X023 MAIN POWER (FUSE) 2 POWER E

2 1C (R) / 1D (R) BATTERY SUPPLY
SS08K098 7 SS07K144 8
X024 CAB TO ENGINE MAIN CONNECTOR E2

3 3235 (O) / - ACCELEROMETER SIGNAL
4 2590 (TN) EXTERNAL SWITCH FHPL UP
5 2591 (TN) EXTERNAL SWITCH FHPL DOWN
6 5920F (R) / 5920B (R) ISO BUS CAN SUPPLY POSITIVE
7 5910F (G) / 5900B (G) ISO BUS CAN SIGNAL LOW
8 5915F (B) / 5915B (B) ISO BUS CAN SUPPLY GROUND
9 5900F (Y) / 5910B (B) ISO BUS CAN SIGNAL HIGH
10 5970A (O) ISO BUS ECU SIGNAL
11 5980 (O) ISO BUS IMPLEMENT SIGNAL
20 60AA (B/W) / 60AC (B/W) SENSOR GROUND
22 2530 (N) / 2530 (S) FRONT HITCH V REF
26 3220 (LG) / 5520 (LG) EHR 5V Ref
32 - / 2260 (O) PTO FRONT - SPEED SIGNAL
34 1010C (G) / 1010 (G) IGNITION RELAY (COIL)
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46 2250L (K) / 2250 (K) PTO FRONT - SUPPLY
47 3070D (P) / - ’B’ PILLAR SKT SUPPLY
48 9032B (Y) / - IGN+ TO POWER SKT
49 172B (W) / 172A (W) BATTERY ISOLATOR RELAY COIL (OFF)
SS08K099 9 BRI4400B-03 10
X025 MAIN POWER (FUSE) 3 POWER B

SS08K100 11 SS07K143 12
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X026 MAIN HARNESS CONNECTOR - E1 - ENIGNE TO CAB

1 5400BJ (Y) / 5400D (Y) CAN H
2 5420BJ (G) / 5420D (G) CAN L
12 6315 (N) REVERSIBLE FAN OPTION - RELAY CONTROL
14 6408D (O) / 6408D (G) FUSED B+ TO ECU (1)
15 6408N (G) / 6408M (G) FUSED B+ TO ECU (1)
22 - / 2040 (LG) WATER IN FUEL SENSOR
25 10J (G) / 10G (G) IGNITION SUPPLY
26 1030BB (U) / 1030B (U) HEADLAMP DIP BEAM
29 1073A (P) WORKLAMP FRONT FEED
30 376 (P) HORN FEED
36 1027BB (U) / 1027B (U) HEADLAMP MAIN BEAM
37 1027E (U) / 1027A (U) HEADLAMP MAIN BEAM
38 2095A (G) / 2095 (G) INSTRUMENT SIGNAL GROUND
41 1006A (N) / 1006 (N) ALTERNATOR WARNING LAMP
43 71D (W) / 71C (W) IGNITION SWITCHED FEEDS (UNFUSED)
47 2050AF (G) / - PTO SUPPLY / DOG SUPPLY
48 6300 (N) / - FAN SPEED
49 5020H (TN) / - EDC PROC +5V REF VOLTAGE DROP POSN/RATE
51 6408F (G) / 6408N (G) FUSED B+ TO ECU (1)
SS08K101 13 BRI4400B-03 14
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X028 DIAGNOSTIC CONNECTOR 2

A 57RG (B) EARTH (ALL)
B 6408N (G) FUSED B+ TO ECU (1)
C 5500E (R) EHR CAN HIGH
D 5510E (U) EHR CAN LOW
F 5960C (W) RS232 OUTPUT TECU
G 5955D (G) RS232 INPUT TECU
SS08K102 15 SS08H181 16
CAB RIGHT HAND BEHIND OPERATOR’S SEAT
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X030 DIAGNOSTIC CONNECTOR

A 57AL (B) EARTH (ALL)
B 6408E (G) FUSED B+ TO ECU (1)
C 5400E (Y) CAN H
D 5420E (G) CAN L
E 6418 (K) ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO K
G 2200Z (G) SERVICE MODE INITIATE
H 5910B (Y) ISO BUS CAN SIGNAL HIGH
J 5900B (G) ISO BUS CAN SIGNAL LOW
SS08K103 1 SS08H181 2
X030A EARTH HEADER 2

X 57BU (B) EARTH (ALL)
SS08K104 3 BRI4404B 4
BEHIND RIGHT HAND TRIM
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X030B EARTH HEADER 2

X 57XX (B) EARTH (ALL)
SS08K105 5 BRI4404B 6
X030C EARTH HEADER 2

X 57BB (B) EARTH (ALL)
SS08K106 7 BRI4404B 8
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X031 ADIC DIAGNOSTIC CONNECTOR

2 7640Z (TN) DIAGNOSTIC PLUG RS232 IN
3 57BT (B) EARTH (ALL)
SS08K107 9 SS08F181 10
X032 TIMER RELAY FOR BATTERY ISOLATOR AND HEATED MIRROR

1 666C (P) DOMELAMP SWITCH FEED
4 57HM (B) EARTH (ALL)
5 1927 (R) MIRROR ILLUMINATION
6 1L (R) BATTERY SUPPLY
7 172 (W) BATTERY ISOLATOR RELAY COIL (OFF)
9 57SL (B) EARTH (ALL)
SS08K108 11 SS08M012 12
FRONT RIGHT HAND CAB
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X 57 (B) EARTH (ALL)
SS08K109 13 BRI4474B 14

X 57CR (B) EARTH (ALL)
SS08K110 15 BRI4404B 16
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X033 WINDSCREEN WIPERS FRONT & REAR (K001 / K002)

1 1120 (G) RR WINDSHIELD WIPER PARK RETURN
2 1121B (G) RR WINDSHIELD WASH
6 28 (Y) WIPER MOTOR (PARK RETURN)
7 587 (LG) WINDSHIELD WIPER INTERMITTENT DELAY
8 1019B (G) WINDSHIELD WIPER FEED
9 57J (B) EARTH (ALL)
SS08K111 17 SS08M012 18
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X034 IGNITION / LIGHTS RELAY (K003 / K004)

A30 150E (N) BATTERY FEED (UNFUSED)(ALL)
A85 57AG (B) EARTH (ALL)
A86 1010A (G) IGNITION RELAY (COIL)
A87 1011 (Y) SUPPLY TO FUSES
B30 1023 (N) LIGHT SWITCH FEED
B85 57BC (B) EARTH (ALL)
B86 1024 (R) RIGHT & LEFT HAND SIDELAMP FEED
B87 1023A (N) LIGHT SWITCH FEED
SS08K112 19 SS08M019 20
X035 STARTER MOTOR ON / BLOWER MOTOR RELAY (K005 / K006)

A30 150W (N) BATTERY FEED (UNFUSED)(ALL)
A85 57AC (B) EARTH (ALL)
A86 1001L (W) STARTER SOLENOID FEED
A87 1001Y (W) STARTER SOLENOID FEED
B30 982 (G) BLOWER MOTOR FEED
B85 57CJ (B) EARTH (ALL)
B86 181J (G) BLOWER MOTOR FEED
B87 982A (G) BLOWER MOTOR FEED
SS08K113 21 SS08M019 22

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X036 CONTROL RELAYS (K007 / K012)

A1 825 (Y) PNEUMATIC TRAILER SOLENOID +12V
A2 57CZ (B) EARTH (ALL)
A3 10E (G) IGNITION SUPPLY
A5 8000X (N) TRAILER BRAKE SOLENOID
B1 57SZ (B) EARTH (ALL)
B2 3150A (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
B3 8060B (U) TRAILER BRAKE SUPPLY
B4 8000B (N) TRAILER BRAKE SOLENOID
B5 8070 (P) TRAILER PARK BRAKE SOLENOID
C1 8010A (TN) TRAILER BRAKE PRESSURE
C2 57BM (B) EARTH (ALL)
C3 8060A (U) TRAILER BRAKE SUPPLY
C5 8000C (N) TRAILER BRAKE SOLENOID
D1 1027C (U) HEADLAMP MAIN BEAM
D2 57BA (B) EARTH (ALL)
D3 1027 (U) HEADLAMP MAIN BEAM
D5 1027B (U) HEADLAMP MAIN BEAM
E1 840B (G) R & L STOPLAMP SIGNAL
E2 57BJ (B) EARTH (ALL)
E3 810 (G) STOPLAMPS
E5 810D (G) STOPLAMPS
F1 1030AE (U) HEADLAMP DIP BEAM
F2 57AZ (B) EARTH (ALL)
F3 1030AA (U) HEADLAMP DIP BEAM
F5 1030B (U) HEADLAMP DIP BEAM
SS08K114 23 SS08M006 24
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X037 ENGINE SHUTDOWN / GET U HOME RELAY (K013 / K014)

A30 6413B (O) ENGINE SHUTDOWN RELAY SUPPLY
A85 6407 (O) ENGINE SHUTDOWN SIGNAL (EDC16)
A86 150AP (N) BATTERY FEED (UNFUSED)(ALL)
A87 150AN (N) BATTERY FEED (UNFUSED)(ALL)
B30 1024 (R) RIGHT & LEFT HAND SIDELAMP FEED
B85 1052 (Y) GET U HOME LIGHTS RELAY
B86 1030AC (U) HEADLAMP DIP BEAM
B87 1030AB (U) HEADLAMP DIP BEAM
SS08K115 25 SS08M019 26
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X053 FLASHER ECU

A2 249 (LG) SMV LAMPS RH
A3 349 (TN) TRAILER TURN LAMPS RH
A4 250 (LG) SMV LAMPS LH
A5 350 (TN) TRAILER TURN LAMPS LH
A7 1034 (LG) TURN SIGNAL WARNING LAMP (TERM C3
B5 1033 (LG) TURN SIGNAL WARNING LAMP (TERM C2)
C1 49A (G) RIGHT HAND TURN SIGNAL
C2 50A (G) LEFT HAND TURN SIGNAL
C3 1039 (LG) NASO LIGHTS INPUT
SS08K117 1 SS08F179 2
BEHIND RIGHT HAND TRIM TOP THE FUSEBOX
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X059A LEVER MOUNTED PTO BRAKE SWITCH

2 2120 (TN) PTO BRAKE SIGNAL
4 2120A (TN) PTO BRAKE SIGNAL
SS08K118 3 SS07K157 4
BEHIND RIGHT HAND SWITCH PANEL
X059B LEVER MOUNTED PTO MATING HALF

2 2120B (TN) PTO BRAKE SIGNAL
4 2120B (TN) PTO BRAKE SIGNAL
SS08K119 5 SS07K157 6
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X060 FUSE BOX MAIN B+ FEED

SS08M135 1 BRI4474B 2
BEHIND RIGHT HAND FUSEBOX
X067 REAR PTO BRAKE SWITCH

1 2120A (TN) PTO BRAKE SIGNAL
SS08K121 3 SS07E264 4
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X070 MAXI - FUSE MODULE MF1 TO MF6

M1 150E (N) BATTERY FEED (UNFUSED)(ALL)
M2 150V (N) BATTERY FEED (UNFUSED)(ALL)
M3 150AF (N) BATTERY FEED (UNFUSED)(ALL)
M4 150Y (N) BATTERY FEED (UNFUSED)(ALL)
M5 150G (N) BATTERY FEED (UNFUSED)(ALL)
M6 150F (N) BATTERY FEED (UNFUSED)(ALL)
SS08K122 1 SS08M007 2
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X071 MINI FUSE MODULE F041 TO F060

3A 71 (W) IGNITION SWITCHED FEEDS (UNFUSED)
3B 71D (W) IGNITION SWITCHED FEEDS (UNFUSED)
4A 3070D (P) ’B’ PILLAR SKT SUPPLY
4B 150AJ (N) BATTERY FEED (UNFUSED)(ALL)
5A 9032C (Y) IGN+ TO POWER SKT.
5B 1011E (Y) SUPPLY TO FUSES
6A 6408K (G) FUSED B+ TO ECU (1)
7A 6408A (G) FUSED B+ TO ECU (1)
9A 6408D (O) FUSED B+ TO ECU (1)
10A 6325 (N) REVERSIBLE FAN OPTION - RELAY FEED
10B 1011K (Y) SUPPLY TO FUSES
11A 3031 (N) EPB +12 HOT
11B 150BC (N) BATTERY FEED (UNFUSED)(ALL)
12A 160R (Y) BATTERY SUPPLY ELECTRONICS
13A 7000 (U) TRANS CONTROL SUPPLY
14A 2050 (G) PTO SUPPLY / DOG SUPPLY
14B 160C (U) BATTERY SUPPLY ELECTRONICS
15A 5200 (N) EDC VALVE SUPPLY
16A 2250 (K) PTO FRONT - SUPPLY
17A 2540 (N) FRONT HITCH +12v IGN
20A 1H (R) BATTERY SUPPLY
20B 1E (R) BATTERY SUPPLY
SS08K123 3 SS08M008 4
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1A 10J (G) IGNITION SUPPLY
1B 1011D (Y) SUPPLY TO FUSES
2A 1013 (R) RIGHT HAND LAMPS
3A 1014 (R) LEFT HAND LAMPS
3B 1023A (N) LIGHT SWITCH FEED
4A 1012 (R) ILLUMINATION
5A 1030 (U) HEADLAMP DIP BEAM
5B 1023 (N) LIGHT SWITCH FEED
6A 1027 (U) HEADLAMP MAIN BEAM
6B 150T (N) BATTERY FEED (UNFUSED)(ALL)
7A 1073 (P) WORKLAMP FRONT FEED
7B 150P (N) BATTERY FEED (UNFUSED)(ALL)
8A 998D (G) WORK LAMP-REAR FEED (INNER)
9A 1071 (P) WORKLAMP FRONT FEED
10A 998C (G) WORK LAMP-REAR FEED (INNER)
10B 150AB (N) BATTERY FEED (UNFUSED)(ALL)
11A 4011 (P) ROTATING BEACON SWITCH SUPPLY
11B 150BA (N) BATTERY FEED (UNFUSED)(ALL)
12A 3009 (G) FLASHER UNIT SUPPLY B+
13A 6408 (G) FUSED B+ TO ECU (1)
14A 9031 (P) ADIC MEMORY B+
14B 150AG (N) BATTERY FEED (UNFUSED)(ALL)
15A 5000 (P) EDC MEMORY POWER
16A 1072A (P) WORKLAMP FRONT RELAY SUPPLY
17A 1072B (P) WORKLAMP FRONT RELAY SUPPLY
17B 150JA (N) BATTERY FEED (UNFUSED)(ALL)
18A 1099 (R) FEED FRONT WORKLAMP INNER
20A 3079 (R) RADIO +12V IGNITION
20B 137 (W) RADIO FEED
SS08K124 5 SS08M008 6
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1A 666 (P) DOMELAMP SWITCH FEED
1B 150AC (N) BATTERY FEED (UNFUSED)(ALL)
2A 150 (N) BATTERY FEED (ALL)
3A 981 (G) A/C CLUTCH RELAY FEED
4A 3070A (P) ’B’ PILLAR SKT SUPPLY
5A 982 (G) BLOWER MOTOR FEED
5B 150AD (N) BATTERY FEED (UNFUSED)(ALL)
6A 138A (P) RADIO KAM
7A 150B (N) BATTERY FEED (UNFUSED)(ALL)
7B 150J (N) BATTERY FEED (UNFUSED)(ALL)
8A 150AE (N) BATTERY FEED (UNFUSED)(ALL)
9A 3271A (O) LOADER RELAY FEED
9B 1011A (Y) SUPPLY TO FUSES
10A 9032D (Y) IGN.+ TO POWER SKT.
11A 1019 (G) WINDSHIELD WIPER FEED
12A 1038 (TN) WINDSHIELD WIPER FEED-REAR
13A 810 (G) STOPLAMPS
13B 1011B (Y) SUPPLY TO FUSES
14A 3000A (G) FLASHER UNIT SUPPLY (TERMINAL 49)
15A 10 (G) IGNITION SUPPLY
16A 8060 (U) TRAILER BRAKE SUPPLY
17A 9032 (Y) IGN+ TO POWER SKT.
18A 181A (G) BLOWER MOTOR FEED
18B 1011C (Y) SUPPLY TO FUSES
19A 1925 (R) MIRROR CONTROL +12V
20A 1050 (G) BLOWER MOTOR FEED
SS08K125 7 SS08M008 8
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X074 RELAY MODULE (K015 - K020)

A1 5597A (S) EHR MASTER ENABLE
A2 57GH (B) EARTH (ALL)
A3 2250F (K) PTO FRONT - SUPPLY
A5 5515 (S) EHR +12V IGN.
B1 2005 (O) AIR CON CLUTCH RELAY
B2 57CK (B) EARTH (ALL)
B3 981 (G) A/C CLUTCH RELAY FEED
B5 1018 (LG) AIR CONDITIONER CLUTCH
C1 173A (W) BATTERY ISOLATOR RELAY COIL +12V
C2 57CC (B) EARTH (ALL)
C3 172A (W) BATTERY ISOLATOR RELAY COIL (OFF)
C4 172B (W) BATTERY ISOLATOR RELAY COIL (OFF)
D1 1010B (G) IGNITION RELAY (COIL)
D2 57AF (B) EARTH (ALL)
D3 160 (U) BATTERY SUPPLY ELECTRONICS
D5 160C (U) BATTERY SUPPLY ELECTRONICS
E1 1090 (R) REAR WORKLAMP RELAY SIGNAL
E2 57AS (B) EARTH (ALL)
E3 998C (G) WORK LAMP-REAR FEED (INNER)
E5 998 (G) WORK LAMP-REAR FEED (INNER)
F1 1092 (R) FRONT WORKLAMP RELAY SIGNAL
F2 57AR (B) EARTH (ALL)
F3 1073 (P) WORKLAMP FRONT FEED
F5 1073A (P) WORKLAMP FRONT FEED
SS08K126 9 SS08M006 10
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X076 DIODE BLOCK

1A 1013AG (R) RIGHT HAND LAMPS
1B 1024A (R) RIGHT & LEFT HAND SIDELAMP FEED
2A 1013AF (R) RIGHT HAND LAMPS
2B 1013AE (R) RIGHT HAND LAMPS
3A 1030AD (U) HEADLAMP DIP BEAM
3B 1024B (R) RIGHT & LEFT HAND SIDELAMP FEED
4A 1030AF (U) HEADLAMP DIP BEAM
4B 1030C (U) HEADLAMP DIP BEAM
5A 825B (Y) PNEUMATIC TRAILER SOLENOID +12V
5B 830A (R) STOPLAMP SWITCH RH
6A 825A (Y) PNEUMATIC TRAILER SOLENOID +12V
6B 820A (R) STOPLAMP SWITCH LH
7A 171A (W) BATTERY ISOLATOR RELAY COIL
7B 1000A (W) SAFETY START SWITCH SUPPLY
10A 1030AJ (U) HEADLAMP DIP BEAM
10B 1027AA (U) HEADLAMP MAIN BEAM
19A 150AH (N) BATTERY FEED (UNFUSED)(ALL)
19B 150AM (N) BATTERY FEED (UNFUSED)(ALL)
20A 150AI (N) BATTERY FEED (UNFUSED)(ALL)
20B 1D (R) BATTERY SUPPLY
SS08K127 11 SS08M010 12
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X080 ARMREST 1

A1 5200AT (N) EDC VALVE SUPPLY
A2 5400D (Y) CAN H
A3 5420D (G) CAN L
A4 5500W (R) / 5500B (R) EHR CAN HIGH
A5 5510W (U) / 5510B (U) EHR CAN LOW
A6 5955C (G) RS232 INPUT TECU
A7 5960E (W) / 5960C (W) RS232 OUTPUT TECU
A8 2250S (K) PTO FRONT - SUPPLY
B1 7000BM (U) TRANS CONTROL SUPPLY
B2 2045 (O) PTO SWITCH TO MODULE
B3 2046 (O) PTO SWITCH (VCC)
B4 2248 (K) PTO FRONT - SWITCH (VCCS)
B5 2245 (K) PTO FRONT - SWITCH TO MODULE
B6 2065 (N) PTO ENGAGED
B7 2270 (O) PTO FRONT - WARNING LAMP
B8 57RE (B) EARTH (ALL)
C2 5915 (B) EDC VALVE SUPPLY
C3 5900 (G) ISO BUS CAN SIGNAL LOW
C4 5910 (Y) ISO BUS CAN SIGNAL HIGH
C5 5920 (R) ISO BUS CAN SUPPLY POSITIVE
C8 57RF (B) EARTH (ALL)
SS08K128 1 SS08F314 2
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X081 SEAT CONNECTOR

1 6355A (R) +5V LOW POWER REFERENCE
2 7245 (P) DEADMAN
3 181K (G) BLOWER MOTOR FEED
4 57CN (B) EARTH (ALL)
SS08K129 3 SS08F193 4
IN CAB RIGHT OF OPERATOR’S SEAT
X082 LOADER POWER

1 3271A (O) / 3271 (U) LOADER RELAY FEED
2 57FP (B) EARTH (ALL)
SS08K130 5 SS08F267 6
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X084 LOADER VALVE 2

1 3274 (R) / 3279 (Y) LOADER VALVE #2 OUT
2 3275 (R) / - LOADER VALVE #2 RETURN
SS08K131 7 SS08M031 8
X085 LOADER VALVE 1

1 3272 (O) / 3272C (O) LOADER VALVE #1 OUT
2 3273 (O) / 3273C (O) LOADER VALVE #1 RETURN
SS08K132 9 SS08M031 10
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1 57CG (B) EARTH (ALL)
SS08K133 11 BRI4404B 12

1 57CH (B) EARTH (ALL)
SS08K134 13 BRI4404B 14
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X086C EARTH HEADER 1

1 57BH (B),57RD (B) EARTH (ALL)
SS08K135 15 BRI4404B 16
X086D EARTH HEADER 1

1 57CF (B) EARTH (ALL)
SS08K136 17 BRI4474B 18
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X088 ARMREST 2

A1 181L (G) / 181P (G) BLOWER MOTOR FEED
A2 5400BJ (Y) / 5400H (Y) CAN H
A3 5420BJ (G) / 5420H (G) CAN L
A4 5500V (R) / 5500D (R) EHR CAN HIGH
A5 5510V (U) / 5510D (U) EHR CAN LOW
B2 9000 (N) / 9000A (N) DIVERTER VALVE
C2 5915F (B) EDC VALVE SUPPLY
C3 5900F (G) ISO BUS CAN SIGNAL LOW
C4 5910F (Y) ISO BUS CAN SIGNAL HIGH
C5 5920F (R) ISO BUS CAN SUPPLY POSITIVE
SS08K137 19 SS08F314 20
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X091 CCM CENTRAL CONTROL UNIT (CN2)

1 7915 (P) TCM CLUTCH B RETURN
2 7225 (W) TRANS HI RANGE SOL - RET
3 7935 (P) TCM CLUTCH D RETURN
6 7925 (P) TCM CLUTCH C RETURN
7 7408 (W) HYDROSTAT 1 SOLENOID GND
8 7900 (TQ) CLUTCH ’A’ SIGNAL
13 9050 (P) CN1a 92 -10
15 2151 (K) EPTO DRIVE RELAY UPPER SPEED
17 2152 (K) ESPTO DRIVE RELAY LOWER SPEED
18 7022 (S) REVERSE ALARM GROUND SIGNAL
23 6355 (R) +5V LOW POWER REFERENCE
24 6315 (N) REVERSIBLE FAN OPTION - RELAY CONTROL
SS08K139 1 BRI4416B-02 2
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X092 CCM CENTRAL CONTROL UNIT (CN1a)

4 7431 (TQ) SUPPLY
6 7920 (TQ) CLUTCH ’C’ SIGNAL
7 7930 (TQ) CLUTCH ’D’ SIGNAL
10 9051 (P) CN2 98 -13
11 7910 (TQ) CLUTCH ’B’ SIGNAL
13 7407 (K) HYDROSTAT 1 SOLENOID +
14 5000A (P) EDC MEMORY POWER
15 5400T (Y) CAN H
16 5420T (G) CAN L
SS08K140 3 BRI4416B-02 4
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X093 CCM CENTRAL CONTROL UNIT (CN1b)

11 2050K (G) PTO SUPPLY / DOG SUPPLY
16 5020 (TN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
22 820B (R) STOPLAMP SWITCH LH
23 830B (R) STOPLAMP SWITCH RH
24 2250N (K) PTO FRONT - SUPPLY
SS08K141 5 BRI4420B 6
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X094 CCM CENTRAL CONTROL UNIT (CN3a)

1 7589 (U) BRAKE PRESSURE SIGNAL
2 7970 (P) TRANS MED/REV
8 7775 (K) B CLUTCH PRESSURE SIGNAL
9 7785 (O) A CLUTCH PRESSURE SIGNAL
10 7584 (U) PARKLOCK SENSOR SWITCH SIGNAL
15 1039 (LG) NASO LIGHTS INPUT
17 5210 (O) EDC VALVE ENABLE
20 2159 (U) PTO UPPER SPEED
SS08K142 7 BRI4416B-02 8
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X095 CCM CENTRAL CONTROL UNIT (CN3b)

1 7945 (P) TCM CLUTCH E RETURN
2 9036 (TN) 50KPH DUMP SOLENOID RETURN
3 7235 (Y) TRANS LOW RANGE SOL - RET
5 9035 (TN) 50KPH DUMP SOLENOID
6 9033 (TN) 50KPH SOLENOID+
7 7985 (G) TRANS REVERSE RANGE
10 9034 (TN) 50KPH SOLENOID-
12 7586 (U) PARKLOCK SOLENOID
13 7940 (TQ) CLUTCH ’E’ SIGNAL
19 7411 (Y) TRANS HYDROSTAT INPUT SPEED SENSOR (CVT)
20 7400 (Y) TRANS RPM SPEED SENSOR TO TCM INPUT
22 7760 (W) TORQUE SENSOR
24 2120 (TN) PTO BRAKE SIGNAL
26 7295 (W) DRIVE DISABLE SIGNAL
SS08K143 9 BRI4420B 10
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X096 CASE EARTH CCM & ACU

1 61,61A,61G (B,B/O,B) CASE GROUND
SS08K144 11 BRI4404B 12
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X097 CCM CENTRAL CONTROL UNIT (CN4)

2 3274A (R) LOADER VALVE #2 OUT
3 7275A (R) TCM SERIAL DATA OUT-DISPLY DATA IN
4 2157 (U) ESPTO NEUTRAL
7 2155 (N) ESPTO ACTUATOR POWER +12V
8 2156 (N) ESPTO ACTUATOR POS SIGNAL
9 7245 (P) DEADMAN
10 3014C (R) HANDBRAKE WARNING LAMP SIGNAL
11 7770 (U) TRANS FORWARD PRESSURE SWITCH
12 2153 (R) ESPTO ACTUATOR UPPER SPEED
14 7960 (W) TRANS SLOW/FAST
16 7730 (TN) NOT IN PARKLOCK
17 8050 (R) TRANS REV PRESSURE
18 2158 (U) ESPTO LOWER SPEED
21 5830 (R) HIGH FLOW PUMP LINK
23 2154 (N) ESPTO ACTUATOR LOWER SPEED
26 3155A (N) HANDBRAKE TRANS INTERLOCK
SS08K145 13 BRI4416B-02 14
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X098 ACU AUXILIARY CONTROL UNIT (CN2)

3 3286 (TN) SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
6 3281 (TN) SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
SS08K146 15 BRI4416B-02 16
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X099 ACU AUXILIARY CONTROL UNIT (CN1a)

7 3285 (TN) SUSPENSION LOCKOUT SOLENOID LOWER
8 2250K (K) PTO FRONT - SUPPLY
14 5000B (P) EDC MEMORY POWER
15 5400S (Y) CAN H
16 5420S (G) CAN L
20 5200N (N) EDC VALVE SUPPLY
SS08K147 17 BRI4416B-02 18
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X100 ACU AUXILIARY CONTROL UNIT (CN1b)

17 3220 (LG) AXLE HEIGHT SENSOR 5V REF
21 1001Z (W) STARTER SOLENOID FEED
23 3295 (O) FRONT SUSPENSION PRESSURE SWITCH SIGNAL
SS08K148 1 BRI4420B 2
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X101 ACU AUXILIARY CONTROL UNIT (CN3b)

5 4054 (W) LINK LEVEL DUMP SOLENOID
6 4056 (W) LINK LEVEL TOP LINK RETRACT SOLENOID
7 4058 (W) LINK LEVEL RIGHT LINK LOWER SOLENOID
14 4055 (W) LINK LEVEL TOP LINK EXTEND SOLENOID
15 4057 (W) LINK LEVEL RIGHT LINK RAISE SOLENOID
SS08K149 3 BRI4420B 4
X102 ACU AUXILIARY CONTROL UNIT (CN3a)

16 5574 (P) FENDER 3RD EHR SWITCH – UP
17 5576 (P) FENDER 3RD EHR SWITCH – DOWN
SS08K150 5 BRI4416B-01 6
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X106 ROOF TO CAB HARNESS - ROOF

A1 998D (G) / 998 (G) WORK LAMP-REAR FEED (INNER)
A2 28 (Y) WIPER MOTOR (PARK RETURN)
A3 56 (W) WIPER MOTOR-HIGH
A4 58 (R) WIPER MOTOR-LOW
A5 1019A (G) / 1019 (G) WINDSHIELD WIPER FEED
A6 1038B (TN) / 1038 (TN) WINDSHIELD WIPER FEED-REAR
A7 1120 (G) RR WINDSHIELD WIPER PARK RETURN
A8 4011 (P) ROTATING BEACON SWITCH SUPPLY
B1 1013B (R) / 1013 (R) RIGHT HAND LAMPS
B2 249 (LG) SMV LAMPS RH
B3 666A (P) / 666 (L) DOMELAMP SWITCH FEED
B5 1092 (R) FRONT WORKLAMP RELAY SIGNAL
B6 1925C (R) / 1925 (R) MIRROR CONTROL +12V
B7 1071B (P) WORKLAMP FRONT FEED
B8 1071A (P) WORKLAMP FRONT FEED
C1 1014D (R) / 1014 (R) LEFT HAND LAMPS
C2 250 (LG) SMV LAMPS LH
C3 138A (P) / 138 (L) RADIO KAM
C4 3079 (R) RADIO +12V IGNITION
C5 1927A (R) / 1927 (R) MIRROR ILLUMINATION
C6 3052 (P) / - DOME LAMP TO DOOR SWITCH
SS08M136 7 SS08F314 8
REAR RIGHT HAND C-PILLAR
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X107 AUX HEADLAMP SWITCH

SS08M137 9 BRI4437B 10
X107_A AUX HEADLAMP SWITCH

SS08M138 11 SS08H119 12
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X108 AUX HEADLAMP SWITCH

1 1027E (U) HEADLAMP MAIN BEAM
SS08M139 13 BRI4437B 14
X108_A AUX HEADLAMP SWITCH

SS08M140 15 SS08H119 16
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X110 RIGHT HAND FENDER CONNECTOR 2 HPL RAISE/LOWER SWITCH

1 5100B (K) / 5100 (K) EDC EXTERNAL SWITCH UP
2 5200B (N) / 5200 (N) EDC VALVE SUPPLY
3 5095A (K) / 5095 (K) EDC VALVE DOWN EDC EXTERNAL SWITCH DOWN
4 2057 (W) PTO FENDER SWITCH LH - RH LINK
5 2050E (G) / 2050 (G) PTO SUPPLY / DOG SUPPLY
6 2056A (W) / 2056 (W) PTO FENDER PTO SWITCH ON
SS08K157 1 SS07E067 2
RIGHT HAND REAR FENDER
X111 RIGHT HAND FENDER CONNECTOR 1 TAIL LAMP

1 1013C (R) / 1013 (R) RIGHT HAND LAMPS
2 810C (G) / 810 (G) STOPLAMPS
3 3004B (G) / 3004 (G) RIGHT HAND TURN SIGNAL WARNING LAMP
4 57AV (B) EARTH (ALL)
5 998B (G) / 998 (G) WORK LAMP-REAR FEED (INNER)
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SS08K158 3 SS07E067 4
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X113 GROUND SPEED PTO SWITCH LINK

1 (W)
2 (W)
SS09G073 5 SS08M031 6
RIGHT HAND TOP OF TRANSMISSION
X114 ISO 11786 SIGNAL INTERFACE

1 2320 (P) / 2320 (P/K/Y) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2 2300 (P) / 2300 (P/B/Y) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
3 2330 (P) / 2330 (P/LG/Y) PTO SPEED ISO11876 SKT.PIN#3
4 2310 (P) / 2310 (P/G/Y) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
5 3062 (P) IMPLEMENT SOCKET SWITCH
6 1050A (G) / 1050 (G/W) ACCESSORY FEED
7 61B (B/O) / 61 (B) CASE GROUND
SS08M141 7 SS08K549 8
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X115A 30 AMPERE POWER SOCKET POSITIV

1 150C (N) BATTERY FEED (ALL)
2 9032A (Y) / 9032B (Y) IGN+ TO POWER SKT.
SS08K159 9 SS07K168 10
X115B 30 AMPERE POWER SOCKET NEGATIV

1 57CW (B) / 57CR (B) EARTH (ALL)
SS08K160 11 SS08F111 12
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X116A REAR POWER SOCKET IMPLEMENT POSITIVE

1 150BF (N) BATTERY FEED (ALL)
2 9032D (Y) IGN.+ TO POWER SKT.
SS08K161 13 SS07K168 14
X116B REAR POWER SOCKET IMPLEMENT NEGATIVE

SS08K162 15 SS08F111 16
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X117 POWER STUDS

1 57PT (B) / 57 (B) EARTH (ALL)
2 3070A (P) / 3070 (P/W) ’B’ PILLAR SKT SUPPLY
SS08K163 17 SS07K168 18
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X121 HAND BRAKE

1 57BL (B) EARTH (ALL)
2 3014B (R) HANDBRAKE WARNING LAMP SIGNAL
3 9031B (P) ADIC MEMORY B+
4 3150 (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
SS08K164 1 SS08F192 2
LEFT HAND SIDE OPERATOR’S SEAT
X123 WASHER MOTOR REAR

1 1121A (G) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
SS08K165 3 SS08F222 4
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X125 WASHER MOTOR FRONT

1 97 (LTG) WINDSHIELD WASHER FEED
SS08K166 5 SS08F222 6
X126 LEFT HAND FENDER CONNECTOR 1 TAIL LAMP

1 1014C (R) / 1013 (R) LEFT HAND LAMPS
2 810B (G) / 810 (G) STOPLAMPS
3 3005B (G) / 3004 (G) LEFT HAND TURN SIGNAL WARNING LAMP
4 57AW (B) / 57AY (B) EARTH (ALL)
5 998A (G) / 998 (G) WORK LAMP-REAR FEED (INNER)
6 57AN (B) / 57AP (B) EARTH (ALL)
SS08K167 7 SS07E067 8
LEFT HAND REAR FENDER
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X127 LEFT HAND FENDER CONNECTOR 2 HPL RAISE /LOWER SWITCH

1 5100A (K) / 5100 (K) EDC EXTERNAL SWITCH UP
2 5200C (N) / 5200 (N) EDC VALVE SUPPLY
3 5095B (K) / 5095 (K) EDC EXTERNAL SWITCH DOWN
5 2057 (W) PTO FENDER SWITCH LH - RH LINK
6 2056B (W) / 2056 (W) PTO FENDER PTO SWITCH ON
SS08K168 9 SS07E067 10
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X130 CIGAR LIGHTER (ILLUMINATION)

SS08K169 1 BRI4437B 2
REAR LEFT HAND C-PILLAR
X131 CIGAR LIGHTER (POWER)

1 57CV (B) EARTH (ALL)
2 150A (N) BATTERY FEED (ALL)
SS08K170 3 SS08F250 4
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X132 8 AMPERE SOCKET

1 57CT (B) EARTH (ALL)
2 9032C (Y) IGN.+ TO POWER SKT.
SS08K171 5 SS08F250 6
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X151 ROOF EARTH

1 57,57A,57B (B) EARTH (ALL)
SS09G121 1 BRI4474B 2
BEHIND RIGHT HAND C-PILLAR COVER TOP
X154 DOOR SWITCH RIGHT HAND

1 3052A (P) DOME LAMP TO DOOR SWITCH
SS09F050 3 BRI4437B 4
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X156 CONSOLE LAMP RIGHT HAND

SS08K177 5 SS08F250 6
RIGHT HAND INSIDE CAB ROOF
X157 RADIO 2

SS08K179 7 SS08F180 8
RIGHT HAND CAB ROOF
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X158 RADIO 1

4 3077 (Y) RADIO +12VB
7 3079A (R) RADIO +12V IGNITION
SS08K181 9 SS08F180 10
RIGHT HAND CAB ROOF
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X163 GRABRAIL SIDE LAMP RIGHT HAND

1 249 (LTG) SMV LAMPS RH
2 1013C (R) RIGHT HAND LAMPS
X163 SMV LAMP RIGHT HAND FRONT (NORTH AMERICA ONLY)

1 249A (LTG) SMV LAMPS RH
SS08K186 1 SS08F147 2
RIGHT HAND CAB ROOF
(NORTH AMERICA ONLY)
SS09G122 3 SS08K508 4
RIGHT HAND CAB ROOF
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X164 WORKLAMP GRABRAIL RIGHT HAND FRONT

2 1097B (R) FEED FRONT WORKLAMP OUTER
4 57L (B) EARTH (ALL)
SS08K187 5 SS08F147 6
RIGHT HAND CAB ROOF
SS09G123 7 SS08F147 8
RIGHT HAND CAB ROOF
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X165 WORKLAMP ROOF FRONT LEFT HAND 2

A 1098B (W) FRONT WORKLAMP RELAY GROUND
B 57AA (B) EARTH (ALL)
SS08K189 9 SS08F166 10
FRONT RIGHT HAND CAB ROOF
X166 ELECTRIC MIRROR LEFT HAND

1 1922A (G) MIRROR CONTROL COMMON
4 1927A (R) MIRROR ILLUMINATION
5 57AC (B) EARTH (ALL)
SS09G126 11 SS08F325 12
LEFT HAND FRONT CAB ROOF
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SS09G125 13 SS08F325 14
LEFT HAND FRONT CAB ROOF
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X167 MIRROR CONTROL

7 1922 (G) MIRROR CONTROL COMMON
SS08K193 15 SS08F326 16
CAB ROOF
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X168 WORKLAMPS ECU

B1 4011 (L) ROTATING BEACON SWITCH SUPPLY
B2 138B (L) RADIO KAM
B3 57X (B) EARTH (ALL)
B4 1098A (W) FRONT WORKLAMP RELAY GROUND
B5 1098B (W) FRONT WORKLAMP RELAY GROUND
B7 1097A (R) FEED FRONT WORKLAMP OUTER
B8 1097B (R) FEED FRONT WORKLAMP OUTER
C1 997 (G) WORK LAMP-REAR FEED (OUTER)
C2 4012 (L) ROTATING BEACON FEED
C3 998A (G) WORK LAMP-REAR FEED (INNER)
C4 998B (G) WORK LAMP-REAR FEED (INNER)
C6 1092 (R) FRONT WORKLAMP RELAY SIGNAL
C7 1071A (L) WORKLAMP FRONT FEED
C8 1071B (L) WORKLAMP FRONT FEED
SS08K195 17 SS08K548 18
CAB ROOF
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X169 ELECTRIC MIRROR RIGHT HAND

1 1922B (G) MIRROR CONTROL COMMON
5 57AD (B) EARTH (ALL)
SS08K196 19 SS08F325 20
SS09G124 21 SS08F325 22
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X170 ROTATING BEACON RIGHT HAND

1 4012B (L) ROTATING BEACON FEED
SS08K198 1 SS08F177 2
RIGHT HAND CAB ROOF
X171 SMV LAMP REAR RIGHT HAND (NORTH AMERICA ONLY)

1 249B (LTG) SMV LAMPS RH
SS08K200 3 SS08K508 4
REAR RIGHT HAND CAB ROOF
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X173 WORKLAMP REAR RIGHT

2 997B (G) WORK LAMP-REAR FEED (OUTER)
SS08K201 5 SS08F147 6
X175 RADIO SPEAKER RIGHT HAND REAR

SS08K204 7 SS08F177 8
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X176 LICENCE PLATE RIGHT HAND

1 1014A (R) LEFT HAND LAMPS
2 998A (W) WORK LAMP-REAR FEED (INNER)
SS08K206 9 SS08K508 10
X177 WIPER MOTOR REAR

1 1120 (G) RR WINDSHIELD WIPER PARK RETURN
2 57D (B) EARTH (ALL)
3 1038 (TN) WINDSHIELD WIPER FEED-REAR
SS08K208 11 SS08F181 12
REAR CAB ROOF
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X180 LICENCE PLATE LEFT HAND

1 1014B (R) LEFT HAND LAMPS
2 978B (W) LICENCE PLATE LAMP
SS08K210 1 SS08K508 2
REAR LEFT HAND CAB ROOF
X181 RADIO SPEAKER LEFT HAND REAR

SS08K212 3 SS08F177 4
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X182 WORKLAMP LEFT HAND REAR

2 997A (G) WORK LAMP-REAR FEED (OUTER)
SS08K214 5 SS08F147 6
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X184 SMV LAMP REAR LEFT HAND (NORTH AMERICA ONLY)

1 250B (LTG) SMV LAMPS LH
2 57Q (B) EARTH (ALL)
SS08K216 7 SS08K508 8
X185 ROTATING BEACON LEFT HAND

1 4012A (L) ROTATING BEACON FEED
SS08K217 9 SS08F177 10
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X186 DOOR SWITCH LEFT HAND

1 3052B (L) DOME LAMP TO DOOR SWITCH
SS08K219 11 BRI4437B 12
TOP REAR LEFT HAND CAB DOOR
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X190 INTERIOR LAMP A

1 3057,3057A (P) PUDDLE LAMP RETURN
SS08K222 1 BRI4437B 2
CAB ROOF
X191 INTERIOR LAMP B1

1 666A (L) DOMELAMP SWITCH FEED
SS08K223 3 BRI4460C 4
CAB ROOF
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X192 INTERIOR LAMP B2

1 3052A,3052B (L) DOME LAMP TO DOOR SWITCH
SS08K224 5 SS08F177 6
CAB ROOF
X193 PUDDLE LAMP LEFT HAND

1 3057A (L) PUDDLE LAMP RETURN
2 666C (L) DOMELAMP SWITCH FEED
SS09G129 7 SS08K508 8
FRONT LEFT HAND CAB ROOF
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SS09E028 9 SS08K508 10
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X195 SIDE LAMP GRABRAIL LEFT HAND

1 250 (LTG) SMV LAMPS LH
2 1014C (R) LEFT HAND LAMPS
X195 SMV LAMP LEFT HAND FRONT (NORTH AMERICA ONLY)

1 250A (LTG) SMV LAMPS LH
2 57T (B) EARTH (ALL)
SS09G128 11 SS08F147 12
SS08M220 13 SS08K508 14
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X196 WORKLAMP GRABRAIL LEFT HAND

2 1097A (R) FEED FRONT WORKLAMP OUTER
4 57V (B) EARTH (ALL)
SS09G127 15 SS08F147 16
SS08M191 17 SS08F147 18
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X197 WORKLAMP LEFT HAND FRONT UPPER

A 1098A (W) FRONT WORKLAMP RELAY GROUND
B 57AB (B) EARTH (ALL)
SS08K232 19 SS08F166 20
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X201 WIPER MOTOR FRONT (CABINE)

1 28 (Y) WIPER MOTOR (PARK RETURN)
2 57M (B) EARTH (ALL)
4 1019 (G) WINDSHIELD WIPER FEED
SS08K233 1 SS08F162 2
FRONT CAB ROOF
X207 ANTENNE PLUS

1 3079B (R) RADIO +12V IGNITION
SS08M146 3 BRI4437B 4
CAB ROOF
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X211 LOADER VALVE OPTION A

SS08K523 1 SS08K508 2
X212 LOADER VALVE OPTION B

SS08K524 3 SS08K508 4
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X213 ENGINE CONTROL UNIT - A

1 Y/B
2 U/B
3 W/G
8 W/B
9 N/B
11 G
12 W
13 O/U
16 S/Y
17 S/B
18 N/B
19 G
20 W
21 B
22 Y/G
23 Y/B
27 R
28 S/B
31 O/W
32 O/U
33 B/P
36 K/N
40 U/B
41 W/Y
43 R/G
46 U/R
47 N/W
48 S/R
49 O
50 R
51 O/B
52 W/U
53 W/R
54 Y/R
58 O/G
SS09G144 5 SS08F239 6
TOP ENGINE
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X214 EARTH POINT - ELECTRONIC MODULE

SS09G105 7 BRI4404B 8
LEFT HAND ENGINE
X215 GRID HEATER RELAY

1 6586 (P) ECU TO GRID HEATER RELAY RETURN
2 6408H (G) FUSED B+ TO ECU (1)
SS09G146 9 SS08K508 10
LEFT HAND ENGINE
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X216 FUEL HEATER RELAY

SS08K241 11 SS08F092 12
LEFT HAND ENGINE
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X218 ENGINE MODULE BOSCH EDC 16

1 6408P (G) FUSED B+ TO ECU (1)
5 6408F (G) FUSED B+ TO ECU (1)
24 6320 (N) FAN 5V REF.
53 6331 (O) FAN SPEED SENSOR GROUND
61 5420D (G) CAN L
62 5400D (Y) CAN H
72 6407 (O) ENGINE SHUTDOWN
79 2040A (LG) WATER IN FUEL SENSOR
93 6586 (P) ECU TO GRID HEATER RELAY RETURN
SS09G143 13 SS08F204 14
TOP ENGINE
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X219 VISCTRONIC FAN

2 6331 (O) FAN SPEED SENSOR GROUND
3 6408Z (G) FUSED B+ TO ECU (1)
5 6320 (N) FAN 5V REF.
INA 15 SS08F162 16
TOP ENGINE
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X220 FRONT LAMPS

1 57JF (B) / 57A (B) EARTH (ALL)
2 376 (P) / 376 (L) HORN FEED
5 1073A (P) / 1073 (L) WORKLAMP FRONT FEED
6 57JG (B) / 57B (B) EARTH (ALL)
7 1030A (U) / 1030 (U) HEADLAMP DIP BEAM
8 1027A (U) / 1027 (U) HEADLAMP MAIN BEAM
SS09G120 1 SS08F134 2
TOP LEFT HAND ENGINE
X221 BRAKE FLUID LEVEL

SS09G119 3 SS08K508 4
TOP LEFT HAND ENGINE
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X223 AIR CLEANER SWITCH

SS09F035 5 BRI4437B 6
X224 AIR CLEANER SWITCH

1 57JB (B) EARTH (ALL)
SS09F034 7 BRI4437B 8
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X225 A/C PRESSURE SWITCH

SS09F033 9 SS08F107 10
RIGHT HAND SIDE FRONT TOP ENGINE
X226 A/C CLUTCH

2 57JC (B) EARTH (ALL)
SS09G118 11 SS08K508 12
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X227 FRONT HITCH AND FRONT PTO

6 2530 (S) FRONT HITCH V REF
9 2250 (K) PTO FRONT - SUPPLY
10 2556 (N) / 2556 (O) FRONT HITCH SWITCH COMMON RAIL
SS09F049 13 SS07K176 14
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X230 D.I.A. ENGINE INLINE

1 57HB (B) EARTH (ALL)
SS09G117 1 SS08K508 2
BOTTON RIGHT HAND SIDE ENGINE
X231 STARTER SOLENOID B+

1 150 (N) BATTERY FEED (UNFUSED)(ALL)
SS09F085 3 BRI4404B 4
REAR RIGHT HAND OF ENGINE
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X232 STARTER SOLENOID 1

SS09G066 5 BRI4403C 6
REAR RIGHT HAND OF ENGINE
X233 RADAR GUN

2 57JD (B) EARTH (ALL)
SS09F094 7 SS08F150 8
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X234 FRONT AXLE (SELF LEVEL)

1 5520 (LG) EHR 5V Ref
2 3230 (U) / 3230 (O) AXLE HEIGHT SENSOR POSITION
SS09G072 9 SS08F207 10
FRONT RIGHT HAND ENGINE
X235 STEERING ANGLE SENSOR

SS09G071 11 SS08F150 12
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X235 STEERING ANGLE SENSOR (AUTO GUIDANCE)

1 3100 (G) STEERING SENSOR +5v
3 3140 (LTG) STEERING SENSOR GROUND
INA 13 SS08F150 14
X236 ALTERNATOR B+

1 150 (N) BATTERY FEED (UNFUSED)(ALL)
SS09F088 15 SS08H126 16
FRONT TOP LEFT HAND ENGINE
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X237 ALTERNATOR D+

SS09G070 17 SS08K527 18
FRONT TOP LEFT HAND ENGINE
X239 REVERSIBLE FAN

2 6305 (N) / 6315 (G) REVERSIBLE FAN OPTION - RELAY CONTROL
3 57RJ (B) / 57RH (B) EARTH (ALL)
SS08K262 19 SS08H196 20
REAR LEFT HAND OF ENGINE
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X242 WATER IN FUEL SENSOR

1 2040B (LG) WATER IN FUEL SENSOR
2 57JE (B) EARTH (ALL)
3 10J (G) IGNITION SUPPLY
SS08K263 1 SS08F069 2
REAR LEFT HAND ENGINE
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X251 PTO SPEED SENSOR

1 2055AX (G) PTO SYNCHRO GROUND SPEED ENGAGED
SS09F097 1 SS08F069 2
REAR RIGHT HAND TRANSMISSION
X253 TRAILER SOCKET

1 1013D (N) RIGHT HAND LAMPS
1 810A (R) STOPLAMPS
1 1014E (B) LEFT HAND LAMPS
1 349 (G) TRAILER TURN LAMPS RH
1 57EG (W) EARTH (ALL)
1 350 (Y) TRAILER TURN LAMPS LH
SS09F101 3 BRI4480B 4
REAR LEFT HAND TRANSMISSION
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X254 TRAILER BRAKES - AIR

1 2095C (G) / 2095D (G) INSTRUMENT SIGNAL GROUND
4 8020B (N) TRAILER BRAKE PRESSURE
5 57EH (B) EARTH (ALL)
6 8070 (P) TRAILER PARK BRAKE SOLENOID
SS09G116 5 SS08F134 6
X255 TRAILER BRAKES HYDRAULIC

4 57FB (B) EARTH (ALL)
SS09G115 7 SS08F131 8
RIGHT HAND TRANSMISSION
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X256 DRAFT PIN RIGHT HAND

3 5075A (K) EDC VOLTAGE TO PINS
SS09G114 9 SS08F069 10
X257 AXEL SPEED SENSOR (HALL)

1 2050BA (G) PTO SUPPLY / DOG SUPPLY
3 60BC (B/W) SENSOR GROUND
SS09G060 11 SS08F072 12
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X259 FRONT SUSPENSION CONNECTOR

2 3250 (O) / 3250 (O/G/S) RAISE SOLENOID RET
4 3270 (O) / 3270 (O/P/S) LOWER SOLENOID RET
5 3280 (O) / 3280 (O/U/S) SUSPENSION LOCKOUT SOLENOID UPPER
6 3281 (TN) / 3290 (O/Y/S) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
7 3285 (TN) / 3300 (O) SENSE LINE CONTROL SOLENOID
8 3286 (TN) / 3310 (O) RAISE LOCKOUT SOLENOID
SS09G061 13 SS07K176 14
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X260 LOW HYDRAULIC CHARGE SWITCH

1 7160 (P) HYD LOW CHARGE WARNING
SS09F081 1 SS08K527 2
X262 PTO TWIST SENSOR

1 2050AA (G) PTO SUPPLY / DOG SUPPLY
3 60AK (B/W) SENSOR GROUND
SS09F048 3 SS08F069 4
TOP OF TRANSMISSION
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X263 17TH DUMP SOLENOID

SS09G140 5 SS08K508 6
TOP OF TRANSMISSION
X264 17TH GEAR SOLENOID

SS09G133 7 SS08K508 8
TOP OF TRANSMISSION
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X265 FUEL TANK SENSOR

SS09F032 9 SS08K508 10
FUEL TANK
X266 DRAFT PIN LEFT HAND

3 5075B (K) EDC VOLTAGE TO PINS
SS09F047 11 SS08F069 12
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X267 ROCK SHAFT POTENTIOMETER

1 60AG (B/W) SENSOR GROUND
3 7525F (G) TRANS SENSOR SUPPLY 5v
SS09F046 13 SS08F072 14
X268 EDC VALVE RAISE

SS09F043 15 SS08F062 16
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X269 EDC VALVE LOWER

SS09F042 17 SS08F062 18
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X273 TRANSMISSION OIL PRESSURE SENSOR

A 60CB (B/W) SENSOR GROUND
B 5020 (G) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
C 2012 (Y) TRANS OIL PRESSURE WARNING LAMP
SS09G139 1 SS08H141 2
X276 DIFF. LOCK SOLENOID

2 57ES (B) EARTH (ALL)
SS09G135 3 SS08K508 4
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X277 REAR P.T.O BRAKE SOLENOID

2 57ET (B) EARTH (ALL)
SS09G138 5 SS08K508 6
X278 REAR P.T.O SOLENOID

SS09G136 7 SS08K508 8
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X279 4WD SOLENOID

2 57EX (B) EARTH (ALL)
SS09G137 9 SS08K508 10
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X280 CREEPER GEAR SOLENOID

1 7000 (U) TRANS CONTROL SUPPLY
2 7006 (R)
SS09G134 1 SS08K508 2
X281 CREEPING SENSING SWITCH (REAR)

1 7000N (U) TRANS CONTROL SUPPLY
SS09F037 3 SS08K508 4
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X282 CREEPING SENSING SWITCH (FRONT)

SS09F036 5 SS08K508 6
X285 REVERSE SYNCHRO SOLENOID

1 8040 (G) TRANS REV SOLENIOD
SS09F045 7 SS08K508 8
TOP OF TRANSMISSION
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X286 FORWARD SYNCHRO SOLENOID

1 8030 (LG) TRANS FWD SOLENIOD
SS09F044 9 SS08K508 10
TOP OF TRANSMISSION
X287 1-4 SYNCHRO SOLENOID

SS09F031 11 SS08K508 12
TRANSMISSION TOP COVER
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X288 5-8 SYNCHRO SOLENOID

SS09F030 13 SS08K508 14
X289 FLY WHEEL TORQUE SENSOR

1 2050AB (G) PTO SUPPLY / DOG SUPPLY
3 60AJ (B/W) SENSOR GROUND
SS09G064 15 SS08F069 16
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X290 TRANS OIL TEMPERATURE SENSOR

A 7500 (G) TRANS OIL TEMP. SENSOR
B 60AD (B/W) SENSOR GROUND
SS09F082 1 SS08M018 2
X291 CLUTCH C1 SOLENOID

SS09F040 3 SS08K508 4
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SS09F041 5 SS08K508 6

SS09F038 7 SS08K508 8
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SS09F039 9 SS08K508 10
X295 LOW RANGE SWITCH

A 7000L (U) TRANS CONTROL SUPPLY
B 7230 (S) TRANSMISSION LOW RANGE
SS09F083 11 SS08M018 12
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X296 HIGH RANGE SWITCH

A 7000K (U) TRANS CONTROL SUPPLY
B 7220 (S) TRANSMISSION HIGH RANGE
SS09G065 13 SS08M018 14
X297 SYNCHRO POSITION POTENTIOMETER

1 7525E (G) TRANS SENSOR SUPPLY 5v
SS09G147 15 SS08F072 16
TOP OF TRANSMISSION
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X298 4/5 SYNCHRONISIER POTENTIOMETER

2 7960 (P) TRANS SLOW/FAST
3 60AH (B/W) SENSOR GROUND
SS09F027 17 SS08F072 18
X299 GROUND SPEED PTO ENGAGED SWITCH

1 2050AD (G) PTO SUPPLY / DOG SUPPLY
2 2055 (W) PTO SYNCHRO GROUND SPEED ENGAGED
SS09F089 19 SS08K508 20
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X304 CAN TERMINATOR RESISTOR

1 5515F (S) EHR +12V IGN.
2 5510H (U) / 5510 (U) EHR CAN LOW
3 5500H (R) / 5500 (R) EHR CAN HIGH
4 57FM (B) EARTH (ALL)
SS08K286 1 SS07K251 2
TOP OF TRANSMISSION
X304 MAIN EXTENSION

1 5515F (S) / 5515C (S) EHR +12V IGN.
2 5510H (U) / 5510M (U) EHR CAN LOW
3 5500H (R) / 5500M (R) EHR CAN HIGH
4 57FM (B) / 57MA (B) EARTH (ALL)
SS08M157 3 SS07K251 4
TOP OF TRANSMISSION
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X305 EHR VALVE CONNECTOR 1

1 5515A (S) EHR +12V IGN.
SS09F026 5 SS08F107 6

1 5515B (S) EHR +12V IGN.
SS09F025 7 SS08F107 8
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1 5515C (S) EHR +12V IGN.
2 5510E (U) EHR CAN LOW
3 5500E (R) EHR CAN HIGH
4 57FF (B) EARTH (ALL)
SS09F024 9 SS08F107 10

1 5515D (S) EHR +12V IGN.
4 57FG (B) EARTH (ALL)
SS09F023 11 SS08F107 12
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X321 DIVERTER SOLENOID

1 9000 (N) DIVERTER VALVE
2 57FJ (B) EARTH (ALL)
SS09G086 1 SS08K508 2
TRANSMISSION
X326 EARTH TRANSMISSION

SS09G062 3 BRI4404B 4
LEFT HAND TOP OF TRANSMISSION
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X332 CORNER LAMP RIGHT HAND

A 1073B (L) WORKLAMP FRONT FEED
B 57H (B) EARTH (ALL)
SS09G092 1 SS08F138 2
FRONT RIGHT HAND HOOD
X333 HEADLAMP RIGHT HAND

A 1030C (U) HEADLAMP DIP BEAM
B 57D (B) EARTH (ALL)
C 1027C (U) HEADLAMP MAIN BEAM
SS09G091 3 SS08M192 4
FRONT RIGHT HAND HOOD
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X334 HORN

SS09G090 5 BRI4437B 6
FRONT HOOD
X335 HORN

1 376 (L) HORN FEED
SS09G089 7 BRI4437B 8
FRONT HOOD
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X336 HEADLAMP LEFT HAND

A 1030D (U) HEADLAMP DIP BEAM
B 57C (B) EARTH (ALL)
C 1027D (U) HEADLAMP MAIN BEAM
SS09G088 9 SS08M192 10
FRONT LEFT HAND HOOD
X337 CORNER LAMP LEFT HAND

A 1073A (L) WORKLAMP FRONT FEED
B 57F (B) EARTH (ALL)
SS09F096 11 SS08F138 12
FRONT LEFT HAND HOOD
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X392 FRONT HITCH LOWER

1 (R)
2 (R)
3 (Y)
4 (U)
INA 1 SS08H142 2
LEFT HAND FRONT HITCH
X393 FRONT PTO SOLENOID

1 (N)
2 (P)
INA 3 SS08F062 4
FRONT HITCH
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X394 FRONT HITCH RAISE

1 (R)
2 (U)
3 (G)
INA 5 SS08F072 6
LEFT HAND FRONT HITCH
X395 FRONT HITCH POSITION SENSOR

1 (B)
2 (R)
3 (W)
SS08K192 7 SS08F072 8
FRONT HITCH
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X400 DIVERTER SWITCH

2 181AA (G) BLOWER MOTOR FEED
4 9000B (N) DIVERTER VALVE
INA 1 SS07K157 2
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X401 EHR 3 SWITCH FENDER RIGHT AND LEFT

1 5574 (L) FENDER 3RD EHR SWITCH – UP
2 5200W (N) EDC VALVE SUPPLY
3 5576 (L) FENDER 3RD EHR SWITCH – DOWN
SS08K183 3 SS08F072 4
SS08K197 5 SS08F072 6
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X402 REAR FENDER 3RD REMOTE LEFT

3 5574B (P) / 5574 (L) FENDER 3RD EHR SWITCH – UP
4 5576B (P) / 5576 (L) FENDER 3RD EHR SWITCH – DOWN
SS08K227 7 SS08J065 8
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X403 WORKLAMP C - PILLAR RIGHT AND LEFT

2 998 (G) WORK LAMP-REAR FEED (INNER)
SS08K287 9 SS08F147 10
SS08K236 11 SS08F147 12
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X404 LICENSE LAMP RIGHT AND LEFT

1 1013B (R) / 1013 (R) RIGHT HAND LAMPS
SS08K295 13 BRI4449C 14
SS08K294 15 BRI4449C 16
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X405 LICENSE LAMP RIGHT AND LEFT

1 57AW (B) / 57 (B) EARTH (ALL)
SS08K072 17 BRI4449C 18
SS08K298 19 BRI4449C 20
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X406 REAR PTO SWITCH RIGHT AND LEFT

1 2050 (G) PTO SUPPLY / DOG SUPPLY
SS08K084 21 SS08F072 22
SS08K116 23 SS08F072 24
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X407 HPL SWITCH RIGHT AND LEFT

2 5200AP (N) EDC VALVE SUPPLY
SS08K156 25 SS08F072 26
SS08K174 27 SS08F072 28
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X408 REAR FENDER 3RD REMOTE RIGHT

3 5574A (P) / 5574 (L) FENDER 3RD EHR SWITCH – UP
4 5576A (P) / 5576 (L) FENDER 3RD EHR SWITCH – DOWN
SS08K175 29 SS08J065 30
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X409 STOP TAIL LIGHT RIGHT AND LEFT

4 810 (G) STOPLAMPS
SS08K318 31 SS08F170 32
SS08K321 33 SS08F170 34
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X422 LOW BRAKE PRESSURE LINE SWITCH 1

INA 1 BRI4490C 2
REAR RIGHT HAND AXLE
X423 LOW BRAKE PRESSURE LINE SWITCH 2

INA 3 BRI4490C 4
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X424 HYDRAULIC TRAILER BRAKE SOLENOID 1

INA 5 BRI4452C 6
X425 HYDRAULIC TRAILER BRAKE SOLENOID 2

1 8000C (N) TRAILER BRAKE SOLENOID
INA 7 BRI4452C 8
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X426 LOW PUMP OUTPUT PRESS SWITCH 1

INA 9 BRI4490C 10
X427 LOW PUMP OUTPUT PRESS SWITCH 2

INA 11 BRI4490C 12
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X429 BRAKE DE-ICER

2 57FN (B) EARTH (ALL)
SS09G113 13 SS07K217 14
LEFT HAND SIDE REAR AXLE
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X430 AIR BRAKE PRESSURE SENSOR

2 8020B (TN) TRAILER BRAKE PRESSURE
SS09G112 1 SS08F207 2
RIGHT HAND BY REAR AXLE
X431 PNEUMATIC TRAILER BRAKE SOLENOID

2 57EK (B) EARTH (ALL)
SS09G111 3 SS07K217 4
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X432 PARK BRAKE SOLENOID

1 8070 (L) TRAILER PARK BRAKE SOLENOID
2 57EL (B) EARTH (ALL)
SS09G110 5 SS07K217 6
X434 HAZARD SWITCH

2 1021 (P) HAZARD SWITCH SUPPLY (BATTERY)
3 1020A (G/W) HAZARD SWITCH SUPPLY
8 1020 (G/S) HAZARD SWITCH SUPPLY
SS08M162 7 SS08F094 8
FRONT INSIDE CAB
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X436 ISO 11786 SIGNAL SOCKET

1 2320 (L/K/Y) TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2 2300 (L/B/Y) THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
3 2330 (L/G/Y) PTO SPEED ISO11876 SKT.PIN#3
4 2310 (L/G/Y) IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
5 5190B (R/W/B) HPL INTERLOCK / LIFT-O-MATIC
6 1050 (G/W) ACCESSORY FEED
SS09F100 9 SS08K544 10
RIGHT HAND SWITCH PANEL
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X441 STUD 8 AMPERE PLUS

1 3070 (P/W) ’B’ PILLAR SKT SUPPLY
SS08K306 1 BRI4401C 2
X442 STUD 8 AMPERE MINUS

SS08K307 3 BRI4401C 4
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X443 CONNECTOR TRAILER SOCKET

1 1013F (R) RIGHT HAND LAMPS
3 1014G (R) LEFT HAND LAMPS
4 349W (G) TRAILER TURN LAMPS RH
5 57EG (B) EARTH (ALL)
6 350B (Y) TRAILER TURN LAMPS LH
SS09G109 5 SS07E067 6
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X455 REV. ALARM

1 1P (R) BATTERY SUPPLY
SS08K308 1 SS08K527 2
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X466 BATTERY ISOLATOR

2 57NN (B) EARTH (ALL)
3 57NP (B) EARTH (ALL)
SS09F087 1 SS08F323 2
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X474 HYDRAULIC FILTER BLOCKED (VACUUM SWITCH)

A 7130A (N) HYD FILTER WNG LP
B 57EP (B) EARTH (ALL)
SS09F099 1 SS08M018 2
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X482 BATTERY ISOLATOR CONTROL SWITCH

1 171 (W) BATTERY ISOLATOR RELAY COIL
2 1J (R) BATTERY SUPPLY
3 172 (W) BATTERY ISOLATOR RELAY COIL (OFF)
SS09G108 1 SS08F094 2
RIGHT HAND C-PILLAR
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X485 COLOUR DISPLAY

1 5500J (R) EHR CAN HIGH
2 5510J (U) EHR CAN LOW
5 5910F (G) ISO BUS CAN SIGNAL HIGH
6 5900F (Y) ISO BUS CAN SIGNAL LOW
9 5960 (Y) RS232 OUTPUT TECU
10 5955A (Y) RS232 INPUT TECU
13 5000 (L) EDC MEMORY POWER
15 7000AT (U) TRANS CONTROL SUPPLY
21 5962 (R) USB + 5V Ref.
22 5966 (G) USB Data +
23 5964 (W) USB Data -
24 5968 (B) USB Ground
SS08K317 3 SS08H198 4
IN CAB RIGHT HAND
X488 USB CONNECTOR

1
INA 5 INA 6
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X491 RELAY 1 (FRONT LOADER)

30 3271B (U) LOADER RELAY FEED
85 3271C (U) LOADER RELAY FEED
87 3272A (O) LOADER VALVE #1 OUT
SS09G131 1 SS08H131 2
UNDER RIGHT HAND SIDE CAB TRIM
X492 RELAY 2 (FRONT LOADER)

30 3271D (U) LOADER RELAY FEED
85 3271E (U) LOADER RELAY FEED
87 3273B (O) LOADER VALVE #1 RETURN
SS09G132 3 SS08H131 4
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X493 FRONT LOADER CONTROL

1 3274A (R) / 3274 (R) LOADER VALVE #2 OUT
2 3275A (R) / 3275 (R) LOADER VALVE #2 RETURN
INA 5 SS08F267 6
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X505 SUSPENSION RAISE SOLENOID

1 3240 (O/B/S) RAISE SOLENOID PWR
2 3250 (O/G/S) RAISE SOLENOID RET
SS09G085 1 SS08H128 2
X506 SUSPENSION LOWER SOLENOID

1 3260 (O/N/S) LOWER SOLENOID PWR
2 3270 (O/P/S) LOWER SOLENOID RET
SS09G084 3 SS08H128 4
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X507 UPPER LOCKOUT SOLENOID

A 3280 (O/U/S) SUSPENSION LOCKOUT SOLENOID UPPER
B 3290 (O/Y/S) SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
SS09F098 5 SS08M018 6
FRONT LEFT HAND ENGINE
X508 LOWER LOCKOUT SOLENOID

A 3300 (O) SENSE LINE CONTROL SOLENOID
B 3310 (O) RAISE LOCKOUT SOLENOID
SS09G083 7 SS08M018 8
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X551 EXHAUST BRAKE SWITCH

1 10AA (G) IGNITION SUPPLY
SS08K349 1 SS08F146 2
FRONT LEFT HAND CAB FLOOR
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X555 ADDITIONAL ROOF HEADLAMPS

1 1013AK (R) RIGHT HAND LAMPS
3 57 GE (B) EARTH (ALL)
4 1072A (P) WORKLAMP FRONT RELAY SUPPLY
5 1072B (P) WORKLAMP FRONT RELAY SUPPLY
6 1099 (R) FEED FRONT WORKLAMP INNER
7 1027AA (U) HEADLAMP MAIN BEAM
11 1027BB (U) HEADLAMP MAIN BEAM
12 1030BB (U) HEADLAMP DIP BEAM
SS08K351 3 SS07E065 4
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X555A CONNECTOR BRIDGE

9 1027AB (U) HEADLAMP MAIN BEAM
10 1027BC (U) HEADLAMP MAIN BEAM
11 1027AB (U) HEADLAMP MAIN BEAM
12 1027BC (U) HEADLAMP MAIN BEAM
SS08K352 5 SS07E065 6
X555C MAIN REAR INTERFACE

SS08K354 7 SS07E065 8
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X560 SWITCH WORK LAMPS 6 FRONT

1 1098E (W) FRONT WORKLAMP RELAY GROUND
2 1098F (W) FRONT WORKLAMP RELAY GROUND
7 57GT (B) EARTH (ALL)
8 1013S (R) RIGHT HAND LAMPS
9 57GX (B) EARTH (ALL)
10 1013PA (R) RIGHT HAND LAMPS
SS08K355 1 SS08F094 2
RIGHT HAND C PILLAR
X561 SWITCH HEADLIGHT ROOF

3 1027R (U) HEADLAMP MAIN BEAM
7 57GG (B) EARTH (ALL)
8 1013T (R) RIGHT HAND LAMPS
SS08K356 3 SS08F094 4
RIGHT HAND C PILLAR
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X563 WORKLIGHTS CONNECTOR (TO ROOF)

1 998E (G) / 998E (Y) WORK LAMP-REAR FEED (INNER)
2 998F (G) WORK LAMP-REAR FEED (INNER)
3 - / 1027N (U) HEADLAMP MAIN BEAM
4 - / 1027X (U) HEADLAMP MAIN BEAM
5 1030W (U) HEADLAMP DIP BEAM
6 1030X (U) HEADLAMP DIP BEAM
7 996 (P) / 1097 (R) BLOWER MOTOR HIGH SPEED (3RD)
8 997G (G) WORK LAMP-REAR FEED (OUTER)
9 1098D (W) FRONT WORKLAMP RELAY GROUND
SS08K357 5 SS07E065 6
RIGHT HAND C PILLAR
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X573 EXHAUST BRAKE SOLENOID

2 6408P (G) FUSED B+ TO ECU (1)
INA 1 SS07K220 2
TOP OF ENGINE
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X600 ISO IMPLEMENT SOCKET (FRONT)

1 57MT (B) EARTH (ALL)
2 57MV (B) EARTH (ALL)
3 5975 (O) ISO RELAY 2 POWER OUT
4 5985 (U) ISO RELAY 1 POWER OUT
INA 1 SS08H129 2
X601 ISO IMPLEMENT SOCKET (REAR)

1 57MT (B) EARTH (ALL)
2 57MV (B) EARTH (ALL)
SS08K369 3 SS08H129 4
REAR OF TRACTOR
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X602 ISO RELAY 1 REAR (K040)

30 150AW (N) BATTERY FEED (UNFUSED)(ALL)
85 5980 (U) ISO BUS IMPLEMENT SIGNAL
86 57MX (B) EARTH (ALL)
SS08K370 5 SS08H131 6
REAR OF TRACTOR
X603 ISO RELAY 2 REAR (K041)

30 150AX (N) BATTERY FEED (UNFUSED)(ALL)
86 57MY (B) EARTH (ALL)
SS08K371 7 SS08H131 8
REAR OF TRACTOR
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X605 EARTH

1 57MZ (B) EARTH (ALL)
INA 9 SS08G301 10
X606 FUSE PF4

1 150AT (N) BATTERY FEED (UNFUSED)(ALL)
INA 11 SS08G301 12
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X607 FUSE PF5

1 150AV (N) BATTERY FEED (UNFUSED)(ALL)
INA 13 SS08G301 14
X608 ISO BUS POWER SUPPLY

1 150AS (N) BATTERY FEED (UNFUSED)(ALL)
INA 15 SS08G301 16
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X611 HEATED MIRROR SWITCH

2 1925A (R) MIRROR CONTROL +12V
7 57CY (B) EARTH (ALL)
9 57PW (B) EARTH (ALL)
10 1012M (R) ILLUMINATION
SS08K376 1 SS08F094 2
X613 TECU POWER IN / OUT

1 5980D (U) ISO BUS IMPLEMENT SIGNAL
2 5970 (O) ISO BUS ECU SIGNAL
3 7000AR (U) TRANS CONTROL SUPPLY
SS08K377 3 SS08H195 4
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X614 TECU BY - PASS

1 5980C (U) ISO BUS IMPLEMENT SIGNAL
2 5970B (O) ISO BUS ECU SIGNAL
3 7000AV (U) TRANS CONTROL SUPPLY
SS08K378 5 SS08H196 6
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X615 TECU VT / SWCD INPUT

1 5900A (G) / 5900G (Y) / 5900G ISO BUS CAN SIGNAL LOW
(G)
2 5910A (Y) / 5910G (G) / 5910G ISO BUS CAN SIGNAL HIGH
(Y)
3 5920A (R) / 5920G (RB) / 5920G ISO BUS CAN SUPPLY GROUND
(R)
4 5915A (B) / 5915G (BA) / 5915G ISO BUS CAN SUPPLY POSITIVE
(B)
5 - / 5960B (O) / 5960B (Y) RS232 OUTPUT TECU
6 5500B (R) / 5500AB (R) / 5500K EHR CAN HIGH
(R)
7 5510B (U) / 5510AB (U) / 5510K EHR CAN LOW
(U)
8 - / 5000 (L) EDC MEMORY POWER
9 - / 5955 (O) / 5955 (Y) RS232 INPUT TECU
11 - / 7000AS (U) / 7000AT (U) TRANS CONTROL SUPPLY
12 - / 1012J (R) ILLUMINATION
13 - / 57SW (B) / 57G (B) EARTH (ALL)
SS08K379 7 SS08F317 8
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X616 TECU UNIT CN1

1 5910D (G) ISO BUS CAN SIGNAL HIGH
2 5900D (Y) ISO BUS CAN SIGNAL LOW
4 5400P (Y) CAN H
5 5420P (G) CAN L
10 5000C (P) EDC MEMORY POWER
11 57TA (B) EARTH (ALL)
14 5980D (U) ISO BUS IMPLEMENT SIGNAL
15 5970 (O) ISO BUS ECU SIGNAL
16 7000AR (U) TRANS CONTROL SUPPLY
21 61T (B/O) CASE GROUND
SS08K381 9 SS08H130 10
X618 ISO BUS CAN TERMINATOR

1 5920E (R ISO BUS CAN SUPPLY POSITIVE
2 5900E (Y) ISO BUS CAN SIGNAL LOW
3 5915E (B) ISO BUS CAN SUPPLY GROUND
4 5910E (G) ISO BUS CAN SIGNAL HIGH
SS08K384 11 SS08H142 12
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X618 ISO BUS CAN EXTENSION

1 5920E (R) ISO BUS CAN SUPPLY POSITIVE
INA 13 SS08M114 14
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X619 TECU VT / SWCD OUTPUT

1 5900 (G) / 5900G (Y) / 5900C ISO BUS CAN SIGNAL LOW
(G)
2 5910 (Y) /5910G (G) / 5910C (Y) ISO BUS CAN SIGNAL HIGH
3 5920 (R) / 5920C (R) ISO BUS CAN SUPPLY GROUND
4 5915 (B) / 5915C (B) ISO BUS CAN SUPPLY POSITIVE
5 5955E (G) / 5955 (O) / 5955 (Y) RS232 OUTPUT TECU
6 5500W (R) / 5500M (R) / 5500A EHR CAN HIGH
(R)
7 5510W (U) / 5510M (U) / 5510A EHR CAN LOW
(U)
8 5000DE (P) / 5000 (L) EDC MEMORY POWER
9 5960E (W) / 5960B (O) / 5960 RS232 INPUT TECU
(Y)
11 7000R (U) / 7000AS (U) / TRANS CONTROL SUPPLY
7000AT (U)
12 1012J (R) ILLUMINATION
13 57SW (B) / 57A (B) EARTH /(ALL)
SS08K386 15 SS08F317 16
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X620 FRONT BREAK AWAY (OPTION)

1 5980B (U) / 5980 (U) ISO BUS IMPLEMENT SIGNAL
2 5970C (O) / 5970A (O) ISO BUS ECU SIGNAL
3 2250P (K) / - PTO FRONT - SUPPLY
SS08K387 1 SS08F181 2
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X621 CONTROL UNIT FAST STEER

A1 3170 (O) FSS – ENABLE
A2 3173 (R) FSS – HYDRAULIC VALVE HIGH SIDE DRIVER
A4 5400 (Y) CAN H
A5 5420 (G) CAN L
A6 3174 (G) FSS – HYDRAULIC VALVE LOW SIDE DRIVER
A7 57C (B) EARTH (ALL)
A8 57B (B) EARTH (ALL)
B1 3171 (O) FSS – LAMP
B4 3172 (L) FSS – STEERING PROXIMITY SENSOR POSITION
B5 3178 (G/Y) FSS – POSITION SENSOR SECONDARY POSITIVE
B6 3179 (N) FSS – POSITION SENSOR SECONDARY NEGATIVE
B8 160 (U) BATTERY SUPPLY ELECTRONICS
C1 3175 (W) FSS – POSITION SENSOR PRIMARY POSITIVE
C2 3176 (B) FSS – POSITION SENSOR PRIMARY NEGATIVE
C3 3177 (U) FSS – POSITION SENSOR SECONDARY COMMON
C4 3180 (B) FSS – SAFETY SWITCH
C8 10D (G) IGNITION SUPPLY
INA 3 SS08F179 4
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X623 FAST STEER CONNECTOR

1 5000D (L) EDC MEMORY POWER
2 5200AB (N) / 5200AB (N) EDC VALVE SUPPLY
3 57HV (B) / 57A (B) EARTH (ALL)
4 5400V (Y) / 5400 (Y) CAN H
5 5420 (G) CAN L
SS08K389 5 SS08F317 6
X624 FAST STEER CONTROL SWITCH

3 3170 (O) FSS – ENABLE
4 3180 (B) FSS – SAFETY SWITCH
7 3171 (O) FSS – LAMP
8 10E (G) IGNITION SUPPLY
SS09G107 7 SS08F094 8
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X625 PROXIMITY SENSOR

2 3172 (L) FSS – STEERING PROXIMITY SENSOR POSITION
SS08K391 9 SS08F298 10
STEERING CONSOLE
X626 POSITION TRANSDUCER

1 3179 (N) FSS – POSITION SENSOR SECONDARY NEGATIVE
2 3175 (W) FSS – POSITION SENSOR PRIMARY POSITIVE
3 3177 (U) FSS – POSITION SENSOR SECONDARY COMMON
4 3176 (B) FSS – POSITION SENSOR PRIMARY NEGATIVE
5 3178 (G/Y) FSS – POSITION SENSOR SECONDARY POSITIVE
SS08K392 11 SS08F294 12
REAR OF ENGINE
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X627 FAST STEER SOLENOID VALVE

1 3173 (R) FSS – HYDRAULIC VALVE HIGH SIDE DRIVER
2 3174 (G) FSS – HYDRAULIC VALVE LOW SIDE DRIVER
SS08K393 13 SS08F062 14
REAR OF ENGINE
X628 ISO RELAY 2 FRONT (K043)

86 57MY (B) EARTH (ALL)
INA 15 SS08H131 16
LEFT HAND ENGINE
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X629 ISO RELAY 1 FRONT (K042)

85 5980 (U) ISO BUS IMPLEMENT SIGNAL
86 57MX (B) EARTH (ALL)
INA 17 SS08H131 18
LEFT HAND ENGINE
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X630 EARTH

1 57MZ (B) EARTH (ALL)
INA 1 SS08G301 2
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X657 ISO BUS IMPLEMENT SOCKET (REAR)

1 5920B (R) ISO BUS CAN SUPPLY POSITIVE
2 5900B (Y) ISO BUS CAN SIGNAL LOW
3 5915B (B) ISO BUS CAN SUPPLY GROUND
4 5910B (G) ISO BUS CAN SIGNAL HIGH
SS08K398 1 SS08H142 2
REAR OF TRACTOR TOP OF TRANSMISSION
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X660 ISO IMPLEMENT CONNECTOR

1 5920B (R) ISO BUS CAN SUPPLY POSITIVE
2 5900B (G) ISO BUS CAN SIGNAL LOW
3 5915B (B) ISO BUS CAN SUPPLY GROUND
4 5910B (Y) ISO BUS CAN SIGNAL HIGH
6 5980 (O) ISO BUS IMPLEMENT SIGNAL
INA 1 SS08J116 2
RIGHT HAND TOP OF TRANSMISSION
X662 FRONT AXLE POSITION SENSOR

2 3230 (O) AXLE HEIGHT SENSOR POSITION
3 60 (B) SENSOR GROUND
SS08K323 3 SS08F072 4
RIGHT HAND FRONT AXLE
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X681 HYDRAULICS MASTER SWITCH

1 5210 (O) EDC VALVE ENABLE
3 5597 (S) EHR MASTER ENABLE
5 5835(S) HYDRAULIC MASTER SWITCH HIGH FLOW PUMP LINK
7 57PV (B) EARTH (ALL)
8 1012L (R) ILLUMINATION
9 57RP (B) EARTH (ALL)
10 1012X (R) ILLUMINATION
SS08K395 1 SS08F094 2
RIGHT HAND C PILLAR
X683A HEATED SCREEN B+

1 1P (R) BATTERY SUPPLY
2 1N (R) BATTERY SUPPLY
SS08K396 3 BRI4459B 4
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X683B HEATED SCREEN D+

1 1006B (N) / 1006D (N) ALTERNATOR WARNING LAMP
SS08K400 5 BRI4437B 6
X684 FRONT HITCH DETECT

1 5200L (N) EDC VALVE SUPPLY
SS08K401 7 SS08K508 8
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X688 EXTREMITY LAMP LEFT HAND

1 50A (G) LEFT HAND TURN SIGNAL
2 57MS (B) EARTH (ALL)
SS08K402 9 SS08H127 10
X689 EXTREMITY LAMP RIGHT HAND

1 49A (G) RIGHT HAND TURN SIGNAL
2 57MR (B) EARTH (ALL)
SS08K403 11 SS08H127 12
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X694 AIR CON POWER

1 982B (G) / 982B (R) BLOWER MOTOR FEED
2 982C (G) / 982C (R) BLOWER MOTOR FEED
3 57NZ (B) / 57ZA (B) EARTH (ALL)
4 57PA (B) / 57ZB (B) EARTH (ALL)
SS08K404 1 SS07F064 2
LEFT HAND REAR TRACTOR BEHIND OPERATOR’S SEAT
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X695 AIR CON CONTROL
MANUAL
1 5420M (G) CAN L
2 5400M (Y) CAN H
3 - / (O/R) DEFOG OUTPUT
6 2005 (O) / 2006B (U) AIR CON CLUTCH RELAY
SS08K406 3 SS08F131 4
ATC
1 5420Z (G) CAN L
2 5400Z (Y) CAN H
3 9229 (O/R) / 9229 (O) DEFOG OUTPUT
5 2006B (U) / 2006 (U) DE-ICING SWITCH - AIR CONDITIONER
6 2005 (O) / 2005 (P) AIR CON CLUTCH RELAY
SS08M015 5 SS08F131 6
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X697 MEHR 1

1 5515J (S) EHR +12V IGN.
2 5610H (U) HTS PROGRAM
4 57WC (B) EARTH (ALL)
SS09F092 7 SS08F107 8
X698 MEHR 2

1 5515K (S) EHR +12V IGN.
2 5510Q (U) EHR CAN LOW
3 5500Q (R) EHR CAN HIGH
4 57MD (B) EARTH (ALL)
SS09G074 9 SS08F107 10
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X699 MEHR 3

1 5515L (S) EHR +12V IGN
2 5510S (U) EHR CAN LOW
3 5500S (R) EHR CAN HIGH
4 57WE (B) EARTH (ALL)
SS09G075 11 SS08F107 12
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X702 TERMINATING RESISTOR

2 5510V (U) EHR CAN LOW
3 5500V (R) EHR CAN HIGH
INA 1 SS07K251 2
X705 TURN RIGHT (TOP)

1 3163 (O) AUTO GUIDANCE STEERING SOLENOID VLV R FEED
2 3164 (O) AUTO GUIDANCE STEERING SOLENOID VLV R RETURN
INA 3 SS08K508 4
REAR TOP OF ENGINE
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X706 TURN LEFT ( BOTTON)

1 3165 (O) AUTO GUIDANCE STEERING SOLENOID VLV L FEED
2 3166 (O) AUTO GUIDANCE STEERING SOLENOID VLV L RETURN
INA 5 SS08K508 6
REAR TOP OF ENGINE
X707 SOLENOIDS CONNECTOR

SS08K415 7 SS08F131 8
LEFT HAND ENGINE
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X709 STEERING PRESSURE SENSOR

A 3161 (O) AUTO GUIDANCE STEERING PRESS SENSOR RETURN
B 3167 (O) AUTO GUIDANCE STEERING PRESS SNSR +5V REF
C 3160 (O) AUTO GUIDANCE STEERING PRESS SENSOR SIGNAL
SS08K416 9 SS08H141 10
REAR TOP OF ENGINE
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X710 AUTO GUIDANCE SOLENOIDS

3 3163A (O) / 3163 (O) AUTO GUIDANCE STEERING SOLENOID VLV R FEED
5 3165A (O) / 3165 (O) AUTO GUIDANCE STEERING SOLENOID VLV L FEED
SS08K417 1 SS08F131 2
X711 AUTO GUIDANCE SENSORS

1 3100 (G) STEERING SENSOR +5V
4 3160 (O) AUTO GUIDANCE STEERING PRESS SENSOR SIGNAL
5 3161 (O) AUTO GUIDANCE STEERING PRESS SENSOR RETURN
6 3167 (O) AUTO GUIDANCE STEERING PRESS SNSR +5V REF
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SS08K418 3 SS08F131 4
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X712 AG DUMP SOLENOID

INA 5 SS08K508 6
REAR TOP LEFT HAND ENGINE
X714 AUTO GUIDANCE CONTROL SWITCH

2 5200AK (N) EDC VALVE SUPPLY
3 3185 (N) AUTO GUIDANCE REMOTE ENGAGE
5 5200AL (N) EDC VALVE SUPPLY
6 3187A (N) AUTO GUIDANCE ROADING SELECT
7 57NB (B) EARTH (ALL)
SS08K420 7 SS08F094 8
RIGHT HAND C-PILLAR
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X715 ROOF CONNECTOR DATA 1

1 5500T (R) / 5500R (R) EHR CAN HIGH
2 5510T (U) / 5510R (U) EHR CAN LOW
5 7655G (Y) RS232 GROUND
SS08K421 9 SS08F131 10
BEHIND RIGHT HAND C-PILLAR COVER TOP
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X716 CERES CONTROLLER A

1 57NC (B) EARTH (ALL)
2 7640G (TN) DIAGNOSTIC PLUG RS232 IN
3 5500P (R) EHR CAN HIGH
6 3185 (N) AUTO GUIDANCE REMOTE ENGAGE
11 5200AJ (N) EDC VALVE SUPPLY
13 5510P (U) EHR CAN LOW
19 3160 (O) AUTO GUIDANCE STEERING PRESS SENSOR SIGNAL
21 3186 (S) CERES PPS IN
29 3167 (O) AUTO GUIDANCE STEERING PRESS SNSR +5V REF
31 7650G (W) DIAGNOSTIC PLUG RS232 OUT
38 3100 (G) STEERING SENSOR +5V
39 3161 (O) AUTO GUIDANCE STEERING PRESS SENSOR RETURN
SS08K446 11 SS08M009 12
REAR LEFT HAND CAB BENEATH STORAGE TRAY
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X717 DATA LOGGER

2 7640D (N) DIAGNOSTIC PLUG RS232 IN
3 7650 (W) DIAGNOSTIC PLUG RS232 OUT
5 7655D (Y) RS232 GROUND
10 3181 (S) AUTO GUIDANCE PPS SIGNAL INPUT TO GPS
11 57NE (B) EARTH (ALL)
SS08K423 13 SS08M164 14
BEHIND RIGHT HAND C-PILLAR COVER
X718 EARTH

1 57NC; 57NL (B) EARTH (ALL)
SS08K424 15 SS08H193 16
BEHIND REAR RIGHT HAND TRIM
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X719 GPS RECEIVER

1 5500AC (R) EHR CAN HIGH
SS08K425 17 SS08H194 18
TOP CAB ROOF
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X720 CERES CONTROLLER B

1 57NE (B) EARTH (ALL)
2 7650D (W) DIAGNOSTIC PLUG RS232 OUT
3 3187 (N) AUTO GUIDANCE ROADING SELECT
7 3181 (S) AUTO GUIDANCE PPS SIGNAL INPUT TO GPS
8 7640D (TN) DIAGNOSTIC PLUG RS232 IN
14 7655D (Y) RS232 GROUND
SS08K426 1 SS08M113 2
REAR LEFT HAND CAB BENEATH STORAGE TRAY
X723 RELAY BASE CRANK ISOLATE

30 5200AB (N) EDC VALVE SUPPLY
85 57NH (B) EARTH (ALL)
87A 5200AG (N) EDC VALVE SUPPLY
SS08K427 3 SS08H131 4
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X724 RELAY BASE SOL VALVE B

30 3163A (O) AUTO GUIDANCE STEERING SOLENOID VLV R FEED
85 57NJ (B) EARTH (ALL)
86 3187B (N) AUTO GUIDANCE ROADING SELECT
SS08K428 5 SS08H131 6
X725 RELAY BASE SOL VALVE A

30 3165A (O) AUTO GUIDANCE STEERING SOLENOID VLV L FEED
85 57NK (B) EARTH (ALL)
86 3187C (N) AUTO GUIDANCE ROADING SELECT
SS08K429 7 SS08H131 8
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X726 ROOF CONNECTOR POWER

1 5200AH (N) EDC VALVE SUPPLY
3 57NA (B) EARTH (ALL)
SS08K430 9 SS08H195 10
X727 ROOF CONNECTOR DATA 2

1 5500AB (R) EHR CAN HIGH
2 5510AB (U) EHR CAN LOW
SS08K431 11 SS08F131 12
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X734 LAMP FEED

1 1012L (R) ILLUMINATION
2 57PW (B) EARTH (ALL)
SS08K438 1 SS08K508 2
X736 USB INTERFACE

1 5962 (R) USB + 5V REF.
2 5964 (W) USB DATA -
3 5966 (G) USB DATA +
4 5968 (B) USB GROUND
SS09G148 3 SS09E014 4
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X745 ELECTRONIC PARK BRAKE INTERFACE CONN

A1 3031 (N) EPB +12 HOT
A2 3150A (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
A4 3036 (O) EPB SHUTTLE PARK SWITCH INPUT
A7 3017 (G) EPB SYSTEM FAILURE WARNING LIGHT
A8 57RK (B) EARTH (ALL)
B3 3150 (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
B4 1001AG (W) STARTER SOLENOID FEED
C1 10X (G) IGNITION SUPPLY
C2 5400NC (Y) CAN H
C3 5420NC (G) CAN L
C7 3039 (U) EPB SHUTTLE PARK SWITCH OUTPUT
X745 ELECTRONIC PARK BRAKE LESS EPL OPTION

A1 3031A (U) EPB +12 HOT
A2 3150A (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
B3 3150B (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
INA 1 SS08F314 2
REAR LEFT HAND CAB
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X746 RELAY - LESS ELECTRONIC PARK BRAKE

30 3031B (U) EPB +12 HOT
85 3031C (U) EPB +12 HOT
86 3150B (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
87 3150A (W) HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
INA 3 SS08H131 4
X748 ELECTRIC SHIFT PTO

1 2050AW (G) PTO SUPPLY / DOG SUPPLY
2 5020Z (TN) EDC PROC +5V REF VOLTAGE DROP POSN/RATE
3 2151 (K) EPTO DRIVE RELAY UPPER SPEED
4 2152 (K) ESPTO DRIVE RELAY LOWER SPEED
5 2155 (N) ESPTO ACTUATOR POWER +12V
6 60BY (B/W) SENSOR GROUND
7 2156 (N) ESPTO ACTUATOR POS SIGNAL
8 2157 (U) ESPTO NEUTRAL
9 2158 (U) ESPTO LOWER SPEED
10 2159 (U) PTO UPPER SPEED
11 2153 (R) ESPTO ACTUATOR UPPER SPEED
12 2154 (N) ESPTO ACTUATOR LOWER SPEED
13 3155A (N) HANDBRAKE TRANS INTERLOCK
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INA 5 BRI4419B 6
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X750 HEATER BLOWER SPEED SWITCH

A 9228 (G) AC-AUTOMATIC BLOWER SPEED
B 9211 (G) AC-BLOWER SPEED LOW (1)
C 9212 (K) AC-BLOWER SPEED MED.1 (2)
D 9213 (K) AC-BLOWER SPEED MED.2 (3)
E 9227 (P) AC-BLOWER SWITCH SUPPLY
SS08K443 1 SS07K257 2
CAB LEFT HAND C-PILLAR
X751 POTENTIOMETER TEMPERATURE ADJUSTMENT

A 9216 (LTG) AC-TEMPERATURE POTI CAB
B 57ZN (B) EARTH (ALL)
SS08K444 3 SS08M001 4
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X752 AIR CONDITION MODE SWITCH

1 9217A (N) AC-SWITCH MAX DEFROST
2 982L (R) BLOWER MOTOR FEED
3 9218A (S) AC-SWITCH ECONOMY
7 57 ZM (B) EARTH (ALL)
9 57ZL (B) EARTH (ALL)
SS08K445 5 SS07E264 6
X753 AIR CONDITION ASSEMBLY

A 9222 (Y) AC-SIGNAL OUTLET TEMPERATURE SENSOR
B 9221 (P) AC-EVAPORATOR TEMPERATURE SENSOR
C 9220 (U) AC-LOW PRESSURE SWITCH INPUT
E 982D (R) BLOWER MOTOR FEED
F 9226 (Y) AC-SIGNAL WATER VALVE
G 9219 (U) AC-LOW PRESSURE SWITCH OUTPUT
SS08K180 7 SS07K258 8
CAB REAR LEFT HAND
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X754 AIR CONDITION BLOWER UNIT

1 982F (R) BLOWER MOTOR FEED
3 57ZD (B) EARTH (ALL)
4 9225 (U) AC-BLOWER SPEED
6 9224 (O) AC-SIGNAL AMBIENT TEMPERATURE SENSOR
7 9223 (R) AC-SIGNAL CAB TEMPERATURE SENSOR
8 57ZC (B) EARTH (ALL)
SS08K447 9 SS08M003 10
CAB REAR LEFT HAND
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X755 AIR CONDITION AUTOMATIC TEMPERATURE CONTROL UNIT

1 5420Z (G) CAN L
2 5400Z (Y) CAN H
3 9226 (Y) AC-SIGNAL WATER VALVE
4 982G (W) BLOWER MOTOR FEED
5 9225 (U) AC-BLOWER SPEED
6 982H (R) BLOWER MOTOR FEED
15 2005 (P) AIR CON CLUCH RELAY
16 9229 (O) AC-DE-FOG
17 982J (R) BLOWER MOTOR FEED
18 57ZE (B) EARTH (ALL)
21 9223 (R) AC-SIGNAL CAB TEMPERATURE SENSOR
22 9222 (Y) AC-SIGNAL OUTLET TEMPERATURE SENSOR
23 9221 (P) AC-EVAPORATOR TEMPERATURE SENSOR
24 9224 (O) AC-SIGNAL AMBIENT TEMPERATURE SENSOR
25 9217 (N) AC-SWITCH MAX DEFROST
26 9218 (S) AC-SWITCH ECONOMY
27 9228 (G) AC-AUTOMATIC BLOWER SPEED
28 9211 (G) AC-BLOWER SPEED LOW (1)
29 9216 (LTG) AC-TEMPERATURE POTI CAB
30 9212 (K) AC-BLOWER SPEED MED.1 (2)
34 2006 (U) DE-ICING SWITCH - AIR CONDITIONER
35 9220 (U) AC-LOW PRESSURE SWITCH INPUT
36 9219 (U) AC-LOW PRESSURE SWITCH OUTPUT
SS08K448 11 SS07F067 12
CAB REAR LEFT HAND
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X756 LOW PRESSURE SWITCH

1 9215 (U) / (U/K) AC-SWITCH ON
2 2006A (U) / (U/R) DE-ICING SWITCH - AIR CONDITIONER
SS08K449 13 SS08M031 14
X757 AIR CONDITION OPERATING MODE SWITCH

2 9210 (G) AC-SWITCH POWER
3 9215 (U) AC-SWITCH ON
SS08K450 15 SS07E264 16
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X758 BLOWER SPEED SWITCH

A 9211 (G) AC-BLOWER SPEED LOW (1)
B 9212 (K) AC-BLOWER SPEED MED.1 (2)
C 9213 (K) AC-BLOWER SPEED MED.2 (3)
D 9214 (G) AC-BLOWER SPEED HIGH.2 (2)
E 982A (R) BLOWER MOTOR FEED
F 9210 (G) AC-SWITCH POWER
SS08K451 17 SS07K257 18
X759 BLOWER MOTOR

3 9211 (G) AC-BLOWER SPEED LOW (1)
8 9214 (G) AC-BLOWER SPEED HIGH.2 (2)
SS08K452 19 SS08M003 20
CAB REAR LEFT HAND
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X776 ARMREST (GARU)

1 5200AT (N) EDC VALVE SUPPLY
2 7000BM (U) TRANS CONTROL SUPPLY
4 2250S (K) PTO FRONT - SUPPLY
11 5910 (Y) ISO BUS CAN SIGNAL HIGH
12 5900 (G) ISO BUS CAN SIGNAL LOW
13 5910F (Y) ISO BUS CAN SIGNAL HIGH
14 5900F (G) ISO BUS CAN SIGNAL LOW
18 5400E (Y) CAN H
19 5420E (G) CAN L
21 5400G (Y) CAN H
22 5420G (G) CAN L
23 5500B (R) EHR CAN HIGH
24 5510B (U) EHR CAN LOW
26 5500D (R) EHR CAN HIGH
27 5510D (U) EHR CAN LOW
30 5955C (G) RS232 INPUT TECU
31 5960C (W) RS232 OUTPUT TECU
32 57RE (B) EARTH (ALL)
33 57RF (B) EARTH (ALL)
SS08K405 1 BRI4420B 2
GARU
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X777 SWITCH ADJUST MOTOR

1 181R (G) BLOWER MOTOR FEED
2 57D (B) EARTH (ALL)
5 181T (G) BLOWER MOTOR FEED
6 181N (G) BLOWER MOTOR FEED
INA 3 SS08F094 4
LEFT HAND ON GARU
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X787 CONNECTOR ADJUST MOTOR

1 181M (G) / 181P (G) BLOWER MOTOR FEED
2 57A (B) / 57B (B) EARTH (ALL)
3 57D (B) / 57E (B) EARTH (ALL)
4 181T (G) / 181S (G) BLOWER MOTOR FEED
5 9000B (N) / 9000A (N) DIVERTER VALVE
INA 1 SS08F131 2
INSIDE OF THE ARMREST UNIT
X788 ELECTRIC ADJUST MOTOR

1 181S (G) BLOWER MOTOR FEED
INA 3 SS08M031 4
INSIDE OF THE ARMREST UNIT
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X810 BATTERIE TO CAB. MINUS SUPPLY

SS09G076 1 SS08J112 2
X812 ISO BUS BREAK AWAY FRONT

1 5920E (R) ISO BUS CAN SUPPLY POSITIVE
INA 3 SS08H142 4
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X813 POWER FUSE PF 6 ISO BUS FRONT

1 150AT (N) BATTERY FEED (UNFUSED)(ALL)
INA 5 SS08G301 6
X814 POWER FUSE PF 7 ISO BUS FRONT

1 150AV (N) BATTERY FEED (UNFUSED)(ALL)
INA 7 SS08G301 8
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X815 ISO BUS POWER SUPPLY FRONT

1 150AS (N) BATTERY FEED (UNFUSED)(ALL)
INA 9 SS08G301 10
X816 HIGH MOUNT HEADLAMP SWITCH

INA 11 SS08F094 12
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X817 FRONT HITCH AND FRONT PTO

1 2044 (O) / (N) PTO SOLENOID-FRONT RETURN(-)
2 2043 (O) / (P) PTO SOLENOID-FRONT
4 60AE (B/W) / (S) SENSOR GROUND
5 2570 (R) / - FRONT HITCH RAISE SOLENOID
6 2530B (N) / - FRONT HITCH V REF
7 2510 (N) / (W) FRONT HITCH POSITION SIGNAL
9 1010B (G) / (R) IGNITION RELAY (COIL)
10 2556 (O) / (U) FRONT HITCH SWITCH COMMON RAIL
11 2590 (TN) / (G) EXTERNAL SWITCH FHPL UP
12 2591 (TN) / (Y) EXTERNAL SWITCH FHPL DOWN
SS08K455 13 SS07K176 14
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X818 HEADLAMP 2 LEFT HAND GRAB RAIL

1 1027B (UW) HEADLAMP MAIN BEAM
2 1030B (UR) HEADLAMP DIP BEAM
SS08M167 15 SS08F072 16
LEFT HAND ON GRABRAIL
X819 HEADLAMP 1 RIGHT HAND GRAB RAIL

1 1027A (UW) HEADLAMP MAIN BEAM
2 1030A (UR) HEADLAMP DIP BEAM
SS08M166 17 SS08F072 18
RIGHT HAND ON GRABRAIL
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X820 GARU SWCD

10 5955 (Y) RS232 INPUT TECU
SS08M233 1 SS08H198 2
RIGHT HAND SIDE CAB
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X821 LOADER VALVE 1

1 3272 (L) LOADER VALVE #1 OUT
1 3273 (U) LOADER VALVE #1 RETURN
INA 3 BRI4437B 4
FRONT LOADER CONSOLE RIGHT HAND SIDE OF ENGINE
X822 LOADER VALVE 2

1 3274 (L) LOADER VALVE #2 OUT
1 3275 (U) LOADER VALVE #2 RETURN
INA 5 BRI4437B 6
FRONT LOADER CONSOLE RIGHT HAND SIDE OF ENGINE
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X823 MEGA FUSE (125A) GRIDHEATER / FUELHEATER

1 (R) SUPPLY B+
2 (R) HIGH CURRENT RELAY
SS08M168 7 BRI4474B 8
BOTTOM REAR ENGINE
X825 INJECTOR CYLINDER 1 & 2 (EDC16)

1 N/B PLUS
2 S/R MINUS
3 S/Y PLUS
4 N/W MINUS
SS08K066 9 SS08F274 10
LEFT HAND TOP ENGINE
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1 (W/G) / (S/R) PLUS
2 (U/O) / (W/U) MINUS
3 (S/B) PLUS
4 B/P / (N/G) MINUS
SS08K067 11 SS08F274 12

1 U/B PLUS
2 O/W MINUS
3 U/R PLUS
4 Y/B MINUS
SS08K068 13 SS08F274 14
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X828 BOOST PRESSURE / TEMPERATURE SENSOR (EDC16)

1 Y/B
2 (S/W) / (W/R)
3 (R/B) / (O/U)
4 U/B
SS08K069 15 SS08F268 16
LEFT HAND ENGINE
X829 OIL PRESSURE / TEMPERATURE SENSOR (EDC16)

1 Y/G
2 K/B
3 N/B
4 Y/R
SS08K070 17 SS08F268 18
FRONT LOWER RIGHT HAND ENGINE
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X830 RAIL PRESSURE SENSOR (EDC16)

1 W/B
2 R/G
3 S/B
SS08K071 1 SS08F270 2
X831 COOLANT TEMPERATURE SENSOR

1 (P/R) / O/G
2 W/Y
SS09F022 3 SS08F271 4
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X832 FUEL TEMPERATURE SENSOR

1 W/U
2 O/B
SS08K073 5 SS08F271 6
LEFT HAND ENGINE
X833 HIGH PRESSURE PUMP

1 G
2 O
SS08K074 7 SS08F271 8
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X834 INCREMENT SPEED SENSOR

1 W
2 R
3 B
SS09G106 9 SS08F270 10
X835 CAMSHAFT SPEED SENSOR

1 W
2 R
3 G
SS08K076 11 SS08F270 12
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X840 REAR PTO SWITCH

1 (Y) NORMALY OPEN
2 (W) NORMALY CLOSED
3 (B) PTO LAMP
4 (R) SUPPLY +12V
SS08M209 1 SS07E276 2
IN ARMREST
X841 FRONT PTO SWITCH

1 (Y) NORMALY OPEN
2 (W) NORMALY CLOSED
3 (B) PTO LAMP
4 (R) SUPPLY +12V
SS08M219 3 SS07E276 4
IN ARMREST
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X842 EHR FLOW CONTROL ENCODER

1 (G) OUTPUT SIGNAL SWITCH
2 (U) ENCODER OUTPUT B
3 (Y) ENCODER OUTPUT A
4 (B) GROUND
5 (R) SUPPLY +5V
SS08M201 5 SS07E081 6
IN ARMREST
X843 EHR FLOAT / JOYSTICK

1 (R) SUPPLY +5V
2 (B) OUTPUT SWITCH
SS08M223 7 SS07E070 8
IN ARMREST
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X844 JOYSTICK 1

2 (G) OUTPUT 3 BUTTON
3 (Y) OUTPUT 2 BUTTON
4 (B) OUTPUT 1 BUTTON
5 (W) OUTPUT SIGNAL Y-AXIS
6 (W) OUTPUT SIGNAL X-AXIS
7 (N) GROUND
8 (R) SUPPLY +5V
SS08M207 9 SS08M200 10
IN ARMREST
X845 JOYSTICK 2

1 (W) OUTPUT SIGNAL Z-AXIS
4 (B) OUTPUT 1 BUTTON
5 (W) OUTPUT SIGNAL Y-AXIS
6 (W) OUTPUT SIGNAL X-AXIS
7 (N) GROUND
8 (R) SUPPLY +5V
INA 11 SS08M200 12
IN ARMREST
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X846 SENSOR TRANSMISSION RATIO

2 (S) ENCODER OUTPUT 2
3 (U) ENCODER OUTPUT 1
4 (LN) SENSOR GROUND
5 (R) SENSOR +5V
6 (W) SENSOR SIGNAL OUTPUT
7 (Y) SERIAL LINK CLOCK
8 (W) SERIAL LINK DATA
9 (N) GROUND
10 (R) SUPPLY +5V SWITCH PANEL
SS08M205 13 SS08M196 14
IN ARMREST
X847 INTEGRATED CONTROL SWITCH PANEL

1 (B) CAN LOW
2 (Y) CAN HIGH
3 (S) GROUND
4 (W) SUPPLY +12V
SS08M199 15 SS07E276 16
IN ARMREST
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X848 REAR HITCH POSITION / DRAFT POTENTIOMETER

1 (N) SIGNAL POSITION OUTPUT REAR
2 (G) SIGNAL DRAFT OUTPUT REAR
3 (O) GROUND
4 (U) SUPPLY +5V
SS08M197 17 SS07E276 18
IN ARMREST
X849 FRONT EDC SETTING

1 (S) SWITCH OUTPUT
2 (R) SUPPLY SWITCH +5V
3 (Y) SIGNAL POTENTIOMETER OUTPUT
4 (B) GROUND
5 (R) SUPPLY +5V
SS08N079 19 SS08N072 20
IN ARMREST
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X850 EL. DRAFT CONTROL REAR POTENTIOMETER PANEL

1 (U) REAR SENSITIVITY OUTPUT
2 (Y) REAR DROP RATE OUTPUT
3 (G) REAR SLIP OUTPUT
4 (O) REAR HEIGHT LIMIT OUTPUT
5 (B) GROUND
6 (R) SUPPLY +5V
9 (W) FRONT HEIGHT OUTPUT
10 (S) FRONT HEIGHT ENABLE SWITCH
SS08M195 1 SS08M196 2
IN ARMREST
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X853 EL. HYDRAULIC REMOTE 1&2 CONTROL

1 (G) EHR2 POTENTIOMETER SIGNAL OUTPUT TRACK 1
3 (B) GROUND
4 (R) SUPPLY +5V
5 (B) GROUND
6 (R) SUPPLY +5V
7 (W) EHR2 POTENTIOMETER SIGNAL OUTPUT TRACK 2
SS08M215 3 SS08M196 4
IN ARMREST
X854 EL. HYDRAULIC REMOTE LAMPS 1&2 SWITCH

2 (W) EHR2 TIMER LED OUTPUT
3 (W) EHR2 MOTOR MODE LED OUTPUT
6 (W) LED POWER OUTPUT +12V
7 (W) EHR2 MOTOR / PROGRAM SWITCH
SS08M217 5 SS08M200 6
IN ARMREST
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X855 EL. HYDRAULIC REMOTE 3&4 CONTROL

3 (B) GROUND
4 (R) SUPPLY +5V
5 (B) GROUND
6 (R) SUPPLY +5V
SS08M211 7 SS08M196 8
IN ARMREST
X856 EL. HYDRAULIC REMOTE LAMPS 3&4 SWITCH

SS08M213 9 SS08M200 10
IN ARMREST
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X857 EL. HYDRAULIC REMOTE 5 & 6 CONTROL

3 (B) GROUND
4 (R) SUPPLY +5V
5 (B) GROUND
6 (R) SUPPLY +5V
INA 11 SS08M196 12
IN ARMREST
X858 EL. HYDRAULIC REMOTE LAMPS 5 & 6 SWITCH

INA 13 SS08M200 14
IN ARMREST
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X859 EL. HYDRAULIC REMOTE 1&2 TIMER LED

SS08N073 15 SS08M208 16
IN ARMREST
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SS08N075 1 SS08M208 2
IN ARMREST

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INA 3 SS08M208 4
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X862 GARU PCB SWCD

9 5955 (Y) RS232 INPUT TECU
SS08M221 5 SS08M196 6
IN ARMREST
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X870 MARKER LIGHTS

1 1013E (R) RIGHT HAND LAMPS
2 1014F (R) LEFT HAND LAMPS
3 349C (G) TRAILER TURN LAMPS RH
4 350C (Y) TRAILER TURN LAMPS LH
INA 1 SS08F181 2
X871 AXLE SPEED SENSOR (IND)

SS09G063 3 SS08K508 4
REAR TOP OF TRANSMISSION
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X890 BATTERY POSITIVE STUD

1 (B)
SS09F093 1 INA 2
X891 STARTER MOTOR POSITIVE

1 (B)
SS09G067 3 SS09G141 4
REAR ENGINE RIGHT HAND
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X892 BATTERY TO GROUND

SS09G077 5 INA 6
X893 BATTERY TO GROUND

SS09F086 7 SS09G141 8
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X920 CABINE POWER

SS09G068 1 BRI4474B 2
X921 CABINE ELECTRONIC

SS09G069 3 BRI4404B 4
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X922

1 (B)
INA 5 INA 6
X923 ISOLATOR KAM

1 1C (R) BATTERY SUPPLY
INA 7 SS09G142 8
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X924

1 (B)
INA 9 INA 10
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Wiring harness - Electrical symbol

Fuse Speaker
Battery Diode
Motor Switch
Earth / Ground Point Resistor
L.E.D. (Light emitting diode) Solenoid
Potentiometer or Sensor Alternator
Lamp Page Break
Connector Pressure Switch
Timer Relay Relay
Electrical Clutch AC Sockets
Horn
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Wiring harness - Static description

The wiring diagrams have been drawn in a horizontal style. They have been divided into sub sections whereby an in-
dividual function is contained to one sheet wherever possible. The diagrams are split into various build configurations
depending on the type of transmissions fitted, cab controls and type of hydraulic remote valves.
There are a number of guides to help assist in reading and understanding the wiring diagrams.
1. The wiring diagrams (1) are designed to be read in a landscape format. The titles and diagram keys (2) are located
on the opposite pages along with the wire colour code table, (3) which is located below the key.
The title and key details the frame number and frame description. The key then details all the components used
within that particular page.
SS09B053 1
2. Every component and connector has its own unique reference number.
3. Every wire has a code assigned to it, this code refers to its function, the code is also physically marked on the
actual wire. A key of all wire codes can be found in this section, refer to Wiring harness - Overview (A.30.A).
Letters before the number indicate the wire colour. For example, ’B, 57’ indicates that the wire colour is black and
the wire reference of 57, indicates it is a ground (earth) wire.
4. The wiring diagrams are drawn in sections according to a vehicle function. However where a single component
is used in a number of circuits such as a processor or multi function switch, it is drawn either on its own or on the
circuit which it influences the most.
5. The wiring is drawn with the battery and all of the power supplies, ie, fuses and relays in the opening pages. Each
supply is then given a reference to the page of the associated function. On the referenced page there will be a
corresponding reference back to the power supply page.
As an example, the references are written as ’WB055 sheet 14’. The WB055 is a unique sequential reference
(WB is an abbreviation for Wire Break), and the Sheet 14 is the location for the continuation of the circuit.
6. The components, ie, switches, solenoids, etc, are given an identifying reference within the drawing and to easier
identify the type of component a key is provided before a numerical reference. For example a switch will have the
prefix, ’S-’ a solenoid will have the prefix ’Y-’. The table below provides a complete listing of these codes. Each
component will also have another number assigned to each terminal, for example ’X377-7’, this is the connector
number reference and pin reference for that connector.
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Component Type Component reference

Alternator G-002
Audible Device H-001
Battery G-001
Circuit Breaker Q-001
Connector X-001
Capacitor C-001
Diode V-001
Mini Fuse F-001
Maxi Fuse MF-001
Power Fuse PF-001
Ground GND-001
Lamp E-001
Module A-001
Motor M-001
Relay K-001
Resistor R-001
Sensor / Sender B-001
Solenoid / Injector Y-001
Splice SP-001
Switch S-001
Sockets J-001
Splice Blocks, Antenna W-001
Sub - Assembly Z-001
Wire Break Description Abbreviation

Wire Break WB-001
Mini Fuse Break FB-001
Maxi Fuse Break MFB-001
Mega Fuse Break MGFB-001
Power Fuse Break PFB-001
Ground Break GB-001
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Wiring harness - Overview

Wire Colour Codes

B Black S Slate (Grey) G Green P Purple
Green
Brown
Wire Code References

1 R BATTERY SUPPLY
10 G IGNITION SUPPLY
11 G IGNITION SUPPLY (2ND)
12 U MAIN BEAM HEADLAMP FUSE SUPPLY
13 U DIP BEAM HEADLAMP FUSE SUPPLY
15 U LIGHTING SWITCH SUPPLY
28 Y WIPER MOTOR (PARK RETURN)
29 G MAIN FUEL SENDER SIGNAL
31 Y ENGINE OIL PRESSURE SENDER SIGNAL
39 G TEMPERATURE GAUGE SIGNAL
44 L FLASHER UNIT (49A)
49 G RIGHT HAND TURN SIGNAL
50 G LEFT HAND TURN SIGNAL
56 W WIPER MOTOR-HIGH
57 B EARTH (ALL)
58 R WIPER MOTOR-LOW
60 B/W SENSOR GROUND
61 B CASE GROUND
63 U WIPER MOTOR-PARK FEED
65 W DUAL POWER/4 WHEEL DRIVE SWITCH FEED
71 W IGNITION SWITCHED FEEDS (UNFUSED)
84 G WINDSHIELD WASHER SWITCH FEED
90 G DUAL POWER / FOUR WHEEL DRIVE SWITCH
97 LG WINDSHIELD WASHER FEED
137 W RADIO FEED
138 P RADIO KAM
150 N BATTERY FEED (ALL)
155 G BATTERY FEED (FUSED)
160 U BATTERY SUPPLY ELECTRONICS
170 K/N/B BATTERY ISOLATOR CONTROL SWITCH
171 W/TQ/B BATTERY ISOLATOR RELAY COIL
172 W/TQ/Y BATTERY ISOLATOR RELAY COIL (OFF)
173 W BATTERY ISOLATOR RELAY COIL +12V
182 P THERMOSTATIC SWITCH FEED
249 LG SMV LAMPS RH
250 LG SMV LAMPS LH
349 LN TRAILER TURN LAMPS RH
350 LN TRAILER TURN LAMPS LH
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365 G LOW FUEL WARNING LAMP (DELAY ON)
366 O LOW FUEL WARNING LAMP (DELAY SWITCH)
376 P HORN FEED
587 LG WINDSHIELD WIPER INTERMITTENT DELAY
649 O COOLANT TEMPERATURE SWITCH
650 TQ COOLANT LEVEL SWITCH
666 P DOMELAMP SWITCH FEED
787 G AUXILIARY FUEL PUMP SUPPLY
810 G STOPLAMPS
820 R STOPLAMP SWITCH LH
825 Y PNEUMATIC TRAILER SOLENOID +12V
830 U STOPLAMP SWITCH RH
840 G R & L STOPLAMP SIGNAL
976 W/N/B LICENCE PLATE LAMP / WORKLAMP DIODE
978 W LICENCE PLATE LAMP
979 S BLOWER MOTOR HIGH SPEED (4th)
980 N THERMOSTAT SWITCH SUPPLY
981 G A/C CLUTCH RELAY FEED
984 P TEMPERATURE CONTROL POT. INPUT
986 P TEMPERATURE CONTROL POT. OUTPUT
989 P BLOWER MOTOR MEDIUM SPEED (2nd)
996 P BLOWER MOTOR HIGH SPEED (3RD)
997 G WORK LAMP-REAR FEED (OUTER)
998 G WORK LAMP-REAR FEED (INNER)
999 G BLOWER MOTOR LOW SPEED (1st)
1000 W SAFETY START SWITCH SUPPLY
1002 P IMPLEMENT LAMP SWITCH SUPPLY
1003 G SUPPLY TO GAUGES
1004 G SUPPLY TO HORN AND HEADLAMP FLASH
1005 S AIR CLEANER WARNING LAMP
1006 N ALTERNATOR WARNING LAMP
1007 W ETHER START BUTTON SUPPLY
1008 N ETHER START SOLENOID SUPPLY
1010 G IGNITION RELAY (COIL)
1011 Y SUPPLY TO FUSES
1012 R ILLUMINATION
1013 R RIGHT HAND LAMPS
1014 R LEFT HAND LAMPS
1015 P DOME LAMP SWITCH FEED
1016 P HORN FEED
1017 LG AIR CON. THERMOSTATIC SWITCH FEED
1018 LG AIR CONDITIONER CLUTCH
1019 G WINDSHIELD WIPER FEED
1020 G HAZARD SWITCH SUPPLY
1021 P HAZARD SWITCH SUPPLY (BATTERY)
1022 N THERMOSTART
1023 N LIGHT SWITCH FEED
1024 R RIGHT & LEFT HAND SIDELAMP FEED
1025 G HZD SWITCH IGN FEED
1026 U HIGH BEAM INDICATOR LAMP
1027 U HEADLAMP MAIN BEAM
1028 U HEADLAMP MAIN BEAM FUSE
1029 U HEADLAMP DIP BEAM FUSE
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1030 U HEADLAMP DIP BEAM
1031 R INSTRUMENT ILLUMINATION
1032 LG TURN SIGNAL WARNING LAMP (TERM C)
1035 W ENGINE OIL PRESSURE WARNING LAMP
1036 N IGNITION SWITCH (BATTERY)
1037 LG FLASHER UNIT (TERM 49A)
1038 LN WINDSHIELD WIPER FEED-REAR
1039 LTG NASO LIGHTS INPUT
1040 LG FLASHER SWITCH TO RELAY-RHS CUT OUT
1041 LG FLASHER SWITCH TO RELAY-LHS CUT OUT
1042 U RELAY FEED ELECTRONICS
1043 U RELAY FEED TO FUSES
1044 W/U/S GRID HEATER FEEDBACK
1050 G ACCESSORY FEED
1051 Y SIDE LIGHTS RELAY COIL FEED
1052 Y GET YOU HOME LIGHTS RELAY
1070 R FRONT WORKLAMP SWITCH FEED
1072 P WORKLAMP FRONT RELAY SUPPLY
1080 R FRONT SCREEN HEATER
1082 Y REAR SCREEN HEATER
1085 N FRONT SCREEN HEATER RELAY CONTROL
1086 N REAR SCREEN HEATER RELAY CONTROL
1090 R REAR WORKLAMP RELAY SIGNAL
1091 R FRONT WORKLAMP LOWER RELAY SIGNAL
1092 R FRONT WORKLAMP RELAY SIGNAL
1093 R FENDER WORKLAMP RELAY SIGNAL
1096 R WORKLAMP FENDER MOUNTED
1097 R FEED FRONT WORKLAMP OUTER
1098 W FRONT WORKLAMP RELAY GROUND
1099 R FEED FRONT WORKLAMP INNER
1119 G RR WINDSHIELD WIPER
1120 G RR WINDSHIELD WIPER PARK RETURN
1121 G RR WINDSHIELD WASH
1130 N ENGINE HEATER CONTROL TO IGN SWITCH
1135 G THERMOSTART WARNING LAMP
1140 K THERMOSTART INITIATE SIGNAL TO RELAY
1141 N GRID HEATER +
1142 N GRID HEATER FUSE TO PWR. RELAY
1143 N POWER RELAY TO GRID HEATER
1150 N CAL/SEL SWITCH
1160 R REVERSE ALARM
1900 LG/B/S HEATED FRONT WINDSCREEN SW SIGNAL
1901 LN/LG/S HEATED FRONT WINDSCREEN POWER
1902 O/LN/S HEATED FRONT WINDSCREEN WARNING LAMP
1903 P/B/S HEATED REAR SCREEN SW SIGNAL
1904 Y/B/S HEATED REAR SCREEN POWER
1905 U/W/S HEATED REAR SCREEN WARNING LAMP
1920 O LH MIRROR CONTROL SIDE-SIDE
1921 Y LH MIRROR CONTROL UP-DOWN
1922 G MIRROR CONTROL COMMON
1923 O RH MIRROR CONTROL SIDE-SIDE
1924 Y RH MIRROR CONTROL UP-DOWN
1925 R MIRROR CONTROL +12V
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1927 R MIRROR ILLUMINATION
1928 R HEATED MIRROR RELAY COIL +12V FROM SW
2001 N BATTERY TEMPERATURE SENSOR
2002 N BATTERY TEMP SENSOR (ALT OUTPUT)
2005 O/U AIR CON CLUTCH RELAY
2006 U DE-ICING SWITCH - AIR CONDITIONER
2007 Y/U AIR CONDITIONER LOW PRESSURE
2008 N/TQ LIFT PUMP SUPPLY
2009 G FUEL PUMP SUPPLY
2010 LG AIRCON PLUG TO DE-ICING SWITCH
2011 P HORN RETURN
2012 Y TRANS OIL PRESSURE WARNING LAMP
2013 Y PTO OVERSPEED WARNING LAMP
2014 G ENGINE OIL PRESSURE SENDER (+5 VOLT)
2015 W TACHOMETER SENSOR-SIGNAL
2016 Y REAR AXLE SPEED SENSOR-SIGNAL
2017 B BULB TEST (EIC)
2018 B RADAR PRESENT
2019 B ENGINE RPM (TACHO MODULE TO TPM)
2020 Y ENGINE SHUT DOWN (TACHO MODULE TO TPM)
2021 Y AXLE GROUND SPEED (TACHO MODULE TO TPM)
2022 B PTO 540/1000 RPM (TACHO MODULE TO TPM)
2023 S TPM TO EIC (AXLE SPEED DRIVE)
2024 S RADAR SIGNAL DRIVE
2025 S AUDIO ALARM CONTROL
2026 S IMPLEMENT SWITCH SIGNAL
2027 R RADAR ASSEMBLY (GUN) POWER
2028 G RADAR ASSEMBLY (GUN) SIGNAL
2029 P INSTRUMENT MEMORY SUPPLY
2030 N ELECTRONIC DRAFT CONTROL
2031 Y RADAR PRESENT
2040 LG WATER IN FUEL SENSOR
2041 P FUEL SHUT OFF
2042 O PTO SOLENOID-REAR
2043 O PTO SOLENOID-FRONT
2044 O PTO SOLENOID-FRONT RETURN(-)
2045 O PTO SWITCH TO MODULE
2046 O PTO SWITCH (VCC)
2047 O PTO SWITCH (VCCO)
2048 O PTO SWITCH (VCCS)
2049 O PTO SWITCH 1000RPM WARNING LAMP
2050 G PTO SUPPLY / DOG SUPPLY
2051 O PTO SOLENOID RETURN (-)
2052 W PTO LUBE SOL
2053 P PTO LUBE SOL RETURN
2055 W PTO SYNCHRO GROUND SPEED ENGAGED
2056 W PTO FENDER PTO SWITCH ON
2057 W PTO FENDER SWITCH LH - RH LINK
2059 W FENDER PTO SWITCH INPUT
2060 O PTO 540/1000 SWITCH
2062 W PTO TWIST SENSOR
2065 N PTO ENGAGED
2068 N PTO SOFT START
2069 U PTO MANAGEMENT ON
2070 O ENGINE SHUT OFF RELAY +12V
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2080 O ENGINE SHUT OFF RELAY
2087 O EXHAUST BRAKE SOLENOID
2090 W/U STARTER RELAY TO START INHIBIT SWITCH
2095 G INSTRUMENT SIGNAL GROUND
2100 G A/C CONDENSER MOTOR FEED
2120 LN PTO BRAKE SIGNAL
2130 N PTO BRAKE SOLENOID
2140 O PTO SPEED SENSOR
2150 P PTO EXT. SWITCH OFF
2151 K EPTO DRIVE RELAY UPPER SPEED
2152 K ESPTO DRIVE RELAY LOWER SPEED
2153 R ESPTO ACTUATOR UPPER SPEED
2154 N ESPTO ACTUATOR LOWER SPEED
2155 N ESPTO ACTUATOR POWER +12V
2156 N ESPTO ACTUATOR POS SIGNAL
2157 U ESPTO NEUTRAL
2158 N ESPTO LOWER SPEED
2159 U ESPTO UPPER SPEED
2200 G SERVICE MODE INITIATE
2245 K PTO FRONT - SWITCH TO MODULE (MOM)
2248 K PTO FRONT - SWITCH (VCCS)
2250 K PTO FRONT - SUPPLY
2260 O PTO FRONT - SPEED SIGNAL
2270 O PTO FRONT - WARNING LAMP
2300 P THEORETICAL GROUND SPEED ISO 11786 SKT.PIN#2
2310 P IN/OUT OF WORK-HPL MODE ISO11786 SKT.PIN#4
2320 P TRUE GROUND SPEED ISO 11786 SKT.PIN#1
2330 P PTO SPEED ISO11876 SKT.PIN#3
2500 N FRONT HITCH SOLENOID
2510 N FRONT HITCH POSITION SIGNAL
2520 N FRONT HITCH SET POSITION SIGNAL
2530 N FRONT HITCH V REF
2540 N FRONT HITCH +12v IGN
2550 N FRONT HITCH OVERIDE SWITCH
2556 N/Y/S FRONT HITCH SWITCH COMMON RAIL
2560 N FRONT HITCH 0v REF
2570 R FRONT HITCH RAISE SOLENOID
2571 S FRONT HITCH RAISE SOLENOID RETURN(-)
2575 W STEYR EFH TRANSPORT SIGNAL – BOSCH EFH MODULE
2576 W STEYR EFH WORK SIGNAL – BOSCH EFH MODULE
2577 P STEYR EFH DIAGNOSTIC LAMP – BOSCH EFH MODULE
2578 G STEYR EFH TRANSPORT SWITCH – EOLBAU ARMREST
2579 N STEYR EFH WORK SWITCH – EOLBAU ARMREST
2580 R FRONT HITCH LOWER SOLENOID
2581 S FRONT HITCH LOWER SOLENOID RETURN (-)
2582 LG STEYR - EXT SWITCHES
2583 LN STEYR - EXT SWITCHES
2584 W OILMOTOR MODE
2585 LN EFH RAISE SWITCH
2586 LN EFH WORK SWITCH
2587 N EFH EXTERNAL SWITCH +
2588 P EFH EXTERNAL SWITCH UP
2589 R EFH EXTERNAL SWITCH DOWN
2590 LN EXTERNAL SWITCH FHPL UP
2591 LN EXTERNAL SWITCH FHPL DOWN
2592 N EFH VALVE DOWN +
2593 N EFH VALVE DOWN -
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2594 O EFH POSITION SENSOR +
2595 P EFH POSITION SENSOR SIGNAL
2596 R EFH POSITION SENSOR -
2597 LN EFH PRESSURE SENSOR SIGNAL
2598 S EFH ACCUMULATOR 14 BAR
2599 N EFH ACCUMULATOR 40 BAR
2600 Y REAR AXLE SPEED MONITOR
3000 G FLASHER UNIT SUPPLY (TERMINAL 49)
3001 G LEFT HAND FLASHER CIRCUIT
3002 G RIGHT HAND FLASHER CIRCUIT
3003 W RADIO FEED
3004 G RIGHT HAND TURN SIGNAL WARNING LAMP
3005 G LEFT HAND TURN SIGNAL WARNING LAMP
3006 G AUXILIARY FUEL TANK SENDER
3007 G FUEL GAUGE FEED
3008 U WORKLAMP WARNING LIGHT
3009 G FLASHER UNIT SUPPLY B+
3010 R FOGLAMP FEED
3011 R FOGLAMP FEED
3012 G HANDBRAKE WARNING FEED
3013 LG AUXILIARY FUEL TANK SIGNAL
3014 R HANDBRAKE WARNING LAMP SIGNAL
3015 P ACCESSORY SOCKET (POWER)
3016 S BRAKE FLUID LEVEL SIGNAL
3017 G EPB SYSTEM FAILURE WARNING LIGHT
3018 G FLASHER UNIT BUZZER FEED
3019 G EPB SYSTEM OPERATION STATUS LIGHT
3020 Y DUAL POWER SOLENOID SUPPLY
3022 Y DUAL POWER (HIGH) WARNING LAMP
3023 P EPB SYSTEM BATTERY ISOLATOR INTERLOCK
3024 Y 2WD SOLENOID
3025 Y FOUR WHEEL DRIVE SOLENOID (MANUAL)
3026 Y BRAKE PEDAL SWITCH - RIGHT
3027 Y FOUR WHEEL DRIVE SOLENOID (AUTO)
3028 Y/G BRAKE PEDAL SWITCH - LEFT
3029 LN EPB +5V REFERENCE
3030 W ACCESSORY RELAY SIGNAL
3031 N EPB +12 HOT
3032 G EPB +12 IGNITION
3033 O EPB MOTOR SUPPLY “A”
3034 Y EPB POSITION SIGNAL
3035 O EPB MOTOR SUPPLY “B”
3036 O EPB SHUTTLE PARK SWITCH INPUT
3037 Y EPB PROPORTIONAL BRAKE SIGNAL
3038 Y EPB HAND THROTTLE SWITCH
3039 O EPB SHUTTLE PARK SWITCH OUTPUT
3045 Y FOUR WHEEL DRIVE WARNING LAMP
3050 P AUXILIARY FEED CONNECTOR SUPPLY
3051 P CIGAR LIGHTER SUPPLY
3052 P DOME LAMP TO DOOR SWITCH
3053 S SPEAKER RIGHT HAND
3054 S SPEAKER NEGATIVE RH
3055 S SPEAKER LEFT HAND
3056 N SPEAKER NEGATIVE LH
3057 P PUDDLE LAMP RETURN
3060 P IMPLEMENT SOCKET RELAY
3061 P IMPLEMENT SOCKET
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3062 P IMPLEMENT SOCKET SWITCH
3070 P ’B’ PILLAR SKT SUPPLY
3073 W MICROPHONE
3074 B SCREEN FOR 3073
3075 O TRAILER SOCKET (ACCESSORY FEED)
3076 O ACCESSORY SWITCH FEED
3077 Y RADIO +12VB
3078 O RADIO +12V ILLUMINATION
3079 R RADIO +12V IGNITION
3080 P CONSOLE LAMP
3081 Y TELEPHONE OUT
3082 O TELEPHONE OUT 1
3083 N TELEPHONE MUTE
3084 V AUXILIARY INPUT COMMON RAIL
3085 W AUXILIARY INPUT (LEFT CHANNEL)
3086 R AUXILIARY INPUT (RIGHT CHANNEL)
3087 S BUTTONS COMMON
3088 G BUTTONS ‘TELEPHONE’
3089 U BUTTONS ‘VOICE’
3090 Y SEAT PUMP SUPPLY
3091 P SPEAKER RR-RHS +
3092 P SPEAKER RR-RHS -
3093 S SPEAKER FRT-RHS +
3094 S SPEAKER FRT-RHS -
3095 W SPEAKER FRT-LHS +
3096 S SPEAKER FRT-LHS -
3097 G SPEAKER RR-LHS +
3098 G/B SPEAKER RR-LHS -
3100 G STEERING SENSOR +5v
3120 K STEERING SENSOR SIGNAL
3140 LG STEERING SENSOR GROUND
3150 W HANDBRAKE SWITCH (N.C CONTACT) OFF SIG
3155 W HANDBRAKE TRANS INTERLOCK
3160 O/G/Y AUTO GUIDANCE STEERING PRESS SENSOR SIGNAL
3161 O/G/B AUTO GUIDANCE STEERING PRESS SENSOR RETURN
3163 O/W AUTO GUIDANCE STEERING SOLENOID VLV R FEED
3164 O/W/B AUTO GUIDANCE STEERING SOLENOID VLV R RETURN
3165 O/R AUTO GUIDANCE STEERING SOLENOID VLV L FEED
3166 O/R/B AUTO GUIDANCE STEERING SOLENOID VLV L RETURN
3167 O/N AUTO GUIDANCE STEERING PRESSURE SENSOR +5V REF
3168 O/K AUTO GUIDANCE DUMP SOLENOID FEED (HSD)
3169 O/S AUTO GUIDANCE DUMP SOLENOID RETURN (CURSEN)
3170 O FAST STEER SYSTEM (FSS)- ENABLE
3171 O/R FSS - LAMP
3172 L FSS - STEERING PROXIMITY SENSOR POSITION
3173 R/G FSS - HYD. VALVE HIGH SIDE DRIVER
3174 G/B FSS - HYD. VALVE LOW SIDE DRIVER
3175 W FSS - POSITION SENSOR PRIMARY POSITIVE
3176 B FSS - POSITION SENSOR PRIMARY NEGATIVE
3177 U FSS - POSITION SENSOR SECONDARY COMMON
3178 G/Y FSS - POSITION SENSOR SECONDARY POSITIVE
3179 N FSS - POSITION SENSOR SECONDARY NEGATIVE
3180 B FSS - SAFETY SWITCH
3181 S/O AUTO GUIDANCE PPS SIGNAL INPUT TO GPS
3185 N/R/Y AUTO GUIDANCE REMOTE ENGAGE
3186 S CERES PPS IN
3187 N/O/Y AUTO GUIDANCE ROADING SELECT
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3200 O SUSPENSION SWITCH FEED
3210 U SUSPENSION SWITCH RETURN
3215 U SUSPENSION LAMP
3220 O AXLE HEIGHT SENSOR 5V REF
3230 U AXLE HEIGHT SENSOR POSITION
3235 O/R/S ACCELEROMETER SIGNAL
3240 O RAISE SOLENOID PWR
3250 O RAISE SOLENOID RET
3260 O LOWER SOLENOID PWR
3270 O LOWER SOLENOID RET
3271 U LOADER RELAY FEED
3272 O LOADER VALVE #1 OUT
3273 O LOADER VALVE #1 RETURN
3274 R LOADER VALVE #2 OUT
3275 R LOADER VALVE #2 RETURN
3276 G LOADER VALVE
3277 U LOADER VALVE #3 COIL
3278 U LOADER VALVE #3 RELAY
3280 O SUSPENSION LOCKOUT SOLENOID UPPER
3281 LN SUSPENSION LOCKOUT SOLENOID UPPER RETURN (-)
3285 LN SUSPENSION LOCKOUT SOLENOID LOWER
3286 LN SUSPENSION LOCKOUT SOLENOID LOWER RETURN (-)
3290 O SUSPENSION LOCKOUT LAMP (OR SOLENOID RET)
3295 LN/U/Y FRONT SUSPENSION PRESSURE SWITCH SIGNAL
3300 O SENSE LINE CONTROL SOLENOID
3310 U RAISE LOCKOUT SOLENOID
3500 W POWER STEERING PRESSURE SIGNAL
4001 R TRANSMISSION OIL WARNING LAMP (TEMP)
4002 R TRANSMISSION OIL WARNING LAMP SWITCH
4010 N RETURN TO DIG
4011 P ROTATING BEACON SWITCH SUPPLY
4012 P ROTATING BEACON FEED
4013 U TRANS CONTROL FEED
4014 U FORWARD CLUTCH SOLENOID FEED
4015 U REVERSE CLUTCH SOLENOID FEED
4016 U TORQUE CONVERTOR LOCK-UP RELAY FEED
4017 U TORQUE CONVERTOR LOCK-UP LAMP
4018 S TORQUE CONVERTOR LOCK-UP SOLENOID FEED
4019 S HYDRAULIC FILTER BY-PASS SWITCH FEED
4020 S HYDRAULIC FILTER BY-PASS LAMP
4021 S BACK-UP ALARM RELAY FEED
4022 S BACK-UP ALARM FEED
4025 Y 4 IN 1 BUCKET FEED
4040 G LINK LEVEL SWITCH SUPPLY
4050 W LINK LEVEL RAISE
4051 W LINK LEVEL LOWER
4052 W LINK LEVEL EXTEND SIDE
4053 W LINK LEVEL RETRACT SIDE
4054 W LINK LEVEL SAFETY VALVE (DUMP)
4055 W LINK LEVEL TOP LINK EXTEND SOLENOID
4056 W LINK LEVEL TOP LINK RETRACT SOLENOID
4057 W LINK LEVEL RIGHT LINK RAISE SOLENOID
4058 W LINK LEVEL RIGHT LINK LOWER SOLENOID
4060 W/G/Y HYDRAULIC SELECT FRONT
4061 W/R/Y HYDRAULIC SELECT REAR
4100 TQ TRANS RANGE ENABLE SWITCH SUPPLY
4101 TQ TRANS RANGE ENABLE
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4120 P/R BEACON RELAY COIL
5000 P EDC MEMORY POWER
5005 N EDC KEY SWITCH FEED
5010 B/W EDC EARTH
5011 B EDC EARTH CASE RFI
5015 R EDC CONTROLS BACKLIGHTING
5020 LN EDC PROC +5V REF VOLTAGE DROP POSN/RATE
5021 K EDC PROCESSOR REF VOLT (+5V) ROCKSHAFT
5022 K EDC PROCESSOR REF VOLT +5V QUADRANT
5023 K EDC PROCESSOR REF VOLT +5V HEIGHT LIMIT
5025 LN EDC LOWER SIGNAL
5030 LN EDC RAISE SIGNAL
5035 LN EDC RETURN REF. VOLTAGE EARTH
5040 LN EDC DRAFT POSITION
5045 LN EDC DROP RATE
5050 LN EDC QUADRANT
5055 LN EDC CLOCK LINE TO DISPLAY
5060 LN SERIAL DATA TO CLUSTER
5065 LN EDC RIGHT PIN
5070 LN EDC LEFT PIN
5075 K EDC VOLTAGE TO PINS
5080 K EDC ROCKSHAFT
5085 K/U EDC VALVE UP
5087 K EDC VALVE UP RETURN
5090 K EDC VALVE DOWN
5095 K EDC EXTERNAL SWITCH DOWN
5097 K EDC VALVE DOWN RETURN
5100 K EDC EXTERNAL SWITCH UP
5105 S EDC IMPLEMENT STATUS SWITCH
5110 K EDC LAMP SIGNAL
5115 K EDC SLIP SIGNAL
5120 K EDC HEIGHT LIMIT SIGNAL
5125 TQ EDC RAISE SIGNAL-RAISE WORK SWITCH
5130 TQ EDC WORK SIGNAL-RAISE WORK SWITCH
5132 TQ EDC FLOAT
5133 TQ EDC STOP
5135 TQ EDC +WHEEL SPEED SIGNAL
5140 TQ EDC -WHEEL SPEED SIGNAL
5145 TQ EDC SLIP LIMIT POT
5150 G EDC EXTERNAL SWITCH SUPPLY
5155 U EDC LOWER LIMIT POT
5160 TQ EDC HEIGHT LIMIT POT FEED
5170 LN SERIAL DATA FROM CLUSTER
5175 R ADIC KEY PAD DISABLE
5180 TQ EDC SLIP INDICATOR LAMP
5190 R HPL INTERLOCK / LIFT-O-MATIC
5200 N EDC VALVE SUPPLY
5205 N INTERNAL FENDER HITCH SWITCH - UP
5210 N EDC VALVE ENABLE
5215 N INTERNAL FENDER HITCH SWITCH - DOWN
5220 Y EDC RAISE LAMP
5230 Y EDC LOWER LAMP
5240 O EDC RAISE SIGNAL-RAISE WORK SWITCH No.2
5250 O EDC WORK SIGNAL-RAISE WORK SWITCH No.2
5270 N JOYSTICK LED – FRONT
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5300 K ECU FLASH PROGRAM SIGNAL
5400 Y CAN H
5420 G CAN L
5500 Y EHR CAN HIGH
5510 G EHR CAN LOW
5515 S EHR +12V IGN.
5520 LG EHR 5V Ref
5532 G EHR NEUTRAL SWITCH VALVE #2
5533 K EHR NEUTRAL SWITCH VALVE #3
5535 LG EHR FLOAT SWITCH VALVE#1
5536 LN EHR FLOAT SWITCH VALVE#2
5537 N EHR FLOAT SWITCH VALVE#3
5538 O EHR FLOAT SWITCH VALVE#4
5541 O EHR MAX.FLOW SWITCH VALVE #1
5542 B EHR MAX.FLOW SWITCH VALVE #2
5543 S EHR MAX.FLOW SWITCH VALVE #3
5544 TQ EHR MAX.FLOW SWITCH VALVE #4
5551 O EHR POTENTIOMETER SIGNAL VALVE#1
5553 W EHR POTENTIOMETER SIGNAL VALVE#3
5564 P EHR TIMED FLOW SWITCH #4
5574 P FENDER 3RD EHR SWITCH – UP
5576 P FENDER 3RD EHR SWITCH – DOWN
5580 TQ JOYSTICK REAR LAMP (MC)
5585 TQ JOYSTICK FRONT LAMP (MC)
5595 S EHR MASTER STOP SWITCH
5596 S EHR MASTER STOP LAMP
5597 S EHR MASTER ENABLE
5600 R HTS LIVE SIGNAL
5610 R HTS PROGRAM
5620 R HTS ON/OFF SWITCH
5625 R LIFT-O-MATIC SWITCH
5630 R/U/Y HTS MANUAL SWITCH
5640 R/S/Y HTS AUTO SWITCH
5700 W EHR J-STICK X+
5710 W EHR J-STICK X ACTIVE SWITCH
5720 W EHR J-STICK X FULL FLOW SWITCH
5730 W EHR J-STICK X FLOAT SWITCH
5740 W EHR J-STICK Y+
5750 W EHR J-STICK Y ACTIVE SWITCH
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5760 W EHR J-STICK Y FULL FLOW SWITCH
5770 W EHR J-STICK Y FLOAT SWITCH
5820 S EDC ROCKSHAFT POT
5830 S/R/Y HIGH FLOW PUMP LINK
5835 S/U/Y HYDRAULIC MASTER SWITCH HIGH FLOW PUMP LINK
5840 W FRONT HITCH DETECT INPUT
5900 G ISO BUS CAN SIGNAL LOW
5910 Y ISO BUS CAN SIGNAL HIGH
5915 B ISO BUS CAN SUPPLY GROUND
5920 R ISO BUS CAN SUPPLY POSITIVE
5930 LN ROTARY ENCODER SUPPLY
5935 O ROTARY ENCODER SIGNAL - "HOME"
5940 O ROTARY ENCODER SIGNAL - "ESC"
5955 B/LN RS232 INPUT T.E.C.U.
5960 W/LN RS232 OUTPUT T.E.C.U.
5962 R USB + 5V REF.
5964 W USB DATA -
5966 G USB DATA +
5968 B USB GROUND
5970 O ISO BUS ECU SIGNAL
5975 O ISO RELAY 2 POWER OUT
5980 U ISO BUS IMPLEMENT SIGNAL
5985 U ISO RELAY 1 POWER OUT
5990 O ROTARY ENCODER SIGNAL - "ENTER"
6000 K ENGINE SPEED SIGNAL
6001 B ENGINE ECU RESISTOR #1
6002 W ENGINE ECU RESISTOR #2
6003 R ENGINE ECU RESISTOR #3
6004 G ENGINE ECU RESISTOR #4
6057 TQ ENGINE STARTER RELAY GROUND
6010 Y THROTTLE POSITION SWITCH
6100 U ENGINE COLD ADVANCE CONTROL
6200 R MANIFOLD (GRID) HEATER SUPPLY
6300 N FAN SPEED
6305 N REVERSIBLE FAN OPTION - MOTOR FEED
6310 N FAN SOLENOID
6315 N REVERSIBLE FAN OPTION - RELAY CONTROL
6320 N FAN SPEED SENSOR 5V REF.
6325 N REVERSIBLE FAN OPTION - RELAY FEED
6327 R REVERSIBLE FAN RELAY POWER OUT
6330 N VISTRONIC FAN INPUT
6331 O FAN SPEED SENSOR GROUND
6355 N +5V LOW POWER REFERENCE
6401 G ECU TO THROTTLE POT.+5V
6402 G ECU TO THROTTLE POT. VAR
6403 G ECU TO THROTTLE POT.-
6404 G THROTTLE POT. TO LOW IDLE SWITCH
6405 G ECU TO THROTTLE POT. SWITCH
6407 O/Y/B ENGINE SHUTDOWN SIGNAL (EDC16)
6413 O ENGINE SHUTDOWN RELAY SUPPLY
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6414 G FUSED IGN.+ TO ECU
6415 G ECU TO J1939 INTERFACE CAN#1 CONN.(HI)
6416 G ECU TO J1939 INTERFACE CAN#1 CONN.(LO)
6417 N/A SCREEN BRAID FOR 6415 & 6416
6418 K ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO K
6419 K ECU TO J1941(ISO) INTERFACE #2 CONNECTOR ISO L
6431 K ECU TO DIAGNOSTIC REQUEST SWITCH (DIG 15)
6432 K ECU SWITCHED BATTERY OUTPUT TO DIAGNOSTIC REQUEST
SWITCH
6460 S HAND THROTTLE SWITCH (NOT IDLE)
6500 N CONSTANT ERPM ON/OFF
6530 N CONSTANT ERPM INCREASE
6540 N CONSTANT ERPM DECREASE
6550 N CONSTANT ERPM SET LAMP
6560 U ECU TO FUEL FILTER HEATER
6570 G ECU TO FUEL FILTER HEATER RETURN
6580 K ECU TO GRID HEATER RELAY#1
6585 O ECU TO GRID HEATER RELAY#2
6586 P ECU TO GRID HEATER RELAY RETURN
6590 LG ECU DIGITAL GROUND
6610 N ECU IGNITION SUPPLY
6620 O ECU COOLANT TEMP. SIGNAL
6630 O ECU COOLANT TEMP. GROUND
6640 O ECU AC PRESSURE NOT HIGH SWITCH
6650 O ECU BOOST GROUND
6660 O ECU BOOST TEMP.
6670 O ECU 5V BOOST
6680 O ECU BOOST PRESSURE
6690 O ECU SOLENOID VALVE SHUT OFF
6700 O ECU CRANK SHAFT OUTPUT SHAFT
6710 O ECU ENGINE SPEED
7000 U TRANS CONTROL SUPPLY
7001 U TRANS DISPLAY ILLUMINATION
7002 U TRANS MAIN CLUTCH SOL (C3/C4)
7003 U TRANS DUMP SOL
7004 U TRANS FRONT CLUTCH SOL (C1/C2)
7005 U TRANS CREEPER GR SOL
7007 R TRANS DUAL POWER PRESSURE SWITCH HIGH
7008 R TRANS DUAL POWER PRESSURE SWITCH LOW
7009 W TRANS RANGE DISABLE SWITCH
7022 S REVERSE ALARM GROUND SIGNAL
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7025 R/TQ/Y TRANS DISPLAY ENABLE
7030 U TRANS RANGE INDICATOR SWITCH COMMON
7035 N TRANS DUMP SOLENOID FEED
7040 N TRANS CREEPER SWITCH
7050 R TRANS RELAY SUPPLY - RUN
7060 R TRANS RELAY SUPPLY - START
7068 U TRANS CVT POWER SUPPLY (CVT)
7070 R TRANS FEED (IGN +)
7071 N FEED HYD FILTER RESTRICTION IND LAMP
7080 LG DIFF-LOCK SOLENOID FEED
7090 LG DIFF-LOCK SWITCH TO BRAKE SWITCH
7100 N DIFF-LOCK RELAY TO BRAKE SWITCH
7110 R PTO INHIBITOR SWITCH TO TRANS
7120 Y DIFF-LOCK WNG LP (MANUAL)
7125 LG DIFF-LOCK WNG LP (AUTO)
7126 LG DIFF LOCK PRESSURE SWITCH
7130 N HYD FILTER WNG LP
7135 N HYD FILTER PRESSURE SWITCH
7140 O DIFF-LOCK OFF SOLENOID
7150 S LOW OIL PRESSURE WRN FEED
7155 U VANE PUMP PRESSURE SENSOR SIGNAL
7160 R HYD LOW CHARGE WARNING
7170 W DIFF LOCK SWITCH (AUTO ON)
7175 Y DIFF LOCK SWITCH (MANUAL ON)
7180 U CREEPER SWITCH MOM SIGNAL
7190 K TRANS SOLENOID VALVE SUPPLY
7195 K TRANS SOLENOID VALVE RETURN
7196 Y TRANS FR/REV LOW SIDE RETURN (CVT)
7197 Y TRANS RANGE LOW SIDE RETURN (CVT)
7198 U TRANS HYDROSTATIC LOW SIDE RETURN (CVT)
7200 S TRANSMISSION SHIFT DOWN
7210 S TRANSMISSION SHIFT UP
7220 S TRANSMISSION HIGH RANGE
7225 W TRANS HI RANGE SOL - RET
7230 S TRANSMISSION LOW RANGE
7235 Y TRANS LOW RANGE SOL - RET
7240 S TRANSMISSION DISPLAY SWITCH
7245 LN DEADMAN
7250 S TRANSMISSION FORWARD SIGNAL
7260 S TRANSMISSION REVERSE SIGNAL
7265 K TRANS NEUTRAL SWITCH TO PROCESSOR (GR.SW 1)
7267 LG TRANS NEUTRAL SWITCH 2 TO PROCESSOR
7270 R TCM SERIAL DATA IN-DISPLAY DATA OUT
7275 W TCM SERIAL DATA OUT-DISPLAY DATA IN
7280 W LIMP HOME SWITCH 18x18 TRANS.
7290 W DIRECTIONAL INTERRUPT RELAY TO SOLENOID
7295 W DRIVE DISABLE SIGNAL
7321 P SOLENOID 2 18x9 RETURN
7341 Y SOLENOID F1 18x9 RETURN
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7351 S SOLENOID F2 18x9 RETURN
7355 S SOLENOID R 18x9 TRANSMISSION
7356 U SOLENOID R 18x9 RETURN
7360 W SOLENOID A 18x9 TRANSMISSION
7361 P SOLENOID A 18x9 RETURN
7370 Y SOLENOID B 18x9 TRANSMISSION
7371 P SOLENOID B 18x9 RETURN
7380 Y SOLENOID C 18x9 TRANSMISSION
7381 P SOLENOID C 18x9 RETURN
7390 Y SOLENOID PMW (F1) 18x9 TRANSMISSION
7391 P SOLENOID PWM (F1) 18x9 RETURN
7392 O SOLENOID PWM (F2) 18x9 TRANSMISSION
7393 O SOLENOID PWM (F2) 18x9 RETURN
7395 P SOLENOID CREEP 18x9 TRANSMISSION
7396 P SOLENOID CREEP 18x9 RETURN
7400 Y TRANS RPM SPEED SENSOR TO TCM INPUT
7401 P TRANS RPM SPEED SENSOR
7402 Y TRANS WHLSP FORWARD (CVT)
7403 Y TRANS WHLSP REVERSE (CVT)
7404 Y TRANS HYDROSTAT FORWARD (CVT)
7405 Y TRANS HYDROSTAT REVERSE (CVT)
7406 LG TRANS BI-DI SPEED SENSOR RET (CVT)
7407 K HYDROSTAT 1 SOLENOID +
7408 L HYDROSTAT 1 SOLENOID GND
7410 Y TRANS RPM SPEED SENSOR TO TCM OUTPUT
7411 Y/K/B TRANS HYDROSTAT INPUT SPEED SENSOR (CVT)
7420 Y TCM TO CLUTCH POSITION SWITCH
7425 Y DRIVE SIGNAL
7430 Y CLUTCH POSITION SIGNAL
7431 TQ CLUTCH ’A’ SUPPLY
7440 Y TCM TO TRACTOR EIC-AXLE OUTPUT
7450 W TRANS CREEPER INTERLOCK SUPPLY
7460 W TRANS CREEPER CLUTCH ENGAGED
7470 S TRANS CREEPER CLUTCH DISENGAGED
7475 R TRANS AUTO OFF
7476 R TRANS AUTO ON
7482 G TRANS AUTO ON/INCREASE
7492 G TRANS AUTO OFF/DECREASE
7500 G TRANS OIL TEMP. SENSOR
7560 G TRANS WARNING LAMP
7570 B/W SIGNAL GROUND
7579 U PARKLOCK SWITCH
7580 U CREEPER SOLENOID MONITOR
7581 O CREEPER POSITION SIGNAL
7582 U CREEPER RAIL SWITCH NOT
7583 U PARKLOCK SWITCH #2
7584 U PARKLOCK SENSOR SWITCH SIGNAL
7585 U PARKLOCK SOLENOID #2
7586 U/G/Y PARKLOCK SOLENOID
7587 U PARKLOCK OVERRIDE SWITCH
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7588 U PARKLOCK POSITION SIGNAL
7589 U BRAKE PRESSURE SIGNAL
7590 O TRANS CREEPER GEAR STATUS LAMP
7600 N TRANS FEATHERING SOLENOID
7620 N TRANS FEATHERING SOL. MONITOR
7630 N TRANS MAIN CLUTCH PRESSURE SWITCH
7640 LN DIAGNOSTIC PLUG RS232 IN
7650 W DIAGNOSTIC PLUG RS232 OUT
7655 Y/LN RS232 GROUND
7660 R TRANS CLUTCH DISCONNECT
7670 R TRANS FRONT SYNCHRO POSITION
7700 LN TRANS SHUTTLE DUMP SWITCH
7710 LN TRANS OIL TEMPERATURE SWITCH
7730 TN NOT IN PARKLOCK
7735 LN TRANS MID SPEED SIGNAL +
7740 LN TRANS MID SPEED SIGNAL -
7750 R TCM TO DOG 30/40 KPH SELECT
7755 P/G/S DOG ENABLE
7760 W TORQUE SENSOR
7775 K B CLUTCH PRESSURE SIGNAL
7785 O A CLUTCH PRESSURE SIGNAL
7790 TQ TRANS RANGE INPUT DIGITAL FEEDBACK (CVT)
7800 TQ TRANS FR / REV INPUT DIGITAL FEEDBACK (CVT)
7846 TQ TRANS BRAKE SOLENOID (CVT)
7847 TQ TRANS HYDROSTATIC - POSITIVE SOLENOID (CVT)
7848 TQ TRANS HYDROSTATIC - NEGATIVE SOLENOID (CVT)
7850 G TRANS DIAGNOSTIC PROGRAM VOLTAGE
7855 G TRANS DIAGNOSTIC EA
7860 G TRANS DIAGNOSTIC RCV
7865 G TRANS DIAGNOSTIC XMT
7870 G TRANS DIAGNOSTIC RTS
7875 K TRANS DIAGNOSTIC CTS
7880 B/W T C M SIGNAL GROUND
7890 TQ TRANS L-LINE DIAGNOSTIC (CVT)
7900 TQ CLUTCH ’A’ SIGNAL
7910 TQ CLUTCH ’B’ SIGNAL
7915 P TCM CLUTCH B RETURN
7920 TQ CLUTCH ’C’ SIGNAL
7925 P TCM CLUTCH C RETURN
7930 TQ CLUTCH ’D’ SIGNAL
7935 P TCM CLUTCH D RETURN
7940 TQ CLUTCH ’E’ SIGNAL
7945 P TCM CLUTCH E RETURN
7950 TQ CLUTCH SUPPLY
7960 P TRANS SLOW/FAST
7965 P HI/LO SYNCHRO SIGNAL
7970 P TRANS MED/REV
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7980 K TRANS MED RANGE
7982 W TRANS MED RANGE RET
7985 G TRANS REVERSE RANGE
7990 K TRANS BRAKE
7995 K BRAKE FLUID LEVEL
7996 R BRAKE PEDALS UNLATCHED SIGNAL
8000 N TRAILER BRAKE SOLENOID
8030 LG TRANS FWD SOLENOID
8035 P TRANS FWD SOL RET
8040 LG TRANS REV SOLENOID
8045 P TRANS REV SOL RET
8050 R TRANS REV PRESSURE
8060 U TRAILER BRAKE SUPPLY
8070 P/W/S TRAILER PARK BRAKE SOLENOID
9000 LN DIVERTER VALVE
9010 LN DIVERTER VALVE SUPPLY
9020 LN HYDRAULIC REMOTE VALVE SOL
9025 LN HYDRAULIC REMOTE VALVE SWITCH
9027 W CAL/ SEL INPUT ADIC
9028 W ADIC MEMORY B+
9031 P ADIC MEMORY B+
9032 Y IGN.+ TO POWER SKT.
9033 LN 50KPH SOLENOID+
9034 LN 50KPH SOLENOID-
9035 LN 50KPH DUMP SOLENOID
9036 LN 50KPH DUMP SOLENOID RETURN
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A002 Armrest Control Unit (GARU) Wiring harness - Electrical schematic frame 23 (A.30.A)
A004 Navigation Controller Wiring harness - Electrical schematic frame 25 (A.30.A)
A005 GPS Receiver Wiring harness - Electrical schematic frame 25 (A.30.A)
A006 Blower Motor Treiber Wiring harness - Electrical schematic frame 27 (A.30.A)
A007 Colour Display Wiring harness - Electrical schematic frame 43 (A.30.A)
A008 GARU SWCD Wiring harness - Electrical schematic frame 23 (A.30.A)
A009 Auto Guidance Data Logger Wiring harness - Electrical schematic frame 25 (A.30.A)
A010 Auxiliary Control Unit Wiring harness - Electrical schematic frame 18 (A.30.A)
A011 Integrated Control Switch Panel Wiring harness - Electrical schematic frame 23 (A.30.A)
A012 Electronic Park Brake Interface Conn. Wiring harness - Electrical schematic frame 45 (A.30.A)
A014 Keypad Wiring harness - Electrical schematic frame 21 (A.30.A)
A017 Air Condition Control Unit Wiring harness - Electrical schematic frame 27 (A.30.A)
A021 El.Hydraulic Remote Valve 1 Wiring harness - Electrical schematic frame 26 (A.30.A)
A032 Multi Function Handle Electonic Modul Wiring harness - Electrical schematic frame 23 (A.30.A)
A040 Mirror Control Wiring harness - Electrical schematic frame 29 (A.30.A)
A050 Active CAN Terminator Wiring harness - Electrical schematic frame 53 (A.30.A)
A054 Iso Bus Control Unit Wiring harness - Electrical schematic frame 47 (A.30.A)
A057 Engine Control Unit Wiring harness - Electrical schematic frame 10 (A.30.A)
A061 Control Unit Fast Steer Wiring harness - Electrical schematic frame 20 (A.30.A)
A063 Instrument Cluster Unit Wiring harness - Electrical schematic frame 21 (A.30.A)
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A066 Central Control Unit Wiring harness - Electrical schematic frame 13 (A.30.A)
A067 Foot Throttle Wiring harness - Electrical schematic frame 13 (A.30.A)
A068 Worklamps Control Unit Wiring harness - Electrical schematic frame 33 (A.30.A)
A070 Iso Bus Control Unit CAN Plus Wiring harness - Electrical schematic frame 53 (A.30.A)
A071 Iso Bus Control Unit CAN Minus Wiring harness - Electrical schematic frame 53 (A.30.A)
A072 Iso Bus Control Unit CAN Minus Wiring harness - Electrical schematic frame 53 (A.30.A)
A073 Iso Bus Control Unit CAN Plus Wiring harness - Electrical schematic frame 53 (A.30.A)
A076 Mid.Mount El.Hydraulic Remote Valve 2 Wiring harness - Electrical schematic frame 26 (A.30.A)
SENSORS
B003 Steering Pressure Sensor Wiring harness - Electrical schematic frame 25 (A.30.A)
B005 Draft Pin Left Hand Wiring harness - Electrical schematic frame 15 (A.30.A)
B006 Draft Pin Right Hand Wiring harness - Electrical schematic frame 15 (A.30.A)
B010 Axel speed Sensor (Ind.) Wiring harness - Electrical schematic frame 13 (A.30.A)
B011 Front Axle Position Sensor Wiring harness - Electrical schematic frame 18 (A.30.A)
B012 Water In Fuel Sensor Wiring harness - Electrical schematic frame 11 (A.30.A)
B013 Boost Pressure Sensor Wiring harness - Electrical schematic frame 10 (A.30.A)
B014 Oil Pressure Sensor Wiring harness - Electrical schematic frame 10 (A.30.A)
B015 Rail Pressure Sensor Wiring harness - Electrical schematic frame 10 (A.30.A)
B019 Increment Speed Sensor Wiring harness - Electrical schematic frame 10 (A.30.A)
B020 Proximity Sensor Wiring harness - Electrical schematic frame 20 (A.30.A)
B021 Position Transducer Wiring harness - Electrical schematic frame 20 (A.30.A)
B024 Fuel Tank Sensor Wiring harness - Electrical schematic frame 21 (A.30.A)
B025 PTO Twist Sensor Wiring harness - Electrical schematic frame 17 (A.30.A)
B026 PTO Speed Sensor Wiring harness - Electrical schematic frame 17 (A.30.A)
B027 Front Hitch Position Sensor Wiring harness - Electrical schematic frame 19 (A.30.A)
B029 Transmission Oil Temp Sensor Wiring harness - Electrical schematic frame 14 (A.30.A)
B035 Fly Wheel Speed Sensor Wiring harness - Electrical schematic frame 13 (A.30.A)
B036 Transmission Oil Pressure Sensor Wiring harness - Electrical schematic frame 14 (A.30.A)
B040 Air Brake Pressure Sensor Wiring harness - Electrical schematic frame 44 (A.30.A)
B042 Radar Sensor Wiring harness - Electrical schematic frame 15 (A.30.A)
B050 Temperature Outside Wiring harness - Electrical schematic frame 27 (A.30.A)
B051 Temperature Cabine Wiring harness - Electrical schematic frame 27 (A.30.A)
B053 Temperature Outlet Sensor Wiring harness - Electrical schematic frame 27 (A.30.A)
B054 Temperature Evaporator Sensor Wiring harness - Electrical schematic frame 27 (A.30.A)
B061 Hand Throttle-Sensor Wiring harness - Electrical schematic frame 23 (A.30.A)
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B063 Joystick Sensor Y Wiring harness - Electrical schematic frame 23 (A.30.A)
B064 Joystick Sensor X Wiring harness - Electrical schematic frame 23 (A.30.A)
B065 Joystick Sensor Y Wiring harness - Electrical schematic frame 23 (A.30.A)
B066 Joystick Sensor X Wiring harness - Electrical schematic frame 23 (A.30.A)
B067 Joystick Sensor Knob Wiring harness - Electrical schematic frame 23 (A.30.A)
DIODES
V001 Get U Home Diode Wiring harness - Electrical schematic frame 33 (A.30.A)
V004 Dipped Beam Headlamps Diode Wiring harness - Electrical schematic frame 33 (A.30.A)
V005 Brake Light Diode Wiring harness - Electrical schematic frame 40 (A.30.A)
V006 Brake Light Diode Wiring harness - Electrical schematic frame 40 (A.30.A)
V007 El. Battery Isolator Diode Wiring harness - Electrical schematic frame 08 (A.30.A)
V010 Main Beam Headlamps Diode Wiring harness - Electrical schematic frame 33 (A.30.A)
LAMPS AND LEDS

E002 Headlamp 2 Left Hand Grabrail Wiring harness - Electrical schematic frame 37 (A.30.A)
E003 Lamp Feed Wiring harness - Electrical schematic frame 43 (A.30.A)
E004 Puddle Lamp Left Hand Wiring harness - Electrical schematic frame 39 (A.30.A)
E006 Interior Lamp Wiring harness - Electrical schematic frame 39 (A.30.A)
E007 Headlamp Left Hand Wiring harness - Electrical schematic frame 37 (A.30.A)
E008 Headlamp Right Hand Wiring harness - Electrical schematic frame 37 (A.30.A)
E009 Console Lamp Right Hand Wiring harness - Electrical schematic frame 34 (A.30.A)
E010 Grabrail Side Lamp RH / SM Vehicle RF Wiring harness - Electrical schematic frame 34 (A.30.A)
E011 Extremity Light Right Hand Wiring harness - Electrical schematic frame 32 (A.30.A)
E012 Extremity Light Left Hand Wiring harness - Electrical schematic frame 32 (A.30.A)
E013 Headlamp 1 Right Hand Grabrail Wiring harness - Electrical schematic frame 37 (A.30.A)
E014 Side Lamp Grabrail LH / SM Vehicle LF Wiring harness - Electrical schematic frame 34 (A.30.A)
E015 Worklamp Rear Left 4 Wiring harness - Electrical schematic frame 35 (A.30.A)
E016 License Plate Left Hand Wiring harness - Electrical schematic frame 34 (A.30.A)
E017 License Plate Right Hand Wiring harness - Electrical schematic frame 34 (A.30.A)
E018 Stop & Tail Lamp Right Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E019 Stop & Tail Lamp Left Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E020 Worklamp Rear Right 4 Wiring harness - Electrical schematic frame 35 (A.30.A)
E021 Worklamp Front Left 6 Wiring harness - Electrical schematic frame 35 (A.30.A)
E022 Worklamp Front Right 6 Wiring harness - Electrical schematic frame 35 (A.30.A)
E023 Trailer Lamps Wiring harness - Electrical schematic frame 38 (A.30.A)
E024 Worklamp C Pillar Left Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E025 Worklamp C Pillar Right Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E026 Corner Lamp Right Hand Wiring harness - Electrical schematic frame 37 (A.30.A)
E027 Corner Lamp Left Hand Wiring harness - Electrical schematic frame 37 (A.30.A)
E028 Worklamp Front Left 4 Wiring harness - Electrical schematic frame 35 (A.30.A)
E029 Worklamp Roof Front Left Hand 2 Wiring harness - Electrical schematic frame 33 (A.30.A)
E030 Worklamp Grabrail Left Hand Wiring harness - Electrical schematic frame 33 (A.30.A)
E031 Worklamp Left Hand Rear Wiring harness - Electrical schematic frame 33 (A.30.A)
E032 Worklamp Rear Right Hand Wiring harness - Electrical schematic frame 33 (A.30.A)
E033 Worklamp Roof Front Left Hand 2 Wiring harness - Electrical schematic frame 33 (A.30.A)
E034 Worklamp Grabrail Right Hand Front Wiring harness - Electrical schematic frame 33 (A.30.A)
E035 Rotating Beacon Left Hand Wiring harness - Electrical schematic frame 33 (A.30.A)
E036 Rotating Beacon Right Hand Wiring harness - Electrical schematic frame 33 (A.30.A)
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E038 Dipped Beam Left Wiring harness - Electrical schematic frame 36 (A.30.A)
E039 Dipped Beam Right Wiring harness - Electrical schematic frame 36 (A.30.A)
E042 Worklamp Left Hand Wiring harness - Electrical schematic frame 37 (A.30.A)
E055 License Lamp Right Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E057 License Lamp Left Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
E100 Rear PTO Lamp Wiring harness - Electrical schematic frame 24 (A.30.A)
E101 Front PTO Lamp Wiring harness - Electrical schematic frame 24 (A.30.A)
E102 El.Hydraulic Remote 1 Timer LED Wiring harness - Electrical schematic frame 24 (A.30.A)
E103 El.Hydraulic Remote 1 Motor LED Wiring harness - Electrical schematic frame 24 (A.30.A)
FUSES (PF - POWER FUSE, MF - MAXI FUSE, F - MINI FUSE)

F001 Interior and step lighting and relay mirror Wiring harness - Electrical schematic frame 02 (A.30.A)
heating
F002 Cigar lighter and power socket, cab Wiring harness - Electrical schematic frame 02 (A.30.A)
(potential 30)
F003 Coupling of the A/C compressor Wiring harness - Electrical schematic frame 02 (A.30.A)
F004 Screw terminal red (potential 30) Wiring harness - Electrical schematic frame 02 (A.30.A)
F005 Blower motor Wiring harness - Electrical schematic frame 02 (A.30.A)
F006 Station memory and work lamp control unit Wiring harness - Electrical schematic frame 02 (A.30.A)
F007 Switch - Main headlights and hazard light Wiring harness - Electrical schematic frame 02 (A.30.A)
switch
F008 Starter switch Wiring harness - Electrical schematic frame 02 (A.30.A)
F009 Front loader power Wiring harness - Electrical schematic frame 02 (A.30.A)
F010 Rear power socket (potential 15) Wiring harness - Electrical schematic frame 02 (A.30.A)
F011 Front windscreen wiper Wiring harness - Electrical schematic frame 02 (A.30.A)
F012 Rear windscreen wiper / switch, windscreen Wiring harness - Electrical schematic frame 02 (A.30.A)
washing system, front/rear
F013 Relay, brake lights Wiring harness - Electrical schematic frame 02 (A.30.A)
F014 Headlight switch and flasher Wiring harness - Electrical schematic frame 02 (A.30.A)
F015 Brake light switch and pedal lock Wiring harness - Electrical schematic frame 03 (A.30.A)
F016 Trailer brake Wiring harness - Electrical schematic frame 03 (A.30.A)
F017 Power socket, cab (potential 15) Wiring harness - Electrical schematic frame 03 (A.30.A)
F018 Air blower motor relay and driver’s seat / Wiring harness - Electrical schematic frame 03 (A.30.A)
Armrest adjust
F019 Heated mirrors Wiring harness - Electrical schematic frame 03 (A.30.A)
F020 Radar sensor, normal signal socket / keypad Wiring harness - Electrical schematic frame 03 (A.30.A)
F021 Water sensor for the fuel filter, brake fluid Wiring harness - Electrical schematic frame 03 (A.30.A)
level switch
F022 Side marker lights, right Wiring harness - Electrical schematic frame 04 (A.30.A)
F023 Side marker lights, left / licence plate lights Wiring harness - Electrical schematic frame 04 (A.30.A)
F024 Illumination - Lighting / cigar lighter - ICU - Wiring harness - Electrical schematic frame 04 (A.30.A)
VT - heated mirror switch - EHR-lock switch
F025 Dipped beam headlights relay, get you home Wiring harness - Electrical schematic frame 04 (A.30.A)
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F026 Main beam headlights Wiring harness - Electrical schematic frame 04 (A.30.A)
F027 Front work lamp (bonnet) Wiring harness - Electrical schematic frame 04 (A.30.A)
F028 Work lamp control unit / Roof rear worklamps Wiring harness - Electrical schematic frame 04 (A.30.A)
F029 Work lamp control unit / Roof front Wiring harness - Electrical schematic frame 04 (A.30.A)
worklamps + grabrail
F030 Work lamp (C-pillar) Wiring harness - Electrical schematic frame 04 (A.30.A)
F031 Rotating beacon (via work lamp control unit) Wiring harness - Electrical schematic frame 04 (A.30.A)
F032 Flasher unit Wiring harness - Electrical schematic frame 05 (A.30.A)
F033 Diagnostics plug 1/2 Wiring harness - Electrical schematic frame 05 (A.30.A)
F034 ICU 3 and hand brake switch Wiring harness - Electrical schematic frame 05 (A.30.A)
F035 Potential 30 for electronics Wiring harness - Electrical schematic frame 05 (A.30.A)
F036 4 Work lamps front roof relay Wiring harness - Electrical schematic frame 05 (A.30.A)
F037 4 Work lamps rear roof relay Wiring harness - Electrical schematic frame 05 (A.30.A)
F038 6 Work lamps front roof relay Wiring harness - Electrical schematic frame 05 (A.30.A)
F040 Radio memory Wiring harness - Electrical schematic frame 05 (A.30.A)
F043 Engine electronics (potential 15) Wiring harness - Electrical schematic frame 05 (A.30.A)
F044 Front-mounted equipment socket (B+) Wiring harness - Electrical schematic frame 05 (A.30.A)
F045 Power supply - 8 A socket (potential 15) Wiring harness - Electrical schematic frame 05 (A.30.A)
C-pillar left
F046 Engine controller B+ supply Wiring harness - Electrical schematic frame 06 (A.30.A)
F047 Engine controller B+ supply Wiring harness - Electrical schematic frame 06 (A.30.A)
F049 Viscotronic fan, relay heater grid, relay fuel Wiring harness - Electrical schematic frame 06 (A.30.A)
filter heater, exhaust brake
F050 Reversible fan Wiring harness - Electrical schematic frame 06 (A.30.A)
F051 Electronic park brake Wiring harness - Electrical schematic frame 06 (A.30.A)
F052 ICU 3 supply Wiring harness - Electrical schematic frame 06 (A.30.A)
F053 Transmission control supply (potential 15) Wiring harness - Electrical schematic frame 06 (A.30.A)
F054 PTO rear Wiring harness - Electrical schematic frame 06 (A.30.A)
F055 Supply Ignition Fast Steer / ARU 1 / A/C Wiring harness - Electrical schematic frame 07 (A.30.A)
pressure switch / ACU-CN1a / CCM-CN1a
F056 PTO front Wiring harness - Electrical schematic frame 07 (A.30.A)
F057 Supply Ignition / ACU auxiliary unit CN1a Wiring harness - Electrical schematic frame 07 (A.30.A)
front hitch
F060 Time relay battery isolator - battery isolator Wiring harness - Electrical schematic frame 07 (A.30.A)
control switch
F061 Battery Isolator Wiring harness - Electrical schematic frame 07 (A.30.A)
F070 Supply Memory Wiring harness - Electrical schematic frame 08 (A.30.A)
F071 Reserve Wiring harness - Electrical schematic frame 08 (A.30.A)
MF1 Supply to F-009, F-013, F-018, F-021, Wiring harness - Electrical schematic frame 01 (A.30.A)
F-045, F-050
F-037, F-038
MF3 Supply to V-019, F-030, K-005, K-013 Wiring harness - Electrical schematic frame 01 (A.30.A)
MF4 Supply to F-027, K-015 Wiring harness - Electrical schematic frame 01 (A.30.A)
MF5 Supply to F-026, F-031, F-051 Wiring harness - Electrical schematic frame 01 (A.30.A)
F-005, F-044
PF1 Power Fuse, Main power supply B+ (250A) Wiring harness - Electrical schematic frame 08 (A.30.A)
PF2 Power Fuse, Power Supply CCU Wiring harness - Electrical schematic frame 08 (A.30.A)
PF4 Power Fuse, ISO Bus Rear Wiring harness - Electrical schematic frame 47 (A.30.A)
PF5 Power Fuse, ISO Bus Rear Wiring harness - Electrical schematic frame 47 (A.30.A)
PF6 Power Fuse, ISO Bus Front Wiring harness - Electrical schematic frame 47 (A.30.A)
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PF7 Power Fuse, ISO Bus Front Wiring harness - Electrical schematic frame 47 (A.30.A)
PF8 Mega Fuse, Grid & Fuel Heater (125A) Wiring harness - Electrical schematic frame 08 (A.30.A)
PF9 Power Fuse, Reserve Wiring harness - Electrical schematic frame 08 (A.30.A)

G001 12v Battery Wiring harness - Electrical schematic frame 08 (A.30.A)
AUDIBLE DEVICE
H002 Horn Wiring harness - Electrical schematic frame 37 (A.30.A)
H003 Radio Speaker RHR Wiring harness - Electrical schematic frame 41 (A.30.A)
H004 Radio Speaker RHF Wiring harness - Electrical schematic frame 41 (A.30.A)
H005 Radio Speaker LHF Wiring harness - Electrical schematic frame 41 (A.30.A)
H006 Radio Speaker LHR Wiring harness - Electrical schematic frame 41 (A.30.A)
H058 Reverse Alarm Wiring harness - Electrical schematic frame 16 (A.30.A)

J001 Rear Power Socket Implement Wiring harness - Electrical schematic frame 31 (A.30.A)
J002 30Amp Power Socket Wiring harness - Electrical schematic frame 31 (A.30.A)
J003 Iso Bus Implement Socket Rear Wiring harness - Electrical schematic frame 47 (A.30.A)
Iso Implement Socket (Rear) Wiring harness - Electrical schematic frame 53 (A.30.A)
J004 Iso Bus Implement Socket Front Wiring harness - Electrical schematic frame 47 (A.30.A)
Iso Implement Socket (Front) Wiring harness - Electrical schematic frame 53 (A.30.A)
J006 8 Amp Socket Wiring harness - Electrical schematic frame 31 (A.30.A)
J007 Cigar Lighter Wiring harness - Electrical schematic frame 31 (A.30.A)
J008 Power Studs Wiring harness - Electrical schematic frame 31 (A.30.A)
J009 DIA Engine inline Wiring harness - Electrical schematic frame 31 (A.30.A)
RELAYS
K001 Wiper Module Front & Rear Wiring harness - Electrical schematic frame 42 (A.30.A)
K002
K004 Lights Relay Wiring harness - Electrical schematic frame 32 (A.30.A)
K005 Starter Motor On Wiring harness - Electrical schematic frame 08 (A.30.A)
K006 Blower Motor Wiring harness - Electrical schematic frame 27 (A.30.A)
K007 Dipped Beam Headlamps Wiring harness - Electrical schematic frame 37 (A.30.A)
K008 Stop Lamps Relay Wiring harness - Electrical schematic frame 40 (A.30.A)
K009 Main Beam Headlamps Wiring harness - Electrical schematic frame 37 (A.30.A)
K010 Hydraulic Trailer Brake Wiring harness - Electrical schematic frame 44 (A.30.A)
K011 Electronic Park Brake Wiring harness - Electrical schematic frame 45 (A.30.A)
K012 Pneumatic Trailer Brake Wiring harness - Electrical schematic frame 44 (A.30.A)
K013 Engine Shutdown Wiring harness - Electrical schematic frame 01 (A.30.A)
K014 Get U Home Wiring harness - Electrical schematic frame 33 (A.30.A)
K015 Front Worklamps Hood Wiring harness - Electrical schematic frame 37 (A.30.A)
K016 Rear Worklamps C Pillar Relay Wiring harness - Electrical schematic frame 40 (A.30.A)
K017 Power Supply ECU Wiring harness - Electrical schematic frame 06 (A.30.A)
K018 EL.Battery Isolator Wiring harness - Electrical schematic frame 08 (A.30.A)
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K019 Air Condition Clutch Relay Wiring harness - Electrical schematic frame 27 (A.30.A)
K020 El.Hydraulic Remote Lock Relay Wiring harness - Electrical schematic frame 26 (A.30.A)
K021 Timer Relay Battery Isolator Wiring harness - Electrical schematic frame 08 (A.30.A)
K022 Heated Mirror Timer Relay Wiring harness - Electrical schematic frame 29 (A.30.A)
K025 4 Worklamps Rear Relay Wiring harness - Electrical schematic frame 35 (A.30.A)
K026 4 Worklamps Front Relay Wiring harness - Electrical schematic frame 35 (A.30.A)
K027 6 Worklamps Front Relay Wiring harness - Electrical schematic frame 35 (A.30.A)
K028 Headlamp Dipped Beam Wiring harness - Electrical schematic frame 36 (A.30.A)
K029 Headlamp Main Beam Wiring harness - Electrical schematic frame 36 (A.30.A)
K040 ISO Relay 1 Rear Wiring harness - Electrical schematic frame 47 (A.30.A)
K041 ISO Relay 2 Rear Wiring harness - Electrical schematic frame 47 (A.30.A)
K042 ISO Relay 1 Front Wiring harness - Electrical schematic frame 47 (A.30.A)
K043 ISO Relay 2 Front Wiring harness - Electrical schematic frame 47 (A.30.A)
K047 Less EPL Wiring harness - Electrical schematic frame 45 (A.30.A)
K050 Relay Base Crank Isolate Wiring harness - Electrical schematic frame 25 (A.30.A)
K051 Relay Base Solenoid B Wiring harness - Electrical schematic frame 25 (A.30.A)
K052 Relay Base Solenoid A Wiring harness - Electrical schematic frame 25 (A.30.A)
K055 Front Loader Relay 1 Wiring harness - Electrical schematic frame 46 (A.30.A)
K056 Front Loader Relay 2 Wiring harness - Electrical schematic frame 46 (A.30.A)
MOTORS
M001 Blower Motor Wiring harness - Electrical schematic frame 28 (A.30.A)
M003 Starter Motor Wiring harness - Electrical schematic frame 08 (A.30.A)
M004 Wiper Motor Front Wiring harness - Electrical schematic frame 42 (A.30.A)
M005 Wiper Motor Rear Wiring harness - Electrical schematic frame 42 (A.30.A)
M006 Washer Motor Front Wiring harness - Electrical schematic frame 42 (A.30.A)
M007 Washer Motor Rear Wiring harness - Electrical schematic frame 42 (A.30.A)
M009 Seat- Compressor Wiring harness - Electrical schematic frame 16 (A.30.A)
M010 Armrest Control Unit (GARU) Wiring harness - Electrical schematic frame 23 (A.30.A)
M011 Blower Motor Wiring harness - Electrical schematic frame 27 (A.30.A)
CIRCUIT BREAKER
Q001 Battery Isolator Wiring harness - Electrical schematic frame 08 (A.30.A)
RESISTORS / POTENTIOMETERS
R001 Fuel Heater Wiring harness - Electrical schematic frame 10 (A.30.A)
R003 Resistor SJ5 Wiring harness - Electrical schematic frame 27 (A.30.A)
R005 Clutch Potentiometer Wiring harness - Electrical schematic frame 14 (A.30.A)
R007 Synchro Position Potentiometer Wiring harness - Electrical schematic frame 13 (A.30.A)
R009 4/5 Synchronisierpotentiometer Wiring harness - Electrical schematic frame 14 (A.30.A)
R016 CAN Terminating Resistor Wiring harness - Electrical schematic frame 51 (A.30.A)
R017 Seat- Heating Wiring harness - Electrical schematic frame 16 (A.30.A)
R020 Rockshaft Potentiometer Wiring harness - Electrical schematic frame 15 (A.30.A)
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R021 Rear Hitch Position Potentimeter Wiring harness - Electrical schematic frame 23 (A.30.A)
R022 Rear Hitch Draft Potentiometer Wiring harness - Electrical schematic frame 23 (A.30.A)
R023 EL.Draft Control Rear Sensitivity Poti. Wiring harness - Electrical schematic frame 23 (A.30.A)
R024 EL.Draft Control Rear Drop Rate Poti. Wiring harness - Electrical schematic frame 23 (A.30.A)
R025 EL.Draft Control Rear Hight Limit Poti. Wiring harness - Electrical schematic frame 23 (A.30.A)
R026 EL.Draft Control Rear Slip Poti. Wiring harness - Electrical schematic frame 23 (A.30.A)
R027 Front Height Seting Wiring harness - Electrical schematic frame 23 (A.30.A)
R030 Potentiometer Temp. Adjustment Wiring harness - Electrical schematic frame 27 (A.30.A)
R031 El.Hydraulic Remote 1 Control Wiring harness - Electrical schematic frame 24 (A.30.A)
SWITCHES
S001 Front Hitch Raise Wiring harness - Electrical schematic frame 19 (A.30.A)
S004 Fast Steer Control Switch Wiring harness - Electrical schematic frame 20 (A.30.A)
S005 Auto Guidance Control Switch Wiring harness - Electrical schematic frame 25 (A.30.A)
S006 Battery Isolator Control Switch Wiring harness - Electrical schematic frame 08 (A.30.A)
S008 Exhaust Brake Wiring harness - Electrical schematic frame 21 (A.30.A)
S009 Front Hitch Lower Wiring harness - Electrical schematic frame 19 (A.30.A)
S010 Hydraulics Master Switch Wiring harness - Electrical schematic frame 15 (A.30.A)
S013 Blower Speed Switch Wiring harness - Electrical schematic frame 28 (A.30.A)
S014 Air Condition Operating Mode Switch Wiring harness - Electrical schematic frame 28 (A.30.A)
S015 Heater Blower Speed Switch Wiring harness - Electrical schematic frame 27 (A.30.A)
S016 Air Conditioning Mode Switch Wiring harness - Electrical schematic frame 27 (A.30.A)
S017 Air Condition Pressure Switch Wiring harness - Electrical schematic frame 27 (A.30.A)
S018 Low Pressure Switch Wiring harness - Electrical schematic frame 28 (A.30.A)
S020 Brake Pedals Latched switch Wiring harness - Electrical schematic frame 21 (A.30.A)
S021 Main Light Switch Wiring harness - Electrical schematic frame 32 (A.30.A)
S022 Air Cleaner Switch Wiring harness - Electrical schematic frame 22 (A.30.A)
S023 Switch Worklamps 6 Front Wiring harness - Electrical schematic frame 35 (A.30.A)
S024 Rear Hitch Switch Left Hand Wiring harness - Electrical schematic frame 15 (A.30.A)
S026 Switch Headlight Roof Wiring harness - Electrical schematic frame 36 (A.30.A)
S027 Low Brake Pressure Line Switch 1/ 2 Wiring harness - Electrical schematic frame 44 (A.30.A)
S028 Hydraulic Filter Blocked (Vaccum Switch) Wiring harness - Electrical schematic frame 22 (A.30.A)
S029 Brake Fluid Level Wiring harness - Electrical schematic frame 21 (A.30.A)
S031 Front Height Enable Wiring harness - Electrical schematic frame 23 (A.30.A)
S034 EHR 3 Switch Fender Right Wiring harness - Electrical schematic frame 18 (A.30.A)
S035 EHR 3 Switch Left Fender Left Wiring harness - Electrical schematic frame 18 (A.30.A)
S037 Low Hydraulic Charge Switch Wiring harness - Electrical schematic frame 22 (A.30.A)
S041 Door Switch Right Hand Wiring harness - Electrical schematic frame 39 (A.30.A)
S042 Door Switch Left Hand Wiring harness - Electrical schematic frame 39 (A.30.A)
S044 Stop Lamp Switch Right Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
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S045 Stop Lamp switch Left Hand Wiring harness - Electrical schematic frame 40 (A.30.A)
S047 Rear PTO Switch Right Hand Wiring harness - Electrical schematic frame 17 (A.30.A)
S049 Lever Mounted PTO Brake Switch Wiring harness - Electrical schematic frame 17 (A.30.A)
S050 Rear Hitch Switch Right Hand Wiring harness - Electrical schematic frame 15 (A.30.A)
S053 Low Pump Output Press Switch 1 / 2 Wiring harness - Electrical schematic frame 44 (A.30.A)
S057 Creeper Sensing Switch rear Wiring harness - Electrical schematic frame 14 (A.30.A)
S058 Creeper Sensing Switch front Wiring harness - Electrical schematic frame 14 (A.30.A)
S060 Switch Adjust Motor Wiring harness - Electrical schematic frame 23 (A.30.A)
S061 Low Pressure Switch Wiring harness - Electrical schematic frame 27 (A.30.A)
S065 Front and Rear Wiper Switch Wiring harness - Electrical schematic frame 42 (A.30.A)
S083 Rear PTO Switch Left Hand Wiring harness - Electrical schematic frame 17 (A.30.A)
S090 Park Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S091 Neutral- Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S092 Deadman Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S094 FWD- Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S095 REV- Switch Wiring harness - Electrical schematic frame 14 (A.30.A)
S096 Seat- Switch Wiring harness - Electrical schematic frame 16 (A.30.A)
S100 High Mount Headlamp Switch Wiring harness - Electrical schematic frame 37 (A.30.A)
S110 Shuttle Forward Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S111 Shuttle Reverse Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S112 Range Increase Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S113 Range Decrease Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S114 EHR1/5 Extend Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S115 EHR1/5 Retract Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S116 Rear Hitch Fast Raise Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S117 Rear Hitch Fast Lower Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S118 HTS Step Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S119 Shift Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S121 EHR Flow Control Encoder Wiring harness - Electrical schematic frame 24 (A.30.A)
S122 Switch Loader Valve 1 Wiring harness - Electrical schematic frame 23 (A.30.A)
S123 Switch Loader Valve 2 Wiring harness - Electrical schematic frame 23 (A.30.A)
S124 MID-EHR 1&2 / 3&4 Wiring harness - Electrical schematic frame 23 (A.30.A)
S125 Switch Wiring harness - Electrical schematic frame 23 (A.30.A)
S126 EHR Float / Joystick Wiring harness - Electrical schematic frame 23 (A.30.A)
S127 EHR El.Hydraulic Remote 1 Timer / Motor Wiring harness - Electrical schematic frame 24 (A.30.A)
Switchch
S128 El.Hydraulic Remote 2 Timer / Motor Switch Wiring harness - Electrical schematic frame 24 (A.30.A)
ANTENNA
W001 Antenna Plus Wiring harness - Electrical schematic frame 41 (A.30.A)
CONNECTOR
X005 GPS Receiver Wiring harness - Electrical schematic frame 50 (A.30.A)
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X028 Diagnostic Connector 2 Wiring harness - Electrical schematic frame 48 (A.30.A)
X030 Diagnostic Connector 1 Wiring harness - Electrical schematic frame 48 (A.30.A)
X031 ADIC Diagnostic Connector Wiring harness - Electrical schematic frame 48 (A.30.A)
X436 ISO 11786 Signal Socket Wiring harness - Electrical schematic frame 21 (A.30.A)
X488 USB Connector Wiring harness - Electrical schematic frame 43 (A.30.A)
SOLENOID
Y001 Exhaust Brake Solenoid Wiring harness - Electrical schematic frame 10 (A.30.A)
Y004 Upper Lockout Solenoid Wiring harness - Electrical schematic frame 18 (A.30.A)
Y005 Lower Lockout Soleniod Wiring harness - Electrical schematic frame 18 (A.30.A)
Y010 Loader Valve Option B Wiring harness - Electrical schematic frame 46 (A.30.A)
Y011 High Pressure Pump Wiring harness - Electrical schematic frame 10 (A.30.A)
Y012 EDC Valve Raise Wiring harness - Electrical schematic frame 15 (A.30.A)
Y013 EDC Valve Lower Wiring harness - Electrical schematic frame 15 (A.30.A)
Y015 Fast Steer Solenoid Wiring harness - Electrical schematic frame 20 (A.30.A)
Y016 Front PTO Solenoid Wiring harness - Electrical schematic frame 19 (A.30.A)
Y021 Brake De-Icer Wiring harness - Electrical schematic frame 44 (A.30.A)
Y022 Pneumatic Trailer Brake Solenoid Wiring harness - Electrical schematic frame 44 (A.30.A)
Y023 Park Brake Solenoid Wiring harness - Electrical schematic frame 44 (A.30.A)
Y031 17th Dump Solenoid Wiring harness - Electrical schematic frame 14 (A.30.A)
Y036 Loader Valve Option A Wiring harness - Electrical schematic frame 46 (A.30.A)
Y037 Hydraulic Trailer Brake Solenoid 1 / 2 Wiring harness - Electrical schematic frame 44 (A.30.A)
Y038 Diff Lock Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y044 Auto Guidance Dump Solenoid Wiring harness - Electrical schematic frame 25 (A.30.A)
Y050 Steering Solenoid Right Hand Wiring harness - Electrical schematic frame 25 (A.30.A)
Y051 Steering Solenoid Left Hand Wiring harness - Electrical schematic frame 25 (A.30.A)
Y052 Heating Valve Wiring harness - Electrical schematic frame 27 (A.30.A)
Y061 Injector 1 Wiring harness - Electrical schematic frame 11 (A.30.A)
Y069 Diverter Solenoid Wiring harness - Electrical schematic frame 13 (A.30.A)
Y082 Air Condition Clutch Wiring harness - Electrical schematic frame 27 (A.30.A)
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ASSEMBLY
Z001 Blower Assembly Wiring harness - Electrical schematic frame 27 (A.30.A)
Z003 El.Hydraulic Remote Lamps 1 & 2 & Swich Wiring harness - Electrical schematic frame 24 (A.30.A)
Z006 Diode Block Wiring harness - Electrical schematic frame 33 (A.30.A)
Z007 Joystick 2 Wiring harness - Electrical schematic frame 23 (A.30.A)
Z011 Joystick 1 Wiring harness - Electrical schematic frame 23 (A.30.A)
Z032 Multi Function Handle Wiring harness - Electrical schematic frame 23 (A.30.A)
Z038 Electric Mirror Right Hand Wiring harness - Electrical schematic frame 29 (A.30.A)
Z039 Electric Mirror Left Hand Wiring harness - Electrical schematic frame 29 (A.30.A)
Z043 Front Hitch Setting Wiring harness - Electrical schematic frame 23 (A.30.A)
Z044 Rear Hitch Setting Wiring harness - Electrical schematic frame 23 (A.30.A)
Z062 Shuttle Lever Wiring harness - Electrical schematic frame 14 (A.30.A)
Z065 Seat Assembly Wiring harness - Electrical schematic frame 16 (A.30.A)
Z069 Air Condition Assembly Wiring harness - Electrical schematic frame 27 (A.30.A)
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Wiring harness - Electrical schematic frame 01 Power Distribution

(Maxifuses 1 - 6)

nent
K013 X037 Engine Shutdown
MF1 X060, X070 Supply to F009, F013, F018, F021, F045, F050
MF2 X070 Supply to F006, F007, F008, F036, F037, F038
MF3 X070 Supply to V019, F030, K005, K013
MF4 X070 Supply to F027, K015
MF5 X070 Supply to F026, F031, F051
MF6 X070 Supply to F001, F002, F003, F004, F005, F044
Z002 X070 Maxi Fuseholder
Additional Connectors: -
Wire Colour Codes

Green
Brown
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SS09G001 1
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(Fuses 1 - 14)
MAXXUM 110 Multicontroller [Z9BE40001 - ], MAXXUM 110 Multicontroller [Z9BE60001 - ], MAXXUM 115 Multicontroller [Z9BE40001 - ], MAXXUM 115 Multicontroller
[Z9BE60001 - ], MAXXUM 120 Multicontroller [Z9BE40001 - ], MAXXUM 120 Multicontroller [Z9BE60001 - ], MAXXUM 125 Multicontroller [Z9BE40001 - ], MAXXUM
125 Multicontroller [Z9BE60001 - ], MAXXUM 130 Multicontroller [Z9BE40001 - ], MAXXUM 130 Multicontroller [Z9BE60001 - ], MAXXUM 140 Multicontroller
[Z9BE40001 - ], MAXXUM 140 Multicontroller [Z9BE60001 - ]
Component Connector Description

F001 X073 Interior and step lighting and relay mirror heating
F002 X073 Cigar lighter and power socket, cab (potential 30)
F003 X073 Coupling of the A/C compressor
F004 X073 Screw terminal red (potential 30)
F005 X073 Blower motor
F006 X073 Station memory and work lamp control unit
F007 X073 Switch - Main headlights and hazard light switch
F008 X073 Starter switch
F009 X073 Front loader power
F010 X073 Rear power socket (potential 15)
F011 X073 Front windscreen wiper
F012 X073 Rear windscreen wiper / switch, windscreen washing system, front/rear
F013 X073 Relay, brake lights
F014 X073 Headlight switch and flasher
K003 X034 Ignition Relay
Z002 X073 Fusemodul
Wire Colour Codes

N Brown R Red LG Light Green K Pink
LN Light Brown O Orange U Blue W White
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SS09G002 1
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(Fuses 15 - 21)

F015 X073 Brake light switch and pedal lock
F016 X073 Trailer brake
F017 X073 Power socket, cab (potential 15)
F018 X073 Air blower motor relay and driver’s seat / Armrest adjust
F019 X073 Heated mirrors
F020 X073 Radar sensor, normal signal socket / keypad
F021 X072 Water sensor for the fuel filter, brake fluid level switch
Z002 X073 Fusemodul
Z002 X072 Fusemodul
X024
Wire Colour Codes

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SS09G003 1
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(Fuses 22 - 30)

F022 X072 Side marker lights, right
F023 X072 Side marker lights, left / licence plate lights
F024 X072 Illumination - Lighting / cigar lighter - ICU - VT - heated mirror switch - EHR-lock switch
F025 X072 Dipped beam headlights relay, get you home
F026 X072 Main beam headlights
F027 X072 Front work lamp (bonnet)
F028 X072 Work lamp control unit / Roof rear worklamps
F029 X072 Work lamp control unit / Roof front worklamps + grabrail
F030 X072 Work lamp (C-pillar)
Z002 X072 Fusemodul
Wire Colour Codes

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SS09G004 1
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(Fuses 31 - 45)

F031 X072 Rotating beacon (via work lamp control unit)
F032 X072 Flasher unit
F033 X072 Diagnostics plug 1/2
F034 X072 ICU 3 and hand brake switch
F035 X072 Potential 30 for electronics
F036 X072 4 Work lamps front roof relay
F037 X072 4 Work lamps rear roof relay
F038 X072 6 Work lamps front roof relay
F040 X072 Radio memory
F043 X071 Engine electronics (potential 15)
F044 X071 Front-mounted equipment socket (B+)
F045 X071 Power supply - 8 A socket (potential 15) C-pillar left
S007 X003 Starter Switch
Z002 X072 Fusemodul
Z002 X071 Fusemodul
X024
Wire Colour Codes

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SS09G005 1
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(Fuses 46 - 54)

F046 X071 Engine controller B+ supply
F047 X071 Engine controller B+ supply
F049 X071 Viscotronic fan, relay heater grid, relay fuel filter heater, exhaust brake
F050 X071 Reversible fan
F051 X071 Electronic park brake
F052 X071 ICU 3 supply
F053 X071 Transmission control supply (potential 15)
F054 X071 PTO rear
K017 X074 Power Supply ECU
Z002 X071 Fusemodul
X026
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 328
SS09G006 1
84276322A 31/05/2010
A.30.A / 329

(Fuses 55 - 60)

F055 X071 Supply Ignition Fast Steer / ARU 1 / A/C pressure switch / ACU-CN1a / CCM-CN1a
F056 X071 PTO front
F057 X071 Supply Ignition / ACU auxiliary unit CN1a front hitch
F060 X071 Time relay battery isolator - battery isolator control switch
F061 X076 Battery Isolator
Z002 X071 Fusemodul
Z006 X076 Diode Block
X110, X127, X620
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 330
SS09G007 1
84276322A 31/05/2010
A.30.A / 331
Wiring harness - Electrical schematic frame 08 Start / Charging (Starting

& Charging W/Isolator)

F070 X923 Supply Memory
F071 X924 Reserve
G001 X608, X892, 12 V Battery
X815, X890,
X810
G002 X236, X237 Alternator
K005 X035 Starter Motor On
K018 X074 EL.Battery Isolator
K021 X032 Timer Relay Battery Isolator
M003 X231, X232 Starter Motor
PF1 X920 Power Fuse, Main power supply B+ ( 250 A)
PF2 X921 Power Fuse, Power Supply CCU
PF8 X823 Mega Fuse, Grid & Fuel Heater ( 125 A)
PF9 X922 Power Fuse, Reserve
Q001 X466, X891 Battery Isolator
S006 X482 Battery Isolator Control Switch
V007 X076 El. Battery Isolator Diode
X021, X023, X024, X025, X026
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 332
SS09G055 1
84276322A 31/05/2010
A.30.A / 333
Wiring harness - Electrical schematic frame 09 Start / Charging (Starting

& Charging without Isolator)

F070 X923 Supply Memory
F071 X924 Reserve
G001 X608, X892, 12 V Battery
X815, X890,
X810
G002 X236, X237 Alternator
M003 X231, X232 Starter Motor
PF1 X920 Power Fuse, Main power supply B+ ( 250 A)
PF2 X921 Power Fuse, Power Supply CCU
PF8 X823 Mega Fuse, Grid & Fuel Heater ( 125 A)
PF9 X922 Power Fuse, Reserve
X021, X023, X025
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 334
SS09G009 1
84276322A 31/05/2010
A.30.A / 335
Wiring harness - Electrical schematic frame 10 Engine Control Unit

(Engine ECU 1)

A057 X213, X218 Engine Control Unit
B013 X828 Boost Pressure Sensor
B014 X829 Oil Pressure Sensor
B015 X830 Rail Pressure Sensor
B016 X831 Coolant Temperature Sensor
B017 X832 Fuel Temperature Sensor
B018 X835 Camshaft Speed Sensor
B019 X834 Increment Speed Sensor
K023 X215 Grid Heater Relay
K024 X216 Fuel Heater Relay
R001 - Fuel Heater
R002 - Grid Heater
Y001 X573 Exhaust Brake Solenoid
Y011 X833 High Pressure Pump
X026, X219
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 336
SS09G010 1
84276322A 31/05/2010
A.30.A / 337
Wiring harness - Electrical schematic frame 11 Engine Control Unit

(Engine ECU 2)

A057 X213, X218 Engine Control Unit
B012 X242 Water In Fuel Sensor
Y061 X825 Injector 1
X026, X239
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 338
SS09G011 1
84276322A 31/05/2010
A.30.A / 339

(Power Earthing)

- - SP-021, 087, 101, 102, 131, 136, 143
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 340
SS09G012 1
84276322A 31/05/2010
A.30.A / 341
Wiring harness - Electrical schematic frame 13 Transmission Controller

(Transmission 1)

A066 X091, X092, Central Control Unit
X093, X094,
X095, X097,
X099
A067 X015 Foot Throttle
B010 X871 Axel speed Sensor (Ind.)
B035 X289 Fly Wheel Speed Sensor
R007 X297 Synchro Position Potentiometer
S054 X299 Ground Speed PTO Engaged Switch
S055 X296 High Range Switch
S056 X295 Low Range Switch
Y025 X292 Clutch C2 Solenoid
Y030 X264 17th Gear Solenoid
Y038 X276 Diff Lock Solenoid
Y039 X280 Creeper Solenoid
Y040 X279 4WD Solenoid
Y041 X286 Forward Synchro Solenoid
Y069 X321 Diverter Solenoid
- X113 Ground Speed PTO Switch Link
X020, X022
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 342
SS09G013 1
84276322A 31/05/2010
A.30.A / 343

(Transmission 2)

X093, X094,
X095, X097
B029 X290 Transmission Oil Temp Sensor
B036 X273 Transmission Oil Pressure Sensor
R005 X002 Clutch Potentiometer
R009 X298 4/5 Synchronisierpotentiometer
S003 X001 Clutch Switch
S057 X281 Creeper Sensing Switch rear
S058 X282 Creeper Sensing Switch front
S091 X012 Neutral- Switch
S092 X012 FWD- OR- REV Switch
S094 X012 FWD- Switch
S095 X012 REV- Switch
Y031 X263 17th Dump Solenoid
Y042 X285 Reverse Synchro Solenoid
Y067 X287 1-4 Synchro Solenoid
Y068 X288 5-8 Synchro Solenoid
Z062 X012 Shuttle Lever
X020, X022
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 344
SS09G014 1
84276322A 31/05/2010
A.30.A / 345

(Electronic Draft Control)

X093, X094,
X097
B005 X266 Draft Pin Left Hand
B006 X256 Draft Pin Right Hand
B042 X233 Radar Sensor
R020 X267 Rockshaft Potentiometer
S010 X681 Hydraulics Master Switch
S024 X407 Rear Hitch Switch Left Hand
S050 X407 Rear Hitch Switch Right Hand
Y012 X268 EDC Valve Raise
Y013 X269 EDC Valve Lower
X020, X022, X024, X110, X127
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 346
SS09G015 1
84276322A 31/05/2010
A.30.A / 347

(5V Supply, Sensor Ground, Seat)

X095, X097
H058 X018 Reverse Alarm
M009 X081 Seat- Compressor
R017 X081 Seat- Heating
S096 X081 Seat- Switch
Z065 X081 Seat Assembly
X020, X022, X026
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 348
SS09G016 1
84276322A 31/05/2010
A.30.A / 349

(Power Take Off)

X094, X095,
X097
B025 X262 PTO Twist Sensor
B026 X251 PTO Speed Sensor
S011 X067 Rear PTO Brake Switch
S047 X406 Rear PTO Switch Right Hand
S049 X059A Lever Mounted PTO Brake Switch
S083 X406 Rear PTO Switch Left Hand
Y018 X277 Rear PTO Brake Solenoid
Y019 X278 Rear PTO Solenoid
- X059B Lever Mounted PTO Mating Half
X022, X110, X127, X748
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 350
SS09G017 1
84276322A 31/05/2010
A.30.A / 351
Wiring harness - Electrical schematic frame 18 Auxiliary Control Unit

(Suspention Front Axle, EHR’S, Link Levelling)

A010 X098, X099, Auxiliary Control Unit
X100, X101,
X102
B011 X662 Front Axle Position Sensor
S034 X401 EHR 3 Switch Fender Right
S035 X401 EHR 3 Switch Left Fender Left
Y002 X505 Suspension Raise Solenoid
Y003 X506 Suspension Lower Solenoid
Y004 X507 Upper Lockout Solenoid
Y005 X508 Lower Lockout Soleniod
X020, X022, X024, X227, X234, X259, X817
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 352
SS09G056 1
84276322A 31/05/2010
A.30.A / 353
Wiring harness - Electrical schematic frame 19 Auxiliary Control Unit

(Front Hitch, PTO)

A010 X098, X099,
X100, X101
A066 X097 Central Control Unit
B027 X395 Front Hitch Position Sensor
S001 X394 Front Hitch Raise
S009 X392 Front Hitch Lower
X684 X684 Front Hitch Detect
Y016 X393 Front PTO Solenoid
X024, X026, X227, X817
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 354
SS09G019 1
84276322A 31/05/2010
A.30.A / 355
Wiring harness - Electrical schematic frame 20 Fast Steer (Steering

Control Unit)

A061 X621 Control Unit Fast Steer
B020 X625 Proximity Sensor
B021 X626 Position Transducer
S004 X624 Fast Steer Control Switch
Y015 X627 Fast Steer Solenoid
X623
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 356
SS09G020 1
84276322A 31/05/2010
A.30.A / 357
Wiring harness - Electrical schematic frame 21 Lighting (Instrument

Cluster)

A014 X008 Keypad
A063 X005, X006, Instrument Cluster Unit
X009
B004 X235 Steering Angle Sensor (Auto Guidance)
B024 X265 Fuel Tank Sensor
S008 X551 Exhaust Brake
S020 X016 Brake Pedals Latched switch
S029 X221 Brake Fluid Level
- X114 ISO 11786 Signal Socket
X020, X022, X024, X026, X106, X114
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 358
SS09G021 1
84276322A 31/05/2010
A.30.A / 359
Wiring harness - Electrical schematic frame 22 Instruments (Instrument

Cluster)

A063 X005, X009 Instrument Cluster Unit
S022 X223, X224 Air Cleaner Switch
S028 X474 Hydraulic Filter Blocked (Vaccum Switch)
S037 X260 Low Hydraulic Charge Switch
X020, X026, X683B
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 360
SS09G022 1
84276322A 31/05/2010
A.30.A / 361
Wiring harness - Electrical schematic frame 23 Electronic Control Unit 1

(Arm Rest)

A002 X776 Armrest Control Unit (GARU)
A008 X820, X862 GARU SWCD
A011 X847, X848 Integrated Control Switch Panel
A032 X846 Multi Function Handle Elektonic Modul
B061 X846 Hand Throttle-Sensor
B063 X844 Joystick Sensor Y
B064 X844 Joystick Sensor X
B065 X845 Joystick Sensor Y
B066 X845 Joystick Sensor X
B067 X845 Joystick Sensor Knob
M010 X788 Armrest Control Unit (GARU)
R021 X848 Rear Hitch Position Potentimeter
R022 X848 Rear Hitch Draft Potentiometer
R023 X850 EL.Draft Control Rear Sensitivity Poti.
R024 X850 EL.Draft Control Rear Drop Rate Poti.
R025 X850 EL.Draft Control Rear Hight Limit Poti.
R026 X850 EL.Draft Control Rear Slip Poti.
R027 X849 Front Height Seting
S031 X849 Front Height Enable
S060 X777 Switch Adjust Motor
S110 X846 Shuttle Forward Switch
S111 X846 Shuttle Reverse Switch
S112 X846 Range Increase Switch
S113 X846 Range Decrease Switch
S114 X846 EHR1/5 Extend Switch
S115 X846 EHR1/5 Retract Switch
S116 X846 Rear Hitch Fast Raise Switch
S117 X846 Rear Hitch Fast Lower Switch
S118 X846 HTS Step Switch
S119 X846 Shift Switch
S122 X844 Switch Loader Valve 1
S123 X844 Switch Loader Valve 2
S124 X844 MID-EHR 1&2 / 3&4
S125 X845 Switch
S126 X843 EHR Float / Joystick
Z007 X844, X845 Joystick 2
Z011 X844 Joystick 1
Z032 X846 Multi Function Handle
Z043 X849 Front Hitch Setting
Z044 X850 Rear Hitch Setting
- X400 Bridge Diverter Switch
X022, X080, X088, X787
Wire Colour Codes

84276322A 31/05/2010
A.30.A LN
/ 362 Light Brown O Orange U Blue W White
SS09G023 1
84276322A 31/05/2010
A.30.A / 363
Wiring harness - Electrical schematic frame 24 Electronic Control Unit 2

(Arm Rest)

E100 X840 Rear PTO Lamp
E101 X841 Front PTO Lamp
E102 X854, X859 El.Hydraulic Remote 1 Timer LED
E103 X854, X859 El.Hydraulic Remote 1 Motor LED
R031 X853 El.Hydraulic Remote 1 Control
S002 X841 Front PTO Switch
S012 X840 Rear PTO Switch
S121 X842 EHR Flow Control Encoder
S127 X854, X859 EHR El.Hydraulic Remote 1 Timer / Motor Switch
S128 X854, X859 El.Hydraulic Remote 2 Timer / Motor Switch
Z003 X854, X859 El.Hydraulic Remote Lamps 1 & 2 & Switch
X080
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 364
SS09G024 1
84276322A 31/05/2010
A.30.A / 365
Wiring harness - Electrical schematic frame 25 Steering (Auto Guidance)


A004 X716, X720 Navigation Controller
A005 X719 GPS Receiver
A009 X717 Auto Guidance Data Logger
B003 X709 Steering Pressure Sensor
B004 X235 Steering Angle Sensor
K050 X723 Relay Base Crank Isolate
K051 X724 Relay Base Solenoid B
K052 X725 Relay Base Solenoid A
S005 X714 Auto Guidance Control Switch
Y044 X712 Auto Guidance Dump Solenoid
Y050 X705 Steering Solenoid Right Hand
Y051 X706 Steering Solenoid Left Hand
X623, X707, X710, X711, X715, X726, X727
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 366
SS09G025 1
84276322A 31/05/2010
A.30.A / 367
Wiring harness - Electrical schematic frame 26 Electronic Hydraulic

Remotes (Power System)

A021 X305 El.Hydraulic Remote Valve 1
A076 X698 Mid.Mount El.Hydraulic Remote Valve 2
K020 X074 El.Hydraulic Remote Lock Relay
X020, X304
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 368
SS09G026 1
84276322A 31/05/2010
A.30.A / 369
Wiring harness - Electrical schematic frame 27 Heating (Climate Control

- Auto)

A006 X754 Blower Motor Treiber
A017 X755 Air Condition Control Unit
B050 X754 Temperature Outside
B051 X754 Temperature Cabine
B053 X753 Temperature Aoutlet Sensor
B054 X753 Temperature Evaporator Sensor
K006 X035 Blower Motor
K019 X074 Air Condition Clutch Relay
M011 X754 Blower Motor
R003 - Resistor SJ5
R004 - Resistor SJ4
R006 - Resistor SJ6
R030 X751 Potentiometer Temp. Adjustment
S015 X750 Heater Blower Speed Switch
S016 X752 Air Conditioning Mode Switch
S017 X225 Air Condition Pressure Switch
S061 X753 Low Pressure Switch
Y052 X753 Heating Valve
Y082 X226 Air Condition Clutch
Z001 X754 Blower Assembly
Z069 X753 Air Condition Assembly
X024, X694, X695
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 370
SS09G027 1
84276322A 31/05/2010
A.30.A / 371
Wiring harness - Electrical schematic frame 28 Heating (Climate Control

- Manual)

K019 X074 Air Condition Clutch Relay
M001 X759 Blower Motor
S013 X758 Blower Speed Switch
S014 X757 Air Condition Operating Mode Switch
S017 X225 Air Condition Pressure Switch
S018 X756 Low Pressure Switch
Y082 X226 Air Condition Clutch
X024, X694, X695
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 372
SS09G028 1
84276322A 31/05/2010
A.30.A / 373
Wiring harness - Electrical schematic frame 29 Heated Mirrors


A040 X167 Mirror Control
K022 X032 Heated Mirror Timer Relay
S019 X611 Heated Mirror Switch
Z038 X169 Electric Mirror Right Hand
Z039 X166 Electric Mirror Left Hand
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 374
SS09G029 1
84276322A 31/05/2010
A.30.A / 375
Wiring harness - Electrical schematic frame 30 Heating (Heated Screens)


K044 X764 Front Screen Heater Relay
K045 X764 Rear Screen Heater Relay
MF7 X761 Supply heated windscreen front
MF8 X761 Supply heated screen rear
R049 X800, X801 Front Screen Heater A
R050 X802, X803 Front Screen Heater B
R051 X769 Rear Screen Heater
S071 X766 Screen Heater Switch
Z002 X761 Maxi Fuseholder
X683A, X767
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 376
SS09G030 1
84276322A 31/05/2010
A.30.A / 377
Wiring harness - Electrical schematic frame 31 Cab Accessory

(Implement Sockets, Cigar Lighter)

J001 X116A, X116B Rear Power Socket Implement
J002 X115A, X115B 30Amp Power Socket
J006 X132 8 Amp Socket
J007 X130, X131 Cigar Lighter
J008 X441, X442 Power Studs
J009 X230 DIA Engine inline
X024, X115A, X115B, X116A, X116B, X117
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 378
SS09G031 1
84276322A 31/05/2010
A.30.A / 379
Wiring harness - Electrical schematic frame 32 Lighting


A062 X053 Flasher Unit
E011 X689 Extremity Light Right Hand
E012 X688 Extremity Light Left Hand
K004 X034 Lights Relay
S021 X004 Main Light Switch
S046 X434 Hazard Switch
X007
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 380
SS09G032 1
84276322A 31/05/2010
A.30.A / 381
Wiring harness - Electrical schematic frame 33 Lighting Auxiliary

(Worklamps/Beacons)

A068 X168 Worklamps Control Unit
E029 X197 Worklamp Roof Front Left Hand 2
E030 X196 Worklamp Grabrail Left Hand
E031 X182 Worklamp Left Hand Rear
E032 X173 Worklamp Rear Right Hand
E033 X165 Worklamp Roof Front Left Hand 2
E034 X164 Worklamp Grabrail Right Hand Front
E035 X185 Rotating Beacon Left Hand
E036 X170 Rotating Beacon Right Hand
K014 X037 Get U Home
V001 X076 Get U Home Diode
V004 X076 Dipped Beam Headlamps Diode
V010 X076 Main Beam Headlamps Diode
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 382
SS09G033 1
84276322A 31/05/2010
A.30.A / 383
Wiring harness - Electrical schematic frame 34 Lighting (Side, Console

& Licence Plate Lamps)

E009 X156 Console Lamp Right Hand
E010 X163 Grabrail Side Lamp RH / SM Vehicle RF
E014 X195 Side Lamp Grabrail LH / SM Vehicle LF
E016 X180 License Plate Left Hand
E017 X176 License Plate Right Hand
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 384
SS09G034 1
84276322A 31/05/2010
A.30.A / 385
Wiring harness - Electrical schematic frame 37 Lighting

(Headlamps/Worklamps Hood)

E002 X818 Headlamp 2 Left Hand Grabrail
E007 X336 Headlamp Left Hand
E008 X333 Headlamp Right Hand
E013 X819 Headlamp 1 Right Hand Grabrail
E026 X332 Corner Lamp Right Hand
E027 X337 Corner Lamp Left Hand
H002 X334, X335 Horn
K007 X036 Dipped Beam Headlamps
K009 X036 Main Beam Headlamps
K015 X074 Front Worklamps Hood
S100 X816 High Mount Headlamp Switch
X026, X107, X107_A, X108, X108_A, X220, X555, X555A, X555C
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 386
SS09G057 1
84276322A 31/05/2010
A.30.A / 387
Wiring harness - Electrical schematic frame 38 Lighting (Trailer)


E023 X444 Trailer Lamps
X020, X253, X443, X870
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 388
SS09G038 1
84276322A 31/05/2010
A.30.A / 389
Wiring harness - Electrical schematic frame 39 Lighting (Interior Lights)


E004 X193 Puddle Lamp Left Hand
E006 X190, X191, Interior Lamp
X192
S041 X154 Door Switch Right Hand
S042 X186 Door Switch Left Hand
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 390
SS09G039 1
84276322A 31/05/2010
A.30.A / 391
Wiring harness - Electrical schematic frame 40 Lighting (Stop / Tail

Lamps & Worklamps)

E018 X409 Stop & Tail Lamp Right Hand
E019 X409 Stop & Tail Lamp Left Hand
E024 X403 Worklamp C Pillar Left Hand
E025 X403 Worklamp C Pillar Right Hand
E055 X404, X405 License Lamp Right Hand
E057 X404, X405 License Lamp Left Hand
K008 X036 Stop Lamps Relay
K016 X074 Rear Worklamps C Pillar Relay
S044 X014 Stop Lamp Switch Right Hand
S045 X013 Stop Lamp switch Left Hand
V005 X076 Brake Light Diode
V006 X076 Brake Light Diode
X111, X126
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 392
SS09G040 1
84276322A 31/05/2010
A.30.A / 393
Wiring harness - Electrical schematic frame 41 Radio


A064 X157, X158 Radio
H003 X175 Radio Speaker RHR
H004 X161 Radio Speaker RHF
H005 X194 Radio Speaker LHF
H006 X181 Radio Speaker LHR
W001 X207 Antenna Plus
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 394
SS09G054 1
84276322A 31/05/2010
A.30.A / 395
Wiring harness - Electrical schematic frame 42 Washers & Wipers


K001 / K002 X033 (1-5) Wiper Module Front & Rear
K001 / K002 X033 (6-10) Wiper Module Front & Rear
M004 X201 Wiper Motor Front
M005 X177 Wiper Motor Rear
M006 X125 Washer Motor Front
M007 X123 Washer Motor Rear
S065 X011 Front and Rear Wiper Switch
X106
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 396
SS09G042 1
84276322A 31/05/2010
A.30.A / 397
Wiring harness - Electrical schematic frame 43 Colour Display

(Instruments)

A007 X485 Colour Display
E003 X734 Lamp Feed
- X488 USB Connector
X615, X619, X736
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 398
SS09G043 1
84276322A 31/05/2010
A.30.A / 399
Wiring harness - Electrical schematic frame 44 Braking (Trailer Brakes)


B040 X430 Air Brake Pressure Sensor
K010 X036-C Hydraulic Trailer Brake
K012 X036-A Pneumatic Trailer Brake
S027 X422, X423 Low Brake Pressure Line Switch 1/ 2
S053 X426, X427 Low Pump Output Press Switch 1 / 2
Y021 X429 Brake De-Icer
Y022 X431 Pneumatic Trailer Brake Solenoid
Y023 X432 Park Brake Solenoid
Y037 X424, X425 Hydraulic Trailer Brake Solenoid 1 / 2
X020, X254, X255
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 400
SS09G044 1
84276322A 31/05/2010
A.30.A / 401
Wiring harness - Electrical schematic frame 45 Braking (Electronic Park

Lock Less)

A012 X745 Electronic Park Brake Interface Conn
K011 X036-B Electronic Park Brake
K047 X746 Less EPL
S030 X121 Handbrake Switch
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 402
SS09G045 1
84276322A 31/05/2010
A.30.A / 403
Wiring harness - Electrical schematic frame 46 Front Loader (Power

System)

A066 X097 Central Control Unit
K055 X491 Front Loader Relay 1
K056 X492 Front Loader Relay 2
Y010 X822 Loader Valve Option B
Y036 X821 Loader Valve Option A
X024, X082, X084, X085, X211, X212, X493, X821, X822
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 404
SS09G046 1
84276322A 31/05/2010
A.30.A / 405
Wiring harness - Electrical schematic frame 47 Isobus (Isobus Power)


A054 X616 Iso Bus Control Unit
J003 X601 Iso Implement Socket (Rear)
J004 X600 Iso Implement Socket (Front)
K040 X602 ISO Relay 1 Rear
K041 X603 ISO Relay 2 Rear
K042 X629 ISO Relay 1 Front
K043 X628 ISO Relay 2 Front
PF4 X606 Power Fuse, ISO Bus Rear
PF5 X607 Power Fuse, ISO Bus Rear
PF6 X813 Power Fuse, ISO Bus Front
PF7 X814 Power Fuse, ISO Bus Front
X024, X613, X614, X620, X660
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 406
SS09G047 1
84276322A 31/05/2010
A.30.A / 407
Wiring harness - Electrical schematic frame 48 Diagnostics (Sockets)


- X028 (A,B,F,G) Diagnostic Connector 2
- X030 (A,B,G.E) Diagnostic Connector 1
- X031 ADIC Diagnostic Connector
X026
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 408
SS09G048 1
84276322A 31/05/2010
A.30.A / 409
Wiring harness - Electrical schematic frame 49 CAN Bus 1 (Vehicle Bus)


(18,19,21,22)
A010 X099 (15,16) Auxilary Control Unit
A012 X745 (C2,C3) Electronic Park Brake Interface Conn
A014 X008 (2,3) Keypad
A017 X755 (1,2) Air Condition Control Unit
A054 X616 (4,5) Iso Bus Control Unit
A057 X218 (51,52) Engine Control Unit
A061 X621 (A4,A5) Control Unit Fast Steer
A063 X009 (25,26) Instrument Cluster Unit
A066 X092 (15,16) Central Control Unit
- X030 (C,D) Diagnostic Connector 1
X026, X080, X088, X623, X695
Wire Colour Codes

84276322A 31/05/2010
A.30.A / 410
SS09G049 1
84276322A 31/05/2010
A.30.A / 411
Wiring harness - Electrical schematic frame 50 EHR CAN 1


A004 X716 (3,13) Navigation Controller
A007 X485-1 Colour Display
A010 X099 (21,22) Auxiliary Control Unit
A066 X092 (21,22) Central Control Unit
X005 X719 (1,12) GPS Receiver
X028 X028 (C,D) Diagnostic Connector 2
X615, X619, X715, X727
Wire Colour Codes

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SS09G050 1
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Wiring harness - Electrical schematic frame 51 EHR CAN 2


R016 X304 CAN Terminating Resistor
X020, X080, X088, X304
Wire Colour Codes

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SS09G051 1
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Wiring harness - Electrical schematic frame 52 CAN Bus 1 (Vehicle Bus -

Mid Mounts)

R016 X702 CAN Terminating Resistor
X304
Wire Colour Codes

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SS09G052 1
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Wiring harness - Electrical schematic frame 53 Can System (ISOBUS

CAN)

A007 X485 Colour Display
A050 X618 Active CAN Terminator
A054 X616 Iso Bus Control Unit
A070 X030-1 Iso Bus Control Unit CAN Plus
A071 X030-2 Iso Bus Control Unit CAN Minus
A072 X616 Iso Bus Control Unit CAN Minus
A073 X616 Iso Bus Control Unit CAN Plus
J003 X657 Iso Bus Implement Socket Rear
J004 X812 Iso Bus Implement Socket Front
- X030 (H,J) Diagnostic Connector 1
X024, X080, X088, X615, X618, X619, X660
Wire Colour Codes

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SS09G053 1
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Alternator - Remove
Prior operation:
1. Remove the right hand belt guard.
SS09J020 1

sory drive belt tensioner clockwise (1) and detach the
accessory drive belt from the alternator pulley (2).
BAIL07APH050AVA 2
3. Disconnect the alternator electrical connectors and

reposition the wiring loom to one side.
SS09J018 3
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4. Remove the alternator retaining bolts, and remove

the alternator.
BAIS09APH327AVA 4
Next operation:
Alternator - Install (A.30.A)
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Alternator - Install
Prior operation:
Alternator - Remove (A.30.A)
NOTE: Ensure the battery ground (negative) cable is disconnected from the battery when installing the alternator.
1. Install the alternator to the engine mounting bracket
and tighten the bolts to the specified torque of, 25
Nm (18 lbft).
BAIS09APH327AVA 1
SS09J018 2

sory drive belt tensioner clockwise (1) and install the
accessory drive belt onto the alternator pulley (2).
BAIL07APH050AVA 3
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4. Install the belt guard.
SS09J020 4
Next operation:
Reconnect the battery cable - see Battery - Connect (A.30.A).
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Alternator - Preliminary test

CAUTION - Service Precautions

1. To avoid damage to the components of the alterna-
tor charging system, service precautions must be ob-
served as follows:
- NEVER make or break any of the charging circuit
connections, including the battery, when the engine
is running.
- NEVER short any of the charging components to
ground.
- ALWAYS disconnect the battery ground cable (neg-
ative) when charging the battery on the tractor using
a battery charger.
- ALWAYS observe correct polarity when installing
the battery or using a slave battery to start the en-
gine.
NOTICE: ALWAYS CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE
Preliminary Checks
2. Prior to electrical testing thoroughly inspect the
charging and electrical system.
Check all leads and connections for continuity and
tightness.
1. Check the battery state of charge.

Using a hydrometer check the individual battery
cells. The battery should be at least 70 % charged
and in good condition.
2. Check the drive belt

Inspect the alternator drive belt and pulley, ensuring
that both are clean, free from oil and grease and in
good condition.
The alternator drive belt is automatically tensioned
by a spring tensioner mounted at the front of the
engine, refer to Alternator - Static description
(A.30.A). If the belt tension is suspect, check the
tensioner assembly as follows:
Remove the fan belt, for further information refer to

Fan and drive Belt - Remove (B.50.A).
BSE2983A 1
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Inspection and Repair

3. Checking of the tensioner assembly operation should
be carried out, with the tensioner assembly still at-
tached to the front of the engine. To check the spring
load, place a “breakback" torque bar preset to, 52 -
63 lbf.ft ( 70 - 85 Nm) ( 7.1 - 8.7 kgf.m), onto the pul-
ley arm 15 mm socket. Raise the lever up through
an arc of 20 ° maximum. If the torque bar does not
“break" within the range, install a new fan belt ten-
sioner. For further information refer to Fan and drive
Belt tensioner - Remove (B.50.A)
Ensure the tensioner pulley rotates freely by hand.
If it does not rotate freely by hand, install a new fan
belt tensioner. For further information refer to Fan
and drive Belt tensioner - Remove (B.50.A)
4. Re-Assembly
To install the fan belt tensioner, refer to Fan and

drive Belt tensioner - Install (B.50.A).
Install the fan belt. For further information, refer to
Fan and drive Belt - Install (B.50.A)
Check the Alternator Charge Warning Lamp

5. Turn on the key start switch and check that the warn-
ing lamp is fully illuminated.
If the warning lamp is not fully illuminated check the
bulb. If the bulb is not the cause of the fault carry
out the Alternator wiring connections test as detailed
under ‘initial tests’ in this section.
If the warning lamp is illuminated start the engine and
run above idling speed. The lamp should go out.
If the lamp does not go out, stop the engine and re-
move the wire from the D+ terminal. If the lamp now
goes out a faulty alternator component is indicated.
If the warning lamp remains illuminated, check for a
short circuit to earth (ground) between the ‘D+’ cable
end and the warning lamp.
INITIAL TESTS
6. The initial tests may be performed without removing
any of the charging circuit components from the trac-
tor and enable the following items to be checked:
- Alternator wire connections
- Alternator charging current and controlled voltage
- Alternator charging circuit volt drops
- Alternator maximum output performance
Test equipment required:

7. - Voltmeter ( 0 - 30 volts moving coil type
- Millivoltmeter ( 0 - 1 volt)
- Ammeter ( 0 - 200 Amperes moving coil type)
- 1.5 Ohm 200 Amperes variable load resistor
NOTE: Most commercial test equipment incorporates sev-
eral testing devices within a single unit . Use such equip-
ment in accordance with the manufacturers instructions.
8. For further information refer to Alternator - Electri-
cal test (A.30.A) for testing procedures.
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Alternator - Electrical test

Alternator Wiring Connections Test

1. Disconnect the battery

2. Disconnect the D+ (2) and B+ (3) terminals from
the alternator.
3. Reconnect the battery and turn the key start on
but do not start the engine. Connect a voltmeter (4)
between each terminal and earth (ground), (1). Bat-
tery voltage should be registered.
If battery voltage is not registered a continuity fault

in the external cable circuitry must be traced and
remedied, refer to the circuit diagram (see Wiring
harness - Electrical schematic frame 08 Start BAIS06CCM694AVA 1
/ Charging (Starting & Charging W/Isolator)
(A.30.A).
4. Connect the D+ terminal, warning lamp (thin

brown) wire, to earth (ground). The warning lamp
should illuminate.
5. Disconnect the battery and reconnect the re-
moved alternator cable connections to the alternator.
NOTE: If the warning lamp fails to illuminate when the cable
is reconnected to the alternator, a fault is indicated in the
alternator regulator or rotor circuits. Ensure that the D+
terminal is clean.
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Charging Current And Controlled Voltage Tests

The following test should be performed at 20 °C (68
°F), a lower temperature will create a higher voltage
and a higher temperature will create a lower voltage.
1. Ensure all tractor electrical components are
switched off and the key start switch is in the ‘off’
position.
2. Disconnect the battery negative terminal and dis-
connect the B+ terminal (4) of the alternator.
3. Connect an ammeter (1), between the removed
(thick brown) cable (3) and the B+ alternator terminal.
terminal and earth (ground)
5. Reconnect the battery. Start and run the engine at BAIS06CCM695AVA 2
2000 RPM. and observe the ammeter and voltmeter
readings.
The voltmeter should register in excess of battery

voltage and when the ammeter reading falls to 5 Am-
peres the voltmeter reading should stabilise at 14.1
V +/- 0.15
If the voltmeter reading exceeds the above value the

alternator regulator is faulty.
If the voltmeter reading is below the specified value a
faulty alternator component or a high resistance fault
in the external connections of the charging system is
indicated.
If the ammeter registers zero amperes a faulty alter-

nator component is indicated.
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Charging Circuit Volt Drop Tests

(a) Insulated-Side Volt Drop Tests
Ensure the key start switch is in the ‘off’ position.

nect the B+ cable (1) from the alternator
2. Connect a millivoltmeter (4) between the battery
positive terminal and the B+ cable (5). (Positive side
to cable).
3. Securely connect an ammeter (2) between the B+
terminal of the alternator and the B+ cable (negative
side to cable)
4. Reconnect the battery negative cable and connect
a variable load resistor (3), with the slider in the min-
imum current draw position (maximum resistance), BAIS06CCM696AVA 3
across the battery terminals.
RPM.
6. Slowly increase the current loading of the resis-
tor (decrease resistance) until the ammeter registers
120 Amperes.
7. Observe the millivoltmeter reading which should
not exceed 400 millivolts.
If the reading is in excess of 400 millivolts, a high


volts, then a faulty alternator component is indicated.
8. Stop the engine.
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(b) Ground-Side Volt Drop Test


2. The circuit is the same as that used in the pre-
vious test except for the millivoltmeter (4) which is
now connected between the battery negative termi-
nal and the alternator frame (negative side to frame).
RPM.
4. Slowly increase the current loading of the resistor
(decrease resistance) until the ammeter (2) registers
120 Amperes
exceed 200 millivolts. BAIS06CCM697AVA 4
If the reading is in excess of 200 millivolts a high


volts then a faulty alternator component is indicated.
6. Stop the engine.

NOTE: Ensure the variable load resistor (3) is in the mini-
mum current draw position (maximum resistance).
Alternator Maximum Output Performance Test

5. With reference to 5.

nect the B+ cable (5) from the alternator.
3. Securely connect an ammeter (2) between the
B+ terminal (1) of the alternator and the B+ cable
(negative side to cable).
terminal and earth (ground).
5. Reconnect the battery, start and increase the en-
gine speed to 2000 RPM.
6. Slowly increase the current loading of the resistor BAIS06CCM698AVA 5
(3) (decrease resistance) until the ammeter registers
120 Amperes.
fall below 13 volts.
If the reading falls below 13 volts a faulty alternator

component is indicated.
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Regulator and rotor field circuit test

6. Test equipment required:
- 12 volt battery
- Multimeter
- 2.2 Watt Test Lamp
NOTICE: Prior to removal of the alternator cables from the
alternator ensure that the key start switch is in the ‘off’ po-
sition and the battery negative cable is disconnected.
1. Disconnect all of the alternator cables.

2. Connect a 12 volt battery and a 2.2 Watt test lamp
(2) in series between the D+ (1) and the alternator
frame (negative side to frame).
3. The test lamp should illuminate.
If the test lamp is not illuminated a fault is indicated

in the rotor circuit. Check brushes, slip rings and
continuity of rotor field windings.
If examination indicates these parts to be satisfactory

the regulator may be suspect. BAIS06CCM699AVA 6
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Battery - Remove
WARNING
B026

storage holder.
SS09J019 1

BAIL08APH002AVA 2
BAIL08APH003AVA 3
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Disconnect the battery positive cable (2).
Remove the battery clamp (3).
Remove the battery (4).
BAIL08APH005AVA 4
Next operation:
Battery - Install (A.30.A)
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Battery - Install
Prior operation:
Battery - Remove (A.30.A)
WARNING
B026
NOTE: Before installing the battery check the following:

• Make sure the battery is clean and dry and the
vent caps are properly installed.
• Smear the terminals with petroleum jelly, do
not use conventional lubricating greases as
these can promote electrolytic corrosion.
• Make sure the battery tray and clamps are
clean and free from stones or small objects
which may puncture the battery casing.
• Make sure the battery terminal polarity is cor-
rect and that the terminal connections are suf-
ficiently tight, but not overtightened.
1. Install the battery (1).
Install the battery clamp (2).
Connect the battery positive cable (3).
Connect the battery negative cable (4).
BAIL08APH005AVB 1
BAIL08APH003AVA 2
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BAIL08APH002AVA 3

pins (2).
SS09J019 4
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Battery - Disconnect

storage holder.
SS09J019 1

BAIL08APH002AVA 2
BAIL08APH003AVA 3
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BAIL08APH004AVA 4
Next operation:
Battery - Connect (A.30.A)
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Battery - Connect
Prior operation:
1. Connect the battery negative cable (1).
BAIL08APH004AVA 1
BAIL08APH003AVA 2
BAIL08APH002AVA 3
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pins (2).
SS09J019 4
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Battery - Testing Charging Overview


Before charging the battery ensure Battery clean and serviceable Cleaning reveals battery damage,
the electrolyte is at an acceptable replace battery as necessary.
level. Clean the battery casing and
cell covers with sodium bicarbonate
(baking soda) and hot water and
clean the battery terminals if neces-
sary.
If the battery has failed the Heavy
load test, conduct the charge accep-
tance test to determine whether the
battery will accept a charge.
Charge the battery using either After charging, to ensure the battery
the standard charge procedure or is suitable for service conduct the
slow charge procedure for deeply heavy load discharge test, Battery -
discharged /sulphated batteries. Testing (A.30.A).
Refer to correct battery manufac-
turers charging procedure detailed
in Battery - General specification
(A.30.A).
Battery - Testing Open Circuit Voltage Test - State of Charge Test


To remove any surface charge from Refer to the voltages in the specific
the battery, operate the vehicle on gravity test table in Battery - Gen-
full beam for one minute then turn off eral specification (A.30.A).
and leave the vehicle for 5 minutes.
Measure the open circuit voltage by
connecting a digital voltmeter across
the battery terminals.
Battery - Testing Specific Gravity - State of charge test

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NOTE: State of charge tests are used to determine if there is sufficient charge in the battery to perform a heavy load
test, but does NOT verify the ability of a battery to crank the engine.
Check the electrolyte level. If nec-
essary add distilled water to the rec-
ommended level of 17mm above the
plates. Recharge for 2 hours then
leave for 15 minutes before testing.
(refer to ’charging overview’).
Shake the battery to mix the elec-
trolyte. Remove the vent caps and
extract electrolyte using a hydrome-
ter. Note the specific gravity reading
(SG) for each cell, beginning with the
cell closest to the positive terminal.
Adjust the hydrometer readings for
any temperature variations (±0.004
SG for every ±5.5°C from which the
hydrometer is calibrated.
Record the SG readings for each A variance of no more than 0.025 A variance greater than 0.025 be-
cell. between any two cells. Proceed to tween any two cells indicates a de-
step 4 fective cell and the battery should be
replaced.
Refer to the SG table in Battery -
General specification (A.30.A)
Battery - Testing Flat or discharged battery suspected


Perform Visual check of Battery and Battery has no external defects Clean, repair or replace battery as
cables. Refer to Battery - Testing Action required.
(A.30.A). Proceed to step 2
Perform a state of charge test Bat- Refer to Battery - General specifi-
The battery must be fully charged
tery - Testing (A.30.A) cation (A.30.A). If battery is above
before proceeding to step 3 (Heavy
75% charge proceed to step 3.
load test, Battery - Testing
(A.30.A)).
Perform a heavy load test (refer to Is the reading below 9.6 V ? If result is below 9.6 V the battery
Battery - Testing (A.30.A)). Action has an unacceptable output capacity
If NO the battery has an acceptable and should be test charged before
ouput capacity and will accept a nor- attempting a full recharge.
mal charge
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Battery - Testing Visual check


Remove the battery cover. Visually No cracking evident and no damage A cracked case or broken posts may
check the battery, (correctly identify to posts, proceed to step 2 lead to electrolyte leakage, the bat-
battery manufacturer, refer to Bat- tery should be replaced.
tery - Static description (A.30.A)).
Is the battery case cracked or the
battery posts broken?
Are the cables and connections Cables in good condition, clean and Clean, tighten, repair or replace ca-
damaged, dirty of loose? tight on posts, proceed to step 3. bles as required and then proceed to
step 3.
Is there corrosion around the battery No corrosion, proceed to step 4 Clean the terminals using water and
terminals? sodium bicarbonate (baking soda).
A wire brush may be required to re-
move heavy corrosion. Dry the bat-
tery and proceed to step 4
Is the battery strap or clamp loose? Battery secure, proceed to step 5. Tighten as necessary and proceed to
step 5.
Check the electrolyte fluid level. The Electrolyte at correct level, proceed Electrolyte level low, top up using
electrolyte should be around 17mm to step 6. distilled or de-mineralised water. Do
above the plates. Is the electrolyte not use tap or rain water. Proceed to
level low in any of the cells? step 6.
Using a hydrometer, Is the elec- Electrolyte is clear, proceed to ’state Cloudy or discoloured electrolyte
trolyte excessively cloudy or dis- of charge test’, refer to Battery - may be caused by overcharging or
coloured ? Testing (A.30.A). vibration. This can cause a high self
discharge of the battery. Correct the
cause then replace the battery.
Battery - Testing Heavy Load Discharge Test


Confirm that the battery state of refer to Battery - Testing (A.30.A) or
charge is at least 75 % (> 12.4 V). Battery - Testing (A.30.A).
Determine the capacity rating of the
battery as stated on the battery label
(should be 800 CCA (107 Ah) or 960
CCA (132 Ah). Connect the heavy
load tester across the battery termi-
nals, observing the correct polarity.
Load the battery at a rate equal to
three times the Amp-hour (Ah) rating
or half the cold cranking amps (CCA)
rating.
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To remove the surface charge, apply
the heavy load tester to the battery
for 15 seconds at the specified dis-
charge current then disconnect and
leave for 5 minutes.
Apply the load for no more than 15 Voltage greater than 9.6 V. The bat- The voltage is less than 9.6 V. The
seconds and note the voltage read- tery has an acceptable output capac- battery has an unacceptable output
ing. Is the voltage less than 9.6 V? ity and will accept a normal charge if capacity and should be test charged
required or can be returned to ser- before attempting a full recharge and
vice. then retesting.
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Index

SYSTEMS - A

Wiring harness - Electrical schematic frame 02 Power Distribution (Fuses 1 - 14) . . . . . . . . . . . . . . . . . . . . . . . . . 320
Wiring harness - Electrical schematic frame 03 Power Distribution (Fuses 15 - 21) . . . . . . . . . . . . . . . . . . . . . . . . 322
Wiring harness - Electrical schematic frame 08 Start / Charging (Starting & Charging W/Isolator) . . . . . . . . . . . 332
Wiring harness - Electrical schematic frame 09 Start / Charging (Starting & Charging without Isolator) . . . . . . . 334
Wiring harness - Electrical schematic frame 10 Engine Control Unit (Engine ECU 1) . . . . . . . . . . . . . . . . . . . . . . 336
Wiring harness - Electrical schematic frame 11 Engine Control Unit (Engine ECU 2) . . . . . . . . . . . . . . . . . . . . . . 338
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Wiring harness - Electrical schematic frame 12 Power Distribution (Power Earthing) . . . . . . . . . . . . . . . . . . . . . . 340
Wiring harness - Electrical schematic frame 13 Transmission Controller (Transmission 1) . . . . . . . . . . . . . . . . . . 342
Wiring harness - Electrical schematic frame 14 Transmission Controller (Transmission 2) . . . . . . . . . . . . . . . . . . 344
Wiring harness - Electrical schematic frame 15 Transmission Controller (Electronic Draft Control) . . . . . . . . . . . 346
Wiring harness - Electrical schematic frame 16 Transmission Controller (5V Supply, Sensor Ground, Seat) . . 348
Wiring harness - Electrical schematic frame 17 Transmission Controller (Power Take Off) . . . . . . . . . . . . . . . . . . 350
Wiring harness - Electrical schematic frame 18 Auxiliary Control Unit (Suspention Front Axle, EHR’S, Link Levelling)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Wiring harness - Electrical schematic frame 19 Auxiliary Control Unit (Front Hitch, PTO) . . . . . . . . . . . . . . . . . . . 354
Wiring harness - Electrical schematic frame 20 Fast Steer (Steering Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . 356
Wiring harness - Electrical schematic frame 21 Lighting (Instrument Cluster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Wiring harness - Electrical schematic frame 22 Instruments (Instrument Cluster) . . . . . . . . . . . . . . . . . . . . . . . . . 360
Wiring harness - Electrical schematic frame 23 Electronic Control Unit 1 (Arm Rest) . . . . . . . . . . . . . . . . . . . . . . 362
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Wiring harness - Electrical schematic frame 24 Electronic Control Unit 2 (Arm Rest) . . . . . . . . . . . . . . . . . . . . . . 364
Wiring harness - Electrical schematic frame 25 Steering (Auto Guidance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Wiring harness - Electrical schematic frame 26 Electronic Hydraulic Remotes (Power System) . . . . . . . . . . . . . 368
Wiring harness - Electrical schematic frame 27 Heating (Climate Control - Auto) . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Wiring harness - Electrical schematic frame 28 Heating (Climate Control - Manual) . . . . . . . . . . . . . . . . . . . . . . . 372
Wiring harness - Electrical schematic frame 29 Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Wiring harness - Electrical schematic frame 30 Heating (Heated Screens) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Wiring harness - Electrical schematic frame 31 Cab Accessory (Implement Sockets, Cigar Lighter) . . . . . . . . . 378
Wiring harness - Electrical schematic frame 32 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Wiring harness - Electrical schematic frame 33 Lighting Auxiliary (Worklamps/Beacons) . . . . . . . . . . . . . . . . . . . 382
Wiring harness - Electrical schematic frame 34 Lighting (Side, Console & Licence Plate Lamps) . . . . . . . . . . . . 384
Wiring harness - Electrical schematic frame 37 Lighting (Headlamps/Worklamps Hood) . . . . . . . . . . . . . . . . . . . 386
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Wiring harness - Electrical schematic frame 38 Lighting (Trailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Wiring harness - Electrical schematic frame 39 Lighting (Interior Lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Wiring harness - Electrical schematic frame 40 Lighting (Stop / Tail Lamps & Worklamps) . . . . . . . . . . . . . . . . . . 392
Wiring harness - Electrical schematic frame 41 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Wiring harness - Electrical schematic frame 42 Washers & Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Wiring harness - Electrical schematic frame 43 Colour Display (Instruments) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Wiring harness - Electrical schematic frame 44 Braking (Trailer Brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Wiring harness - Electrical schematic frame 45 Braking (Electronic Park Lock Less) . . . . . . . . . . . . . . . . . . . . . . 402
Wiring harness - Electrical schematic frame 46 Front Loader (Power System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Wiring harness - Electrical schematic frame 47 Isobus (Isobus Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Wiring harness - Electrical schematic frame 48 Diagnostics (Sockets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Wiring harness - Electrical schematic frame 49 CAN Bus 1 (Vehicle Bus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
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Wiring harness - Electrical schematic frame 50 EHR CAN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Wiring harness - Electrical schematic frame 51 EHR CAN 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Wiring harness - Electrical schematic frame 52 CAN Bus 1 (Vehicle Bus - Mid Mounts) . . . . . . . . . . . . . . . . . . . . 416
Wiring harness - Electrical schematic frame 53 Can System (ISOBUS CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Alternator - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Alternator - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
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Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Battery - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery - Testing Charging Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Battery - Testing Flat or discharged battery suspected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Battery - Testing Heavy Load Discharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
Battery - Testing Open Circuit Voltage Test - State of Charge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Battery - Testing Specific Gravity - State of charge test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Battery - Testing Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Connector - Component Diagram 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Connector - Component diagram 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Connector - Component diagram 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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ELECTRICAL POWER SYSTEM - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ELECTRICAL POWER SYSTEM - Static description PROTECTING THE ELECTRONIC AND ELECTRICAL SYS-
TEMS DURING BATTERY CHARGING OR WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuse and relay box - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Fuse and relay box - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wiring harness - Electrical schematic frame 01 Power Distribution (Maxifuses 1 - 6) . . . . . . . . . . . . . . . . . . . . . . 318
Wiring harness - Electrical symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Wiring harness - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Wiring harness - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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ELECTRONIC SYSTEM - 50.A

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Contents

SYSTEMS - A
TECHNICAL DATA
Control module
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Configure Configure GA CONTROLLER H ROUTINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Configure KA - Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Configure LA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Configure Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Configure Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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Configure RV - 16x16 Transmission, Electronic Draft Control, Rear PTO, Front Wheel Drive, Differential
Lock, Front Electronic Hydraulic Remote Valves, Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Configure - Front Axle Suspension, Rear Electronic Hydraulic Remote Valves, Front PTO, Front Hitch 258
FUNCTIONAL DATA
Control module
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Electronic schema Instrument Cluster - ICU3 Module IE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Electronic schema Electronic Less Park Lock (EPL) - Module XA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Electronic schema Central Control Unit 16/17x16 (RV module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Electronic schema Auxiliary Control Unit (RP module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Electronic schema Arm Rest Control Unit (LC module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Electronic schema Small Wide Colour Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

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Electronic schema ISO-BUS Control Unit (TECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Electronic schema Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Electronic schema Fast Steer (KA Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Electronic schema Engine control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Electronic schema Auto Guidance Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Electronic schema Electro-Hydraulic Remotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

SERVICE
ELECTRONIC SYSTEM
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRONIC SYSTEM
Control module - Configure

MAXXUM 140
HH Service Menu Figure Number

H1 Calibration procedures 1
H2 View stored calibration values 2
H3 Configurations 11
H4 View software revision level 52
H5 Switch operation test 55
H6 Vehicle information view 58
H7 Vehicle test modes 61
H8 Clear Electrically Erasable Programmable Read Only Memory 66
(EEPROM)
H9 Voltmeter 70
HA Demonstration mode 75
HB Display stored fault codes 79
HC Clear all stored fault codes 84
Shortcuts for transmission setups (not available using the service -
switch)
HE Display frequency inputs 88
HF View controller hardware information 91
DR Module: 24x24 Transmission, Electronic Draft Control, Rear PTO, Front Wheel Drive, Differential Lock, Engine.
DS Module (Vehicles without Multi-controller): 16x16 Transmission, Electronic Draft Control, Rear PTO, Front Wheel
Drive, Differential Lock, Engine.
DT Module (Vehicles with Multi-controller): 16x16 Transmission, Electronic Draft Control, Rear PTO, Front Wheel
Drive, Differential Lock, Engine.
The illustrations in this procedure depict the DS module (16x16 transmission), controllers for other transmission vari-
ants will be displayed as appropriate, the actual steps remain the same as below.
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H1 - CALIBRATION PROCEDURES
This menu is used to calibrate:
1. Electronic Draft Control Valve. Refer to HITCH Electronic draft control - Calibrate (H.10.D).
2. Transmission Clutches, determining the current required to turn the input / output shaft at the required speed. Fly-
wheel speed sensor and PTO torque sensor, Refer to . TRANSMISSION Semi-Powershift - Calibrate (C.20.D)
3. Transmission Clutches, determining the current required to turn the input / output shaft at the required speed.
Flywheel speed sensor and PTO torque sensor, Refer to . TRANSMISSION Power Shuttle - Calibrate (C.20.C)
4. Engine (for PTO torque sensor). Refer to REAR PTO Hydraulic - Calibrate (C.40.C).
5. Differential lock (for steering angle sensor). Refer to FRONT AXLE - Calibrate (D.10.A).
H1 Menu Screen Select Diagram
BAIL09APH266AVC 1
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H2 - VIEW STORED CALIBRATION VALUES

This menu is used to display the calibration values stored in the controllers for:
1. Transmission clutches and synchronisers
2. Differential lock (for steering angle sensor)
3. Engine (for PTO torque sensor)
4. Electronic draft control valve
5. Rear PTO clutch
BAIL09APH267AVC 2
TRANSMISSION VALUES
16x16 Transmission H2 Calibration Values
Channel Description Value Range
Ch 1 Clutch 1 calibration current 101-280
Ch 5 Forward synchroniser calibration current 200-350
Ch 6 Reverse synchroniser calibration current 200-350
Ch 7 4 synchroniser calibration current 200-350
Ch 8 5 synchroniser calibration current 200-350
Ch 9 Synchroniser position signal - forward 655-963
Ch 10 Synchroniser position signal - reverse 61-376
Ch 11 Synchroniser position signal - low range 61-376
Ch 12 Synchroniser position signal - low range 655-963
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24x24 Transmission H2 Calibration Values

Ch 1 Lo clutch calibration current 40-260
Ch 2 Hi clutch calibration current 40-260
Ch 3 Forward synchroniser calibration current 101-320
Ch 4 Reverse synchroniser calibration current 101-320
Ch 5 Synchroniser position signal - forward 200-350
Ch 6 Synchroniser position signal - reverse 200-350
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ELECTRONIC DRAFT CONTROL VALVE VALUES

Select the Electronic Draft Control sub-system by depressing the “dimming" key.
BAIS09APH313AVA 3
NOTE: The default calibration value set during the H8 procedure is 50 for both the raise and lower solenoids.
The lower central display will display “ch _".

The required channel can be selected by using the “h" and “m" keys.
After a delay the code followed by the calibration value will be displayed. (see the table below for the description of
each channel).
Depress the “dimming" key to continue navigating through the “HH" menus.
BAIL06CCM446AVA 4
Channel Description Display Value Range

Ch 1 Raise solenoid R50 20 - 80
Ch 2 Lower solenoid L50 20 - 80
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PTO VALUES
Select the PTO sub-system by depressing the “dimming" key.
BAIS09APH314AVA 5
NOTE: The default calibration value set during the H8 procedure is 280 for the PTO solenoid.

After a delay the calibration value will be displayed. (see the table below for the description of each channel).
BAIL06CCM446AVA 6

Ch 1 PTO oil temperature 10 - 120
Ch 2 Rear PTO solenoid calibration value 100 - 420
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DIFFERENTIAL LOCK (FOR STEERING ANGLE SENSOR) VALUES

Select the differential lock sub-system by depressing the “dimming" key.
BAIS09APH315AVA 7
NOTE: The default calibration value set during the H8 procedure is 12287 for the steering angle sensor.

After a delay the calibration value will be displayed. (see the table below for the description of the channel).
BAIL06CCM446AVA 8

Ch 1 Steering angle sensor calibration value 1000 - 8000
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ENGINE (FOR PTO TORQUE SENSOR) VALUES

Select the engine sub-system by depressing the “dimming" key.
BAIS09APH316AVA 9
NOTE: The default calibration value set during the H8 procedure is 3999 for the PTO torque sensor.
The lower central display will display “ch _ ".

BAIL06CCM446AVA 10

Ch 1 PTO torque sensor calibration value 500 - 8000
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H3 - CONFIGURATIONS
This menu is used to display the configurations available for:
1. Transmission
• Ch.1 Quick fill time adjustment
• Ch.2 Sharp shuttle option (16x16 only).
• Ch.3 Set fly shift speed threshold (24x24 only).
• Ch.4 Driver selectable shuttle modes (16x16 only).
• Ch.5 40 km/h maximum speed restriction.
• Ch.6 Creeper option enable.
• Ch.7 Anti-creep enable.
• Ch.8 and Ch.9 Large tyre option (6 cylinder electronic engines only)
2. Electronic Draft Control
• Ch.1 Diameter of the external hydraulic lift rams
• Ch.2 Enable / Disable Electronic Draft Control
• Ch.3 Enable / Disable Slip Control
3. Electronic engine
• Ch.1 PTO dynamometer test with maximum power boost.
• Ch.2 Auto modes option.
• Ch.3 Grid heater selection.
4. Headland Turn Sequence
• Ch.1 HTS option enable
5. Differential Lock and Four Wheel Drive
• Ch.1 Not used
• Ch.2 Four wheel drive braking speed selection
• Ch.3 Front axle angles (auto difflock)
6. Rear PTO
• Ch.1 PTO management option
• Ch.2 PTO fender switches options
• Ch.3 PTO clutch calibration adjustment
• Ch.4 PTO quickfill time adjustment
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BAIS09APH317AVA 11
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TRANSMISSION OPTIONS
Select the transmission sub-system by depressing the “dimming" key.
BAIL09APH224AVA 12
After a delay the current setting will be displayed. (see the table below for the description of each channel).
BAIL06CCM446AVA 13
Channel Description
Ch 1 Quick fill time adjustment (16x16 and 24x24 transmission)
Ch 2 Sharp shuttle option (16x16 transmission)
Ch 3 Set fly-shift speed threshold (24x24 transmission)
Ch 4 Ch.4 Driver selectable shuttle modes (16x16 transmission)
Ch 5 40 km/h maximum speed restriction (16x16 transmission)
Ch 6 Creeper option enable
Ch 7 Anti-creep enable (16x16 transmission)
Channel 1 - Quick Fill Time Adjustment (16x16)

This channel is used to adjust the transmission quick fill setting.
The transmission oil temperature must be at least 60 °C.
If the oil is not warm enough the lower display will alternate between ’Cold’ and the current temperature. Quick fill
adjustment will not be possible until the required temperature has been reached.
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BAIL06CCM500AVA 14
If a four digit number beginning with ’2’ is displayed at any time during calibration, it is a standard error code.
The fault condition must be corrected before the adjustment can be performed.
Quickfill Adjustment 16x16 Transmission

With the shuttle and range levers in neutral, use the upshift or downshift switch to select "C1" or "C2".
The selected clutch and it’s quickfill setting will be displayed.
BAIL09APH213AVA 15
To test and/or adjust the quickfill setting, for "C1" or "C2" shift the shuttle lever to forward and release the clutch pedal.
The lower central display will display "C" while the pressure is increased in C3 and C4 to stop the rotation of the
transmission gears in preparation for testing C1 or C2.
BVE0768A 16
The lower central display will display the clutch and current quick fill setting.
Use the "upshift" or "downshift" switch to adjust the quickfill settings within the range of 3 to 19 (30 to 190 ms).
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BAIL09APH217AVA 17
NOTE: Do not fully depress the clutch pedal.
To test the quickfill setting, engage by slightly depressing and releasing the clutch pedal.
C3 and C4 are disabled while C1 and C2 are engaged for around one second.
The display will change briefly to display "C" while the pressure increases in C3 and C4.
Lower the quickfill setting until engagement noise can no longer be heard when engaging C1 or C2.
Raise the quickfill setting until engagement noise can be clearly heard, and then lower the setting by2.
BVE0768A 18
To adjust C3 and C4 clutches, shift the range lever to high and the shuttle lever to neutral.
BVE0773A_Profi 19
To change between C3 and C4, depress the upshift or downshift switch.

The clutch selected is displayed along with the quickfill setting.
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BAIL09APH214AVA 20
NOTICE: Make sure that the parking brake is released as the tractor will move when testing these clutches.
To test/adjust the quick fill setting, shift the shuttle lever into forward and release the clutch pedal.
To test the quickfill setting, you can also actuate the shuttle lever without the clutch pedal. The lower central display
will display "C" while the pressure is increased in C2 to drive the input side of C3 and C4.
BAIL09APH215AVA 21
The lower central display will display the clutch and current quickfill setting.
Use the upshift or downshift switch to set the quickfill setting to between 3 and 19 (30 and 190 ms).
BAIL09APH216AVA 22
NOTE: Do not fully depress the clutch pedal.
To test the quickfill setting, engage by slightly depressing and releasing the clutch pedal.
C3 and C4 are enabled for the quickfill time plus 0.1 seconds.
The display may change briefly to display "C".
Lower the quickfill setting until engagement noise can no longer be heard when engaging C1 or C2.Lower the quickfill
setting until the tractor does not move when engaging C3 or C4.
Raise the quickfill setting until the tractor is stationary, and then lower the setting by 2.
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BVE0776A 23
Quickfill Adjustment 24x24 Transmission

Shift the shuttle lever to neutral and select "Lo" or "Hi" using the upshift or downshift switches.
The lower central display will display the selected clutch and its quickfill setting.
BAIL09APH218AVA 24
To adjust the quickfill setting depress the clutch pedal and use the upshift or downshift switch to adjust the quickfilll
setting within the range of 3 to 9 (30 to 90 ms).
To test the quickfill setting shift the shuttle lever to forward and slowly release the clutch pedal.
Too much quickfill will cause a noticeable tractor movement, too little will cause a slow response.
Press the "dimming" button to continue navigating the "HH" menus.
Channel 2 - Sharp Shuttle Option 16x16 Transmission

Select channel 2 using the "h" and "m" buttons.
The options available are:

1 - Sharp shuttle enabled.
0 - Sharp shuttle disabled.
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BAIL09APH219AVA 25
To save the desired option, depress and hold the "h" or "m" button until the instrument cluster bleeps, indicating that
the selection has been saved.
Channel 3 - Set Fly-shift Speed Threshold (24x24 Transmission)

This option is used to select the fly-shift threshold in km/h.
Using the "h" or "m" buttons select between 1, 5, 10, and 40.
BAIL09APH220AVA 26
Selecting 40 disables the fly-shift engagement.
Channel 4 - Driver Selectable Shuttle Modes (16x16 Transmission)

This channel is used to select memory shuttle.

"Yes" - Memory shuttle enabled.
"no" - Memory shuttle disabled.
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BVF1096A 27
An alternative shortcut method is also available to allow the shuttle mode to be selected without the use of a service
switch. With the keyswitch in the off position, shift the shuttle lever to reverse and press and hold the upshift switch
while turning the key switch to the on position (do not start the engine). The lower central display will display “Yes” or
“No” and the shuttle mode can then be selected using the same procedure as above.
Channel 5 - 40 km/h Maximum Speed Restriction (16x16 Transmission)

This channel is used to restrict the transmission to 40 km/h.

"Yes" - 40 km/h restriction enabled.
"no" - 40 km/h restriction disabled.
BVF1096A 28
Channel 6 - Creeper Option

This channel is used to enable or disable the creeper.

"Yes" - Creeper gear enabled.
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"no" - Creeper gear disabled.
BVF1096A 29
Channel 7 - Anti-creep Option

This channel is used to enable or disable the anti-creep function.

"Yes" - Anti-creep enabled.
"no" - Anti-creep disabled.
BVF1096A 30
Channels 8 and 9 - Large Tyre Option (6 Cylinder Electronic Engines Only)

These channels are used to select whether the Large Tyre option is enabled or disabled. If the Large Tyre option is
enabled then the software will restrict the ground speed to 50kph or 40kph, as appropriate. The Large Tyre option is
set using channel 9 which is not visible by default, it must first be made visible using channel 8.
With the lower central display showing "ch8" press and hold the "m" button for 20 seconds, during which the display
will flash "_ _ _ _ ".
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BAIL09APH221AVA 31
After 20 seconds the instrument cluster will bleep indicating channel 9 is enabled.

"Lto" - Large tyre option enabled.
"OFF" - Large tyre option disabled.
BAIL09APH222AVA 32
EDC Options
Select the EDC sub-system by depressing the “dimming" key.
BAIL06CCM446AVA 33
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Channel Description
Ch 1 Hydraulic RAM size
Ch 2 EDC enable/disable
Ch 3 Slip control enable/disable
Channel 2 - Enable/Disable EDC

This channel is used to enable or disable the EDC system.

"Yes" - EDC enabled.
"no" - EDC disabled.
BVF1096A 34
NOTE: If the EDC system is disabled using this channel, then the Slip Option will automatically be disabled.
Channel 3 - Enable/Disable Slip Control

This channel is used to enable or disable the EDC system.

"Yes" - Slip Control enabled.
"no" - Slip Control disabled.
BVF1096A 35
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ELECTRONIC ENGINE OPTIONS

Select the Electronic Engine sub-system by depressing the “dimming" key.
BAIL09APH225AVA 36
BAIL06CCM446AVA 37
Channel Description
Ch 1 Dyno power boost test option
Ch 2 Auto modes option
Ch 3 Grid heater selection
Channel 1 - Dyno Power Boost Test Option

This channel is used to enable or disable the power boost test.

"Yes" - Dyno power test enabled.
"no" - Dyno power test disabled.
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BVF1096A 38
NOTE: When enabled the dyno power boost test will only remain active for 45 minutes.
Channel 2 - Auto Modes Option

This channel is used to enable or disable the auto modes e.g. Autoshift,CRPM and Powerboost.

"Yes" - Auto modes enabled.
"no" - Auto modes disabled.
BVF1096A 39
Channel 3 - Grid Heater Selection

This channel is used to enable or disable the grid heater option.

"Yes" - Grid heater fitted.
"no" - Grid heater not fitted.
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BVF1096A 40
HTS OPTIONS
Select the HTS sub-system by depressing the “dimming" key.
BAIL09APH226AVA 41
BAIL06CCM446AVA 42
Channel Description
Ch 1 HTS enable options
Channel 1 - HTS Enable Options

This channel is used to enable or disable the HTS option.
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"Yes" - HTS enabled
"no" - HTS disabled
BVF1096A 43
DIFFLOCK AND FOUR WHEEL DRIVE OPTIONS

Select the difflock and FWD sub-system by depressing the “dimming" key.
BAIL09APH227AVA 44
BAIL06CCM446AVA 45
Channel Description
Ch 1 Not used
Ch 2 FWD braking speed selection
Ch 3 Front axle angles
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Channel 1 - Not Used
Channel 2 - FWD Braking Speed Selection

This channel is used to select the ground speed below which four wheel braking will not occur. This channel will only
be available if the Four Wheel Drive option has been selected.
Use the "h" and "m" buttons to choose "1", "2", "3" or four. The values that these options represent are shown in the
table below.
Option 0 1 2 3 4
FWD disengage 0 km/h 1.6 km/h 3.2 km/h 4.8 km/h 6.4 km/h
speed
Channel 3 - Front Axle Angles

This channel is used to select the steering angle at which the auto diffflock and auto FWD functions engage and
disengage.
Use the "h" and "m" buttons to choose "0" "1", "2", "3" or "4". The values that these options represent are shown
below.
NOTE:
There is a 3 ° hysteresis on the standard axle steering angle .
There is a 2 km/h hysteresis on the vehicle speed.
Standard axle steering angles

Auto FWD Auto Difflock Auto Difflock Auto FWD
0 - 10 km/h 0 - 10 km/h 10 - 15 km/h 10 - 20 km/h
Right Left Right Left Right Left Right Left
Option 0 25 ° 21.25 ° 15 ° 13.5 ° 5° 4.5 ° 20 ° 17.5 °
Option 1 40 ° 32.5 ° 15 ° 13.5 ° 5° 4.5 ° 35 ° 29 °
Option 2 15 ° 13.5 ° 10 ° 9.25 ° 5° 4.5 ° 35 ° 29 °
Option 3 10 ° 9.25 ° 5° 4.5 ° 5° 4.5 ° 10 ° 9.25 °
Rear PTO Options

Select the rear PTO sub-system by depressing the “dimming" key.
BAIL09APH255AVA 46
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BAIL06CCM446AVA 47
Channel Description
Ch 1 Rear PTO management options
Ch 2 Rear PTO fender switches options
Ch 3 Rear PTO clutch calibration adjustment
Ch 4 Rear PTO quick fill time
Channel 1 - Rear PTO Management Options

This channel is used to enable or disable the rear PTO management.

"Yes" - Rear PTO management enabled
"no" - Rear PTO management disabled
BVF1096A 48
Channel 2 - Rear PTO Fender Switches Option

This channel is used to enable or disable the rear PTO fender switches.

"Yes" - Rear PTO fender switches enabled
"no" - Rear PTO fender switches disabled
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BVF1096A 49
Channel 3 - Rear PTO Clutch Calibration Adjustment

This channel is used to adjust the rear PTO clutch calibration current.
The lower central display will display the current clutch calibration value.
BVE0779A_555 50
Press the "h" button to increase or the "m" button to decrease the calibration value.
To save the desired value, depress and hold the "h" or "m" button until the instrument cluster bleeps, indicating that
Channel 4 - Rear PTO Quick Fill Time

This channel is used to adjust the rear PTO quick fill time, to be used for fine tuning if required.
The lower central display will display the current clutch calibration value.
Use the "h" and "m" buttons to change the displayed value between "3" and "9", representing the quick fill time of
between 30ms to 90ms.
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BVE0792A_556 51
To save the desired value, depress and hold the "h" or "m" button until the instrument cluster bleeps, indicating that
H4 SOFTWARE VERSION INFORMATION
BAIL09APH256AVA 52
Select the H4 menu by pressing the "dimming" button.
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BAIL09APH259AVA 53
The lower central display will display a sequence of numbers as shown below.
BAIL09APH262AVA 54
The first set of four digits displayed indicates the software identifier which uniquely defines the application software
loaded in the module.
The second and third set of four numbers displayed indicates the release version of the application software.
At the end of the routine the display returns to "H4" and then it is possible to navigate further "HH" menus.
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H5 - SWITCH DIAGNOSTICS
BAIL09APH257AVA 55
BAIL09APH260AVA 56
The lower central display will display "d _ _" indicating switch operation can be tested.
On detection of a switch transition the display will display "d" followed by the switch number for which the transition
was detected.
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BVE0047A 57
The available switch numbers are given in the table below.
Identifier Con- Pin Switch / Input Controller

troller Number
Connec-
tor
d0 No switch or two switches activated at the same time
d1 CN1B 30 EDC fender lower switch All
d2 CN1B 29 EDC fender raise switch All
d3 CN1B 18 EDC work switch All
d4 CN1B 20 EDC raise switch All
d5 CN3A 6 EDC stop switch DT only
d6 Cn1B 22 EDC float switch DT only
d10 CN3A 16 Seat switch All
d11 CN3A 19 Handbrake switch All
d12 CN3A 12 Left foot brake switch All
d13 CN3A 11 Right foot brake switch All
d14 CN1A 8 Clutch pedal switch (with shuttle lever out of neutral) All
d15 CN1B 12 Shuttle lever forward switch (with clutch depressed) All
d16 CN1B 13 Shuttle lever forward switch (with clutch depressed) All
d17 CN1B 23 Transmission downshift switch DR and DS only
d18 CN1B 22 Transmission downshift switch DR and DS only
d19 CN3A 23 Transmission range shift switch DS only
d25 CN1B 27 Shuttle lever switch (clutch depressed, change from into DR and DS only
neutral from F or R)
d26 CN1B 26 16x16 transmission high range switch DS and DT only
24x24 transmission 1/2 and 3/4 neutral switch DR only
d27 CN1B 19 16x16 transmission low range switch DS and DT only
24x24 transmission high/medium range switch DR only
d29 CN1B 24 EDC raise/work fault switch DR and DS only
d30 CN3A 14 Transmission autoshift switch DS only
d34 CN3A 8 Transmission creeper switch All
d35 CN3A 26 Creeper selector fork disengage switch All
d36 CN3A 9 Creeper selector fork engage switch All
d38 CN3B 31 Differential lock switch - automatic All
d39 CN3B 30 Differential lock switch - manual All
d41 CN3A 25 Four wheel drive switch - manual All
d42 CN3A 24 Four wheel drive switch - automatic All
d44 CN3A 12 Rear PTO switch - normally open All
d45 CN3A 13 Rear PTO switch - normally closed All
d47 CN3B 24 Rear PTO brake switch All
d48 CN3B 33 Rear PTO ground speed switch All
d49 CN3B 23 Rear PTO auto switch All
d50 CN3A 21 HTS record switch DS and DT only
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Identifier Con- Pin Switch / Input Controller

troller Number
Connec-
tor
d51 CN3A 20 HTS playback switch DS and DT only
d52 CN3A 15 HTS step switch DS and DT only
d54 CN3A 22 CRPM on/off switch DS and DT only
d55 CN3A 5 CRPM decrease engine speed switch DS and DT only
d56 CN3A 4 CRPM increase engine speed switch DS and DT only
d57 CN3B 11 CRPM selection switch DS and DT only
d59 CN3A 17 Hand throttle not at idle switch DS and DT only
d60 CN3B 32 Foot throttle not at idle switch DS and DT only
d63 CN3B 4 Rear PTO fender switch (normally closed) All
d64 CN3B 2 Rear PTO fender switch (normally open) All
d101 Via CAN - Transmission shuttle switch DT only
bus
d102 Via CAN - Transmission upshift switch DT only
bus
d103 Via CAN - Transmission downshift switch DT only
bus
d104 Via CAN - HTS step switch DT only
bus
d105 Via CAN - Transmission autoshift switch DT only
bus
d106 Via CAN - Transmission range shift switch DT only
bus
H6 VIEW VEHICLE INFORNATION
H6 Menu Screen Selection Diagram
BAIL09APH258AVA 58
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BAIL09APH261AVA 59
The transmission speed and the engine horsepower will be displayed in succession as shown below.
BAIL09APH268AVA 60
H7 TRANSMISSION TEST MODES
H7 Menu Screen Selection Diagrams

This menu is used to check the clutch disconnect switch adjustment and to test the transmission synchronisers.
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BAIL09APH269AVA 61
Channel Description
Ch 1 Clutch switch test
Ch 2 Forward / reverse synchro test
Ch 3 Gear 4 / 5 synchro test
Channel 1 - Clutch switch test

This channel is used to display the clutch pedal position and is useful for evaluating the clutch pedal switch adjustment
and the inching bite point.
Shift the shuttle lever to forward or reverse.
NOTE: An audible click will be heard when the clutch pedal makes contact with the switch.
Operate the clutch pedal at a steady rate, fully depressing and releasing.
The lower central display will indicate that one of the following adjustments may be required:
When the pedal is fully depressed, a figure should be displayed, between 2000 and 2500.
When the pedal has been fully released, a figure should be displayed, between 3500 and 4000
dn - Adjust the adjustment bolt (1) clockwise
uP - Adjust the adjustment bolt (2) counter clockwise
Adjust the adjustment bolt in the required direction and fully depress and release the pedal again.
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BVF1162A 62
If the switch is adjusted correctly the lower central display will display two different numerical values and “dn" or “uP"
will no longer be displayed.
Cycle the clutch pedal a few times more to confirm the adjustment is correct.
BVF1163A 63
Channel 2 - Forward / Reverse Synchroniser Test

NOTE: When depressing the upshift or downshift switch, the display of gears will still indicate a change of gear. When
the maximum gear available within the range is reached an audible tone will be heard. This will have no effect during
this test.
This channel is used to check the operation of the synchroniser.

This channel can also be used when pressure testing the synchroniser actuating circuit.
The engine must be running with the transmission in neutral and the clutch pedal released.
NOTE: Depressing and holding the upshift or downshift switch will maintain full pressure in the synchroniser actuating
circuit for pressure testing.
Depress either the upshift or downshift switch to display the position of the potentiometer movement.
Forward - upshift switch (value approximately 80)
Reverse - downshift switch (value approximately 20)
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BVF1197A 64
Channel 3 - 1-4 / 5-8 Range Synchroniser Test (16x16 only)

NOTE: When depressing the upshift or downshift switch, the display of gears will still indicate a change of gear. When
the maximum gear available within the range is reached an audible tone will be heard. This will have no effect during
this test.
This channel is used to check the operation of the synchroniser.

This channel can also be used when pressure testing the synchroniser actuating circuit.
The engine must be running with the transmission in neutral and the clutch pedal released.
NOTE: Depressing and holding the upshift or downshift switch will maintain full pressure in the synchroniser actuating
circuit for pressure testing.
Depress either the upshift or downshift switch to display the position of the potentiometer movement.
1-4 to 5-8 range - upshift switch (value approximately 80)
5-8 to 1-4 range - downshift switch (value approximately 20)
BVF1197A_526 65
H8 - CLEAR ELECTRICAL ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)

This menu clears calibration values and stored error codes by resetting all EEPROM values back to default.
EEPROM is where all calibration values and error codes are stored. This memory is retained even if there is no power
to the controller, i.e. if the battery is disconnected.
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BAIL09APH271AVA 66
NOTICE: By selecting the screen display with the controller identifier “DS" or displayed will reset the EEPROM in all
the sub-systems.
If only a specific sub-system EEPROM requires to be reset, select the sub-system that requires the EEPROM to be
reset by depressing the “dimming" key, as the example shown.
BAIL09APH273AVA 67
The lower central display will display “EECL" .
BVE0682A 68
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CAUTION
H8 will clear all calibrations values and stored error codes.
B006
NOTE: If the “m" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the “m" key to confirm the resetting of the EEPROM.
The lower central display will countdown from 05 to 01, then “EE" will be displayed to indicate the EEPROM has been
cleared.
Turn the keystart OFF.
BVE0121A 69
H9 - VOLTMETER
This menu is used to verify the operation of various potentiometers, voltage supplies, and solenoid current circuits.
If an intermittent fault is detected within a circuit, a ’wiggle’ test can be performed on the related wiring while watching
the display for sudden changes in values, to help locate the area where the fault exists.
NOTE: The vehicle may be driven while in this menu.
Common to all sub-systems.
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BAIL09APH275AVA 70
Select the H9 menu by depressing the "dimming" key.
BAIL09APH276AVA 71
The lower central display will display "ch _ _"
BVE0780A 72
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The required channel can be selected by using the "h" and "m" keys.
After a delay the value will be displayed. Compare the value displayed with the typical reading shown in the table
below.
NOTE: The value is the input voltage or signal into the controller. This cannot be directly translated into a voltage due
to the internal processes of the controller. A zero equates to 0 volts.
If the value displayed varies by more than 10 % to that shown in the table below, a fault is indicated in either the
component or the wiring harness relevant to that channel.
NOTE: Check the connectors of the effected circuit, including the controller connectors, prior to replacing any com-
ponents.
BVF1117A 73
Channel ECU pin Description Typical Reading

1 CN1b-1 Clutch pedal position 72 Released 26 Depressed
2 CN1b-14 Transmission oil temperature sender 75 % @ 40 °C.
3 CN1b-11 Fuse 12 sense 96
5 CN1b-16 5 Volt sensor supply 49
CN1b-17
6 CN1b-25 8 Volt sensor supply 79
7 CN1a-1 +12 Volt F source 44
CN1a-2
CN1a-3
8 CN1a-8 +12 Volt D voltage source 41 (with shuttle lever in forward)
9 CN1a-20 +12 Volt H voltage source 44
10 CN1a-25 +12 Volt VT input ( See explanation ) 44
CN1a-34
30 CN1a-5 EDC raise solenoid current 0 turned off / 66 turned in
31 CN1a-12 EDC lower solenoid current 0 turned off / 66 turned in
32 CN1b-2 Lift arm position sensing potentiometer 6 Lowered / 79 Raised
33 CN1b-3 Lift control potentiometer 25 Lowered / 74 Raised
34 CN1b-4 Drop rate control potentiometer 84 clockwise / 14 anti-clockwise
35 CN1b-5 Height limit control potentiometer 84 clockwise / 14 anti-clockwise
36 CN1b-6 Sensitivity control potentiometer 84 clockwise / 14 anti-lockwise
37 CN1b-7 Slip limit control potentiometer 84 clockwise / 14 anti-clockwise
38 CN1b-9 Right hand load sensing pin 42 With no implement
39 CN1b-10 Left hand load sensing pin 42 With no implement
40 CN1b-8 Draft load control potentiometer 84 clockwise 14 anti-clockwise
43 CN2-8 Clutch 1 solenoid current (DS and DT modules) 85 Engaged / 0 Disengaged
45 CN2-2 Clutch C3 solenoid current (DS and DT modules) 85 Engaged / 0 Disengaged
Low clutch solenoid current (DR module)
High clutch solenoid current (DR module)
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53 CN2-8 Clutch 1 solenoid fast current (DS and DT
modules)
modules)
Low clutch solenoid current (DR module)
High clutch solenoid current (DR module)
modules)
modules)
43 CN2-8 Clutch 1 solenoid current 85 Engaged / 0 Disengaged
44 CN2-1 Clutch 1 solenoid current 85 Engaged / 0 Disengaged
45 CN2-2 Clutch C3 solenoid current 85 Engaged / 0 Disengaged
Low clutch solenoid current
46 CN2-3 Clutch C4 solenoid current 85 Engaged / 0 Disengaged
High clutch solenoid current
53 CN2-8 Clutch 1 solenoid fast current
54 CN2-1 Clutch 2 solenoid fast current
modules)
Low clutch solenoid fast current (DR module only)
modules)
High clutch solenoid fast current (DR module only)
63 CN2-7 Forward synchro current
64 CN2-6 Reverse synchro current
65 CN2-7 Forward synchro fast current
66 CN2-6 Reverse synchro fast current
67 CN3b-1 4-5 synchro current (DS and DT modules)
68 CN2-13 5-4 synchro current (DS and DT modules)
69 CN3b-1 4-5 synchro fast current (DS and DT modules)
70 CN2-13 5-4 synchro fast current (DS and DT modules)
72 CN3a-18 Forward / reverse synchroniser potentiometer
73 CN3a-3 4-5 synchro potentiometer
75 CN3a-23 Range switch (DS module only)
Shuttle lever confirmation switch (DT only)
76 CN1b-12 Shuttle lever forward switch 30 Released 68 Depressed
77 CN1b-13 Shuttle lever reverse switch 30 Released 68 Depressed
78 CN3a 10 Left brake pedal switch
79 CN3a 11 Right brake pedal switch
89 CN3a-2 Hand throttle potentiometer 2 (DR and DS 4 Low idle / 36 High idle
modules)
90 CN3a 1 Hand throttle potentiometer 1 (DR and DS 6 Low idle / 73 High idle
Via CAN modules) 0-100%
Hand throttle potentiometer 1 (DT module only)
91 CN3a-7 Foot throttle potentiometer 0-100%
94 CN3b-22 Engine flywheel speed sensor voltage (DS and
DT modules)
95 CN3b-21 PTO torque sensor voltage (DS and DT modules) 49
96 CN2-20 PTO speed sensor voltage 45
Explanations:
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VF Input: This is the input voltage into the controller to transmission components not directly affected by the clutch
pedal switch, i.e. forward and reverse synchroniser solenoids, creeper solenoid and four wheel drive solenoid.
VD Input: This is the input voltage into the controller to transmission components which are affected by the clutch
pedal switch, i.e. PWM solenoids C3 (24x24 Lo) and C4 (24x24 Hi).
VH Input: This is the input voltage into the controller to electronic draft control components, i.e. raise and lower
solenoids.
VT Input: This is the input voltage into the controller to rear PTO and Differential lock, i.e. rear PTO clutch,
Rear PTO brake, and differential lock solenoids.
BVE0690A 74
Clutch solenoids activated when driving
HA - DEMONSTRATION MENU
Used to demonstrate engine power boost.
HA Menu Screen Select Diagram
BAIS09APH319AVA 75
Select the HA menu by depressing the "dimming" key.

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BAIS09APH320AVA 76

After a delay the current setting will be displayed. (see the table below for the description the channel).
BVE0780A 77
Channel Description
Ch 1 Engine power boost demonstration
Channel 1 - Engine Power Boost Demonstration

Power boost will only be active under the following conditions:
• No PTO torque sensor or calibration fault codes

• PTO is fully engaged
• Wheel speed is greater than 0.5 Km/h.
• Engine speed is greater than 1300 rev/min.
• Coolant temperature is below 105 °C.
• PTO has at least 250 Nm torque applied
The lower central display will display “Pbd" (Power boost demonstration).
Start the engine and operate the vehicle to activate engine power boost. The power boost lamp on the ADIC will be
illuminated when power boost is enabled.
Engine power boost will work as normal, but using the CRPM adjustment switch will turn the powerboost on and off.
CRPM increase switch (1) to turn power boost ON
CRPM decrease switch (2) to turn power boost OFF
NOTE: Power boost demonstration will be disabled after turning the keystart OFF.
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BVF1118A 78
HB - DISPLAY STORED FAULT CODES

This menu is used to display fault codes which are stored in the EEPROM of the controller.
A maximum of ten fault codes for each sub-system can be stored.
HB Menu Screen Select Diagram
BAIL09APH271AVB 79
Select the required sub-system by depressing the "dimming" key, as the example shown.
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BAIS09APH312AVC 80
The lower central display will display "_ _ _ _", if no fault code is stored in the selected sub-system.
BVF1089A 81
The lower central display will display "F", if a fault code is stored in the selected sub-system.
BVF1088A 82
The lower central display will the automatically cycle through as the example:
2024 Fault code
01 Hour of first occurrence
19 Hour of last occurrence
19 Number of occurrences of the fault
Depress the “h" or “m" key to change to the next fault code in the list.
The lower central display will display “_ _ _" at the end of the list.
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BVE0796A 83
HC - CLEAR STORED FAULT CODES

HC Menu Screen Select Diagram
BAIS09APH321AVA 84
NOTE: Always make a note of the fault codes stored, before clearing.
Select the HC menu by depressing the “dimming" key.
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BAIS09APH322AVA 85
The lower central display will display “F CL".
BVE0684A 86
Depress and hold the “m" key to confirm the clearing of the memory.
The lower central display will countdown from 05 to 01, then “EE" will be displayed to indicate the fault codes have
been cleared.
BVE0121A 87
HE - DISPLAY ALL SPEED INPUTS

This menu is used to verify the operation of various frequency inputs.

HE Menu Screen Select Diagram
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BAIS09APH323AVA 88
Select the HE menu by depressing the "dimming" key.
BAIS09APH324AVA 89

Refer to the table below for the available channels.
After a delay the value will be displayed.
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BVE0780A 90
Channel Description Typical Reading Notes

1 Wheel speed
2 Radar
3 Not used
4 Rear PTO speed
5 Not used
6 Not used
7 PTO twist speed sensor
8 Engine flywheel speed
9 Measurement of PTO twist
HF - VIEW CONTROLLER HARDWARE INFORMATION

This menu allows the hardware identification, hardware version and serial number to be displayed. Common to all
sub-systems
.
HF Menu Screen Select Diagram
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BAIS09APH325AVA 91
Select the HF menu by depressing the "dimming" key.
BAIS09APH326AVA 92
The lower central display will automatically cycle through as the example:
517 Hardware identification
1000 Hardware version
1234 Serial number
5678 Serial number
and return to allow navigation of the “HH" menus.
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BVE0722A 93

MAXXUM 140
DV- (vehicles with multi-controller) Front PTO, Front Hitch, Front Axle Suspension, Electronic Hydraulic Remotes.
DU - (Options) Front PTO, Front Hitch, Front Axle Suspension, Electronic Hydraulic Remotes
The illustrations in this procedure depict the DU module, For vehicles with multicontroller (DV module), the actual
steps remain the same as below.
HH Service Menu Figure

Number
H3 Configurations 9
H6 Not used -
H7 Not used -
H8 Clear Electrically Erasable Programmable Read Only Memory (EEPROM) 32
H9 Voltmeter 36
HD Not used -
HJ Electronic hydraulic remote control valve set-up 59
1. Electronic Hydraulic Remote levers

2. Front Axle Suspension
3. Front hitch
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BAIL09APH279AVA 1


3. Front hitch
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BAIL09APH280AVA 2
ELECTRONIC HYDRAULIC REMOTE LEVER VALUES

Select the electronic hydraulic remote sub-system by depressing the “dimming" key.
BAIS09APH282AVA 3
The lower central display will display “ch _ _".
After a delay the lower central display will cycle through the code followed by the calibration value for each code in
that channel. (see the table below for the description of each channel).
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BVE0780A_543 4
Channel Description Code Value Range

Ch 1 Lever 1 - Neutral position n 20 - 30
Lever 1 - Float position F 45 - 55
Lever 1 - Lower (retract) position L 5 - 15
Lever 1 - Raise (extend) position R 35 - 45
FRONT AXLE SUSPENSION VALUES

Select the front axle suspension sub-system by depressing the “dimming" key.
BAIS09APH283AVA 5
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BVE0780A_543 6

Ch 1 Front axle up position u 500 - 900
Front axle down position d 150 - 400
FRONT HITCH VALUES

Select the front hitch sub-system by depressing the “dimming" key.
BAIS09APH284AVA 7
BVE0780A_543 8

Ch 1 Front hitch up position u 500 - 900
Front hitch down position d 150 - 400
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H3 - CONFIGURATIONS
Used to display the configurations available for:
1. Electronic Hydraulic Remotes (EHR)

• Ch.1 Enable / Disable EHR
• Ch.2 Front hitch EHR valve selection
• Ch. 3 Enable / Disable EHR joystick
• Ch. 4 Number of EHR’s present - setup
•Enable / Disable front axle suspension
3. Front Hitch
•Enable / Disable front hitch
4. Front PTO
•Enable / Disable front PTO
BAIS09APH285FVA 9
ELECTRONIC HYDRAULIC REMOTES (EHR) OPTIONS

Select the EHR sub-system by depressing the “dimming" key.
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BAIS09APH286AVA 10
BVE0780A_543 11
Channel Description
Ch. 1 Enable / Disable EHR
Ch. 2 Front hitch height limit EHR valve selection
Ch. 3 Enable / Disable EHR joystick
Ch. 4 Number of EHR’s present - setup
Channel 1 - Enable / Disable EHR

Scroll through the available options using the “h" or “m" key.
No - Disable EHR
Yes - Enable EHR
Depress and hold the “h" or “m" key to store the selection, an audible tone will be heard to confirm the selection.
BVF1096A_544 12
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Channel 2 - Front Hitch Height Limit EHR Valve Selection

NOTE: The default setting is EHR valve four.
This is used to select a specific EHR valve to control the front hitch height limit.
The lower central display will display “FEhr" then change to the valve stored to control the front hitch height limit, as
the example shown.
BVF1134A 13
Depress the EHR timer switch of the new valve to be selected three times.
The lower central display will change to display the valve selected, as the example shown.
Turn the keystart OFF to store the selection.
BVF1137A 14
Channel 3 - Enable / Disable EHR Joystick

No - Disable EHR joystick
Yes - Enable EHR joystick
BVF1096A_544 15
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Channel 4 - Number of EHR’s present - setup

Scroll through the available options using the "h" or "m" key.
Use the "h" or "m" key to select channel 4.
Depress and hold the "h" or "m" key to store the selection, an audible tone will be heard to confirm the selection.
Depress the "dimming" key to continue navigating through the "HH" menus.
FRONT AXLE SUSPENSION OPTIONS

Select the front axle suspension sub-system by depressing the "dimming" key.
BAIS09APH287AVA 16
After a delay the current setting will be displayed. (see the table below for the description of the channel).
BVE0780A_543 17
Channel Description
Ch 1 Enable / Disable front axle suspension
Channel 1 - Enable / Disable Front Axle Suspension

No - Disable front axle suspension
Yes - Enable front axle suspension
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BVF1096A_544 18
FRONT HITCH OPTIONS

Select the front hitch sub-system by depressing the “dimming" key.
BAIS09APH288AVA 19
BVE0780A_543 20
Channel Description
Ch 1 Enable / Disable front hitch
No - Disable front hitch
Yes - Enable front hitch
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BVF1096A_544 21
FRONT PTO OPTIONS

Select the front PTO sub-system by depressing the “dimming" key.
BAIS09APH289AVA 22
BVE0780A_543 23
Channel Description
Ch 1 Enable / Disable front PTO
No - Disable front PTO
Yes - Enable front PTO
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BVF1096A_544 24
H4 - VIEW SOFTWARE REVISION LEVEL

BAIS09APH290FVA 25
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BAIS09APH291AVA 26
The lower central display will automatically cycle through the software release, as the example shown and return to
allow navigation of the "HH" menus.
BVE0114A_545 27
H5 - SWITCH OPERATION TEST

This menu displays a designated code when a switch transition is detected.
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BAIS09APH292FVA 28
Select the H menu by depressing the "dimming" key.
BAIS09APH293AVA 29
The lower central display will display "d_ _"
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BVE0047A_546 30
When a switch is operated, a code will be displayed and an audible tone should be heard to indicate the correct
function.
If a switch code is not displayed and the audible tone not heard, a ’wiggle’ test can be performed on the related wiring,
while watching the display or listening for the audible tone, to help locate the fault.
NOTE: If the keystart switch is turned to the “crank" position, with the shuttle lever in neutral and the clutch pedal
down, a switch disagreement error may occur.
BVE0805A 31
Identifier Con- Pin Switch / Input Special Requirements

troller Number
Connec-
tor
d0 No switch or two switches activated at the same time -
d85 C325 30 Time/Flow number 1 switch -
d89 C325 29 Front suspension lockout switch -
d90 C325 11 Front PTO (normally open) switch -
d91 C325 12 Front PTO (normally closed) switch -
d92 C325 18 Front hitch enable switch -
d93 VIA CAN Seat switch -
d94 C327 21 Electronic Hydraulic Remotes (EHR) stop switch -
d95 C327 16 EHR number 1 motor mode switch Rolling gate - position I
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BAIS09APH294FVC 32
NOTICE: By selecting the screen display with the controller identifier "DU“ displayed will reset the EEPROM in all the
sub-systems.
reset by depressing the “dimming" key, as the example shown.
BAIS09APH295AVA 33
The lower central display will display “EECL".
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BVE0682A_547 34
CAUTION
B006
Depress and hold the “m" key to confirm the resetting of the EEPROM.
cleared.
BVE0121A_548 35
H9 - VOLTMETER
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BAIS09APH298FVA 36
BAIS09APH299AVA 37
The lower central display will display "ch_ _"
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BVE0780A_543 38
below.
ponents.
BVF1138A 39

3 Fuse 12 sense 96
5 5 Volts sensor supply 49
6 8 Volts sensor supply 79
7 +12 Volt VF input (See explanation) 44
8 +12 Volt VD input (See explanation) 41 clutch pedal up, FNR in gear Tractor will drive if
0 clutch pedal down, FNR in the engine is running
neutral
9 +12 Volt VH input (See explanation) 44
10 +12 Volt VT input (See explanation) 44
18 Engine rev/min 100 % @ 3000 rev/min
19 Wheel speed 100 % @ 50 Km/h
20 Remote 1 lever position potentiometer 40 Lower (retract)
10 Raise (extend)
50 Float
25 Neutral
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10 Raise (extend)
50 Float
25 Neutral
10 Raise (extend)
50 Float
25 Neutral
10 Raise (extend)
50 Float
25 Neutral
24 Remote joystick X axis (left to right) 40 Lower (retract) Shows "0" if not fitted.
10 Raise (extend)
25 Neutral
25 Remote joystick Y axis (forward to backwards) 40 Lower (retract) Shows "0" if not fitted.
10 Raise (extend)
25 Neutral
26 Front axle position 120 Lowest
950 Highest
27 Front hitch height control 0 Lowest
99 Highest
28 Front hitch position 10 Lowest
90 Highest
Explanations:
VF Input: This is the input voltage into the controller to suspended front axle components, i.e. Front axle lower and
lockout solenoids.
VD Input: This is the input voltage into the controller to suspended front axle raise solenoid.
VH Input: This is the input voltage into the controller to front PTO and front hitch components, i.e. Front PTO solenoid
and front hitch height solenoid.
VT Input: This is a second input voltage into the controller.
Used to demonstrate front axle suspension.
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BAIS09APH300FVA 40
Select the HA menu by depressing the "dimming" key.
BAIS09APH301AVA 41
The lower central display will display "ch_ _"

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BVE0780A_543 42
Channel Description
Ch 1 Front Axle Suspension demonstration
Channel 1 - Front Axle Suspension Demonstration

This demonstration mode allows the suspension to be locked at speeds above the normal 12 Km/h automatic en-
gagement parameter.
The lower central display will display “FSd" (Front Axle Suspension demonstration).
Start the engine and operate the vehicle to demonstrate front axle suspension.
Use the lockout switch (1) to lock the suspension as normal. The light in the switch will be illuminated to indicate the
front axle suspension had been locked.
NOTE: Front axle suspension demonstration will be disabled after turning the keystart OFF.
BVF1139A 43

This menu is used to display fault codes which are stored in the EEPROM of the controller. Common to all sub-
systems.
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BAIS09APH302FVA 44
Select the HB menu by depressing the "dimming" key.
BAIS09APH303AVA 45
The central display will display "_ _ _ _", if no fault is stored in the selected sub-system.
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BVF1089A_549 46
BVF1088A_550 47
4180 Fault code

Depress the “h" or “m" key to change to the next fault code in the list.
BVE0803A 48
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BAIS09APH304FVA 49
Select the HC menu by depressing the “dimming" key.
BAIS09APH305AVA 50
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BVE0684A_551 51
Depress and hold the “m" key to confirm the clearing of the memory.
NOTE: The lower central display will countdown from 05 to 01, then “EE" will be displayed to indicate the fault codes
have been cleared.
BVE0121A_548 52

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BAIS09APH306FVA 53
Select the HE menu by depressing the "dimming" key.
BAIS09APH307AVA 54
The lower central display will display "ch_ _".

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BVE0780A_543 55

0 Not used
1 Not used
2 Not used
3 Not used
4 Front PTO speed
5 Not used
6 Not used
7 Not used
8 Not used

sub-systems.
BAIS09APH308FVA 56
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Select the HF menu by depressing the "dimming" key.
BAIS09APH309AVA 57

1234 Serial number
5678 Serial number
BVE0722A_552 58
HJ - ELECTRONIC HYDRAULIC REMOTE CONTROL VALVE SET-UP

This menu allows the Electronic Hydraulic Remote (EHR) control valve numbers to be reset.
The EHR valve stores a number to indicate its position in the remote control valve stack, i.e. valve number 1,2,3, or 4.
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HJ Menu Screen Select Diagram
BAIS09APH310FVA 59
Select the HJ menu by depressing the "dimming" key.
BAIS09APH311AVA 60
The lower central display will display "EEhr".
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BVE0736A 61
NOTE: HJ will clear all the EHR valve numbers.

Depress and hold the “m" key to confirm the resetting of the valve numbers.
The lower central display will countdown from 05 to 01, then “CEhr" will be displayed to indicate the valve numbers
have been reset.
Refer to the calibrations chapter of the electrical systems section for a detailed explanation of EHR valve number
programming ELECTRONIC SYSTEM - Calibrate (A.50.A).
BVE0737A 62
Control module - Configure Configure GA CONTROLLER H

ROUTINES
MAXXUM 140
GA- 12x12 PTO Controller - Rear PTO, Differential Lock, Four Wheel Drive
H3 Configurations 5
H6 Not used -
H7 Not used -
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H8 Clear Electrically Erasable Programmable Read Only 20

Memory (EEPROM)
H9 Voltmeter 24
HA Not used -
HD Not used -
1. Rear PTO clutch
BVE0195A 1
Refer to the calibrations chapter of the electrical systems section for detailed explanation of each system.

1. Rear PTO clutch
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BVE0196A 2
PTO VALUES
Select the PTO sub-system by depressing the "dimming" button.
BVE0197A 3
NOTE: The default calibration value is 280 for the PTO solenoid.
After a delay the calibration value will be displayed (see the table below for the description of each channel).
Depress the "dimming" button to continue navigating through the "HH" menus.
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BVE0780A 4

Ch1 PTO oil temperature 10 - 120
Ch1 PTO solenoid 100 - 450
H3 - CONFIGURATIONS
This menu is used to display the configurations available for :
1. Four Wheel Drive and Difflock
- Four wheel braking engagement speed selection
2. Rear PTO
- PTO clutch calibration adjustment
- PTO quickfill time adjustment
BVF1150A 5
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FOUR WHEEL DRIVE OPTIONS

Select the four wheel drive sub-system by depressing the "dimming" button.
BVE0198A 6
BVE0780A 7
The options correspond to the ground speed, below Description

which four wheel braking will not occur.
Ch1 Four wheel braking engagement speed selection
Channel 1- Four Wheel Braking Engagement Speed Selection

The options correspond to the ground speed, below which four wheel braking will not occur.
BVE0040A 8
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Option 0 Option 1 Option 2 Option 3 Option 3

Four wheel Default 1.6 km/h 3.2 km/h 4.8 km/h 6.4 km/h
braking 0 km/h
engagement, if
wheel speed is
greater than or
equal to:
NOTE: The four wheel drive braking speed will default to 6.4 km/h on a new electronic module
REAR PTO OPTIONS

Select the PTO sub-system by depressing the "dimming" button.
BVF1149A 9
The lower display will display "ch_ _".
BVE0780A 10
Channel Description
Ch 3 PTO clutch calibration adjustment
Ch 4 PTO quickfill time adjustment
Channel 3 - PTO Clutch Calibration Adjustment

This channel is used to manually adjust the calibration value to optimize the PTO engagement.
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BVE0779A 11
Channel 4 - PTO Clutch Quickfill Time Adjustment (fine tuning if required)

Allows the amount of time to fill the clutch pack to be adjusted..
BVE0792A 12
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BVE0199A 13
Select the H4 menu by depressing the "dimming" button.
BVE0243A 14
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BVE0114A 15

BVE0244A 16
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BVE0245A 17
The lower central display will display "d_ _".
BVE0047A 18
function.
BVF1161A 19
NOTE: If the key start switch is turned to the "crank" position, with the shuttle lever in neutral and the clutch pedal
Identifier Pin Number Switch / Input Special

Requirements
d0 No switch or two switches activated at the same time
d10 9 Seat switch -
d12 15 Left foot brake switch -
d13 23 Right foot brake switch -
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d38 24 Differential lock switch - -

automatic
d39 17 Differential lock switch - -
manual
d41 34 Four wheel drive switch - -
manual
d42 25 Four wheel drive switch - -
automatic
d44 22 Rear PTO switch - normally -
open
d45 31 Rear PTO switch - normally -
closed
d47 33 Rear PTO brake switch -
d48 16 Rear PTO ground speed -
switch
d61 2 +12 VD Supply Shuttle lever - Forward

This menu clear calibration values and stored error codes by resetting all EEPROM values back to default.
to the controller, i.e. if the battery if disconnected.
BVE0247A 20
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BVE0248A 21
The lower central display will display "EECL".
BVE0682A 22
CAUTION
B006
NOTE: If the "m" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the "m" key to confirm the resetting of the EEPROM.
The lower central display will countdown from 05 to 01, then "EE" will be displayed to indicate the EEPROM has been
cleared.
Turn the key start OFF.
BVE0121A 23
H9 - VOLTMETER
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If an intermittent fault is detected within a circuit, a "wiggle" test can be performed on the related wiring while watching
BVE0249A 24
BVE0250A 25
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BVE0780A 26
below.
to the internal process of the controller. A zero equates to 0 volts.
BVF1117A 27
ponents.
Channel Description Typical Reading

4 22
5 +5 Volt sensor supply 498
10 +12 VT voltage source 600
21 Steering angle sensor > 80 (Range ???)
22 Engine oil pressure 20 to 600 steps
23 Engine coolant temperature 20 to 950 steps
24 Air brake pressure 20 to 500 steps
25 Fuel level 50 to 400 steps (60=full; 340=empty)

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BVF1155A 28
Select the required sub-system by depressing the "dimming" button, as the example shown.
BVF1156A 29
The lower central display will display "_ _ _ _", if no fault code is stored in the selected sub-system.
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BVF1089A 30
BVF1088A 31
5024.......Fault code
01..........Hour of first occurrence
19..........Hour of last occurrence
19.........Number of occurrences of the fault
Depress the "h" or "m" key to change to the next fault code in the list.
BVF1154A 32
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BVF1157A 33
NOTE: Always make a note of the error codes stored, before clearing.
Select the HC menu by depressing the "dimming" button.
BVF1158A 34
The lower central display "F CL".
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BVE0684A 35
NOTE: If the "m" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the "m" button to confirm the clearing of the memory.
BVE0121A 36

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BVF1159A 37
Select the HE menu by depressing the "dimming" button.
BVF1160A 38
After a delay the value will be displayed
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BVE0780A 39

1 Rear PTO speed
2 Not used
3 Wheel speed
4 Engine speed

This menu allows the hardware identification, hardware version and serial number to be displayed.
BVE0714A 40
Select the HF menu by depressing the "dimming" button.
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BVE0743A 41
The lower central display will automatically cycle through as the example shows:
517.....Hardware identification
1000.....Hardware version
0301.....Hardware version
1234.....Serial number
5678.....Serial number
and return to allow the navigation of the "HH" menus.
BVE0722A 42

MAXXUM 140
HJ - Enhanced ADIC
HK - Basic ADIC
NOTE: HJ Enhanced ADIC is shown in the screen displays.

H1 Not used -
H2 Not used -
H3 Configurations 1
H6 Not used -
H7 Not used -
H9 Voltmeter 21
HA Not used -
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HD Select Diagnostic mode (Display of fault codes) 34
H3 - CONFIGURATIONS
This menu displays the configurations available for:
Engine shutdown
Cab (less cab / with cab)
Rear axle (heavy duty / light duty)
Air brake
BAIL09APH228AVA 1
ENGINE SHUTDOWN OPTIONS

Select the engine shutdown sub-system by depressing the “dimming" button.
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BAIL09APH229AVA 2
NOTE: The default setting is NO.
Scroll through the available options using the “h" or “m" button.
Refer to the common rail fuel injection / mechanical fuel injection engine shutdown options table below.
NOTE: The mechanical engine shutdown is controlled by the ADIC with enhanced keypad.
Depress and hold the “h" or “m" button to store the selection, an audible tone will be heard to confirm the selection.
Depress the “dimming" button to continue navigating through the “HH" menus.
BAIL09APH230AVA 3
Common Rail Fuel Injection Engine Shutdown Options

Options CONDITIONS REQUIRED CONDITIONS WHICH OVERRIDE
FOR ENGINE SHUTDOWN ENGINE SHUTDOWN OPTIONS
(All conditions must be met)
Operating Condition Operator Operator Vehicle Vehicle
Present Not Station- Moving
Present ary
The engine will not shut down unless
No engine a critical engine fault is detected,
NO - - - -
shutdown which will override this option and
shutdown the engine
Engine oil pressure - Low * * * *
Always
Engine coolant temperature - High * * * *
YES1 shutdown
Driveline oil temperature - High * *
engine
Driveline oil pressure - Low * *
Engine oil pressure - Low * *
Stationary Engine coolant temperature - High * *
YES2 engine
shutdown
Mechanical Fuel Injection Engine Shutdown Options
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.(All conditions must be met)
Present ary
No engine The engine will not shut down under
NO - - - -
shutdown any operating condition
Always
YES1 shutdown
engine
Stationary Engine coolant temperature - High * *
YES2 engine
shutdown
CAB (LESS CAB / WITH CAB) OPTIONS

Select the cab sub-system by depressing the “dimming" button.
BAIL09APH231AVA 4
NOTE: The default setting is with cab.
Cab - The buzzer volume is reduced.
No cab - The buzzer volume is increased.
BAIL09APH232AVA 5
REAR AXLE (HEAVY DUTY / LIGHT DUTY) OPTIONS

Select the rear axle sub-system by depressing the “dimming" button.
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BAIL09APH233AVA 6
NOTE: The default setting is heavy duty rear axle.
BAIL09APH234AVA 7
AIR BRAKE OPTIONS

Select the air brake sub-system by depressing the “dimming" button.
BAIL09APH235AVA 8
NOTE: The default setting is “No" without air brakes.
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BAIL09APH236AVA 9

This menu displays the software release of the unit.
BAIL09APH237AVA 10
Select the H4 menu by depressing the “dimming" button.
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BAIL09APH238AVA 11
allow navigation of the “HH" menus.
BVE0114A_568 12

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BAIL09APH239AVA 13
Select the H5 menu by depressing the “dimming" button.
BAIL09APH240AVA 14
The lower central display will display “d _ _".
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BVE0047A_569 15
function.
BVE0117A 16
Identifier Controller Pin Number Switch / Input Special

Connector Requirements
d65 CN3- 7 Handbrake switch -
d66 CN3- 18 Main high beam lamp switch -
d67 CN1- 15 Sidelights switch -
d68 CN3- 17 Brakes not latched (Japan ONLY) -
d70 CN1- 5 Left turn signal indicator -
d71 CN1- 6 Right turn signal indicator -
d72 CN3- 1 Implement status (mechanical status draft -
control only)

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BAIL09APH241AVA 17
BAIL09APH242AVA 18
The lower display will display "EECL".
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BVE0682A_570 19
CAUTION
B006
NOTE: If the “m" button is released before the countdown finishes, the procedure will be aborted.
Depress and hold the “m" button to confirm the resetting of the EEPROM.
cleared.
BVE0121A_571 20
H9 - VOLTMETER
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BAIL09APH243AVA 21
BAIL09APH244AVA 22
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BVE0780A_573 23
The required channel can be selected by using the “h" and “m" buttons.
below.
ponents.
BVF1087A 24

4 Programming voltage Vpp 22
5 +5V sensor supply 498
10 +12 VT voltage source 600
21 Steering angle sensor > 80 (Range ???)
22 Engine oil pressure sensor 20 - 600
23 Engine coolant temperature sensor 20 - 950
24 Air brake pressure 40 - 500
25 Fuel level sensor 50 - 40060 = Full
340 = Empty
Explanations:
Vpp Input: This is the input voltage into the controller to retain the volatile memory.

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BAIL09APH245AVA 25
Select the HB menu by depressing the "dimming" button.
BAIL09APH246AVA 26
The lower central display will display “_ _", if no fault code is stored.
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BVF1089A_574 27
The lower central display will display “F", if a fault code is stored.
BVF1088A 28
14100 Fault code

Depress the “h" or “m" button to change to the next fault code in the list.
BVE0683A 29
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BAIL09APH247AVA 30
NOTE: Always make a note of the fault codes stored, before clearing the memory.
Select the HC menu by depressing the “dimming" button.
BAIL09APH248AVA 31
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BVE0684A_576 32
NOTE: If the “m" button is released before the countdown finishes, the procedure will be aborted.
Depress and hold the “m" button to confirm the clearing of the memory.
been cleared.
BVE0121A_571 33
HD - FAULT CODE MANAGEMENT

This menu allows the fault code management options to be changed.
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HD Menu Screen Select Diagram
BAIL09APH249AVA 34
Select the HD menu by depressing the "dimming" button.
BAIL09APH250AVA 35
NOTE: The default setting is E (Error code reduction).
The lower central display will display the current setting.
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BVE0686A 36
E - Error code reduction
Only critical fault codes are displayed and non critical fault codes are stored.
L - Live fault codes
All fault codes are displayed.
F - Factory mode
Displays all fault codes, then after approximately six minutes returns to error code reduction.
Depress and hold the “h" or “m" button to store the selection.
Turn the keystart OFF, then ON to start the selected option.
BVE0685A 37

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BAIL09APH251AVA 38
BAIL09APH252AVA 39
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BVE0780A_573 40

18 Engine speed 0 - 3000 rev/min.
19 Wheel speed 0 - 55 Km/h.
20 Radar speed 0 - 55 Km/h.
96 Rear PTO speed sensor 0 - 1200 rev/min.
97 Front PTO speed sensor 0 - 1200 rev/min.

BAIL09APH253AVA 41
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BAIL09APH254AVA 42

1234 Serial number
5678 Serial number
BVE0722A_577 43
Control module - Configure KA - Steering Control

MAXXUM 140
HH TURN ASSIST H ROUTINES

H3 View/Change options (not used) -
H6 Vehicle information (not used) -
H7 Tests mode (not used) -
H8 Clear Electrically Erasable Programmable Read-Only Memory 12
(EEPROM)
H9 Voltmeter 16
HA Demonstration menu (not used) -
HD Set error code state (not used) -
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HJ (Not used) -
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This menu is used to calibrate the steering controller.
Park the tractor on a flat surface and set the engine speed to 1300 RPM (U21 will indicate low RPM).
Make sure that the transmission oil temperature is at least 5 °C (U19 will indicate low transmission oil temperature).
Depress the Fast Steer enable switch (the LED on the instrument panel will be lit). (U71 will indicate Fast Steer enable
switch off).
Enter the H1 menu via the analog digital instrument cluster (ADIC) Fast Steer System (KA Module) sub menu.
The display will automatically display PRO for the proximity sensor or LVDT for the LVDT (linear variable differential
transformer) sensor or deF to adopt the default values for both the proximity and LVDT sensors. Use the H and M
buttons to switch between these three settings.
Proximity Sensor Calibration

Use the "dimming" button to enter the PRO calibration routine.
The display should show O_ _ _, this is for the steering wheel in the disengage position.
Press and hold the M button until the signal has been stable for two seconds this is confirmed by a beep, then a
display of Oxxx, where xxx is the digital representation of the voltage.
The display should then got to C_ _ _,, this is for the steering wheel in the engage position. Holding the steering
wheel in the engage position, depress the M button until the signal has been stable for two seconds, this is confirmed
by a beep, then a display of Cxxx, where xxx is the digital representation of the voltage. The display then returns to
the H1 menu.
LVDT Calibration
Select the H1 menu and select LVDT using the "dimming" button. The system should automatically pilot the solenoid
and measure the LVDT values in both positions and overwrite the default values.
The display will show a 5 second count down as the calibration is carried out. When the calibration is complete, the
display will change to show donE.
Resetting the default values

Enter the H1 menu and select deF using the "dimming" button. Press the "dimming" button to enter the default pa-
rameters routine.
Press and hold the M button, after 2 seconds there will be a beep and the calibration parameters will be reset to their
default values. The display will then change to show donE.
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BAIL06CCM601FVB 1
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H2 VIEW STORED CALIBRATION VALUES

This menu is used to display the calibration values stored in the steering controller.
BAIL06CCM653FVB 2
Select the steering sub-system by depressing the “dimming" button.
BAIL06CCM654AVB 3
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BAIL06CCM446AVA 4
Channel Description Default Value Range

Ch 1 Proximity switch open 350 0 to 999
Ch 2 Proximity switch closed 295 0 to 999
Ch 3 LVDT secondary signal 1 open 400 400 to 750
Ch 4 LVDT secondary signal 2 open 500 400 to 750
Ch 5 LVDT secondary signal 1 closed 500 400 to 750
Ch 6 LVDT secondary signal 2 closed 400 400 to 750
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H3 - VIEW/CHANGE OPTIONS
Not used.
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This menu is used to display the software level of the controller.
BAIL06CCM657FVA 5
BAIL06CCM658AVA 6
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BAIL06CCM460AVB 7
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BAIL06CCM659FVA 8
BAIL06CCM660AVA 9
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The lower central display will display "d _ _"
BVE0047A 10
function.
BAIL06CCM667AVA 11
H5 - Switch Diagnostics
Switch Controller Switch / Input Special Requirements
Identifica- Connector
tion Num-
bers
d117 A1 Enable switch -
d118 C4 Safety switch -
d119 B4 Proximity switch -
d120 - LVDT -
The H5 menu is used to check the operation of the switch inputs (analogue and digital) to an electronic control module.
When a switch transition is detected (either low-high or high-low) the display will show "d" followed by a number
indicating which circuit the transition occurred.
If the same circuit has two transitions in a row, the display changes to "d0" when the second transition occurs.
Navigate to H5. Once the display shows "d--, the switch operation can be tested (see Switch Diagnostics table above).
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H6 - VEHICLE INFORMATION
Not used.
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H7 - TESTS MODE
Not used
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H8 - CLEAR ELECTRICALLY ERASABLE PROGRAMMABLE READ-ONLY MEMORY (EEP-

ROM)
BAIL06CCM670FVA 12
CAUTION
B006
NOTE: If the navigation “down" button is released before the countdown finishes, the procedure will be aborted.
BAIL06CCM671AVA 13
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BVE0682A 14
Depress and hold the “m" button to confirm the resetting of the EEPROM.
cleared.
BVE0121A 15
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H9 - VOLTMETER
BAIL06CCM672FVA 16
BAIL06CCM673AVA 17
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The lower central display will display "ch _"
BAIL06CCM446AVA 18
The required channel can be selected by using the "h" and "m" buttons.
below.
ponents.

1 LVDT secondary winding 1 450 to 750
2 LVDT secondary winding 2 450 to 750
3 Proximity sensor 50 to 800
4 Electrovalve 350 to 500 mA
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Not used.
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BAIL06CCM674FVA 19
Select the steering sub-system by depressing the "dimming" button, as the example shown.
BAIL06CCM680AVA 20
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The lower central display will display "_ _ _", if no fault code is stored in the selected sub-system.
BAIL06CCM487AVA 21
BVF1088A 22
The lower central display will the automatically cycle through as the example:
15010 Fault code
BAIL06CCM488AVB 23
Depress the “h" or “m" button to change to the next fault code in the list.
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HC - CLEAR ALL STORED FAULT CODES
BAIL06CCM681FVA 24
Select the HC menu by depressing the “dimming" button.
BAIL06CCM682AVA 25
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BVE0684A 26
Depress and hold the “m" button to confirm the clearing of the memory.
been cleared.
BVE0121A 27
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HD - SET ERROR CODE STATE

Not used.
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HE - DISPLAY FREQUENCY INPUTS


BAIL06CCM683FVA 28
BAIL06CCM684AVA 29
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The lower central display will display "ch _"

BAIL06CCM446AVA 30

1 Engine Speed (CAN) 0 - 2700 RPM
2 Wheel Speed (CAN) 0 - 40 km/h
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sub-systems.
BAIL06CCM685FVA 31
BAIL06CCM686AVA 32
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0609 Serial number
0054 Serial number
BAIL06CCM687AVA 33
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HJ - NOT USED
Not used.
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FAST STEER CALIBRATION "U" CODES

Code
U19 Transmission oil temperature too low (below 5 °C)
Possible failures:
1. Oil temperature too low. Increase oil temperature and repeat calibration.
2. Check transmission temperature sensor.
Code
U21 ERPM is below 1300 RPM, increase engine speed
Possible failures:
1. Operator has not set engine speed correctly.
2. Open circuit for the engine speed sensor going to the instrument cluster. (Mechanical Engines Only)
3. Instrument cluster is not receiving power.
4. Broken CAN
NOTE: Use the H9 in the transmission module to see if the engine speed is being detected.
Code
U71 Fast Steer enable switch off
Possible failures:
1. Turn on the enable switch and repeat calibration
2. Check for faulty enable switch.
Check enable switch connection.
Code
U72 Proximity sensor open out of range
Possible failures:
1. Incorrect position of the steering wheel.
2. Faulty proximity sensor.
Check proximity sensor connection.
Code
U73 Proximity sensor closed out of range
Possible failures:
1. Incorrect position of the steering wheel.
2. Faulty proximity sensor.
Check proximity sensor connection.
Code
U74 LVDT calibration unsuccessful (out of range at the fifth attempt)
Possible failures:
1. Faulty LVDT sensor.
2. Faulty Fast steer hydraulic valve
3. Incorrect assembly of hydraulic valve
Check LVDT sensor.
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Control module - Configure LA Module

MAXXUM 140
LA- ARMREST
H1 Not used -
H2 Not used -
H3 Not used -
H5 Not used -
H6 Number of auxiliary valves 4
H7 Not used -
(EEPROM)
H9 Not used -
HA Not used -
HD Not used -
HE Not used -
HF Display controller hardware data 18
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BAIL09APH188FVA 1
BAIL09APH189AVA 2
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BAIL09APH190AVA 3
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H6 - NUMBER OF AUXILIARY VALVES
BAIL09APH191FVA 4
Select the H6 by depressing the "dimming" button.
BAIL09APH192AVA 5
The lower central display will automatically display the following:

4 (2) ...... Number of auxiliary valve and return to allow the navigation of the "HH" menus.
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BAIL09APH193AVA 6
NOTE: When you change the number of EHR- valves, look for the description of the controller DH/DV symbol EHR-
valves channel 4.
H8 - CLEAR ELECTRONICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEP-

ROM)
This menu clears calibration values and stored error codes by resetting all EEPROM values back to the default con-
figuration.
All calibration values and error codes are saved in the EEPROM. This memory is not cleared when the power supply
to the control unit is interrupted, for example when disconnecting the battery.
H8 Menu Select Screen Diagram
BAIL09APH211FVA 7
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BAIL09APH212AVA 8
BAIL09APH194AVA 9
NOTICE: H8 will clear all calibration values and stored error codes.
NOTE: If the "h" or "m" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the "h" or "m" key to confirm the resetting of the EEPROM.
NOTE: A countdown from 05 to 01 is shown on the lower central display.
Turn keystart OFF.
BAIL09APH195AVA 10
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HB DISPLAY OF STORED ERROR CODES

BAIL09APH196FVA 11
Select the HB menu by depressing the "dimming" key.
BAIL09APH197AVA 12

4100 ....... EHR Error Codes
01 .......... Hour of first occurrence
19 .......... Hour of last occurrence
19 .......... Number of occurrences of the fault
Depress the "h" or "m" key to change to the next fault code in the list.
Depress the "dimming" button to the continue navigating through the "HH" menus.
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BAIL09APH198AVA 13
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BAIL09APH199FVA 14
Select the HC menu by pressing the "dimming" button.
BAIL09APH200AVA 15
The lower central display will display "F CL".
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BAIL09APH201AVA 16
NOTE: If the "h" or "m" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the "h" or "m" key to confirm the clearing of the memory.
NOTE: A countdown from 05 to 01 is shown on the lower central display . "EE" is then displayed. The error codes
are now cleared.
BAIL09APH195AVA 17
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HF DISPLAY CONTROLLER HARDWARE DATA

BAIL09APH202FVA 18
BAIL09APH203AVA 19

527 (*545) .. Hardware identification
1000 ........... Hardware version
0301 ........... Hardware version
1234 ........... Serial number
5678 ........... Serial number
and return to allow navigation of the "HH" menus.
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BAIL09APH205AVA 20
Control module - Configure Armrest

LC - Armrest (ARU)
HH Service menu Figure

H1 Not used -
H2 Not used -
H3 Not used -
H4 Display software version level 1
H5 Switch diagnostics 4
H6 Not used -
H7 Not used -
H8 Not used -
H9 Voltmeter 8
HA Not used -
HD Not used -
HE Not used -
HF Display controller hardware information 20
HJ Not used -
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H4 - DISPLAY SOFTWARE VERSION LEVEL

BAIL08CVT234 1
Select the H4 menu by depressing the "menu" key.
BAIL08CVT235 2
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The upper section of the display will automatically cycle through the software release, as the example shown and
return to allow navigation of the "HH" menus.
BAIL08CVT236 3
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BAIL08CVT237 4
Select the H5 menu by depressing the “menu" key.
BAIL08CVT238 5
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The top section of the display will display “d _ _".
BAIL09HHP155AVC 6
function.
If a switch code is not displayed and the audible tone not heard, a ’wiggle’ test can be performed on the related wiring
BAIL09HHP256AVB 7
Identifier Switch / Input

d5 Multi function handle (MFH) - Rear hitch work switch
d6 MFH - Rear hitch raise switch
d17 MFH - Downshift switch
d18 MFH - Upshift switch
d19 MFH - 2nd function switch
d92 Front hitch height limit enable switch
d95 EHR 1 program / motor mode switch
d104 MFH - Headland management control (HMC) step switch
d136 MFH - Reverse switch
d137 MFH - Forward switch
d153 Joystick 1 - switch 1
d159 EHR flow control encoder switch
d165 EHR float control switch
d177 MFH - Autoguidance engage on/off switch
d178 MFH EHR 1 extend switch
d179 MFH EHR 1 retract switch
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H9 - VOLTMETER
BAIL08CVT241 8
BAIL06CCM180AVC 9
The upper section of the display will display “ch _ _".
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BAIL08CVT242 10
The required channel can be selected by using the navigation “up" and “down" keys.
below.
ponents.
BAIL08CVT243 11

27 Front hitch - height limit control 0 anti-clockwise
100 clockwise
33 Rear hitch - position control 0 anti-clockwise
100 clockwise
34 Rear hitch - drop rate control 0 anti-clockwise
100 clockwise
35 Rear hitch - height limit control 0 anti-clockwise
100 clockwise
36 Rear hitch - sensitivity control 0 anti-clockwise
100 clockwise
37 Rear hitch - slip control 0 anti-clockwise
100 clockwise
40 Rear hitch - draft control 0 anti-clockwise
100 clockwise
97 Joystick 1 - X position 0.0 at centre
100.0 left/right
98 Joystick 1 - Y position 0.0 at centre
100.0 up/down
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101 EHR No.1 lever position 97.0 raise, 55.0 neutral
12.0 lower, 1.0 float
140 Multifunction handle position 0.0 fully back
100.0 fully forward
143 Joystick 1 - proportional rocker 50 centre
0 pressed down,
100 pressed up
145 Vref 1 92.7
149 EHR flow encoder 0.0 to 6.1 as control is rotated
152 12V ignition 72.0
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This menu is used to display the fault codes, which are stored in the EEPROM of the electronic control unit.
BAIL09HHP206FVC 12
Select the HB menu by depressing the "menu" key.
BAIL08CVT245 13
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"_ _ _ _" is displayed in the upper section of the display, when no fault code is stored in the selected sub-system.
BAIL09HHP063AVB 14
"F" is displayed in the upper section of the display, if a fault code is stored in the selected sub-system.
The sequence of the data display runs through in the upper section of the display, for example, as follows:
18001 Fault code

05 Operating hours at the time of the first occurrence
49 Operating hours at the time of the last occurrence
54 Frequency of occurrence
BAIL08CVT247 15
Press the "Up" or "Down" navigation key to change to the next fault code in the list.
As soon as the end of the list is reached, "_ _ _" is displayed in the upper section of the display.
Depress the "menu" key to continue navigating the "HH" menus.
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HC - CLEAR ALL STORED FAULT CODES
BAIL08CVT248 16
NOTE: Always write the stored fault codes down before clearing.
Select the HC menu by depressing the "menu" key.
BAIL08CVT249 17
"F CL" is displayed in the upper section of the display.
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BAIL09HHP209AVB 18
NOTE: If the "Down" navigation key is released before the end of the countdown, the process is aborted.
To confirm clearing the memory, press and hold the "Down" navigation key.
NOTE: The upper section of the display will countdown from 05 to 01, then "EE" will be displayed to indicate the fault
codes have been cleared.
Depress the "menu" key to continue navigating through the "HH" menus.
BAIL08CVT251 19
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HF - DISPLAY CONTROLLER HARDWARE INFORMATION

This menu makes possible hardware identification; the hardware version and serial number are displayed.
HF Menu Screen Selection Diagram
BAIL08CVT252 20
Select the HF menu by depressing the "menu" key.
BAIL08CVT253 21
The upper section of the display will automatically cycle through as the example:
0000 Serial number
0802 Serial number
0001 Serial number
After that the "HH" menu can be used again.
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BAIL09HHP262AVA 22
NOTE: The last three sets of 4 digits displayed represent the 12 digit module serial number. This number should
correspond to the serial number shown on the module’s label. Note that the serial number shown on the display will
include leading zeros that may not be present on the module label. In this example the serial number is 802001.
Control module - Configure Instrument Cluster

Instrument Cluster Unit (ICU3)

IE - Enhanced ICU3, IF - Basic ICU3
NOTE: The illustrations in this procedure depict the IE module however the instructions remain the same for the IF
module.

H1 Not used -
H2 Not used -
H3 Configurations 1
H6 Not used -
H7 Not used -
H8 Clear Electrically Erasable Programmable Read Only 19
Memory (EEPROM)
H9 Voltmeter 23
HA Not used -
HD Not used -
HH Return to main menu -
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H3 - CONFIGURATIONS
This menu displays the configurations available for:
Engine Shutdown Options

Error Code Reduction
AFS 200 Selection
Steering Sensor Selection
Air Brake Selection
BAIL06CCM167AVE 1
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Select the engine shutdown sub-system by depressing the “menu" key.
BAIL08CVT011 2
NOTE: The default setting is NO.
Scroll through the available options using the navigation “up" or “down" key.
Refer to the common rail fuel injection engine shutdown options table below.
BAIL08CVT012 3
Depress and hold the navigation “up" or “down" key to store the selection, an audible tone will be heard to confirm
the selection.
Depress the “menu" key to continue navigating through the “HH" menus.

(All conditions must be met)
Present ary
No engine
NO The engine will not shut down - - - -
shutdown
Always
YES1 shutdown
engine
Engine coolant temperature - High * *
Stationary
An external device is requesting the
YES2 engine * *
engine to shutdown
shutdown
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Error Code Reduction Options

Select the error code reduction sub-system by depressing the “menu" key.
BAIL06CCM170AVB 4
"Factory" - factory error mode, displays all error codes for a period of 6 minutes then reverts to error code reduction
(ECR).
"ECR" - error code reduction mode, only displays critical errors.
"Live" - live error code mode, displays all error codes.
BAIL06CCM171AVD 5
the selection.
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AFS 200 Selection

Select the AFS 200 sub-system by depressing the “menu" key.
BAIL08CVT013 6
NOTE: The default setting is “No" without AFS 200.
BAIL08CVT014 7
the selection.
Steering Sensor Selection Options

Select the steering sensor sub-system by depressing the “menu" key.
BAIL08CVT017 8
NOTE: The default setting is “No" without steering sensor.
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BAIL08CVT018 9
the selection.
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Air Brake Options

Select the air brake sub-system by depressing the “menu" key.
BAIL08CVT019 10
NOTE: The default setting is “No" without air brakes.
BAIL08CVT020 11
the selection.
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BAIL08CVT021 12
BAIL08CVT022 13
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The display will automatically cycle through the software release as the example shown below, and will then return to
allow navigation of the “HH" menus.
BAIL08CVT045 14
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BAIL08CVT023 15
BAIL08CVT024 16
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The top section of the display will display “d _ _".
BAIL09HHP236AVB 17
function.
If a switch code is not displayed and the audible tone not heard, a ’wiggle’ test can be performed on the related wiring
BAIL09HHP320AVA 18
Channel Controller Pin Number Switch / Input Special

Connector Requirements
d11 CN3 7 Parking brake switch -
d66 CN3 18 Main high beam switch -
d67 CN1 15 Side lights -
d68 CN3 17 Brakes not latched (Japan ONLY) -
d70 CN1 5 Left turn signal indicator -
d71 CN1 6 Right turn signal indicator -
d74 CN3 9 Exhaust brake switch -
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H8 - CLEAR ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEP-

ROM)
This menu clears calibration values and stored error codes by resetting all EEPROM values back to default. EEPROM
is where all calibration values and error codes are stored. This memory is retained even if there is no power to the
controller, i.e. if the battery is disconnected. There are two options available. "Clear net config" and "clear settings".
"Clear net config" is used to erase the stored network configuration, this will clear the current configuration stored in
the instrument cluster and rebuild the configuration at the next key ON. This should be used if the cluster has been
changed or if the HH menus are showing modules which are not fitted to the machine.
"Clear settings" will return all instrument cluster settings back to their default setting.
NOTE: To change any configuration settings H3 menu mode must be used. H8 will not affect these settings.
NOTE: To remove all stored error codes without erasing the calibration values use the HC menu.
The "CLEAR SETTINGS" option will clear all of the following information stored in the instrument cluster’s non-volatile
memory, and set the parameters to their default values (indicated in brackets).
BAIL08CVT027 19
Turn the key switch on without starting the vehicle.

Select "Clear Settings" by depressing the “down" key.
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BAIL08CVT028 20
The top section of the display will display “EECL".
BAIL08CVT029 21
CAUTION
B006
NOTE: If the navigation “down" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the navigation “down" key to confirm the resetting of the EEPROM.
The upper section of the display will countdown from 5 to 1, then “EE" will be displayed to indicate the EEPROM has
been cleared.
BAIL08CVT030 22
It is not possible to continuing through the "H" menus after an H8 procedure. The only possible action is to turn the
ignition key switch off to allow the reset values to be stored.
NOTE: The ’Clear Network Config’ procedure is carried out in the same way as ’Clear Settings’.
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H9 - VOLTMETER
BAIL08CVT031 23
The top section of the display will display “ch _ _".
BAIL08CVT032 24
below.
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ponents.
BAIL08CVT046 25
Channel Controller Pin Number Description Typical Notes

Connector Reading
4 Programming voltage Vpp 12 V See explanations
below
5 CN1 19 +5 Volt sensor supply 5V
10 CN1 24 +12 Volt VT input 12.0 (voltage in See explanations
Volts) below
21 CN3 22 Steering angle sensor 23.0 full right
lock
128.0 full left
lock
24 CN3 15 Air brake pressure 9.0 bar Low pressure
warning at 5.4 bar
25 CN3 14 Fuel level sensor 30 - 270 30 = Full
270 = Empty
51 CN3 21 Vane pump 23.5
108 CN3 15 Air brake pressure (new sensor) 9.0 bar Low pressure
warning at 5.4 bar
Explanations:
Vpp Input: This is the input voltage into the controller to retain the volatile memory.
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BAIL08CVT033 26
Select the HB menu by depressing the “menu" key.
"NO ERROR" will appear in the top section of the display if no fault code is stored.
BAIL09HHP202AVC 27
The upper section of the display will then automatically cycle through as the example:
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14900 Fault code

BAIL08CVT035 28
Depress the navigation “up" or “down" key to change to the next fault code in the list.
The top section of the display will display “_ _ _" at the end of the list.
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BAIL08CVT036 29
Select the HC menu by depressing the “menu" key.

The top section of the display will display “EE CL".
BAIL08CVT047 30
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Depress and hold the navigation “down" key to confirm the clearing of the memory.
The top section of the display will countdown from 05 to 01, then “EE" will be displayed to indicate the fault codes
have been cleared.
BAIL08CVT037 31
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BAIL08CVT038 32
Select the HE menu by depressing the “menu" key.
The top section of the display will display “ch _ _".
BAIL09HHP215AVC 33
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BAIL08CVT048 34

1 H_Rec_status from EPL 0 - 4000 Hz.
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BAIL08CVT039 35
Select the HF menu by depressing the “menu" key.
BAIL09HHP251AVA 36
0000 Serial number
0802 Serial number
0001 Serial number
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BAIL09HHP252AVA 37
Control module - Configure RV - 16x16 Transmission, Electronic

Draft Control, Rear PTO, Front Wheel Drive, Differential Lock, Front
Electronic Hydraulic Remote Valves, Engine.

H3 Configurations 8
H6 Vehicle information view 57
H7 Vehicle test modes 60
(EEPROM)
H9 Voltmeter 72
HD Not used -
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1. Electronic Draft Control Valve. For further information, refer to Control valve - Calibrate EDC valve (H.10.D)
2. Transmission Clutches, determining the current required to turn the input / output shaft at the required speed.
Flywheel speed sensor and PTO torque sensor. For further information, refer to TRANSMISSION Semi-Power-
shift - Calibrate 16x16 Transmission (C.20.D)
3. Differential lock (for steering angle sensor). For further information, refer to FRONT AXLE - Calibrate (D.10.A)
H1 - Menu Screen Select Diagram
BAIL09HHP105FVB 1
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1. Transmission clutches and synchronisers
2. Differential lock (for steering angle sensor)
3. Electronic draft control valve
BAIL09HHP107FVB 2
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TRANSMISSION VALUES
Select the transmission sub-system by depressing the “menu" key.
The upper section of the display will display “ch _".
BAIL09HHP109AVB 3
After a delay the channel number followed by the clutch and calibration value will be displayed (refer to the table below
for a description of each channel).
Channel Description Code

Ch 1 Clutch 1 calibration current A
Ch 2 Clutch 2 calibration current B
Ch 3 Clutch 3 calibration current C
Ch 4 Clutch 4 calibration current D
Ch 5 Forward synchroniser calibration current E
Ch 6 Reverse synchroniser calibration current F
Ch 7 4 synchroniser calibration current -
Ch 8 5 synchroniser calibration current -
Ch 9 Forward/reverse synchroniser potentiometer - forward position -
Ch 10 Forward/reverse synchroniser potentiometer - reverse position -
Ch 11 4/5 synchroniser potentiometer - 4 position -
Ch 12 4/5 synchroniser potentiometer -5 position -
Ch 13 Clutch 5 calibration current -
Depress the "Menu" key to continue navigating through the “HH" menus.
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DIFFERENTIAL LOCK (FOR STEERING ANGLE SENSOR) VALUES

Select the differential lock sub-system by depressing the “menu" key.
BAIL09HHP111AVB 4
After a delay the calibration value will be displayed, (refer to the table below for the description of each channel).
BAIL09HHP122AVB 5

Ch 1 Steering angle sensor > 1000
NOTE: The default calibration value is 12287 for the steering angle sensor.
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ELECTRONIC DRAFT CONTROL VALVE VALUES

Select the Electronic Draft Control sub-system by depressing the “menu" key.
BAIL09HHP113AVB 6
After a delay the channel followed by the stored calibration value will be displayed, (refer to the table below for the
description of each channel).
BAIL09HHP115AVB 7

Ch 1 Raise solenoid R 20 - 80
Ch 2 Lower solenoid L 20 - 80
NOTE: The default calibration value is 50 for both the raise and lower solenoids.
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H3 - CONFIGURATIONS
This menu is used to display the configurations available for:
• Ch.1 Diameter of the External Hydraulic Lift Rams
• Ch.2 Enable / Disable Electronic Draft Control
• Ch.3 Enable / Disable Slip Control
2. Transmission
• Ch.1 Quick Fill Time Adjustment
• Ch.2 Sharp Shuttle Option
• Ch.3 Not Used
• Ch.4 Driver Selectable Shuttle Modes
• Ch.5 40 km/h Maximum Speed Restriction
• Ch.6 Creeper Option Enable / Disable
• Ch.7 Anti-Creep Enable
• Ch.8 Large Tyre Option
• Ch.9 Large Tyre Option
3. Electronic Engine
• Ch.1 Dynamometer Power Boost Test
• Ch.2 Auto Modes Option (Autoshift, CRPM, Power boost)
• Ch.3 Grid Heater Selection
• Ch 4 Fuel Filter Heater Selection
• Ch 5 Engine Brake Selection
• Ch 6 Engine Fan Selection
4. Front EHR
• Ch.1 Front EHR Option Selection
• Ch.2 Front Loader / Front Hitch Selection
• Ch.3 Not Used
• Ch.4 Number of EHR Setup
• Ch.5 High Flow Pump Selection
5. Rear PTO
• Ch.1 PTO Management Selection
• Ch.2 PTO Fender Switches Selection
• Ch.3 PTO Drop Out Speed Selection
• Ch.4 Electronic Shiftable PTO Selection
6. Differential Lock and Four Wheel Drive
• Ch.1 Not Used
• Ch.2 Not Used
• Ch.3 Front Axle Angles (Terralock)
• Ch.4 Four Wheel Drive Brake Engagement Speed Selection
7. Headland Management Control (HMC)
• Ch.1 HMC Enable / Disable Selection
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BAIL09HHP277FVA 8
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ELECTRONIC DRAFT CONTROL OPTIONS

Select the Electronic Draft Control sub-system by depressing the "menu" key.
BAIL09HHP124AVB 9
The required channel can be selected by using the navigation “up" and “down" keys, (refer to the table below for the
Channel Description
Ch 1 Diameter of the External Hydraulic Lift Rams
Ch 2 Enable / Disable Electronic Draft Control
Ch 3 Enable / Disable Slip Control
Channel 1 - Diameter Of The External Hydraulic Lift Rams

Scroll through the available options using the navigation “up" or “down" key
The options available are in (mm):

• 80
• 90
• 100
BAIL09HHP125AVB 10
To save the desired option, depress and hold the navigation "up" or "down" key until the instrument cluster bleeps,
indicating that the selection has been saved.
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Channel 2 - Enable / Disable Electronic Draft Control

Scroll through the available options using the navigation “up" or “down" key

• YES - Enable Electronic Draft Control
• NO - Disable Electronic Draft Control
BAIL09HHP126AVB 11
Channel 3 - Enable / Disable Slip Control


• YES - Enable Slip Control
• NO - Disable Slip Control
BAIL09HHP127AVB 12
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TRANSMISSION OPTIONS
Select the transmission sub-system by depressing the “menu" key.
BAIL09HHP119AVB 13
After a delay the current setting will be displayed, (refer to the table below for the description of each channel).
Channel Description
Ch 1 Quick Fill Time Adjustment
Ch 2 Sharp Shuttle Option
Ch 3 Not Used
Ch 4 Driver Selectable Shuttle Modes
Ch 5 40 km/h Maximum Speed Restriction
Ch 6 Creeper Option Enable / Disable
Ch 7 Anti-Creep Enable
Ch 8 Large Tyre Option
Ch 9 Large Tyre Option
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Channel 1 - Quick Fill Time Adjustment

This channel is used to adjust the transmission’s quick fill setting.
1. Warm the driveline oil to at least 60°C. If the oil is too cold the display will alternate between “Cold” and the oil
temperature in °C. Quickfill adjustment is not possible until the oil warms up.
BAIL09HHP278AVB 14
2. If a four-digit number beginning with 2 is displayed at any time during the calibration procedure, it is a standard
error code. The fault condition must be corrected before calibration can be performed.
3. To select C1 or C2, shift the range lever and shuttle lever to neutral, then use the upshift or downshift switch to
select C1 or C2. The selected clutch and its quickfill setting will be displayed.
BAIL09HHP282AVA 15
4. To adjust and/or test the quickfill setting for C1 or C2, shift the shuttle lever to forward and release the clutch pedal.
The display will change to “C” while pressure is ramped up in C3 and C4 to stop rotation of the transmission gears
in preparation for testing C1 or C2.
BAIL09HHP283AVA 16
5. The lower central display will change to display the clutch and the current quickfill setting, e.g. “C1 4”. The quickfill
setting can be adjusted within the range of 3 to 9 (30 to 90 ms) by using the upshift and downshift switches.
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BAIL09HHP284AVA 17
6. To test the quickfill setting, engage the clutch by slightly depressing and releasing the clutch pedal. Do not push
the pedal all the way down. C3 and C4 will turn off while C1 or C2 is engaged for about 1 second. The display will
change to “C” again briefly while the pressure ramps up again in C3 and C4.
BAIL09HHP285AVA 18
7. Reduce the quickfill setting if necessary until there is no “clunk” noise when C1 or C2 engages. Then increase the
quickfill setting until there is a distinct clunk. Then reduce the setting by 2.
8. To select C3 or C4, shift the range lever to high and the shuttle lever to neutral, then use the upshift or downshift
switch to select C3 or C4. The selected clutch and its quickfill setting will be displayed.
BAIL09HHP286AVA 19
9. To adjust and/or test the quickfill setting for C3 or C4, shift the shuttle lever to forward and release the clutch pedal.
The display will change to “C” while pressure is ramped up in C2 to drive the input side of C3 and C4. Be sure the
park brake is released. Be sure the area around the tractor is clear, as the tractor will move when testing these
clutches.
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BAIL09HHP287AVA 20
10. The lower central display will change to display the clutch and the current quickfill setting, e.g. “C3 4”. The quickfill
setting can be adjusted within the range of 3 to 9 (30 to 90 ms) by using the upshift and downshift switches.
11. To test the quickfill setting, engage the clutch by slightly depressing and releasing the clutch pedal. Do not push
the pedal all the way down. C3 and C4 will turn on for the quickfill time plus 0.1 seconds. The display may change
to “C” again briefly.
BAIL09HHP285AVA 21
12. Reduce the quickfill setting if necessary until there is no tractor movement when C3 or C4 engages. Then increase
the quickfill setting until there is a noticeable tractor movement. Then reduce the setting by 2.
13. Test the quickfill setting by slowly releasing the clutch pedal, or by starting up or shuttle shifting without using the
clutch pedal. Too much quickfill will cause an initial jerk. Too little quickfill will cause slow response. Powershifts
can also be tested, though this is probably the poorest way to tune the quickfill times.
During the adjustment procedure the following U-codes may be displayed:

U25 Range lever is in low, shift out of low.
Channel 2 - Sharp Shuttle Option

This channel is used to select whether the sharp shuttle option is enabled or disabled.
BAIL09HHP121AVB 22
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Use the navigation "up" and "down" keys to toggle between "Yes" and "No", indicating whether the sharp shuttle option
is enabled (Yes) or disabled (No).
To save the desired option, depress and hold the navigation "up" or "down" key for 1 second until the instrument
cluster bleeps, indicating that the selection has been saved.
Channel 4 - Driver Selectable Shuttle Modes

This channel is used to select whether the selectable shuttle mode option is enabled or disabled.
BAIL09HHP121AVC 23
Use the navigation "up" and "down" keys to toggle between "Yes" and "No", indicating whether the selectable shuttle
mode option is enabled (Yes) or disabled (No).
Channel 5 - 40 km/h Maximum Speed Restriction

This channel is used to select whether the 40 km/h maximum speed restriction option is enabled or disabled.
BAIL09HHP121AVD 24
Use the navigation "up" and "down" keys to toggle between "Yes" and "No", indicating whether the 40 Km/h maximum
speed restriction option is enabled (Yes) or disabled (No).
Channel 6 - Creeper Option Enable / Disable

This channel is used to select whether the creeper option is enabled or disabled.
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BAIL09HHP121AVE 25
Use the navigation "up" and "down" keys to toggle between "Yes" and "No", indicating whether the creeper option is
enabled (Yes) or disabled (No).
Channel 7 - Anti-Creep Enable

This channel is used to select whether the anti-creep option is enabled or disabled.
BAIL09HHP121AVF 26
Use the navigation "up" and "down" keys to toggle between "Yes" and "No", indicating whether the anti-creep option
is enabled (Yes) or disabled (No).
Channel 8 and 9 - Large Tyre Option

These channels are used to select whether the Large Tyre option is enabled or disabled. If the Large Tyre option is
enabled then the software will restrict the ground speed to 40 Km/h. The Large Tyre option is set using channel 9
which is not visible by default, it must first be made visible using channel 8.
With the display showing “ch8”, press and hold the “m” button on the instrument cluster for 20 seconds, during this
time the display will flash “- - - -" . After 20 seconds has elapsed the instrument cluster will beep indicating that channel
9 has now been enabled.
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BAIL09HHP280AVA 27
Enter channel 9, the lower display will show either “Lto”, indicating that the Large Tyre option is enabled or “OFF”
indicating that the option is disabled. Use the navigation “up” or “down” keys to toggle the display between “Lto” and
“OFF”.
BAIL09HHP281AVA 28
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ELECTRONIC ENGINE OPTIONS

Select the electronic engine sub-system by depressing the “menu" key.
BAIL09HHP129AVB 29
Channel Description
Ch 1 Dynamometer Power Boost Test
Ch 2 Auto Modes Option
Ch 3 Grid Heater Selection
Ch 4 Fuel Filter Heater Selection
Ch 5 Engine Brake Selection
Ch 6 Engine Fan Selection
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Channel 1 - Dynamometer Power Boost Test

This channel is used to allow the tractor to be dynamometer tested with maximum power boost.
NOTE: The power boost is only active for 45 minutes.
Scroll through the available options using the “up" or “down" key.

• OFF - dyno power boost test mode is off (normal vehicle operation - default setting for this channel)
• "Std" - dyno power boost test mode is on (straight unboosted curve without any limitations)
• "bSt" - dyno power boost test mode is on (straight boosted curve without any limitations)
BAIL09HHP131AVB 30
Channel 2 - Auto Modes Option

This channel is used to enable or disable the vehicles auto modes. e.g., Autoshift, CRPM and Power boost
The “up" or “down" keys are used to toggle between "Yes" and "No" indicating whether auto modes are enabled
(yes) or disabled (no).
BAIL09HHP132AVB 31
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Channel 3 - Grid Heater Selection


• YES - Grid heater fitted
• NO - Grid heater not fitted
BAIL09HHP127AVB 32
Channel 4 - Fuel Filter Heater Selection


• YES - Fuel filter heater fitted
• NO - Fuel filter heater not fitted
BAIL09HHP133AVB 33
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Channel 5 - Engine Brake Selection


• YES - Engine brake fitted
• NO - Engine brake not fitted
BAIL09HHP133AVC 34
Channel 6 - Engine Fan Selection


• V - Visctronic fan fitted
• r - Reversible fan fitted
BAIL09HHP133AVD 35
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FRONT EHR OPTIONS

Select the Front EHR sub-system by depressing the “menu" key.
BAIL09HHP142AVC 36
Channel Description
Ch 1 Front EHR Option Selection
Ch 2 Front Loader / Front Hitch Selection
Ch 3 Not Used
Ch 4 Number of EHR Setup
Ch 5 High Flow Pump Selection
Channel 1 - Front EHR Option Selection

This channel is used to enable/disable the front EHR.

• Yes - Enable front EHR
• No - Disable front EHR
BAIL09HHP120AVB 37
Channel 2 - Front Loader / Front Hitch Selection

This channel is used to select if the front EHRs are used in conjunction with the front hitch or the front loader.
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• "nonE" - Neither selected
• Htch - Front hitch selected
• "LOAd" - Front loader selected
NOTE: If Front Hitch is selected then the Front EHR valve 1 will be reserved for front hitch operation.
If Front Loader is selected then the front EHR valves 1-3 will be reserved for front loader operation.
If None is selected then all the front EHR valves will be available for use.
NOTE: If the Front EHRs are to be used to control the Front Hitch then the Front Hitch option must also be enabled
in the Auxiliary Control Module (RP module, Front Hitch system, H3, channel 1 set to “YES”).
BAIL09HHP143AVB 38
Channel 4 - Number of EHR Setup

When a new module is installed or the H8 procedure is completed, automatic detection for the number of remotes is
used. If at any time the number of fitted remotes needs to be changed then this setup channel is used.

• 2
• 3
• 4
BAIL09HHP144AVB 39
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Channel 5 - High Flow Pump Selection

This channel is used to disable/enable the high flow pump.

• Yes - Enable high flow pump
• No - Disable high flow pump
BAIL09HHP145AVB 40
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REAR PTO OPTIONS

Select the Rear PTO sub-system by depressing the “menu" key.
BAIL09HHP135AVC 41
Channel Description
Ch 1 PTO Management Selection
Ch 2 PTO Fender Switches Selection
Ch 3 PTO Drop Out Speed Selection
Channel 1 - PTO Management Selection

This channel is used to enable/disable the PTO management for the PTO control system.

• YES - Enable PTO management
• NO - Disable PTO management
BAIL09HHP120AVB 42
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Channel 2 - PTO Fender Switches Selection

This channel is used to disable/enable the rear PTO fender switch.

• YES - Enable rear PTO fender switches
• NO - Disable rear PTO fender switches
BAIL09HHP121AVB 43
Channel 3 - PTO Drop Out Speed Selection

This channel is used to adjust the engine speed below which the PTO will drop out.
After a delay the current setting will be displayed.
BAIL09HHP136AVB 44
Use the navigation "up" and "down" keys to increase or decrease the setting in 10 RPM increments between 0
- 550 RPM.
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DIFFERENTIAL LOCK AND FOUR WHEEL DRIVE OPTIONS

Select the differential lock and four wheel drive sub-system by depressing the “menu" key.
BAIL09HHP138AVB 45
Channel Description
Ch 1 Not Used
Ch 2 Not Used
Ch 3 Front Axle Angles (Terralock)
Ch 4 Four Wheel Drive Brake Engagement Speed Selection
Channel 1 - Not used
Channel 2 - Not used
Channel 3 - Front Axle Angles (Terralock)

This channel is used to select the steering angle at which the Auto Difflock and Auto Four Wheel Drive functions
engage and disengage.
The available options (0, 1, 2 or 3) are shown in the table below with a description of each option.
Standard/suspended Axle
0-10 km/h 0 - 10 0 - 10 0 - 10 10 - 15 10 - 15 10 - 20 10 - 20
km/h km/h km/h km/h km/h km/h km/h
Auto Four Auto Four Auto Auto Auto Auto Auto Auto Four
Wheel Wheel Difflock Difflock Difflock Difflock Four Wheel
Drive Drive Wheel Drive
Drive
Degrees Degrees Degrees Degrees Degrees Degrees Degrees Degrees
Right Left Right Left Right Left Right Left
Option 0 20 ° 18.5 ° 15 ° 14.25 ° 10 ° 9.5 ° 15 ° 14.2 °
Option 1 45 ° 37.5 ° 20 ° 18.5 ° 10 ° 9.5 ° 40 ° 34 °
Option 2 15 ° 14.2 ° 10 ° 9.5 ° 10 ° 9.5 ° 15 ° 14.2 °
Option 3 11.7 ° 10.9 ° 5° 4.5 ° 10 ° 9.5 ° 15 ° 14.2 °
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BAIL09HHP139AVB 46
Channel 4 - Four Wheel Drive Brake Engagement Speed Selection

This channel is used to select the ground speed below which four wheel drive braking will not occur.
The available options (0, 1, 2, 3 or 4) are shown in the table below with a description of each option.
Option 4 Option 3 Option 2 Option 1 Option 0

Four wheel braking engagement, if wheel speed is Default 4.8 km/h. 3.2 km/h. 1.6 km/h. 0 km/h.
greater than or equal to: 6.4 km/h.
BAIL09HHP140AVB 47
HEADLAND MANAGEMENT CONTROL (HMC) OPTIONS

Press the "menu" key to call up the 'HMC' sub-system.
"ch _ _" is displayed in the upper section of the display.
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BAIL09HHP307AVA 48
The relevant channel can be called up using the navigation "Up" and "Down" keys.
Channel Description
Channel 1 HMC option selection
Channel 1 - HMC option selection.

This channel is used to activate or deactivate the HMC.
Scroll through the available options using the "Up" or "Down" navigation keys.
The available options are:

• YES - HMC activate
• NO - HMC deactivate
BAIL09HHP126AVC 49
To store the desired option, press and hold the "Up" or "Down" navigation button until the instrument cluster
indicates by a beep that the selection has been stored.
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BAIL09HHP148FVB 50
BAIL09HHP149AVB 51
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BAIL09HHP150AVB 52
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BAIL09HHP153FVB 53
BAIL09HHP154AVB 54
The upper section of the display will display "d _ _"
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BAIL09HHP155AVB 55
function.
BAIL09HHP156AVB 56
Channel Controller Pin Number Description

Connector
0 - - No switch activated or 2 switches activated at the same time
d1 CN1B 30 Fender EDC switch - lower
d2 CN1B 29 Fender EDC switch - raise
d5 via CAN - EDC work switch (on hand controller)
d6 via CAN - EDC raise switch (on hand controller)
d7 CN3A 15 NASO lighting link (disconnect and reconnect the flasher unit -
not for ISO lighting)
d8 CN1B 21 Crank detect switch
d10 CN4 9 Seat switch
d11 CN4 10 Parking brake switch
d12 CN1B 22 Left foot brake switch
d13 CN1B 23 Right foot brake switch
d14 CN1A 8 Clutch pedal switch (with transmission in forward or reverse)
d15 CN1B 12 Shuttle lever switch - forward
d16 CN1B 13 Shuttle lever switch - reverse
d17 via CAN - Transmission downshift switch (on hand controller)
d18 via CAN - Transmission upshift switch (on hand controller)
d19 via CAN - Transmission range switch (on hand controller)
d20 CN4 17 Reverse clutch pressure switch
d21 CN4 11 Forward clutch pressure switch
d23 CN1B 27 Momentary shuttle lever forward/reverse switch
d24 CN4 16 Momentary shuttle lever neutral switch
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Channel Controller Pin Number Description

Connector
d31 CN3A 14 Air conditioning pressure switch
d32 CN3A 17 EDC lock switch
d33 CN1B 19 Radar present input (disconnect radar to test)
d38 via CAN - Differential lock switch - manual
d39 via CAN - Differential lock switch - automatic
d41 via CAN - Four wheel drive switch - manual
d42 via CAN - Four wheel drive switch - automatic
d43 CN4 21 High flow pump link (disconnect pump link to test)
d44 CN3A 12 Rear PTO switch - normally open
d45 CN3A 13 Rear PTO switch - normally closed
d46 CN4 24 Hi flow pump not present input
d47 CN3B 24 Rear PTO brake switch
d48 CN3B 33 Rear PTO ground speed switch
d49 via CAN - Rear PTO management switch
d50 via CAN - Headland Management Control (HMC) switch - program mode
d53 CN1B 24 Transmission oil pressure switch (bridge switch to test with
engine off)
d55 via CAN - Engine speed switch - decrease
d56 via CAN - Engine speed switch - increase
d60 CN3B 32 Foot throttle not at idle switch
d63 CN3A 18 Rear PTO fender switch - normally open
d64 CN3A 3 Rear PTO fender switch - normally closed
d80 via CAN - HMC auto switch
d81 via CAN - HMC manual switch
d93 CN4 25 Front HPL present link (disconnect and reconnect the 13 way
connector)
d94 CN3A 16 EHR lock switch
d95 via CAN - EHR 1 program / motor mode switch
d104 via CAN - HMC step switch (on hand controller)
d105 Not used - -
d111 CN3A 20 PTO speed selection switch - speed 1 (1000)
d112 CN4 18 PTO speed selection switch - speed 2 (1000E)
d113 CN4 4 PTO speed selection switch (neutral)
d122 via CAN - CRPM speed 1 selection switch
d123 via CAN - CRPM speed 2 selection switch
d125 via CAN - Autoguidance engage on/off switch (on ICP)
d126 via CAN - Engine brake pedal switch
d127 via CAN - Reversible fan switch
d136 via CAN - Forward switch (on hand controller)
d137 via CAN - Reverse switch (on hand controller)
d139 via CAN - Joystick EHR select switch
d159 via CAN - EHR flow encoder switch
d165 via CAN - EHR float switch
d177 Not used - -
d180 via CAN - EHR 2 extend switch (on hand controller)
d181 via CAN - EHR 3 extend switch (on hand controller)
d185 via CAN - Rear slip switch
d186 via CAN - Ride control switch
d187 via CAN - Rear hitch inching raise switch
d188 via CAN - Rear hitch inching lower switch
d196 via CAN - Auto field switch (on ICP)
d197 via CAN - Auto transport switch (on ICP)
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CN1a = . X092. CN1b = . X093 CN2 = . X091

CN3a = . X094 CN3b = . X095 CN4 = . X097
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H6 - VEHICLE INFORMATION VIEW

This menu displays the vehicle specific information.

BAIL09HHP160FVB 57
BAIL09HHP161AVB 58
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• 19 = number of gears
• 40 = Transmission speed
• 120 = Engine power
BAIL09HHP162AVB 59
At the end of the cycle the display will return to continue navigating through the “HH" menus.
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H7 - TEST MODES
This menu is used to check the clutch disconnect switch adjustment and to test the transmission synchronisers.
BAIL09HHP164FVB 60
BAIL09HHP166AVA 61
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The upper section of the display will display "ch _ _"
BAIL09HHP167AVB 62
Channel Description
Ch 1 Clutch switch adjustment
Ch 2 Forward/reverse synchroniser test
Ch 3 4/5 synchroniser test
Channel 1 - Clutch Switch Adjustment

This channel is used to display the clutch pedal position and is useful for evaluating the clutch pedal switch
adjustment and also the inching bite point The transmission is disabled in this channel.
Place the shuttle lever into the forward position The display will show ’n’ if the lever is in neutral.
• When the display shows "CP", cycle the clutch pedal.
• When the clutch pedal is released the display will show a value in the range 8-14, if the switch is correctly adjusted.
• If the switch is incorrectly adjusted the display will show "CL" and the screw will need to be rotated clockwise, or
the display will show "CCL" and the screw will need to be rotated in an anti-clockwise direction.
Adjust the screw in the direction indicated by the display and cycle the clutch pedal and repeat the procedure
until the display shows the correct value.
BAIL09HHP279AVA 63
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Channel 2 - Forward/Reverse Synchroniser Test

This channel is used to test the forward/reverse synchroniser.
• The synchroniser position will be displayed as a value in the range 20-80.
• Press the upshift button to increase the forward synchroniser solenoid pressure.
BAIL09HHP256AVD 64
• Press the downshift button to increase the reverse synchroniser solenoid pressure.
BAIL09HHP256AVE 65
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Channel 3 - 4/5 Synchroniser Test

This channel is used to test the 4/5 synchroniser.
• The synchroniser position will be displayed as a value in the range 20-80.
• Press the upshift button to increase the 4/5 synchroniser solenoid pressure.
BAIL09HHP256AVD 66
• Press the downshift button to increase the 5/4 synchroniser solenoid pressure.
BAIL09HHP256AVE 67
• Press the range switch to move the synchroniser to the neutral position.
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ROM)
BAIL09HHP183FVB 68
NOTICE: By selecting the screen display with the controller identifier "RV" displayed will reset the EEPROM in all the
sub-systems.
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Select the sub-system that requires the EEPROM to be reset by depressing the “menu" key, as the example shown.
BAIL09HHP185AVB 69
The upper section of the display will display “EECL" .
BAIL09HHP186AVB 70
CAUTION
B006
The upper section of the display will countdown from 5 to 1, then “EE" will be displayed to indicate the EEPROM has
been cleared.
BAIL09HHP187AVB 71
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H9 - VOLTMETER
BAIL09HHP189FVB 72

The upper section of the display will display "ch _"
BAIL09HHP191AVC 73
The required channel can be selected by using the navigation "up" and "down" keys.
below.
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NOTE: Check the connectors of the affected circuit, including the controller connectors, prior to replacing any com-
ponents.

1 CN4-20 Clutch pedal position 75 Released 29 Depressed
2 CN1B-14 Transmission temperature sender 75 % at 40 °C.
3 CN1B-11 Fuse 38 sense 99
5 CN1B-16 +5 Volt sensor supply 48
6 CN1B-25 +8 Volt sensor supply 79
7 CN1B-1 +12 Volt VF voltage source ( See explanation ) 43
CN1B-2
CN1B-3
8 CN1A-8 +12 Volt VD voltage source ( See explanation ) 43 (with transmission in F or R)
9 CN1A-20 +12 Volt VH input ( See explanation ) 43
10 CN3B-25 +12 Volt VT input ( See explanation ) 43
CN3B-34
11 CN4-9 Seat switch 69 in seat
36 out of seat
12 CN1B-34 Transmission output speed sensor 50 (engine not running)
13 CN3B-22 Flywheel speed sensor 50 (engine not running)
18 - Engine speed 850 - 2350 RPM
19 - Wheel speed 2780 @ 10 km/h
20 - Radar speed 2780 @ 10 km/h
29 CN3A-9 Creeper position potentiometer 26 Off - 54 On
30 CN2-4 Electronic draft control valve raise solenoid 0 Off - 66 On
31 CN2-5 Electronic draft control valve lower solenoid 0 Off - 66 On
32 CN1B-2 Lift arm position potentiometer 6 Lowered 79 Raised
33 via CAN Lift control potentiometer 0 Lowered 100 Raised
34 via CAN Drop rate control potentiometer 0 Clockwise 100 Counter clockwise
35 via CAN Height limit control potentiometer 0 Clockwise 100 Counter clockwise
36 via CAN Sensitivity control potentiometer 0 Clockwise 100 Counter clockwise
37 via CAN Slip limit control potentiometer 0 Clockwise 100 Counter clockwise
38 CN1B-9 Right hand load sensing pin 46
39 CN1B-10 Left hand load sensing pin 46
40 via CAN Draft load control potentiometer 0 Clockwise 100 Counter clockwise
43 CN2-8 Clutch A solenoid current 70 Engaged 0 Disengaged
44 CN2-1 Clutch B solenoid current 70 Engaged 0 Disengaged
45 CN2-5 Clutch C solenoid current 70 Engaged 0 Disengaged
46 CN2-3 Clutch D solenoid current 70 Engaged 0 Disengaged
47 CN3B-1 Clutch E solenoid current 70 Engaged 0 Disengaged
49 CN3B-18 Rear PTO solenoid current 0 Off - 99 On
50 CN4-16 Shuttle lever neutral switch 30 not pressed - 65 pressed
52 CN3B-2 Creeper solenoid current 99 Engaged 0 Disengaged
58 CN3B-3 Low range solenoid current 70 Engaged 0 Disengaged
59 CN2-7 Mid range solenoid current 70 Engaged 0 Disengaged
60 CN2-2 High range solenoid current 70 Engaged 0 Disengaged
61 CN2-13 19th gear solenoid current 70 Engaged 0 Disengaged
62 CN3B-10 19th gear dump solenoid current 70 Engaged 0 Disengaged
66 CN3B-4 Reverse synchroniser solenoid current 70 Engaged 0 Disengaged
71 CN33A-2 Mid / Reverse synchroniser position sensor 16 in Mid
42 in N
70 in Rev
74 CN4-14 Low / High synchroniser position sensor 16 in High
42 in N
70 in Low
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76 CN1B-12 Shuttle lever forward switch 30 Released 68 Depressed
77 CN1B-13 Shuttle lever reverse switch 30 Released 68 Depressed
90 via CAN Hand throttle 0 at idle - 100 at max. RPM
91 CN1B-1 Foot throttle potentiometer 10 at idle - 85 at max. RPM
97 via CAN EHR joystick (X) 0 at centre - 100 left/right
98 via CAN EHR joystick (Y) 0 at centre - 100 up/down
109 CN1B-7 Transmission oil pressure sensor -
133 CN2-14 PTO twist sensor voltage 50 (engine not running)
Explanations:
VF Input: This is the input voltage into the controller to transmission components not directly affected by the clutch
pedal switch, i.e. forward and reverse synchroniser solenoids, creeper solenoid and four wheel drive solenoid.
VD Input: This is the input voltage into the controller to transmission components which are affected by the clutch
pedal switch, i.e. PWM solenoids.
VH Input: This is the input voltage into the controller to electronic draft control components, i.e. raise and lower
solenoids.
VT Input: This is the input voltage into the controller to rear PTO and Differential lock, i.e. rear PTO clutch,
Rear PTO brake, and differential lock solenoids.
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Used to demonstrate engine power boost.
HA - Menu Screen Select Diagram
BAIL09HHP193FVB 74
Select the HA sub-system by depressing the "menu" key.

BAIL09HHP195AVB 75
After a delay the current setting will be displayed. (refer to the table below for the description of the channel).
Channel Description
Ch 1 Engine power boost demonstration
Channel 1 - Engine Power Boost Demonstration

Power boost will only be active under the following conditions:
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• No PTO torque sensor or calibration fault codes

• PTO is fully engaged
• Wheel speed is greater than 0.5 km/h.
• Engine speed is greater than 1300 rev/min.
• Coolant temperature is below 105 °C.
• PTO has at least 250 Nm torque applied
The upper section of the display will display “Pbd" (Power boost demonstration).
Start the engine and operate the vehicle to activate engine power boost. The power boost lamp on the ICU2 will be
illuminated when power boost is enabled.
Engine power boost will work as normal, but using the CRPM adjustment switch will turn the power boost on and off.
CRPM increase switch (1) to turn power boost ON
CRPM decrease switch (2) to turn power boost OFF
NOTE: Power boost demonstration will be disabled after turning the keystart OFF.
BAIL09HHP197AVB 76
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HB - Menu Screen Select Diagram
BAIL09HHP199FVB 77
Select the required sub-system by depressing the "menu" key, as the example shown.
BAIL09HHP202AVB 78
The upper section of the display will display "- - - -", if no fault code is stored in the selected sub-system.
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BAIL09HHP203AVB 79
The upper section of the display will display "F", if a fault code is stored in the selected sub-system.
BAIL09HHP234AVB 80
The fault code would then automatically cycle through as the example:
1054 Fault code
Depress the navigation “up" or “down" key to change to the next fault code in the list.
The upper section of the display will display “- - -" at the end of the list.
BAIL09HHP204AVB 81
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This menu is used to clear all stored fault codes in the module or sub system.
HC - Menu Screen Select
BAIL09HHP206FVB 82
Select the HC menu by depressing the “menu" key.
BAIL09HHP208AVB 83
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The upper section of the display will display “F CL".
BAIL09HHP209AVB 84
The upper section of the display will countdown from 05 to 01, then “EE" will be displayed to indicate the EEPROM
has been cleared.
BAIL09HHP210AVB 85

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HE - Menu Screen Select Diagram
BAIL09HHP212FVB 86
Select the HE menu by depressing the "menu" key.
BAIL09HHP214AVB 87
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The required channel can be selected by using the navigation “up" and “down" keys, (refer to the table below for the
available channels).
BAIL09HHP215AVB 88

1 Wheel speed (transmission output speed) 8000 @ 10 km/h
2 Radar 3700 @ 10 km/h
3 Not used -
4 Rear PTO speed 1100 @ 2000 RPM
5 CDE speed sensor -
6 Not used -
7 PTO angle 4500 to 13500 (degrees * 100)
8 Engine flywheel speed 560 @ 850 RPM
9 PTO twist -15 to 140 (degrees)

BAIL09HHP216AVB 89
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sub-systems.
HF - Menu Screen Select Diagram
BAIL09HHP219FVB 90
BAIL09HHP221AVB 91
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2000 Serial number
4752 Serial number
BAIL09HHP222AVB 92

The EHR valve stores a number to indicate its position in the remote control valve stack, i.e. valve number 1,2, 3, or 4.
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HJ - Menu Screen Select Diagram
BAIL09HHP225FVC 93
Select the HJ menu by depressing the "menu" key.
BAIL09HHP227AVB 94
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The upper section of the display will display "EEhr".
BAIL09HHP228AVB 95

NOTE: If the navigation "down" button is released before the countdown finishes, the procedure will be aborted.
Depress and hold the navigation "down" key to confirm the clearing of the valve numbers.
The upper section of the display will countdown from 05 to 01, then "CEhr" will be displayed to indicate the valve
numbers have been cleared.
BAIL09HHP229AVB 96
Disconnect the connectors from each remote valve, except valve number one.
Turn the keystart ON and enter HJ menu again.
The cluster will flash "EHR_" followed by "EHR1" with an audible bleep, indicating the first valve has been recognised
and renumbered.
The display will then flash "EHR 2", indicating the controller is ready for the next valve to be connected.
Reconnect each valve in the correct order, as each valve is recognised the cluster will bleep and flash the next valve
to be connected.
Depress and hold the navigation "down" key , the display will change to "End" to indicate programming is complete.
NOTE: If the maximum possible number of valves are fitted, the procedure will end automatically when the last valve
is connected and the display will change to "END".
Turn the keystart OFF to store the new valve numbers.
Calibrate the remote valves, for further information refer to PRIMARY HYDRAULIC POWER SYSTEM Electro-hy-
draulic remote valve - Calibrate (A.10.C).
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Control module - Configure - Front Axle Suspension, Rear

Electronic Hydraulic Remote Valves, Front PTO, Front Hitch
RP Control Module
HH Service Menu Figure

Number
H3 Configurations 10
H6 Not used -
H7 Not used -
H9 Voltmeter 35
HD Not used -
HK Not used -
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1. Electronic Hydraulic Remote levers. For further information, refer to PRIMARY HYDRAULIC POWER SYSTEM
Electro-hydraulic remote valve - Calibrate (A.10.C).
2. Front axle suspension. For further information, refer to Control valve - Calibrate Front suspended axle (D.40.C).
3. Front hitch. For further information, refer to HITCH Front hitch - Calibrate (H.10.B).
BAIL09HHP002FVA 1
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2. Front axle suspension
3. Front hitch
BAIL09HHP004FVA 2
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ELECTRONIC HYDRAULIC REMOTE LEVER VALUES

Select the electronic hydraulic remote sub-system by depressing the "menu" key.
BAIL09HHP006AVA 3
The upper section of the display will display "ch - -".
BAIL09HHP007AVB 4
After a delay the channel followed by the stored calibration values will be displayed, (refer to the table below for the
BAIL09HHP096AVA 5

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FRONT AXLE SUSPENSION VALUES

Select the front axle suspension sub-system by depressing the "menu" key.
BAIL09HHP009AVA 6
BAIL09HHP010AVB 7
After a delay the channel followed by the stored calibration values will be displayed (refer to the table below for the

Ch 1 Front axle upper limit u 512 - 972
Front axle lower limit d 150 - 512
FRONT HITCH VALUES

Select the front hitch sub-system by depressing the "menu" key.
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BAIL09HHP012AVA 8
The upper section of the display will display "ch - - ".
BAIL09HHP013AVB 9
After a delay the channel followed by the stored calibration values will be displayed (refer to the table below for the

Ch 1 Front hitch upper limit u 700 - 963
Front hitch lower limit d 41 - 400
H3 - CONFIGURATIONS
Used to display the configurations available for:
1. Electronic Hydraulic Remotes (EHR)
• Ch.1 Enable / Disable EHR
• Ch.2 Not used
• Ch.3 Not used
• Ch.4 Number of EHR’s Present - Setup
• Ch.5 Top and Side Link Control Option Selection
• Ch.1 Enable / Disable front axle suspension
3. Front Hitch
• Ch.1 Enable / Disable front hitch
• Ch.2 Enable / Disable front hitch fender switches
4. Front PTO
• Ch.1 Enable / Disable front PTO
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BAIL09HHP015FVA 10
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ELECTRONIC HYDRAULIC REMOTES (EHR) OPTIONS

Select the EHR sub-system by depressing the "menu" key.
BAIL09HHP017AVA 11
The lower central display will display "ch - -".
The required channel can be selected by using the "up" and "down" buttons.
BAIL09HHP018AVB 12
Channel Description
Ch 1 Enable / Disable rear EHR
Ch 2 Not Used
Ch 3 Not Used
Ch 4 Number of EHR’s present - setup
Ch 5 Enable / Disable top and side link control
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Channel 1 - Enable / Disable Rear EHR

Scroll through the available options using the navigation "up" or "down" key.

• YES - Enable Rear EHR
• NO - Disable Rear EHR
BAIL09HHP019AVA 13

This channel is not used.

This channel is not used.
Channel 4- Number of EHR’s Present - Setup

When a new module is installed or the H8 procedure is completed, automatic detection for the number of remotes is
used. If at any time the number of fitted remotes needs to be changed then this setup channel is used.
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• 2
• 3
• 4
• 5
BAIL09HHP020AVA 14
Channel 5- Enable / Disable Top and Side Link Control


• YES - Enable top/side link control
• NO - Disable top/side link control
BAIL09HHP021AVA 15
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FRONT AXLE SUSPENSION OPTIONS

Select the front axle suspension sub-system by depressing the "menu" key.
BAIL09HHP023AVA 16
BAIL09HHP024AVB 17
After a delay the current setting will be displayed (refer to the table below for the description of the channel).
Channel Description
Ch 1 Enable / Disable front axle suspension
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Channel 1 - Enable / Disable Front Axle Suspension


• YES - Enable front axle suspension
• NO - Disable front axle suspension
BAIL09HHP025AVA 18
FRONT HITCH OPTIONS

Select the front hitch sub-system by depressing the "menu" key.
BAIL09HHP027AVA 19
BAIL09HHP028AVB 20
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After a delay the current setting will be displayed (refer to the table below for the description of the channel).
Channel Description
Ch 1 Enable / Disable front hitch
Channel 1 - Enable / Disable Front Hitch


• YES - Enable front hitch
• NO - Disable front hitch
BAIL09HHP025AVA 21
FRONT PTO OPTIONS

Select the front PTO sub-system by depressing the "menu" key.
BAIL09HHP031AVA 22
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BAIL09HHP032AVB 23
After a delay the current setting will be displayed (refer to the table below for the description of each channel).
Channel Description
Ch 1 Enable / Disable front PTO
Channel 1- Enable / Disable Front PTO


• YES - Enable front PTO
• NO - Disable front PTO
BAIL09HHP025AVA 24
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BAIL09HHP033FVA 25
BAIL09HHP036AVA 26
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BAIL09HHP037AVA 27
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BAIL09HHP039FVA 28
Select the H menu by depressing the "menu" key.
BAIL09HHP041AVA 29
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The upper section of the display will display "d_ _".
BAIL09HHP042AVB 30
function.
NOTE: If the keystart switch is turned to the "crank" position, with the shuttle lever in neutral and the clutch pedal
Identifier Con- Pin Switch / Input Special Requirements

troller Number
Connec-
tor
d8 CN1B 21 Crank detect switch -
d69 CN1B 23 Front suspension pressure switch -
d75 via CAN Right hand link extend switch -
d76 via CAN Right hand link retract switch -
d77 CN1B 22 Front hitch external common switch -
d78 CN1B 26 Front hitch external raise switch -
d79 CN1B 19 Front hitch external lower switch -
d89 via CAN Front suspension lock switch -
d90 CN1B 11 Front PTO switch (normally open) -
d91 CN1B 12 Front PTO switch (normally closed) -
d92 via CAN Front hitch height limit switch -
d95 via CAN EHR No. 1 program/motor mode switch -
d108 via CAN Top link extend switch -
d109 via CAN Top link retract switch -
d159 via CAN EHR flow encoder switch -
d165 via CAN EHR float switch -
d178 via CAN EHR 1 extend switch (on hand controller) -
d179 via CAN EHR 1 retract switch (on hand controller) -
d180 via CAN EHR 2 extend switch on hand controller) -
d181 via CAN EHR 2 retract switch (on hand controller) -
d183 CN3A 16 EHR 3 extend switch (on rear fender) -
d184 CN3A 17 EHR 3 retract switch (on rear fender) -
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ROM)
NOTE: H8 will not change the configuration settings. The H3 menu mode must be used for this.
NOTE: To erase only the stored error codes and not affect the calibration data use the HC menu mode.
BAIL09HHP044FVA 31
NOTICE: By selecting the screen display with the controller identifier "RP" displayed this will reset the EEPROM in
all the sub-systems.
reset by depressing the "menu" key, as the example shown.
BAIL09HHP046AVA 32
The upper section of the display will display "EECL".
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BAIL09HHP047AVB 33
CAUTION
B006
Depress and hold the navigation "down" key to confirm the resetting of the EEPROM.
The upper section of the display will countdown from 5 to 1, then "EE" will be displayed to indicate the EEPROM has
been cleared.
BAIL09HHP048AVA 34
NOTE: If the "down" key is released before the countdown finishes, the procedure will be aborted.
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H9 - VOLTMETER
BAIL09HHP050FVA 35
BAIL09HHP052AVA 36
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BAIL09HHP053AVB 37
below.
ponents.
BAIL09HHP235AVA 38
Chan- Description Connector Pin Typical Reading

nel
5 +5 Volts voltage supply to the CN1B 16 49
sensors
7 +12 Volt VF input signal (see CN1A 1, 2 &3 45
explanation)
8 +12 Volt VD input signal (see CN1A 8 45
explanation)
9 +12 Volt VH input signal (see CN1A 20 45
explanation)
10 +12 Volt VT input signal (see CN3B 25 & 34 45
explanation)
14 Amperage of the front PTO solenoid CN2 7 0 when FPTO is Off
valve 99 when FPTO is On
15 Amperage of the upper lock CN2 6 0 when locked out
solenoid suspended front axle 30 to 55 when active
16 Amperage of the lower lock solenoid CN2 13 0 when locked out
suspended front axle 30 to 46 when active
26 Front axle position CN1B 6 120 lower limit
950 upper limit
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Chan- Description Connector Pin Typical Reading

nel
28 Front hitch position CN1B 2 10 lower limit
90 upper limit
97 EHR 1 Joystick (X) green via CAN 100 < 0 > 100
98 EHR 2 Joystick (Y) blue via CAN 100 < 0 > 100
Explanations:
VF Input: This is the input voltage into the controller to suspended front axle components, i.e. Front axle lower and
lockout solenoids.
VD Input: This is the input voltage into the controller to suspended front axle raise solenoid.
VH Input: This is the input voltage into the controller to front PTO and front hitch components, i.e. Front PTO solenoid
and front hitch height solenoid.
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Used to demonstrate front axle suspension.
BAIL09HHP056FVB 39
Select the HA menu by depressing the "menu" key.
BAIL09HHP058AVA 40
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BAIL09HHP059AVB 41
After a delay the current setting will be displayed, (refer to the table below for the description of the channel).
Channel Description
Ch 1 Front Axle Suspension demonstration
Channel 1 - Front Axle Suspension Demonstration

This demonstration mode allows the suspension to be locked at speeds above the normal 12 Km/h automatic en-
gagement parameter.
The lower central display will display "FSd" (Front Axle Suspension demonstration).
Start the engine and operate the vehicle to demonstrate front axle suspension.
Use the lockout switch to lock the suspension as normal. The light in the switch will be illuminated to indicate the front
axle suspension had been locked.
NOTE: Front axle suspension demonstration will be disabled after turning the keystart OFF.
BAIL09HHP099AVA 42
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This menu is used to display fault codes which are stored in the EEPROM of the controller. Common to all sub-
systems.
BAIL09HHP060AVC 43
Select the HB menu by depressing the "menu" key.
BAIL09HHP063AVA 44
The upper section of the display will display "- - - -", if no fault is stored in the selected sub-system.
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BAIL09HHP064AVB 45
The upper section of the display will display "F", if a fault code is stored in the selected sub-system.
The upper section of the display will then automatically cycle through as the example:
4124 Fault code

BAIL09HHP065AVA 46
Depress the navigation "up" or "down" key to change to the next fault code in the list.
The upper section of the display will display "_ _ _" at the end of the list.
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BAIL09HHP067FVA 47
Select the HC menu by depressing the "menu" key.
BAIL09HHP069AVA 48
The upper section of the display will display "FCL"
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BAIL09HHP070AVA 49
NOTE: If the navigation "down" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the navigation "down" key to confirm the clearing of the memory.
NOTE: The upper section of the display will countdown from 05 to 01, then "EE" will be displayed to indicate the fault
codes have been cleared.
BAIL09HHP071AVA 50
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BAIL09HHP073FVA 51
Select the HE menu by depressing the "menu" key.
BAIL09HHP075AVA 52
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BAIL09HHP076AVB 53

0 Not used
1 Not used
2 Not used
3 Not used
4 Not used
5 Not used
6 Not used
7 Not used
8 Not used
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sub-systems.
BAIL09HHP078FVA 54
BAIL09HHP080AVA 55
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0000 Serial number
2000 Serial number
4752 Serial number
and return to allow navigation of the "HH" menus.
BAIL09HHP081AVA 56
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The EHR valve stores a number to indicate its position in the remote control valve stack, i.e. valve number 1,2, 3, 4
or 5. If a valve assembly has been replaced it will be necessary to reprogram the number of each valve within the
complete assembly. New valves are supplied without an assigned number.
NOTE: The renumbering procedure for all of the valves, either rear or mid mount valves, must be completed before
commencing the procedure for the other set of valves.
HJ Menu Screen Select Diagram
BAIL09HHP083FVB 57
With all of the rear remotes connected, navigate the H-menus and select the HJ menu by depressing the "menu" key.
BAIL09HHP085AVA 58
The upper section of the display will display "EEhr".
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BAIL09HHP086AVB 59

NOTE: If the navigation "down" key is released before the countdown finishes, the procedure will be aborted.
Depress and hold the navigation "down" key to confirm the resetting of the valve numbers.
The upper section of the display will countdown from 05 to 01, then "CEhr" will be displayed to indicate the valve
numbers have been reset.
BAIL09HHP087AVA 60
Disconnect the connectors from each of the remote valves, except for valve number 1.
Turn the keystart ON and enter HJ menu again. The cluster display will momentarily flash ’Ehr_’ followed by ’Ehr1’,
an audible beep will be heard, indicating that number 1 valve has been recognised and renumbered. The display will
then change to flash ’Ehr2’ to signify that the controller is ready for the next valve to be connected.
Connect each remote valve in the correct order. As each valve is connected an audible beep will signify the valve is
recognised.
As each valve is connected the display will change to show the next valve number to be connected until ’Ehr_5’ is
displayed.
If there are less than 5 rear remotes then the procedure can be exited by depressing and holding the navigation ’down’
key , the display will change to ’End’ to indicate programming is complete. If the maximum number of valves are fitted
then the procedure will end automatically and display ’End’.
Turn the keystart OFF to store the new valve numbers.
Calibrate the remote valves. For further information, refer to PRIMARY HYDRAULIC POWER SYSTEM Electro-
hydraulic remote valve - Calibrate (A.10.C).
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Control module - Fault code index

MAXXUM 140
16x16 Transmission Calibration ’U’ Error Codes

Code Description Possible Failure
Err An error has occurred during 1) Short or open circuit solenoid for clutch 1 is detected.
calibration – the calibration 2) Short or open circuit solenoid for clutch 2 is detected
procedure cannot continue – 3) Short or open circuit solenoid for clutch 3 is detected
key off 4) Short or open circuit solenoid for clutch 4 is detected.
U20 Parking brake is not set 1) Open circuit for the parking brake feed into the transmission module.
2) Faulty parking brake switch
3) Switched 12v supply fuse blown
Note: Use the H5 switch diagnostics to detect if the parking brake is
connected
U21 ERPM is below 1150, increase 1) Operator has not set the correct engine speed
throttle 2) Open circuit for the engine speed sensor going to the cluster –
Mechanical. Engines only.
3) Instrument cluster is not powered
4) Broken CAN
Note: Use the H9 in the transmission module to see if the engine speed
is being detected
U22 ERPM is above 1350, reduce 1) Operator has not set the correct engine speed
throttle
U23 Shuttle lever is in neutral, shift 1) Operator has not selected forward on the shuttle lever
it to forward 2) Open circuit between the shuttle lever and the transmission module
Note: Use the H5 switch diagnostics to detect if the switch is connected
U25 Range lever is in low, shift out 1) Operator has not moved the range lever out of neutral
of low 2) The low range switch is faulty.
3) The gear linkage is out of adjustment
Note: Use the H5 switch diagnostics to detect if the switch is connected.
U26 Clutch pedal is not up, release 1) Operator has not released the clutch pedal
clutch pedal 2) The clutch potentiometer / linkage is sticking or broken
Note: Use the H9 in the transmission module to see if the clutch input
is OK
U27 C3 calibration value too low 1) RPM dropped too soon
2) Clutch pressure is not being controlled properly
3) Engine speed adjusted whilst completing calibration.
U28 C3 calibration value too high 1) RPM did not drop.
2) No pressure to clutch.
3) Mechanical failure breaking the torque path.
3) Engine speed adjusted whilst completing calibration
U30 C4 calibration value too high 1) RPM did not drop
3) Mechanical failure breaking the torque path
U31 Wheel speed sensed 1) Parking brake not applied
2) Brakes not working
Note: If the brakes are OK move the vehicle forward slightly and repeat
calibration
3) Engine speed adjusted whilst completing calibration.
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2) Clutch pressure is not being controlled properly.
U37 Synchroniser potentiometer 1) Synchroniser potentiometer has been painted through production
signal is out of range for 2) Synchroniser potentiometer / connector has been damaged.
reverse 3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the synchroniser potentiometer signal.
If OK then repeat calibration to free up synchroniser.
signal is out of range for 2) Synchroniser potentiometer / connector has been damaged.
forward 3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the synchroniser potentiometer signal.
U39 Synchroniser did not move 1) The forward & reverse solenoid connectors need to be swapped.
toward reverse, even at 2) The reverse solenoid is faulty.
maximum pressure 3) No oil Pressure to shift the synchroniser.
4) Synchroniser potentiometer has been painted through production
5) Synchroniser potentiometer / connector has been damaged.
Note: Remove the Transmission top cover and watch the synchroniser
movement to help detect failure or use H9 and look at the potentiometer
signal in voltmeter.
U40 Synchroniser did not move 1) The forward & reverse solenoid connectors need to be swapped.
toward forward, even at 2) The forward solenoid is faulty.
maximum pressure 3) No oil Pressure to shift the synchroniser.
signal is out of range for 4 2) Synchroniser potentiometer / connector has been damaged
position 3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the Synchroniser potentiometer signal.
signal is out of range for 5 2) Synchroniser potentiometer / connector has been damaged
position 3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the Synchroniser potentiometer signal.
U43 Synchroniser did not move 1) The Four & Five solenoid connectors need to be swapped.
toward 4 2) The four solenoid is faulty.
3) No oil Pressure to shift the synchroniser.
U44 Synchroniser did not move 1) The Four & Five solenoid connectors need to be swapped.
toward 5, even at max pressure 2) The five solenoid is faulty.
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U45 50kph clutch 5 calibration 1) RPM did not drop
values too low 2) Clutch pressure is not being controlled properly.
U46 50kph clutch 5 calibration 1) RPM did not drop
values too high 2) No pressure to clutch.
U47 50kph clutch 5 solenoid not 1) Open circuit to clutch 5 solenoid
present 2) Solenoid Failure
U80 Flywheel torque sensor 1) Faulty flywheel torque sensor
calibration unsuccessful, try 2) Did not complete the calibration procedure correctly, refer to
again transmission calibration section
U81 No signal from flywheel torque 1) Flywheel speed sensor not fitted.
sensor 2) Check speed sensor connection
U82 No 12VD – No power for C3 1)Check module fuses
and C4 solenoids 2) Check battery voltage
3) Check Module connection.
U83 4-5 synchroniser did not shift 1) Sticky synchroniser, repeat calibration procedure
to 4 for calibration of flywheel 2) Check solenoid connection
torque sensor 3) Check vehicle hydraulic pressure
U84 Insufficient current sensed on 1) Harness connection to synchroniser
synchroniser test 2) Faulty Synchroniser
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U37 Synchroniser potentiometer signal is 1) Synchroniser potentiometer has been painted through
out of range for reverse production
2) Synchroniser potentiometer / connector has been damaged
3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the Synchroniser potentiometer
signal. If OK then repeat calibration to free up synchroniser.
out of range for forward production
3) Synchroniser assembly. is very tight / sticky.
Note: Use the voltmeter to check the Synchroniser potentiometer
signal. If OK then repeat calibration to free up synchroniser.
U39 Synchroniser did not move toward 1) The forward & reverse solenoid connectors need to be
reverse, even at maximum pressure swapped
2) The reverse solenoid is faulty
4) Synchroniser potentiometer has been painted through
production
Note: Remove the Transmission top cover and watch the
synchroniser movement to help detect failure or use H9 and look
at the potentiometer signal in voltmeter.
U40 Synchroniser did not move toward 1) The forward & reverse solenoid connectors need to be
forward, even at maximum pressure swapped
2) The forward solenoid is faulty
production
Note: Remove the Transmission top cover and watch the
synchroniser movement to help detect failure or use H9 and look
at the potentiometer signal in voltmeter.
U82 No 12VD – No power for High and 1) Check module fuses
Low clutch solenoids 2) Check battery voltage
3) Check Module connection
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Electronic Draft Control Calibration ’U’ Error Codes

Note: There are no ’U’ error codes defined for the electronic draft control calibration procedure. However the
following error codes may be displayed during the procedure.
1068 Height limit control not fully clockwise 1) The height limit control is not turned fully clockwise
2) The height limit control is faulty
PTO Torque Calibration ’U’ Error Codes

U51 Engine speed error 1) Check engine speed sensor is fitted
2) Open circuit for the engine speed sensor going to the cluster
– Mechanical Engines only.
4) Broken CAN link
Note: Use the HE menu function in the transmission module to
see if the engine speed is being detected
U52 Constant ERPM switch detected 1) CRPM switch operated greater than 3 times, repeat start
procedure
U55 PTO started 1) PTO turned on while completing the calibration procedure.
Repeat the calibration
U58 PTO twist sensor open circuit -
U59 PTO twist sensor short circuit -
U70 PTO twist sensor not calibrated -
Front Suspension Calibration ’U’ Error Codes

U01 Front axle potentiometer open circuit - 1) Check the wiring harness
ACP will not work 2) Check the displayed potentiometer reading during calibration.
If less than 51 then replace the potentiometer
U02 Front axle potentiometer threshold is 1) Check the potentiometer installation
higher than set limit 2) Check the displayed potentiometer reading during calibration.
If greater than 970 then change the potentiometer
3) Check the wiring harness
U03 Front axle potentiometer short circuit - 1) Check the wiring harness
ACP will not work 2) Check if signal ground on potentiometer is open circuit
3) Change the potentiometer
U04 Front axle potentiometer threshold is 1) Change the potentiometer
lower than set limit
U05 Suspension is not reaching its 1) Check the range of the potentiometer, calibration will not work
minimum / maximum position during if the range of the potentiometer is less than 150
ACP procedure 2) Check the suspension mechanics
3) Check the potentiometer linkage
U07 Suspension is stationary during the 1) Check the raise solenoid harness
raise command in the ACP procedure 2) Check the suspension mechanics
3) Check the pressure of the accumulators
4) Check the hydraulic pressure
5) Disconnect implement
U08 Suspension unable to reach maximum 1) Check the raise valve installation
height within 20 seconds 2) Check the unload solenoid installation
3) Check the suspension mechanics
U09 Suspension is stationary during 1) Check the unload solenoid harness
the lowering command in the ACP 2) Check the suspension mechanics
procedure 3) Check the hydraulic pressure
U10 Suspension unable to reach minimum 1) Check unload solenoid installation
height within 25 seconds 2) Check the hydraulic pressure
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U11 Unable to calibrate suspension 1) The lockout switch was pressed more than 3 times to initiate
calibration
U12 ACP stopped, vehicle not stationary 1) Parking brake not applied
2) Rear axle speed sensor faulty
U13 Front suspension option not activated 1) Use H3 to enable the front suspension option
U14 Insufficient potentiometer range for -
optimal suspension performance
Rear Hydraulic Electronic Remote Valves Calibration ’U’ Error Codes

Note: If a lever is not calibrated then the Program Lamp is switched on regardless of the state of Program
Switch. This does not apply if the Program Switch is switched off during the middle of a calibration
sequence.
U61 Lever No.1 not in neutral -
Ensure that the corresponding lever is set to the neutral position before starting the calibration procedure for
that lever
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Front Hitch Calibration ’U’ Error Codes

U110 Position potentiometer value too high TBD
or the hitch is not lowered
U111 Position potentiometer value too low TBD
or the hitch is not raised
Steering Calibration ’U’ Error Codes

U21 ERPM is below 1300, increase throttle 1) Operator has not set the correct engine speed
2).Open circuit for the engine speed sensor going to the cluster
– mechanical engines only.
4) Broken CAN bus
Note: Use the HE menu to see if the engine speed is being
detected
U71 Calibration attempted while enable 1) The enable switch is in the off position
switch is off 2) The enable switch is in the on position at start up but needs
to be cycled through off then on to enable the system
U72 Proximity sensor input is out of range 1) Incorrect position of steering wheel
- open 2) Faulty proximity sensor
3) Check the proximity sensor connection
- closed 2) Faulty proximity sensor
U74 LVDT calibration has been 1) Faulty LVDT sensor
unsuccessful (out of range after 2) Faulty fast steer hydraulic valve
4th attempt) 3) Incorrect assembly of hydraulic valve
4) Check the LVDT sensor connection
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EDC - Error Codes

Code Description
1002 Radar Disconnected (POOR OR NO SIGNAL FROM TRACTOR PERFORMANCE MONITOR
RADAR)
1003 Speed Sensor Error
1004 Wheel Speed Sensor Signal Too High
1006 Slip Control Potentiometer Voltage Too Low
1007 Slip Control Potentiometer Voltage Too High
1008 Raise / Work Switch Failure (Command Arm)
1009 Both External Switches Operated At The Same Time
1010 Height Limit Control Potentiometer Voltage Too Low
1011 Height Limit Control Potentiometer Voltage Too High
1012 Drop Rate Control Potentiometer Voltage Too Low
1013 Drop Rate Control Potentiometer Voltage Too High
1014 Right Hand Load Sensing Pin Signal Too Low
1015 Right Hand Load Sensing Pin Signal Too High
1016 Left Hand Load Sensing Pin Signal Too Low
1017 Left Hand Load Sensing Pin Signal Too High
1018 Both Load Sensing Pins Disconnected
1019 Load Sensing Pin 8V Voltage Too Low
1020 Load Sensing Pin 8V Voltage Too High
1021 Draft Sensitivity Control Potentiometer Voltage Too Low
1022 Draft Sensitivity Control Potentiometer Voltage Too High
1023 Command Arm/Control Panel Disconnected
1024 Perform The Hydraulic Lift Calibration
1025 Position Control Potentiometer Voltage Too Low
1026 Position Control Potentiometer Voltage Too High
1027 Lift Arm Position Sensing Control Voltage Too Low
1028 Lift Arm Position Sensing Control Voltage Too High
1029 Hydraulic Control Valve Disconnected
1030 Signal Ground Open Circuit
1031 Chassis Harness Disconnected
1032 Draft Control Potentiometer Voltage Too High
1033 Draft Control Potentiometer Voltage Too Low
1049 Wheel Speed Sensor Open Circuit
1053 5 Volt Reference Short To +12V
1054 5 Volt Reference Short To Ground
1059 8V Reference Error (Draft Load Pins)
1063 EDC Hydraulic Valve Lower Solenoid Open Circuit
1064 EDC Hydraulic Valve Raise Solenoid Open Circuit
1065 EDC Hydraulic Valve Lower Solenoid Short Circuit
1066 EDC Hydraulic Valve Raise Solenoid Short Circuit
1067 Hydraulic Valve Supply Voltage Too Low
1068 Height Limit Control Not Set To Maximum During Calibration
1070 Hydraulic Ram Configuration Not Set
Transmission - Error Codes

Code Description
2001 “N” – shuttle too fast error
2002 Flash “N” error
2003 “CP” – clutch pedal required
2004 “P” – parking brake error
2005 Creeper selection error
2011 Clutch pedal potentiometer – signal too low
2012 Clutch pedal potentiometer – signal too high
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Code Description
2013 Upshift and downshift buttons pressed at same time
2015 High and low range switches both closed
2016 Creeper solenoid short to ground or high voltage
2021 Chassis harness disconnected
2024 All clutches and synchronisers require calibration
2026 Engine speed too high
2027 Engine speed too low
2035 Dump solenoid - short to ground or high voltage
2036 Dump solenoid - open circuit
2037 Clutch pedal switch – open circuit
2038 Clutch 4 solenoid - short to ground or high voltage (16x16)
2038 High range PWM valve - short to ground or high voltage (24x24)
2039 Clutch 4 solenoid - open circuit (16x16)
2039 High range PWM valve - open circuit (24x24)
2040 Low range PWM valve - short to ground or high voltage (24x24)
2041 Low range PWM valve - open circuit (24x24)
2047 Clutch pedal switch set too high
2048 Clutch pedal switch set too low
2049 Wheel speed sensor open circuit, short to ground or high voltage
2051 Oil temperature sensor – open circuit
2052 Oil temperature sensor - short to ground or high voltage
2053 5V reference voltage – too high
2054 5V reference voltage – too low
2055 No signal from wheel speed sensor
2056 Low range switch open
2057 High range switch open
2058 Seat switch closed
2059 Shuttle lever switch disagreement
2061 Forward / reverse synchroniser potentiometer - signal too high
2062 Forward / reverse synchroniser potentiometer - signal too low
2063 Forward synchroniser did not engage
2064 Reverse synchroniser did not engage
2065 Forward synchroniser solenoid - open circuit
2066 Reverse synchroniser solenoid - open circuit
2067 Forward synchroniser solenoid - short to ground or high voltage
2068 Reverse synchroniser solenoid - short to ground or high voltage
2070 Shuttle lever forward switch – voltage too high
2071 Shuttle lever forward switch – voltage too low
2072 Shuttle lever reverse switch – voltage too high
2073 Shuttle lever reverse switch – voltage too low
2075 No signal from flywheel speed sensor
2076 Flywheel speed sensor – open circuit
2077 Flywheel speed sensor - short circuit or high voltage
2081 4 / 5 range synchroniser potentiometer - signal high
2082 4 / 5 range synchroniser potentiometer - signal low
2083 1-4 range synchroniser engaged error
2084 5-8 range synchroniser engaged error
2085 1-4 range synchroniser solenoid - open circuit
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Code Description
2086 5-8 range synchroniser solenoid - open circuit
2087 1-4 range synchroniser solenoid - short to ground or high voltage
2088 5-8 range synchroniser solenoid - short to ground or high voltage
2091 Clutch 3 not calibrated
2093 High clutch not calibrated
2094 Low clutch not calibrated
2098 Clutch 5 solenoid - short circuit
2099 Clutch 5 solenoid - open circuit
2100 Clutch 5 dump solenoid - short circuit
2101 Clutch 5 dump solenoid - open circuit
2124 Flywheel torque sensor not calibrated (16x16)
2124 Flywheel torque sensor fitted in error (24x24)
Engine - Error Codes

Code Description
3001 Foot Throttle Sensor - Signal Not Plausible
3002 Foot Throttle Sensor - Signal Above Range Maximum
3003 Foot Throttle Sensor - Signal Below Range Minimum
3004 Foot Throttle sensor - No Signal
3006 Coolant Temperature Signal - Signal Not Plausible
3007 Coolant Temperature Signal - Signal Above Range Maximum
3008 Coolant Temperature Signal - Signal Below Range Minimum
3010 Air Intake Temperature Sensor- Signal Above Range Maximum
3011 Air Intake Temperature Sensor - Signal Below Range Minimum
3015 Fuel Temperature Sensor - Signal Above Range Maximum
3016 Fuel Temperature Sensor - Signal Below Range Minimum
3019 Boost Pressure Sensor - Signal Above Range Maximum
3022 Boost Pressure Sensor - Signal not Plausible
3023 Atmospheric Pressure Sensor - Signal Not Plausible
3024 Atmospheric Pressure Sensor - Signal Above Range Maximum
3025 Atmospheric Pressure Sensor Signal Below Range Minimum
3028 Oil Pressure Too Low
3029 Oil Pressure Sensor - Short Circuit To Battery
3030 Oil Pressure Sensor - Short Circuit to Ground
3032 Oil Pressure Sensor - Value too High
3033 Oil Temperature Sensor - Signal Not Plausible
3034 Oil Temperature Sensor - Signal Above Range Maximum
3035 Oil Temperature Sensor - Signal Below Range Minimum
3037 Boost pressure sensor - signal low
3038 Constant Engine RPM Activate / Select Switch - Short Circuit to Battery
3047 High Pressure Pump Relay - Short Circuit to Battery
3048 High Pressure Pump Relay - Short Circuit To Ground
3051 Battery Voltage To ECM - Voltage Too High
3052 Battery Voltage To ECM - Voltage Too Low
3060 Cylinder 1 - Unclassifiable Error In Injector
3061 Cylinder 1 - Injector Cable Short Circuit (Low side to Battery)
3063 Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)
3065 Cylinder 5 - Injector Cable Short Circuit (Low Side To Battery)
3067 Cylinder 5 - Injector Cable Short Circuit (High Side Ground)
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Code Description
3079 Cylinder 2 - Injector Cable Short Circuit (High side to Ground)
3088 Crankshaft Sensor - No Signal
3089 Crankshaft Sensor - Invalid Signal
3090 Camshaft Sensor - No Signal
3091 Camshaft Sensor - Invalid Signal
3093 Offset Between Camshaft And Crankshaft - Outside Boundaries
3095 Operating With Camshaft Sensor Only - Backup Mode
3096 ECM Busoff On CAN A
3102 Rail Pressure Sensor CP3 - Signal Below Range Minimum
3104 Rail Pressure Relief Valve - Open
3105 Rail Pressure Relief Valve - Pressure Shock Requested
3106 Rail Pressure Relief Valve - Did Not Open After Pressure Shock
3107 Metering Unit - Short Circuit To Ground
3108 Metering Unit - Short Circuit To Battery
3110 Rail Pressure Sensor Monitoring - Signal Above Range Maximum
3111 Rail Pressure Sensor Monitoring - Signal Below Range Minimum
3112 Rail Pressure Sensor CP3 - Signal Above Maximum Range
3121 PTO Twist Sensor - Open Circuit
3122 PTO Twist Sensor - Short Circuit To Ground
3123 PTO Twist Sensor - Not Calibrated
3124 Hand Throttle - Channel 2 Signal Above Range Maximum
3125 Hand Throttle - Channel 2 Signal Below Range Minimum
3126 Hand Throttle - Channel 1 Signal Above Range Maximum
3127 Hand Throttle - Channel 1 Signal Below Range Minimum
3128 Hand Throttle - Channel Difference Error
3129 Hand Throttle - Idle Switch Closed Circuit
3130 Hand Throttle - Idle Switch Open Circuit
3131 Grid Heater Always Switched On
3137 Metering Unit - Open Load
3138 Metering Unit - Temperature Too High
3141 Fuel Flow Setpoint Too Low
3142 High Pressure Test - Test Active
3145 Terminal 15 - No Signal
3147 Oil temperature Too High
3148 Coolant Temperature Sensor Dynamic Test - Failure
3154 Grid Heater Relay - Short Circuit To Battery
3155 Grid Heater Relay - Short Circuit To Ground
3156 Grid Heater Relay - No Load
3157 ECM Not Detected On CAN Bus
3158 Invalid ECM Checksum
3159 Invalid Engine Reference Torque
3176 Setpoint Of Metering Unit Not Plausible In Overrun
3177 Engine Overspeed Detected
3179 Timeout Of CAN Message BC2EDC2
3180 Timeout Of CAN Message VM2EDC
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Code Description
3182 Timeout Of CAN Message RxCCVS
3185 Timeout Of CAN Message TF
3188 Cylinder 1 Warning - Open Load
3210 Bank 1 - General Short Circuit To Injection Cable
3211 Bank 1 - Injection Cable Short Circuit Low Side To Ground
3213 Bank 1 - Unclassifiable Error
3218 Bank 2 - General Short Circuit To Injection Cable
3219 Bank 2 - Injection Cable Short Circuit Low Side To Ground
3227 Injection Processor (CY33X) Error - Internal Reset / Clock Loss / Voltage Too Low
3228 Injection Processor (CY33X) Error - Unlocked / Initialisation Failure
3229 Injection Processor (CY33X) Error - Injections Limited By Software
3230 Injection Processor (CY33X) Error - SPI Communication Failure
3231 Injection Processor Error - Internal Reset / Clock Loss / Voltage Too Low
3232 Injection Processor Error - Unlocked / Initialisation Failure
3233 Injection Processor Error - Test Mode
3234 Injection Processor Error - SPI Communication Failure
3238 ECM Internal SPI Communications Error - CJ940
3239 ECM EEPROM - Read Operation Failure
3240 ECM EEPROM - Write Operation Failure
3241 ECM EEPROM - Default Value Used
3242 ECM (Locked) Recovery Occurred
3243 ECM Recovery (Suppressed) - Recovery Occurred
3244 ECM Recovery (Visible) - Recovery Occurred
3245 ECM Processor - Watchdog Not Plausible
3246 Shutoff Paths During Initialisation - Watchdog
3247 Shutoff Paths During Initialisation - Supply Voltage Too High
3248 Shutoff Paths During Initialisation - Supply Voltage Too Low
3249 TPU Monitoring - Time Deviation Between TPU And System Not Plausible
3250 Dataset - Variant Defect
3251 Dataset - Requested Variant Could Not Be Set
3252 Controller Watchdog - SPI Communication Failure
3253 ADC Monitoring - Reference Voltage Too Low
3254 ADC Monitoring - Reference Voltage Too High
3255 ADC Monitoring - Test Impulse Error
3256 ADC Monitoring - Queue Error
3263 ECM BusOff On CAN C
3265 Overrun Monitoring
3266 Redundant Engine Speed In Overrun Monitoring
3278 ECM Internal Supply Voltage Too High
3279 ECM Internal Supply Voltage Too Low
3280 Sensor Supply Voltage 1 Too High
3281 Sensor Supply Voltage 1 Too Low
3297 Rail Pressure Positive Deviation High And High Fuel Flow Setpoint Value
3301 Rail Pressure Negative Deviation Too High On Minimum Metering
3305 Rail Pressure Below Minimum Limit In Controller Mode
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Code Description
3309 Rail Pressure Above Maximum Limit In Controlled Mode
3313 Rail Pressure Drop Rate Too High
3316 Minimum Number Of Injections Not Reached - Stop Engine
3334 Timeout Of CAN Message TSC1 PE Torque (When Active)
3335 Timeout Of CAN Message TSC1 PE Torque (When Inactive)
3338 Timeout Of CAN Message TSC1 VE Speed (When Inactive)
3339 Timeout Of CAN Message TSC1 VE Speed (When Active)
3345 Total Throttle Failure
3367 Coolant Temperature Test Failure
3368 INFO: Torque Limitation Due To OBD Performance Limiter By Legislation
3369 INFO: Torque Reduction Due To Smoke Reduction
3370 INFO: Torque Limitation Due To Engine Protection (Against Excessive Torque, Engine Overspeed
And Overheat
3371 INFO: Torque Limitation Due To Fuel Quantity Limitation Because Of Injector System Errors
3375 Constant Engine RPM Increase / Decrease Switch – Short Circuit To Battery
3376 Engine Controller Software Does Not Support Power Management (Engine Power Management
Option Enabled, But Engine Software Not Compatible)
3377 Constant Engine RPM Switch Detected But Option Is Not Enabled
3999 Unknown ECM SPN Error Code
Rear EHR - Error Codes

Code Description
4001 Signal Of Aux-Stick (Aux 1) - Out Of Range Low (DV Module Only)
4002 Signal Of Aux-Stick (Aux 1) - Out Of Range High (DV Module Only)
4003 Signal From Remote Flow Potentiometer 1 (Aux 1) - Out Of Range (DV Module Only)
4008 Signal From Remote Valve 2 Timer potentiometer 1 - Out Of Range (DV Module Only)
4016 Signal From Remote Valve Timer potentiometer 1 - Out Of Range (DV Module Only)
4040 ARU Supply Voltage – too low (<8V) (DV Module Only)
4041 ARU Supply Voltage – too high (>18V) (DV Module Only)
4042 ARU CAN bus off (DV Module Only)
4043 ARU Controller Fault (register check) (DV Module Only)
4044 ARU Controller Fault (flash memory) (DV Module Only)
4045 ARU Controller Fault (data memory) (DV Module Only)
4100 Rear Remote No.1 No Control Message Received
4101 Rear Remote No.1 Control Message Not Plausible
4102 Rear Remote No.1 EEPROM Error
4103 Rear Remote No.1 Switched To Failsafe
4104 Rear Remote No.1 Under Voltage
4105 Rear Remote No.1 Over Voltage
4106 Rear Remote No.1 Spool Movement Too Low
4107 Rear Remote No.1 Spool Movement Too High
4108 Rear Remote No.1 Float Position Not Reached
4109 Rear Remote No.1 Manually Operated
4110 Rear Remote No.1 Driver Faulty
4111 Rear Remote No.1 Potentiometer Faulty
4112 Rear Remote No.1 Unable To Reach Neutral
4113 Rear Remote No.1 Spool Not In Neutral At Key On
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Code Description
4170 Rear EHR Control No.1 Not Calibrated (DU Module Only)
4171 Rear EHR Control No.1 Open Circuit (DU Module Only)
4172 Rear EHR Control No.1 Short Circuit (DU Module Only)
4176 Rear EHR Timer Switch No.1/No.2 - Not Connected (DU Module Only)
4183 Rear EHR Timer Switch No.3 / No.4 Not Connected (DU Module Only)
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Code Description
4190 Rear Remote No.1 No Communications
4194 Rear EHR No.1 Motor Mode Switch Faulty (DU Module Only)
Rear PTO - Error Codes

Code Description
5003 Rear PTO Brake Output Open Circuit
5005 Rear PTO Brake Switch Open Circuit
5007 Rear PTO Solenoid Stuck Off
5008 Rear PTO Solenoid Circuit Over Current
5033 Rear PTO Cab Normally Closed Switch - Open Circuit
5034 Rear PTO Fender Switch Open Circuit / Short To Ground
5035 Rear PTO Fender Switch - Input Short To +12 Volts
5036 Rear PTO Failure To Start
5037 Rear PTO Cab Normally Open Switch Stuck Closed
5042 Rear PTO Management Switch Stuck Closed
5043 Rear PTO Fender Switch Stuck On
5098 Rear PTO Fender Switch Option Not Enabled
5099 Auto PTO Mode Not Enabled
Four Wheel Drive - Error Codes

Code Description
6020 FWD Switch Error
6021 FWD Solenoid - Stuck On
6022 FWD Solenoid - Stuck Off
6023 FWD Solenoid - Open Circuit
Difflock - Error Codes

Code Description
7014 Difflock Switch Error
7017 Difflock Solenoid - Open Circuit
7024 Steering Angle Sensor Not Calibrated
7032 Steering Angle Sensor - Signal Too Low
Front PTO - Error Codes

Code Description
8007 Front PTO Solenoid Stuck On
8008 Front PTO Solenoid Open Circuit
8033 Front PTO Cab Normally Closed Switch Open Circuit
8037 Front PTO Cab Normally Open Switch Stuck Closed
8099 Front PTO Option Not Enabled
Front Hitch - Error Codes

Code Description
9001 Front Hitch Position Sensor - Short Circuit To 12V
9002 Front Hitch Position Sensor - Open Circuit / Short Circuit To 0V
9006 Front Hitch Position Potentiometer - Not Calibrated
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Suspended Front Axle - Error Codes

Code Description
10001 Upper Lockout Solenoid Error
10002 Raise Solenoid Error
10003 Lower Solenoid Error
10004 Front Axle Position Sensor- Threshold Higher Than Set Limit
10005 Front Axle Position Sensor- Threshold Lower Than Set Limit
10008 Go Down Error - Suspension Unable To Return To Set Point
10009 Lower Lockout Solenoid Error
10024 Front Suspension Not Calibrated
Steering Controller - Error Codes

Code Description
15001 Exceeding Safe Operating Wheel Speed With System Still Enabled Or Active
15002 Steering Wheel Control Proximity Sensor Open Circuit
15003 Steering Wheel Control Proximity Sensor - Short Circuit
15006 Split Valve LVDT Open Circuit
15007 Split Valve LVDT Short Circuit
15008 Change Valve Solenoid Open Circuit
15009 Change Valve Solenoid Short Circuit Across
15010 Safety Switch Fail
15012 Split Valve Spool Stuck Open
15013 Change Valve Or Split Valve Spools Stuck Closed
15014 Split Valve Spool Stuck In Transition Zone - Can’t Identify Which Steering Mode The Tractor
Is Definitely In
15015 Oil Too Cold (Less Than - 5 °C)
15024 System Not Calibrated
Air Conditioning Controller - Error Codes

Code Description
16111 Cab Sensor Open Or Shorted To Power
16112 Cab Sensor Shorted To Ground
16113 Outlet Sensor Open Or Shorted To Power
16114 Outlet Sensor Open Or Shorted To Ground
16115 Evaporator Sensor Open Or Shorted To Power
16116 Evaporator Sensor Shorted To Ground
16117 Outside Air Sensor Open Or Shorted To Power
16118 Outside Air Sensor Shorted To Ground
16120 Blower Speed Select Potentiometer Open Or Shorted To Power
16121 Temperature Select Potentiometer Open Or Shorted To Power
16122 Mode Select Potentiometer Open Or Shorted To Power
16125 High Pressure Switch (+) Input Shorted To Power
16126 High Pressure Switch (+) Input Shorted To Ground
16127 High Pressure Switch (-) Input Shorted To Power
16128 High Pressure Switch (-) Input Shorted To Ground
16129 High Pressure Cycling Error (2 in 1 minute)
16130 Low Pressure Switch (+) Input Shorted To Power
16131 Low Pressure Switch (+) Input Shorted to Ground
16132 Low Pressure Switch (-) Input Shorted to Power
16133 Low Pressure Switch (-) Input Shorted to Ground
16134 Low Pressure Switch Open For Greater Than 1 Minute
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Control module - Fault code index


Err An error has occurred during 1) Short or open circuit solenoid for clutch 1 is detected.
calibration - the calibration procedure 2) Short or open circuit solenoid for clutch 2 is detected.
cannot continue - key off 3) Short or open circuit solenoid for clutch 3 is detected.
4) Short or open circuit solenoid for clutch 4 is detected.
U20 Handbrake is not set 1) Open circuit for the handbrake feed into the transmission
module
2) Faulty handbrake switch
Note: Use the H5 switch diagnostics to detect if the handbrake
is connected
2) Open circuit for the engine speed sensor going to the cluster -
Mech. Engines only
4) Broken CAN
Note: Use the H9 in the transmission module to see if the engine
speed is being detected
U22 ERPM is above 1350, reduce throttle 1) Operator has not set the correct engine speed
U23 Shuttle lever is in neutral, shift it to 1) Operator has not selected forward on the shuttle lever
forward 2) Open circuit between the shuttle lever and the transmission
module
Note: Use the H5 switch diagnostics to detect if the switch is
connected
U25 Range lever is in low, shift out of low 1) Operator has not moved the range lever out of neutral
2) The low range switch is faulty
3) The gear linkage is out of adjustment
Note: Use the H5 switch diagnostics to detect if the switch is
connected
U26 Clutch pedal is not up, release clutch 1) Operator has not released the clutch pedal
pedal 2) The clutch potentiometer / linkage is sticking or broken
Note: Use the H9 in the transmission module to see if the clutch
input is OK
U27 C3 calibration value is too low 1) RPM dropped too soon
U28 C3 calibration value is too high 1) RPM did not drop
2) No pressure to clutch
U31 Wheel speed sensed - tractor moving 1) Handbrake not applied
2) Brakes not working
Note: If the brakes are OK move the vehicle forward slightly
and repeat the calibration
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out of range for the reverse position production
3) Synchroniser assembly is very tight / sticky
Note: Use the voltmeter to check the synchroniser potentiometer
signal. If OK then repeat calibration to free up synchroniser
out of range for the forward position production
signal. If OK then repeat calibration to free up synchroniser
U39 Synchroniser did not move towards 1) The forward & reverse solenoid connectors need to be
reverse, even at maximum pressure swapped
2) The reverse solenoid is faulty
3) No oil pressure to the shift synchroniser
production
Note: Remove the transmission top cover and watch the
synchroniser movement to help detect failure or use H9 and
look at the potentiometer signal in voltmeter
U40 Synchroniser did not move towards 1) The forward & reverse solenoid connectors need to be
forward, even at maximum pressure swapped
2) The forward solenoid is faulty
production
out of range for the 4 position production
signal. If OK then repeat the calibration to free up the
synchroniser
out of range for the 5 position production
signal. If OK then repeat the calibration to free up the
synchroniser
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U43 Synchroniser did not move towards 4, 1) The Four & Five solenoid connectors need to be swapped
even at maximum pressure 2) The four solenoid is faulty
production
U44 Synchroniser did not move towards 5, 1) The Four & Five solenoid connectors need to be swapped
even at maximum pressure 2) The five solenoid is faulty
production
U45 50kph clutch 5 calibration value is too 1) RPM dropped too soon
low 2) Clutch pressure is not being controlled properly
U46 50kph clutch 5 calibration value is too 1) RPM did not drop
high 2) No pressure to clutch
U47 50kph clutch 5 solenoid not present 1) Tractor is not a 50kph vehicle
2) Open circuit to clutch 5 solenoid
3) Solenoid failure
U51 Engine speed error 1) Engine speed must be between 1550 and 1650 rpm
2) CAN bus error
U55 PTO started 1) The PTO was started during the PTO twist sensor calibration.
Ensure the PTO is turned off
U58 PTO sensor open circuit 1) Wiring or connectors to PTO twist sensor
U59 PTO sensor short circuit to ground 1) Wiring or connectors to PTO twist sensor
U80 Flywheel torque sensor calibration 1) Faulty flywheel torque sensor
unsuccessful, try again 2) Did not complete the calibration procedure correctly, refer to
transmission calibration section
U81 No signal from flywheel torque sensor 1) Flywheel speed sensor not fitted
2) Check speed sensor connection
U82 No 12VD - No power for C3 and C4 1) Check module fuses
solenoids 2) Check battery voltage
3) Check module connection
U83 4-5 synchroniser did not shift to 4 for 1) Sticky sensor, repeat calibration procedure
calibration of flywheel torque sensor 2) Check solenoid connection
3) check vehicle hydraulic pressure
Electronic Draft Control Calibration ’U’ Error Codes

Note: There are no ’U’ error codes defined for the electronic draft control calibration procedure. However the
following error codes may be displayed during the procedure.
1068 Height limit control not fully clockwise 1) The height limit control is not turned fully clockwise
2) The height limit control is faulty
1070 EDC hydraulic ram size not configured Ram size not configured on a new controller or following H8
procedure
Note: Use EDC H3, channel 1 to configure
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Front Suspension Calibration ’U’ Error Codes

U01 Front axle potentiometer open circuit 1) Check the wiring harness
– ACP will not work 2) Check the displayed potentiometer reading during calibration.
If the value is less than 10 then check the potentiometer
U02 Front axle potentiometer threshold is 1) Check the potentiometer installation
higher than set limit 2) Check the displayed potentiometer reading during calibration.
If the value is greater than 972 then check the potentiometer
3) Check the wiring harness
U03 Front axle potentiometer short circuit 1) Check the wiring harness
– ACP will not work 2) Check if signal ground on potentiometer is open circuit
3) Change the potentiometer
U04 Front axle potentiometer threshold is 1) Change the potentiometer
lower than set limit
U05 Suspension is not reaching its 1) Check the range of the potentiometer, calibration will not work
minimum / maximum position during if the range of the potentiometer is less than 150
ACP procedure 2) Check the suspension mechanics
U07 Suspension is stationary during the 1) Check the raise solenoid harness
raise command in the ACP procedure 2) Check the suspension mechanics
4) Check the pressure of the accumulators
U08 Suspension unable to reach maximum 1) Check the raise valve installation
height within 20 seconds 2) Check the unload solenoid installation
U09 Suspension is stationary during 1) Check the unload solenoid harness
the lowering command in the ACP 2) Check the suspension mechanics
procedure 3) Check the potentiometer linkage
U10 Suspension unable to reach minimum 1) Check unload solenoid installation
height within 25 seconds 2) Check the hydraulic pressure
U11 Unable to calibrate suspension 1) The lockout switch was pressed more than 3 times to initiate
calibration
U12 ACP stopped, vehicle not stationary 1) Handbrake not applied
2) Rear axle speed sensor faulty
U13 Valve 30 (upper lockout) solenoid 1) Check the wiring harness
open circuit. (RM module only)
U14 Valve 31 (lower lockout) solenoid open 1) Check the wiring harness
circuit. (RM module only)
U15 Valve 30 (upper lockout) and Valve 31 1) Check the wiring harness
(lower lockout) solenoid connectors
swapped. (RM module only)
U16 Valve 30 (upper lockout) and Valve 31 1) Check the wiring harness
(lower lockout) current sense inputs
swapped. (RM module only)
U17 Front suspension pressure switch 1) Check the wiring harness
open circuit. (RM module only) 2) Check the pressure switch
U18 Front suspension pressure switch 1) Check the wiring harness
short circuit. (RM module only) 2) Check the pressure switch
U19 Insufficient potentiometer range for 1) Incorrect adjustment of front axle potentiometer linkage
optimal suspension operation
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Rear Electronic Hydraulic Remote Valves Calibration ’U’ Error Codes

U61 Lever No.1 not in neutral Ensure the lever is in neutral before starting the calibration
procedure for this lever
Front Hitch Calibration ’U’ Error Codes

U110 Position potentiometer value too low Hitch was not raised before height limit control was changed
or the hitch is not raised from ON to OFF position
U110 Position potentiometer value too high Hitch was not lowered before height limit control was changed
or the hitch is not lowered from ON to OFF position
Steering Calibration ’U’ Error Codes

U19 Oil temperature below 5 °C 1) Open circuit for the temperature sensor input to the
transmission module
2) Faulty temperature sensor
Note: Use the H9 menu in the transmission module to see if the
temperature sensor input is okay
2) Open circuit for the engine speed sensor going to the cluster
– mechanical engines only
4) Broken CAN bus
Note: Use the HE menu to see if the engine speed is being
detected
U71 Calibration attempted while enable 1) The enable switch is in the off position
switch is off 2) The enable switch is in the on position at start up but needs
to be cycled through off then on to enable the system
– open 2) Faulty proximity sensor
– closed 2) Faulty proximity sensor
U74 LVDT calibration has been 1) Faulty LVDT sensor
unsuccessful (out of range after 2) Faulty steering hydraulic valve
4th attempt) 3) Incorrect assembly of hydraulic valve
4) Check the LVDT sensor connection
EPL Calibration ’U’ Error Codes

U114 Hand brake applied 1) Blue cable (on the handbrake switch connector) cut off
2) Mismatch between the handbrake switch status hardwired to
the EPL and the VCU_HB_SWITCH parameter in the VCU2EPL
CAN message
U115 Shuttle lever not in the park position 1) Pins A4 or C7 of the EPL module short to ground
2) Pins A4 or C7 of the EPL module cut off
3) Pins A4 or C7 of the EPL module short to supply voltage
4) Shuttle lever damaged
U116 APP position too high 1) Wrong mechanical adjustment of the EPL transmission lever
2) Possible wear in the braking pads
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U117 APP position too low 1) Stiffness of the system is too high – possible mechanical
interferences
2) Wrong mechanical installation of the EPL
U118 Error codes active preventing 1) High recovery level error code is being activated
completion of initialization procedure
U119 Bowden cable not connected 1) Bowden cable not connected
U120 Inclinometer self test failed 1) Inclinometer broken
U121 Inclinometer calibration procedure not –
OK
U122 Inclinometer offset out of range 1) Check the inclinometer installation
2) Vehicle not on flat ground
3) Remove any rear attachment
4) Incorrect wheels could be installed
U123 Vehicle moving 1) Vehicle not stationary
2) Vehicle speed sensor failed
Electronic Draft Control (EDC) – Error Codes

Code Description
1002 Radar disconnected
1003 Speed sensor error
1004 Wheel speed sensor – signal too high
1006 Slip control potentiometer error
1008 Raise / work switch failure (command arm)
1009 Both external switches operated at the same time
1010 Height limit control potentiometer error
1012 Drop rate control potentiometer error
1014 R/H load sensing pin – signal too low
1015 R/H load sensing pin – signal too high
1016 L/H load sensing pin – signal too low
1017 L/H load sensing pin – signal too high
1018 Both load sensing pins disconnected
1019 Load sensing pin 8V reference – voltage too low
1020 Load sensing pin 8V reference – voltage too high
1021 Draft sensitivity control potentiometer error
1024 Perform the hydraulic lift calibration
1025 Position control potentiometer error
1027 Lift arm position sensor – voltage too low
1028 Lift arm position sensor – voltage too high
1029 Hydraulic control valve disconnected
1033 Draft control potentiometer error
1049 Wheel speed sensor open circuit
1053 5 Volt reference – short to +12v
1054 5 Volt reference – short to ground
1063 Hydraulic valve lower solenoid – open circuit
1064 Hydraulic valve raise solenoid – open circuit
1065 Hydraulic valve lower solenoid – short circuit
1066 Hydraulic valve raise solenoid – short circuit
1067 Hydraulic valve supply voltage – voltage too low
1068 Height limit control not set to maximum during calibration
1070 Hydraulic ram configuration not set
16 x 16 Transmission – Error Codes

Code Description
2005 Creeper selection error
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Code Description
2009 Seat switch input – voltage too low
2010 Seat switch input – voltage too high
2011 Clutch pedal potentiometer – voltage too low
2012 Clutch pedal potentiometer – voltage too high
2015 High and low range switches both closed
2016 Creeper solenoid short to ground or high voltage
2024 All clutches and synchronisers require calibration
2037 Clutch pedal disconnect switch – open circuit
2038 Clutch 4 solenoid short to ground or high voltage
2039 Clutch 4 solenoid – open circuit
2040 Clutch 3 solenoid – short to ground or high voltage
2043 Clutch 2solenoid – open circuit
2047 Clutch pedal disconnect switch set too high
2048 Clutch pedal disconnect switch set too low
2049 Wheel speed (transmission output speed) sensor – open circuit, short to ground or high voltage
2051 Oil temperature sensor – open circuit
2052 Oil temperature sensor – short circuit
2053 5V reference - voltage too high
2054 5V reference - voltage too low
2055 Wheel speed (transmission output speed) sensor – no signal
2056 Low range switch open
2057 High range switch open
2058 Seat switch closedn
2059 Shuttle lever switch disagreement
2061 Forward / reverse synchroniser potentiometer - signal too high
2062 Forward / reverse synchroniser potentiometer - signal too low
2063 Forward synchroniser did not engage
2064 Reverse synchroniser did not engage
2065 Forward synchroniser solenoid - open circuit
2066 Reverse synchroniser solenoid - open circuit
2067 Forward synchroniser solenoid - short to ground or high voltage
2068 Reverse synchroniser solenoid - short to ground or high voltage
2070 Shuttle lever forward switch – voltage too high
2071 Shuttle lever forward switch – voltage too low
2072 Shuttle lever reverse switch – voltage too high
2073 Shuttle lever reverse switch – voltage too low
2075 Flywheel speed sensor - signal error
2076 Flywheel speed sensor – open circuit
2077 Flywheel speed sensor – short circuit
2079 Flywheel speed sensor – no signal
2081 4 / 5 range synchroniser potentiometer – signal high
2082 4 / 5 range synchroniser potentiometer – signal low
2083 1- 4 range synchroniser engaged error
2084 5 - 8 range synchroniser engaged error
2085 1- 4 range synchroniser solenoid - open circuit
2086 5- 8 range synchroniser solenoid - open circuit
2087 1- 4 range synchroniser solenoid - short to ground or high voltage
2088 5- 8 range synchroniser solenoid - short to ground or high voltage
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Code Description
2098 Clutch 5 solenoid - short circuit
2099 Clutch 5 solenoid - open circuit
2100 Clutch 5 dump solenoid - short circuit
2101 Clutch 5 dump solenoid - open circuit
2110 Momentary shuttle lever neutral switch - too low
2111 Momentary shuttle lever neutral switch - too high
2124 Flywheel torque sensor not calibrated
2316 Transmission oil pressure sensor - not configured
2317 Transmission oil pressure sensor - configuration error
2501 Transmission oil pressure sensor – open circuit or short circuit to ground
2502 Transmission oil pressure sensor – short circuit to +5V
Engine – Error Codes

Code Description
3001 Foot throttle sensor – signal not plausible
3002 Foot throttle sensor – signal above range maximum
3003 Foot throttle sensor – signal below range minimum
3006 Coolant temperature signal – signal not plausible
3007 Coolant temperature signal – signal above range maximum
3008 Coolant temperature signal – signal below range minimum
3010 Air intake temperature sensor – signal above range maximum
3011 Air intake temperature sensor – signal below range minimum
3015 Fuel temperature sensor – signal above range maximum
3016 Fuel temperature sensor – signal below range minimum
3019 Boost pressure sensor – signal above range maximum
3022 Boost pressure sensor – signal not plausible
3023 Atmospheric pressure sensor – signal not plausible
3024 Atmospheric pressure sensor – signal above range maximum
3025 Atmospheric pressure sensor – signal below range minimum
3028 Oil pressure too low
3029 Oil pressure sensor – short circuit to battery
3030 Oil pressure sensor – short circuit to ground
3031 Oil pressure sensor – hardware error
3032 Oil pressure sensor – value too high
3033 Oil temperature sensor – signal not plausible
3034 Oil temperature sensor – signal above range maximum
3035 Oil temperature sensor – signal below range minimum
3037 Boost pressure sensor – signal low
3047 High pressure pump relay – short circuit to battery
3048 High pressure pump relay – short circuit to ground
3051 Battery voltage to ECM – voltage too high
3052 Battery voltage to ECM – voltage too low
3060 Cylinder 1 – unclassifiable error in injector
3061 Cylinder 1 – injector cable short circuit (low side to battery)
3063 Cylinder 1 – injector cable short circuit (high side to ground)
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Code Description
3088 Crankshaft sensor – no signal
3089 Crankshaft sensor – invalid signal
3090 Camshaft sensor – no signal
3091 Camshaft sensor – invalid signal
3093 Offset between camshaft and crankshaft – outside boundaries
3095 Operating with camshaft sensor only – backup mode
3096 ECM busoff on CAN A
3102 Rail pressure sensor CP3 – signal below range minimum
3104 Rail pressure relief valve – open
3105 Rail pressure relief valve – pressure shock requested
3106 Rail pressure relief valve – did not open after pressure shock
3107 Metering unit – short circuit to battery
3108 Metering unit – short circuit to ground
3110 Rail pressure sensor monitoring – signal below range minimum
3111 Rail pressure sensor monitoring – signal above range maximum
3112 Rail pressure sensor CP3 – signal above maximum range
3120 PTO twist sensor – not plausible
3121 PTO twist sensor – open circuit
3122 PTO twist sensor – short circuit to ground
3123 PTO twist sensor – not calibrated
3131 Grid heater always switched on
3137 Metering unit – open load
3138 Metering unit – temperature too high
3141 Fuel flow setpoint too low
3142 High pressure test – test active
3145 Terminal 15 – no signal
3147 Oil temperature too high
3148 Coolant temperature sensor dynamic test – failure
3154 Grid heater relay – short circuit to battery
3155 Grid heater relay – short circuit to ground
3156 Grid heater relay – no load
3157 ECM not detected on CAN bus
3159 Invalid engine reference torque
3160 Fan actuator – short circuit to battery
3161 Fan actuator – short circuit to ground
3162 Fan actuator – no load
3163 Fan actuator – temperature too high
3166 Fuel filter heater relay - short to ground
3167 Fuel filter heater relay - short to battery
3168 Fuel filter heater relay - no load
3169 Fuel filter heater relay - signal not plausible
3176 Setpoint of metering unit not plausible in overrun
3177 Engine overspeed detected
3179 Timeout of CAN message BC2EDC2
3180 Timeout of CAN message VM2EDC
3182 Timeout of CAN message RxCCVS
3185 Timeout of CAN message TF
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Code Description
3188 Cylinder 1 warning – open load
3210 Bank 1 – general short circuit to injection cable
3211 Bank 1 – injection cable short circuit low side to ground
3213 Bank 1 – unclassifiable error
3218 Bank 2 – general short circuit to injection cable
3219 Bank 2 – injection cable short circuit low side to ground
3221 Bank 2 – unclassifiable error
3227 Injection processor (CY33X) error – internal reset / clock loss / voltage too low
3228 Injection processor (CY33X) error – unlocked / initialisation failure
3229 Injection processor (CY33X) error – injections limited by software
3230 Injection processor (CY33X) error – SPI communication failure
3231 Injection processor error – internal reset / clock loss / voltage too low
3232 Injection processor error – unlocked / initialisation failure
3233 Injection processor error – test mode
3234 Injection processor error – SPI communication failure
3238 ECM internal SPI communications error – CJ940
3239 ECM EEPROM – read operation failure
3240 ECM EEPROM – write operation failure
3241 ECM EEPROM – default value used
3242 ECM (locked) recovery occurred
3243 ECM recovery (suppressed) – recovery occurred
3244 ECM recovery (visible) – recovery occurred
3245 ECM processor – watchdog not plausible
3246 Shutoff paths during initialisation – watchdog
3247 Shutoff paths during initialisation – supply voltage too high
3248 Shutoff paths during initialisation – supply voltage too low
3249 TPU monitoring – time deviation between TPU and system not plausible
3250 Dataset – variant defect
3251 Dataset – requested variant could not be set
3252 Controller watchdog – SPI communication failure
3253 ADC monitoring – reference voltage too low
3254 ADC monitoring – reference voltage too high
3255 ADC monitoring – test impulse error
3256 ADC monitoring – queue error
3263 ECM BusOff on CAN C
3265 Overrun monitoring
3266 Redundant engine speed in overrun monitoring
3278 ECM internal supply voltage too high
3279 ECM internal supply voltage too low
3280 Sensor supply voltage 1 high
3281 Sensor supply voltage 1 low
3297 Rail pressure positive deviation high and high fuel flow setpoint value
3301 Rail pressure negative deviation too high on minimum metering
3305 Rail pressure below minimum limit in controller mode
3309 Rail pressure above maximum limit in controlled mode
3313 Rail pressure drop rate too high
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Code Description
3316 Minimum number of injections not reached – stop engine
3334 Timeout of CAN message TSC1–PE Torque (when active)
3335 Timeout of CAN message TSC1–PE Torque (when inactive)
3338 Timeout of CAN message TSC1–VE Speed (when inactive)
3339 Timeout of CAN message TSC1–VE Speed (when active)
3367 Coolant temperature test failure
3368 INFO: Torque limitation due to OBD Performance Limiter by legislation
3369 INFO: Torque reduction due to smoke reduction
3370 INFO: Torque limitation due to Engine Protection (against excessive torque, engine overspeed and
overheat)
3371 INFO: Torque limitation due to Fuel Quantity Limitation because of injector system errors
Rear Electronic Hydraulic Remote Valves – Error Codes

Code Description
4100 Rear remote no.1 – no control message received
4101 Rear remote no.1 – control message not plausible
4102 Rear remote no.1 – EEPROM error
4103 Rear remote no.1 – switched to failsafe
4104 Rear remote no.1 – under voltage
4105 Rear remote no.1 – over voltage
4106 Rear remote no.1 – spool movement too low
4107 Rear remote no.1 – spool movement too high
4108 Rear remote no.1 – float position not reached
4109 Rear remote no.1 – manually operated
4110 Rear remote no.1 – driver faulty
4111 Rear remote no.1 – potentiometer faulty
4112 Rear remote no.1 – unable to reach neutral
4113 Rear remote no.1 – spool not in neutral at key on
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Code Description
4170 Rear EHR control No.1 – not calibrated
4173 Rear EHR control No.2 – not calibrated
4177 Rear EHR control no.3 – not calibrated
4180 Rear EHR control no.4 – not calibrated
4190 Rear remote no.1 – no communications
4216 Rear remote no.1 – spool not calibrated
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Front Electronic Hydraulic Remote Valves – Error Codes

Code Description
4500 Front remote no.1 – no control message received
4501 Front remote no.1 – control message not plausible
4502 Front remote no.1 – EEPROM error
4503 Front remote no.1 – switched to failsafe
4504 Front remote no.1 – under voltage
4505 Front remote no.1 – over voltage
4506 Front remote no.1 – spool movement too low
4507 Front remote no.1 – spool movement too high
4508 Front remote no.1 – float position not reached
4509 Front remote no.1 – manually operated
4510 Front remote no.1 – driver faulty
4511 Front remote no.1 – potentiometer faulty
4512 Front remote no.1 – unable to reach neutral
4513 Front remote no.1 – spool not in neutral at key on
4560 Front remote no.1 – no communications
4564 EHR joystick - no communicationsr
Rear PTO – Error Codes

Code Description
5003 Rear PTO brake output – open circuit
5005 Rear PTO brake switch – open circuit
5007 Rear PTO solenoid – stuck off
5008 Rear PTO solenoid – open circuit
5015 Rear PTO fuse sense input - open circuit
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Code Description
5027 Rear PTO speed sensor – open circuit
5033 Rear PTO cab normally closed switch – open circuit
5034 Rear PTO fender switch – open circuit / short to ground
5035 Rear PTO fender switch – input shorted to 12V
5037 Rear PTO cab normally open switch – stuck closed
5043 Rear PTO fender switch stuck on
5044 Rear PTO speed sensor – short to ground
5098 Rear PTO fender switch option not enabled
Four Wheel Drive – Error Codes

Code Description
6023 FWD solenoid – open circuit
Difflock – Error Codes

Code Description
7017 Difflock solenoid – open circuit
7024 Steering angle sensor not calibrated
7032 Steering angle sensor – signal too low
7101 Autoguidance isolation solenoid - solenoid return short to battery
7102 Autoguidance isolation solenoid - solenoid return short to ground
7103 Steering angle plausibility error (autoguidance only)
7104 Timeout of NAV2XCM CAN message
Front PTO – Error Codes

Code Description
8007 Front PTO solenoid – stuck on
8008 Front PTO solenoid – open circuit
8033 Front PTO cab normally closed switch – open circuit
8037 Front PTO cab normally open switch – stuck closed
8099 Front PTO option not enabled
Front Hitch – Error Codes

Code Description
9001 Front hitch position sensor – short circuit to 12V
9002 Front hitch position sensor – open circuit / short circuit to 0V
9003 Front hitch fender up switch error
9004 Front hitch fender down switch error
9005 Front hitch fender common switch error
9006 Front hitch position potentiometer – not calibrated
Suspended Front Axle – Error Codes

Code Description
10001 Upper lockout solenoid error
10002 Raise solenoid error
10003 Lower solenoid error
10004 Front axle position sensor – threshold higher than set limit
10005 Front axle position sensor – threshold lower than set limit
10008 Go down error – suspension unable to return to set point
10009 Lower lockout solenoid error
10024 Front suspension not calibrated
Instrument Cluster – Error Codes

Code Description
14013 Steering angle sensor – short circuit to Vcc
14014 Steering angle sensor – short circuit to ground or open circuit
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Code Description
14015 5V supply voltage – too high
14016 5V supply voltage – too low
14021 Cranking line – shorted to 12V
14022 Cranking line – shorted to ground
14051 Fuel level sensor – short circuit to Vcc or open circuit
14052 Fuel level sensor – short circuit to ground
14061 Air brake pressure sensor – short circuit to VCC or option set but sensor not connected
14100 Air brake pressure – not configured
14104 EFH – present but not configured
14106 Steering sensor – present but not configured
14900 Transmission controller missing (RT)
14901 Engine controller missing (EDC16)
14902 Auxiliary controller missing (RM)
14904 Armrest controller missing (LC)
14906 Steering controller missing (KA)
14908 TECU missing (OA)
14909 SWCD missing (VA)
14910 Climate controller missing
Steering Controller – Error Codes

Code Description
15002 Steering wheel control proximity sensor – open circuit
15003 Steering wheel control proximity sensor – short circuit
15006 Split valve LVDT – open circuit
15007 Split valve LVDT – short circuit
15008 Change valve solenoid – open circuit
15009 Change valve solenoid – short circuit across
15010 Safety switch fail
15011 Maximum engagement time elapsed (5 minutes)
15012 Split valve spool – stuck open
15013 Change valve or split valve spools – stuck closed
15014 Split valve spool stuck in transition zone – can’t identify which steering mode the tractor is definitely
in.
15024 System not calibrated
Air Conditioning Controller – Error Codes

Code Description
16111 Cab temperature sensor open or shorted to power
16112 Cab temperature sensor shorted to ground
16113 Outlet temperature sensor open or shorted to power
16114 Outlet temperature sensor shorted to ground
16115 Evaporator temperature sensor open or shorted to power
16116 Evaporator temperature sensor shorted to ground
16117 Outside air temperature sensor open or shorted to power
16118 Outside air temperature sensor shorted to ground
16120 Blower speed select potentiometer open or shorted to power
16121 Temperature select potentiometer open or shorted to power
16122 Mode select potentiometer open or shorted to power
16125 High pressure– low pressure switch (+) input shorted to power
16126 High pressure– low pressure switch (+) input shorted to ground
16127 High pressure– low pressure switch (–) input shorted to power
16128 High pressure– low pressure switch (–) input shorted to ground
16129 High pressure cycling error (2 in 1 minute)
16130 Low pressure switch (+) input shorted to power
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Code Description
16131 Low pressure switch (+) input shorted to ground
16132 Low pressure switch (–) input shorted to power
16133 Low pressure switch (–) input shorted to ground
16134 Low pressure switch open for greater than 1 minute
Armrest – Error Codes

Code Description
18003 Hand throttle number 2 – voltage too low
18004 Hand throttle number 2 – voltage too high
18005 Engine droop control – voltage too low
18006 Engine droop control – voltage too high
18007 Multi-function handle – switch error
18008 Multi-function handle – voltage too low
18009 Multi-function handle – voltage too high
18010 Powershift throttle – voltage too low
18011 Powershift throttle – voltage too high
18012 CVT mode switch error
18013 Multi-function handle – encoder position error
18014 Rear hitch position control potentiometer – voltage too low
18015 Rear hitch position control potentiometer – voltage too high
18016 Rear hitch draft control potentiometer – voltage too low
18017 Rear hitch draft control potentiometer – voltage too high
18018 Rear hitch height limit potentiometer – voltage too low
18019 Rear hitch height limit potentiometer – voltage too high
18020 Rear hitch drop rate potentiometer – voltage too low
18021 Rear hitch drop rate potentiometer – voltage too high
18022 Rear hitch sensitivity control potentiometer – voltage too low
18023 Rear hitch sensitivity control potentiometer – voltage too high
18024 EHR flow encoder position error
18025 Rear hitch slip control potentiometer – voltage too low
18026 Rear hitch slip control potentiometer – voltage too high
18027 EHR 5 lever position – voltage too low
18028 EHR 5 lever position – voltage too high
18031 Front hitch position / pressure control potentiometer – voltage too low
18032 Front hitch position / pressure control potentiometer – voltage too high
18033 Front hitch position / pressure mix potentiometer – voltage too low
18034 Front hitch position / pressure mix potentiometer – voltage too high
18035 Front hitch position height limit potentiometer – voltage too low
18036 Front hitch position height limit potentiometer – voltage too high
18037 Front hitch height limit enable switch error
18038 Front hitch position drop rate potentiometer – voltage too low
18039 Front hitch position drop rate potentiometer – voltage too high
18046 EHR float control switch error
18049 Joystick 1 X-axis position – voltage too low
18050 Joystick 1 X-axis position – voltage too high
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Code Description
18051 Joystick 1 Y-axis position – voltage too low
18052 Joystick 1 Y-axis position – voltage too high
18053 Joystick 1 proportional rocker switch – voltage too low
18054 Joystick 1 proportional rocker switch – voltage too high
18055 Joystick 2 X-axis position – voltage too low
18056 Joystick 2 X-axis position – voltage too high
18057 Joystick 2 Y-axis position – voltage too low
18058 Joystick 2 Y-axis position – voltage too high
18059 Joystick 2 proportional rocker switch – voltage too low
18060 Joystick 2 proportional rocker switch – voltage too high
18061 Reference voltage – short circuit to ground
18062 Reference voltage – short circuit to 12V
18063 EEEPROM error
18064 MFH communication error
18065 MFH basic assurance test error
18066 EHR 1 lever implausibility error
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Control module - Electronic schema Instrument Cluster - ICU3

Module IE
Component Identification and Connectors

1. Battery Isolator
2. Instrument Cluster Unit (ICU3)
3. Indicator Flasher Unit
4. Handbrake Switch
5. Alternator
6. Sensor Signal Ground
7. Chassis Ground
8. Power Ground
9. Brake Pedal Switches and Trailer Brake Relays
10. Implement Connector (only Enhanced)
11. Worklamp Controller
12. Get-U-Home Lights Relay
X005 Instrument Cluster Unit CN1

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SS10A436 1
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Control module - Electronic schema Electronic Less Park Lock (EPL) -

Module XA

1. EPL Connector
2. Relais Less EPL
3. Trailer Brake Relay
5. Chassis Ground
6. Power Ground
X745 Electronic Park Brake Interface Conn
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SS10A437 1
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Control module - Electronic schema Central Control Unit 16/17x16 (RV

module)

2. Transmission control 16/17x16
3. Hydraulic Master switch
4. PTO (rear) Control
5. Four wheel drive / Differential lock control
6. Sensor Ground
7. Chassis Ground
8. Power Ground
X091 CCM Central Control Unit (CN2)

X092 CCM Central Control Unit (CN1a)
X093 CCM Central Control Unit (CN1b)
X094 CCM Central Control Unit (CN3a)
X095 CCM Central Control Unit (CN3b)
X097 CCM Central Control Unit (CN4)
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SS10A438 1
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Control module - Electronic schema Auxiliary Control Unit (RP module)


1. Electro-Hydraulic Remotes (EHR’s)
2. Front Axle Suspension Control
3. PTO (front) Control
4. Front Hydraulic Power Lift (HPL) Control
6. Chassis Ground
7. Power Ground
X098 ACU Auxiliary Control Unit (CN2)

X099 ACU Auxiliary Control Unit (CN1a)
X100 ACU Auxiliary Control Unit (CN1b)
X101 ACU Auxiliary Control Unit (CN3b)
X102 ACU Auxiliary Control Unit (CN3a)
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SS10A450 1
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Control module - Electronic schema Arm Rest Control Unit (LC module)

1. Speed / Engine RPM Control
2. Hitch Control (Integrated Control Panel)
3. Hitch Settings
5. Electro Hydraulic Remotes Control
6. Front Hitch Setting
7. Multi Function Handle Controller
8. Rear PTO and Front PTO Lamps
9. Rear PTO Switch
10. Front PTO Switch
11. Sensor Ground
12. Chassis Ground
13. Power Ground
X776 Armrest (GARU)

X840 Rear PTO Switch
X841 Front PTO Switch
X842 EHR Flow Control Encoder
X843 EHR Float / Joystick
X846 Sensor Transmission Ratio
X847 Integrated Control Switch Panel
X848 Rear Hitch Position / Draft Potentiometer
X850 EL.Draft Control Rear Potentiometer Panel
X853 El.Hydraulic Remote 1&2 Control
X854 El.Hydraulic Remote Lamps 1&2 & Switch
X862 GARU PCB SWCD
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SS10A440 1
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Control module - Electronic schema Small Wide Colour Display


1. Small Wide Colour Display (SWCD screen)
2. USB Socket
3. Sensor Ground
4. Chassis Ground
5. Power Ground
6. ISO BUS Implement Connector Front
X820 GARU SWCD
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SS10A441 1
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Control module - Electronic schema ISO-BUS Control Unit (TECU)


1. ISO BUS Control Unit (TECU)
2. ISO BUS Implement Connector Rear
3. Sensor ground
4. Chassis ground
5. Supply ground
X616 TECU Unit - CN1
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SS10A442 1
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Control module - Electronic schema Automatic Temperature Control


1. Climate control module
2. Power Relay
3. Blower speed switch
4. Air conditioning switch
5. Temperature transmitter
6. High pressure switch
7. Low pressure switch
8. Evaporator temperature sensor
9. Outlet temperature sensor
10. Cab temperature sensor
11. Outside temperature sensor
12. A/C compressor clutch relay
13. Compressor
14. Blower speed control
15. Blower motor
16. Water valve
17. Sensor Ground
18. Chassis Ground
19. Power Ground
X755 Air Condition Auto Temp. Control Unit
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SS10A443 1
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Control module - Electronic schema Fast Steer (KA Module)


1. Fast Steer control unit
2. Steering wheel proximity sensor
3. Turn Assist ON/OFF switch
4. LVDT sensor (position transmitter)
5. Hydraulics solenoid valve
6. Sensor signal ground
7. Chassis ground
8. Supply ground
X621 Control Unit Fast Steer
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SS10A444 1
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Control module - Electronic schema Engine control Module


1. Engine control module
2. Diagnostics plug - CAN 1
3. Diagnostics plug CAN 2
4. Main relay
5. Fuel filter water sensor
6. EBR (Exhaust Brake ) actuator
7. Fuel filter heater relay
8. Heating element relay
9. Boost pressure / boost temperature sensor
10. Oil pressure / oil temperature sensor
11. Rail pressure sensor
12. Coolant temperature sensor
13. Fuel temperature sensor
14. Camshaft speed sensor
15. Crankshaft speed sensor
16. High pressure pump
17 Injector, No. 1 cylinder
18. Injector, No. 2 cylinder
23. Sensors ground
24. Chassis ground
25. Supply ground
X213 Engine Control Unit - A

X218 Engine Module Bosch
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SS10A445 1
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Control module - Electronic schema Auto Guidance Module


1. Navigation Controller (Ceres)
2. Crank Relay
3. Manual override pressure sensor
4. Steering angle sensor
5. Diagnostic connector
6. GPS (global positioning system) receiver
7. Select switch
8. Steering solenoids
9. Sensor ground
10. Chassis Ground
11. Power Ground
X716 Ceres Controller A

X720 Ceres Controller B
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SS10A446 1
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Control module - Electronic schema Electro-Hydraulic Remotes


1. Supply relay EHRs
2. CAN BUS terminating resistor
3. EHR 1 Rear
4. EHR 2 Rear
5. EHR 3 Rear
6. EHR 4 Rear
7. EHR 1 Front (MID)
10. Sensor signal ground
11. Chassis ground
12. Supply ground
X305 EHR Valve Connector 1

X309 not used
X697 MEHR 1
X698 MEHR 2
X699 MEHR 3
X700 not used
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SS10A447 1
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ELECTRONIC SYSTEM - Calibrate

Calibration Set Up Procedures
Required When :
1. A calibration Fault code is Present.
NOTE: The Fault code will not be displayed on the screen,
but can be viewed in H-menu mode HB
2. The non volatile memory has been reset (H8) in the
controller.
NOTE: After a full memory reset, in H8, it will be necessary
to perform the tractor configuration procedure. Refer to H3
in the H-Menu Chapter of the Electrical Systems Section.
3. The microprocessor has been replaced.
4. A PWM solenoid valve has been replaced.
5. A potentiometer has been replaced.
6. A mechanical repair has been effected.
7. TRANSMISSION ONLY - The shift quality or clutch
featherability has noticeably deteriorated.
8. EDC ONLY - A new lift arm potentiometer is fitted,
in which case error code 1024 will have to be in-
duced by disconnecting the potentiometer with the
key switch in the "ON" position and then re-connect-
ing it.
Set Up Procedure:
9. Prior to conducting a clutch and synchroniser calibra-
tion, the following points should be checked:-
The transmission oil is at the correct temperature -
this can be checked in mode H9 All transmissions
should be calibrated at a minimum temperature of 40
°C.
10. The parking brake is applied.
11. The air conditioning (if fitted) is switched off.
12. All electrical and hydraulic services are deselected.
13. Electronic Lift only - A weight of approximately 200
Kg is placed on the lift arms ( to overcome any resis-
tance of the lift linkage).
14. Electronic lift only - All EDC controls are turned fully
clockwise.
15. Electronic lift only - The raise / work switch is posi-
tioned in the WORK position.
NOTE: If the set up procedure has not been followed cor-
rectly a “U" Fault Code will be displayed.
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Index

SYSTEMS - A

Control module - Electronic schema Electronic Less Park Lock (EPL) - Module XA . . . . . . . . . . . . . . . . . . . . . . . 330
Control module - Electronic schema Central Control Unit 16/17x16 (RV module) . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Control module - Electronic schema Auxiliary Control Unit (RP module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Control module - Electronic schema Arm Rest Control Unit (LC module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Control module - Electronic schema Small Wide Colour Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Control module - Electronic schema ISO-BUS Control Unit (TECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Control module - Electronic schema Automatic Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Control module - Electronic schema Fast Steer (KA Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Control module - Electronic schema Engine control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Control module - Electronic schema Auto Guidance Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
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Control module - Electronic schema Electro-Hydraulic Remotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Control module - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control module - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control module - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Control module - Configure - Front Axle Suspension, Rear Electronic Hydraulic Remote Valves, Front PTO, Front
Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Control module - Configure Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Control module - Configure Configure GA CONTROLLER H ROUTINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Control module - Configure Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Control module - Configure KA - Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Control module - Configure LA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Control module - Configure RV - 16x16 Transmission, Electronic Draft Control, Rear PTO, Front Wheel Drive, Dif-
ferential Lock, Front Electronic Hydraulic Remote Valves, Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Control module - Electronic schema Instrument Cluster - ICU3 Module IE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Control module - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
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Control module - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
ELECTRONIC SYSTEM - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
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FAULT CODES - 50.A

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Contents

SYSTEMS - A
FAULT CODES - 50.A
FUNCTIONAL DATA
ELECTRONIC SYSTEM
Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - FAULT CODES
ELECTRONIC SYSTEM - Fault code index

Reference Description Controller
10004 Front Axle Position Sensor Threshold
Higher Than Set Limit
Higher Than Set Limit
Lower Than Set Limit
Lower Than Set Limit
10008 Go Down Error - Suspension Unable
to Return to Set Point
10008 Go Down Error - Suspension Unable
to Return to Set Point
10024 Front Suspension Not Calibrated
1002 Radar Disconnected
1002 Radar Disconnected
1003 Speed Sensor Error
1004 Wheel Speed Sensor Signal Too High
1006 Slip Control Potentiometer Error
1006 Slip Control Potentiometer Voltage
Too Low
Too Low
Too High
Too High
1008 Raise / Work Switch Failure
(Command Arm)
1008 Raise / Work Switch Failure
(Command Arm)
1009 Both External Switches Operated At
The Same Time
1009 Both External Switches Operated At
The Same Time
1010 Height Limit Control Potentiometer
Voltage Too Low
Voltage Too Low
1010 Height Limit Potentiometer Error
Voltage Too High
Voltage Too High
1012 Drop Rate Control Potentiometer
Error
Voltage Too Low
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Voltage Too Low
Voltage Too High
Voltage Too High
1014 Right Hand Load Sensing Pin Signal
Too Low
Too Low
Too High
1015 Right Hand Sensing Pin Signal Too
High
1016 Left Hand Load Sensing Pin Signal
Too Low
Too Low
Too High
Too High
1018 Both Load Sensing Pins
Disconnected
1018 Both Load Sensing Pins
Disconnected
1019 Load Sensing Pin 8V Reference
Voltage Too Low
Voltage Too Low
Voltage Too High
Voltage Too High
1021 Draft Sensitivity Control
Potentiometer Error
Potentiometer Voltage Too Low
Potentiometer Voltage Too Low
Potentiometer Voltage Too High
Potentiometer Voltage Too High
1023 Command Arm/Control Panel
Disconnected
1024 Perform The Hydraulic Lift Calibration
1025 Position Control Potentiometer Error
1025 Position Control Potentiometer
Voltage Too Low
Voltage Too Low
Voltage Too High
Voltage Too High
1027 Lift Arm Position Sensing Control
Voltage Too Low
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Voltage Too Low
Voltage Too High
Voltage Too High
1032 Draft Control Potentiometer Voltage
Too High
Too High
1033 Draft Control Potentiometer Error
Too Low
Too Low
1053 5 Volt Reference Short to +12V
1059 8 Volt Reference Error (Draft Load
Pins)
1063 EDC Hydraulic Valve Lower Solenoid
Open Circuit
Open Circuit
1064 EDC Hydraulic Valve Raise Solenoid
Open Circuit
Open Circuit
Short Circuit
Short Circuit
Short Circuit
Short Circuit
1067 Hydraulic Valve Supply Voltage
Voltage Too Low
1067 Hydraulic Valve Supply Voltage
Voltage Too Low
1068 Height Limit Control Not Set To
Maximum During Calibration
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14011 Engine Speed Sensor Open Circuit
Or Short To High Voltage (Mechanical
Engine)
14012 Engine Speed Sensor Short To
Ground (Mechanical Engine)
14013 Steering Angle Sensor - Short Circuit
to VCC
14014 Steering Angle Sensor - Short Circuit
to Ground or Open Circuit
14015 5V Supply Voltage - Too High
14015 5V Supply Voltage - Too High
14016 5V Supply Voltage - Too Low
14016 5V Supply Voltage - Too Low
14021 Cranking Line - Shorted to +12V
14022 Cranking Line - Shorted to Ground
14041 Engine Coolant Temperature Sensor
Open Circuit Or Short To High Voltage
(Mechanical Engine)
14042 Engine Coolant Temperature Sensor
Short To Ground (Mechanical Engine)
14051 Fuel Level Sensor Open Circuit Or
Short To High Voltage
14051 Fuel Level Sensor Open Circuit Or
14052 Fuel Level Sensor Short To Ground
14052 Fuel Level Sensor Short To Ground
14061 Air Brake Pressure Sensor - Short
Circuit to VCC or Option Set But
Sensor Not Connected
14061 Air Brake Pressure Sensor Short
To High Voltage Or Option Set But
Sensor Not Connected
14082 Engine Oil Pressure Sensor Short To
Ground (Mechanical Engine)
14091 Wheel Speed Sensor Open Circuit Or
14092 Wheel Speed Sensor Short To
Ground
14100 Air Brake Option Needs To Be Set
14101 Fuel Contaminated Sensor not
Connected (mech. engine)
14104 Electronic Front Hitch Present But
Not Configured
14106 Steering Sensor Present But Not
Configured
14200 Error With Electrical Programmable
Read Only Memory (EEPROM)
14900 Transmission Controller Missing
(RE/RN)
14900 Transmission Controller Missing
14901 Engine Controller Missing (EDC16)
14901 Engine Controller Missing
14902 Auxiliary Controller Missing (RW/RN)
14902 Auxiliary Controller Missing
14903 Small Control Module (SCM) Missing
14904 Armrest (ARU) Not Connected
14904 Armrest Controller Missing (LC)
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14905 Keypad Missing
14906 Steering Controller Missing (KA)
14906 Steering Controller Missing (KA)
14907 Gear Display Missing
14908 TECU Missing (OA)
14909 SWCD Missing (VA)
14910 Climate Controller Missing
15002 Steering Wheel Control Proximity
Sensor Open Circuit.
Sensor Open Circuit.
Sensor - Short Circuit
Sensor - Short Circuit
15006 STEERING Hydraulic Fast steer
system Processor - Spit Valve LVDT
- Open circuit
15006 Split Valve LVDT - Open Circuit
15007 Split Valve LVDT - Short Circuit
15007 Split Valve LVDT - Short Circuit
15008 Change Valve Solenoid - Open Circuit
15008 Change Valve Solenoid - Open Circuit
15009 Change Valve Solenoid - Short Circuit
Across
15009 Change Valve Solenoid - Short Circuit
Across
15011 Maximum Engagement Time Elapsed
(5 Minutes)
15012 Split Valve Spool - Stuck Open
15012 Split Valve Spool - Stuck Open
15013 Change Valve Or Split Valve Spools -
Stuck Closed
15013 Change Valve Or Split Valve Spools -
Stuck Closed
15014 Split Valve Spool Stuck In Transition
Zone - Can’t Identify Which Steering
Mode The Tractor Is Definitely In
15014 Split Valve Spool Stuck in Transition
Zone - Unable to Identify Steering
Mode
15024 System Not Calibrated
16111 Cab Sensor Open Or Shorted To
Power
16111 Cab Temperature Sensor Open or
Shorted to Power Plus
16112 Cab Sensor Shorted To Ground
16112 Cab Temperature Sensor Shorted to
Ground
16113 Outlet Sensor Open Or Shorted To
Power
16113 Outlet Temperature Sensor Open or
16114 Outlet Sensor Open Or Shorted To
Ground
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16114 Outlet Temperature Sensor Shorted
to Ground
16115 Evaporator Sensor Open Or Shorted
To Power
16115 Evaporator Temperature Sensor
Open or Shorted to Power Plus
16116 Evaporator Sensor Shorted To
Ground
16116 Evaporator Temperature Sensor
Shorted to Ground
16117 Outside Air Sensor Open Or Shorted
To Power
16117 Outside Air Temperature Sensor
16118 Outside Air Sensor Shorted To
Ground
16118 Outside Air Temperature Sensor
Shorted to Ground
16120 Blower Speed Select Potentiometer
Open Or Shorted To Power
16121 Temperature Select Potentiometer
Open Or Shorted To Power
16121 Temperature Select Potentiometer
16122 Mode Select Potentiometer Open Or
Shorted To Power
16125 High Pressure Switch (+) Input
Shorted To Power
16125 High Pressure- Low Pressure Switch
(+) Input Shorted to Power Plus
16126 High Pressure Switch (+) Input
Shorted To Ground
(+) Input Shorted to Ground
16127 High Pressure Switch (-) Input
Shorted To Power
(-) Input Shorted to Power Plus
16128 High Pressure Switch (-) Input
Shorted To Ground
(-) Input Shorted to Ground
16129 High Pressure Cycling Error (2 in 1
Minute)
16129 High Pressure Cycling Error (2 in 1
Minute)
16130 Low Pressure Switch (+) Input
Shorted To Power
Shorted To Ground
Shorted To Ground
16132 Low Pressure Switch (-) Input Shorted
To Power
To Power
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To Ground
To Ground
16134 Low Pressure Switch Open For
Greater Than 1 Minute
16134 Low Pressure Switch Open For
Greater Than 1 Minute
18003 Hand Throttle Number 2 - Voltage
Too Low
18004 Hand Throttle Number 2 - Voltage
Too High
18005 Engine Drop Control - Voltage Too
Low
18006 Engine Drop Control - Voltage Too
High
18007 Multi-function Handle - Switch Error
18008 Multi-function Handle - Voltage Too
Low
18009 Multi-function Handle - Voltage Too
High
18010 Powershift Throttle - Voltage Too Low
18011 Powershift Throttle - Voltage Too High
18012 CVT Mode Switch Error
18013 Multi-function Handle - Encoder
Position Error
18014 Rear Hitch Position Control
Potentiometer - Voltage Too Low
18015 Rear Hitch Position Control
Potentiometer - Voltage Too High
18016 Rear Hitch Draft Control
18017 Rear Hitch Draft Control
18018 Rear Hitch Height Limit Potentiometer
- Voltage Too Low
18019 Rear Hitch Height Limit Potentiometer
- Voltage Too High
18020 Rear Hitch Drop Rate Potentiometer
- Voltage Too Low
18021 Rear Hitch Drop Rate Potentiometer
- Voltage Too High
18022 Rear Hitch Sensitivity Control
18023 Rear Hitch Sensitivity Control
18024 EHR Flow Encoder Position Error
18025 Rear Hitch Slip Control Potentiometer
- Voltage Too Low
18026 Rear Hitch Slip Control Potentiometer
- Voltage Too High
18027 EHR 5 Lever Position - Voltage Too
Low
High
Low
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High
18031 Front Hitch Position / Pressure
Control Potentiometer - Voltage Too
High
18032 Front Hitch Position / Pressure
Control Potentiometer - Voltage Too
Low
18033 Front Hitch Position / Pressure Mix
18034 Front Hitch Position / Pressure Mix
18035 Front Hitch Position Height Limit
18036 Front Hitch Height Limit
18037 Front Hitch Height Limit Enable
Switch Error
18038 Front Hitch Position Drop Rate
18039 Front Hitch Position Drop Rate
Low
High
Low
High
Low
High
18046 EHR Float Control Switch Error
Low
High
18049 Joystick 1 X-Axis Position - Voltage
Too Low
Too High
18051 Joystick 1 Y-Axis Position - Voltage
Too Low
Too High
18053 Joystick 1 Proportional Rocker Switch
- Voltage Too Low
18054 Joystick Proportional Rocker Switch -
Voltage Too High
Too Low
Too High
Too Low
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Too High
- Voltage Too Low
- Voltage Too High
18061 Reference Voltage - Short Circuit To
Ground
18062 Reference Voltage - Short Circuit To
12V
18063 EEEPROM Error
18064 Multi-function Handle Communication
Error
18065 Multi-function Handle Basic
Assurance Test Error
18066 EHR 1 Lever Implausibility Error
2001 CR - Shuttle Too Fast Error
2002 Flashing N Error
2003 CP - Clutch Pedal Required
2004 P - Handbrake Error
2005 Creeper Selection Error
2005 Creeper Selection Error
2009 Seat Switch Input - Voltage Too Low
2010 Seat Switch Input - Voltage Too High
2011 Clutch Pedal Potentiometer - Voltage
Too Low
2011 Clutch Pedal Potentiometer Signal
Low
2012 Clutch Pedal Potentiometer - Voltage
Too High
2012 Clutch Pedal Potentiometer Signal
High
2013 Upshift and Downshift Switches Both
Closed
2015 High and Low Range Switches Both
Closed
2015 High and Low Range Switches Both
Closed
2016 Creeper Solenoid Short To Ground
Or High Voltage
2016 Creeper Solenoid Short To Ground
Or High Voltage
2021 CHASSIS HARNESS
DISCONNECTED
2021 Transmission Harness Disconnected
2024 All Clutches and Synchronisers
Require Calibration
2024 All Clutches and Synchronisers
Require Calibration
2027 Engine Speed Too Low
2035 Dump Solenoid Short To Ground Or
High Voltage
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2037 Clutch Pedal Disconnect Switch -
Open Circuit
2037 Clutch Pedal Disconnect Switch
Open Circuit
2038 Clutch C4 Solenoid Short To Ground
Or High Voltage (16x16)
2038 High Range PWM Valve Short To
Ground Or High Voltage (24x24)
2039 Clutch C4 Solenoid Open Circuit
(16x16)
(16x16)
2039 High Range PWM Valve Open Circuit
(24x24)
2040 Low Range PWM Valve Short To
Ground Or High Voltage (24x24)
(16x16)
(16x16)
2041 Low Range PWM Valve Open Circuit
(24x24)
(16x16)
(16x16)
(16x16)
(16x16)
2047 Clutch Pedal Disconnect Switch Set
Too High
Too High
Too Low
Too Low
2049 Wheel Speed Sensor - Open Circuit
2049 Wheel Speed Sensor Open Circuit,
Short To Ground or High Voltage
2051 Oil Temperature Sensor Open Circuit
2051 Oil Temperature Sensor Open Circuit
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2052 Oil Temperature Sensor - Short
Circuit
2052 Oil Temperature Sensor Short To
Ground Or High Voltage
2053 5 Volt Reference Voltage Too High
2053 5 Volt Reference Voltage Too High
2054 5 Volt Reference Voltage Too Low
2054 5 Volt Reference Voltage Too Low
2055 No Signal From Wheel Speed Sensor
2055 Wheel Speed (Transmission Output
Speed) Sensor - No Signal
2056 Low Range Switch Open
2056 Low Range Switch Open
2057 High Range Switch Open
2057 High Range Switch Open
2058 Seat Switch Closed
2058 Seat Switch Closed
2059 Shuttle Lever Switch Disagreement
2061 Forward/Reverse Synchroniser
Potentiometer Signal Too High
Potentiometer Signal Too High
Potentiometer Signal Too Low
Potentiometer Signal Too Low
2063 Forward Synchroniser Did Not
Engage
2063 Forward Synchroniser Did Not
Engage
2064 Reverse Synchroniser Did Not
Engage
2064 Reverse Synchroniser Did Not
Engage
2065 Forward Synchroniser Solenoid Open
Circuit
2065 Forward Synchroniser Solenoid Open
Circuit
2066 Reverse Synchroniser Solenoid
Open Circuit
2066 Reverse Synchroniser Solenoid
Open Circuit
2067 Forward Synchroniser Solenoid Short
To Ground Or High Voltage
2067 Forward Synchroniser Solenoid Short
2068 Reverse Synchroniser Solenoid Short
2068 Reverse Synchroniser Solenoid Short
2069 Reverse Synchroniser No Longer
Engaged
2070 Shuttle Lever Forward Switch Voltage
Too High
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Too High
Too High
Too Low
Too Low
Too Low
2072 Shuttle Lever Reverse Switch Voltage
Too High
Too High
Too High
Too Low
Too Low
Too Low
2075 Flywheel Speed Sensor Signal Error
2075 No Signal From Flywheel Speed
Sensor
2076 Flywheel Speed Sensor Open Circuit
2076 Flywheel Speed Sensor Open Circuit
2077 Flywheel Speed Sensor - Short
Circuit
2077 Flywheel Speed Sensor Short Circuit
Or High Value
2079 Flywheel Speed Sensor - No Signal
2081 4/5 Range Synchroniser
Potentiometer Signal High (16x16)
Potentiometer Signal High (16x16)
Potentiometer Signal Low (16x16)
Potentiometer Signal Low (16x16)
2083 1-4 (9-12) Range Synchroniser Error
(16x16)
2083 1-4 (9-12) Range Synchroniser Error
(16x16)
2084 5-8 (13-16) Range Synchroniser
Engaged Error (16x16)
Engaged Error (16x16)
Solenoid Open Circuit (16x16)
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Solenoid Short To Ground Or High
Voltage (16x16)
Voltage (16x16)
Voltage (16x16)
Voltage (16x16)
2091 Clutch C3 Not Calibrated (16x16)
2093 High Clutch Not Calibrated (24x24)
2094 Low Clutch Not Calibrated (24x24)
2097 Clutch C5 (17th Gear) Not Calibrated
(16x16)
2098 Clutch C5 (17th Gear) Solenoid Short
Circuit (16x16)
2098 Clutch C5 (17th Gear) Solenoid Short
Circuit (16x16)
2099 Clutch C5 (17th Gear) Solenoid Open
Circuit (16x16)
2099 Clutch C5 (17th Gear) Solenoid Open
Circuit (16x16)
2100 Clutch C5 (17th Gear) Dump Solenoid
Short Circuit (16x16)
Short Circuit (16x16)
Open Circuit (16x16)
Open Circuit (16x16)
2110 Momentary Shuttle Lever Neutral -
Too Low
2111 Momentary Shuttle Lever Neutral -
Too High
2124 Flywheel Torque Sensor Fitted In
Error (24x24)
2124 Flywheel Torque Sensor Not
Calibrated (16x16)
2316 Transmission Oil Pressure Sensor -
Not Configured
2317 Transmission Oil Pressure Sensor -
Configuration Error
2501 Oil Pressure Sensor - Open Circuit
Or Short Circuit To Ground
2502 Oil Pressure Sensor - Short Circuit
To +5V
3001 Foot Throttle Sensor - Signal Not
Plausible
3001 Foot Throttle Sensor - Signal Not
Plausible
84276322A 31/05/2010
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3002 Foot Throttle Sensor - Signal Above
Range Maximum
3002 Foot Throttle Sensor - Signal Above
Range Maximum
3003 Foot Throttle Sensor - Signal Below
Range Minimum
3003 Foot Throttle Sensor - Signal Below
Range Minimum
3006 Coolant Temperature Sensor - Signal
Not Plausible
3007 Coolant Temperature Signal - Signal
Above Range Maximum
3008 Coolant Temperature Signal - Signal
Below Range Minimum
3010 Air Intake Temperature Sensor -
Signal Above Range Maximum
Signal Below Range Minimum
3015 Fuel Temperature Sensor - Signal
Above Maximum
3016 Fuel Temperature Sensor - Signal
Below Range Minimum
3019 Boost Pressure Sensor - Signal
Above Range Maximum
3022 Boost Pressure Sensor - Signal Not
Plausible
3023 Atmospheric Pressure Sensor -
Signal Not Plausible
3024 Atmospheric Pressure Sensor -
3025 Atmosperic Pressure Sensor - Signal
Below Range Minimum
To Battery
To Ground
3032 Oil Pressure Sensor - Value Too High
3033 Oil Temperature Sensor - Signal Not
Plausible (Compared With Coolant
Temperature)
3034 Oil Temperature Sensor - Signal
Above Range Maximum
3035 Oil Temperature Sensor - Signal
Below Range Minimum
3037 Boost Pressure Sensor - Signal Low
3038 Constant Engine RPM Activate/Select
Switch - Short Circuit to Battery
3047 Main Relay Failure - Short Circuit To
Battery
3047 Main Relay Failure - Short Circuit To
Battery
84276322A 31/05/2010
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3048 Main Relay Failure - Short Circuit to
Ground
3048 Main Relay Failure - Short Circuit to
Ground
3051 Battery Voltage To Engine Controller
- Voltage Too High
3052 Battery Voltage To Engine Controller
- Voltage Too Low
3060 Cylinder 1 - Unclassifiable Error In
Injector
3061 Cylinder 1 - Injector Cable Short
Circuit (Low Side To Battery)
Circuit (High Side To Ground)
Injector
Injector
Injector
Injector
Injector
3089 Crankshaft Sensor - Invalid Signal
3093 Offset Between Camshaft And
Crankshaft - Outside Boundaries
3095 Operating With Camshaft Sensor
Only - Backup Mode
3096 CAN A LINE NO SIGNAL
3096 ECM Bussoff On CAN A
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3102 Rail Pressure Sensor CP3 - Signal
Below Range Minimum
3104 Rail Pressure Relief Valve - Open
3105 Rail Pressure Relief Valve - Pressure
Shock Requested
3106 Rail Pressure Relief Valve - Did Not
Open After Pressure Shock
3107 Fuel Metering Unit - Short Circuit To
Battery
3107 Fuel Metering Unit - Short To Battery
3108 Fuel Metering Unit - Short Circuit To
Ground
3108 Fuel Metering Unit - Short To Ground
3112 Rail Pressure Sensor CP3 - Signal
Above Maximum Range
3120 PTO Twist Sensor - Not Plausible
3122 PTO Twist Sensor - Short Circuit To
Ground
3122 PTO Twist Sensor - Short Circuit To
Ground
3124 Hand Throttle - Channel 2 Signal
Above Range Maximum
Below Range Minimum
Above Range Maximum
Below Range Minimum
3128 Hand Throttle - Channel Difference
Error
3129 Hand Throttle - Idle Switch Closed
Circuit
3130 Hand Throttle - Idle Switch Open
Circuit
3131 Grid Heater Always Switched On
3137 Metering Unit - Open Load
3147 Oil Temperature Too High
3148 Coolant Temperature Sensor
Dynamic Test - Failure
3148 Coolant Temperature Sensor
Dynamic Test - Failure
3154 Grid Heater Relay - Short Circuit To
Battery
3155 Grid Heater Relay - Short Circuit To
Ground
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3156 Grid Heater Relay - No Load
3158 Invalid ECM Checksum
3159 Invalid Engine Reference Torque
3160 Fan Actuator - Short Circuit to Battery
3162 Fan Actuator - Open Load
3163 Fan Actuator - No Load
3166 Fuel Filter Heater Relay - Short
Circuit To Ground
3167 Fuel Filter Heater Relay - Short
Circuit To Battery
3168 Fuel Filter Heater Relay - No Load
3169 Fuel Filter Heater Relay - Signal Not
Plausible
3176 Setpoint Of Metering Unit Not
Plausible In Overrun
3177 Engine Overspeed Detected
3179 Time-out Of CAN Message BC2EDC2
3180 Time-out Of CAN Message
VCM2EDC
3182 Timeout Of CAN Message RxCCVS
3185 Timeout Of CAN Message TF
3192 Cylinder 2 warning - Open Load
3210 Bank 1 - General Short Circuit To
Injector Cable
3211 Bank 1 - Injector cable Short Circuit
Low Side To Ground
3218 Bank 2 - General Short Circuit On
Injector Cable
3219 Bank 2 - Injector Cable Short Circuit
Low Side To Ground
3227 Injection Processor Error - Internal
Reset/Clock Loss/Voltage Too Low
3228 Injection Processor Error -
Unlocked/Initialization Error
3229 Injection Processor Error - Injections
Limited By Software
3230 Injection Processor Error - SPI
Communication Failure
3231 Injection Processor Error - Internal
3232 Injection Processor Error -
Unlocked/Initialization Failure
3233 Injection Processor Error - Test Mode
3234 Injection Processor Error - SPI
Communication Failure
3238 Engine Controller Internal SPI
Communication Error
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3239 Engine Controller EEPROM - Read
Operation Error
3240 Engine Controller EEPROM - Write
Operation Failure
3241 Engine Controller EEPROM - Default
Value Used
3242 Engine Controller (Locked) Recovery
Occurred
3243 Engine Controller Recovery
(Suppressed) - Recovery Occurred
3244 Engine Controller Recovery (Visible)
- Recovery Occurred
3245 Engine Controller - Watchdog Not
Plausible
3246 Shutoff Paths During Initialization -
Watchdog
3247 Shutoff Paths Failed During
Initialization - Supply Voltage Too
High
3248 Shutoff Paths During Initialization -
Supply Voltage Too Low
3249 TPU Monitoring - Time Deviation
Between TPU And System Not
Plausible
3250 Dataset - Variant Defect
3251 Dataset - Requested Variant Could
Not Be Set
3252 Controller Watchdog - SPI
Comunication Failure
3253 ADC Monitoring - Reference Voltage
Too Low
3254 ADC Monitoring - Reference Voltage
Too High
3255 ADC Monitoring Test Impulse Error
3256 ADC Monitoring Queue Error
3263 CAN C Line No Signal
3263 CAN C Line No Signal
3265 Overrun Monitoring
3266 Redundant Engine Speed in Overrun
Monitoring
3278 Engine Controller Supply Voltage Too
High
3279 Engine Controller Internal Supply
Voltage Too Low
3280 Sensor Supply Voltage 1 - High
3281 Sensor Supply Voltage 1 - Low
3297 Rail Pressure Poistive Deviation High
And High Fuel Flow Setpoint Value
3301 Rail Pressure Negative Deviation Too
High On Minimum Metering
3301 Rail Pressure Negative Deviation Too
High On Minimum Metering
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3305 Rail Pressure Below Minimum Limit
In Controller Mode
3309 Rail Pressure Above Maximum Limit
In Controlled Mode
3309 Rail Pressure Above Maximum Limit
In Controlled Mode
3313 Rail Pressure Drop Rate Too High
3316 Minimum Number Of Injections Not
Reached - Stop Engine
3316 Minimum Number Of Injections Not
Reached - Stop Engine
3334 Timeout Of CAN Message TCS1-PE
Torque - When Active
3334 Timeout Of CAN Message TCS1-PE
Torque - When Active
3335 Timeout Of CAN Message TSC1-PE
Torque - When Inactive
3338 Timeout Of CAN Message TSC1-VE
Speed - When Inactive
3339 Timeout Of CAN Message TSC1-VE
Speed - When Active
3345 Total Throttle Failure
3368 Torque Limitation Due To OBD
Performance Limiter By Legislation
3369 Torque Reduction Due To Smoke
Reduction
3370 Torque Limitation Due To Engine
Protection (Against Excessive
Torque, Engine Overspeed And
Overheat)
3371 Torque Limitation Due To Fuel
Quantity Limitation Because Of
Injector System Errors
3375 Constant Engine RPM Increase /
Decrease Switch - Open Circuit
3376 Engine Controller Software Does Not
Support Power Management
3377 Constant Engine RPM Switch
Detected But Option Is Not Enabled
4001 Signal Of Aux Stick (Aux 1) Out Of
Range Low
Range High
4003 Signal From Remote Flow Pot 1 (Aux
1) Out Of Range
Range Low
Range High
2) Out Of Range
Range Low
Range High
84276322A 31/05/2010
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3) Out Of Range
4) Out Of Range
4040 ARU Supply Voltage - Too Low (<8V)
4041 ARU Supply Voltage - Too High
(>18V)
4042 ARU CAN Bus Off
4043 ARU Controller Fault (Register
Check)
4044 ARU Controller Fault (Flash Memory)
4045 ARU Controller Fault (Data Memory)
4100 Rear Remote No.1 No Control
Message Received
Message Received
4101 Rear Remote No.1 Control Message
Not Plausible
Not Plausible
4103 Rear Remote No.1 Switched To
Failsafe
4106 Rear Remote No.1 Spool Movement
Too Low
Too Low
Too High
4108 Rear Remote No.1 Float Position Not
Reached
4109 Rear Remote No.1 Manually
Operated
4111 Rear Remote No.1 Potentiometer
Faulty
4112 Rear Remote No.1 Unable To Reach
Neutral
4113 Rear Remote No.1 Spool Not In
Neutral At Key On
Message Received
Message Received
Not Plausible
Not Plausible
Failsafe
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Too Low
Too High
Reached
Operated
Faulty
Neutral
Neutral At Key On.
Message Received
Message Received
Not Plausible
Not Plausible
Failsafe
Too Low
Too High
Reached
Operated
Faulty
Neutral
Neutral At Key On
Message Received
Message Received
Not Plausible
Not Plausible
Failsafe
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Too Low
Too High
Reached
Operated
Faulty
Neutral
Neutral At Key On
4170 Rear EHR Control No.1 Not
Calibrated
Calibrated
4171 Rear EHR Control No.1 Open Circuit
4172 Rear EHR Control No.1 Short Circuit
Calibrated
Calibrated
4176 Rear EHR Timer Switch No.1 / No.2
Not Connected
Calibrated
Calibrated
Calibrated
Calibrated
4183 Rear EHR Timer Switch No.3 / No.4
Not Connected
4190 Rear Remote No.1 No
Communications
Communications
Communications
Communications
Communications
Communications
Communications
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Communications
4194 Rear EHR No.1 Motor Mode Switch
Faulty
Faulty
Faulty
Faulty
4216 Rear Remote No.1 - Spool Not
Calibrated
Calibrated
Calibrated
Calibrated
4500 Front Remote No.1 - No Control
Message Received
4501 Front Remote No.1 Control Message
Not Plausible
4502 Front Remote No.1 EEPROM Error
4503 Front Remote No.1 Switched To
Failsafe
4504 Front Remote No.1 Under Voltage
4505 Front Remote No.1 Over Voltage
4506 Front Remote No.1 Spool Movement
Too Low
Too High
4508 Front Remote No.1 Float Position Not
Reached
4509 Front Remote No.1 Manually
Operated
4510 Front Remote No.1 Driver Faulty
4511 Front Remote No.1 Potentiometer
Faulty
4512 Front Remote No.1 Unable To Reach
Neutral
4513 Front Remote No.1 Spool Not In
Neutral At Key On
4514 Front Remote No.2 No Control
Message Received
4515 Front Remote no.2 Control Message
Not Plausible
Failsafe
Too Low
Too High
Reached
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Operated
Faulty
Neutral
Neutral At Key On
4528 Front Remote No.3 No Control
Message Received
4529 Front Remote No.3 Control Message
Not Plausible
Failsafe
Too Low
Too High
Reached
Operated
Faulty
Neutral
Neutral At Key On
4560 Front RemoteNo.1 No
Communications
4561 Front Remote No.2 No
Communications
4562 Front Remote No.3 No
Communications
5003 Rear PTO Brake Solenoid Output
Open Circuit
5003 Rear PTO Brake Solenoid Output
Open Circuit
5008 Rear PTO Solenoid - Open Circuit
5008 Rear PTO Solenoid Circuit Over
Current
5015 PTO Fuse Sense Input - Open Circuit
5027 Rear PTO Speed Sensor - Open
Circuit
5033 Rear PTO Cab Normally Closed
Switch Open Circuit
5033 Rear PTO Cab Normally Closed
Switch Open Circuit
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5034 Rear PTO Fender Switch Open
Circuit / Short To Ground
5034 Rear PTO Fender Switch Open
Circuit / Short To Ground
5035 Rear PTO Fender Switch Input Short
To 12V+
5035 Rear PTO Fender Switch Input Short
To 12V+
5036 Rear PTO Failure To Start
5037 Rear PTO Cab Normally Open Switch
- Stuck Closed
5037 Rear PTO Management Switch
Normally Open Stuck Closed
5042 Rear PTO Management Switch Stuck
Closed
5044 Rear PTO Speed Sensor - Short To
Ground
5098 Rear PTO Fender Switch Option Not
Enabled
5098 Rear PTO Fender Switch Option Not
Enabled
5099 Rear PTO management option not
activated
6020 Four Wheel Drive Switch Error
6021 Four Wheel Drive Solenoid Stuck On
6022 Four Wheel Drive Solenoid Stuck Off
6023 Four Wheel Drive Solenoid Open
Circuit
6023 Four Wheel Drive Solenoid Open
Circuit
7014 Differential Lock Switch Error
7017 Differential Lock Solenoid - Open
Circuit
7017 Differential Lock Solenoid - Open
Circuit
7024 Steering Angle Sensor Not Calibrated
7032 Steering Angle Sensor - Signal Too
Low
7032 Steering Angle Sensor - Signal Too
Low
7101 Autoguidance Isolation Solenoid
Return - Short To Battery
7102 Autoguidance Isolation Solenoid
Return - Short To Ground
7104 Timeout of NAV2XCM CAN Message
8007 Front PTO Solenoid - Stuck On
8007 Front PTO Solenoid - Stuck On
8008 Front PTO Solenoid - Open Circuit
8008 Front PTO Solenoid - Open Circuit
8033 Front PTO Switch In Cab Normally
Closed Open Circuit
8033 Front PTO Switch In Cab Normally
Closed Open Circuit
8037 Front PTO Cab Normally Open
Switch Stuck Closed
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8037 Front PTO Cab Normally Open
Switch Stuck Closed
8099 Front PTO Option Not Enabled
9001 Front Hitch Position Sensor - Short
Circuit To 12V
9001 Front Hitch Position Sensor - Short
Circuit To 12V
9002 Front Hitch Position Sensor - Open
Circuit Or Short To Ground
9002 Front Hitch Position Sensor - Open
Circuit Or Short To Ground
9003 Front Hitch Fender Up Switch Error
9004 Front Hitch Fender Down Switch
Error
9005 Front Hitch Fender Common Switch
Error
9006 Front Hitch Position Potentiometer -
Not Calibrated
3006 Coolant Temperature Sensor - Signal EDC
Not Plausible
Above Range
Below Range Minimum
3015 Fuel Temperature Sensor - Signal EDC
Above Maximum
3016 Fuel Temperature Sensor - Signal EDC
Below Range Minimum
3019 Boost Pressure Sensor - Signal EDC
Above Range Maximum
3022 Boost Pressure Sensor - Signal Not EDC
Plausible
3023 Atmospheric Pressure Sensor - EDC
Signal Not Plausible
3029 Oil Pressure Sensor - Short Circuit EDC
To Battery
3030 Oil Pressure Sensor - Short Circuit EDC
To Ground
3031 Oil Pressure Sensor - Hardware Error EDC
3032 Oil Pressure Sensor - Value Too High EDC
3033 Oil Temperature Sensor - Signal Not EDC
Plausible (Compared With Coolant
Temperature)
3034 Oil Temperature Sensor - Signal EDC
Above Range Maximum
3035 Oil Temperature Sensor - Signal EDC
Below Range Minimum
3037 Boost Pressure Sensor - Signal Low EDC
3051 Battery Voltage To Engine Controller EDC
- Voltage Too High
3052 Battery Voltage To Engine Controller EDC
- Voltage Too Low
3060 Cylinder 1 - Unclassifiable Error In EDC
Injector
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3061 Cylinder 1 - Injector Cable Short EDC
3064 Cylinder 5 - Unclassifiable Error in EDC
Injector
Injector
Injector
Injector
Injector
3089 Crankshaft Sensor - Invalid Signal EDC
3093 Offset Between Camshaft And EDC
Crankshaft - Outside Boundaries
3095 Operating With Camshaft Sensor EDC
Only - Backup Mode
3102 Rail Pressure Sensor CP3 - Signal EDC
Below Range Minimum
3104 Rail Pressure Relief Valve - Open EDC
3105 Rail Pressure Relief Valve - Pressure EDC
Shock Requested
3106 Rail Pressure Relief Valve - Did Not EDC
Open After Pressure Shock
3110 Rail Pressure Sensor Monitoring - EDC
3112 Rail Pressure Sensor CP3 - Signal EDC
Above Maximum Range
3131 Grid Heater Always Switched On EDC
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3137 Metering Unit - Open Load EDC
3147 Oil Temperature Too High EDC
3154 Grid Heater Relay - Short Circuit To EDC
Battery
3155 Grid Heater Relay - Short Circuit To EDC
Ground
3156 Grid Heater Relay - No Load EDC
3161 Fan Actuator - Short Circuit to Ground EDC
3188 Cylinder 1 Warning - Open Load EDC
3192 Cylinder 2 warning - Open Load EDC
3210 Bank 1 - General Short Circuit To EDC
Injector Cable
3211 Bank 1 - Injector cable Short Circuit EDC
Low Side To Ground
3213 Bank 1 - Unclassifiable Error EDC
3218 Bank 2 - General Short Circuit On EDC
Injector Cable
3219 Bank 2 - Injector Cable Short Circuit EDC
Low Side To Ground
3221 Bank 2 - Unclassifiable Error EDC
3227 Injection Processor Error - Internal EDC
3279 Engine Controller Internal Supply EDC
Voltage Too Low
2026 Engine Speed Too High TCU
2036 Dump Solenoid Open Circuit TCU
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Index

SYSTEMS - A
FAULT CODES - 50.A

ELECTRONIC SYSTEM - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84276322A 31/05/2010
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CNH Österreich GmbH Steyrerstraße 32 4300 St. Valentin Austria
SERVICE - Technical Publications & Tools
PRINTED IN FRANCE
© 2010 CNH GLOBAL N.V.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE IH policy is one of continuous improvement and the right to change prices, specification or equipment
at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE IH Dealer.
84276322A 31/05/2010
SERVICE MANUAL
ENGINE AND PTO IN

84276322A 31/05/2010
B
Contents
ENGINE AND PTO IN - B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A

AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A

ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

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ENGINE - 10.A

84276322A 31/05/2010
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Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General specification 4 Cylinder 2 Valve Mechanical - F4CE0484B*D . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General specification 4 Cylinder 2 Valve Mechanical - F4CE9484G*J . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAXXUM 110 Multicontroller, MAXXUM 110
General specification 6 Cylinder 2 Valve Mechanical Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

MAXXUM 115 Multicontroller, MAXXUM 125 Multicontroller, MAXXUM 140 Multicontroller, MAXXUM 115, MAXXUM
125, MAXXUM 140
General specification 4 Cylinder 4 valve Electronic Boosted Engines - F4DE9487B*J, F4DE9487A*J,

F4DE948A*J100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General specification 4 Cylinder 4 Valve Electronic Unboosted - F4DE9484E*J100, F4DCE9484D*J101,
F4DE9484B*J101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
120, MAXXUM 130
General specification 6 Cylinder 4 Valve Boosted - F4DE9684R*J102, F4DE9687X*J, F4DE9687J*J . 18

125, MAXXUM 140
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dimension - Stretch Bolt Check for reuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Valve drive
Camshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve assembly Valve - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve guide - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve assembly Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Camshaft Bushing - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Crankshaft
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting rod and piston
Piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Piston Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cylinder block
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder head
Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Valve seat - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FUNCTIONAL DATA
Valve drive
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Camshaft - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rocker assembly - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rocker assembly - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auxiliary drive
Crankshaft
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting rod - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Flywheel
Balancer
Cylinder block
Cylinder head
SERVICE
ENGINE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Disconnect (Engine / Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connect (Engine / Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Overhaul External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Overhaul Internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Valve drive
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Camshaft Tappet - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Camshaft Push rod - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Valve assembly - Check Decarbonising and Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Crankshaft
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Timing gear
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Flywheel
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Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Cylinder block
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cylinder head
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Valve cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Rear cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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ENGINE AND PTO IN - ENGINE
ENGINE - Torque
PART TORQUE
Nm (lb ft)
Bolts securing connecting rod
caps: 1st phase 30 +/- 3 (22.1269 +/- 2.2127)
2nd phase 60 +/- 5 (44.2537 +/- 3.6878)
Angle closed 3rd phase 60 ° +/- 5 °
Nuts securing engine cover (6 cylinder engines refer to figure 3
4 cylinder engines refer to figure 4)
M8 125 25 ± 5 (18.4391 ± 3.6878)
Bolts securing engine flywheel: 1st phase 30 +/- 4 (22.1269 +/- 2.9502)
2nd phase 60 ° +/- 5 °
Bolts securing pulley and
damper: 1st phase 50 ± 5 (36.8781 ± 3.6878) +
2nd phase 90 ° +/- 5 °
Cooling nozzles (mechanical engines only) 15 ± 3(11 ± 2)
Bolts securing injectors on cylinder head: 110 ± 5 (81.1318 ± 3.6878)
Nut securing P.A.P. gear: 105 ± 7 (77.4440 ± 5.1629)
Nut securing compressor gear: 125 ± 19 (92.1953 ± 14.0137)
Bolts securing timing gear: 36 ± 4 (26.5522 ± 2.9502)
Unions securing piston lubrication nozzles: 15 ± 3 (11.0634 ± 2.2127)
Bolts securing timing system
casing
M8 1.25x40 24 ± 4 (17.7015 ± 2.9502)
M10 1.5x30 47 ± 5 (34.6654 ± 3.6878)
Bolts securing front cover
M10 1.5x30 24 ± 4 (17.7015 ± 2.9502)
Bolts securing main bearing
caps with angle closed
M12 1.50 12.9 1st phase 50 +/- 6 (36.8781 +/- 4.4254)
2nd phase 80 +/- 6 (59.0050 +/- 4.4254)
Angle closed 3rd phase + 90 ° +/- 5 °
Viti fissaggio Ladder Frame:
M10 1.5x25 43 ± 5 (31.7152 ± 3.6878)
Bolts securing lifting brackets:
M12 1.75x25 7 ± 12 (5.1629 ± 8.8507)
M10 43 ± 5 (31.7152 ± 3.6878)
Bolts securing cooler (refer to
figure 7)
M8 1.25x35 25 ± 5 (18.4391 ± 3.6878)
M8 1.25x100 25 ± 5 (18.4391 ± 3.6878)
M12 Connector 25 ± 5 (18.4391 ± 3.6878)
Bolts securing valve cover
M8 Nuts 24 ± 4 (17.7015 ± 2.9502)
Engine Vent Fastener (Ccv)
M8 1.25x45 24 ± 4 (17.7015 ± 2.9502)
M8 1.25x35 24 ± 4 (17.7015 ± 2.9502)
Bolts securing oil sump 6 cylinder engines (refer to figure 8) ♦
Tightening Bolts No 31 & 34 M10 1.5x45 50 ± 5 (36.8781 ± 3.6878)
Tightening Bolts No 4-14; 17-27; 32-33 M10 1.5x90 70 ± 5 (51.6293 ± 3.6878)
Tightening Bolts No 1-3, 28-30 M10 1.5x125 70 ± 5 (51.6293 ± 3.6878)
Tightening Bolts No 15-16 M10 15x190 70 ± 5 (51.6293 ± 3.6878)
Bolts securing oil sump 4 cylinder engines (refer to figure 9) ♦
Tightening Bolts No 23 & 26 M10 1.5x45 50 ± 5 (36.8781 ± 3.6878)
Tightening Bolts No 3-10; 13-20; 24-25 M10 1.5x90 70 ± 5 (51.6293 ± 3.6878)
Tightening Bolts No 1-2, 21-22 M10 1.5x125 70 ± 5 (51.6293 ± 3.6878)
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PART TORQUE
Nm (lb ft)
Tightening Bolts No 11-12 M10 15x190 70 ± 5 (51.6293 ± 3.6878)
Bolts / Plugs On Head
1/2 in Nptf 24 ± 4 (17.7015 ± 2.9502)
3/4 in Nptf 36 ± 5 (26.5522 ± 3.6878)
1/4 in Nptf 12 ± 2 (8.8507 ± 1.4751)
♦ Lubricate With Engine Oil Before Assembly

(continued)
TORQUE WRENCH SETTINGS
PART TORQUE
Nm (lb ft)
Bolts securing 6 cylinder head (refer to figure 1) ♦
Step 1. Tightening bolts No 1-2-7-8-9-10-15-16-17-18-23-24- 55 (40.5659)
25-26 M12 1.75x150
Step 2. +90 °
Step 3. +90 °
Step 1. Tightening bolts No 3-4-5-6-11-12-13-14-19-20-21-22 35 (25.8147)
M12 1.75x130
Step 2. +90 °
Step 3. +90 °
Bolts securing 6 cylinder head (refer to figure 2) ♦
Step 1. Tightening bolts No 1-2-7-8-9-10-15-16-17-18 M12 55 (40.5659)
1.75x150
Step 2. +90 °
Step 3. +90 °
Step 1. Tightening bolts No 3-4-5-6-11-12-13-14 M12 1.75x130 35 (25.8147)
Step 2. +90 °
Step 3. +90 °
Bolts securing heater grille:
M6 10 ± 2 (7.3756 ± 1.4751)
Bolts securing intake manifold:
M8 1.25x25 25 ± 5 (18.4391 ± 3.6878)
M8 1.25x60 25 ± 5 (18.4391 ± 3.6878)
Bolts securing exhaust manifold on 6 cylinder head: (refer to
figure 5)
M12 1.75x25 80 ± 5 (62.6928 ± 3.6878)
Bolts securing exhaust manifold on 4 cylinder head: (refer to
figure 6)
M8 1.25x25 25 ± 5 (18.4391 ± 3.6878)
M8 1.25x14 25 ± 5 (18.4391 ± 3.6878)
Bolts securing connecting rod caps (6 cylinder engines):
M11 1.25 10.9 Flg 1st phase 30 +/- 3 (22.1269 +/- 2.2127)
2nd phase 60 +/- 5 (44.2537 +/- 3.6878)
Torque/Angle 3rd phase +60 ° +/- 5 °
Bolts securing connecting rod caps (4 cylinder engines):
M10 1.25x52 10.9 Flg 1st phase 30 +/- 3 (22.1269 +/- 2.2127)
2nd phase 60 +/- 5 (44.2537 +/- 3.6878)
Torque/Angle 3rd phase +60 ° +/- 5 °
Bolts securing flywheel
M12 85 ± 10 (62.6928 ± 7.3756)
M10 49 ± 5 (36.1405 ± 3.6878)
Bolts securing camshaft thrust plate:
M8 1.25x25 10.9 Flg 24 ± 4 (17.7015 ± 2.9502)
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Bolts securing camshaft gear:

M8 1.25x20 9.8 Flg 36 ± 4 (26.5522 ± 2.9502)
Bolts securing rocker arms: 36 ± 5 (26.5522 ± 3.6878)
Bolts securing rocker arm adjusters:
3/8 24 Unf Hex Nut 24 ± 4 (17.7015 ± 2.9502)
Bolts securing rocker arm casing: 24 ± 4 (17.7015 ± 2.9502)
Bolts securing phonic wheel:
M12 1.25 10.9 Flg Hex 1st phase 50 ± 5 (36.8781 ± 3.6878)
2nd phase + 90 ° +/- 5 °
Fuel connector fastener on head side 50 ± 5 (36.8781 ± 3.6878)
Fuel connector fastener on Common Rail side 20 ± 2 (14.7512 ± 1.4751)
Common Rail fastener
M8 1.25x10 9.8 Flg Hex 24 ± 4 (17.7015 ± 2.9502)
M8 1.25x50 9.8 Flg Hex 24 ± 4 (17.7015 ± 2.9502)
M8 1.25x90 9.8 Flg Hex 24 ± 4 (17.7015 ± 2.9502)
Fastener for high-pressure pipes from Common Rail to cylinder
head
M14 1.5 20 ± 2 (14.7512 ± 1.4751)
Fastener for fuel filter mounting on crankcase
M12 1.75x25 9.8 Fig Hex 77 ± 8 (56.7923 ± 5.9005)
Turbo / exhaust manifold fastener (refer to figure 10)
M8 1.25 25 ± 5 (18.4391 ± 3.6878)
Oil delivery/return pipe fastener
M12 1.5 35 ± 5 (25.8147 ± 3.6878)
Oil dipstick pipe fastener: 24 ± 4 (17.7015 ± 2.9502)
♦ Lubricate With Engine Oil Before Assembly

(continued)
TORQUE WRENCH SETTINGS
PART TORQUE
Nm (lb ft)
Bolts securing oil pump:
M8 1.25x30 8.8 Hex 1st phase 8 ± 1 (5.9005 ± 0.7376)
2nd phase 24 ± 4 (17.7015 ± 2.9502)
Main oil delivery bolts (plugs)
M10 — 1 6 ± 1 (4.4254 ± 0.7376)
M14 — 1.5 11 ± 2 (8.1132 ± 1.4751)
Oil cooler / oil filter assembly fastener: 24 ± 4 (17.7015 ± 2.9502)
Coolant pump / crankcase fastener:
M8 1.25x25 8.8 Hex 1st phase 24 ± 4 (17.7015 ± 2.9502)
2nd phase 43 ± 6 (31.7152 ± 4.4254)
Tightener fastener
M10 1.5x60 9.8 Fig -
Fan mounting fastener
M10 33 ± 5 (24.3395 ± 3.6878)
Fan pulley fastener -
Fan spacer or accessory pulley fastener (when required)
M6 10 ± 2 (7.3756 ± 1.4751)
M10 43 ± 6 (31.7152 ± 4.4254)
M12 77 ± 12 (56.7923 ± 8.8507)
Additional counterweight fastener (refer to figure 11)
M10 1.5x80 48 ± 8 (35 ± 6)
M10 1.5x100 48 ± 8 (35 ± 6)
Alternator fastener
M8 1.25x30 9.8 Fig Hex 24 ± 4 (17.7015 ± 2.9502)
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M12 1.75x120 10.9 Fig Hex 43 ± 6 (31.7152 ± 4.4254)

M12 Nut 1.75 G Fig Hex 24 ± 4 (17.7015 ± 2.9502)
M10 1.5x25 9.8 Fig Hex -
M10 1.5x40 9.8 Fig Hex -
M10 Nut 1.5 9 Fig Hex -
M16 1.5 Hex -
Stud bolts for mounting fuel pump:
M8 12 ± 2 (8.8507 ± 1.4751)
Bolts securing injection pump:
M8 1.5 24 ± 4 (17.7015 ± 2.9502)
Tightening nut fixing injection pump gear
M18 1.5 105 ± 5 (77.4440 ± 3.6878)
Fastener for fittings from injection pump to Common Rail:
M12 1.5 20 ± 2 (14.7512 ± 1.4751)
Bolts securing injectors: Electronic Engine 8,5 ± 0,8
Bolts securing injector connectors: 1,5 ± 0,25 (1.1063 ± 0.1844)
Oil pressure regulator sensor fastener: 8 ± 2 (5.9005 ± 1.4751)
Camshaft speed sensor fastener in gearbox:
M6 8 ± 2 (5.9005 ± 1.4751)
Crankshaft speed sensor fastener on front cover
M6 8 ± 2 (5.9005 ± 1.4751)
Temperature sensor fastener on cylinder head:
M14 1.5x12 Hex 20 ± 3 (14.7512 ± 2.2127)
Air temperature sensor fastener on intake manifold:
M6 1x20 3 ± 1 (2.2127 ± 0.7376)
Air pressure and temperature sensor fastener on intake manifold:
M5 3 ± 1 (2.2127 ± 0.7376)
Fuel pressure sensor fastener: 35 ± 5 (25.8147 ± 3.6878)
Fuel temperature sensor fastener:
M14 1.5x12 Hex 20 ± 3 (14.7512 ± 2.2127)
Gear fastener on air compressor:
5/8 in18 Unf 125 ± 19 (92.1953 ± 14.0137)
Air compressor fastener on crankcase:
M12 Nut 81 ± 12 (59.7425 ± 8.8507)
♦ Lubricate with engine oil before assembly
Tightening sequence for 6 cylinder head bolts
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80736 1
Tightening sequence for 4 cylinder head bolts
80362 2
Tightening sequence for 6 cylinder engine cover nuts
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80737 3
Tightening sequence for 4 cylinder engine cover nuts
80365 4
Tightening sequence for 6 cylinder exhaust manifold bolts
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B.10.A / 10
80738 5
Tightening sequence for 4 cylinder exhaust manifold bolts
80363 6
Tightening sequence for cooler bolts
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80367_89 7
Tightening sequence for engine oil sump bolts (6 cylinder engines)
80739 8
Tightening sequence for engine oil sump (4 cylinder engines)
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80366 9
Tightening sequence for turbocharger nuts and bolts
Sequence:
- Pre-tightening4-3-1-2
- Tightening 1-4-2-3
80364 10
Tightening sequence for additional counterweight bolts (4 cylinder engines only)
80368 11
84276322A 31/05/2010
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Tighten torques engine/ transmission, cab front mounting bolt
BVE0598A_32 12
ENGINE - General specification 4 Cylinder 2 Valve Mechanical -

F4CE0484B*D
Engine Type: 4 cylinder 2 Valve Mechanical- F4CE0484B*D - Tier2
Compression ratio 17.5:1
Maximum power 74 kW
101 Hp
Rated Engine Speed 2200 RPM
Maximum torque @ 1400 RPM 400 Nm
Slow idling speed of engine without load 850 RPM

Fast idling speed of engine without load 2400 RPM
Turbocharger type HOLSET

Lubrication Forced via lobe pump, pressure relief valve,
oil filter
Oil pressure with engine hot
– at slow idling 1.2 bar (17.40 psi)
– at fast idling 3.8 bar (55.10 psi)
Cooling system Fluid–based
Coolant pump drive: Via belt
Thermostat:
– starts to open - fully open 81 - 96 °C (177.80 - 204.80 °F)
Filling CASE AKCELA NO. 1 ENGINE OIL SAE
15W-40
– engine sump min 7 l (1.85 US gal)
max 10 l (2.64 US gal)
– engine sump + filter 11 l (2.91 US gal)
Type 4-cylinders
Cycle Diesel, 4–stroke
Fuel system Turbocharged
Fuel injection Direct
Number of cylinders 4
Bore 104 mm (4.09 in)
Stroke 132 mm (5.20 in)
Total displacement 4485 cm³ 273.6 in³
Valve Clearance (engine cold) Inlet 0.25 mm (0.01 in)± 0.5 mm (0.02 in)
Exhaust 0.50 mm (0.02 in)± 0.5 mm (0.02 in)
Fuel system
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Engine Type: 4 cylinder 2 Valve Mechanical- F4CE0484B*D - Tier2

Injection Pump: Delphi (Mechanical)
Nozzles Bosch
Injection order 1–3–4–2
ENGINE - General specification 4 Cylinder 2 Valve Mechanical -

F4CE9484G*J
Engine Type: 4 cylinder 2 Valve Mechanical- Tier3 F4CE9484G*J,

Compression ratio 17.5:1
Maximum power 82 kW
110 Hp
Rated Engine Speed 2200 RPM
Maximum torque @ 1400 RPM 400 Nm
Slow idling speed of engine without load 850 RPM

Fast idling speed of engine without load 2375 RPM

Lubrication Forced via lobe pump, pressure relief valve,
oil filter
Thermostat:
Filling CASE AKCELA NO. 1 ENGINE OIL SAE
15W-40
– engine sump min 7 l (1.85 US gal)
Type 4-cylinders
Fuel system Turbocharged with Aftercooler
Bore 104 mm (4.09 in)
Valve Clearance (engine cold) Inlet 0.25 mm (0.01 in)± 0.5 mm (0.02 in)
Fuel system
Injection Pump: Bosch (Mechanical)
Nozzles Bosch
Injection order 1–3–4–2
ENGINE - General specification 6 Cylinder 2 Valve Mechanical

Engine
MAXXUM 115 Multicontroller, MAXXUM 125 Multicontroller, MAXXUM 140 Multicontroller, MAXXUM 115, MAXXUM 125, MAXXUM 140
84276322A 31/05/2010
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Engine Type: 6 cylinder 2 F4CE9484L*J600 F4CE9484K*J601 F4CE9484J*J601

Valve Mechanical- Tier3
Compression ratio 17.5:1 17.5:1 17.5:1
Maximum power @ rated 86 kW 93 kW 104 kW
engine speed 2200 RPM
117 Hp 126 Hp 141 Hp
Maximum torque @ 1400 516 Nm @ 1250 RPM 560 Nm @ 1250 RPM 625 Nm @ 1250 RPM
RPM
Slow idling speed of engine 850 RPM 850 RPM 850 RPM
without load
Fast idling speed of engine 2375 RPM 2375 RPM 2375 RPM
without load
Lubrication Forced via lobe pump, pressure relief valve, oil filter
Thermostat:
Filling CASE AKCELA NO. 1 ENGINE OIL SAE 15W-40
– engine sump capacity min 7 l (1.85 US gal)
Bore 104 mm (4.09 in)
Valve Clearance (engine cold) 0.25 mm (0.01 in)± 0.5 mm (0.02 in)
Inlet
Fuel system
Injection Pump: Bosch (Mechanical)
Nozzles Bosch
Injection order 1, 5, 3, 6, 2, 4
ENGINE - General specification 4 Cylinder 4 valve Electronic

Boosted Engines - F4DE9487B*J, F4DE9487A*J, F4DE948A*J100
Engine Type: 4 cylinder 4 F4DE9487B*J F4DCE9487A*J F4DE9484A*J100
Valve Electronic- Tier3
132 Hp 141 Hp 141 Hp
RPM
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Engine Type: 4 cylinder 4 F4DE9487B*J F4DCE9487A*J F4DE9484A*J100

without load
without load
Thermostat:
– engine sump capacity + 10 l (2.64 US gal)
filter

Number of valves per cylinder 4
Bore 104 mm (4.09 in)
Inlet
Fuel system
Injection Pump: Electronic High Pressure Common Rail (Bosch)
Nozzles Bosch
Injection order 1, 3, 4, 2
ENGINE - General specification 4 Cylinder 4 Valve Electronic

Unboosted - F4DE9484E*J100, F4DCE9484D*J101, F4DE9484B*J101
Engine Type: 4 cylinder 4 F4DE9484E*J100 F4DCE9484D*J101 F4DE9484B*J101

112 Hp 121 Hp 132 Hp
RPM
without load
without load
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Engine Type: 4 cylinder 4 F4DE9484E*J100 F4DCE9484D*J101 F4DE9484B*J101

Thermostat:
– engine sump capacity + 10 l (2.64 US gal)
filter

Number of valves per cylinder 4
Bore 104 mm (4.09 in)
Inlet
Fuel system
Injection Pump: Electronic High Pressure Common Rail (Bosch)
Nozzles Bosch
Injection order 1, 3, 4, 2
ENGINE - General specification 6 Cylinder 4 Valve Boosted -

F4DE9684R*J102, F4DE9687X*J, F4DE9687J*J
Engine Type: 6 cylinder 4 F4DE9484R*J102 F4DE9687X*J101 F4DE9487J*J101

141 Hp 152 Hp 167 Hp
RPM
without load
without load
Thermostat:
84276322A 31/05/2010
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Engine Type: 6 cylinder 4 F4DE9484R*J102 F4DE9687X*J101 F4DE9487J*J101

– engine capacity - sump + 15 l (3.96 US gal)
filter
Bore 104 mm (4.09 in)
Inlet
Fuel system
Injection Pump: Electronic High Pressure Common Rail Bosch (EDC16C39)
Nozzles Bosch
Injection Pressure 300 - 1800 bar (4350.00 - 26100.00 psi)
Injection order 1, 5, 3, 6, 2, 4
ENGINE - Special tools

TOOL No. Description
380000979 Puller for engine injection pump union gear
380000665 Tool to extract crankshaft front seal
380000663 Tool to extract crankshaft rear seal
380001099 Injector extractor
380000666 Crankshaft front seal installer
380000664 Crankshaft rear seal installer
380000988 Flywheel locking adaptor plate (to be used with
380000732)
380000732 Engine turning tool (to be used with 380000988)
380000667 Drift for camshaft bushing disassembly and reassembly
380000158 Torque screwdriver for injector solenoid valve connector
nut setting
380001003 Connecting Rod Check Gauge
380000301 Engine stand (revolving)
380001298 Engine stand to Cylinder block brackets
380001073 Engine lifting brackets
380200013
380000569 Tractor splitting kit
380140055 Fuel supply/leakage test kit
380000500 Engine support brackets (to be used with 380000569)
380000844 Engine support brackets (to be used with 380000500)
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Locally Fabricated Tools
BVE0405A 1
Cab Jacking Tool x2 (Tractors with standard cab)
ENGINE - Dimension - Stretch Bolt Check for reuse.

NOTE: This check is required to be carried out prior to reusing the following stretch bolts:
Cylinder Head .
Rocker Post .
Main Bearing .
Connecting Rod (Refer to ENGINE - Torque (B.10.A)).
Before reusing the retaining stretch bolts, make two (2) measurements, using a micrometer, on the tread outer diam-
eter at points D1 and D2. The two points measured should be as close as reasonably possible to the two ends of the
bolts threaded section.
bail06ccm024asa 1
If D1-D2< 0,1 mm (0.0039 in), the bolt can be reused.
If D1-D2> 0,1 mm (0.0039 in), the bolt must be renewed.
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Valve drive Camshaft - Dimension
BAIL07APH360FSA 1
The data given refers to the normal pin diameter
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Valve assembly Valve - Dimension
80672 1
Intake and Exhaust Valve Data.
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Valve drive Valve guide - Dimension
80676_98 1
Valve Guide data. (Refer to Valve drive Valve guide - Measure (B.10.A)).
Valve assembly Spring - Dimension

Valve Springs
DATA FOR CHECKING THE INTAKE AND EXHAUST VALVE SPRINGS
Before assembly, check the valve spring flexibility. Compare the elastic deformation and load data with those of the
new springs.
50676_197 1
For H/H1/H2 dimensions see below: .
Description Height Under a load

of
Valve spring height: –
84276322A 31/05/2010
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Description Height Under a load

of
free spring H 47.75 mm (1.880 in) 0 kg (0.00 lb)
H1 P1 35.33 mm (1.39 in) 339.8 kg

(749.13 lb)
H2 P2 25.2 mm (0.99 in) 741 kg
(1633.63 lb)
Camshaft Bushing - Dimension
BAIL07APH367FMA 1
* Height to be obtained after driving the bush
For camshaft data refer to Valve drive Camshaft - Dimension (B.10.A)
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Crankshaft - Dimension
BAIL07APH420FMA 1
MAIN CRANKSHAFT TOLERANCES
TOLERANCES CHARACTERISTIC SUBJECT OF GRAPHIC SYMBOL

TOLERANCE
SHAPE Circularity
Cylindricity
ORIENTATION Parallelism
Perpendicularity
Straightness
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Total oscillation
Taper
CLASS OF IMPORTANCE GRAPHIC SYMBOL

ASSIGNED TO PRODUCT
CHARACTERISTICS
CRITICAL
IMPORTANT
SECONDARY
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80746_212 2
Refer to Crankshaft - Measure (B.10.A).
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Connecting rod and piston Piston - Dimension
BAIL07APH363ESA 1
Piston with pin tunnel and plastic rings
NOTE: * Value measured on 101 mm (3.98 in) diameter.
BAIL07APH364ESA 2
Mondial piston ,pins and split rings
NOTE: * Value measured on 101 mm (3.98 in) diameter.
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Connecting rod and piston Connecting rod - Dimension
BAILAPH07366BMA 1
CONNECTING ROD, PISTON PIN BUSHING AND HALF BEARING DATA
* Inside diameter to be measured after installing in the small end and regrinding with a reamer.
NOTE: The connecting rod - connecting rod cap mating surfaces are knurled for a better coupling. It is therefore
recommended not to remove the knurling. The rods are manufactured using a fracture breaking technique making
each rod and cap unique and having only one way of installation. Refer to Connecting rod and piston - Measure
(B.10.A).
Piston Pin - Dimension

Part Dimension
Piston pin 37.994 - 38.000 mm (1.4958 - 1.4961 in)
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Cylinder block - Dimension
BAIL07APH373HMA 1
NOTE: If the cylinders need regrinding make sure all are bored to the same oversize 0.4 mm (0.0157 in)
84276322A 31/05/2010
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Cylinder head - Dimension
70325_97 1
Cylinder Head mating surface check.
The dimension (A) should be 105 mm (4.1339 in) ± 0.25 mm (0.0098 in)
Maximum metal removal should not exceed dimension (B) by 1 mm (0.0394 in)
NOTE: After grinding check valve seating. Regrind the valve seats if required to obtain the specified value.
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Cylinder head Valve seat - Dimension

Valve Seat Data
70331_100 1
Cylinder Head Seat Data
70332_101 2
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Valve drive Camshaft - Static description
BAIL07APH368GMA 1
(A) - Intake (B) - Exhaust
Internal exhaust gas recirculation is employed to return some exhaust gas back into the combustion chamber to re-
duce exhaust emissions. An extra lobe on the cam shaft enables exhaust gas recirculation via the exhaust valve
during the intake cycle by keeping the exhaust valve open for a short while. The exhaust gases are partially redi-
rected into the cylinders in order to reduce the maximum combustion temperature values which are responsible for
the production of nitrogen oxide (NOx), and this reduces the emissions reaching the atmosphere.
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Valve drive Rocker assembly - Component identification

Component Parts of Rocker Arm Assembly
80695 1
1.Bolts 2.Support
3.Spindles (Refer to Valve drive Rocker 4.Rocker arms (Refer to Valve drive Rocker assembly - Dimension
assembly - Dimension (B.10.A)). (B.10.A)).
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Valve drive Rocker assembly - Static description
CRIL04E014G01 1
Valve control
(1) Rocker arm

(2) Arbour support
(3) Adjusting screw
(4) Rod
(5) Lock cones
(6) Cup
(7) Spring
(8) Tappet
(9) Distributing shaft
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Auxiliary drive - Static description

A poly-V belt (4) transmits the motion of drive shaft (5) to water pump (1) alternator (2) and fan (6).
The belt is stretched by means of automatic belt tensioner (3).
CRIL04J021G01 1
Auxiliary component drive
(1) Water pump

(2) Alternator
(3) Belt tensioner
(4) Poly-V belt
(5) Drive shaft
(6) Fan pulley
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Crankshaft - Static description

It is made of steel and rests on five induction-hardened supports .
Inside the drive shaft are the lubricating oil ducts .
The following items are force fitted on the front shank: oil pump drive gear (1), phonic wheel, damper flywheel and
auxiliary component drive pulley.
The following items are force fitted on the rear shank: distributing shaft drive gear (2) and engine flywheel mounting
hub (5).
The main half bearing are made of steel with anti-friction alloy coating.
The second main half bearing (4) is equipped with a shoulder to restrain the drive shaft end play.
CRIL04J014F01 1
Crankshaft
(1) Oil pump control gear

(2) Crankshaft control gear
(3) Main half bearing
(4) Shoulder half bearings
(5) Hub for engine flywheel
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Connecting rod and piston - Exploded view
80647 1
1. Retaining rings 2. Pin

3. Piston 4. Piston rings
5. Bolts 6. Half bearings
7. Connecting rod 8. Bushing
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Connecting rod and piston Connecting rod - Component

identification
80339 1
Each connecting rod is marked: -

On the body and cap with a number indicating their coupling and the cylinder in which it is mounted. In the event of
replacement, number the new rod with the same number as the replaced connecting rod. -
On the body of the connecting rod with a letter indicating the weight class of the connecting rod mounted in production:
V, 1600 to 1640 g (3.5274 to 3.6156 lb) (marked in yellow)
W, 1641 to 1680 g (3.6178 to 3.7038 lb) (marked in green)
X, 1681 to 1720 g (3.7060 to 3.7920 lb) (marked in blue)
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Connecting rod and piston - Static description

They are steel-stamped, of the oblique cut type, with separation of the cap obtained by an advanced technology
(fracture split) instead of mechanic machining.
The connecting rod half bearings are made of steel, with anti-friction alloy coating.
CRIL04D023F 1
Connecting rods
84276322A 31/05/2010
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The combustion chamber is machined in the piston crown. The crown of the piston is cooled by the engine oil supplied
by the sprayer.
There are three grooves that house the compression rings; the 1st of which is V shaped and is obtained using a cast
iron insert.
The following references are engraved on the crown of the piston:
- (1) Spare part and engineering change number.
- (2) Arrow indicating the direction of insertion of the piston in the cylindrical liner; it must be facing towards the front
side of the engine block.
- (3) Date of manufacture.
- (4) Stamp indicating testing of the 1st hollow insert.
CRIL04J015F01 2
Pistons
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Flywheel - Static description

The flywheel (1) locates onto the crankshaft in one position only , using dowels in the crankshaft to provide the
correct position for the fastening screw holes (2) .
CRIL04J020G01 1
Engine flywheel
84276322A 31/05/2010
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Balancer - Static description

The additional weights are located inside the oil sump, fastened to the engine block.
The additional weights must be timed as indicated below:
Make the signs (A) engraved on the gears for timing,
Insert the pin into the hole (B) in the balancing mass to bloc rotation of this temporarily.
BACD04APH077FSA 1
Additional counterweight timing operations
(1) Retaining bolts

(2) Mounting
(3) Retaining bolts
(4) Gear
(5) Balancing weight
(6) O-ring
(7) Ring
(8) Gear
(9) Counter-rotating shaft
(10) Half bearings
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Cylinder block - Static description

The cylinder block is an alloy cast iron with deep cylinder skirts, and it also incorporates the coolant circulation cham-
bers and the engine member lubricating circuit ducts.
The cylinder bores are machined integral with the cylinder block, during the manufacturing process.
Cylinders are in line and vertical and numbered 1 to 4 from the front to the rear of the engine.
The block incorporates hydraulic tappets which do not require adjustment unless engine is being reassembled.
CRIL04J013G01 1
Crankcase
(1) Cylinder Number 1

(2) Seat for the water pump
(3) Seat for the oil pump
(4) Seat for distributing shaft bushings
(5) Bed supports
84276322A 31/05/2010
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Cylinder head - Static description

The seats of the following parts are obtained from the cast-iron cylinder head:
- Insert valve seats (4)
- Injector (6)
- Thermostat (5)
Moreover, the following components are inserted on the heads:

- Single - block exhaust manifold (1)
- Intake manifold (2) with seat for cold start air heater (3).
CRIL04J018G01 1
F4GE0454C engine
Detail of the cylinder head with valve seats
84276322A 31/05/2010
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CRIL04E016F01 2
Valves and valve seats
(1) Intake valve (2) Exhaust valve

(A) Intake side (S) Exhaust side
The valve seats inserted in the cylinder head have the following inclination:
- 45 ° (exhaust valves)
- 60 ° (intake valves)
The exhaust valves (2) differ from the intake valves (1) in that they have only one notch at the stem end.
CRIL04E017F 3
The detail of the figure 4 shows the oil seals mounted on valve stems
84276322A 31/05/2010
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CRIL04J019F01 4
Valve guides : (B) Intake - (C) Exhaust
(ØA) = 8.019 - 8.039 mm
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ENGINE - Remove
Prior operation:
Separate the front axle and front support from the engine - see Front - Remove (Front support and front axle)
(E.10.B).
DANGER
Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Make sure that
units or parts are supported by suitable slings or hooks. Make sure that no-one is in the vicinity of the load
to be lifted. Failure to comply could result in serious injury or death.
B012
1. Remove the engine hood - see Engine hood - Re-

move (E.20.A).
2. Disconnect the exhaust manifold from the tur-
bocharger (1). Remove the exhaust support retain-
ing bolts (2) and remove the exhaust manifold.
BVE0277A_34 1
3. Loosen the hose clamp (1) and disconnect the

coolant hose connecting the cab heater to the radi-
ator.
BVE0278A_35 2
4. Disconnect the battery positive cable (1) and the

electrical connectors (2) from the starter motor.
BVE0406A 3
84276322A 31/05/2010
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5. Loosen the hose clamps (1) and disconnect the driv-

eline oil cooler hoses.
Disconnect the tractor performance monitor radar
electrical connector (2) (if fitted).
NOTE: Note the position of the driveline oil cooler hoses.
BVE0279A_36 4
6. Disconnect the engine harness electrical connectors.
BVE0403A_37 5
7. Disconnect the cab heater coolant hose (1).

Disconnect the air conditioning hoses (2) and (3).
BVE0217A_38 6
8. Disconnect the steering cylinder oil supply hoses (1)

and (2).
NOTE: Note the position of the steering cylinder oil supply
hoses.
BVE0218A_39 7
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Tractors with Mechanical Fuel Injection Pump

9. Loosen the retaining nut (1) and detach the throttle
cable from the fuel injection pump (2).
BVE0222A_40 8
All Tractors
10. Disconnect the brake fluid lines (1), (2) and (3) from
the brake fluid reservoir.
BVE0219A_41 9
11. Disconnect the differential lock oil supply pipe (1).
BVE0282A_42 10
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12. Remove the retaining screw (1) and detach the fly-
wheel speed sensor (if fitted).
BVE0323A_43 11
Tractors with Standard Cab

13. Loosen the cab front mounting bolt while holding the
nut (1) under the cab floor. Remove the bolt and
washers. Repeat this step for the left hand side of
the cab.
BVE0233A_44 12
14. Using the locally fabricated tool (1), raise the cab
evenly.
BVE0404A_45 13
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Tractors with Air Conditioning

15. Loosen the drive belt tensioner securing nut (1), ten-
sioner bolt (2) and remove the air conditioning com-
pressor drive belt.
Disconnect the air conditioning pressure sensor elec-
trical connector (3) and the air conditioning air com-
pressor clutch electrical connector (4).
BVE0297A 14
16. Remove the air conditioning compressor, condenser,

receiver dryer and pipe work from the engine as a
complete assembly without disconnecting the pipe
work.
NOTICE: If it is not possible to remove the air conditioning
components as a complete assembly, the air conditioning
system must be evacuated (refer to the climate control sec-
tion).
It is an offence to vent the air conditioning system into the
atmosphere
BVE0298A 15
All Tractors
17. Remove the relay retaining bolts (1) and detach the
relay.
Remove the cab heater pipe support retaining bolt
(2).
BVE0299A 16
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18. Disconnect the fuel tank to fuel cooler supply line (1)
from the fuel cooler and allow the fuel to drain back
into the fuel tank.
Disconnect the fuel cooler to fuel filter supply line (2)
from the fuel cooler.
Disconnect the engine controller electrical connec-
tors (3).
BVE0300A 17
19. Disconnect the fuel supply and return lines (1) from
the fuel tank level sender.
BVE0281A_46 18

coolant hose from the expansion tank.
Disconnect the air cleaner vacuum switch electrical
connector (2).
Loosen the hose clamp (3) and disconnect the air
cleaner hose from the turbocharger.
BVE0301A 19
21. Disconnect the brake reservoir electrical connectors

(1) and the coolant level sender electrical connector
(2).
BVE0302A 20
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22. Disconnect the alternator electrical connectors.
BVE0303A 21
23. Remove the engine harness clamp retaining bolts

and reposition the engine harness on top of the en-
gine.
BVE0304A 22
24. Remove the air cleaner mounting frame retaining

bolts.
BVE0305A 23
25. Remove the air cleaner mounting frame retaining

bolts.
BVE0306A 24
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26. Using a suitable chain, connect the air cleaner

mounting frame to a hoist and remove the air cleaner
mounting frame.
BVE0307A 25
27. Remove the coolant expansion tank pipe support

bracket retaining bolt (1) and the alternator guard re-
taining bolt (2).
BVE0308A 26
28. Remove the fan belt tensioner and the support

bracket.
BVE0309A 27
29. Attach the lifting brackets to the engine.
BVE0310A 28
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30. Using a suitable chain, connect the engine to a hoist.

Remove the engine to transmission retaining bolts
and remove the engine.
BVE0311A 29
Next operation:
ENGINE - Install (B.10.A)
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ENGINE - Install
Prior operation:
ENGINE - Remove (B.10.A)
DANGER
B012
WARNING
Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS.
B020
1. Attach the lifting brackets to the engine.
BVE0310A 1
2. Using a suitable chain, connect the engine to a hoist.
BVE0311A 2
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3. Align the engine to the transmission and install the

engine to transmission retaining bolts. Tighten to the
specified torque value.
BVE0598A_47 3
4. Install the fan belt tensioner and the support bracket.
BVE0309A 4
5. Install the coolant expansion tank pipe support

bracket retaining bolt (1) and the alternator guard
retaining bolt (2).
BVE0308A 5
6. Using a suitable chain, connect the air cleaner

mounting frame to a hoist and install the air cleaner
mounting frame.
BVE0307A 6
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7. Install the air cleaner mounting frame retaining bolts.
BVE0306A 7
8. Install the air cleaner mounting frame retaining bolts.
BVE0305A 8
9. Install the engine harness clamp retaining bolts.
BVE0304A 9
BVE0303A 10
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11. Connect the brake reservoir electrical connectors (1)

and the coolant level sender electrical connector (2).
BVE0302A 11
12. Connect the coolant hose to the expansion tank and

tighten the hose clamp (1).
Connect the air cleaner vacuum switch electrical con-
nector (2).
Connect the air cleaner hose to the turbocharger and
tighten the hose clamp (3).
BVE0301A 12
13. Connect the fuel supply and return lines (1) to the
fuel tank level sender.
BVE0281A_46 13
14. Connect the fuel supply lines (1) and (2) to the fuel
cooler.
Connect the engine controller electrical connectors
(3).
BVE0300A 14
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15. Attach the relay and tighten the relay retaining bolts
(1).
Install the cab heater pipe support retaining bolt (2).
BVE0299A 15
Tractors with Air Conditioning

16. Install the air conditioning compressor, condenser,
receiver dryer and pipe work to the engine as a com-
plete assembly without disconnecting the pipe work.
BVE0298A 16
17. Install the air conditioning compressor drive belt.

Tighten the tensioner bolt (2), and the tensioner
securing nut (1).
Connect the air conditioning pressure sensor electri-
cal connector (3) and the air conditioning compressor
clutch electrical connector (4).
BVE0297A 17
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18. Using the locally fabricated tool (1), lower the cab
evenly.
BVE0404A_45 18
19. Install the cab front mounting bolt, washers and nut.
Tighten to the specified torque value. Repeat this
step for the left hand side of the cab.
BVE0233B_48 19
20. Attach the flywheel speed sensor and install the re-
taining screw (1) (if fitted).
BVE0323A_43 20
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21. Connect the differential lock oil supply pipe (1).
BVE0282A_42 21
22. Connect the brake fluid lines (1), (2) and (3) to the
brake fluid reservoir.
BVE0219A_41 22

23. Attach the throttle cable to the fuel injection pump (2)
and tighten the retaining nut (1).
BVE0222A_40 23
All Tractors
24. Install the front axle and the front support - see Front
- Install (Front support and front axle) (E.10.B).
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25. Connect the steering cylinder oil supply hoses (1)

and (2).
BVE0218A_39 24
26. Connect the cab heater hose (1).

Connect the air conditioning hoses (2) and (3).
BVE0217A_38 25
27. Connect the engine harness electrical connectors.
BVE0403A_37 26
28. Connect the driveline oil cooler hoses and tighten the
hose clamps (1).
Connect the tractor performance monitor radar elec-
trical connector (2) (if fitted).
BVE0279A_36 27
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29. Connect the battery positive cable (1) and the elec-
trical connectors (2) to the starter motor.
BVE0406A 28
30. Connect the hose connecting the cab heater to the

radiator and tighten the hose clamp (1).
BVE0278A_35 29
31. Install the exhaust manifold and the retaining bolts

(2). Connect the exhaust to the turbocharger (1).
BVE0277A_34 30
32. Install the engine hood - see Engine hood - Install

(E.20.A).
33. Bleed the brake system - see SERVICE BRAKE Hy-
draulic - Bleed (D.30.C).
34. Refill the driveline with the correct specification oil -
see Consumables Lubrications and Coolants.
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ENGINE - Disconnect (Engine / Transmission)
DANGER
B012
1. Drain the cooling system - see ENGINE COOLANT

SYSTEM - Drain fluid (B.50.A).
2. Disconnect the battery cable - see Battery - Discon-
nect (A.30.A).
3. Using a suitable sling, connect the front weights to a
hoist and remove the front weights (if fitted).
BSB0181A_10 1
4. Disconnect the exhaust manifold from the tur-

bocharger (1). Remove the exhaust support retain-
ing bolts (2) and remove the exhaust manifold.
BVE0277A 2

coolant hose connecting the cab heater to the radi-
ator.
BVE0278A 3
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6. Disconnect the battery positive cable (1) from the

starter motor.
BVE0280A 4
7. Loosen the hose clamps (1) and disconnect the driv-

eline oil cooler hoses.
Disconnect the tractor performance monitor radar
electrical connector (2) (if fitted).
NOTE: Note the position of the driveline oil cooler hoses.
BVE0279A 5
8. Disconnect the engine harness electrical connectors.
BVE0403A 6
9. Disconnect the cab heater coolant hose (1).

Disconnect the air conditioning hoses (2) and (3).
BVE0217A 7
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10. Disconnect the steering cylinder oil supply hoses (1)

and (2).
NOTE: Note the position of the steering cylinder oil supply
hoses.
BVE0218A 8

11. Loosen the retaining nut (1) and detach the throttle
cable from the fuel injection pump (2).
BVE0222A 9
All Tractors
12. Disconnect the brake fluid lines (1), (2) and (3) from
the brake fluid reservoir.
BVE0219A 10
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13. Disconnect the fuel supply and fuel return lines (1)
from the fuel tank level sender.
BVE0281A 11
14. Disconnect the differential lock oil supply pipe (1).
BVE0282A 12
15. Remove the retaining screw (1) and detach the fly-
wheel speed sensor (if fitted).
BVE0323A 13
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16. Loosen the cab front mounting bolt while holding the
nut (1) under the cab floor. Remove the bolt and
washers. Repeat this step for the left hand side of
the cab.
BVE0233A 14
17. Using locally fabricated tool (1), raise the cab evenly.
BVE0404A 15
Tractors with Standard axle

18. Remove the four wheel driveshaft - see Shaft - Re-
move (Standard axle) (D.14.C).
Tractors with Suspended axle

19. Remove the drive shaft cover plate.
BAIL07APH076AVA 16
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20. Remove the drive shaft bearing carrier.
BAIL07APH077AVA 17
21. Release the circlip (1) and drift the sleeve (2) back-
wards.
BAIL07APH081AVA 18
All Tractors
BVE0283A 19
All Tractors
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22. Position splitting kit (4) 380000569 underneath the

tractor.
23. Use the supports (3), in the splitting kit to support the
transmission on the splitting stand.
24. Remove the engine to transmission lower retaining
bolts.
25. Remove two rear oil pan retaining bolts from the left
hand side. Repeat this step for the right hand side.
26. Install the adaptor plate (1) 380000844 and the en-
gine support brackets (2) 380000500 between the
engine and the wheeled splitting trolley.
27. Position wooden wedges (1) between the front axle
and the front support. These prevent articulation of
the front axle.
BVE0410A_15 20
28. Check that all necessary hoses tubes and electrical

connectors have been disconnected. It may be nec-
essary to disconnect additional items due to other op-
tional equipment that has been installed on the trac-
tor.
Recheck that the engine and transmission are safely
supported on the splitting stand. Remove the engine
to transmission retaining bolts.
Remove the front support and engine from the trans-
mission.
BVE0320A 21
Next operation:
ENGINE - Connect (Engine / Transmission) (B.10.A)
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ENGINE - Connect (Engine / Transmission)

Prior operation:
ENGINE - Disconnect (Engine / Transmission) (B.10.A)
1. Align the front support and engine assembly to the

transmission and install the engine to transmission
retaining bolts. Tighten to the specified torque value.
Remove the tractor splitting kit.
BVE0598A 1
Tractors with Standard axle

2. Install the four wheel driveshaft - see Shaft - Install
(Standard axle) (D.14.C).
Tractors with Suspended axle

3. Drift the sleeve back onto the drive shaft (1) and in-
stall the circlip (2) .
BAIL07APH081AVB 2
4. Install the drive shaft bearing carrier.
BAIL07APH077AVA 3
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5. Install the drive shaft cover plate.
BAIL07APH076AVA 4

6. Using the locally fabricated tool (1), lower the cab
evenly.
BVE0404A 5
7. Install the cab front mounting bolt, washers and nut.

Tighten to the specified torque value. Repeat this
step for the left hand side of the cab.
BVE0233B 6
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8. Attach the flywheel speed sensor and install the re-

taining screw (1) (if fitted).
BVE0323A 7
9. Connect the differential lock oil supply pipe (1).
BVE0282A 8
10. Connect the brake fluid lines (1), (2) and (3) to the
brake fluid reservoir.
BVE0219A_19 9
11. Connect the fuel supply and fuel return lines (1) to
the fuel tank level sender.
BVE0281A 10
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12. Attach the throttle cable to the fuel injection pump (2)
and tighten the retaining nut (1).
BVE0222A 11
All Tractors
13. Connect the steering cylinder oil supply hoses (1)
and (2).
BVE0218A 12
14. Connect the cab heater hose (1).

Connect the air conditioning hoses (2) and (3).
BVE0217A 13
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15. Connect the engine harness electrical connectors.
BVE0403A 14
16. Connect the driveline oil cooler hoses and tighten the
hose clamps (1).
Connect the tractor performance monitor radar elec-
trical connector (2) (if fitted).
BVE0279A 15
17. Connect the battery positive cable (1) to the starter

motor.
BVE0280A 16
18. Connect the hose connecting the cab heater to the

radiator and tighten the hose clamp (1).
BVE0278A 17
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19. Install the exhaust manifold and the retaining bolts

(2). Connect the exhaust to the turbocharger (1).
BVE0277A 18

hoist and install the front weights (if fitted).
BSB0181A_10 19
21. Connect the battery cable - see Battery - Connect

(A.30.A).
23. Refill the cooling system - see ENGINE COOLANT
SYSTEM - Filling (B.50.A).
24. Bleed the brakes - see SERVICE BRAKE Hydraulic
- Bleed (D.30.C).
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ENGINE - Overhaul External Components

Prior operation:
Battery - Disconnect (A.30.A) ENGINE - Remove (B.10.A)
1. Some of the operations described in this section can

be carried out directly with the engine fitted on the
vehicle, depending on access to the engine bay and
on the version.
NOTE: The operations for removing the engine, as those
for overhaul, must be performed by skilled personnel using
specific tools. Refer to ENGINE - Torque (B.10.A).
2. Operations for preparing the engine for assembly on
the rotating stand
To be able to fit the brackets 380001298 (for fixing
the engine to the overhaul stand, 380000301 to the
crankcase, it is necessary to work from the left–hand
side of the engine:
Remove the fuel filters (6) from the mounting (1);
Disconnect the electrical connection (2) from the
mounting (1) and the one to the heater (again lo-
cated on the filter mounting);
Disconnect the fuel pipes (3) - (4) - (5) from the
mounting (1);
Remove the bracket supporting the mounting (1)
from the crankcase.
80372 1
NOTE: To disconnect the fuel pipes (3) — (4) — (5), Figure
1 from the relevant fittings, you need to press the clip (1)
as shown in Figure (B).
After disconnecting the piping, put the clip (1) back in its
locking position Figure (A) to prevent it getting buckled.
3. Disconnect the high-pressure fuel pipe ( (7), Figure
1) from the rail choke tube and from the high-pres-
sure pump (8) and remove it from the crankcase by
taking out the bracket.
Disconnect the pipe (9) from the high-pressure pump
(8).
NOTE: Due to the high pressure in the piping from the
high-pressure pump to the rail and from here to the elec-
tro-injectors, never:
- disconnect the pipes with the engine running,
- reuse disconnected pipes.
WARNING
Do NOT loosen or tighten high pressure fuel lines while 80628 2
the engine is running. Failure to comply will result in
death or serious injury.
M1042
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4. Unscrew the fixing screws and remove the starter

motor (2) from its seat.
BAIL07APH375BMA 3
5. Working from the right-hand side of the engine, dis-

connect the lubricating pipe (1) from the top of the
cooler to the turbo-blower (2).
Remove the thermostat body together with the seal.
6. Unscrew and remove bolt (3) retaining lubrication re-
turn pipe to crankcase.
7. Unscrew and remove turbocharger to exhaust man-
ifold retaining nuts (4) and lubrication pipe securing
bolts (2).
8. Supporting the turbocharger, lift from exhaust mani-
fold and remove gasket.
BAIL06CCM058ASA 4
9. Fit brackets 380001298 into the holes (1) and (2)

in the crankcase on both sides and, using these
brackets, secure the engine to the rotating stand
380000301. Drain off the engine oil by removing the
plug from the sump.
80401 5
84276322A 31/05/2010
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BAIL07APH407GMA 6
Injection System Components
1 Connection for electro-injectors 2 Engine coolant temperature sensor

3 Fuel pressure sensor cable 4 Engine oil pressure and temperature sensor
5 Crankshaft sensor 6 Electro-injector
7 Air pressure temperature sensor 8 Timing system phase sensor
9 Fuel temperature sensor 10 Pressure regulator wiring
11 EDC7C control unit
10. Disconnect the engine cable from the connectors: (
(1), figure 6) electro–injector wiring (6); (7) air pres-
sure/temperature sensor; (3) fuel pressure sensor;
(11) control unit; (10) high– pressure pump sensor;
(8) timing system phase sensor; (2) engine coolant
temperature sensor on thermostat; (5) engine speed
sensor.
Take off the clamps fastening it to the crankcase and
remove it completely.
84276322A 31/05/2010
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11. Disconnect the following from the rail (2): fuel pipe
(7). Disconnect the fuel pipes (5) from the rail (2)
and from the manifolds (6) for the electro-injectors.
Remove the screws (1) and detach the rail (2).
NOTE: When locking the fittings (4) securing the pipes (6)
to the rail (2), using an appropriate wrench, you must pre-
vent the flow limiters, if fitted, (3) from turning.
80376 7
12. Disconnect the piping from the fuel return pressure

limiter (1), working on the connections as described
in ENGINE - Overhaul (B.10.A).
Undo the nuts (3) and take off the tappet cover (4).
BAIL07APH408AMA 8
13. Remove the nuts (3) and remove the fuel manifolds
(4). Remove the nuts (6) and disconnect the electric
cables from the electro–injectors (5).
Take out the screws (1) and remove the electro–in-
jector wiring mounting (2) together with its seal.
.
.
NOTE: Once removed, the fuel manifolds (4) must not be
reused; they must be replaced with new ones.
BAIL07APH414AMA 9
84276322A 31/05/2010
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14. Loosen the tappet adjuster fixing nuts (1) and un-
screw the adjusters.
Take out the screws (2), remove the rocker-arm as-
sembly (3) comprising the mounting (6), rocker arms
(4) and spindles (5) then remove the bridges (7) from
the valves.
Remove the rods (8).
80640 10
15. Take out the screws securing the electro-injectors

and, using tool 380001099 (1), extract the electro-in-
jectors (2) from the cylinder head.
80686 11
16. Working on the tightener (1), extract the belt (12)

from the pulleys of the alternator, coolant pump and
snub pulleys.
Unscrew the bolt (2) and remove the tightener;
Remove the snub pulley (6), unscrew the bolts (7)
and remove the pulley (8) from the mounting be-
neath.
Unscrew the bolts (10) and remove the tightener
mounting.
Unscrew the bolts (11) and remove the mounting (9)
from the crankcase.
Unscrew the bolts (3) and remove the coolant pump
(4).
Unscrew the bolt and remove the engine speed sen-
sor (5)
80378 12
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17. From the opposite side, unscrew the bolts (2) and
(3) securing the intake manifold (1) and remove it
together with the air heater for cold starts.
BAIL07APH400AMA 13
18. Remove the bolts (1) from the cylinder head (2).
BAIL07APH409BMA 14
19. Hook up the brackets, 380001073 (1) with a suitable

sling and, using a hoist, remove the cylinder head (2)
from the crankcase.
BAIL07APH410AMA 15
84276322A 31/05/2010
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20. Remove the oil filter (1).

Unscrew the retaining bolts and remove the alterna-
tor (2).
80380 16
21. Unscrew the retaining bolts (1) and remove the pipe
fitting (2).
80326 17
22. Disconnect the connector (1) from the oil pressure

–temperature sensor.
Unscrew the bolts (2) and remove the oil pressure
temperature sensor (3).
Unscrew the bolts (4) and remove the oil filter mount-
ing (5) from the crankcase together with its seals.
Remove the cooler from its seat.
80400 18
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23. Remove the nuts (1) and detach the high-pressure

pump (2) together with the feed pump (3).
80381 19
24. Install the engine locking tool, 380000988, (1),

Loosen the screws fixing the flywheel to the crank-
shaft.
BSF4479A 20
25. Unscrew the bolts (1), remove the pulley (2), spacer
(3) and pulley (4).
The engine flywheel locking tool can help with disas-
sembly of the damper flywheel (2) fitted on the pulley
(4).
80382 21
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26. Extract the front cover shaft seal. Apply tool

380000665 (4) on the front tang (2) of the crankshaft.
Perforate the inner seal (1) with a drill bit (Æ 3.5 mm
( 0.0138 in.)) through the tool’s guide holes, for a
depth of 5 mm ( 0.1969 in).
Secure the tool to the seal by screwing down the 6
screws supplied. Extract the seal (1) by screwing
down the screw (3).
80595 22
27. Use a suitable hooked device (3) with the aid of the
lever (4) extract the outer seal (2) from the front cover
(1).
80596 23
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28. Take out the screws (1) and remove the oil pump (2).
NOTE: Note down the assembly position of the screws (1)
as they have different lengths.
80330 24
29. Remove two opposing screws (1) where the extrac-

tion pins are to go in (see following figure).
Unscrew the remaining screws securing the flywheel
(3) from the crankshaft (2).
Remove the tool locking the flywheel (4).
BSF4476A_114 25
30. Screw two screws of suitable length into the holes (4)
to sling the flywheel with a lift.
Using the two guide pins (2) previously screwed into
the holes of the crankshaft (3), guide the extraction
of the engine flywheel (1) with the aid of a lift.
80356_115 26
31. Extract the seal, applying tool 380000663 (3) onto

the rear tang (5) of the crankshaft.
Perforate the inner seal with a drill bit (Æ 3.5 mm
( 0.0138 in.)) through the tool’s guide holes, for a
depth of 5 mm ( 0.1969 in.).
Secure the tool 380000663 (3) to the seal (1) by
screwing down the 6 screws supplied (4). Extract
the seal (1) by screwing down the screw (2).
Use a suitable hooked device with the aid of the lever
extract the outer seal from the front cover.
80597 27
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32. Turn the engine over.

Take out the screws (2) and remove the oil sump (1).
Disconnect the high–pressure pump phase sensor.
Unscrew the bolt (3) and remove the timing gear box
(4) from the crankcase.
BAIL07APH411AMA 28
33. Take out the screws (1) and remove the gear (3) from
the camshaft (2).
80397 29
NOTE: For further disassembly of the engine block internal components, crankshaft, pistons, camshaft etc. : Refer
to ENGINE - Overhaul (B.10.A).
INSTALLATION
34. Using a felt tip pen mark the gear tooth (1) mounted
on the engine shaft (2) on the upper surface where a
groove has been created for the ignition timing.
NOTE: Screw two pins into the gear as shown to enable
shaft rotation.
BAIL07APH412AMA 30
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35. Turn the engine shaft and camshaft so that the tooth
with the marked gear coincides with the marks on the
bevel gear.
BAIL07APH413AMA 31
36. Install the bolts (1) to fix the gear (2) to the camshaft
(3). Tighten to 36 Nm (26.55 lb ft).
BAIL06CCM067ASA 32
37. Install rear cover. For further information refer to

Rear cover - Install (B.10.A).
38. Fix tool 380000664 (6) to the rear output shaft (5).
Secure it by bolts (4) and fit the new sealing ring (3).
Position the outer part of the tool (1) onto the shaft (5)
and screw nut (2) until the sealing ring (3) is located
correctly in the housing.
80384 33
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39. Make sure that the mating surfaces are clean.

Install a new seal (1) and lubricate with clean en-
gine oil. CASE AKCELA NO. 1 ENGINE OIL SAE
15W-40 .
BVE0374A 34
40. Install the coolant pump. Tighten the retaining bolts

to the specified torque value. Refer to ENGINE
COOLANT SYSTEM - Torque (B.50.A).
BAIL07APH246AVA 35
41. Remove seal (2)from the front cover (1). Clean the
surface thoroughly.
80347_130 36
42. Thoroughly clean the surface on the engine block

and position gasket (1) on the block.
80348_131 37
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43. Position the oil pump on the block and tighten the
bolts to 24 Nm (17.70 lb ft) ± 4 Nm (2.95 lb ft)
80349 38
44. Position tool 380000666 (4) to the front output shaft

(6) . Secure it by bolts (5) and fit a new seal (7).
Position part (2) on part (4) and screw nut (3) until
the seal is seated in the front cover (1).
80350_133 39
45. Position the damper and pulley on the shaft Tighten

bolts to 110 Nm (81.13 lb ft).± 5 Nm (3.69 lb ft)
80382 40
46. Fit a new gasket. Position the oil pan (1) on the block
and tighten the bolts (2) to the prescribed torque.
For further information refer to ENGINE - Torque
(B.10.A).
BAIL07APH415AMA 41
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47. Check the contact surface of the clutch plate (1). If

scratched machine the plate accordingly. Check the
ring gear teeth (2). If there is any excessive wear
or broken teeth, remove ring gear from the flywheel
using a suitable hammer. Fit a new ring gear by
heating it to 150 °C (302.00 °F) for 15 to 20 minutes.
The chamfer on the inside of the ring gear should be
facing the flywheel.
80617_134 42
48. Screw two manoeuvring hooks on to the flywheel

using holes (4) . Using a suitable hoist bring the
flywheel closer to its seat in the flywheel housing.
Screw two pins (2) of suitable length to fit in holes
(3) and use them as guides. Place the flywheel in
the housing.
80356_135 43
49. Screw the flywheel fixing screws (1) onto the engine
shaft (2). Use the engine locking tool (4) to prevent
the flywheel (3) rotating. Tighten M12 bolts to 85 Nm
(62.69 lb ft)± 10 Nm (7.38 lb ft) and M10 to 49 Nm
(36.14 lb ft)± 5 Nm (3.69 lb ft)
BSF4476A_136 44
50. Fit a new gasket (1), the heat exchanger (2), a gasket
(3) and the oil filter support (4). Tighten the screws
to 24 Nm (17.70 lb ft) ± 4 Nm (2.95 lb ft).
80359_138 45
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51. Lubricate the sealing ring (2) with engine oil and
place on the oil filter (1). Screw the oil filter onto
the support until the sealing ring makes contact with
the housing. Then tighten a further ¾of a turn. Do
not overtighten. Fit a new seal on the oil tempera-
ture/pressure sensor and fit it on the support.
80360_139 46
52. Fit the pipeline union (2) to the block and tighten bolts
to the prescribed torque.
80326_112 47
53. Fit a new gasket to the engine block and position the
cylinder head (2) on the block.
BAIL07APH410AMA 48
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54. Refit the high pressure pump (2) and tighten the nuts
(1) to the specified torque
80381 49
55. Refit the belt tensioner (1) and tighten bolt (2) to the
prescribed torque. Refit the mounting (9) Refit the
pulley (6).
80378 50
56. Tighten the bolts on the cylinder head. in 3 steps

Refer to Cylinder head - Tighten (B.10.A) and EN-
GINE - Dimension (B.10.A). For the required torque
settings, refer to ENGINE - Torque (B.10.A) .
Step 1 .Tighten to the required torque settings.
Step 2 .Tighten a further 90 ° ± 5 ° using a torque
angle tool (3).
Step 3. Tighten again a further 90 ° ± 5 °.
80689_91 51
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57. Fit a new seal (2) lubricated with petroleum jelly and
a new sealing washer (3) on the injector (1) .
80691 52
58. Fit injectors (1) on the cylinder head seats, making

sure the fuel inlet hole (2) is facing the fuel manifold
seat (3) side.
80692 53
59. Use tool 380001099 (1) to fit the injector (2) to its
seat. Screw in the injector bolts without tightening
them.
60. Fit a new seal lubricated with petroleum jelly on to
the fuel manifold (2) and fit it into the cylinder head
seat so that the positioning ball (5) is in line with the
notch on the housing (4) .
NOTE: Disassembled fuel manifolds (2) must not be
reused . They should be replaced with new manifolds.
80693 54
84276322A 31/05/2010
B.10.A / 95
61. Use a torque wrench to gradually and alternately

tighten the injector retaining screws (1) to a torque
of 8.5 Nm (6.27 lb ft) ± 0.8 Nm (0.59 lb ft).
Tighten the fuel manifold (3) nuts (2) to 50 Nm (36.88
lb ft) .
80694 55
62. Refer to Valve drive Rocker assembly - Compo-

nent identification (B.10.A), Valve drive Rocker
assembly - Dimension (B.10.A) and Camshaft
Push rod - Visual inspection (B.10.A).
63. Fit rocker control rods (2). Position the bridges (1) on
valves with marks ( → ) facing the exhaust manifold.
80697 56
64. Check that the tappet adjusters (1) are loose to

prevent them sticking to the rods when refitting the
rocker assembly. Fit the rocker assemblies compris-
ing the support (5), rocker arms (3), and spindles
(4). Secure them to the cylinder head by tightening
the retaining bolts to 36 Nm (26.55 lb ft). To adjust
clearance between rockers and valves refer to Valve
drive Camshaft - Dimension (B.10.A).
80698 57
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65. Apply Loctite 5999 onto the mating surface of the in-
take manifold (1) and tighten the bolts (2) and (3) to
the prescribed torque. Fit temperature and air pres-
sure sensor.
BAIL07APH400AMA 58
66. Check electrical cable (5) condition and replace if

damaged by cutting the support (2) clamps and re-
moving the screws (4) that secure it to the connec-
tions. Fit a new gasket (1) on to the support (2).
BAIL07APH403AMA 59
67. Fit the wiring support (2) and tighten the screws (1)
to the specified torque. Connect the electric cables
to the electro-injectors (3) and using torque wrench
380000158 tighten the retaining nuts to the specified
torque.
BAIL07APH416AMA 60
68. Fit the rocker cover. (Refer to Valve cover - Install

(B.10.A))
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69. Mount the rail (2) and tighten the retaining screws (1)
to the specified torque . Connect new fuel pipes (6)
to the rail and to the manifold for electro-injectors (5).
NOTE: The pipe joints (3) must be tightened to 20 Nm
(14.75 lb ft) .
BAIL07APH417AMA 61
70. Press the clamp (1) in arrow direction (B) and con-
nect the pipe to the rail. Reset the clamp to position
(A).
80628 62
71. Refit exhaust manifold. (Refer to Exhaust manifold

- Install (B.40.A).
72. Install the turbocharger. (Refer to Turbocharger -
Install (B.30.A).
73. Connect pipe (2) to the fuel pressure limiter (1) . Con-
nect the external vent pipe (3) to the rocker cover and
the crankcase.
BAIL07APH418AMA 63
74. Remove the engine from the stand using a suitable

hoist and place on a suitable support. Remove en-
gine lifting brackets.
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75. Refit the oil filling pipe (1) and the starter motor (2).
BAIL07APH375BMA 64
76. Assemble the bracket and support (1) of the fuel filter
(6). Connect the fuel pipes in sequence (9) (3) (4)
and (5).to the pump (8).
80372 65
77. Reconnect the engine harness to all sensors, engine

control module, and rail diffuser.
NOTICE: Always check connections for leaks before running engine at operating level
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ENGINE - Overhaul Internal components

Prior operation:
ENGINE - Overhaul (B.10.A)
1. Take out the screws (1) securing the connecting rod

caps (2) and remove them.
NOTE: Mark the caps to ensure that they are refitted to the
original rod in the original position.
80598 1
2. Extract the pistons together with the connecting rods

from the top of the crankcase.
NOTE: Keep the half bearings in their respective housings
since, if they are used, they must be mounted in the posi-
tion found upon disassembly.
3. Take out the screws (1) and remove the main bearing
caps (2).
80599 2
4. The penultimate main bearing cap (1) and the related

mounting have the half bearing (2) equipped with a
shoulder ring.
NOTE: Note down the assembly position of the top and
bottom half bearings since, if they are reused, they must
be mounted in the position found upon disassembly.
80600_116 3
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5. Using suitable lifting hooks (1) lift and remove the

crankshaft (2) from the cylinder block.
BAIL07APH419AMA 4
6. Remove the main half bearings (1); take out the

screws (2) and remove the oil nozzles (3).
80602 5
7. Take out the screws (1) and remove the plate (2)
retaining the camshaft (3).
NOTE: Note down the assembly position of the plate (2).
80333 6
8. Carefully extract the camshaft (1) from the

crankcase.
80334 7
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9. Extract the tappets (1) from the crankcase.
80603 8
10. Inspect and check the cylinder block dimensions,

(Refer to Cylinder block - Overhaul (B.10.A) Cylin-
der block - Measure (B.10.A) and Cylinder block -
Dimension (B.10.A))
11. Camshaft pin and cam surfaces should be absolutely
smooth. If there is any evidence of seizing or scoring
replace the camshaft and bushes. Refer to Valve
drive Camshaft - Measure (B.10.A) and Cylinder
block - Overhaul (B.10.A)
12. Lubricate the tappets (1) and fit them into the relevant
housings on the block
80336 9
13. Lubricate the camshaft bush and fit the camshaft (1)
taking care not to damage the bush or the housing.
80334_117 10
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14. Position the plate (1) retaining the camshaft (3) with
the slot facing towards the top of the crankcase
and the punchmark facing the operator. Tighten the
screws (2) to the prescribed torque, refer to ENGINE
- Torque (B.10.A).
80337 11
15. Using a Dial Test indicator and a suitable lever, check

the end float of the camshaft (1).
Locate the dial indicator to the end of the camshaft,
using the lever, apply light pressure to move the
camshaft one way. Set the dial indicator to "zero",
apply light pressure in the opposite direction with
the lever. The reading must be 0.23 mm +/- 0.13
( 0.0091 in +/- 0.0051.).
80338 12
16. Fit nozzles (2) and tighten the retaining screws (1) to
the specified torque.
80605 13
17. Inspect and check the crankshaft . Grind journals

and crank pins if seizing , scoring, or excessive oval-
isation is found. Before grinding the pins measure
them with a micrometer (1)to decide the final diam-
eter by which the pins (2) should be reduced. Refer
to Crankshaft - Measure (B.10.A) and Crankshaft
- Dimension (B.10.A).
80631 14
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18. Check that the gear teeth (1) on the shaft (2) are not
damaged or worn. If required remove gear using a
suitable puller (3). When fitting a new gear heat it
to 180 °C (356.00 °F) for 10 minutes in an oven and
then key it to the crankshaft.
BAIL07APH421AMA 15
19. Refit the main bearings that have not been replaced
in the same position they were found at removal.
Main bearings are supplied as spares with 0.250 mm
(0.01 in) - 0.500 mm (0.02 in) undersize on the in-
ternal diameter. Clean the bearings and fit them into
the housings. The second to last bearing (1) is fitted
with shoulder half rings
80606_118 16
20. Using a suitable tool and hoist refit the crankshaft into
the cylinder block.
BAIL07APH419AMA 17
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21. Check the backlash between the crankshaft main

journal and the relevant bearings as follows;
Make sure the parts are perfectly clean and remove
all traces of oil.
Position a length of calibrated wire (3) on the crank-
shaft journals (4) , parallel to the crankshaft centre
line
Fit the caps (1)complete with half bearings (2) on th
relevant supports.
80608_159 18
22. Before reusing the retaining bolts refer to ENGINE -

Dimension (B.10.A)
Screw in the pre lubricated bolts and tighten them in
three successive stages:
1st stage - with a torque wrench tighten to 50 Nm
(36.878 lb ft) ± 3 Nm (2.213 lb ft)
2nd stage - tighten to 80 Nm (59.005 lb ft) ± 5 Nm
(3.688 lb ft)
80609_121 19
23. 3rd stage - Using a suitable angle gauge tighten the

bolts a further 90 ° ± 5 °
24. Remove the support caps
The clearance between the main bearings and the
relevant journals is measured by comparing the
width of the calibrated wire (2) , at the most narrow
point with the graduation of the scale of the scale
on the case containing the calibration wire. The
numbers on the scale indicate the mating clearance
(backlash) in millimetres. If the clearance is found
to be other than as prescribed , change the half
bearings and repeat the check. Once the correct
clearance has been obtained lubricate the bearings
and permanently mount the supports. Tighten the
retaining bolts as previously described.
80641_162 20
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25. The thrust ring clearance is checked by setting a dial

guage (2) with a magnetic base on the crankshaft (3)
as shown. The normal assembly clearance is 0.068 -
0.41 mm (0.003 - 0.016 in) . If the clearance is found
to be greater change the main half bearings of the
second from last rear thrust bearing support (1) and
check the clearance again between the crankshaft
journals and main hal bearings.
80642_163 21
26. Piston assembly - Refer to Connecting rod and pis-

ton - Exploded view (B.10.A)
NOTE: The pistons are supplied as spares with the follow-
ing sizes: Standard and 0.4 mm
27. Clean all parts carefully before proceeding with the
operations described below.
Check that the pistons show no signs of seizure,
scoring, cracking or excessive wear; change them
if they do.
Removing the rings (1) from the piston (2) with suit-
able piston ring pliers (3).
80648 22
28. The piston pin (1) retaining rings (2) should be re-
moved using a marking tool (3).
80649_167 23
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29. For piston dimensions refer to Connecting rod and

piston Connecting rod - Dimension (B.10.A) .
Using a micrometer (2) measure the diameter of the
piston (1) to determine the assembly clearance.
80650_168 24
30. The clearance between the piston and the cylinder

barrel can checked using a feeler gauge (1).
80651_169 25
31. Measure the piston pin (1) using a micrometer (2).
80652_170 26
32. Lubricate the pin and the piston pin seat with engine
oil . The pin should go into the piston with a light
pressure of the fingers and must not drop out.
80653_171 27
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33. Check the thickness of the rings (2) with a microme-

ter (1).
80654_172 28
34. Check the clearance between the rings (3) of the sec-
ond and third slot and the relevant seats in the piston
(2) with a feeler gauge (1).
80655_173 29
35. Because the shape of the first ring is trapezoidal , the

clearance between the slot and the ring should be
measured as follows: Make the piston (1) protrude
from the engine block so that the ring (2) protrudes
half way from the cylinder barrel (3). In this position
use a feeler gauge to check clearance (X) between
the ring and the groove. The value should be as
specified.
80656_174 30
36. Use a feeler gauge (1) to measure the clearance be-

tween the ends of the piston rings (2) fitted into the
cylinder barrel (3).
80657_175 31
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37. Refer to Connecting rod and piston Connecting

rod - Component identification (B.10.A) and Con-
necting rod and piston Connecting rod - Dimen-
sion (B.10.A) to ensure correct usage.
38. The piston crown is marked as follows :
(1) Spare part number and design modification num-
ber
(2) Arrow showing direction of assembly of the piston
in the cylinder liner, it must face the front of the block.
(3) Date of manufacture
(4) Stamping indicating testing of the first groove in-
sert
80589 32
39. Using the pin (3) connect the piston (2) to the con-
necting rod (4) so that the reference arrow (1) for fit-
ting the piston (2) in the cylinder liner and the num-
bers (5) stamped on the connecting rod (4) are ob-
served as in the figure.
BSF4475A 33
40. Insert the rings (2) to retain the piston pin (1).
80661_184 34
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41. To fit the rings (1) on the piston (2) use suitable piston
ring pliers (3). The rings must be fitted with the word
"TOP" facing upwards and their openings staggered
from each other by 120 °.
80648_183 35
42. Fit the half bearings (1) on the connecting rod and
cap.
80661_85 36
NOTE: If it has not been necessary to change the connecting rod bearings they must be fitted in exactly the same
position and order as found on disassembly. Do not modify the bearings in any way.
43. To fit the connecting rod and piston assembly into the
cylinder block, lubricate the piston, rings and cylinder
barrel. Use a suitable piston ring compressor (2) to
fit the piston and connecting rod assembly (1) into
the barrel.
80340_124 37
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44. The arrow on piston should be facing the front of the

cylinder block as shown below.
NOTE: The pistons should be the same weight.
80612_186 38
45. To measure the crankpin clearance proceed as fol-

lows:
Clean the parts thoroughly and remove any trace of
oil
Position a length of calibrated wire (2) on the crank-
shaft journals (1)
Fit the connecting rod caps (3) with the relevant half
bearings (4)
80663_187 39
46. Before reusing the retaining bolts refer to ENGINE -

Dimension (B.10.A).
Lubricate the retaining bolts (1) with engine oil and
then tighten to the prescribed torque using a torque
wrench (2).
1st Stage - 30 Nm (22.13 lb ft)± 3 Nm (2.21 lb ft)
2nd Stage - 60 Nm (44.25 lb ft) ± 5 Nm (3.69 lb ft)
3rd Stage - 60 °± 5 °
80613_86 40
47. Remove the cap and determine the clearance by

comparing thw width of the calibrated wire (1) with
the scale on the packet (2) containing the wire
80664_190 41
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48. If the clearance value is different from prescribed

value , replace half bearings and check again. Once
the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening con-
necting rod retaining bolts to the prescribed torque.
Check by hand that the connecting rods move ax-
ially on the crankshaft journals and their end float
measured with a feeler gauge (2) is 0.10 - 0.33 mm
(0.0039 - 0.0130 in).
49. Use a dial gauge to check piston protrusion at Top
Dead Centre in relation to the top of the engine block.
Protrusion should be 0.28 - 0.52 mm (0.0110 -
0.0205 in).
80666_192 42
50. If valve removal is required refer to Cylinder head -

Disassemble (B.10.A).
51. Check the hydraulic seal of the cylinder head using
the appropriate tools. Use a pump filled with water
heated to approximately 90 °C (194.00 °F) and 2 - 3
bar (29.00 - 43.50 psi) pressure.
Check for leaks from the core plugs (1) If leaks are
found replace plugs using suitable tools.
If there is any leakage from the cylinder head it must
be replaced
NOTE: Before refitting plugs apply a water resistant sealant
to the plug surfaces
80709 43
52. Check the cylinder head surface for distortion using

a rule and a feeler gauge. Distortion found along the
length of the head should not exceed 0.2 mm (0.008
in). If higher values are found, regrind the cylinder
head according to the dimensions shown in figure 44
. The nominal thickness (A) is 105 mm (4.13 in) ±
0.25 mm (0.01 in). Maximum metal removal should
not exceed thickness (B) by 1 mm (0.04 in).
70325_97 44
NOTE: After regrinding check the valve recessing and if necessary regrind the valve seats to obtain the specified
value.
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53. Check valve dimensions refer to Valve assembly

Valve - Dimension (B.10.A).
54. For checking , grinding and decarbonising proce-
dures refer to Valve drive Valve assembly - Check
(B.10.A). For valve guide information refer to Valve
assembly Valve - Dimension (B.10.A)
55. Check the valve seats (2) . If there is scoring, or
signs of burnout, regrind seats using a suitable tool
(1) according to the angle values shown in figure 46.
80711_99 45
70331_100 46
56. If the valve seats cannot be reconditioned by regrind-

ing, they can be replaced by valves supplied as spare
parts. Use a suitable tool to remove just enough ma-
terial to enable the seats to be extracted from the
cylinder head using a punch. Heat the cylinder head
to 80 - 100 °C (176.00 - 212.00 °F) and using a suit-
able tool fit new valve seats. Use a suitable tool to
regrind the valve seats to value shown in figure 47
70332_101 47
57. After regrinding check the valve recessing (3) is as

prescribed using a suitable dial gauge (1) with mag-
netic base. (2) .
80712 48
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58. Check the valve springs - refer to Valve assembly

Spring - Dimension (B.10.A).
59. Lubricate the valve stems (1) and insert them into
the relevant valve guides according to the positions
marked during disassembly. Fit the seals (2) and (3)
on the valve guide.
NOTE: The seals (2) for intake valves are yellow and the
exhaust valve seals (3)are green.
80713 49
60. Position on the cylinder head, the spring (4), and the
upper cap, (3). Use the spring compressor tool (1) to
compress the spring (4), and use the cotters (2) lock
the parts into position.
80707_88 50
61. Check the mating surfaces of the cylinder head and

the engine block are clean. Position the cylinder
head gasket with the word "TOP" facing the head
on the block. The arrow indicates where the gasket
thickness is given.
80714_90 51
62. For cylinder head installation refer to Cylinder head

- Install (B.10.A).
Next operation:
Refer to ENGINE - Overhaul (B.10.A).
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Valve drive Camshaft - Measure

NOTE: The support journal surfaces on the shaft and cams must be finely honed; if there are any signs of seizing or
scoring, replace the camshaft and relevant bushings.
1. Set the shaft on a support and, using a dial gauge
with a 1/100 mm scale placed on the central sup-
port, check that the alignment error is no greater
than 0.04 mm ( 0.0016 in); change the shaft if it
is. Check the diameter of the supporting pins of the
camshaft (2) with the micrometer (1) on two perpen-
dicular axis. (Refer to Valve drive Camshaft - Di-
mension (B.10.A), and Cylinder block - Overhaul
(B.10.A).
80644_164 1
2. Check cam lift.

Exhaust cam = 6.045 mm (0.2380 in)
Inlet cam = 7.582 mm (0.2985 in)
If the camshaft does not meet these specifications
replace the camshaft.
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Valve drive Rocker assembly - Install

Prior operation:
Camshaft Push rod - Visual inspection (B.10.A).
1. Insert pushrods (1) into engine and lubricate the

pushrod sockets/cups with new engine oil CASE
AKCELA NO. 1 ENGINE OIL SAE 15W-40 .
BAIL06CCM093ASA 1
2. Position the bridges (2) on the valves with the refer-

ence marks/dimples facing the exhaust manifold.
3. Position rocker arm supports (3).
4. Ensuring that the tappet adjusters on the rocker
arms are unscrewed, mount the rocker arm assem-
blies, complete with spindles, into the rocker arm
supports, securing into position with the retaining
bolts (1) to the required torque. Refer to ENGINE -
Torque (B.10.A).
BAIL06CCM094ASA 2
5. Set tappet clearance, refer to Camshaft Tappet -

Clearance (B.10.A).
6. Connect the electric cables (2) to the electro injectors
and using special tool 380000158 tighten the retain-
ing nuts to the required torque. Refer to ENGINE -
Torque (B.10.A)
Next operation:
Camshaft Tappet - Clearance (B.10.A).
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Camshaft Tappet - Clearance

Defining TDC for No. 1 Cylinder
1. Remove the starter (Refer to Engine starter - Re-
move (B.80.A):
2. Mount (1) plate of the tool 380000988 complete with
the flywheel rotating spool (2) of the tool 380000732
3. Rotate the engine flywheel in the direction of rotation
. Take care to eliminate gear backlash.
BAIL07APH348AMA 1
4. Turn until the pin (4) of tool 380000988 is engaged

in the socket on the flywheel (3). This indicates that
number 1 cylinder is top dead centre (TDC) on the
firing stroke.
NOTE: On the flywheel there are no references to indicate TDC of all the cylinders. Therefore it is important to deter-
mine TDC for number one cylinder before calculating the position of TDC on the remaining cylinders.
Defining TDC of other cylinders (6 Cylinder engine)

5. This operation can be carried out following the table
below when the firing order is 1 - 5 - 3 - 6 - 2 - 4.
Begin by setting cylinder no. 1 as in the instructions
above. Then remove pin.
Flywheel rotational orientation in relation to TDC cylinder numbers 1 to 6

Amount of Degrees in direction of rotation (DOR)
Cylinder at TDC Position from No.1 @ Flywheel Notch Reference from Phonic wheel
TDC alignment of notch (Visual check only)
1 Reference point 0 ° Aligned Reference point 0 ° 0 Reference
5 120 ° DOR 120 ° DOR 20 Notches
6 360 ° DOR Aligned Reference point 0 ° 0 Reference
Defining TDC of cylinders (4 cylinder engine)

6. This operation can be carried out using the table be-
low when the firing order is 1 - 3 - 4 - 2. Begin by
setting cylinder no. 1 to TDC as already described.
Then remove pin (4) Figure 1.
Flywheel rotational orientation in relation to TDC cylinder numbers 1 to 4

Amount of Degrees in direction of rotation (DOR)
Cylinder at TDC Position from No.1 @ Flywheel Notch Reference from Phonic wheel
TDC alignment of notch (Visual check only)
1 Reference point 0 ° Aligned Reference point 0 ° 0 Reference
4 360 ° DOR Aligned Reference point 0 ° 0 Reference
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NOTE: In cases where a goniometer, an angular measuring gauge, is not available the procedures below can be used
to set TDC of the other cylinders that are not set by the special tool. The TDC of these cylinders can be determined
by rotating the flywheel until the exhaust valve is at the final phase of drainage and the inlet valve is at the beginning
of suction. At this point the rocker arm should be able to be gently rocked. (Take care that the camshaft follower is
not on the EGR lobe.)
Defining TDC (cylinder by cylinder)

7. When the centralising slot in the flywheel, used in
conjunction with pin (4) figure 1 is not available to
determine TDC of no.1 cylinder it will be necessary
to use the method of balanced valves (rocking) as an
alternative to find TDC of all cylinders.
Manual Setting Of The Valves (6 Cylinder)

Start Point and Angular Phonic wheel Adjust the clearance of Balance the valves of
Rotation (Visual check only) valves on cylinder no. cylinder no.
Cyl. 1-6 TDC 0 Reference 1 6
+ 120 ° 20 notches 5 2
+ 120 ° 40 notches 3 4
+ 120 ° 0 reference 6 1
+ 120 ° 20 notches 2 5
+ 120 ° 40 notches 4 3
Manual Setting Of The Valves (4 Cylinder)

Start Point and Angular Phonic wheel Adjust the clearance of Balance the valves of
Rotation (Visual check only) valves on cylinder no. cylinder no.
Cyl. 1-4 TDC 0 Reference 1 4
+ 180 ° 30 notches 3 2
+ 180 ° 0 reference 4 1
+ 180 ° 30 notches 2 3
Valve Lash (clearance) Adjustment

8. To set the clearance between rocker and valves use
a key (1), wrench (3), and feeler gauge (2) Figure 2
shows 4 valve per cylinder engine.
80715_103 2
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9. To set the clearance between rocker and valves use

a key (1), wrench (3), and feeler gauge (2) . Figure
3 shows 2 valve per cylinder engine.
80682 3
NOTICE: The clearance should be set as follows :

inlet valve 0.25 mm (0.0098 in)± 0.05 mm (0.0020 in)
exhaust valve 0.50 mm (0.0197 in)± 0.05 mm (0.0020 in)
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Valve drive Valve guide - Measure

VALVE GUIDES
1. Using a bore gauge, measure the inside diameter of
the valve guides; it must be as indicated in the figure
Valve drive Valve guide - Dimension (B.10.A)).
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Camshaft Tappet - Install

1. Lubricate the tappets and tappet bores with new en-
gine oil CASE AKCELA NO. 1 ENGINE OIL SAE
15W-40 and insert into their seats in the crankcase.
Lubricate follower cam face with new engine oil
CASE AKCELA NO. 1 ENGINE OIL SAE 15W-40
NOTE: Ensure that the tappets are fully seated, free to
rotate and be free to fall under their own weight into the
seat.
80603 1
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Camshaft Gear - Remove

1. Remove screws (1) and remove the gear (2) from the
camshaft (3).
BAIL06CCM067ASA 1
Next operation:
Timing gear - Timing adjust (B.10.A).
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Camshaft Push rod - Visual inspection

1. Before assembly, check the rocker-arm control rods:
They must have no deformation.
There should be no signs of seizure or wear on the
contact surfaces on the ball seats, rocker arm ad-
juster screw and tappets (as indicated), if there are,
then they require to be renewed.
The intake and exhaust valve control rods are iden-
tical and can therefore be interchanged
32655 1
Next operation:
Valve drive Rocker assembly - Install (B.10.A)
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Valve drive Valve assembly - Check Decarbonising and Checking.

1. Decarbonizing, checking and grinding valves
Remove all carbon deposits from the valves using a
wire brush.
Check that the valves show no signs of seizure,
cracking or burning.
If necessary, regrind the valve seats, removing as
little material as possible.
80673 1
2. Using a micrometer (2), measure the valve stem (1):

it must be 6.970 - 6.990 mm (0.2744 - 0.2752 in)).
For further dimensions, refer to Valve assembly
Valve - Dimension (B.10.A).
80674 2
Checking the clearance between the valve stem, guide and valve centring.
3. The checks are made with a dial gauge (1) with a
magnetic base, positioned as illustrated. The assem-
bly clearance is 0.052 - 0.092 mm ( 0.0020 - 0.0036
in.).
Making the valve (2) turn, check that the centring
error is no greater than 0.03 mm ( 0.0012 in).
80710 3
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Crankshaft - Measure
1. Main and connecting rod journal dimensions
If any sign of seizure, scoring or ovality is found
on the main journals or crankpins, they must be re-
ground. Before reconditioning the pins (2), use a mi-
crometer (1) to measure the pins of the shaft to define
the diameter to which the pins must be reduced.
NOTE: It is advisable to note the values on a chart shown
in the following figure.
80631_209 1
2. The undersize classes are: 0.250 - 0.500 mm (

0.0098 - 0.0197 in.)
NOTE: The main journals and crankpins must always be
reconditioned to the same undersize class. After undersiz-
ing, mark the main journal and the crankpin with a stamp
on the side of the crank No. 1.
For undersized crankpins letter (M)
For undersized journals letter (B)
For undersized crankpins and journals letters (MB)
80744_210 2
NOTE THE CRANKSHAFT MAIN JOURNAL AND CRANKPIN MEASUREMENTS ON THE TABLE
* Nominal value
Refer to Crankshaft - Dimension (B.10.A).
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Crankshaft Rear seal - Install

Prior operation:
Rear cover - Install (B.10.A)
1. Fit part (5) of tool 380000664 on to the crankshaft (6)

. Secure it with the screws (4) and fit the new seal
(3) onto it.
Position part (1) on part (5), screw down the nut (2)
until the seal (3) is completely fitted in the housing.
BACD04APH069ASA 1
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Timing gear - Timing adjust

1. Use a marker pen to mark the tooth of the driving
gear (1) mounted on the crankshaft (2) on the side of
which the reference mark (→) is stamped for timing.
NOTE: Screw in two pins to help in the operation of turning
the crankshaft.
80615 1
2. Rotate the crankshaft (4) and camshaft (2) so that

when mounting the driven gear (1) on the camshaft,
the marks stamped on the gears (3) coincide.
80341 2
3. Screw down the bolts (1) securing the gear (2) to the
camshaft (3) and tighten to 36 Nm (26.6 lb ft).
80342 3
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Connecting rod and piston - Measure

NOTE: For dimensions of Piston and/or Connecting rod, refer to and Connecting rod and piston Piston - Dimen-
sion (B.10.A) and Connecting rod and piston Connecting rod - Dimension (B.10.A)
NOTE: The pistons are supplied as spare parts oversized by 0.4 mm (0.0157 in)
1. Connecting rod-piston component parts
1. Retaining rings
2. Pin
3. Piston
4. Piston rings
5. Screws
6. Half bearings
7. Connecting rod
8. Bushing
80647_217 1
Connecting Rods
2. CONNECTING ROD, PISTON PIN BUSHING AND
HALF BEARING DATA
Inside diameter to be measured after installing in the
small end and regrinding with a reamer.
Refer to Connecting rod and piston Connecting
rod - Dimension (B.10.A)
NOTE: The connecting rod - connecting rod cap mating
surfaces are knurled for a better coupling. It is therefore
recommended not to remove the knurling. The rods are
manufactured using a fracture breaking technique making
each rod and cap unique and having only one way of in-
stallation.
3. Connecting rods are supplied as spare parts in class
W and marked in green*.
Removing material is not permissible.
NOTE: Each connecting rod is marked:
- On the body and cap with a number indicating their cou-
pling and the cylinder in which it is mounted. In the event of
replacement, number the new rod with the same number
as the replaced connecting rod.
- On the body of the connecting rod with a letter indicating
the weight class of the connecting rod mounted in produc-
tion: (Refer to Connecting rod and piston Connecting
rod - Component identification (B.10.A)
-- V, 1600 to 1640 (3.5274 to 3.6156 lb) (marked in yellow);
--V, 1641 to 1680 (3.6178 to 3.7038 lb) (marked in green);
-- V, 1681 to 1720 (3.7060 to 3.7920 lb) (marked in blue);
Bushings
4. Check that the bushing in the small end has not come
loose and shows no sign of scoring or seizure. If this
is not so, change it.
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5. Disassembly and assembly are performed with a

suitable drift.
When driving in, make sure that the oilways in the
bushing and small end coincide. Using a boring ma-
chine, regrind the bushing to obtain the prescribed
diameter.
Pistons - Measuring the Piston Diameter

6. Measuring the piston (1) diameter using a microme-
ter (2) to determine the assembly clearance.
NOTE: The diameter must be measured at a distance of
12 mm (0.4724 in) from the base of the piston skirt.
80650 2
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Flywheel - Visual inspection

NOTE: When coupling the engine with mechanical gearboxes with a clutch, check the state of the surface of the
flywheel and if necessary machine them to keep a nominal thickness of the engine flywheel of 49.6 ± 0.13 mm (1.9528
± 0.0051 in.).
1. Check the condition of the teeth of the ring gear (2).
If you find any breakage or excessively worn teeth,
remove it from the engine flywheel (1) with a general
drift and mount the new one, previously heated to a
temperature of 150 °C (302 °F) for 15 to 20 min.; the
bevel, made on the inside diameter of the ring gear,
must face the engine side of the flywheel.
80617 1
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Cylinder block - Overhaul

1. After disassembling the engine, thoroughly clean the
cylinder-crankcase assembly. Use the appropriate
rings for transporting the cylinder assembly.
Carefully check the crankcase is not cracked.
Check the condition of the plugs. If they are rusty or
if there is the slightest doubt about their seal, change
them.
Examine the surfaces of the cylinder liners; they
should show no sign of enlargement, scoring, ovality,
taper or excessive wear.
To check the internal diameter of the cylinder liners
for ovality, taper and wear, use a bore gauge (1),
fitted with a dial gauge zero-set on the ring gauge
(2) of the diameter of the cylinder liner. (Refer to
Cylinder block - Measure (B.10.A)). 80744 1
NOTE: If regrinding, all the liners must have the same over-
size (0.5 mm (0.0197 in.)).
NOTE: If the ring gauge is not available, use a micrometer.
2. Check the main bearing seats, proceeding as fol-
lows:
– fit the main bearing caps on the supports without
bearings;
– tighten the retaining bolts to the prescribed torque;
(refer to ENGINE - Torque (B.10.A))
– using an appropriate dial gauge for interiors, check
that the diameter of the seats is as prescribed. (refer
to ENGINE - General specification (B.10.A))
If the measurement is any greater, change the
crankcase.
Cylinder head mating surface check

After having located any deformed areas, level off the
mating surface using a grinding machine.
The flatness error must be no greater than 0.075 mm
( 0.0030 in). Check the condition of the cylinder block
plugs (1); if they are rusty or if there is the slightest
doubt about their seal, change them.
BUSHINGS
3. The camshaft bushings (2) must be forced into their
respective seats.
The internal surfaces must show no sign of seizure
or wear.
Using the bore meter (1), measure the diameter of
the front and rear bushings (2) and of the intermedi-
ate seats for the camshaft. (refer to Cylinder block
- Dimension (B.10.A) Valve drive Camshaft - Mea-
sure (B.10.A) and ENGINE - General specification
(B.10.A))
Measurements must be made at two perpendicular
points.
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4. To change the front bushing (1), use 380000667 for

disassembly and assembly.
NOTE: Upon assembly, the bushing (1) must be directed
so that the lubrication holes coincide with the holes in the
seats in the crankcase.
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Cylinder block - Measure

1. Measurements should be performed on each cylin-
der at three different heights in the cylinder and on
two planes perpendicular with each other. One par-
allel to the longitudinal axis of the engine (A) , and
the other perpendicular (B) . Maximum wear is usu-
ally found on plane (B) .
If ovality, taper or general wear is noted, bore and
recondition the cylinder liners. The cylinder liners
must be reground in relation to the diameter of the
pistons supplied as spare parts oversized by 0.5
mm ( 0.0197 in) over the nominal value and to the
prescribed assembly clearance. (Refer to Cylinder
block - Dimension (B.10.A) and Cylinder block -
Overhaul (B.10.A)
BAIL07APH372AMA 1
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Cylinder head - Disassemble

1. Valve disassembly
The intake (1) and exhaust (2) valve heads have the
same diameter.
The central recess (→) of the head of the exhaust
valve (2) distinguishes it from the intake one.
NOTE: Before removing the valves from the cylinder head,
number them so as to fit them back on, if they are not re-
placed, in the positioned found upon disassembly.
A = intake side - S = exhaust side
80706 1
2. Valves are removed using a general valve spring

compressor tool, (1), applying pressure on the cap
(3) so that, by compressing the springs (4), it is pos-
sible to remove the cotters (2). Then remove the cap
(3) and springs (4).
Repeat this operation on all valves.
Overturn the cylinder head and extract the valves (5).
80707 2
3. Remove the seals (1) and (2) from the relevant valve
guides.
NOTE: The seals (1) for the intake valves are yellow.
The seals (2) for the exhaust valves are green.
80708 3
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Cylinder head - Install

NOTE: Before each assembly, always check that the threads of the holes and bolts show no signs of wear or traces
of dirt.
1. Prior to the fitting of the cylinder head to the
crankcase, measurements are required to be taken
to determine the correct thickness of head gasket
required.
The gasket is available in 2 thicknesses, 1.25 mm
(0.049 in) gasket type A and 1.15 mm (0.045 in)
gasket type B, select the correct one depending on
the piston protrusion dimension.
NOTE: Ensure that the mating surfaces of the cylinder
head and crankcase are clean.
It is recommended to keep the gasket in its wrapping until
the head is to be fitted on.
BAIL07APH422AMA 1
2. Using the dial gauge, Special Tool number

380000228 (1), fitted with base, Special Tool number
380000364 (2), check the protrusion of the pistons
(3), at T.D.C. from the cylinder block face.
3. For each piston, at a distance of 45 mm (1.77 in)
from the centre of the piston, measure the protru-
sions S1 and S2 from the top face of the crankcase
and then calculate the mean:
S cyl1 = S1+S2 / 2
Repeat this operation for pistons 2, 3, 4, 5, & 6 and
calculate the mean value.
S = S cyl1 + S cyl2 + S cyl3 + S cyl4 + S cyl5 + S
cyl6 / 6
If S is > 0.40 mm (0.015 in) use the gasket type A.
If S is < 0.40 mm (0.015 in) use gasket type B.
4. Position the gasket (1) on the crankcase, ensuring
that the word "TOP" (1) is facing the cylinder head.
NOTE: Do not grease the gasket.
80714_203 2
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5. With the head gasket positioned on the crankcase,

place the cylinder head (2) onto it, slung with the
brackets, Special Tool number 380001073 (1).
BAIL06CCM059ASA 3
6. Before reusing cylinder head retaining bolts, refer to

ENGINE - Dimension (B.10.A).
7. Insert cylinder head retaining bolt and tighten in
sequence to specified torques, refer to ENGINE
- Torque (B.10.A) and Cylinder head - Tighten
(B.10.A).
NOTE: Angle closing is performed using a suitable angle
gauge on the wrench (3).
NOTE: Before each assembly, always check that the
threads of the holes and bolts show no signs of wear or
traces of dirt.
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Cylinder head - Tighten

1. Place the bolts in the correct location in the cylinder
head
NOTE: Highlighted Bolts are shorter
BAIL07APH409BMA 1
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2. Tightening sequence for cylinder head bolts.

NOTE: The 150 mm length cylinder head bolts, are shown
below as the shaded bolt locations.
bail06ccm026gsa 2
For the required torque settings, refer to ENGINE - Torque (B.10.A) .
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Valve cover - Install

1. Install a new gasket (2) on the rocker cover (1). Fig-
ure 1 (Shows cover less breather assembly.)
80705 1
NOTICE: When refitting the valve cover make sure the breather assembly has the breather check valve installed. If
this is missing oil consumption and excessive smoke may occur.
2. The check valve is the orange component (1) in-
stalled in the centre of the blow-by filter.
BAIL07APH374ASA 2
3. Locate the cover over the protruding studs . Screw

on the nuts and tighten to 24 Nm (17.70 lb ft) ± 0.4
Nm (0.30 lb ft). Refer to Figure 3 for tightening se-
quence.
80737 3
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Rear cover - Install

Prior operation:
Timing gear - Timing adjust (B.10.A)
DIAGRAM OF ZONE FOR APPLYING LOCTITE 5205 SEALANT ON THE GEAR COVER
1. Carefully clean the timing gear cover and the
crankcase.
NOTE: Cleaning the surface to seal is both necessary and
unavoidable in order to obtain an effective seal.
Apply LOCTITE 5205 sealant onto the casing to form a
bead (1) with a diameter of a few mm.
It must be uniform (no lumps), with no air bubbles, thin
areas or breaks.
Any flaws must be corrected in as short a time as possible.
Avoid using excess material to seal the joint. Too much
sealant would tend to come out on both sides of the joint
and clog the lubricant passageways.
After applying the sealant, the joints require immediate as-
sembly (10 — 20 minutes).
80343 1
TIGHTENING SEQUENCE FOR GEAR COVER BOLTS

2. Refit the cover (1) to the crankcase.
Screw down the retaining bolts (2) in the position
found during disassembly and tighten the bolts to the
specified torque wrench settings :
M8: . 24 Nm± 4 Nm( 17.7015 lbft ± 2.9502 lbft
M10: 47 Nm± 5 Nm( 34.6654 lbft ± 3.6878 lbft
Refit the phase sensor (3) of the high-pressure
pump.
NOTE: Before each assembly, always check that the
threads of the holes and bolts show no signs of wear or
traces of dirt.
80383 2
Next operation:
Crankshaft Rear seal - Install (B.10.A)
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Index
ENGINE - 10.A
Auxiliary drive - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Balancer - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Camshaft Bushing - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Camshaft Push rod - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Camshaft Tappet - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting rod and piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Connecting rod and piston - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connecting rod and piston Connecting rod - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting rod and piston Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting rod and piston Piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Crankshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Crankshaft - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Cylinder block - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder block - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cylinder block - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Cylinder block - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cylinder head - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Cylinder head - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder head - Tighten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Cylinder head Valve seat - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE - Connect (Engine / Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ENGINE - Dimension - Stretch Bolt Check for reuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE - Disconnect (Engine / Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ENGINE - General specification 4 Cylinder 2 Valve Mechanical - F4CE0484B*D . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ENGINE - General specification 4 Cylinder 2 Valve Mechanical - F4CE9484G*J . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE - General specification 4 Cylinder 4 valve Electronic Boosted Engines - F4DE9487B*J, F4DE9487A*J,
F4DE948A*J100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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ENGINE - General specification 4 Cylinder 4 Valve Electronic Unboosted - F4DE9484E*J100, F4DCE9484D*J101,
F4DE9484B*J101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
MAXXUM 110 Multicontroller, MAXXUM 120 Multicontroller, MAXXUM 130 Multicontroller, MAXXUM 110, MAXXUM 120, MAXXUM
130
ENGINE - General specification 6 Cylinder 2 Valve Mechanical Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
140
ENGINE - General specification 6 Cylinder 4 Valve Boosted - F4DE9684R*J102, F4DE9687X*J, F4DE9687J*J 18
140
ENGINE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ENGINE - Overhaul External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ENGINE - Overhaul Internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ENGINE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ENGINE - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flywheel - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Flywheel - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Piston Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Timing gear - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Valve assembly Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Valve assembly Valve - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Valve drive Camshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Valve drive Camshaft - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Valve drive Rocker assembly - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Valve drive Rocker assembly - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Valve drive Valve assembly - Check Decarbonising and Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Valve drive Valve guide - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve drive Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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FUEL AND INJECTION SYSTEM - 20.A

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Contents
SERVICE
Fuel injection pump
Remove Delphi Rotary Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel injection pump - Remove Delphi Rotary Fuel Pump

ATTENTION: Due to the stringent emission regulations, in most locations the Delphi fuel injection pump is supplied
as a spare part preset from the manufacturer. If, for whatever reason the pump timing is lost, ie, the removal and
installation procedure is not followed correctly or the pump is allowed to be unlocked and rotated whilst off of the
engine, then it will be necessary to return the pump to an authorised agent to have it reset. This is necessary to
maintain the high level of accuracy required to comply with the emission regulations and provide the vehicle with
optimum performance and economy.
1. If it is necessary to change the fuel pump, it is sup-
plied already pre-set as a spare part.
2. If the pump has to be removed and refitted later, with-
out undergoing repair, it must be pre-set while still fit-
ted on the engine and then removed.
3. The following procedure includes this second condi-
tion as it is more complex.
4. Disconnect the battery negative cable and open the
hood.
5. Remove the starter motor (1) from the mounting (2).
80683 1
6. Install special 380000988 to enable the flywheel to

be turned.
7. Carefully turn the flywheel in its direction of rotation
to cancel the clearances of the gears.
8. turn the engine until the pin (1) engages through the
slot in the plate (2) with the recess in the flywheel (3).
BSF4477A 2
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9. Remove the retaining bolts (2) and remove the prim-

ing pump (1) from the engine block.
BRH3327B 3
10. Check through the opening of the priming pump lo-

cation that the camshaft (1) is on the correct cycle
(at TDC) using the raised reference marks (2) on the
shaft.
If the marks are not evident, withdraw the pin from
the flywheel and rotate the engine 360 ° until the
reference marks are visible. Re-insert the pin to lock.
80685 4
11. Disconnect the throttle cable (1).
BRI3821B 5
12. Disconnect the electrical connections to the fuel shut

off solenoid (4) and the cold start advance unit (3).
13. Remove the fuel feed and return pipes and the outlet
pipes to the injectors from the pump (2).
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14. Remove the cover plate (1) from the rear gear casing
for the fuel injection pump drive gear.
BRH3312B 6
15. Prevent the engine from turning using the turning/

holding tool 380000988 and loosen the fuel injection
pump gear retaining nut (2).
16. Partly unscrew the side bolt out (1), move the spacer
washer (2) to allow the bolt to lock the shaft
(3) Shaft unlocked
(4) Shaft locked
Retighten the side bolt (1).
BRI3824B 7
17. Remove the pump drive gear retaining nut.

18. Using the special tool 380000979 (1), remove the
gear from the pump shaft.
BRH3313B 8
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19. Remove the pump retaining bolts (1) and withdraw

the fuel pump (2).
BRI3822B 9
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Fuel injection pump - Install

1. When fitting the fuel pump on the engine, the engine
must be set at top dead centre (T.D.C) on cylinder No
1.
2. Inspect the square section seal (1) on the pump cas-
ing. Replace if required.
BRH3310B 1
3. Install the pump (2) onto the engine and tighten the
retaining nuts (1), to 24 N·m (18 lb ft).
BRI3822B 2
4. Install the pump drive gear retaining nut (1) and ini-
tially tighten to 20 N·m (15 lb ft)
BRH3311B 3
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5. Partly remove the bolt (1), reposition the spacer

washer (2) to the unlock position (3). Tighten the
bolt, locking the above- mentioned washer: in this
way, the fuel pump spindle is free to turn.
BRI3824B 4
6. Fully tighten the pump drive gear retaining nut to 90

N·m (65 lb ft).
7. Install the rear casing cover.
8. Remove the engine flywheel locking pin .
9. Remove the special tool 380000988 from the fly-
wheel.
10. Install the starter motor.
11. Connect the injector pipes and the fuel supply and
return pipes (2).
BRI3821B 5
12. Connect the throttle cable (1).

13. Connect the electrical connections to the fuel shut off
solenoid (4) and cold start advance device (3).
14. Fit the priming pump (1), using a new gasket, onto
the crankcase and tighten the retaining bolts (2) to
the correct torque.
BRH3327B 6
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15. If any work has been done on the supply circuit com-
ponents, it is necessary to bleed the air from the sys-
tem.
16. Disconnect the filter fuel piping (3) and repeatedly
operate the bleed lever of the priming pump (2).
80639 7
17. Continue operating until fuel comes out.

18. Connect the piping (3) to the filter.
19. Connect the battery, for further information refer to
Battery - Connect (A.30.A).
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Index

Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel injection pump - Remove Delphi Rotary Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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AIR INTAKE SYSTEM - 30.A

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Contents
TECHNICAL DATA
Turbocharger
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Torque
Part TORQUE Nm (lb ft)
Turbocharger/exhaust manifold retaining nuts M8 x 1,25 20 - 30 Nm (14.75 - 22.13 lbft)
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Air cleaner - Remove

1. Raise the engine cover.
2. Release the retaining clips. (1) and remove cover.
BAIL07APH334ASA 1
3. Remove outer filter (1).
BAIL07APH335ASA 2
4. Remove inner filter (1).

NOTICE: Do not remove inner element unless it is to be
replaced.
BAIL07APH336ASA 3
Next operation:
Clean the air cleaner element, for further information refer to Air cleaner - Cleaning (B.30.A)
84276322A 31/05/2010
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Air cleaner - Install

1. Install inner filter (1).
NOTICE: If the inner filter element has been removed, a
new inner filter element must be installed.
BAIL07APH336ASA 1
2. Install the outer filter (1).
BAIL07APH335ASA 2
3. Install the air cleaner cover and fasten the retaining

clips (1).
BAIL07APH334ASA 3
4. Close the engine cover.
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Air cleaner - Cleaning

Prior operation:
Air cleaner - Remove (B.30.A)
1. Clean and examine the outer casing and repair or

seal any damaged seams.
2. Remove the outer filter from housing. Do not let dirt
fall on the inner filter.
NOTICE: Do not remove inner element unless it is to be
replaced.
3. To clean the element, hold the top and tap it against
the palm of the other hand to remove the dust. Never
tap it on a hard surface or you can damage the filter.
4. When tapping does not remove the dirt, direct com-
pressed air through the element, from the inside to-
wards the outside.
NOTE: Never blow compressed air from the outside to the
inside of the filter because particles can become embedded
or lodged in the filter and later be released into the engine
causing damage.
5. To prevent damage to the element when cleaning
with compressed air, take the following precautions:
1) Maximum air pressure should not exceed 2 bar
(29.00 psi)2) Move the nozzle up and down when
rotating the element. 3) Keep the nozzle at least 25
mm (0.98 in) from the pleated paper.
NOTE: To keep the interval acceptable it is highly recom-
mended to clean the element with compressed air.
TA6010077 1
6. Every time the element is cleaned, it should be ex-

amined for holes and cracks by holding an electric
light bulb inside the element and looking through it.
If any damage is noted, discard the element and fit a
new one.
7. Replace the element after 3 cleanings or once a year,
whichever comes first.
8. When fitting, make sure the element is seated prop-
erly and the sealing is in good condition.
9. Inner Element
The inner element should not be disturbed unless
damaged, or contaminated by dirt through failure of
the outer element. The element should therefore
only be replaced and not cleaned when contami-
nated.
10. If the inner element is okay leave assembled in the
cleaner body, and change only annually, or every
1200 hours whichever occurs first.
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Turbocharger - Remove
Prior operation:
1. Disconnect the turbocharger exhaust outlet pipe.
BAIL08CVT146AVA 1
2. Remove the charge air cooler in take pipe.
BAIL08CVT126AVA 2
3. Disconnect the vacuum sensor electrical connectors

and remove the turbocharger intake tube.
BAIL07APH232AVA 3
4. Unscrew and remove the flexible lubrication piping

(1) of the turbocharger (5) .
5. Remove the turbocharger oil drain tube (3) retaining
bolt.
6. Remove turbocharger to exhaust manifold retaining
nuts (4) and turbocharger oil drain tube retaining
bolts (2).
7. Remove the turbocharger from the exhaust manifold
and remove gasket.
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BAIL06CCM058ASA 4
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Turbocharger - Install
NOTE: Before installing the turbocharger onto the exhaust manifold, make sure that the turbocharger to exhaust
manifold gasket is fitted.
1. Install the turbocharger (5) and gasket onto the ex-
haust manifold.
2. Connect the turbocharger oil drain tube to the tur-
bocharger, and tighten the retaining bolts (2).
3. Install the turbocharger retaining nuts (4). Tighten
to the specified torque. Refer to Turbocharger -
Torque (B.30.A).
4. Install the turbocharger oil drain tube clamp retaining
bolt (3).
5. Connect the flexible lubrication oil pipe (1) from the
oil filter/cooler.
BAIL06CCM058ASA 1
6. Install the turbocharger intake tube and connect the

vacuum sensor electrical connectors.
BAIL07APH232AVA 2
7. Install the charge air cooler intake pipe.
BAIL08CVT126AVA 3
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8. Connect the turbocharger exhaust outlet pipe.
BAIL08CVT146AVA 4
Next operation:
Connect the battery, for further information refer to Battery - Connect (A.30.A).
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Air cooler - Remove

1. Remove the condenser pivot bolt, release the over-
centre catches, and place the condenser on top of
the engine.
BAIL07APH366AVA 1
2. Disconnect the charge air cooler outlet hoses from

the charge air cooler.
BAIL07APH359AVA 2
3. Remove the charge air cooler.
BAIL07APH059AVA 3
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Air cooler - Install

1. Install the charge air cooler.
BAIL07APH059AVA 1
2. Connect the charge air cooler hoses to the charge

air cooler.
BAIL07APH359AVA 2
3. Place the air conditioning condenser into position

and install the pivot bolt and retaining nut. Install the
air conditioning condenser and latch the over centre
catches.
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Index

Air cleaner - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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EXHAUST SYSTEM - 40.A

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Contents
SERVICE
Silencer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tighten - Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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ENGINE AND PTO IN - EXHAUST SYSTEM
Silencer - Remove
1. Remove the muffler.
BAIL08CVT145AVA 1
2. Disconnect the turbocharger exhaust outlet pipe.
BAIL08CVT146AVA 2
3. Remove the exhaust heat shield.
BAIL08CVT147AVA 3
4. Remove the exhaust.
WARNING
The component is heavy. ALWAYS use a hoist or get
assistance to lift the component. Failure to comply
could result in serious injury or death.
M944
BAIL08CVT148AVA 4
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Silencer - Install
1. Install the exhaust.
Tighten the exhaust retaining bolts. For further infor-
mation refer to ENGINE - Torque (B.10.A).
WARNING
The component is heavy. ALWAYS use a hoist or get
assistance to lift the component. Failure to comply
M944
BAIL08CVT148AVA 1
2. Install the exhaust heat shield.
BAIL08CVT147AVA 2
3. Connect the turbocharger exhaust outlet pipe.
BAIL08CVT146AVA 3
4. Install the muffler.
BAIL08CVT145AVA 4
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Exhaust manifold - Remove

Prior operation:
Turbocharger - Remove (B.30.A)
Vehicles with 6 cylinder engines

1. Remove the retaining bolts (x 12) and remove the
exhaust manifold.
BAIL06CCM055ASA 1
Vehicles with 4 cylinder engines

2. Remove the retaining bolts (x 8) and remove the ex-
haust manifold.
80363 2
84276322A 31/05/2010
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Exhaust manifold - Install

Prior operation:
Turbocharger - Remove (B.30.A)
NOTE: Install a new exhaust manifold gasket.
Vehicles with 6 cylinder engine

1. Install the exhaust manifold.
Tighten the retaining (x 12) bolts. For further infor-
mation refer to ENGINE - Torque (B.10.A).
BAIL06CCM055ASA 1

2. Install the exhaust manifold.
Tighten the retaining (x 8) bolts. For further informa-
tion refer to ENGINE - Torque (B.10.A).
80363 2
84276322A 31/05/2010
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Exhaust manifold - Tighten - Sequence.

1. Tightening sequence for exhaust manifold bolts.
For the required torque settings, refer to ENGINE -
Torque (B.10.A).
bail06ccm029asa 1

2. Tightening sequence for exhaust manifold bolts.
For the required torque settings, refer to ENGINE -
Torque (B.10.A)
80363 2
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Index

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold - Tighten - Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Silencer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Silencer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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ENGINE COOLANT SYSTEM - 50.A

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Contents
TECHNICAL DATA
ENGINE COOLANT SYSTEM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thermostat
Radiator
SERVICE
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Radiator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan and drive
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Viscous drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Viscous drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Sensing system
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Coolant temperature - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Coolant temperature - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Torque

Description Thread Size Torque Values
Coolant pump retaining bolts M8 x 1.25 25 Nm +/- 5 (18.4 lbft +/- 4)
Spring-loaded automatic fan belt M10 x 1.5 43 Nm +/- 5 (31.7 lbft +/- 4)
tensioner
Fan belt fixed pulley(s) retaining M10 x 1.5 45 Nm +/- 5 (33.2 lbft +/- 4)
bolt(s)
Thermostat housing retaining bolts M6 x 1.0 10 Nm +/- 2 (7.4 lbft +/- 1)
(Engines with common rail fuel
injection)
Coolant temperature sensor / sender M14 x 1.5 12 - 20 Nm (8.9 - 14.8 lbft)
Fan blade to viscous coupling M8 17 Nm (12.5 lbft)
retaining nuts
Viscous coupling to mounting pulley - 78 Nm (57.5 lbft)
ENGINE COOLANT SYSTEM - General specification

Description
Coolant Pump
Type Centrifugal
Drive Multi-Ribbed-Belt
Drive Belt
Belt Tension Spring Loaded Automatic Drive Belt Tensioner
Thermostat
Starts to open at: 81 °C
Fully open at: 96 °C
Coolant Expansion Tank Cap
Cap pressure 1 bar (14.5 psi)
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ENGINE COOLANT SYSTEM - Static description

The forced circulation, closed-circuit engine coolant system is composed of the following components:
• Coolant expansion tank: .

• Radiator, which dissipates the heat taken by the coolant from the engine. .
• Viscous fan, which increases the radiator’s dissipating capacity:
• Oil cooler.
• A centrifugal coolant pump housed at the front of the crankcase.
• A thermostat governing coolant circulation.
• The circuit may also extend to the air compressor if the version includes it.
80604 1
Cooling System Diagram - 6 Cylinder Electronic Engine
A = To The Radiator
B = From The Radiator
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80369 2
Cooling System Diagram - 4 Cylinder Electronic Engine
A = To The Radiator
80734 3
Cooling System Diagram - 6 Cylinder Mechanical Engine
A = To The Radiator
80395 4
Cooling System Diagram - 4 Cylinder Mechanical Engine
A = To The Radiator
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ENGINE COOLANT SYSTEM - Overview
BAIL07CCM266AMA 1
A Coolant flow from the thermostat

B Coolant flow to the coolant pump
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Thermostat - Dynamic description

When the thermostat is closed, a recirculating bypass gallery allows the coolant to recirculate from the cylinder head
to the block, to allow faster engine coolant warm-up.
BVE0376A 1
When the coolant has reached normal operating temperature, the thermostat will open and allow coolant to be drawn
through the radiator by the coolant pump. Cooled coolant then returns to the engine.
BVE0377A 2
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Radiator - Dynamic description

Cooling occurs as the coolant passes down through the radiator cores. Air is drawn through the radiator fins by a
viscous fan situated on a pulley mounted between the radiator and the engine block.
BAIL07APH037AVA 1
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ENGINE COOLANT SYSTEM - Filling
WARNING
Do not allow antifreeze to contact skin. Adhere to instructions detailed on antifreeze container.
B024
1. Make sure that the correct grade and quantity

of antifreeze is added to the water. Recom-
mended coolant mixture is 50% water to 50% an-
tifreeze to specification CASE AKCELA PREMIUM
ANTI-FREEZE (MS 1710) AMBRA AGRIFLU.
2. Refill the engine coolant system through the radiator
cap until completely full and reinstall the radiator cap.
BAIL07APH038AVA 1
3. Refill the coolant expansion tank to the COLD FILL

mark.
BAIL07APH040AVA 2
4. Start the engine and run until normal operating tem-

perature is reached. Check for leaks, allow to cool
and recheck the engine coolant level.
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ENGINE COOLANT SYSTEM - Drain fluid
WARNING
The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is
dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap
slowly to the first stop and allow the pressure to escape before fully removing the cap. Coolant should be
kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used.
B097
WARNING
Do not allow antifreeze to contact skin. Adhere to instructions detailed on antifreeze container.
B024
1. Place a suitable container under the vehicle.

Detach the coolant hose and drain the coolant.
BAIL07APH020AVA 1
2. Remove the coolant expansion tank cap.

3. Connect the coolant hose when the coolant system
has finished draining.
Next operation:
Fill the cooling system, for further information refer to ENGINE COOLANT SYSTEM - Filling (B.50.A).
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Thermostat - Remove
Prior operation:
Drain the engine coolant system, for further information refer to ENGINE COOLANT SYSTEM - Drain fluid (B.50.A)
1. Remove the right-hand belt guard.
BAIL07APH036AVA 1

BAIL07APH232AVB 2
3. Disconnect the coolant hose from the thermostat

housing.
BAIL07APH233AVA 3
4. Remove the thermostat housing from the cylinder

block.
BAIL07APH234AVA 4
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5. Remove the thermostat and seal. and the thermo-

stat.
BAIL07APH235AVA 5
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Thermostat - Install
Install the thermostat with a new thermostat seal.
BAIL07APH235AVA 1
2. Install the thermostat housing to the cylinder block.

Tighten the retaining bolts to the specified torque
value. For further information, refer to ENGINE
BAIL07APH234AVA 2
3. Connect the coolant hose to the thermostat housing

and tighten the hose clamp.
BAIL07APH233AVA 3

BAIL07APH232AVB 4
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5. Install the right-hand belt guard.
BAIL07APH036AVA 5
Next operation:
Fill the engine coolant system, for further information refer to ENGINE COOLANT SYSTEM - Filling (B.50.A)
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Thermostat - Test
Prior operation:
Thermostat - Remove (B.50.A).
1. Place the thermostat in a container of water, and

raise the temperature to 212 °F ( 100 °C). If the ther-
mostat fails to open when hot, or fails to close prop-
erly when cooled, it must be replaced.
NOTE: A faulty thermostat may cause the engine to oper-
ate at a too hot or too cold operating temperature. If the
thermostat is not replaced, this could result in damage to
the engine or impaired engine performance.
NOTICE: Do not operate an engine without a thermostat.
RI-1-107 1
Next operation:
Thermostat - Install (B.50.A).
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Water pump - Remove

Prior operation:
Drain the cooling system, for further information refer to ENGINE COOLANT SYSTEM - Drain fluid (B.50.A)
Prior operation:
Remove the drive belt, for further information refer to Fan and drive Belt - Remove (B.50.A)
1. Remove the coolant pump retaining bolts and re-

move the coolant pump.
BAIL07APH246AVA 1
Next operation:
Water pump - Install (B.50.A)
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Water pump - Install

Install a new seal (1) and lubricate with clean en-
gine oil. CASE AKCELA NO. 1 ENGINE OIL SAE
15W-40 .
BVE0374A 1
2. Install the coolant pump. Tighten the retaining bolts

to the specified torque value. For further informa-
tion, refer to ENGINE COOLANT SYSTEM - Torque
(B.50.A).
BAIL07APH246AVA 2
Next operation:
Install the drive belt, for further information refer to Fan and drive Belt - Install (B.50.A)
Next operation:
Refill the engine coolant system, for further information ENGINE COOLANT SYSTEM - Filling (B.50.A)
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Radiator - Remove
Prior operation:
Drain the engine coolant system, for additional information refer to ENGINE COOLANT SYSTEM - Drain fluid
(B.50.A)
1. Disconnect the charge air cooler outlet hose (1), and

retaining clamp (3).
Disconnect the receiver/drier retaining bracket (2)
from the radiator housing.
BAIL07APH359AVA 1
2. Disconnect the charge air cooler to intake manifold

hose and remove the charge air cooler outlet pipe.
BAIL07APH042AVA 2
3. Remove the fan shroud left-hand retaining bolts.
BAIL07APH046AVA 3
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Vehicles with pneumatic trailer brakes

4. Remove the left-hand drive belt guard.
BAIL07APH022AVA 4
Vehicles without pneumatic trailer brakes

BAIL07APH017AVA 5
All vehicles
6. Remove the engine control unit (ECU).
BAIL07APH044AVA 6
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7. Remove the radiator top retaining bracket.
BAIL07APH359AVA 7
8. Disconnect the radiator top hoses.
BAIL07APH361AVA 8
9. Remove the condenser pivot bolt, release the over-

centre catches, and place the condenser on top of
the engine.
BAIL07APH366AVA 9
10. Detach the hose clamps and remove the charge air
cooler intake pipe.
BAIL07APH043AVA 10
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11. Remove the oil cooler pipe retaining bracket.
BAIL07APH060AVA 11
12. Remove the right-hand drive belt guard.
BAIL07APH036AVA 12
13. Disconnect the radiator bottom hoses.
BAIL07APH047AVB 13
14. Remove the fan shroud right hand retaining bolts.
BAIL07APH045AVA 14
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15. Raise and support the vehicle and remove the right
hand front wheel.
BAIL07APH064AVA 15
16. Slide the oil cooler out of its mountings.
BAIL07APH004AVA 16
17. Reposition and support the oil cooler to one side.
BAIL07APH084AVA 17
18. Remove the radiator baffle plate.
BAIS06CCM016AVA 18
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19. Remove the radiator lower retaining bolts.
BAIL07APH048AVA 19
WARNING
The component is heavy. ALWAYS use a hoist or get assistance to lift the component. Failure to comply
M944
20. Remove the radiator assembly.
BAIL07APH360AVA 20
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Radiator - Install
WARNING
The component is heavy. ALWAYS use a hoist or get assistance to lift the component. Failure to comply
M944
1. Install the radiator assembly.
BAIL07APH360AVB 1
2. Install the radiator lower retaining bolts.
BAIL07APH048AVA 2
3. Install the radiator baffle plate.
BAIS06CCM016AVA 3
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4. Release the oil cooler.
BAIL07APH084AVA 4
5. Slide the oil cooler into its mountings and secure in

place.
BAIL07APH004AVA 5
6. Install the right hand front wheel and tighten the

wheel nuts to the specified torque, for further infor-
mation refer to Front wheel - Torque (D.50.C).
BAIL07APH064AVA 6
7. Install the fan shroud right hand retaining bolts.
BAIL07APH045AVA 7
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8. Connect radiator bottom hoses.
BAIL07APH047AVB 8
9. Install the right hand drive belt guard.
BAIL07APH036AVA 9
10. Install the oil cooler pipe retaining bracket.
BAIL07APH060AVA 10
11. Install the charge air cooler intake pipe.
BAIL07APH043AVA 11
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12. Position the condenser, secure with the pivot bolt and
lock the over-centre catches.
BAIL07APH366AVA 12
13. Connect the radiator top hoses.
BAIL07APH361AVA 13
14. Install the radiator top retaining bracket.
BAIL07APH359AVA 14
15. Install the engine control unit (ECU).
BAIL07APH044AVA 15
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16. Install the left hand drive belt guard.
BAIL07APH017AVA 16

17. Install the left hand drive belt guard.
BAIL07APH022AVA 17
All vehicles
18. Install the fan shroud left-hand retaining bolts.
BAIL07APH046AVA 18
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19. Install the charge air cooler outlet pipe and connect
the air cooler to intake manifold hose.
BAIL07APH042AVA 19
20. Connect the charge air cooler outlet hose (1), and
retaining clamp (3).
Connect the receiver/drier retaining bracket (2) to the
radiator housing.
BAIL07APH359AVA 20
Next operation:
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Fan and drive Belt - Remove

Prior operation:
Disconnect the battery, for further information refer to Battery - Disconnect (A.30.A)

BAIL07APH022AVA 1
2. Loosen the air compressor drive belt tensioner (1),

detension and remove the air compressor drive belt
(2).
BAIL07APH240AVA 2

3. Remove the left-hand belt guard.
BAIL07APH017AVA 3
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All vehicles
BAIL07APH036AVA 4
5. Loosen the locknut (1), Detension the air condition-

ing (A/C) drive belt adjuster (2).
BAIL07APH024AVA 5
6. Release the A/C drive belt tensioner (1) and remove

the A/C drive belt (2).
BAIL07APH241AVA 6
7. Detension the accessory drive belt tensioner (1)and

detach the accessory drive belt (2).
BAIL07APH050AVA 7
8. Carefully manoeuvre the accessory drive belt be-

tween the viscous fan and the radiator shroud.
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Fan and drive Belt tensioner - Remove

Air conditioning (A/C) drive belt tensioner
1. Remove the A/C drive belt, for further information
refer to Fan and drive Belt - Remove (B.50.A)
2. Remove the A/C drive belt tensioner.
BAIL07APH244AVA 1
Air compressor drive belt tensioner

3. Remove the air compressor drive belt, for further
information refer to Fan and drive Belt - Remove
(B.50.A)
4. Remove the air compressor drive belt tensioner.
BAIL07APH245AVA 2
Accessory drive belt tensioner

5. Remove the accessory drive belt, for further informa-
tion refer to Fan and drive Belt - Remove (B.50.A).
6. Remove the accessory drive belt tensioner rear re-
taining bolts.
BAIL07APH243AVA 3
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7. Remove the accessory drive belt tensioner.
BAIL07APH405AVA 4
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Fan and drive Belt - Install

All vehicles
1. Carefully manoeuvre the accessory drive belt be-
tween the viscous fan and the radiator shroud.
2. Detension the accessory drive belt tensioner (1) and
install the accessory drive belt (2) around the pulleys.
BAIL07APH050AVA 1
3. Install the drive belt around the pulleys.
BAIL07APH241AVB 2
4. Tension the A/C drive belt adjuster (1) and tighten the
locknut (2).
BAIL07APH024AVB 3
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5. Tighten the A/C compressor drive belt tensioner re-

taining bolts.
BAIL07APH241AVC 4
BAIL07APH036AVA 5

7. Install the left-hand belt guard.
BAIL07APH017AVA 6

8. Install and tension the air compressor drive belt (1)
and tighten the air compressor drive belt tensioner
(2).
BAIL07APH240AVA 7
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9. Install the left-hand drive belt guard.
BAIL07APH022AVA 8
Next operation:
Connect the battery, for further information refer to Battery - Connect (A.30.A)
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Fan and drive Belt tensioner - Install

Accessory drive belt tensioner
1. Install the accessory drive belt tensioner rear retain-
ing bolts.
BAIL07APH243AVA 1
2. Install the accessory drive belt tensioner front retain-

ing bolts.
BAIL07APH405AVA 2
3. Install the accessory drive belt, for further information

refer to Fan and drive Belt - Install (B.50.A).
Air compressor drive belt tensioner

4. Install the air compressor drive belt tensioner.
BAIL07APH245AVA 3
5. Install the air compressor drive belt, for further infor-

mation refer to Fan and drive Belt - Install (B.50.A).
Air conditioning (A/C) drive belt tensioner

6. Install the A/C drive belt, for further information refer
to Fan and drive Belt - Install (B.50.A).
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7. Install the A/C drive belt tensioner.
BAIL07APH244AVA 4
8. Install the A/C drive belt, for further information refer

to Fan and drive Belt - Install (B.50.A)
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Fan and drive Viscous drive - Remove

Prior operation:
Disconnect the battery ground (negative) cable from the battery, for further information refer to Battery - Disconnect
(A.30.A)
Prior operation:
Partially drain the engine coolant system, for further information refer to ENGINE COOLANT SYSTEM - Drain fluid
(B.50.A)
BAIL07APH036AVA 1
2. Disconnect the radiator top hoses.
BAIL07APH420AVA 2
3. Using suitable grips to hold the pulley, detach the

viscous fan.
NOTE: The viscous fan has a left-hand thread.
BAIL07APH094AVA 3
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4. Remove the radiator shroud retaining bolts (on both

sides of the vehicle)
BAIL07APH045AVA 4
5. Remove the radiator shroud and viscous fan to-

gether.
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Fan and drive Viscous drive - Install

1. Install the radiator shroud and viscous fan together.
2. Install the radiator shroud retaining bolts.
BAIL07APH045AVA 1
3. Using suitable grips to hold the pulley, tighten the vis-

cous fan to the specified torque, for further informa-
tion refer to ENGINE COOLANT SYSTEM - Torque
(B.50.A)
NOTE: The viscous fan has a left-hand thread.
BAIL07APH094AVA 2
4. Connect the radiator top hoses.
BAIL07APH420AVA 3
BAIL07APH036AVA 4
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Next operation:
Next operation:
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Sensing system Coolant temperature - Remove

Prior operation:
Drain the engine coolant system, for further information refer to ENGINE COOLANT SYSTEM - Drain fluid (B.50.A)
BAIL07APH036AVA 1

BAIL07APH232AVB 2
3. Disconnect the coolant hose from the thermostat

housing.
BAIL07APH233AVA 3
4. Disconnect the coolant temperature sensor electrical

connector.
BAIL07APH052AVB 4
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5. Remove the coolant temperature sensor.
BAIL07APH236AVA 5
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Sensing system Coolant temperature - Install

1. Apply sealant to the threaded portion of the new
coolant temperature sensor body and tighten the
coolant temperature sensor to the specified torque
value. For further information refer to ENGINE
BAIL07APH236AVA 1
2. Connect the coolant temperature sensor electrical

connector.
BAIL07APH052AVB 2
3. Connect the coolant hose to the thermostat housing.
BAIL07APH233AVA 3

BAIL07APH232AVB 4
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BAIL07APH036AVA 5
Next operation:
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Index

ENGINE COOLANT SYSTEM - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE COOLANT SYSTEM - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE COOLANT SYSTEM - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE COOLANT SYSTEM - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE COOLANT SYSTEM - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fan and drive Viscous drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fan and drive Viscous drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Radiator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sensing system Coolant temperature - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sensing system Coolant temperature - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Thermostat - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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STARTING SYSTEM - 80.A

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Contents
TECHNICAL DATA
Engine starter
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical test Starter Motor Circuit Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical test Starter Motor No Load Bench Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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ENGINE AND PTO IN - STARTING SYSTEM
Engine starter - General specification

Starter Type - Iskra Gear Starter
Rated Voltage 12 V
Rated Power 4.2 Kw
Direction of rotation Clockwise
Maximum No Load Current Draw at 11.5 volts and 4000 120 amps
rev/min.
Engine starter - Torque

Description Torque
Starter Motor mounting bolts M10 x 1.50 x 35mm 43 Nm +/- 5 (31.7 lbft +/- 4)
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Engine starter - Remove

Prior operation:
Disconnect the battery, for further information refer to Battery - Disconnect (A.30.A)
1. Remove the starter motor shield.
BAIL08CVT152AVA 1
2. Remove the positive jump start terminal cover.
BAIL08CVT153AVA 2
3. Disconnect the three starter motor cables (1).

Disconnect the spade connector (2).
Remove the positive cable retaining bracket (3).
Disconnect the negative jump start terminal (4).
Remove the three starter motor mounting bolts and
withdraw the starter motor from the flywheel housing.
BAIL08CVT154AVA 3
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Engine starter - Install

1. Install the starter motor.
Tighten to 43 Nm (32 lb ft)
2. Connect the three starter motor cables (1).
Connect the spade connector (2).
Connect the negative jump start terminal (3).
Install the positive cable retaining bracket (4).
Secure the wiring loom with a cable tie (5).
BAIL07APH117AVA 1
3. Install the positive jump start terminal cover.
BAIL07APH116AVA 2
4. Install the starter motor shield.
BAIL08CVT152AVA 3
Next operation:
Connect the battery ground cable, for further information refer to Battery - Connect (A.30.A)
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Engine starter - Test

1. For easier and rapid diagnosis and for most con-
clusive test results, it is recommended that a bat-
tery-starter tester (high rate discharge tester) incor-
porating a 0 - 20 V voltmeter and a 0 - 1000 A amme-
ter be used to diagnose starting system problems.
When using test equipment follow the manufacturers
recommended test procedures. If test equipment is
not available the following test procedure, using a
standard 0 - 20 V voltmeter and 0 - 1000 A ammeter
can be used to determine the correct operation of the
starter without removing it from the engine.
Before testing :
Check that the battery is fully charged.
Check the complete starting system wiring circuit for
frayed or broken wires or loose terminal connections.
Check the engine is not seized.
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Engine starter - Electrical test Starter Motor Circuit Current Draw

Starter Motor Circuit Current Draw
1. Attach a suitable clamp meter, (1), with a 0 - 1000 A
range, over the battery positive cable.
Connect the voltmeter (2) positive lead to the battery
positive terminal and the voltmeter negative lead to
the battery negative terminal.
To prevent engine start up during cranking remove
the engine processor fuse, Fuse 33, refer to, Fuse
and relay box - General specification (A.30.A).
Crank the engine while observing the voltmeter
and ammeter readings. The voltage should remain
steady at around 10 - 12 V with between 250 - 400
A being drawn.
1b0o2004061139 1
2. If the current draw is within specification the starting

motor (4) is functioning correctly. If the voltage drops
during the test proceed to ‘Starting System Circuit
Resistance’.
3. If the current draw is greater than specified, check
the circuit as outlined below. If the starting system
circuit tests are satisfactory the starting motor is de-
fective and must be replaced or renewed.
4. If the current draw is less than specified, the starting
motor is defective and must be replaced or renewed..
If there is an excessive current draw the circuit should

be checked by recording voltage drops across the
individual components in the circuit
NOTICE: Disconnect the fuel injection pump fuel shut off
solenoid wire.
Battery Positive Cable :

5. Connect the voltmeter positive lead to the battery
positive terminal.
Connect the voltmeter negative lead to the starting
motor solenoid battery terminal.
Crank the engine while observing the voltmeter read-
ing. If the voltage exceeds 0.2 V, check and tighten
the cable connections. Recheck the voltage, if still
excessive install a new cable.
60-55-002 2
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Starting Motor Ground Connections :

6. Connect the voltmeter positive lead to the starting
motor frame.
Connect the voltmeter negative lead to the engine
block.
ing. If the voltmeter reading exceeds 0.2 V check
the ground connections between the starting motor
flange and the rear engine plate.
60-55-003 3
Battery Ground Cable :

7. Connect the voltmeter positive lead to the engine
block.
Connect the voltmeter negative lead to the battery
negative terminal.
ing. If the reading exceeds 0.2 V, check and tighten
the ground cable connections. Recheck the voltage,
if it is still excessive install a new ground cable.
60-55-004 4
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Engine starter - Electrical test Starter Motor No Load Bench Test.

Prior operation:
Engine starter - Remove (B.80.A).
Starting Motor No-Load Test:

1. Secure the starting motor in a vice equipped with soft
jaws.
Connect the battery negative cable (4) to the starting
motor mounting flange.
Connect a voltmeter (3) positive lead to the battery
positive terminal, the voltmeter negative lead to the
battery negative terminal.
Connect the battery positive cable to the starting mo-
tor terminal and attach a suitable clamp meter (1),
over the cable.
Connect a short jumper lead (6) between the sole-
noid battery and solenoid switch terminals.
Hold a hand tachometer (5) on the end of the arma-
ture shaft. Set the starting motor by adjusting the
carbon pile (2) to give 11.7 V. When the armature ro- 1b0o2004061141 1
tates above 4000 RPM. the maximum current draw
should not exceed 150 A.
If the starting motor does not perform to specification,
renew or replace starter motor.
NOTE: A fully charged battery and a battery starter tester
(high rate discharge tester) with a carbon pile (variable load
resistor) should be used to perform this test.
NOTE: Connecting the jumper lead will cause the starter
to operate.
Drive Pinion Assembly

2. Check the operation of the roller clutch. The pinion
should rotate clockwise only. If the pinion is stuck or
rotates in both directions, or if the pinion teeth are
damaged, renew or replace starter motor assembly.
If damaged pinion teeth are evident, check the fly-
wheel ring gear teeth as described in Flywheel - Vi-
sual inspection (B.10.A).
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Index

Engine starter - Electrical test Starter Motor Circuit Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine starter - Electrical test Starter Motor No Load Bench Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine starter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine starter - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN FRANCE
84276322A 31/05/2010
SERVICE MANUAL
TRANSMISSION, DRIVE AND PTO OUT

84276322A 31/05/2010
C
Contents
TRANSMISSION, DRIVE AND PTO OUT - C
POWER COUPLING Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.10.C

MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 125
TRANSMISSION Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.B

MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 125
TRANSMISSION Power Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.C

MAXXUM 100 , MAXXUM 110 , MAXXUM 115 , MAXXUM 125 , MAXXUM 140
TRANSMISSION Semi-Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.D

ADDITIONAL REDUCERS Creeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.30.C

ADDITIONAL REDUCERS Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.30.D

REAR PTO Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.40.C

FRONT PTO Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.42.C

84276322A 31/05/2010
C
POWER COUPLING Clutch - 10.C
MAXXUM 100
MAXXUM 110
MAXXUM 115
MAXXUM 125
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C.10.C / 1
Contents
TECHNICAL DATA
POWER COUPLING Clutch
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Command
Overview (Clutch Components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view (Release Bearing/ Slave Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Command
Overhaul (Release Bearing/ Slave Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSTIC
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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TRANSMISSION, DRIVE AND PTO OUT - POWER COUPLING Clutch
POWER COUPLING Clutch - Torque

Clutch Cover to Flywheel Bolts 35 Nm (25.8 lb ft)

Clutch Pedal Operating Rod Turnbuckle Locknut 34 Nm (25.1 lb ft)
P.T.O. Drive Plate Bolts 129 Nm (95.1 lb ft)
Cross shaft Release Bearing fork Retaining Bolt 47 Nm (34.7 lb ft)
Hydraulic Slave Cylinder Retaining Bolts 25 Nm (18.4 lb ft)
Master Cylinder Retaining Bolts 23 Nm (17.0 lb ft)
Hydraulic Tube Connections 22 Nm (16.2 lb ft)
POWER COUPLING Clutch - General specification

Disc Assembly Type 327 mm (12.9 in) or 348 mm (13.7 in) Single Disc Dry Plate
Material Ceramettallic
Pressure Plate Assembly Type Belleville (diaphragm) Spring (Self Adjusting - No Maintenance)
Release Bearing Type Hydraulically Operated
Master Cylinder Push Rod to Plunger 0.6 mm (0.024 in) Minimum
Clearance
NOTE: The hydraulic clutch oil specification and the transmission input shaft lubricant are described in Consumables
Lubrications and Coolants.
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POWER COUPLING Clutch - Static description

The clutch system of the 12x12 transmission is a hydraulically operated single plate clutch with a 327 mm (12.9 in)
or 348 mm (13.7 in) non asbestos dry friction disc, designed for high durability and low effort operation. The clutch
is conventionally located at the front of the transmission, connecting the engine to the transmission input shaft. The
hydraulic actuation is provided with a simple master/slave cylinder arrangement. This provides self adjustment of
the clutch system to maintain optimum clutch performance. The pressure plate is a diaphragm spring type also self
adjusting and requiring no maintenance.
The tractors with a 12x12 transmission have a safety start switch, linked to the clutch pedal, which ensures the tractor
will not start unless the clutch pedal is depressed.
Operation
In the clutch ‘engaged’ position the spring loaded pressure plate forces the clutch disc into contact with the engine
flywheel.
The frictional contact between the clutch disc material and the surfaces of the flywheel and pressure plate enables
drive from the flywheel to be transmitted via the clutch disc to the input shaft of the transmission.
A clutch operating pedal is connected hydraulically to a release bearing. The release bearing contacts the operating
fingers of the pressure plate.
Depression of the clutch pedal causes the release bearing to move forward and depress the pressure plate diaphragm,
thus drawing the pressure plate away from the clutch disc and releasing the disc from contact with the flywheel. The
frictional drive from the engine to the transmission is thereby disconnected.
When the clutch pedal is released a spring returns the pedal to its free position and the release bearing is drawn away
from the release levers of the pressure plate assembly.
The main springs of the pressure plate assembly then re-assert pressure on the pressure plate moving it towards the
friction disc and into contact with the flywheel, re-establishing the drive between engine and gearbox.
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Command - Overview (Clutch Components)

TAG007 1
1 Hydraulic Oil Reservoir 2 Clutch Pedal

3 Interlock Cable 4 Slave Cylinder Bleed Tube
5 Slave Cylinder Assembly 6 Slave Cylinder Oil Supply Tube
7 Master Cylinder
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Command - Exploded view (Release Bearing/ Slave Cylinder

Assembly)
TAG18008 1
1 Housing 2 “O” Ring

3 Bearing Assembly 4 Snap Ring
5 Wiper Seal 6 “O” Ring
7 Guide Ring 8 Piston
9 Guide Ring 10 Seal Ring
11 Snap Ring 12 Guide Sleeve
13 Seal 14 Back up Seal
15 “O” Ring
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POWER COUPLING Clutch - Remove

Prior operation:
1. Remove the bolts securing the clutch pressure plate

and cover assembly to the flywheel and remove the
pressure plate assembly together with the clutch
disc.
NOTE: The bolts must be slackened evenly and diagonally
across the clutch to prevent distortion of the cover assem-
bly.
TAG18003 1
Release Bearing
2. At the front of the transmission, remove the two tubes
(2) from the hydraulic release bearing (1). Remove
the three bolts securing the release bearing assem-
bly to the transmission front plate and withdraw the
release bearing assembly.
TAG18006 2
Clutch Pedal
3. To remove the clutch pedal, remove the upper in-
strument panel console and then the lower panel.
Disconnect the rod to the master cylinder. Carefully
lever off the pedal return spring, remove the clutch
pedal shaft retaining snap ring, withdraw the shaft
and pull the pedal from the tractor.
Next operation:
POWER COUPLING Clutch - Visual inspection (C.10.C)
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POWER COUPLING Clutch - Visual inspection

Prior operation:
POWER COUPLING Clutch - Remove (C.10.C)
1. Inspect the clutch disc to ensure the linings are not

loose, cracked, worn or contaminated with oil. Check
that the rivets are secure. If signs of overheating due
to clutch slippage or excessive wear are evident, the
disc must be discarded and a new one installed.
NOTICE: Investigate the source of any oil or grease on the
facings and rectify before installing a new disc.
Pressure Plate
2. Examine the pressure plate assembly, ensure the di-
aphragm fingers are all at the same height, there is
no discolouration due to excessive heat and that the
assembly operates smoothly. Check the face of the
pressure plate for cracks, scoring or distortion. Dis-
card the pressure plate if any faults are found.
NOTE: The diaphragm type clutch has no serviceable com-
ponents. A new assembly will be required if any faults are
found during inspection
Release Bearing
3. Inspect the release bearing for the following, oil leak-
age, weak or broken return spring and wear or dam-
age to the release bearing. Repair kits are available
should seals or the bearing assembly require servic-
ing.
Next operation:
Command - Overhaul (Release Bearing/ Slave Cylinder Assembly) (C.10.C)
POWER COUPLING Clutch - Install (C.10.C)
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POWER COUPLING Clutch - Install

Prior operation:
Command - Overhaul (Release Bearing/ Slave Cylinder Assembly) (C.10.C)
1. Install the pressure plate assembly together with the

clutch disc and center the clutch disc.
2. Install the bolts securing the clutch pressure plate
and cover assembly to the flywheel.
NOTE: The bolts must be tighten evenly and diagonally
across the clutch to prevent distortion of the cover assem-
bly.
TAG18003 1
Release Bearing
3. Install the release bearing assembly to the transmis-
sion front plate and tighten the three bolts.
4. Install the two tubes (2) from the hydraulic release
bearing (1).
TAG18006 2
Clutch Pedal
5. Mount the clutch pedal and install shaft. Install the
pedal shaft retaining snap ring.
Carefully lever on the pedal return spring.
6. Connect the rod to the master cylinder.
7. Install the lower panel and then the upper instrument
panel console.
Next operation:
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Command - Overhaul (Release Bearing/ Slave Cylinder Assembly)

Command - Exploded view (Release Bearing/ Slave Cylinder Assembly) (C.10.C)
Prior operation:
POWER COUPLING Clutch - Remove (C.10.C)
1. Remove bearing retaining snap ring (4) and withdraw

the bearing assembly (3).
2. Carefully pry the bearing cage claws open and with-
draw the piston assembly.
3. In the dismantled condition it is wise to replace the
seals with new items as a precautionary measure
against future failure. Inspect the remaining compo-
nents for wear or damage and replace as necessary.
4. When re-assembling coat all seals with clean brake
oil of the correct specification as they are installed
and assembled - see Consumables Lubrications
and Coolants ().
Next operation:
POWER COUPLING Clutch - Install (C.10.C)
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POWER COUPLING Clutch - Troubleshooting

Problem Possible Cause Correction

No drive when gear Rear axle or transmission faulty Engage differential lock. If tractor drives,
selected and clutch pedal fault indicated from output of differential
released unit. If still no drive, possible transmission
or rear axle fault.
Note: If FWD fitted, engage FWD, if tractor
drives, transmission O.K.
Clutch bearing not releasing a). Pedal not releasing fully on hydraulic
system, keeping bearing engaged.
b). Fault in master or slave cylinders.
Friction disc completely worn Replace friction disc
Pressure plate faulty Repair or replace pressure plate
Engine speed increases Clutch friction disc slipping Check clutch adjustment
without a corresponding Worn friction disc
rise in road speed, clutch Pressure plate faulty
pedal released. a). Release bearing of hydraulic clutch not
fully releasing, check that pedal to master
cylinder rod has some free play
b). Master or slave cylinder faulty
Difficulty engaging gears Clutch Dragging (not fully disengaging) Check clutch adjustment
Worn friction disc
Faulty pressure plate
On hydraulic systems:
a). Air in system, bleed system
b). Faulty seals in either master or slave
cylinder
Impossible to engage Clutch not disengaging Check clutch adjustment
gears, engine stalls when Linkage disconnected / faulty (mechanical)
tractor halted, clutch No / low oil (hydraulic system)
pedal depressed Faulty seals in master or slave cylinder (hy-
draulic)
Clutch disc seized onto flywheel, pressure
plate or input shaft splines
Pressure plate faulty, repair or replace as
necessary
Noise from transmission Release bearing worn Replace release bearing
bell housing, noise
changes when pedal is
depressed and released
Clutch pilot bearing worn Replace pilot bearing
Clutch fails to engage Defective clutch friction disc Replace friction disc
smoothly
Defective pressure plate Replace pressure plate
Worn clutch pilot bearing Replace pilot bearing
Defective flywheel Inspect flywheel as detailed in the Engine
Section
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Index

Command - Exploded view (Release Bearing/ Slave Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Command - Overhaul (Release Bearing/ Slave Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Command - Overview (Clutch Components) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER COUPLING Clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER COUPLING Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER COUPLING Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER COUPLING Clutch - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER COUPLING Clutch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER COUPLING Clutch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER COUPLING Clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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TRANSMISSION Mechanical - 20.B
MAXXUM 100
MAXXUM 110
MAXXUM 115
MAXXUM 125
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Contents
TECHNICAL DATA
TRANSMISSION Mechanical
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear and synchroniser

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fork and shift rail

Range fork - Exploded view (High/Medium and Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reverser fork - Exploded view (Forward/Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Speed fork - Exploded view (1/2 and 3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Transmission command
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Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shaft
Clearance (Output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fork and shift rail

Range fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Range fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Speed fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Speed fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Cover
Remove (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Install (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

DIAGNOSTIC
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Mechanical
TRANSMISSION Mechanical - Torque

BVF1110A 1
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BSF4663A_273 2
BVE0599A_30 3
TRANSMISSION Mechanical - Special tools

CAUTION
in this manual.
B008

previous No.
380000569 Tractor splitting kit 297471
X 380001116 Transmission lifting eyebolt -
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BTB0459A_274 1
Transmission to Stand Attachment Bracket - Constructional Detail
Main bracket made from 19 mm (0.75 in) mild steel plate.
(1) Center spigot (locally adjust to suit base stand)

NOTE: Strengthening plate should be of similar material and welds should be secure, preferably continuous.
BVF1147A_275 2
Range Cluster Bearing Adapter Tool
TRANSMISSION Mechanical - General specification

Type 12x12 12 forward and 12 reverse speeds, using straight cut gears, and
friction cone synchronizers
Control system Mechanical levers and linkage
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Adjustments
Output shaft end float 0.038 - 0.089 mm (0.0015 - 0.0035 in)
Output shaft end float adjustment shims 0.076 mm (0.0030 in); 0.125 mm (0.0049 in);
available 0.305 mm (0.0120 in); 0.762 mm (0.0300 in)
Adjustable link rod 83.5 - 84.9 mm (3.29 - 3.34 in)
NOTE: The driveline oil specification and capacity is described in Consumables Lubrications and Coolants.
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TRANSMISSION Mechanical - Sectional view

Gear Description Number of Teeth

40 km/h 30 km/h
( 24.9 mph) ( 18.6 mph)
A Forward/reverse gear drive 33 33
B Reverse gear driven 39 39
C 1st gear drive 31 27
D 2nd gear drive 38 34
E 3rd gear drive 45 40
F High range gear drive 52 49
G Medium range gear drive 35 33
H Low range gear drive 19 19
J Low range gear driven 60 60
K Medium range gear driven 44 46
L High range gear driven 27 31
M 3rd gear driven 34 39
N 2nd gear driven 41 45
P 1st gear driven 49 52
Q Reverse cluster gear drive 40 40
R Reverse cluster gear driven 33 33
S Reverse gear idler 35 35
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SS09D188 1
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TRANSMISSION Mechanical - Detailed view

BSF4416A 1
1 Input shaft 2 Bearing

3 Forward drive gear 4 Forward/Reverse synchronizer
5 Reverse drive gear 6 Bearing
7 1st gear drive (C) 8 2nd gear drive (D)
9 3rd gear drive (E) 10 3/4 synchronizer
11 Bearing 12 High range gear drive (F)
13 Medium range gear drive (G) 14 Low range gear drive (H)
15 Bearing 16 Bearing
17 PTO shaft 18 Output shaft
19 Taper roller bearing 20 Low range gear driven (J)
21 Low range sliding coupling 22 Medium range gear driven (K)
23 High/Medium synchronizer 24 High range gear driven (L)
25 Bearing 26 3rd gear driven (M)
27 2nd gear driven (N) 28 1/2 gears synchronizer
29 1st gear driven (P) 30 Bearing
31 Reverse cluster gear drive (Q) 32 Reverse cluster gear driven (R)
33 Bearing 34 Reverse Gear Idler (S)
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TRANSMISSION Mechanical - Dynamic description

Gear Description Number of Teeth

40 km/h 30 km/h
( 24.9 mph) ( 18.6 mph)
A Forward/reverse gear drive 33 33
B Reverse gear driven 39 39
C 1st gear drive 31 27
D 2nd gear drive 38 34
E 3rd gear drive 45 40
F High range gear drive 52 49
G Medium range gear drive 35 33
H Low range gear drive 19 19
J Low range gear driven 60 60
K Medium range gear driven 44 46
L High range gear driven 27 31
M 3rd gear driven 34 39
N 2nd gear driven 41 45
P 1st gear driven 49 52
Q Reverse cluster gear drive 40 40
R Reverse cluster gear driven 33 33
S Reverse gear idler 35 35
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BSF4402A 1
Power Flows - Neutral
Engine power is transmitted from the flywheel mechanical clutch to the transmission input driveshaft.
Gear Lever Positions
• Shuttle lever in neutral, main shift lever in neutral and range lever in neutral.
BSF1035A 2
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BSF4406A 3
Power Flows - 1st Gear
Input shaft - gear A - forward/reverse synchronizer - gears C-P - 1/2 synchronizer - gears L-F-H-J - low sliding coupler
- output shaft.
• Shuttle lever in forward, main shift lever in 1st gear and range lever in low range.
BVF1039A 4
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BSF4407A 5
Power Flows - 2nd Gear
Input shaft - gear A - forward/reverse synchronizer - gears D-N - 1/2 synchronizer - gears L-F-H-J - low sliding coupler
- output shaft.
• Shuttle lever in forward, main shift lever in 2nd gear and range lever in low range.
BVF1038A 6
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BSF4405A 7
Power Flows - 7th Gear
Input shaft - gear A - forward/reverse synchronizer - 3/4 synchronizer - gears E-M-L-F-G-K - high/medium synchro-
nizer - output shaft.
• Shuttle lever in forward, main shift lever in 3rd gear and range lever in medium range.
BVF1037A 8
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BSF4403A 9
Input shaft - gear A - forward/reverse synchronizer - 3/4 synchronizer - gears F-L - high/medium synchronizer - output
shaft.
• Shuttle lever in forward, main shift lever in 4th gear and range lever in high range.
BVF1036A 10
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BSF4404A 11
Power Flows - Reverse 6th Gear
Input shaft - gears A-S-R-Q-B - forward/reverse synchronizer - gears D-N - 1/2 synchronizer - gears L-F-G-K - high/
medium synchronizer - output shaft.
• Shuttle lever in reverse, main shift lever in 2nd gear and range lever in medium range.
BVF1040A 12
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TRANSMISSION Mechanical - Static description

The transmission provides three selectable ranges. Within each of these ranges a further four ratios may be selected.
This in effect provides a three times four (3x4=12) transmission resulting in 12 ratios, providing twelve forward and
twelve reverse speeds. All shifts except down shifting into low range are synchronized.
The basic transmission can be specified with the 40 km/h (24.9 mph) option in place of the standard 30 km/h (18.6
mph).
BVF1101A 1
Main Shift Lever

The main shift lever (1) operates in a conventional H-pattern and, in conjunction with the clutch pedal, is used to select
any of four gear ratios, whether the tractor is stationary or moving.
Range Lever
The right-hand lever (2) is the range lever which, in conjunction with the clutch pedal, is used to select any one of
three ranges (L - the lowest speed range, M- medium range and H - the highest speed range). This has the effect of
tripling the number of gears, both in forward and reverse, from 4 to 12. The design of the transmission permits easy
changes between the medium and high ranges while the tractor is moving. The tractor must be stopped to change
between the medium and low ranges.
BSE3689A 2
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Shuttle Lever
The shuttle lever (1) is used to select forward or reverse travel when any one of the twelve gears is engaged, provided
that the clutch pedal is depressed. To reverse the direction of travel, reduce engine and tractor speed to a minimum,
depress the clutch and move the shuttle lever rearwards. Re- engage the clutch and increase engine speed, as
required.
BSE3687A 3
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Gear and synchroniser - Overview

Rear Section
BVF1085A_299 1
1 High range gear drive (52/49 teeth) 2 Medium range gear drive (35/33 teeth)
3 Low range gear drive (19 teeth) 4 Low range gear driven (60 teeth)
5 Output shaft 6 Low sliding coupler
7 Medium range gear driven (44/46 teeth) 8 High/ medium synchronizer
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Middle Section
BVF1086A_302 2
1 Lubrication oil supply manifold 2 1st gear drive (31/27 teeth)

3 2nd gear drive (38/34 teeth) 4 3rd gear drive (45/40 teeth)
5 3/4 synchronizer 6 High range gear driven (27/31 teeth)
7 3rd gear driven (34/39 teeth) 8 2nd gear driven (41/52 teeth)
9 1/2 synchronizer 10 1st gear driven (49/52 teeth)
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Gear and synchroniser - Exploded view

PTO Shaft Assembly
BVF1128A 1
1 PTO shaft 2 Circlip

3 Bearing 4 Circlip
5 Oil seal
Front Cover
BVF1129A 2
1 Reverse idler gear (35 teeth) 2 Steel washer

3 Circlip 4 Front cover plate
5 O-ring 6 Sealing washer
7 Reverse idler shaft retaining bolt 8 Lubrication oil transfer tube
9 Circlip 10 Input shaft oil seal
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11 Reverse idler shaft 12 Steel washer

13 Circlip
Input Shaft
BVF1130A 3
1 Input shaft support bearing 2 Input shaft

3 Oil seal 4 Forward/reverse synchronizer
5 Reverse gear driven (39 teeth)
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Forward/ Reserve Synchronizer
BVE0659A_297 4
1 Outer cone/coupling 2 Friction cone

3 Sliding coupler 4 Centre hub
5 Friction cone 6 Outer cone/coupling
7 Spring 8 Detent ball
9 Detent guide
Reverse Gear Cluster
BVF1127A_298 5
1 Bearing 2 Reverse gear cluster

3 Bearing 4 Lubrication oil transfer tube
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Output Shaft Assembly
BVF1131A_300 6
1 Low range gear driven (60 teeth) 2 Washer

3 Spacer 4 Taper roller bearing
5 Low range sliding coupler 6 Output shaft
7 Medium range gear driven (44/46 teeth) 8 High/medium synchronizer
9 Taper roller bearing
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High/Medium Synchronizer
BVE0659A_297 7

9 Detent guide
High/Medium And Low Range Cluster Shaft
BVF1142A_301 8
1 Spacer ring 2 Bearing

3 Cluster shaft 4 Bearing
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Main Shaft
BVF1111A_303 9
1 Lubrication oil supply manifold 2 3/4 synchronizer

3 3rd gear drive (45/40 teeth) 4 Main shaft
5 Bearing
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3/4 Synchronizer
BVE0659A_297 10

9 Detent guide
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Counter Shaft
BVF1112A_304 11
1 3rd gear driven (34/39 teeth) 2 Bearing

3 High range gear driven (27/31 teeth) 4 2nd gear driven (41/45 teeth)
7 Steel thrust washer 8 Circlip
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1/2 Synchronizer
BVE0659A_297 12

9 Detent guide
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Fork and shift rail Range fork - Exploded view (High/Medium and
Low)
SS09D216 1
1 Actuator lever 2 Roll pin

3 Adjustable link rod 4 Synchronizer control housing
5 High/medium detent assembly 6 High/medium synchronizer shift rail
7 Rollpin 8 High/medium synchronizer shift fork
9 Circlip 10 Washer
11 Return spring 12 Washer
13 Actuator shaft retainer 14 Spacer
15 Actuator shaft 16 Low detent assembly
17 Interlock rod 18 Low sliding coupler shift rail
19 Rollpin 20 Low sliding coupler shift fork
21 Circlip 22 Washer
23 Support shaft 24 Link rod actuator
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Fork and shift rail Reverser fork - Exploded view (Forward/Reverse)

BVF1108A 1
1 Shift fork retaining bolt and nut (x2) 2 O-ring

3 Washer 4 Shift lever retaining circlip
5 Cover plate 6 Control cover
7 Forward/reverse detent assembly 8 Forward/reverse status switch
9 Shift lever bushings (x2) 10 O-ring
11 Forward/reverse shift lever 12 Oil seal
13 Forward/reverse shift rail 14 Forward/reverse shift fork
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Fork and shift rail Speed fork - Exploded view (1/2 and 3/4)
SS09D214 1
1 Actuator lever 2 Adjustable link rod

3 Link rod actuator 4 Washer
5 Circlip 6 Support shaft
7 3/4 synchronizer detent assembly 8 Locking bolt
9 3/4 synchronizer shift fork 10 Grub screw
11 3/4 synchronizer shift rail 12 Support shaft
13 Actuator 14 Actuator shaft
15 Spacer 16 Actuator shaft retainer
17 Circlip 18 Washers
19 Return spring 20 Interlock rod
21 1/2 synchronizer detent assembly 22 Locking bolt
23 1/2 synchronizer shift fork 24 1/2 synchronizer shift rail
25 Synchronizer control housing
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TRANSMISSION Mechanical - Remove

Prior operation:
Remove the cab - see USER PLATFORM - Remove (E.34.A).
Remove the fuel tank - see Fuel tank - Remove (B.20.A).
Separate the engine and front support from the transmission - see ENGINE - Disconnect (Engine / Transmission)
(B.10.A).
DANGER
B012
1. Disconnect the wiring harness as required to enable

the separation of the transmission from the rear axle.
2. Remove the battery tray swivel pin (1) and remove
the battery tray and battery.
BVE0342A 1
3. Remove the cab support.
BVE0343A 2
4. Detach the brake tubes support bracket from the

transmission housing.
5. Disconnect the hydraulic pipes between rear axle
and transmission.
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6. Install the lifting eyebolts 380001116, (1) on the

transmission.
Using a suitable chain, attach the transmission to a
hoist.
Position the splitting kit (3) 380000569 underneath
the tractor.
Use the supports (2), in the splitting kit to support the
rear axle on the splitting stand.
WARNING
Always ensure transmission and rear axle sections of
the tractor are fully supported to prevent any move-
ment when the transmission is removed.
B019
BVE0344A 3
7. Remove the transmission to rear axle retaining bolts.

Remove the transmission from the rear axle.
Next operation:
TRANSMISSION Mechanical - Disassemble (C.20.B)
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TRANSMISSION Mechanical - Disassemble

Prior operation:
TRANSMISSION Mechanical - Remove (C.20.B)
WARNING
B026
WARNING
B012
1. Using the locally fabricated stand attachment

bracket, install the transmission to a suitable stand.
BVE029A_276 1
2. Remove the forward/reverse synchronizer control

cover - see Cover - Remove (Forward / Reverse)
(C.20.B).
3. Remove the gearshift cable retaining bracket (1).
BVF1043A_277 2
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4. Remove the high/medium and low synchronizer con-

trol cover - see Fork and shift rail Range fork - Re-
move (C.20.B).
5. Remove the 1/2 and 3/4 synchronizer control cover
- see Fork and shift rail Speed fork - Remove
(C.20.B).
6. Using suitable snap ring pliers remove the PTO shaft
bearing retaining snap ring (1).
BVF1046A_278 3
7. Using a suitable soft faced hammer, remove the PTO

shaft (1).
BVF1047A 4
8. Rotate the transmission 90 °.

Remove the hydraulic release bearing oil supply
pipes (1) and the hydraulic release bearing retaining
bolts (2).
BVF1048A 5
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9. Remove the hydraulic release bearing (1).
BVF1049A 6
10. Remove the front cover plate (1).

NOTE: Ensure the lubrication oil supply pipe is not dam-
aged during removal of the front cover plate.
NOTE: To assist removal, tap the front cover plate through
the forward/reverse synchronizer control cover aperture.
BVF1050A 7
11. Remove the input shaft (1).
BVF1051A 8
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Front Section Removal

12. Remove the forward/reverse synchronizer retaining
snap ring (1).
BVF1052A_279 9
13. Remove the forward/reverse synchronizer (1) with

the reverse cluster (2).
BVF1053A_280 10
14. Remove the reverse driven gear (1).
BVF1054A_281 11
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15. Using a suitable lever in the cut-outs provided (1),

remove the lubrication oil supply manifold (2).
BVF1055A_282 12
Rear Section Removal

Remove the rear plate (1).
NOTE: The counter-shaft front bearing may fall out when
the transmission is rotated.
NOTE: Ensure the range gear cluster remains in the trans-
mission while removing the rear plate.
BVF1056A_283 13
17. Using a suitable universal puller (1) and the locally

fabricated tool (2), remove the range gear cluster
bearing (3).
BVF1057A_284 14
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18. Remove the output shaft assembly (1).
BVF1058A_285 15
19. Remove the high/medium synchronizer rings (1).
BVF1059A_286 16
20. Remove the range gear cluster shaft (1).
BVF1060A_287 17
21. Remove the needle roller bearing (1).
BVF1061A_288 18
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22. Remove the 3/4 synchronizer rings (1).
BFV1062A 19
Middle Section Removal

Support the countershaft and remove the retaining
circlip (1).
NOTE: Support the 1/2 and 3/4 synchronizers while rotat-
ing the transmission.
BVF1064A_289 20
24. Remove the countershaft (1) from the rear end of the
transmission.
BVF1065A_290 21
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25. Remove the 1/2 synchronizer, gears and the

D-washer.
BVF1066A_291 22
26. Using suitable snap ring pliers, remove the main

shaft bearing snap ring (1).
BVF1067A_292 23

Support the main shaft through the top cover aper-
ture and remove the 3/4 synchronizer retaining snap
ring (1).
NOTE: Support the 3/4 synchronizer while rotating the
transmission.
BVF1068A_293 24
28. Remove the main shaft (1) through the bell-housing.
BVF1070A_294 25
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29. Remove the 3/4 synchronizer and 3rd gear drive as-
sembly (1).
BVF1069A_295 26
Next operation:
TRANSMISSION Mechanical - Assemble (C.20.B)
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TRANSMISSION Mechanical - Assemble

Prior operation:
TRANSMISSION Mechanical - Disassemble (C.20.B)
WARNING
B026
WARNING
B012
Middle Section Installation

1. Install the 3/4 synchronizer and 3rd gear drive as-
sembly (1).
BVF1069A_295 1
2. Install the main shaft (1) through the bell-housing.
BVF1070B_306 2
84276322A 31/05/2010
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3. Support the main shaft through the top cover aper-

ture and using suitable circlip pliers install the 3/4
synchronizer retaining snap ring (1).
BVF1071A_307 3

Install the 3/4 synchronizer and main shaft assembly
(1) into the housing.
NOTE: Support the 3/4 synchronizer and main shaft while
rotating the transmission.
BVF1072A_308 4
5. Using suitable snap ring pliers install the main shaft

BVF1067A_292 5

Install the 1/2 synchronizer and gears into the hous-
ing.
BVF1073A_309 6
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7. Install the countershaft (1) through the rear end of the

transmission.
BVF1065B_310 7
8. Support the countershaft, install the D-washer (1)

and using suitable circlip pliers install the counter-
shaft retaining circlip (2).
BVF1074A_311 8

Install the 3/4 synchronizer rings (1).
NOTE: Position the two shafts so the main shaft bearing
is seated on its snap ring and the countershaft bearing is
seated in its cup.
BVF1075A_312 9
10. Install the needle roller bearing (1).
BVF1061A_288 10
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Rear Section Installation

11. Install the range cluster gear shaft (1).
BVF1060A_287 11
12. Install the high/medium synchronizer rings (1).
BVF1059A_286 12
13. Install the output shaft assembly (1).
BVF1058A_285 13
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14. Install the range cluster gear bearing (1).

NOTE: The use of an electronic induction heater will assist
in the installation of the bearing without the need for a hy-
draulic press.
BVF1076A_313 14
15. Install the rear plate assembly. Tighten the retaining

bolts to the specified torque value.
BVF1077A_314 15

Install the lubrication oil supply manifold (1) and the
output shaft rear bearing (2).
BVF1078A_315 16
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Front Section Installation

17. Install the reverse driven gear (1).
BVF1054A_281 17
18. Install the forward/reverse synchronizer (1) with the

reverse gear cluster (2).
BVF1053A_280 18
19. Install the forward/reverse synchronizer retaining

snap ring (1)
BVF1052A_279 19
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20. Thoroughly clean and degrease the mating surfaces

and apply a bead of liquid gasket of approximately 2
mm (0.08 in) diameter following the pattern shown.
BVF1079A 20
21. Install the front plate assembly. Tighten the retaining

BVF1050B 21
22. Install the hydraulic release bearing (2)

Install the oil supply pipes (1) and tighten the retain-
ing bolts to the specified torque value.
BVF1080A 22

Install the PTO shaft into the transmission.
BVF1081A_316 23
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24. Install the PTO shaft bearing retaining snap ring (1).
BVF1046A_278 24
25. Adjust the output shaft end float - see Shaft - Clear-
ance (Output shaft) (C.20.B).
26. Install the 1/2 and 3/4 synchronizer control cover
- see Fork and shift rail Speed fork - Install
(C.20.B).
27. Install the high/ medium and low synchronizer control
cover - see Fork and shift rail Range fork - Install
(C.20.B).
28. Install the gearshift cable retaining bracket (1).
BVF1043A_277 25
29. Install the forward / reverse control cover - see Cover

- Install (Forward / Reverse) (C.20.B).
Next operation:
TRANSMISSION Mechanical - Install (C.20.B)
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TRANSMISSION Mechanical - Install

Prior operation:
TRANSMISSION Mechanical - Assemble (C.20.B)
DANGER
B012
WARNING
Always ensure transmission and rear axle sections of the tractor are fully supported to prevent any movement
when the transmission is installed.
B018

transmission.
hoist.
BVE0344A 1

Align the transmission to the rear axle and install the
transmission to rear axle retaining bolts. Tighten to
the specified torque value.
BVE0599A_49 2
3. Connect the oil pipes between the rear axle and the
transmission.
4. Attach the brake tubes support bracket.
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5. Install the cab support.
BVE0343A 3
6. Install the battery tray and battery. Install the battery

tray swivel pin (1).
BVE0342A 4
7. Connect or Install the wiring harness as required.
Next operation:
Connect the engine and front support to the transmission - see ENGINE - Connect (Engine / Transmission) (B.10.A).
Install the fuel tank - see Fuel tank - Install (B.20.A).
Install the cab - see USER PLATFORM - Install (E.34.A).
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Transmission command - Travel adjust

1. Ensure the tractor is not in gear and the main shift

and range levers are in the neutral position.
Check and if necessary adjust the length of both of
the adjustable link rods.
X = 83.5 - 84.9 mm (3.29 - 3.34 in).
BVF1102A_324 1
2. Loosen the range selection cable adjustment nuts.
BVF1104B_325 2
3. Move the range selection cable (3) to remove the

freeplay until the range lever in the cab is in the po-
sition shown.
Tighten the adjustment nut (1) to the bracket and
tighten the adjustment nut (2).
BVF1105B_326 3
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4. Loosen the range shift cable adjustment nuts.
BVF1104A_327 4
5. Move the range shift cable (3) to equally distribute

the freeplay until the range lever in the cab is in the
position shown.
Tighten the adjustment nuts (1) and (2).
NOTE: Ensure the range lever in the cab is still located in
the detent position.
NOTE: Ensure the range shift lever in the cab is not ob-
structed by the console when selecting a gear.
BVF1105A_328 5
6. Loosen the main shift selection cable adjustment

nuts.
BVF1106B_329 6
7. Move the main shift selection cable (3) to remove the

freeplay until the main shift lever in the cab is in the
position shown.
BVF1107B_330 7
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8. Loosen the main shift cable adjustment nuts.
BVF1106A_331 8
9. Move the main shift cable (3) to equally distribute the

position shown.
NOTE: Ensure the main shift lever in the cab is still located
in the detent position.
NOTE: Ensure the main shift lever in the cab is not ob-
BVF1107A_332 9
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Shaft - Clearance (Output shaft)

NOTE: It is necessary to adjust the running clearance of the components on the output shaft. The clearance is ob-
tained by the placement of shim(s) behind the output shaft front taper roller bearing retainer.
NOTICE: The transmission must remain in the vertical position during this operation.
1. Remove the output shaft front taper roller bearing
retainer.
BVF1098A 1
2. Install a number of adjustment shims (S1) (1) of a

known dimension to achieve output shaft end float.
BVF1099A 2
3. Install the output shaft front taper roller bearing re-

tainer. Tighten the retaining bolts to the specified
torque value.
BVF1098B 3
4. The output shaft end float required is 0.038 - 0.089

mm (0.0015 - 0.0035 in). To achieve this, carry out
the following:
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5. Rotate the output shaft several times to seat the

bearing rollers.
Using a suitable dial gauge (1) and lever (2), mea-
sure the output shaft end float.
This measurement is (M1)
BVF1100A 4
6. Determine the thickness of the shim(s) to be installed

as follows:
R1 S1-(M1-0.063)
Where:
R1 Required shim(s) thickness.
S1 Test shim(s) thickness.
M1 Measured output shaft end float (with test shim(s) (S1) installed).
0.063 Mean of required end float ( 0.038 - 0.089 mm).
NOTE: If required decrease (R1) to the nearest available shim size.

NOTE: Increasing shim thickness increases end float, decreasing shim thickness decreases end float.
7. Remove the test shim(s) (S1) and install the calcu-
lated shim(s) (R1).
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torque value.
BVF1098B 5
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Gear and synchroniser - Measure

1. Inspect the High/Medium range, forward/reverse and

1-2 and 3-4 synchronizer components for wear and
damage as follows:
Inspect the cone (1) for wear and damage and dis-
colouration, if excessive renew the synchronizer.
Check the gap between the cone and end plate, (2),
using a feeler gauge (3), if the gap is less than that
specified renew the synchronizer.
MMG 21 447_271 1
Minimum Gap
1-2 & 3-4 synchronizers 0.5 mm (0.020 in)
Foward/Reverse synchronizer 0.8 mm (0.0315 in)
Hi/Med synchronizer 0.85 mm (0.0335 in)
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Fork and shift rail Range fork - Remove

Fork and shift rail Range fork - Exploded view (High/Medium and Low) (C.20.B)
Prior operation:
Remove the battery tray as described in TRANSMISSION Mechanical - Remove (C.20.B).
Remove the control cables as described in USER PLATFORM - Remove (E.34.A).
NOTE: If the transmission is removed, the prior operations are not necessary.
trol cover (1).
BVF1044A 1
Next operation:
Fork and shift rail Range fork - Install (C.20.B)
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Fork and shift rail Range fork - Install

Fork and shift rail Range fork - Exploded view (High/Medium and Low) (C.20.B)
Prior operation:
Fork and shift rail Range fork - Remove (C.20.B)

BVF1083A_318 1
2. Install the high/medium and low synchronizer control

cover. Tighten the retaining bolts to the specified
torque value.
BVF1044A_319 2
NOTE: If the transmission is removed, the next operations are not necessary, continue with transmission assemble
- see TRANSMISSION Mechanical - Assemble (C.20.B).
Next operation:
Reconnect the control cables as described in USER PLATFORM - Install (E.34.A).
Adjust the control cables as described in Transmission command - Travel adjust (C.20.B).
Install the battery tray as described in TRANSMISSION Mechanical - Install (C.20.B).
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Fork and shift rail Speed fork - Remove

Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) (C.20.B)
Prior operation:
Remove the battery tray as described in TRANSMISSION Mechanical - Remove (C.20.B).
(1).
BVF1045A 1
Next operation:
Fork and shift rail Speed fork - Install (C.20.B)
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Fork and shift rail Speed fork - Install

Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) (C.20.B)
Prior operation:
Fork and shift rail Speed fork - Remove (C.20.B)

BVF1082A_317 1
2. Install the 1/2 and 3/4 synchronizer control cover.

value.
BVF1045B 2
Next operation:
Install the battery tray as described in TRANSMISSION Mechanical - Install (C.20.B).
84276322A 31/05/2010
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Cover - Remove (Forward / Reverse)

Fork and shift rail Reverser fork - Exploded view (Forward/Reverse) (C.20.B)
Prior operation:
Remove the cab floor and the control cables as described in USER PLATFORM - Remove (E.34.A).
NOTE: If the transmission is removed, the prior operation is not necessary.

NOTE: Ensure all gears are in neutral.
cover (1).
BVF1042A 1
Next operation:
Cover - Install (Forward / Reverse) (C.20.B)
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Cover - Install (Forward / Reverse)

Fork and shift rail Reverser fork - Exploded view (Forward/Reverse) (C.20.B)
Prior operation:
Cover - Remove (Forward / Reverse) (C.20.B)

BVF1084A 1
2. Install the forward/reverse synchronizer control

cover. Tighten the retaining bolts to the specified
torque value.
BVF1042B 2
Next operation:
Install the cab floor as described in USER PLATFORM - Install (E.34.A).
84276322A 31/05/2010
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TRANSMISSION Mechanical - Troubleshooting


Transmission is noisy Low driveline oil level. Refill with the specified oil to the correct
during operation level. Locate oil leakage.
Incorrect driveline oil specification. Drain and refill with the specified oil to the
correct level.
Low or no lubrication oil pressure. Pressure test the lubrication circuit - see
Priority valve - Pressure test (A.14.A).
Mechanical failure in the transmission. Inspect the bearings for worn or damaged
parts. Replace part(s) as necessary.
Oil leak from the split pin Engine crankshaft rear main oil seal leak- Replace oil seal.
located in the bottom of age.
the transmission case
Worn or damaged input shaft oil seal, PTO Replace oil seal(s) or re-apply liquid gasket
drive shaft oil seal, transmission front plate- as necessary.
seal or reverse idler retaining bolt oil seal
leakage.
Hydraulic release bearing oil seal(s) (brake Replace oil seal(s) as necessary.
fluid reservoir requires regular topping up).
Difficult or failure to Incorrect selector cable(s) adjustment. Adjust selector cable(s) - see Transmis-
engage gears sion command - Travel adjust (C.20.B).
Damaged or worn shift forks. Inspect, repair or replace as necessary.
Worn synchronizers. Inspect synchronizer ring rubbing surfaces.
Replace as necessary if worn.
Excessive output shaft end float. Inspect bearings, replace as necessary.
Adjust output shaft end float.
Incorrect clutch operation. Air in the hydraulic system. Faulty clutch
pressure plate.
Failure to change between Incorrect selector cable adjustment. Adjust selector cable - see Transmission
forward and reverse command - Travel adjust (C.20.B).
Jumping out of gear Incorrect selector cable(s) adjustment. Adjust selector cable(s) - see Transmis-
sion command - Travel adjust (C.20.B).
Detents in shift covers faulty. Remove shift covers and inspect detent
balls and springs, replace parts as neces-
sary.
Worn synchronizer Inspect teeth of synchronizer assembly, re-
place parts as necessary.
Excessive output shaft end float. Inspect bearings, replace as necessary.
Adjust output shaft end float.
Holding in gear Clutch not releasing. Inspect the clutch and hydraulic release
bearing operation, replace parts as neces-
sary.
Detent(s) in shift covers sticking. Remove shift covers and inspect detent
balls and springs, replace parts as neces-
sary.
Incorrect selector cable(s) adjustment. Adjust selector cable(s) - see Transmis-
sion command - Travel adjust (C.20.B).
Sliding sleeve coupler tight on shaft Clean splines or replace shaft and sliding
splines. sleeve coupler as necessary.
84276322A 31/05/2010
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Index

Cover - Install (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Cover - Remove (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fork and shift rail Range fork - Exploded view (High/Medium and Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fork and shift rail Range fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fork and shift rail Range fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fork and shift rail Reverser fork - Exploded view (Forward/Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fork and shift rail Speed fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fork and shift rail Speed fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Gear and synchroniser - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gear and synchroniser - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Gear and synchroniser - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shaft - Clearance (Output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transmission command - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TRANSMISSION Mechanical - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TRANSMISSION Mechanical - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TRANSMISSION Mechanical - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRANSMISSION Mechanical - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION Mechanical - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSMISSION Mechanical - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TRANSMISSION Mechanical - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION Mechanical - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Mechanical - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Mechanical - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION Mechanical - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION Mechanical - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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TRANSMISSION Power Shuttle - 20.C
MAXXUM 100
MAXXUM 110
MAXXUM 115
MAXXUM 125
MAXXUM 140
84276322A 31/05/2010
C.20.C / 1
Contents
TECHNICAL DATA
TRANSMISSION Power Shuttle
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAXXUM 100, MAXXUM 110, MAXXUM 115, MAXXUM 125, MAXXUM 140
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dynamic description (Electrical Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Dynamic description (Hydraulic Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Control valve
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Exploded view (Lubrication Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40


Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fork and shift rail

Range fork - Exploded view (High/Medium and Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Speed fork - Exploded view (1/2 and 3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cover
Exploded view (Forward/Reverse Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SERVICE
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Speed selection command

Mechanical - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Control valve
Remove (Valve block C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Install (Valve block C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Shaft
Clearance (Output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Clutch and gear

Range clutch - Remove (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Range clutch - Disassemble (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Range clutch - Inspect (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Range clutch - Assemble (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Range clutch - Measure (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Range clutch - Clearance (Gear shaft, clutch C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Range clutch - Install (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Fork and shift rail

Range fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Range fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Speed fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Speed fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Cover
Remove (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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Install (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DIAGNOSTIC
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Power Shuttle
TRANSMISSION Power Shuttle - Torque

BSF4664A 1
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BSF4663A 2
BVE0599A_49 3
TRANSMISSION Power Shuttle - Special tools

CAUTION
in this manual.
B008

previous No.
X 380000291 Clutch piston return spring compressor 295021
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BTB0459A_256 1
BVF1147A 2
Pressure Test Tools

previous No.
380001147 Bypass Connector 297407
X 380000999 Adaptor 7/16 UNF male -
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previous No.
380000543 Quick Release Adaptor 291924
TRANSMISSION Power Shuttle - General specification

Type 24x24 24 forward and 24 reverse speeds,

using straight cut gears, two
multi-wet plate clutches and friction
cone synchronizers
Control system Electro-hydraulic with electronic

management system
Hydraulic Control Valve

Type Separate casting, with internal
cast-in galleries
Control Electronically operated solenoid

coils controlled by electronic
management system
Multi-Wet Plate Clutches

Type Constant running, pressure
lubricated, pressure applied, spring
released
Number of friction plates 6 pieces in each clutch

Number of steel plates 5 pieces in each clutch
Number of belleville washers 7 pieces in each clutch
Belleville washer stack height check Free Height 25.9 mm (1.02 in)
Loaded Height 2400 N (539.5 lb) 12.6 mm (0.50 in)
Number of separating springs 6 pieces in each clutch
Separating spring height check Free Height 5.08 mm (0.20 in)

Operating pressure 17 - 19 bar (246.50 - 275.50 psi)
Adjustments
Output shaft end float 0.038 - 0.089 mm (0.0015 - 0.0035 in)
Output shaft end float adjustment 0.076 mm (0.0030 in), 0.125 mm (0.0049 in),
shims available 0.305 mm (0.0120 in), 0.762 mm (0.0300 in)
C1 cluster gear shaft end float 0.050 - 0.075 mm (0.0020 - 0.0030 in)
C1 cluster gear shaft end float 0.076 mm (0.0030 in), 0.125 mm (0.0049 in),
adjustment shims available 0.305 mm (0.0120 in), 0.762 mm (0.0300 in)
Clutch plate set height 24.2 ±0.1 mm (0.9528 ±0.0039 in)
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Clutch steel plate thicknesses 2 mm (0.0787 in), 2.2 mm (0.0866 in)

available
Adjustable link rod 83.5 - 84.9 mm (3.2874 - 3.3425 in)
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TRANSMISSION Power Shuttle - Static description

The 24 x 24 transmission consists of a dual, multi-wet plate clutch assembly, known as C1 (under drive) and C2 (direct
drive), located directly between the flywheel damper and the input shaft of the transmission. This eliminates the need
for a conventional clutch.
The Dual Command unit provides an under drive to all of the standard direct drive ratios, reducing road speed by 18
% and increasing torque by 22 %, providing the transmission with 24 forward and 24 reverse gears.
Selection of either under drive or direct drive modes is by switches (2 and 3) located on the main shift lever (1).
The selection is carried out by PWM solenoid valves, which are controlled by a controller. This system provides
independent electronic control of the pressure on each clutch.
BSE3688A 1
For convenience, a duplicate set of shift buttons (1) are located on the right-hand control panel.
BSF3936A 2
A shuttle lever located under the left hand side of the steering wheel is used to select forward, reverse or neutral.
Lever position is communicated to the controller via switches located in the shuttle lever.
NOTE: A warning sound will be heard, and the symbol ’N’ will flash in the instrument cluster if shuttle shifting when
the speed is greater than 9 km/h (5.6 mph).
1b0o2004061012 3
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The transmission is powered through a flywheel damper and has no conventional clutch.
BSF4016A_258 4
Low Pressure Regulating Valve with Variable Displacement Load Sensing Hydraulic Pump
The pressure oil to engage the clutches is supplied from the low pressure hydraulic circuit, which is maintained at 17
- 19 bar (246.50 - 275.50 psi) by the low pressure regulating valve (1), located in the valve block in the base of the
remote control valve assembly.
BSF3967A_259 5
Low Pressure Regulating Valve with Fixed Displacement Hydraulic Gear Pump
- 19 bar (246.50 - 275.50 psi) by the low pressure regulating valve (1), located in the valve block on top of the low
pressure distribution block.
BSF4626A 6
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Transmission Control Valve

The control valve assembly is mounted on the right hand side of the transmission. The control valve is supplied with
low pressure oil through point (1) at 17 - 19 bar (246.50 - 275.50 psi).
The control valve assembly incorporates C1 PWM solenoid valve (2), C2 PWM solenoid valve (3), 1/2 synchronizer
status switch (4) transmission oil temperature sensor (5) and the dump solenoid valve (6).
BSF4622A 7
Lubrication Control Valve

Mounted on the C1 and C2 clutch housing is the lubrication control valve (1). This proportions the transmission lubri-
cation oil depending on the operating state of the C1/C2 clutches. This ensures adequate lubrication to the clutches
especially during inching/feathering.
BSF4629A 8
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INPUT SENSORS
The engagement of the clutches are controlled by inputs from various sensors and switches:
Transmission Oil Temperature Sensor

The transmission oil temperature sensor (1) measures the temperature of the oil to provide compensation for hot/cold
oil conditions.
BRE1795E 9
Clutch Pedal Potentiometer and Disconnect Switch

The clutch pedal potentiometer (1) provides the operator with controlled engagement of the feathering clutches (C1
or C2).
The clutch pedal disconnect switch (2) de-energizes the dump solenoid valve which disengages drive.
BVE0692A_260 10
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Shuttle Lever
The shuttle lever (1) provides information to the controller, via switches, for forward, reverse and neutral transmission
drive selection.
The neutral switch is open when the shuttle lever is in neutral, cutting off 12 V power supply to the controller. This
supply is used for C1 and C2 clutch PWM solenoid valves.
BSE2810A_265 11
Forward/Reverse Potentiometer
Provides information to the controller on the position of the forward and reverse synchronizer.
BSF4623A 12
Upshift and Downshift Switches

Located on the main shift lever (1) is the upshift switch (2) and the downshift switch (3). These switches allow the
operator to change between C1 (under drive) and C2 (direct drive) by sending a signal to the controller, without using
the clutch pedal.
BSE3688A_266 13
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High/Medium Synchronizer Status Switch

Provides information to the controller on the position of the high/medium synchronizer.
BRE1759D 14
First/Second Synchronizer Status Switch

Provides information to the controller on the position of the first/second synchronizer.
BRE1795D 15
Third/Fourth Synchronizer Status Switch

Provides information to the controller on the position of the third/fourth synchronizer.
BSF4625A 16
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Rear Axle Speed Sensor

The rear axle speed sensor (1) provides information of transmission output speed to the controller.
BVE0688A 17
Parking Brake Switch

The parking brake switch (1) is located on the parking brake lever. The parking brake has to be applied during cal-
ibration, if it is not applied an error code will be displayed.
The tractor will drive if the parking brake is applied but an audible alarm will be heard.
BRF1854B_262 18
Seat Switch
The seat switch must be operated, i.e. operator seated, before the controller allows the engagement of the forward
or reverse drive.
BRF1851B_263 19
NOTE: The clutch pedal will override a faulty seat switch.
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OUTPUT DEVICES
C1 and C2 Clutch PWM Solenoid Valves and Dump Solenoid Valve

The dump solenoid valve (1) stops the oil supply to the C1 and C2 clutch PWM solenoid valves.
The C1 (2) and C2 (3) clutch PWM solenoid valves control the oil supply to the clutches allowing the engagement/
disengagement of the clutches via a signal supplied from the transmission controller.
BSF4622B 20
Forward/Reverse PWM Solenoid Valves

The reverse (1) and forward (2) PWM solenoid valves control the oil supply to the forward/reverse synchronizer shift
rail, allowing the selection of forward or reverse via a signal from the transmission controller.
BSF4623B 21
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Analogue Digital Instrument Cluster (ADIC)

Provides information to the operator when C2 (direct drive) is engaged with the symbol (1) and if a critical fault occurs
with the transmission operation.
BVF1027A 22
CONTROL DEVICE
Controller
The controller (1) gives accurate control, via PWM solenoid valves, of the two multi-wet plate clutches. This also
enables clutchless shuttle operations and sequential power-shifting. The transmission controller has a diagnostic
facility that can interpret a number of system faults, which can be displayed or stored depending on how critical the
fault detected is.
BSE3118B_264 23
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TRANSMISSION Power Shuttle - Sectional view

Gear Description Number Of Teeth

40 km/h 30 km/h
( 24.9 mph) ( 18.6 mph)
A C1 gear drive 36 36
B Reverse gear drive 33 33
C Reverse gear driven 39 39
D 1st gear drive 31 27
E 2nd gear drive 38 34
F 3rd gear drive 45 40
G High range gear drive 52 49
H Medium range gear drive 35 33
J Low range gear drive 19 19
K Low range gear driven 60 60
L Medium range gear driven 44 46
M High range gear driven 27 31
N 3rd gear driven 34 39
P 2nd gear driven 41 45
Q 1st gear driven 49 52
R Reverse cluster gear drive 40 40
S Reverse cluster gear driven 33 33
T C1 cluster gear drive 35 35
U C1 cluster gear driven 30 30
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bsf4397b 1
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TRANSMISSION Power Shuttle - Detailed view

BSF4415A 1
1 C1 clutch gear drive (A) 2 C1 clutch

3 C2 clutch 4 Bearing
5 Reverse drive gear (B) 6 Bearing
7 Forward/Reverse synchronizer 8 Reverse gear driven (C)
9 Bearing 10 1st gear drive (D)
11 2nd gear drive (E) 12 3rd gear drive (F)
13 3/4 gears synchronizer 14 Bearing
15 High range gear drive (G) 16 Medium range gear drive (H)
17 Low range gear drive (J) 18 Bearing
19 Bearing 20 PTO shaft
21 Output shaft 22 Bearing
23 Low range gear driven (K) 24 Low range synchronizer
25 Medium range gear driven (L) 26 High/medium synchronizer
27 Taper roller bearing 28 High range gear driven (M)
29 Taper roller bearing 30 3rd gear driven (N)
31 2nd gear driven (P) 32 1/2 gears synchronizer
33 1st gear driven (Q) 34 Bearing
35 Reverse cluster gear drive (R) 36 Reverse cluster gear driven (S)
37 C1 cluster gear drive (T) 38 C1 cluster gear driven (U)
39 Input shaft
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TRANSMISSION Power Shuttle - Dynamic description (Electrical

Operation)
Neutral
The forward/reverse shuttle lever must be in neutral to allow engine start up. The other status switches, located on
the High/Medium, 1/2 and 3/4 shift rails provide the controller with the transmission status. Drive will not be permitted
if any of the shift levers are engaged without the clutch pedal being depressed.
With the transmission in neutral the dump solenoid valve is not energized and prevents oil supply from reaching the
C1 and C2 PWM solenoid valves. The controller always defaults the transmission to the C1 (under drive) selection
on start up.
Gear Selection
The clutch pedal must be depressed prior to any shift lever engagement, if not error code ‘CP’ will be displayed on
the instrument cluster and drive will not be permitted by the controller. When the clutch pedal is fully depressed and
a gear/range/direction selection is made, the dump solenoid valve remains de-energized by the action of the fully
depressed clutch pedal operating the disconnect switch. The C1 and C2 PWM solenoid valves are also de-energized
with the clutch pedal fully depressed.
Inching/Feathering
As the clutch pedal is raised from the fully depressed position the dump solenoid valve is energized, allowing oil supply
to the appropriate PWM solenoid valve. With the system in the default, C1 (under drive) mode, the C1 PWM solenoid
valve becomes energized. As the clutch pedal is raised the clutch potentiometer provides increased voltage to the
controller, and the controller in turn provides increased current to the C1 PWM solenoid valve, which regulates the oil
pressure to the C1 clutch. As the clutch pedal and therefore current, is raised the pressure to the C1 clutch is raised
correspondingly until full pressure/engagement is achieved.
Gear Shifting
As the clutch is depressed drive is disengaged between the engine and the transmission as the dump solenoid valve
is de-energized. Shifts are completed in the normal manner and drive is gradually re-established as the pedal is
raised as described in ‘inching/feathering’. The system has an electronic override feature where if the clutch pedal is
released quickly or accidentally the controller will take over and control the engagement speed of the clutch to prevent
sudden and possibly damaging engagements.
Drive
During continuous drive mode, clutch pedal fully released, the appropriate PWM solenoid valve is fully open allowing
full unrestricted oil pressure to the corresponding clutch.
C1 (Under Drive) to C2 (Direct Drive)

Operation of the upshift switch, located on the main shift lever, de-energizes the C1 PWM solenoid valve and en-
ergizes the C2 PWM solenoid valve, pressure oil is switched to the C2 clutch. The clutch engagement time is still
controlled by the controller during this changeover to ensure a smooth shift.
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Auto Take Off (ATO)

The ATO feature allows the operator to engage drive without using the clutch pedal by simply moving the shuttle lever
from neutral to the forward or reverse position.
The ATO function is automatically enabled under normal starting conditions. i.e. operator in the driving seat, clutch
pedal depressed, shuttle lever in neutral.
After selecting the appropriate gear ranges with the main shift lever, simply move the shuttle lever to the forward or
reverse position without depressing the clutch pedal. The ATO function will provide a controlled start from a stationary
position.
BSE2810C_267 1
NOTE: The ATO function will be disabled if the vehicle is at rest with the shuttle lever in the neutral position and the
operator leaves the seat.
If the ATO should be disabled for any reason, the operator should carry out the following procedure to re-enable this
function.
Sit in the seat, release the parking brake and cycle the clutch pedal. The vehicle will then move off in the direction
selected on the shuttle lever.
When enabled, the ATO function will continue to function as long as the operator remains in the seat.
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TRANSMISSION Power Shuttle - Dynamic description (Hydraulic

Operation)
Neutral
Pressure oil supplied by the hydraulic pump enters the transmission control valve. The oil is channeled directly to the
dump solenoid valve, which, with the transmission in neutral, is de-energized (closed), preventing the oil supply from
going through to the C1 and C2 PWM solenoid valves.
Inching/Feathering
With the clutch pedal depressed and the gear/range/direction selected the transmission is still immobilized due to the
dump solenoid valve remaining de-energized by the action of the clutch pedal in the fully depressed position. As the
clutch pedal is raised the dump valve is energized allowing oil supply to the C1 and C2 PWM solenoid valves. Further
lifting of the clutch pedal provides a corresponding increase in oil flow through the appropriate PWM solenoid valve
and a gradual engagement of the clutch.
Drive
With the clutch pedal fully released, full pressure is applied to the appropriate clutch to transfer drive to the forward/
reverse synchronizer.
Gear Shifting
When shifting gear, the action of fully depressing the clutch pedal de-energizes the dump solenoid valve, and the
oil pressure to C1 and C2 PWM solenoid valves is cut, which disconnects the drive between the engine and the
transmission. As the clutch pedal is raised the hydraulic pressure is progressively restored to the clutch to continue
driving.
C1 (Under Drive) to C2 (Direct Drive)

Operation of the upshift switch, located on the main shift lever, de-energizes the C1 PWM solenoid valve and en-
ergizes the C2 PWM solenoid valve, pressure oil is switched to the C2 clutch. The clutch engagement time is still
controlled by the controller during this changeover to ensure a smooth shift.
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Transmission Hydraulic Circuit
BSF4483A 1
1 Low pressure circuit oil supply 2 Dump solenoid valve

3 Lubrication oil supply 4 Reverse PWM solenoid valve
5 Forward PWM solenoid valve 6 Lubrication control valve
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Lubrication Control Valve Operation - Clutch Pedal Fully Depressed
BVF1041A 2
1 Transmission lubrication oil supply 2 Spool

3 C1 clutch engagement oil supply 4 C2 clutch engagement oil supply
5 Clutch friction and steel plates 6 Belleville washers
7 Lubrication oil restriction 8 Control piston
9 C1/C2 clutch lubrication oil supply 10 Spool centralizing spring
11 Stop sleeve 12 Stop sleeve
Figure Colour Key

A Return to reservoir B Lubrication circuit
The spool (2) is centred in the neutral position by the spool centralizing spring (10).
Lubrication oil (1) is supplied at full flow to both the C1 and C2 clutches, transmission bearings and the synchronizers.
The flow of lubrication oil through the clutch friction and steel plates (5) is restricted in the clutch at the lubrication oil
restriction (7).
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Lubrication Control Valve Operation - Inching/Feathering C2 (Direct Drive)
BVF1041B 3

Figure Colour Key

C Low pressure circuit
The lubrication spool (2) is controlled by the oil pressure from the clutch engagement oil supply (4). As the oil pressure
increases, the control piston (8) will apply a force onto the clutch friction and steel plates (5) and begin to transmit
drive (inching/feathering).
The spool (2) will remain centred in the neutral position by the spool centralizing spring (10), which is rated at 13 bar
(188.50 psi). This allows a full flow of lubrication oil to the clutches. The lubrication oil restriction (7) is open fully,
allowing full flow of lubrication oil past the restriction (7), to the clutch friction and steel plates (5).
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Lubrication Control Valve Operation - Driving C2 (Direct Drive)
BVF1041C 4

Figure Colour Key

C Low pressure circuit
As the engagement oil supply (4) pressure increases to 13 bar (188.50 psi), the spool (2) will start to restrict the
lubrication oil flow to the clutches. As the engagement oil supply pressure increases to 15 bar (217.50 psi) the spool
(2) will have moved completely until the stop sleeve (11) touches the stop sleeve (12). The lubrication oil flow is now
restricted due to only one supply from the lubrication control valve.
The lubrication oil on the engaged C2 clutch can not flow past the engaged friction and steel plates therefore the
released clutch will still receive a restricted oil flow through the friction and steel plates.
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TRANSMISSION Power Shuttle - Dynamic description


40 km/h 30 km/h
( 24.9 mph) ( 18.6 mph)
A C1 gear drive 36 36
B Reverse gear drive 33 33
C Reverse gear driven 39 39
D 1st gear drive 31 27
E 2nd gear drive 38 34
F 3rd gear drive 45 40
G High range gear drive 52 49
H Medium range gear drive 35 33
J Low range gear drive 19 19
K Low range gear driven 60 60
L Medium range gear driven 44 46
M High range gear driven 27 31
N 3rd gear driven 34 39
P 2nd gear driven 41 45
Q 1st gear driven 49 52
R Reverse cluster gear drive 40 40
S Reverse cluster gear driven 33 33
T C1 cluster gear drive 35 35
U C1 cluster gear driven 30 30
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BSF4408A 1
Engine power is transmitted from the flywheel mounted damper to the input/PTO driveshaft and C1/C2 clutch housing
which is splined to the shaft.
• Shuttle lever in neutral, main shift lever in neutral and range lever in neutral.
• C1 and C2 clutches are disengaged.
BVF1034A 2
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BSF4414A 3
Input shaft - C1 - gears A-U-T-B - forward/reverse synchronizer - gears D-Q - 1/2 synchronizer - gears M-G-J-K - low
synchronizer - output shaft.

• Shuttle lever in forward, main shift lever in 1st gear and range lever in low range.
• C1 (under drive) clutch engaged.
BVF1033A 4
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BSF4413A 5
Input shaft - C2 - gear B - forward/reverse synchronizer - gears E-P - 1/2 synchronizer - gears M-G-J-K - low synchro-
nizer - output shaft.
• Shuttle lever in forward, main shift lever in 2nd gear and range lever in low range.
• C2 (direct drive) clutch engaged.
BVF1032A 6
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BSF4412A 7
Input shaft - C1 - gears A-U-T-B - forward/reverse synchronizer - gear F - 3/4 synchronizer - gears N-M-G-H-L -
high/medium synchronizer - output shaft.
• Shuttle lever in forward, main shift lever in 3rd gear and range lever in medium range.
BVF1031A 8
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C.20.C / 35
BSF4411A 9
Input shaft - C2 - gear B - forward/reverse synchronizer - 3/4 synchronizer - gear G-M - high/medium synchronizer -
output shaft.
• Shuttle lever in forward, main shift lever in 4th gear and range lever in high range.
BVF1030A 10
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BSF4410A 11
Input shaft - C1 - gears A-U-T-S-R-C - forward/reverse synchronizer - gears D-Q - 1/2 synchronizer - gears M-G-H-L
- high/medium synchronizer - output shaft.
• Shuttle lever in reverse, main shift lever in 1st gear and range lever in medium range.
BVF1029A 12
84276322A 31/05/2010
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BSF4409A 13
Input shaft - C2 - gears B-T-S-R-C - forward/reverse synchronizer - gears E-P - 1/2 synchronizer - gear M - high/
medium synchronizer - output shaft.
• Shuttle lever in reverse, main shift lever in 2nd gear and range lever in high range.
BVF1028A 14
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Control valve - Exploded view

BSF4661A 1
1 Solenoid valve retaining plate 2 Dump solenoid valve

3 Low pressure oil supply 4 Transmission oil temperature sensor
5 C1 low pressure oil supply 6 1/2 synchronizer status switch
7 Spring 8 Plunger
9 C1 PWM solenoid valve 10 Solenoid valve retaining plate
11 Solenoid valve retaining plate 12 C2 PWM solenoid valve
13 C2 low pressure oil supply 14 Additional low pressure oil supply
84276322A 31/05/2010
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Control valve - Exploded view (Lubrication Oil)

NOTE: Apply LOCTITE® 270 onto the retaining bolt (6) when assembling.
BSF4660A 1
Lubrication Oil Control Valve
1 End cap 2 O-ring

3 Valve block 4 End cap
5 O-ring 6 Retaining bolt and washer
7 Stop sleeve 8 Spring
9 Stop sleeve 10 Spool
84276322A 31/05/2010
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Gear and synchroniser - Exploded view

PTO Shaft Assembly
BVF1128A 1
1 PTO shaft 2 Circlip

3 Bearing 4 Circlip
5 Oil seal
Forward/Reverse Synchronizer
BVE0659A_270 2

9 Detent guide
84276322A 31/05/2010
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Reverse Gear Cluster
BVF1127A 3
1 Bearing 2 Reverse gear cluster gears

3 Bearing 4 Lubrication oil transfer tube
Output Shaft Assembly
BVF1131A 4
1 Low range gear driven (60 teeth) 2 Washer

5 Low range sliding coupler 6 Output shaft
9 Taper roller bearing
84276322A 31/05/2010
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High/Medium Synchronizer
BVE0659A_270 5

7 Detent guide 8
9 Detent guide
High/Medium and Low Range Cluster Shaft
BVF1142A 6
1 Spacer ring 2 Bearing

3 Cluster shaft 4 Bearing
84276322A 31/05/2010
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Main Shaft
BVF1111A 7
1 Lubrication oil supply manifold 2 3/4 synchronizer

3 3rd gear drive (45/40 teeth) 4 Main shaft
5 Bearing
84276322A 31/05/2010
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3/4 Synchronizer
BVE0659A_270 8

9 Detent guide
84276322A 31/05/2010
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Countershaft
BVF1112A 9
1 3rd gear driven (34/39 teeth) 2 Bearing

3 High range gear driven (27/31 teeth) 4 2nd gear driven (41/45 teeth)
7 Steel thrust washer 8 Circlip
84276322A 31/05/2010
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1/2 Synchronizer
BVE0659A_270 10

9 Detent guide
84276322A 31/05/2010
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Gear and synchroniser - Overview

Rear Section
BVF1085A 1
1 High range gear drive (52/49 teeth) 2 Medium range gear drive (35/33 teeth)
3 Low range gear drive (19 teeth) 4 Low range gear driven (60 teeth)
5 Output shaft 6 Low sliding coupler
84276322A 31/05/2010
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Middle Section
BVF1086A 2
1 Lubrication oil supply manifold 2 1st gear drive (31/27 teeth)

3 2nd gear drive (38/34 teeth) 4 3rd gear drive (45/40 teeth)
5 3/4 synchronizer 6 High range gear driven (27/31 teeth)
7 3rd gear driven (34/39 teeth) 8 2nd gear driven (41/52 teeth)
84276322A 31/05/2010
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Fork and shift rail Range fork - Exploded view (High/Medium and
Low)
SS09D216 1
1 Actuator lever 2 Rollpin

3 Adjustable link rod 4 Synchronizer control housing
5 High/medium detent assembly 6 High/medium synchronizer shift rail
7 Rollpin 8 High/medium synchronizer shift fork
9 Circlip 10 Washer
11 Return spring 12 Washer
13 Actuator shaft retainer 14 Spacer
15 Actuator shaft 16 Low detent assembly
17 Interlock rod 18 Low sliding coupler shift rail
19 Rollpin 20 Low sliding coupler shift fork
21 Circlip 22 Washer
23 Support shaft 24 Link rod actuator
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Fork and shift rail Speed fork - Exploded view (1/2 and 3/4)
SS09D215 1
1 Actuator lever 2 Adjustable link rod

3 Link rod actuator 4 Washer
5 Circlip 6 Support shaft
7 3/4 synchronizer status switch 8 Spring
9 Actuator rod 10 3/4 synchronizer detent assembly
11 Locking bolt 12 3/4 synchronizer shift fork
13 Grub screw 14 3/4 synchronizer shift rail
15 Support shaft 16 Actuator
17 Actuator shaft 18 Spacer
19 Actuator shaft retainer 20 Circlip
21 Washers 22 Spring
23 Interlock rod 24 1/2 synchronizer detent assembly
25 Locking bolt 26 1/2 synchronizer shift fork
27 1/2 synchronizer shift rail 28 1/2 synchronizer status switch actuator
29 Synchronizer control housing
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Cover - Exploded view (Forward/Reverse Control)

BVF1018A 1
1 Forward/reverse potentiometer 2 Potentiometer spacer

3 O-ring 4 Forward/reverse shift rail end cover
5 Potentiometer operating shaft locating pin 6 Forward/reverse shift rail
7 Forward/reverse piston 8 Oil seal
9 O-ring 10 Forward/reverse shift fork
11 Shift fork retaining bolt and nut 12 Forward/reverse synchronizer control cover
13 Forward/reverse detent assembly 14 Forward PWM solenoid valve
15 PWM solenoid valve retaining plate 16 Forward/reverse shift rail end cover plate
17 Reverse PWM solenoid valve 18 O-ring
19 Potentiometer operating shaft
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TRANSMISSION Power Shuttle - Remove

Prior operation:
(B.10.A).
DANGER
B012

BVE0342A 1
BVE0343A 2

and transmission.
84276322A 31/05/2010
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transmission.
hoist.
the tractor.
WARNING
B019
BVE0344A 3

Next operation:
TRANSMISSION Power Shuttle - Disassemble (C.20.C)
84276322A 31/05/2010
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TRANSMISSION Power Shuttle - Disassemble

Prior operation:
TRANSMISSION Power Shuttle - Remove (C.20.C)
WARNING
B026
WARNING
B012

BVE029A_269 1
2. Remove the C1/C2 clutch housing - see Clutch and

gear Range clutch - Remove (C1/C2) (C.20.C).
3. Remove the gearshift cable retaining bracket (1).
BVF1043A 2
4. Remove the control valve - see Control valve - Re-

move (Valve block C1/C2) (C.20.C).
trol cover - see Fork and shift rail Range fork - Re-
move (C.20.C).
84276322A 31/05/2010
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- see Fork and shift rail Speed fork - Remove
(C.20.C).
7. Using suitable snap ring pliers, remove the PTO shaft
BVF1046A 3
8. Remove the PTO shaft (1).
BVF1153A 4
Front Section Removal

Remove the forward/reverse synchronizer retaining
snap ring (1).
BVF1052A 5
84276322A 31/05/2010
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10. Remove the forward/reverse synchronizer (1) with

the reverse cluster (2).
BVF1053A 6
11. Remove the reverse driven gear (1).
BVF1054A 7
12. Using a suitable lever in the cut-outs provided (1),

remove the lubrication oil supply manifold (2).
BVF1055A 8
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Rear Section Removal

Remove the rear plate (1).
NOTE: The countershaft front bearing may fall out when
the transmission is rotated.
NOTE: Ensure the range gear cluster remains in the trans-
mission while removing the rear plate.
BVF1056A 9
14. Using a suitable universal puller (1) and the locally

fabricated tool (2), remove the range gear cluster
bearing (3).
BVF1057A 10
15. Remove the output shaft assembly (1).
BVF1058A 11
84276322A 31/05/2010
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16. Remove the high/medium synchronizer rings (1).
BVF1059A 12
17. Remove the range gear cluster shaft (1).
BVF1060A 13
18. Remove the needle roller bearing (1).
BVF1061A 14
19. Remove the 3/4 synchronizer rings (1).
BVF1062A 15
84276322A 31/05/2010
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Middle Section Removal

Support the countershaft and remove the retaining
circlip (1).
NOTE: Support the 1/2 and 3/4 synchronizers while rotat-
ing the transmission.
BVF1064A 16
21. Remove the countershaft (1) from the rear end of the
transmission.
BVF1065A 17
22. Remove the 1/2 synchronizer, gears and the

D-washer.
BVF1066A 18
84276322A 31/05/2010
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23. Using suitable snap ring pliers, remove the main

shaft bearing snap ring (1).
BVF1067A 19

Support the main shaft through the top cover aper-
ture and remove the 3/4 synchronizer retaining snap
ring (1).
NOTE: Support the 3/4 synchronizer while rotating the
transmission.
BVF1068A 20
25. Remove the main shaft (1) through the bell-housing.
BVF1070A 21
84276322A 31/05/2010
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26. Remove the 3/4 synchronizer and 3rd gear drive as-
sembly (1).
BVF1069A 22
Next operation:
TRANSMISSION Power Shuttle - Assemble (C.20.C)
84276322A 31/05/2010
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TRANSMISSION Power Shuttle - Assemble

Prior operation:
TRANSMISSION Power Shuttle - Disassemble (C.20.C)
WARNING
B026
WARNING
B012
Middle Section Installation

1. Install the 3/4 synchronizer and 3rd gear drive as-
sembly (1).
BVF1069A 1
2. Install the main shaft (1) through the bell-housing.
BVF1070B 2
84276322A 31/05/2010
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3. Support the main shaft through the top cover aper-

ture and using suitable circlip pliers install the 3/4
synchronizer retaining snap ring (1).
BVF1071A 3
4. Rotate the transmission 90 °

Install the 3/4 synchronizer and main shaft assembly
(1) into the housing.
BVF1072A 4
5. Using suitable snap ring pliers install the main shaft

BVF1067A 5

Install the 1/2 synchronizer and gears into the hous-
ing.
BVF1073A 6
84276322A 31/05/2010
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7. Install the countershaft (1) through the rear end of the

housing.
BVF1065B 7
8. Support the countershaft, install the D-washer (1)

and using suitable circlip pliers install the counter
shaft retaining circlip (2).
BVF1074A 8

Install the 3/4 synchronizer rings (1).
NOTE: Position the two shafts so the main shaft bearing
is seated on its snap ring and the countershaft bearing is
seated in its cup.
BVF1075A 9
10. Install the needle roller bearing (1).
BVF1061A 10
84276322A 31/05/2010
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Rear Section Installation

11. Install the range cluster gear shaft (1).
BVF1060A 11
12. Install the high/medium synchronizer rings (1).
BVF1059A 12
13. Install the output shaft assembly (1).
BVF1058A 13
84276322A 31/05/2010
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14. Install the range cluster gear bearing (1).

draulic press.
BVF1076A 14
15. Install the rear plate assembly. Tighten the retaining

BVF1077A 15

Install the lubrication oil supply manifold (1) and the
output shaft rear bearing (2).
BVF1078A 16
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Front Section Installation

17. Install the reverse driven gear (1).
BVF1054A 17
18. Install the forward/reverse synchronizer (1) with the

reverse gear cluster (2).
BVF1053A 18
19. Install the forward/reverse synchronizer retaining

snap ring (1).
BVF1052A_272 19
84276322A 31/05/2010
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Install the PTO shaft into the transmission.
BVF1081A 20
21. Install the PTO shaft bearing retaining snap ring (1).
BVF1046A 21
22. Adjust the output shaft end float - see Shaft - Clear-
ance (Output shaft) (C.20.C).
23. Install the 1/2 and 3/4 synchronizer control cover.
- see Fork and shift rail Speed fork - Install
(C.20.C).
cover - see Fork and shift rail Range fork - Install
(C.20.C).
25. Install the transmission control valve - see Control
valve - Install (Valve block C1/C2) (C.20.C).
26. Install the gearshift cable retaining bracket (1).
BVF1043A 22
27. Install the C1/C2 clutch housing - see Clutch and

gear Range clutch - Install (C1/C2) (C.20.C).
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Next operation:
TRANSMISSION Power Shuttle - Install (C.20.C)
84276322A 31/05/2010
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TRANSMISSION Power Shuttle - Install

Prior operation:
TRANSMISSION Power Shuttle - Assemble (C.20.C)
DANGER
B012
WARNING
B018

transmission.
hoist.
BVE0344A 1
2. Thoroughly clean and degrease the mating sufaces

BVE0599A_49 2
transmission.
84276322A 31/05/2010
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BVE0343A 3

BVE0342A 4
Next operation:
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TRANSMISSION Power Shuttle - Calibrate

WARNING
The calibration procedure is controlled by the electronic management system. To prevent inadvertent move-
ment of the tractor, park the tractor away from any obstacles, firmly apply the parking brake and block the
wheels, front and rear.
B033
1. Connect the Diagnostics plug 380000843 to the Di-

agnostics socket, or alternatively, hold the upshift
button and start the engine and then press the down-
shift button within 3 seconds.
BAIL06CCM213AVA 1
2. Start the engine, if not already done so.

3. Use the "h" and "m" buttons and the Dimmer but-
ton on the instrument cluster to scroll through the HH
Menu, until the option H1 and the transmission sym-
bol appears on the DR control unit..
BAIS09APH318AVA 2
84276322A 31/05/2010
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4. With H1 displayed press the light dimming button to

confirm selection.
5. CAL will be displayed.
BAIL09APH208AVA 3
6. After a few seconds the display will change to show

oil temperature.
BAIL09APH209AVA 4
7. Set the engine rev/min to 1200 ± 100, Shift the shuttle

lever to forward, ensure that the range lever is in
neutral and release the clutch pedal.
NOTE: The engine speed must be stable, adjust the throttle
slightly to achieve a stable rev/min.
8. The synchronisers will be calibrated first. Press and
hold the upshift switch, SOC will be displayed.Re-
lease the upshift switch.
BAIL09APH209AVD 5
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9. The display will change to show 1 and will cycle

through to 4 and then end when the synchronisers
are calibrated.
BSE3760A 6
10. Release the upshift switch.

11. Clutch calibration can now be performed.
NOTE: The clutches are calibrated using a manual proce-
dure only.
12. Depress the clutch pedal, select a gear and range
and release the handbrake.
NOTE: The oil temperature can be checked during the pro-
cedure by shifting the main lever into neutral. The oil tem-
perature will be displayed in the lower display in °C.
13. With the shuttle lever in neutral press either the
upshift switch to select the ’Hi’ clutch or downshift
switch to select the ’Lo’ clutch. H or L will be dis-
played in the lower display area.
14. Shift the shuttle lever into forward and slowly release
the clutch pedal to check the engagement point. The
clutch pedal position will be displayed when pedal
position is between 10 - 98 %, otherwise the selected
clutch calibration value will be displayed.
BSE3762A 7
15. Adjust the calibration value using the upshift and

downshift switches to obtain a clutch engagement
position of 35 % of clutch pedal travel.
Check the performance of the clutch calibration by
performing shuttle shifts. If required fine tune the
calibration using the upshift and downshift switches.
16. Repeat the above procedure on the other clutch. Af-
ter calibration turn off the key start to store the cali-
bration values.
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TRANSMISSION Power Shuttle - Pressure test

Pressure test ports are provided on the transmission control valve cover to enable the transmission clutches to be
tested to determine the correct function of a number of system components. Components such as solenoids, clutch
pedal operation and micro-processor can be seen to be operating correctly by the results of pressure testing.
NOTE: Prior to pressure testing, make certain that all the points detailed under the tractor preparation are carried out
to ensure maximum safety.
Tractor Preparation
1. Start and drive the tractor to warm the transmission
oil to a minimum operating temperature of 50 °C (122
°F).
2. Apply the parking brake.
3. Remove the four wheel driveshaft.
4. Disconnect the electrical connector from the
high/low/medium range switch and install the ‘Switch
By-Pass Connector’, 380001147 (1), into the tractor
harness end. By installing the switch By-Pass con-
nector, the processor receives a signal indicating
that either high range or medium range is selected,
although the HIGH/LOW/MEDIUM RANGE LEVER
remains in NEUTRAL throughout the testing.
BVE0475A 1
5. Disconnect the differential lock solenoid electrical

connector (1).
BVE0397A_418 2
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C1/C2 Clutch Engagement and Disengagement

6. Remove the C1 (1) and the C2 (2) test port plugs.
BVE0476A 3
7. Install the quick release fitting 380000999 (1) in the

C1 and C2 test ports.
• Test port thread 7/16 – 20 UNF
Attach two 0 - 40 bar (0 - 580 psi) pressure gauges
380000552 (3), using the hose 380000545 (2).
BVE0479A 4
8. Position the shuttle lever in Forward and leave the

High/Low/Medium range lever in Neutral.
9. Set the engine speed to 1500 rev/min to observe the
Observe the readings on the gauges and compare
with those in Fig. 5.
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BVE0536A 5
Pressure Tests for C1 and C2
High Selected (Direct Drive)

(A)
Pressure on C1 and C2 should be zero. Indicates the dump valve solenoid is operational.
Releasing the clutch pedal from the fully depressed position should smoothly and gradually restore C2 to
(B) full pressure. C1 should remain at zero. Indicates the correct C2 PWM solenoid valve and the clutch
pedal operation.
Depressing the clutch pedal should progressively reduce the pressure in C2 and with the pedal fully
(C) depressed zero pressure should be indicated. Indicates the correct C2 PWM solenoid valve, clutch
potentiometer and the dump valve operation.
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Switch From High (Direct Drive) to Low (Underdrive)

C2 pressure should reduce to zero, C1 pressure should rise to full pressure. This should appear to be an
(D)
instantaneous operation with just a slight overlap of pressure between the clutches. This indicates the
correct operation of C1 and C2 PWM solenoid valves.
Low Selected (Underdrive)
(E)
Pressure on C1 and C2 should be zero. This indicates the correct dump valve operation.
Releasing the clutch pedal from the fully depressed position should smoothly and gradually restore C1 to
(F) full pressure. C2 should remain at zero. This indicates the correct C1 PWM solenoid valve and the clutch
pedal operation.
Depressing the clutch pedal should progressively reduce the pressure in C1 and with the pedal fully
(G) depressed zero pressure should be indicated. This indicates the correct C1 PWM solenoid valve, clutch
potentiometer and the dump valve operation.
Switch From Low (Underdrive) to High (Direct Drive)
C1 pressure should reduce to zero, C2 pressure should rise to full pressure. This should appear to be an
(H)
instantaneous operation with just a slight overlap of pressure between the clutches. This indicates the
correct operation of C1 and C2 PWM solenoid valves.
Pressure Testing Notes:

10. Maximum pressure should be between 15 - 18 bar
(218 - 261 psi). If maximum pressure is obtained in
only one of the clutches, suspect a fault in that clutch
circuit, e.g. leaking clutch seals, faulty PWM sole-
noid valve. The pressure at 1500 rev/min. should
be between 13.8 - 16.5 bar (200 - 239 psi).
11. If the pressure is low on both clutches this may in-
dicate a faulty dump solenoid valve or a fault in the
hydraulic supply circuit.
12. Sudden, irregular rises or drops in pressure as the
clutch pedal is operated may indicate a faulty clutch
potentiometer if it occurs in both Low (underdrive)
and High (direct drive), or if only one of the drives
drops pressure this may indicate a faulty PWM valve.
13. If the pressure comes on suddenly as the clutch
pedal is raised, this may indicate that the clutch
pedal switch is incorrectly adjusted.
14. If the pressure is not at absolute zero with the clutch
pedal fully depressed, this may also indicate a incor-
rectly adjusted clutch switch or a possible fault with
the dump solenoid valve.
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Forward / Reverse Synchroniser Pressure Test

15. Slide the operator seat fully rearward.
16. Remove the rubber mat from the cab.
17. Remove the cab floor panel from the cab.
BVE0227A_417 6
18. Remove the test port plugs and install the adap-
tors 380000579 (1) and the quick release fitting
380000492 (2). in the forward (F) and the reverse(R)
test ports.
• Test port thread 7/16 – 20
Attach two 0 - 40 bar (0 - 580 psi) pressure
gauges 380000552, using the quick release coupler
380000543.
BVE0477A 7
NOTE: Due to the operating characteristics of the synchroniser it is not possible to accurately pressure test the syn-
chroniser operating piston during normal tractor operation. The synchroniser will only take the required pressure to
move and then the pressure will be cut. This would be seen only as a momentary blip on a pressure gauge. Therefore
the following procedure, using the calibration mode, should be used to determine if full pressure is being achieved.
19. Enter the transmission calibration procedure.
20. The table below shows the synchroniser calibration
stages and at what stage the pressure can be ex-
pected to be seen.
Stage Synchroniser Pressures

Forward (F) Reverse (R)
SOC 18 bar (261 psi)** 0
1 0 0 - 5 bar (0 - 73 psi)*
2 0 18 bar (261 psi)*
3 0 - 5 bar (0 - 73 psi) 0
4 18 bar (261 psi)** 0
END 0 0
* This pressure slowly increases to overcome the synchroniser detent position and may not be noticed on the
pressure gauge.
** This pressure increases at a faster rate to shift the synchroniser into position.
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Speed selection command Mechanical - Travel adjust

1. Ensure the tractor is not in gear and the main shift

and range levers are in the neutral position.
2. Check and if necessary adjust the length of both of
the adjustable link rods.
X = 83.5 - 84.9 mm (3.29 - 3.34 in).
BVF1102A 1
3. Loosen the range selection cable adjustment nuts.
BVF1104B 2
4. Move the range selection cable (3) to remove the

freeplay until the range lever in the cab is in the po-
sition shown.
BVF1105B 3
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5. Loosen the range shift cable adjustment nuts.
BVF1104A 4
6. Move the range shift cable (3) to equally distribute

the freeplay until the range lever in the cab is in the
position shown.
NOTE: Ensure the range lever in the cab is still located in
the detent position.
NOTE: Ensure the range shift lever in the cab is not ob-
BVF1105A 5
7. Loosen the main shift selection cable adjustment

nuts.
BVF1106B 6
8. Move the main shift selection cable (3) to remove the

position shown.
BVF1107B 7
84276322A 31/05/2010
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9. Loosen the main shift cable adjustment nuts.
BVF1106A 8
10. Move the main shift cable (3) to equally distribute the
position shown.
NOTE: Ensure the main shift lever in the cab is still located
in the detent position.
NOTE: Ensure the main shift lever in the cab is not ob-
BVF1107A 9
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Control valve - Remove (Valve block C1/C2)

Control valve - Exploded view (C.20.C)
Prior operation:
Remove the battery tray as described in TRANSMISSION Power Shuttle - Remove (C.20.C).
Disconnect the plugs from the sensor, switch and valves.
1. Remove the transmission control valve.
BSF4662A 1
Next operation:
Control valve - Install (Valve block C1/C2) (C.20.C)
84276322A 31/05/2010
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Control valve - Install (Valve block C1/C2)

Control valve - Exploded view (C.20.C)
Prior operation:
Control valve - Remove (Valve block C1/C2) (C.20.C)
1. Install the transmission control valve and tighten the

retaining bolts to the specified torque value.
BSF4662B 1
NOTE: If the transmission is removed, the next operations are not necessary, continue with transmission assemble -
see TRANSMISSION Power Shuttle - Assemble (C.20.C).
Next operation:
Reconnect the plugs.
Install the battery tray as described in TRANSMISSION Power Shuttle - Install (C.20.C).
84276322A 31/05/2010
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Shaft - Clearance (Output shaft)

NOTE: It is necessary to adjust the running clearance of the components on the output shaft. The clearance is ob-
tained by the placement of shim(s) behind the output shaft front taper roller bearing retainer.
NOTICE: The transmission must remain in the vertical position during this operation.
1. Remove the output shaft front taper roller bearing
retainer.
BVF1098A 1

known dimension to achieve output shaft end float.
BVF1099A 2

torque value.
BVF1098B 3
4. The output shaft end float required is 0.038 - 0.089

mm (0.0015 - 0.0035 in). To achieve this, carry out
the following:
84276322A 31/05/2010
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5. Rotate the output shaft several times to seat the

bearing rollers.
Using a suitable dial gauge (1) and lever (2), mea-
sure the output shaft end float.
This measurement is (M1)
BVF1100A 4

as follows:
R1 S1-(M1-0.063)
Where:

lated shim(s) (R1).
84276322A 31/05/2010
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torque value.
BVF1098B 5
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Gear and synchroniser - Measure

1. Inspect the High/Medium range, forward/reverse and

1-2 and 3-4 synchronizer components for wear and
damage as follows:
colouration, if excessive renew the synchronizer.
using a feeler gauge (3), if the gap is less than that
specified renew the synchronizer.
MMG 21 447_271 1
Minimum Gap
1-2 & 3-4 synchronizers 0.5 mm (0.020 in)
Foward/Reverse synchronizer 0.8 mm (0.0315 in)
Hi/Med synchronizer 0.85 mm (0.0335 in)
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Clutch and gear Range clutch - Remove (C1/C2)

Prior operation:
TRANSMISSION Power Shuttle - Remove (C.20.C) or
NOTE: If only the clutch C1/C2 repairing is necessary, you need not remove the transmission.
WARNING
B026
WARNING
B012
1. Disconnect the C1/C2 clutch housing oil supply

pipes.
BSF4627A 1
2. Loosen the oil supply pipe unions and reposition the

pipes.
BSF4622C 2
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3. Remove the rubber gromet (1).
BSF4628A 3
4. Remove the C1/C2 clutch housing oil supply unions.
BSF4631A 4
5. Remove the two upper retaining bolts and install two

suitable threaded aligning rods (1) (M10x1.25x 300).
BSF4630A 5

cover - see Cover - Remove (Forward / Reverse)
(C.20.C).
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7. Remove the lower retaining bolts (1).

Install two bolts into the separating holes (2) and sep-
arate the C1/C2 clutch housing from the transmission
housing.
BSF4630B 6
8. Ensure the synchronizer rings (1) and the lubrication

oil supply tube (2) are not damaged when removing
the C1/C2 clutch housing.
BSF4624B 7
9. Carefully reposition the C1/C2 clutch housing and

attach a suitable hoist and lifting strap. Remove the
C1/C2 clutch housing from the transmission housing.
SHG21602 8
Next operation:
Clutch and gear Range clutch - Disassemble (C1/C2) (C.20.C)
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Clutch and gear Range clutch - Disassemble (C1/C2)

Prior operation:
Clutch and gear Range clutch - Remove (C1/C2) (C.20.C)
WARNING
B026
1. Remove the lubrication oil supply tube (1)
BSF4632A 1
2. Remove the lubrication control valve block.
BSF4635A 2
3. Remove the retaining bolts (2), C1 clutch cluster gear

shaft bearing retaining plate (1) and the shim(s) (3).
SHG21604 3
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4. Remove the bearing (1) and the baffle plate (2).
BSF4636A 4
5. Remove the rear plate retaining bolts.
BSF4633A 5
6. Rotate the C1/C2 clutch housing 90 °.

Remove the clutch support manifold retaining bolts.
BSF4637A 6
7. Remove the outer housing from the rear plate.
BSF4665A 7
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8. Remove the polyimide washer (1).

NOTE: The polyimide washer may still be located in the
outer housing.
SHG21605 8
9. Remove the C1 clutch cluster gear shaft (1).
BSF4638A 9
10. Remove the clutch support manifold (3) from the

clutch (2).
NOTE: To aid removal, install two clutch support manifold
retaining bolts (1) into the clutch support manifold (3).
SHG21606 10
11. Remove the C2 clutch drive gear (1).
BSF4639A 11
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12. Remove the C1/C2 clutch assembly (1).
BSF4640A 12
13. Remove the C2 clutch hub (1).
BSF4641A 13
14. Remove the input driveshaft (1).
BSF4642A 14
15. Rotate the back plate 180 °.

Using suitable snap ring pliers, remove the C1 clutch
drive gear retaining snap ring (1).
BSF4643A 15
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16. Remove the C2 clutch drive gear assembly (1).
BSF4644A 16
17. Using a suitable universal puller or hydraulic press,

remove the bearing (2) and the spacer (1), bear-
ing (5) and the needle roller bearing (4) from the C2
clutch drive gear (3).
BSF4645A 17
18. Remove the C1 clutch hub (1) and the steel thrust
washer (2).
BSF4646A 18
19. Rotate the clutch housing 180 °.

Remove the C2 thrust cup (1) and the locating ball
(2).
BSF4651A 19
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20. Compress the clutch housing end plate and using a

suitable lever remove the snap ring (1).
BSF4647A 20
21. Remove the clutch housing end plate (1).
BSF4648A 21
22. Remove the six separating springs (1), six friction

plates (2), five steel plates (3) and one pressure steel
plate against the clutch control piston.
Repeat the clutch plate removal process on the sec-
ond clutch.
BSF4649A 22
23. Using the special tool 380000291 (1) and a suitable

hydraulic press, compress the belleville washers and
remove the snap ring (2).
BSF4652A 23
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24. Remove the snap ring retainer (1).
BSF4654A 24
25. Remove the seven belleville washers (1).

Repeat the bellville washer removal process on the
second clutch.
BSF4653A 25
26. Remove the clutch control pistons by applying com-

pressed air into the oil supply port (1) and blanking
the exhaust port with a suitable bung (2).
NOTE: Temporarily install the C1/C2 clutch support mani-
fold to aid the application of compressed air.
SHG21611 26
27. Remove the annular sealing rings (2), O-rings (3) and
the internal needle roller bearing (4) from the C1/C2
support manifold (1).
SHG21607 27
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Next operation:
Clutch and gear Range clutch - Inspect (C1/C2) (C.20.C)
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Clutch and gear Range clutch - Inspect (C1/C2)

Prior operation:
Clutch and gear Range clutch - Disassemble (C1/C2) (C.20.C)
1. Inspect the clutch separating springs for distortion

or discoloration. Compare each spring shape and
height with a new spring. Replace parts as neces-
sary.
2. Inspect the piston inner and outer components for
scoring or damage. Replace parts as necessary.
3. Inspect the clutch housing for scratches, scores, ex-
cessive wear and piston scuffing. Replace parts as
necessary.
4. Inspect the clutch friction and steel plates for exces-
sive wear. The friction plate material should have a
clear distinctive pattern. All plates should be flat with-
out warping and there should be no excessive dis-
colouration. Replace parts as necessary.
5. The belleville washer set can be checked by mea-
suring the free height and the loaded height (H1) as
follows:
Free height = 25.9 mm (1.02 in)
Loaded height = 12.6 mm (0.50 in)
With a load of 2400 N ( 244 Kg)
If the measured heights are not to specification, re-
place parts as necessary.
BSF4667A 1
Next operation:
Clutch and gear Range clutch - Assemble (C1/C2) (C.20.C)
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Clutch and gear Range clutch - Assemble (C1/C2)

Prior operation:
Clutch and gear Range clutch - Inspect (C1/C2) (C.20.C)
WARNING
B026
NOTICE: The internal needle roller bearing (4) must be installed 3.2 mm (0.126 in) away from the internal shoulder.
Do not press the bearing up to the internal shoulder or bearing distortion may occur.
1. Install a new internal needle roller bearing (4),
O-rings (3), and the annular sealing rings (2) into the
C1/C2 clutch support manifold (1).
SHG21607 1
2. Install a new clutch control piston oil seal (1). Repeat

this step for the second control piston oil seal.
BSF4666A 2
3. Install a new clutch control piston inner oil seal (1).

Repeat this step for the second control piston inner
oil seal.
BSF4658A 3
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4. Lubricate both oil seals with petroleum jelly.

Using the special tool 380000291 (1) and a suitable
hydraulic press, install the control piston (2).
Repeat the control piston installation process on the
second clutch control piston.
NOTE: Allow the oil seals to settle in their seats for at least
15 minutes before installing the clutch control pistons.
BSF4655A 4
5. Install the seven belleville washers (1).
BSF4653A 5
6. Install the snap ring retainer (1).
BSF4654A 6

hydraulic press, compress the belleville washers and
install the snap ring (2).
Repeat the belleville washer installation process for
the second clutch.
BSF4652A 7
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8. Check the clutch plate set height - see Clutch and

gear Range clutch - Measure (C1/C2) (C.20.C).
Install the pressure steel plate against the clutch con-
trol piston.
Install the five steel plates (3), six friction plates (2)
and six separating springs (1).
NOTE: Ensure that the separating springs are installed with
all the gaps aligned and the ends of the gaps facing to-
wards the piston.
BSF4649A 8
9. Compress the clutch plates and secure in place using

three rods positioned through the top lubrication oil
outlet holes.
BSF4656A 9
10. Install the last separating spring (1) and the friction
plate (2).
BSF4657A 10
11. Install and compress the end plate and using a suit-
able lever install the snap ring (1).
Repeat the clutch plate installation process for the
second clutch.
NOTE: When compressing the end plate remove the se-
curing rods.
BSF4647A 11
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12. Install the steel thrust washer (2) and the C1 clutch
hub (1).
BSF4646A 12
13. Rotate the clutch housing 180 °.

Install the locating ball (2) and the C2 thrust cup (1).
BSF4651A 13
14. Install the C2 clutch hub (1).
BSF4650A 14
15. Install the bearing (2) and the spacer (1), bearing (5)
and the needle roller bearing (4) onto the C2 clutch
drive gear (3).
draulic press.
BSF4645A 15
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16. Install the C2 clutch drive gear assembly (1) into the
rear plate.
BSF4644A 16
17. Install the C2 clutch drive gear retaining snap ring (1).
BSF4643A 17
18. Rotate the rear plate 180 °.

Install the input driveshaft (1).
BSF4642A 18
19. Position the rear plate on its side.

Install the C1/C2 clutch assembly onto the input shaft
gear splines.
BSF4659A 19
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20. Install the C2 clutch drive gear (1).
BSF4639A 20
21. Install the clutch support manifold (3) into the clutch
(2).
NOTE: To aid installation, install two clutch support mani-
fold retaining bolts (1) into the clutch support manifold (3).
SHG21606 21
22. Install the C1 clutch cluster gear shaft (1).
BSF4638A 22
23. Install the polyimide washer (1).
SHG21605 23
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24. Install the outer housing onto the rear plate.
BSF4665A 24
25. Install the clutch support manifold retaining bolts and

tighten to the specified torque value.
BSF4637B 25

Install the rear plate retaining bolts and tighten to the
BSF4633B 26
27. Install the shim(s) (3), cluster gear shaft bearing re-
taining plate (1), and the retaining bolts (2).
NOTICE: Adjust the C1 clutch cluster gear shaft end float
- see Clutch and gear Range clutch - Clearance (Gear
shaft, clutch C1) (C.20.C).
SHG21604 27
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value.
BSF4634A 28
29. Install the baffle plate (2) and the bearing (1).
BSF4636A 29
30. Install the lubrication control valve block with a new

gasket. Tighten the retaining bolts to the specified
torque value.
BSF4635B 30
31. Install the lubrication oil supply tube (1).

NOTICE: If the lubrication oil supply tube is not installed
fully, lubrication oil flow into the transmission may be re-
stricted.
BSF4632A 31
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Next operation:
Clutch and gear Range clutch - Install (C1/C2) (C.20.C)
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Clutch and gear Range clutch - Measure (C1/C2)

1. The clutch plate set (five steel plates and six friction
plates) must be checked by measuring the loaded
height (H1) as follows:
Loaded height = 24.2 ±0.1 mm (0.95 ±0.004 in)
With a load of 1600 N ( 163 Kg)
2. If the measured height is not to specification, change
the steel plate(s) thickness to obtain the specified
height.
Steel plates available are 2 mm (0.079 in) or 2.2 mm
(0.087 in) thick.
BSF4668A 1
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Clutch and gear Range clutch - Clearance (Gear shaft, clutch C1)

known dimension to achieve C1 clutch cluster gear
shaft end float. Install the cluster gear shaft bearing
retaining plate (1), and the retaining bolts (2).
SHG21604 1

value.
BSF4634A 2
3. The C1 clutch cluster gear shaft end float required is

0.050 - 0.075 mm (0.0020 - 0.0030 in). To achieve
this, carry out the following:
4. Rotate the cluster gear shaft several times to seat the
bearing rollers.
Using a suitable dial gauge (1), measure the output
shaft end float (2).
This measurement is (M1).
SHG21624 3
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as follows:
R1 = S1-(M1-0.062)
Where:

lated shim(s) (R1).
Install the cluster gear shaft bearing retaining plate
and tighten the retaining bolts to the specified torque
value.
BSF4634A 4
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Clutch and gear Range clutch - Install (C1/C2)

Prior operation:
Clutch and gear Range clutch - Assemble (C1/C2) (C.20.C)
WARNING
B026
WARNING
B012

BVF1145A 1
2. Enure the synchronizer rings (1) and the lubrication

oil supply tube (2) are not damaged when installing
the C1/C2 clutch housing.
BSF4624B 2
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3. Using a suitable hoist and lifting strap. install the

C1/C2 clutch housing into the transmission housing.
SHG21602 3
4. Remove the two threaded aligning rods (1) and install

the two upper retaining bolts.
BSF4630A 4
5. Install the lower retaining bolts and tighten to the

BSF4629B 5
6. Install the C1/C2 clutch housing oil supply unions and

BSF4631B 6
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7. Install the rubber gromet (1).
BSF4628A 7
8. Connect the oil supply pipes.
BSF4627A 8
9. Tighten the oil supply pipes.
BSF4622C 9

cover - see Cover - Install (Forward / Reverse)
(C.20.C).
Next operation:
TRANSMISSION Power Shuttle - Install (C.20.C) or
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Fork and shift rail Range fork - Remove

Fork and shift rail Range fork - Exploded view (High/Medium and Low) (C.20.C)
Prior operation:
NOTE: Ensure all gears are in neutral.
trol cover (1).
BVF1151A 1
Next operation:
Fork and shift rail Range fork - Install (C.20.C)
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Fork and shift rail Range fork - Install

Fork and shift rail Range fork - Exploded view (High/Medium and Low) (C.20.C)
Prior operation:
Fork and shift rail Range fork - Remove (C.20.C)

BVF1083A 1

cover (1). Tighten the retaining bolts to the specified
torque value.
BVF1151B 2
Next operation:
Adjust the control cables as described in Speed selection command Mechanical - Travel adjust (C.20.C).
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Fork and shift rail Speed fork - Remove

Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) (C.20.C)
Prior operation:
(1).
BVF1152A 1
Next operation:
Fork and shift rail Speed fork - Install (C.20.C)
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Fork and shift rail Speed fork - Install

Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) (C.20.C)
Prior operation:
Fork and shift rail Speed fork - Remove (C.20.C)

BVF1082A 1
2. Install the 1/2 and 3/4 synchronizer control cover (1).

value.
BVF1152B 2
Next operation:
Adjust the control cables as described in Speed selection command Mechanical - Travel adjust (C.20.C).
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Cover - Remove (Forward / Reverse)

Cover - Exploded view (Forward/Reverse Control) (C.20.C)
Prior operation:
Remove the cab floor and disconnect the plug as described in USER PLATFORM - Remove (E.34.A).
NOTE: If the transmission is removed, the prior operation is not necessary.

1. Disconnect the oil supply pipe (1).
Remove the forward/reverse synchronizer control
cover (2).
BSF4623C 1
Next operation:
Cover - Install (Forward / Reverse) (C.20.C)
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Cover - Install (Forward / Reverse)

Cover - Exploded view (Forward/Reverse Control) (C.20.C)
Prior operation:
Cover - Remove (Forward / Reverse) (C.20.C)

BSF4624B_268 1

cover (2) and tighten the retaining bolts to the speci-
fied torque value.
Connect the oil supply pipe (1).
BSF4623D 2
NOTE: If the transmission is removed, the next operation is not necessary, continue with transmission assemble -
Next operation:
Reconnect the plug and install the cab floor as described in USER PLATFORM - Install (E.34.A).
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TRANSMISSION Power Shuttle - Troubleshooting

NOTE: If the creeper is not functioning correctly, check for any electronic error codes which may be stored. These
are defined by the error code range of 2001 to 3000 - see Control module - Fault code index (A.50.A).
To retrieve error codes and review appropriate fault finding diagnostic charts - see Control module - Configure
(A.50.A).
Tractor does not drive in Low or no hydraulic pump oil pressure or Pressure test the hydraulic pump - refer to
any gear flow. TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Low or no low pressure circuit oil pressure. Pressure test the low pressure circuit - refer
to TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Low or no oil pressure to the transmission Pressure test the clutches - refer to
clutch(es). TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Low or no oil pressure to the forward or Pressure test the forward or reverse
reverse synchronizer rail piston. synchronizer - refer to TRANSMISSION
Power Shuttle - Pressure test (C.20.C).
Shuttle lever faulty. Check the shuttle lever in H5, replace the
shuttle lever as necessary.
Wiring harness faulty. Repair or replace the wiring harness.
Loose or damaged electrical connector(s). Refit or repair the electrical connector(s) as
necessary.
Dump solenoid valve faulty. Replace the dump solenoid valve.
PWM solenoid valve(s) faulty. Replace the PWM solenoid valve(s) and
re-calibrate the clutch(es).
Corrupt transmission software. Clear the EEPROM using H8 and re-cali-
brate. If the fault persists download the cor-
rect level of software and re-calibrate.
Faulty transmission controller. Replace the transmission controller.
Mechanical failure in the transmission. Inspect clutches for seizure, broken syn-
chronizers or broken gears. Replace
part(s) as necessary.
Poor clutch pedal Incorrect clutch disconnect switch adjust- Adjust the clutch disconnect switch - re-
feathering/inching ment. fer to H7 in Control module - Configure
performance (A.50.A).
Clutch pedal potentiometer faulty. Check the clutch pedal potentiometer - re-
fer to H9 in Control module - Configure
(A.50.A), replace as necessary.
Clutches require calibration. Calibrate the clutches.
Manually adjust the calibration value to
move the clutch engagement point to 35 %
clutch pedal travel.
Quickfill adjustment incorrect. Adjust the quickfill time as necessary - re-
(A.50.A).
Clutch plates worn or damaged. Replace part(s) as necessary.
Transmission jumps out Incorrect selector cable(s) adjustment. Adjust selector cable(s).
of gear, holds in gear or
gears clash when shifting
Clutch pedal potentiometer faulty. Check the clutch pedal potentiometer - re-
(A.50.A), replace as necessary.
Clutch disconnect switch faulty. Check the disconnect switch - refer to H5
in Control module - Configure (A.50.A),
replace as necessary.
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Clutch oil pressure is still present when the Pressure test the clutch(es) - refer to
clutch pedal is fully depressed. TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Internal oil leakage, maintaining clutch en- Check internal clutch components for dam-
gagement. age or wear, replace parts as necessary.
Mechanical failure in the transmission. Inspect the detents in the shift cover, syn-
chronizers for wear or excessive end float
of transmission components. Replace
part(s) as necessary.
Transmission is noisy in Low driveline oil level. Refill with the specified oil to the correct
operation level. Locate oil leakage.
Incorrect driveline oil specification. Drain and refill with the specified oil to the
correct level.
Low or no lubrication oil pressure. Pressure test the lubrication circuit - refer
to TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Mechanical failure in the transmission. Inspect the bearings and for worn or dam-
aged parts. Replace part(s) as necessary.
Transmission clunks Clutches require calibration. Calibrate the clutches.
during feathering/inching Manually adjust the calibration value to
move the clutch engagement point to 35 %
clutch pedal travel.
Quickfill adjustment incorrect. Adjust the quickfill time as necessary - re-
(A.50.A).
Clutch engagement oil pressure erratic. Pressure test the clutch(es) - refer to
TRANSMISSION Power Shuttle - Pres-
sure test (C.20.C).
Clutch plates worn or damaged. Replace part(s) as necessary.
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Index

Clutch and gear Range clutch - Assemble (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Clutch and gear Range clutch - Clearance (Gear shaft, clutch C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Clutch and gear Range clutch - Disassemble (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Clutch and gear Range clutch - Inspect (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Clutch and gear Range clutch - Install (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Clutch and gear Range clutch - Measure (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Clutch and gear Range clutch - Remove (C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control valve - Exploded view (Lubrication Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control valve - Install (Valve block C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Control valve - Remove (Valve block C1/C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Cover - Exploded view (Forward/Reverse Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cover - Install (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Cover - Remove (Forward / Reverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Fork and shift rail Range fork - Exploded view (High/Medium and Low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fork and shift rail Range fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Fork and shift rail Range fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Fork and shift rail Speed fork - Exploded view (1/2 and 3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fork and shift rail Speed fork - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fork and shift rail Speed fork - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Gear and synchroniser - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Gear and synchroniser - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Gear and synchroniser - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shaft - Clearance (Output shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Speed selection command Mechanical - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
TRANSMISSION Power Shuttle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TRANSMISSION Power Shuttle - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TRANSMISSION Power Shuttle - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRANSMISSION Power Shuttle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TRANSMISSION Power Shuttle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TRANSMISSION Power Shuttle - Dynamic description (Electrical Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TRANSMISSION Power Shuttle - Dynamic description (Hydraulic Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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TRANSMISSION Power Shuttle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Power Shuttle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TRANSMISSION Power Shuttle - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TRANSMISSION Power Shuttle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TRANSMISSION Power Shuttle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION Power Shuttle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSMISSION Power Shuttle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION Power Shuttle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Power Shuttle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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TRANSMISSION Semi-Powershift - 20.D

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Contents
TECHNICAL DATA
TRANSMISSION Semi-Powershift
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUNCTIONAL DATA
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic schema (Schematics 1st Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Control valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cover
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SERVICE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Calibrate 16x16 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Calibrate 16x16 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Hydraulic line
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Assemble - Middle Section Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Remove - Middle Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Clutch and gear
Range clutch - Remove - Front Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Range clutch - Disassemble - Front Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Range clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Master clutch - Assemble - C1/C2 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Speed clutch - Remove - Rear Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Speed clutch - Disassemble - Rear Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Speed clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Range clutch - Assemble - C3/C4 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Fork and shift rail
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cover
Remove Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Disassemble - Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Visual inspection Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Assemble Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
DIAGNOSTIC
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Testing - Tractor does not drive in any gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Testing - Tractor drives in ranges but has following fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Testing - The powershifts are not smooth or the tractor loses drive between powershifts: . . . . . . . . . . 182
Testing - The tractor drives in all gears and ranges but has the following fault: . . . . . . . . . . . . . . . . . . . . 183
Testing The tractor drives in all gears and ranges but has the following fault: . . . . . . . . . . . . . . . . . . . . . 184
Testing The tractor drives in all gears and in all ranges but has the following fault: . . . . . . . . . . . . . . . . 184
Testing - Tractor drives in all gears and ranges but has the following fault: . . . . . . . . . . . . . . . . . . . . . . . 185
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Semi-Powershift
TRANSMISSION Semi-Powershift - Special tools
CAUTION
in this manual.
B008

previous No.
X 380001160 Hydraulic Piping Rolling Tool -
X 380001159 16 x 16 Transmission Overhaul kit -
380002598 transmission synchroniser adjuster -
380000843 Diagnostic Connector -
The special tool 380001159 includes the following:

previous No.
X 380001148 Handle (for use with the re-sizer tool) -
X 380001149 Tapered sleeve, C3/C4 piston seal expander -
X 380001150 Tapered sleeve, C1/C2 piston seal expander -
X 380001151 Piston installer (pusher) -
X 380001152 Tapered sleeve, C3/C4 piston seal installer -
X 380001153 Tapered sleeve, C1/C2 piston seal installer -
X 380001154 Seal re-sizer C1/C2/C3/C4 piston seal -
X 380001155 Clutch piston return spring compressor -
X 380001156 Gauge rolled in tube replacement -
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BTB0459A_256 1

BVF1147A 2
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Pressure Test Tools

previous No.
380001147 Bypass Connector 297407
380000543 Quick Release Adaptor 291924
380000545 Hose -
TRANSMISSION Semi-Powershift - General specification

16 forward and 16 reverse speeds
using straight cut gears, four
multi-wet plate clutches, one
Type 16x16
forward reverse friction cone
synchronizer and one main range
friction cone synchronizer
Electro-hydraulic with Electronic

Control System
Management System
Hydraulic Control Valve

Separate Casting, multi spool with
Type
internal cast-in galleries
By electrically operated Pulse

Width Modulated (PWM) solenoid
Control
coils signalled by Electronic
Management System
Hydraulic Accumulator
Diaphragm type, nitrogen charged
Type with 0.7 l (0.185 US gal) hydraulic
oil capacity
Charge Pressure 10 bar (145 psi)
Multi-Wet Plate Clutches

Constant running, pressure
Type lubricated, pressure applied, spring
released
C1 and C2 clutches
Number of Friction Plates 4 in each clutch
Number of Steel Plates 4 in each clutch
Number of wavy springs 4 in each clutch
C3 and C4 clutches
Number of Friction Plates 9 in each clutch
Number of Steel Plates 9 in each clutch
Number of Belleville Washers 4 pairs in each clutch
Belleville washer stack height 24 mm (0.9449 in)
Maximum 7 bar (102 psi) supplied
Pressure Lubrication
by the steering gear pump
1 mm (0.0394 in), 0.30 mm (0.0118
Forward/Reverse synchronizer End-Float Adjustment Shim Sizes in), 0.10 mm (0.0039 in), 0.05 mm
(0.0020 in)
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Synchronizer Wear Check Minimum Gap

Main synchronizer 1-4, 5-8 0.5 mm (0.0197 in)
Forward/Reverse synchronizer 0.8 mm (0.0315 in)
Hi/Lo synchronizer 0.85 mm (0.0335 in)
TRANSMISSION Semi-Powershift - Torque
BVE0599A_49 1
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BVE0172B 2
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1b0o2004061008 3
BSF4012B 4
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BSF4020A 5
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TRANSMISSION Semi-Powershift - Sectional view

40 Kph 30 Kph
A C1 clutch output gear 37
B C2 clutch output gear 28
C Front lower shaft gear 41
D Front lower shaft gear 48
E Reverse gear 33
F Forward gear and/or 37
coupler
G Low main gear 53
H Intermediate lower shaft 37
gear
J Intermediate lower shaft 41
gear
K Intermediate lower shaft 25
gear
L C4 clutch output gear 41 37
M C3 clutch (High) output 45 41
gear
N C3 clutch (Low) output 22 22
gear
O Output gear 38 43
P High range output gear 34 39
R Low range output gear 65
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BSE3841A 1
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TRANSMISSION Semi-Powershift - Dynamic description

MAXXUM 140
This transmission offers 16 or 17 forward, and 16 reverse ratios. An optional reduction gear set (creeper gears) offers
a further 16 ratios, forward and reverse.
In the following text, operational information is based on the 16 x 16 transmission 30 - 40 km/h (19 - 25 mph). How-
ever, the 17 x 16 transmission 50 km/h (31 mph) functions in exactly the same way.
The transmission is controlled by a main shift lever, two powershift buttons and a range change button. A shuttle
lever mounted to the left hand side of the steering wheel selects forward or reverse drive. Transmission and throttle
controls are colour-coded orange.
The transmission provides four power-shift gears in each of the four intermediate ranges A, B, C, and D. clutchless
shifts between gears 4 and 5, 12 and 13 are made by using the range button in conjunction with the powershift buttons.
Range shifts between low and high (8th and 9th gears), can only be made with the clutch pedal fully depressed.
Gear Shift Displays

Depending on the tractor specification, two types of gear shift display may be fitted.
LED Gear Display

An illuminated display (1), to the right of the main shift lever indicates the selected gear.
As each gear is selected, the appropriate number (3) will be illuminated in the display. With Auto Shift activated, the
symbols for the Road range (2) and Field range (4) will also be illuminated. When changing the Auto Shift point,
symbol (5) will flash during the programming procedure.
BRE1527B 1
Digital Gear Shift Display

The digital display provides a comprehensive range of information that includes:
Headland turn symbols (1). (where fitted)

Forward and reverse gears (2). The display shows the current forward gear and the corresponding reverse or ’shuttle’
gear.
Shuttle lever position. Forward, neutral and reverse (3).
Gear span for each range (4).
Field and road auto shift (5) symbols.
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BRE1732B 2
Speed Matching
Speed matching will normally only permit a downshift to a lower gear. It will however, select a higher gear if the engine
attempts to overspeed.
When travelling on the road in High range, gears 13 to 16, the transmission will automatically select a gear to match
the engine speed to the road speed if the following method is adopted:
To upshift: Depress the clutch pedal then decrease engine speed with the foot throttle. When the clutch pedal is
released, the transmission will automatically select a higher gear ratio (provided 16th speed is not already selected)
to approximately match engine speed to road speed.
To downshift: Decrease engine speed, depress the clutch pedal while simultaneously increasing engine speed by
pressing the foot throttle further down. When the clutch pedal is released, the transmission will automatically select a
lower gear (provided 13th. speed is not already selected) matching engine speed to road speed.
NOTE: When operating in Auto Shift high range, the lowest downshift gear will become 9th.
In high range, the operator can manually select another gear without affecting the speed matching function.
With the range lever placed in low, speed matching will operate down to 5th gear.
NOTE: The speed matching function will be disabled if the operator manually selects a gear when in the low range.
Sequential Powershifting
If the Powershift button is depressed and held, the transmission will make sequential ratio changes until the button is
released or until the 16th/17th gear is selected.
Auto Shift Function (where fitted)

With Auto Shift engaged, the transmission will automatically upshift and downshift within the four gears of each range.
Auto Shifting in Field Gears

In the field range, auto shifts can be made within gear spans 1-4 or 5-8. With the main shift lever in the low range
(lever fully rearward), momentarily depress the top of the Auto Shift button (1). The field auto symbol (plough) in the
gear display and the Auto symbol on the switch will illuminate to confirm engagement of the field gear.
Moving off in 1st gear, the transmission will automatically upshift through gears 2 and 3 until 4th gear is engaged.
To Auto Shift through gears 5 to 8, select 5th gear using the range change button and depress the Auto Shift button
again, the transmission will now automatically upshift through gears 5 to 8.
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BSE2812A 3
As the tractor speed reduces, or the load on the engine increases, the transmission will automatically downshift to a
lower gear.
If necessary Auto Shift field range can be extended to include gears 9 to 12. To activate, move the main shift lever
fully forward and select any gear in range ’C’, then depress the Auto Shift button again. To confirm engagement, both
field and road auto symbols will illuminate.
In ranges 1-4, 5-8 and 9-12, Auto Shift may be linked to 3-point hitch operation. Raising the 3-point hitch with the fast
raise switch will put Auto Shift into standby mode, lowering the hitch will re-activate Auto Shift.
NOTE: If the 3-point hitch was in the raised position when the Auto Shift function was activated and has not been
moved, then Auto Shift will operate without lowering the hitch.
Auto Shift will also enter standby mode if the clutch pedal is depressed or the shuttle lever is moved from the forward
drive position.
To cancel Auto Shift press and release the switch or operate the upshift or downshift button.
NOTE: When using engine braking to slow the tractor, operating the upshift or downshift buttons will not disable Auto
Shift unless the selected gear is outside the Auto Shift range.
BRE1465B 4
Auto Shifting in Road Gears

In the road range, Auto Shift will make upshifts or downshifts through gears 9-12 or 13-16. With the main shift lever
moved fully forward, momentarily depress the top of the Auto Shift button (1), the road auto symbol (trailer) will illu-
minate in the gear display to confirm engagement.
The transmission will now make automatic shifts through gears 9 to 12 or 13 to 16 dependant on the range selected.
By depressing the Auto Shift button twice, the transmission can be programmed to automatically upshift or downshift
through gears 9 to 16 including the range change from 12th to 13th gear.
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BRE1735A 5
Changing the Shift Point

To suit different applications, the point at which the transmission makes an automatic gear shift may be adjusted from
the default setting of 20 %. Auto Shift gear changes are related to an increase or decrease in engine speed which
can be set at 5, 10, 15, 20 or 25 percent.
NOTE: For transport operations the shift point will automatically default to 20 % if a lower figure has been set. If the
shift point is set at 25 %, it will remain at that setting.
With the shift point set at 10 %, a transmission upshift will occur every time the engine speed increases by 10 %.
Consequently, as the engine speed decreases by the same amount, the transmission will make a downshift.
It is recommended that during field operations the shift point is set at a low percentage, and for road transport appli-
cations, set at a higher figure.
BRE1462B 6
To change the shift point, depress and hold the top of the Auto Shift button for at least one second. The current shift
point figure appears in the Display of Gears and the ’ramp’ symbol (1) begins to flash. Depress the Auto Shift button
repeatedly to scroll through the shift points.
With the new shift point selected, release the Auto Shift button and pause for five seconds. The new setting will be
memorised and the display will return to normal.
NOTICE: At key-off (engine stop), electronic programme settings made during tractor operation are transferred from
the operating memory to the main memory. To provide sufficient time for the data to transfer, allow a minimum of five
seconds delay before turning the key on again.
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BRE1734A 7
Auto Take Off (ATO)

The ATO feature allows the operator to engage drive without using the clutch pedal by simply moving the shuttle lever
from neutral to the forward or reverse position.
The ATO function is automatically enabled under normal starting conditions. i.e. operator in the driving seat, clutch
pedal depressed, shuttle lever in neutral.
After selecting the appropriate gear ranges with the main shift lever simply move the shuttle lever to the forward or
reverse position without depressing the clutch pedal. The ATO function will provide a controlled start from a stationary
position.
BSE2810C 8
NOTE: The ATO function will be disabled if the vehicle is at rest with the shuttle lever in the neutral position and the
operator leaves the seat.
If the ATO should be disabled for any reason, the operator should carry out the following procedure to re-enable this
function.
Sit in the seat, release the parking brake and cycle the clutch pedal. The vehicle will then move off in the direction
selected on the shuttle lever.
When enabled, the ATO function will continue to function as long as the operator remains in the seat.
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This transmission offers 16 or 17 forward speeds and 16 reverse speeds. The optionally available downstream range-
change unit (creeper unit) augments the transmission by an additional 16 forwards and reverse speeds. The 17th gear
is installed as an "overdrive" in the rear axle, meaning that the machine cannot be equipped with both a downstream
range-change unit and 17th gear.
The instructions in the following text apply to both the 16x16 and 17x16 speed transmission. The gears are changed
using the range shift lever (High / Low) (1), as well as two powershift buttons (2) and a shift button (3) on the rear of
the multi-controller.
SS09G213 1 SS09G214 2
The shuttle lever (4) to the left of the steering wheel or the buttons (5) on the multi-controller are used to select the
forwards and reverse direction of travel.
SS09G215 3 SS09G216 4
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The transmission has four powershift gears in each of the four ranges 1-4, 5-8, 9-12, and 13-16. Changing gears
between gears 4 and 5 as well as 12 and 13 is also possible without actuating the clutch pedal by simultaneously
actuating the shift button (3) and one of the powershift buttons (2).
The gear change between the 8th and 9th gear ("high" and "low" group) can only take place when the clutch pedal is
completely depressed or by pressing the "neutral button" (6) and then selecting the direction of travel.
SS09G217 5 SS09G214 6
NOTE: Changing from gears 4-5 and 12-13 can also be carried out by pressing the clutch pedal instead of the "shift
button"
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Gear shift indicator

The transmission display on the A-pillar provides comprehensive information such as
Direction of travel indicator (7) Symbol for “Forwards” direction of travel.
Neutral gear (all clutches open).
Symbol for “Reverse” direction of travel.
Gear shift indicator (8) "Forwards" gear.
"Reverse" gear.
Gear range indicator (9) A higher or lower gear is possible in this range.
Highest gear in this gear range, in Auto mode.
Symbol for "Manual operation".
"Auto Field" mode.
Symbol for "Auto Transport" mode.
Symbol for creeper unit.
Lowest gear in this gear range, in Auto mode.
Lowest or highest gear in this gear range has been reached. Press the shift
button (3) or shift with the range shift lever (1) to change to the next range.
1st or 17th gear has been reached, no further gear exists.
Engine speed (10) Current engine speed rpm.
Driving speed (11) Current driving speed
SS09G219 7
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Speed matching
The speed matching function is used to shift down to a lower gear. For road travel in the gears 13 to 16/17 or in
"Auto Transport" mode 9 to 16/17 gear the transmission automatically shifts into a suitable gear taking into account
the engine speed and driving speed when the following action is taken:
Downshifting
Press the clutch pedal while travelling and then increase the engine speed using the accelerator pedal. When the
engine speed is increased the transmission automatically shifts to a lower gear (if it is not already in the 13th or 9th
gear). In the speed matching process the gears are aligned with the engine speed and driving speed, and then the
clutch pedal can be released without feeling a jerk.
NOTE: However it shifts into a higher gear if the engine is over revved (coasting with trailer) in order to protect the
engine.
Sequential powershifting
If the powershift button (2) on the multi-controller is held down to shift gears up or down, the transmission will shift the
gears up or down until the button is released or the end of a gear range has been reached.
SS09G218 8
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Automatic shifting (if equipped)

When the automatic shifting function is switched on the transmission automatically shifts up or down a certain number
of gears.
Automatic shifting in the "Auto Field" mode

In the "Auto Field" mode the change in gears is automatically carried out within the gear ranges 1-4, 5-8 or 9-12.
When the range shift lever is set to "Low" (1) press the (12) "Auto Field" mode button. The "Auto Field" symbol is
shown on the gear shift indicator (13) and on the control lamp panel and the LED (14) on the switch next to the symbol
illuminates to confirm that the automatic shifting function of the "Auto Field" mode is activated.
SS09G213 9
Above the "Auto Field" symbol the highest gear is shown and below it the lowest gear which can be shifted using the
"Auto Field" function in this range.
SS09G220 10 SS09G221 11
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Moving off in 1st gear, the transmission will automatically upshift through gears 2 and 3 until 4th gear is engaged. To
shift automatically through gears 5 to 8, together with the shift button (3) engage the 5th gear and then press the "Auto
Field" button again. The transmission shifts automatically from gears 5 to 8 and down again taking into account the
driving speed, engine speed and load on the engine. If necessary the "Auto Field" mode can be extended to include
gears 9 to 12. To switch on this range, move the range shift lever (1) to the "High" position, select any gear in the
gear range 9-12 and then press the "Auto Field" button again.
SS09G213 12 SS09G214 13
In the "Auto Field" mode up to two gears in one gear range can be blocked if required.
Examples of blocked gears Example 1 Example 2 Example 3 Example 4 Example 5

in 5th-8th gear range. (5) 5 (5) (5) 5
6 6 6 (6) 6
Gear is blocked: ( ) 7 7 7 7 (7)
8 (8) (8) 8 (8)
The gears can be blocked in the following way: When driving in the "Auto Field" mode the transmission automatically
shifts e.g. into the 8th gear, however if this is not desired by the driver, shift down to the 7th gear using the powershift
buttons (2)and block the 8th gear. If the tractor travels in the 7th gear and the driver switches into the 8th gear using
the powershift buttons (2) the block is lifted again. Leaving the "Auto Field" modes or stopping the tractor also causes
the gear block to be lifted. In the gear shift indicator the new gear range is now shown above and below the "Auto
Field" symbol (13). It is also possible to block the lower gears 5 and 6 by shifting up using the powershift button (2).
SS09G218 14 SS09G220 15
NOTE: All of the possibilities that were described in the example above for the gear range 5-9 can also be used for
the ranges 1-4 and 9-12.
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The actuation of the rear hitch while in the "Auto Field" mode has the following outcome. If the rear hitch is raised
using the fast raise button (15) on the multi-controller the "Auto Field" shifting function is switched into standby mode
and switched on again when the hitch is lowered. Likewise the automatic shifting function is switched into standby
mode when the clutch pedal is actuated or the tractor reverses. Press the "Auto Field" button (12) again or turn off
the tractor to leave the "Auto Field" mode.
SS09G222 16 SS09J044 17
NOTE: If the rear hitch was raised and not moved when the "Auto Field" mode was switched on, the automatic switch-
ing function works without the need to lower the hitch.
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Automatic shifting in the "Auto Transport" mode

In the "Auto Transport" mode the change in gears is automatically carried out within the gear ranges 9-12, 13-16/17
or 9-16/17. When the range shift lever is set to "High" (1) press the (16) "Auto Transport" mode button once. The
"Auto Transport" symbol is shown on the gear shift indicator (17) and on the control lamp panel and the LED (18) on
the switch next to the symbol illuminates to confirm that the automatic shifting function is activated.
SS09G213 18
The "Auto Transport" mode can be used for the gear ranges 9-12 or 13-17 or also for both gear ranges when the
following action is taken: Engage one gear in the gear range 9-12 and press the (16) "Auto Transport" button once
briefly. It will automatically shift into gears 9-12.
Engage one gear in the gear range 13-17 and press the button (16) once briefly. It will automatically shift into gears
13-17. Engage one gear in 9-17 and press the button (16) twice briefly. It will automatically shift into gears 9-17.
Above the "Auto Transport" symbol the highest gear is shown and below it the lowest gear which can be shifted using
the "Auto Transport" function.
SS09J045 19 SS09J046 20
NOTE: If the tractor is coasting (accelerator pedal released), actuating the powershift buttons (2) deactivates the
transmission's automatic shifting function only if the selected gear lies outside a gear range.
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Changing the shift point

In order to adjust to various operating conditions, the pre-set value of 20 % for the switching point at which the trans-
mission undertakes an automatic gear change can be changed accordingly. The automatic gear change is linked to
the increase or decrease in the engine speed in conjunction with the gas position, and which can be set to 5 %, 10
%, 15 %, 20 % or 25 %.
NOTE: In the "Auto Transport" mode, if a lower value has been set, the switching point automatically sets itself to the
standard value 20 %. If a switching point of 25 % is set it remains at this setting.
For a shift point that is set to 10 % the transmission shifts down each time the engine speed decreases by 10 % with
respect to the position of the accelerator pedal (or hand throttle). The transmission shifts back into the higher gear
as soon as engine speed has increased to the speed which has been specified by the accelerator pedal (or hand
throttle).
For field work during which the PTO speed should stay as constant as possible we recommend setting the switch
point to a low percentage value, and to a higher percentage value for road transport applications.
To change the shift point, press the "Auto Field" Mode (12) button and hold it down for one second. Following this the
current shift point (19) is shown on the gear shift indicator and the "Ramp" symbol (20) starts to flash. Repeatedly
pressing the "Auto Field" (12) button switches through the individual shift points. After selecting the new shift point
release the button (12) and wait for five seconds. The new setting will be memorised and the display will return to the
standard display.
SS09J047 21 SS09J048 22
NOTICE: After turning off the engine (start switch in "OFF" position), the settings for the electronic control made during
operation are transferred from the operating memory to the main memory. To provide sufficient time for the data to
transfer, allow a minimum of five seconds delay before switching on the start switch again.
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Auto Take Off (ATO)

Using the Auto Take Off the driver can start driving without using the clutch pedal by moving the shuttle lever (4) out
of the neutral position into the forwards or reverse position. The ATO function is automatically enabled under normal
starting conditions and when the driver is sitting in the driver’s seat.
SS09G215 23
After selecting the chosen gear ranges using the range shift lever (High / Low) (1), the driver simply moves the shuttle
lever to the position of forward or reverse travel without depressing the clutch pedal. The ATO function will provide a
controlled start from a stationary position.
SS09G213 24
NOTE: The ATO function does not work if the tractor stops and the driver stands up from the driver’s seat.
If the ATO function is deactivated for any reason (a symbol to press the clutch pedal appears on the digital instrument
display) it can be reactivated as follows: While sitting in the driver’s seat, release the park brake and depress the
clutch pedal and release it again. The vehicle will then move off in the direction of travel selected by the shuttle lever
if there are no errors present.
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Transmission Gear Teeth
40 km/h 30 km/h
( 24.9 mph) ( 18.6 mph)
A C1 Clutch Output Gear 37
B C2 Clutch Output Gear 28
C Front Bottom Shaft Gear 41
D Front Bottom Shaft Gear 48
E Reverse Gear 33
F Forward Gear and/or Coupler 37
G Low Main Gear 53
H Intermediate Bottom Shaft Gear 37
J Intermediate Bottom Shaft Gear 41
K Intermediate Bottom Shaft Gear 25
L C4 Clutch Output Gear 41 37
M C3 Clutch (High) Output Gear 27 41
N C3 Clutch (Low) Output Gear 34 22
O Output Gear 41 43
P High Range Output Gear 49 39
R Low Range Output Gear 40
BSF3992A 1
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BSF3992A 2
Engine power is transmitted from the flywheel mounted damper to the input/PTO drive shaft and C1/C2 clutch housing
which is splined to the shaft.
Hydraulic Clutches Engaged

• No clutches applied.
BVE0637A 3
Synchronizer Positions
• In Neutral, clutches C1 and C2 are disengaged, drive is therefore not transmitted beyond the C1/C2 clutch housing.
• All synchronizers are shown in neutral.
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BSF3993A 4
Input shaft - C2 - Forward/Reverse synchronizer - gears F-J-K-G - 1-4/5-8 synchronizer - C4 - gears L-O-P-M-N-R -
Hi/Lo synchronizer - output shaft.

• Clutches C2 and C4 applied.
BVE0638A 5
• Forward, 1-4 and Lo engaged.
• If inching pedal is depressed clutch C4 is disengaged.
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Power Flows - 2nd Gear
BSF3994A 6
Input shaft - C2 - Forward/Reverse synchronizer - gears F-J-K-G - 1-4/5-8 synchronizer - C3 - gears N-R - Hi/Lo

BVE0639A 7
• If inching pedal is depressed clutch C3 is disengaged.
• Powershifting from 1st to 2nd gear, engages clutch C3 and disengages clutch C4, changing the power-flow at the
rear of the transmission.
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Power Flows - 3rd Gear
BSF3995A 8
Input shaft - C1 - gears A-C-D-B - Forward/Reverse synchronizer - gears F-J-K-G - 1-4/5-8 synchronizer - C4 - gears
L-O-P-M-N-R - Hi/Lo synchronizer - input shaft.

BVE0640A 9
• Powershifting from 2nd to 3rd gear involves two clutch changes:
C2 to C1
C3 to C4
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BSF3996A 10
Input shaft - C1 - gears A-C-D-B - Forward/Reverse synchronizer - gears F-J-K-G- 1-4/5-8 synchronizer - C3 - gears
N-R - Hi/Lo synchronizer - output shaft.

BVE0641A 11
• Forward,1-4 and Lo engaged.
• Powershifting from 3rd to 4th gear engages clutch C3 disengages clutch C4.
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BSF3997A 12
Input shaft - C2 - Forward/Reverse synchronizer - 1-4/5-8 synchronizer - C4 - gears L-O-P-M-N-R - Hi/Lo synchronizer
- output shaft.

BVE0642A 13
• Synchroshift from 1-4 to 5-8 with the range change button, transmission controller releases clutches C1 and C3,
then engages clutches C2 and C4.
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BSF3998A 14
Input shaft - C1 - gears A-C-D-B - Forward/Reverse synchronizer - 1-4/5-8 synchronizer - C3 - gears N-R - Hi/Lo

• C1 and C3 clutches applied.
BVE0643A 15
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BSF3999A 16
Input shaft - C1 - gears A-C-D-B - Forward/Reverse synchronizer - 1-4/5-8 synchronizer - C3 - gears M-P - Hi/Lo

BVE0644A 17
• In the high range speeds the Hi/Lo synchronizer is engaged with the output shaft gear (P) providing a higher ratio
drive from the clutch C3 and C4 output.
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Power Flows - 2nd Reverse Gear
BSF4000A 18
Moving the Forward/Reverse synchronizer into reverse engages gear E. Output from the C2 clutch will be transmitted
through gears E-R1-H-K-G reversing the drive into clutch C3.

BVE0645A 19
• The Forward/Reverse synchronizer provides a reverse drive for all forward speeds (1-16).
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TRANSMISSION Semi-Powershift - Static description

MAXXUM 140
BSF3983A 1
The transmission drive can be split into three sections as follows:
C1 and C2 clutches - located at the front of the transmission to work in conjunction with C3 and C4 to give 4 basic
ratios.
BSF4059A 2
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The forward and reverse synchronizer - located in the middle section of the transmission is used to select forward or
reverse drive, and is electro-hydraulically operated by PWM solenoid valves.
1-4 and 5-8 synchronizer - located just behind the forward and reverse synchronizer for range selection.
BSF4059A 3
C3 and C4 clutches located in the rear section of the transmission each supplying a single speed in conjunction with
C1 and C2 to give 4 basic ratios.
High and low synchronizer located at the rear of the transmission when combined with C1, C2, C3, C4 clutches and
1-4/5-8 synchronizer provide 16 forward and 16 reverse ratios.
BSF4060A 4
BSF4016A 5
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The pressure oil to engage the clutches is supplied from the low pressure hydraulic circuit, which is maintained at
17 - 19 bar (246.5 - 275.5 psi) by the low pressure regulating valve (1), located in the valve block in the base of the
remote control valve assembly.
BSF3967A 6
Transmission lubrication oil is supplied through the steering circuit and is controlled to a maximum pressure of ap-
proximately 7 bar (101.5 psi) by the lubrication relief valve (1) located in the transmission side cover.
R5-7-05 TI 7
An oil cooler by-pass valve (1), ensures that the excessive oil pressure generated at cold start up, or if the oil cooler
becomes blocked, by-passes the oil cooler until the oil warms up (oil pressure below 5.8 bar (84.1 psi)).
Oil supply to cooler (2).
Oil return from cooler (3).
The low pressure circuit incorporates a hydraulic accumulator (4). This provides instant additional oil to fill possible
voids when shifts involving multiple clutches are performed.
BVE0623A 8
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INPUT SENSORS
The engagement of the clutches are controlled by inputs from various sensors and switches:-
oil conditions.
BRF1857B 9
Clutch Pedal Potentiometer And Disconnect Switch.

The clutch pedal potentiometer (1), provides the operator with controlled engagement of the feathering (C3,C4)
clutches.
The clutch pedal disconnect switch (2) disengages power to the feathering clutches (C3/C4) PWM valves which dis-
engages drive.
BVE0692A 10
Shuttle Lever.
The shuttle lever (1), provides information to the controller, via switches, for forward, reverse and neutral transmission
drive selection.
Disengages power to all transmission PWM valves when in neutral.
BSE2810A_265 11 BSE2810A_231 12
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Forward/Reverse and 1-4/5-8 Potentiometers.

Provide information to the controller on the position of the forward and reverse synchronizer, potentiometer (1) and
the 1-4/5-8 synchronizer, potentiometer (2).
BRF1856B 13
Gear Shift Lever

The main shift lever (1), is used to select both range gears and main gears. When selecting High or Low ranges
(moving the lever forwards or rearwards) the clutch pedal must always be depressed
BSE2903A 14
Synchronizer Status Switches.

Provide information to the controller on the position of the High/Low synchronizer.
Low status switch (1) and high status switch (2).
BRF1853B 15
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Gear Selector Switches.

The upshift switch (1) and downshift switch (2) allows the operator to change between 8 basic ratios by sending a
signal to the controller, without using the clutch pedal.
BSE2889C 16
Parking Brake Switch.

The parking brake has to be applied during calibration, if it is not applied an error code will be displayed.
The tractor will drive if the handbrake is applied but an audible alarm will be heard.
BRF1854B 17
Seat Switch.
or reverse drive.
BRF1851B_263 18
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OUTPUT DEVICES
Clutch PWM valves,C1, C2, C3 and C4.
Controls the oil supply to the clutches allowing the engagement/disengagement of the clutches via a signal supplied
from the transmission controller.
BRF1852B 19
Forward, Reverse, 1-4 and 5-8 PWM Valves.

Controls the oil supply to the transmission top cover allowing the engagement/disengagement of the synchronizer to
select forward, reverse, 1-4 and 5-8 via a signal from the transmission controller.
BRF1855B 20
Analogue Digital Instrument Cluster (ADIC).

Provides information to the operator if a critical fault occurs with the transmission operation.
BVE0006D 21
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CONTROL DEVICE
Controller.
The controller (1) gives accurate control, via PWM valves, of the four multi-wet plate clutches. This also enables
clutchless shuttle operations, speed matching of the gears, sequential power-shifting and high range gear logic. The
transmission controller has a diagnostic facility that can interpret a number of system faults which can be displayed
or stored depending on how critical the fault detected is.
SS09J066 22
The control valve assembly is mounted on the side of the transmission. The control valve assembly is supplied with
low pressure oil through point (2) at ( 17 - 19 bar (246.5 - 275.5 psi)) through an accumulator (see fig. 17).
The accumulator is necessary to ensure minimum drop in oil pressure when changing gear, particularly when chang-
ing two clutches at once. Oil for lubrication enters at point (1).
The control valve assembly incorporates four PWM valves (4,5,6,7), and a transmission oil temperature sensor in-
stalled at point (3).
BVE0319A 23
Mounted on the rear of the control valve assembly is the lubrication combining valve pack. This incorporates the
lubrication regulating valve (1). The lubrication combining valve (2) with valve spool and spring (4) and the lubrication
shuttle valve (3).
R5-7-05 TI 24
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TRANSMISSION Semi-Powershift - Static description

BSF3983A 1
The transmission drive can be split into three sections as follows:

C1 and C2 clutches - located at the front of the transmission to work in conjunction with C3 and C4 to give 4 basic
ratios.
BSF4059A 2
84276322A 31/05/2010
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The forward and reverse synchronizer - located in the middle section of the transmission is used to select forward or
reverse drive, and is electro-hydraulically operated by PWM solenoid valves.
1-4 and 5-8 synchronizer - located just behind the forward and reverse synchronizer for range selection.
BSF4059A 3
C3 and C4 clutches located in the rear section of the transmission each supplying a single speed in conjunction with
C1 and C2 to give 4 basic ratios.
High and low synchronizer located at the rear of the transmission when combined with C1, C2, C3, C4 clutches and
1-4/5-8 synchronizer provide 16 forward and 16 reverse ratios.
BSF4060A 4
BSF4016A 5
84276322A 31/05/2010
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- 19 bar (247 - 276 psi) by the low pressure regulating valve (1), located in the valve block in the base of the remote
control valve assembly.
BSF3967A 6
Transmission lubrication oil is supplied through the steering circuit and is controlled to a maximum pressure of ap-
proximately 7 bar (102 psi) by the lubrication relief valve (1) located in the transmission side cover.
R5-7-05 TI 7
An oil cooler by-pass valve (1), ensures that the excessive oil pressure generated at cold start up, or if the oil cooler
becomes blocked, by-passes the oil cooler until the oil warms up (oil pressure below 5.8 bar (84 psi))
Oil supply to cooler (2).
Oil return from cooler (3).
The low pressure circuit incorporates a hydraulic accumulator (4). This provides instant additional oil to fill possible
voids when shifts involving multiple clutches are performed.
SS09J060 8
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INPUT SENSORS
The engagement of the clutches are controlled by inputs from various sensors and switches:

oil conditions.
SS09J061 9
Clutch Pedal Potentiometer And Disconnect Switch

The clutch pedal potentiometer (1), provides the operator with controlled engagement of the feathering (C3,C4)
clutches.
The clutch pedal disconnect switch (2) disengages power to the feathering clutches (C3/C4) PWM valves which dis-
engages drive.
BVE0692A 10
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Shuttle Lever
The shuttle lever (4), provides information to the controller, via switches, for forward, reverse and neutral transmission
drive selection.
Disengages power to all transmission PWM valves when in neutral.
SS09G215 11
Forward/Reverse and 1-4/5-8 Potentiometers

Provide information to the controller on the position of the forward and reverse synchronizer, potentiometer (1) and
the 1-4/5-8 synchronizer, potentiometer (2).
BRF1856B 12
Gear Shift Lever

The main shift lever (1), is used to select both range gears and main gears. When selecting High or Low ranges
(moving the lever right or left) the clutch pedal must always be depressed.
SS09G213 13
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Synchronizer Status Switches H/L

Provide information to the controller on the position of the High/Low synchronizer.
Low status switch (1) and high status switch (2).
SS09J062 14
Gear Selector Switches

The upshift and downshift button (2) and shift button (3) allows the operator to change between 8 basic ratios by
sending a signal to the controller, without using the clutch pedal.
SS09G214 15
Parking Brake Switch

The parking brake has to be applied during calibration, if it is not applied an error code will be displayed.
The tractor will drive if the handbrake is applied but an audible alarm will be heard.
BRF1854B 16
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Seat Switch
or reverse drive.
SS09J049 17
OUTPUT DEVICES
Clutch PWM valves,C1, C2, C3 and C4

Controls the oil supply to the clutches allowing the engagement/disengagement of the clutches via a signal supplied
from the transmission controller.
SS09J063 18
Forward, Reverse, 1-4 and 5-8 PWM Valves

Controls the oil supply to the transmission top cover allowing the engagement/disengagement of the synchronizer to
select forward, reverse, 1-4 and 5-8 via a signal from the transmission controller.
BRF1855B 19
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Instrument Cluster (ICU3)

Provides information to the operator if a critical fault (1) occurs with the transmission operation.
SS09J064 20
CONTROL DEVICE
Controller
The controller (1) gives accurate control, via PWM valves, of the four multi-wet plate clutches. This also enables
clutchless shuttle operations, speed matching of the gears, sequential power-shifting and high range gear logic. The
transmission controller has a diagnostic facility that can interpret a number of system faults which can be displayed
or stored depending on how critical the fault detected is.
SS09J059 21
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The control valve assembly is mounted on the side of the transmission. The control valve assembly is supplied with
low pressure oil through point (2) at ( 17 - 19 bar (246.5 - 275.5 psi)) through an accumulator (see fig. 16).
The accumulator is necessary to ensure minimum drop in oil pressure when changing gear, particularly when chang-
ing two clutches at once. Oil for lubrication enters at point (1).
The control valve assembly incorporates four PWM valves (4,5,6,7), and a transmission oil temperature sensor in-
stalled at point (3).
BVE0319A 22
Mounted on the rear of the control valve assembly is the lubrication combining valve pack. This incorporates the
lubrication regulating valve (1). The lubrication combining valve (2) with valve spool and spring (4) and the lubrication
shuttle valve (3).
R5-7-05 TI 23
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TRANSMISSION Semi-Powershift - Hydraulic schema (Schematics

1st Gear)
KEY TO TRANSMISSION HYDRAULIC CIRCUIT SCHEMATIC ILLUSTRATIONS
1. Regulated Pressure Supply from the Variable Dis- Symbols
placement Closed Centre Load Sensing Hydraulic Regulated Pressure Supply
Pump 18 - 20 bar (261 - 290 psi).
2. Lubrication Supply from Steering Motor Return
3. Lubrication Combining Valve Regulated Pressure Line
either to Reservoir or at
4. Lubrication Shuttle Valve Zero Pressure
5. Lubrication Supply to PTO Clutch
Lubrication Oil
6. Lubrication Supply to Transmission Shafts and Syn-
chronisers
7. Lubrication Proportioning Valve C3/C4 Clutches Line Joining Points
8. Lubrication Proportioning Valve C1/C2 Clutches
9. Accumulator 10 bar/ 0.7 litres ( 145 psi/ 0.185 US gal)
Line Restriction
10. Lubrication Relief Valve
Pressure Operated Valve
Pulse Width Modulated

Solenoid Valve
C1 Clutch 1 Solenoid Operated Valve
C2 Clutch 2 Positive Voltage Applied
C3 Clutch 3 Reservoir
C4 Clutch 4 Spring Assisted
PWM = Pulse Width Modulation
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GEAR 1 SELECTED, INCHING PEDAL FULLY DEPRESSED

• Regulated pressured oil at 18 - 20 bar (261 - 290 psi) is supplied to the transmission side cover assembly by the
variable displacement closed centre load sensing hydraulic piston pump (1).
• Lubrication oil is supplied to the transmission side cover assembly from the steering motor/cooler return (2). Max-
imum oil pressure is limited by the lubrication relief valve (10) to 7 bar (102 psi).
• Regulated pressure oil is directed to:
C1 PWM Valve
C2 PWM Valve
C3 PWM Valve
C4 PWM Valve
Lubrication Combining Valve (3).
Since the PWM and solenoid valves are not energised there is no flow of regulated pressure oil.
• Lubrication oil is directed to the lubrication combining valve, spring pressure moves the valve to the left.
• The lubrication oil from the lubrication combining valve is directed to:
C1/C2 Clutches
C3/C4 Clutches
Transmission Shafts and Synchronisers
PTO Clutch
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BVE0782A 1
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GEAR 1 SELECTED, INCHING PEDAL PARTIALLY RAISED

• As the inching pedal is partially raised C2 PWM valve opens fully, allowing full pressure 18 bar (261.0 psi) into
clutch C2.
• C1/C2 lubrication proportioning valve (8) is moved to the left by C2 clutch pressure, increasing C2 clutch lubrica-
tion, reducing C1 clutch lubrication.
• As the inching pedal is released further, C4 PWM valve is progressively energised. As C4 clutch apply pressure
increases from zero to 2 bar (29 psi), oil flows past the lubrication shuttle valve (6) to the left end of the lubrication
combining valve (5), moving it right to its central position. Pressure regulated oil is combined with existing C3/C4
lubrication oil to increase lubrication oil flow during clutch apply. Lubrication to transmission and PTO is reduced
during clutch apply.
• C3/C4 lubrication proportioning valve (7) is moved to the left by C4 clutch apply pressure to increase C4 clutch
lubrication.
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BVE0783A 2
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GEAR 1 SELECTED, INCHING PEDAL FULLY RELEASED

• As the inching pedal is fully released C4 PWM valve is fully energised.
• When C4 clutch apply pressure increases above 15 bar (218 psi) the lubrication combining valve is moved fully
to the right. Pressure regulated oil is no longer combined with lubrication oil. Transmission and PTO lubrication
is restored.
• Clutch apply pressure increases to full pressure 18 bar (261 psi).
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BVE0785A 3
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Control valve - Overview
BVE0172A 1
Control Valve Pressure Test Ports and Solenoid Valve Identification
1 C4 Pressure test port 2 C3 Pressure test port

3 C3/C4 Lube pressure test port 4 Lube inlet connector
5 Lube supply pressure test port 6 Regulated pressure inlet
7 C2 Pressure test port 8 C1/C2 Lube pressure test port
9 C1 pressure test port 10 Transmission bearing / synchroniser lube pressure
11 Oil temperature sender 12 C1 PWM solenoid valve
13 C2 PWM solenoid valve 14 C3 PWM solenoid valve
15 C4 PWM solenoid valve
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Cover - Exploded view
BVE0698A 1
Top Cover Exploded View
1 1-4/5-8 rail detent assembly 2 1-4/5-8 potentiometer

3 Transmission top cover 4 Potentiometer operating shaft
5 Shaft spacer 6 ’O’ ring seal
7 Shaft support 8 ’O’ ring seal
9 Potentiometer spacer 10 Forward/reverse potentiometer
11 Forward/reverse detent assembly 12 Forward/reverse fork rail
13 Forward/reverse shift fork 14 Forward/reverse piston and oil seal
15 End cap 16 Circlip
17 1-4/5-8 shift fork 18 1-4/5-8 fork rail
19 1-4/5-8 piston and oil seal 20 End cap
21 Circlip 22 Reverse PWM solenoid
23 Forward PWM solenoid 24 PWM solenoid retaining plate
25 1-4 PWM solenoid 26 5-8 PWM solenoid
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TRANSMISSION Semi-Powershift - Remove

Prior operation:
(B.10.A).
DANGER
B012

BVE0342A 1
BVE0343A 2

and transmission.
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transmission.
hoist.
the tractor.
WARNING
B019
BVE0344A 3

Next operation:
TRANSMISSION Semi-Powershift - Disassemble (C.20.D)
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TRANSMISSION Semi-Powershift - Service instruction

Prior operation:
TRANSMISSION Mechanical - Remove (C.20.B).
1. It is recommended that the transmission is disassem-

bled in the sequence indicated. Removal of compo-
nents of the transmission with the transmission ori-
ented as shown in the colour diagram will facilitate
operations.
BSE3908A 1
Yellow- Front Section Green/Red- Middle Section

Brown- Rear Section
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2. The transmission must be removed from the trac-

tor before commencing overhaul. Should any single
component be identified as requiring removal refer
to the relevant area within the overhaul procedure
and consider if replacement of this single item can
be achieved without complete disassembly.
NOTICE: Cleanliness during overhaul is important. Ensure
during the rebuilding stage that all contaminant is elimi-
nated, the transmission uses hydraulically actuated com-
ponents and that cleanliness and the removal of any con-
taminant is paramount to a successful overhaul. Pay par-
ticular attention to the control valve when this is removed
during this overhaul stage.
3. During disassembly and re-assembly it is necessary
to place the transmission in the horizontal and verti-
cal positions, therefore a suitable stand is a neces-
sary. See TRANSMISSION Semi-Powershift - Spe-
cial tools (C.20.D) for details.
Alternatively an engine stand of sufficient strength
together with a suitable bracket may be used.
BVE029A 2
Next operation:
TRANSMISSION Mechanical - Install (C.20.B).
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TRANSMISSION Semi-Powershift - Disassemble

Prior operation:
Remove the transmission (refer to TRANSMISSION Mechanical - Remove (C.20.B)).
WARNING
B012

BVE029A 1
2. Remove the transmission top cover (refer to Cover -

Remove (C.20.D)).
Remove the transmission control valve (refer to Con-
trol valve - Remove (C.20.D)).
Remove the high/low rail detent spring (1), detent ball
actuator (2) and the detent ball (3).
BVE0769A 2
3. Remove the low range (1) and high range (2)

switches from the transmission housing.
NOTE: The range switches have different thread diameters
and cannot be interchanged.
BVE0809A 3
4. Clutch and gear Speed clutch - Remove (C.20.D).

5. Gear and synchroniser - Remove (C.20.D).
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6. Clutch and gear Speed clutch - Remove (C.20.D).

7. Clutch and gear Speed clutch - Disassemble
(C.20.D).
8. Clutch and gear Speed clutch - Visual inspection
(C.20.D).
9. Clutch and gear Master clutch - Assemble
(C.20.D).
10. Gear and synchroniser - Disassemble (C.20.D).
11. Gear and synchroniser - Assemble (C.20.D).
12. Clutch and gear Speed clutch - Disassemble
(C.20.D).
13. Clutch and gear Speed clutch - Visual inspection
(C.20.D).
14. Clutch and gear Master clutch - Assemble
(C.20.D).
Next operation:
TRANSMISSION Semi-Powershift - Assemble (C.20.D).
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TRANSMISSION Semi-Powershift - Inspect

Prior operation:
TRANSMISSION Semi-Powershift - Disassemble (C.20.D).
1. Before commencing a detailed inspection of the

transmission components, consider the history of the
transmission. If disassembly and overhaul has been
dictated by a specific failure at relatively low service
hours, a thorough examination of components will
identify re-usable bearing seals and other such
items. If, however, the transmission has operated
considerable service hours, then replacement of all
bearings and seals would be recommended.
2. Wash all components, including the transmission
housing, in a suitable solvent and dry using a lint
free cloth or compressed air. During re-assembly
TRANSMISSION Semi-Powershift - Assemble
(C.20.D) of any item in this chapter use clean trans-
mission oil NEW HOLLAND AMBRA MULTI G
134 AKCELA NEXPLORE (MAT 3525) as a lubricant
unless otherwise stated.
Next operation:
TRANSMISSION Semi-Powershift - Assemble (C.20.D).
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TRANSMISSION Semi-Powershift - Assemble

Prior operation:
TRANSMISSION Semi-Powershift - Disassemble (C.20.D), TRANSMISSION Semi-Powershift - Service instruc-
tion (C.20.D).
1. Install the shaft (3), locking pin (2) and the woodruff
key (4).
Install the selector actuator (5) and tighten the clamp-
ing bolt (1).
BVE0668A_237 1
2. Install the C3/C4 clutch and oil supply manifold as-

sembly into the transmission housing.
BVE0721A_238 2
3. Install the C3 clutch output shaft.
MMG 21 430_239 3
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4. Install the output shaft, high/low synchronizer and

shift fork into the transmission housing as a complete
assembly.
MMG 21 428_240 4
5. Install the high/low selector fork rail (3).

Install the rail locking bolt (2), locknut (1) and tighten
to the specified torque value.
BVE0667A_241 5
6. Install the high range and low range switches.

Tighten to the specified torque value.
NOTE: Note that the switches have differing thread sizes
and cannot be interchanged.
BSF4020A_242 6
7. Install the rear cover assembly.
BSF4031A_243 7
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8. Install the rear cover retaining bolts and tighten to the

BSF4030B 8
9. Rotate the transmission until the rear of the transmis-

sion is in a vertical position.
Using a suitable lever (5), raise the output shaft as-
sembly (1) to enable the installation of the circlip.
Install the roller bearing thrust washer (4), ’D’ shaped
washer (3) and the circlip (2).
MMG 21 486_244 9
10. Rotate the transmission to a vertical position.

Install the main synchronizer and low main gear as-
sembly (1).
BVE0654A 10
11. Using suitable snap ring pliers, expand the snap ring
(1) and install the main synchronizer into the trans-
mission housing.
BVE0653B 11
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12. Rotate the transmission to a horizontal position.

NOTE: Take care when lifting heavy components.
NOTE: It may be necessary to apply petroleum jelly to the
synchronizer components and needle roller bearings to aid
assembly.
13. Loosely install the inner cover assembly (1) into the
BVE0652A_245 12
14. Align the inner cover assembly (1) with the synchro-
nizer, lower shaft and reverse idler gear.
BVE0651A 13

Install the inner cover plate retaining bolts and tighten
NOTE: Make sure the inner cover assembly is aligned with
the synchronizer, lower shaft and reverse gear idler.
BSF4025A 14
16. Gear and synchroniser - Clearance (C.20.D).
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17. Install the PTO input shaft (1).
BVE0648A_251 15
18. Install the C1/C2 clutch (3), output gear (2) and the
front lower shaft (1).
BSF4023A_252 16
19. Install the C1 clutch output gear needle roller bearing

(2), front roller bearing (4) and the baffle plate (1).
MMG 21 407_253 17

mm diameter following the pattern shown.
BSF4017A 18
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21. Install the O-rings (2) and the front cover plate (1).
BVE0705A_254 19
22. Loosely install the C1/C2 clutch support manifold.

Install the C1/C2 clutch support manifold retaining
bolts.
NOTE: Do not tighten the bolts at this stage.
MMG 21 405 20
23. Install the oil transfer tube retaining bracket (1) and
the lubrication oil supply tube (2).
BVE0704A_255 21
24. Tighten the front cover, clutch support manifold and

the bracket retaining bolts to the specified torque
value.
BVE0646A 22
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Next operation:
Install the transmission control valve (refer to Control valve - Overview (C.20.D)).
Install the transmission top cover (refer to Cover - Exploded view (C.20.D)).
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TRANSMISSION Semi-Powershift - Install

Prior operation:
TRANSMISSION Semi-Powershift - Assemble (C.20.D)
DANGER
B012
WARNING
B018

transmission.
hoist.
BVE0344A 1

BVE0599A_49 2
transmission.
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BVE0343A 3

BVE0342A 4
Next operation:
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TRANSMISSION Semi-Powershift - Pressure test

1. Pressure test ports are provided on the transmission
control valve cover, detailed in Figure 3, to enable
the transmission clutches, and lubrication pressures
to be tested to determine the correct function of a
number of system components. Components such
as solenoids, clutch pedal operation and micro–pro-
cessor can be seen to be operating correctly by the
results of pressure testing.
NOTE: Prior to pressure testing, make certain that all the
points detailed under the tractor preparation are carried out
to ensure maximum safety.
2. Tractor Preparation
Start and drive the tractor to warm the transmission
oil to a minimum operating temperature of 50 °C (
122 °F).
Apply the parking brake.
Remove the four wheel driveshaft.
Raise the right hand rear wheel and place a suit-
able support under the axle casing. Remove the right
hand rear wheel.
Disconnect the grey electrical connector from the
high range switch and install the ‘Switch By-Pass
Connector’, 380001147 (1), into the tractor harness
end. By installing the switch By-Pass connector, the
processor receives a signal indicating that the high
range is selected, although the RANGE LEVER re- BVE0171A 1
mains in NEUTRAL throughout the testing.
3. Disconnect the differential lock solenoid electrical
connector (1).
BVE0397A 2
4. C1/C2 and C3/C4 Clutch Engagement and Disen-

gagement Pressure Test
Remove the test port plugs, refer to figure 3 and in-
stall the adaptors:
- C1 / C2 quick release fitting 380000492.
- C3 / C4 7/16 JIC male x 7/16 UNF male and 90 °
quick release fitting 380001146.
• Test port thread 7/16 –20 UNF
NOTE: Table 5 shows C3 clutch feathering test, C4 clutch
feathering test pressures should be the same as C3.
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5. Attach four 0 - 40 bar ( 0 - 600 lbf/in²) pressure

380000543 (2). The testing may be carried out with
two gauges using the following procedure:
- Connect to C1 and C2 test ports and carry out tests
from gears nine through to twelve.
- Connect to C3 and C4 test ports and carry out tests
from gears nine through to twelve.
- Connect to C2 and C3 test ports with gear 10 se-
lected and carry out C3 clutch feathering test.
- Connect to C2 and C4 test ports with gear 9 se-
lected and carry out C4 clutch feathering test.
Position the shuttle lever in Forward and leave the
High/Low range lever in Neutral.
Observe the reading on the gauges and compare
with those in Table 4as the gears are shifted, Table
5 for the feathering tests and Table 6 for Forward/
Neutral/Reverse shuttle test.
6. Lube Supply Pressure Test
Prepare the tractor as described in tractor prepara-
tion.
Remove the test port plug, refer to figure 3 and Install
the quick release fitting 380000492.
• Test port thread 7/16 – 20 UNF
Attach a 0 - 10 bar ( 0 - 145 lbf/in²) pressure
380000543 and the hose 380000545.
The following pressures should be observed.
3 bar ( 44 lbf/in²) - Neutral
2 bar ( 29 lbf/in²) - Forward / Reverse
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BVE0172A_416 3
Pressure Test Ports and Solenoid Valve Identification
1 C4 Pressure test port 2 C3 Pressure test port

3 C3/C4 Lube pressure test port 4 Lube inlet connector
5 Lube supply pressure test port 6 Regulated pressure inlet
7 C2 Pressure test port 8 C1/C2 Lube pressure test port
9 C1 pressure test port 10 Transmission bearing / synchroniser lube pressure
11 Oil temperature sender 12 C1 PWM solenoid valve
13 C2 PWM solenoid valve 14 C3 PWM solenoid valve
15 C4 PWM solenoid valve
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BVE0173A 4
Pressure Testing - Clutch PWM Solenoid Valve Operation
A. C2 and C4 Full Pressure

B. C2 Full Pressure
C3 0 - 2 bar : 2 - 18 bar
C4 18 - 17 bar : 17 - 0 bar
C. C2 and C3 Full Pressure
D. C1 0 - 2 bar : 2 - 18 bar
C2 and C3 18 - 17 bar : 17 - 0 bar
C4 0 - 18 bar
E. C1 and C4 Full Pressure
F. C1 Full Pressure
C3 0 - 2 bar : 2 - 18 bar
C4 18 - 17 bar : 17 - 0 bar
G. C1 and C3 Full Pressure
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BVE0174A 5
Clutch Feathering Tests for C3 Clutch - Gear 10 Selected
A. When the clutch pedal is initially depressed the pressure in C3 will reduce from the fully engaged pressure
by approximately 2 bar.
B. When the clutch pedal is fully depressed C2 and C3 pressures should be zero.
C. Releasing the clutch pedal from the fully depressed position should restore C2 to full pressure and C3
to feathering pressure.
D. Pressure in C3 should progressively increase as the clutch pedal is released indicating the PWM solenoid
valve and clutch potentiometer are functioning correctly.
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BVE0175A 6
Forward/Neutral/Reverse Shuttle Test - Gear 9 Selected
A. C2 and C4 Full Pressure

B. C2 and C4 18 - 0 bar
C. C2 Immediate full pressure
C4 Controlled engagement to full pressure
NOTE: Release the parking brake to perform the shuttle test and make sure the RANGE LEVER remains in
NEUTRAL.
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BVE0176A 7
Clutch Lube Pressure Tests - Gear 9 Selected
A. C2 and C4 Zero Pressure

C1/C2 Lube Approx. 0.5 bar
B. C2 Full Pressure
C4 0 - 2 bar
C1/C2 Lube Approx. 2 bar
C. C2 Full Pressure
C4 Full Pressure
C1/C2 Lube Reduced to 1 bar
Forward / Reverse and 1-4 / 5-8 Range Synchroniser Pressure Test

7. Slide the operator seat fully rearward.
Remove the rubber mat from the cab.
Remove the cab floor panel from the cab.
BVE0227A_417 8
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8. Remove the test port plugs and install the quick re-
lease fitting 380000492 in the forward (F), reverse
(R), 1-4 and 5-8 range test ports.
9. Test port thread 7/16 - 20 UNF
10. Attach four 0 - 40 bar ( 0 - 600 lbf/in2) pressure
380000543.
Enter the transmission calibration procedure
TRANSMISSION Semi-Powershift - Calibrate
(C.20.D).
The table below shows the synchroniser calibration
stages and at what stage the pressure can be ex-
pected to be seen.
NOTE: Due to the operating characteristics of the synchro-
niser it is not possible to accurately pressure test the syn-
chroniser operating piston during normal tractor operation.
The synchroniser will only take the required pressure to
move and then the pressure will be cut. This would be seen
only as a momentary blip on a pressure gauge. Therefore
the following procedure, using the calibration mode, should
be used to determine if full pressure is being achieved.
BVE0177A 9
Stage Synchroniser Pressures (bar)

Forward (F) Reverse (R) 1-4 Range 5-8 Range
SOC 18** 0 0 18**
1 0 0-5* 0 0
2 0 18** 0 0
3 0 0 0-5* 0
4 0 0 18** 0
5 0-5* 0 0 0
6 18** 0 0 0
7 0 0 0 0-5*
8 0 0 0 18**
END 0 0 0 0
* This pressure slowly increases to overcome the synchroniser detent position and may not be noticed on the
pressure gauge.
** This pressure increases at a faster rate to shift the synchroniser into position.
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TRANSMISSION Semi-Powershift - Calibrate 16x16 Transmission

MAXXUM 140
ment of the tractor, park the tractor away from any obstacles, firmly apply the parking brake and block the wheels,
front and rear. Check that the Ground speed display is Zero before commencing.
NOTE: Prior to performing a clutch and synchroniser calibration the transmission oil must be at the correct tempera-
ture, this can be checked using the H9 menu.
The Semi powershift transmission should be calibrated when the transmission oil temperature is between 60 - 105 °C
NOTE: Make sure that the air conditioning (if equipped) is switched off and all electrical hydraulic applications are
deselected.
NOTE: If a four-digit number starting with "2" is displayed at any time during the calibration procedure, it is a standard
NOTE: The illustrations in this procedure depict the DS module, For vehicles with multicontroller (DT module), the
actual steps remain the same as below.
1. There are two methods of entering the calibration
mode:
• Quick entry - Depress the upshift switch and
then depress the downshift switch within 3 sec-
onds while starting the engine.
• HH menu entry - Using the diagnostic connec-
tor 380000843 and H1 calibrations in the HH
menu’s.
Quick Entry
2. Depress the upshift switch (1) and then depress the
downshift (2) switch within 3 seconds while starting
the engine.
BAIL09APH187AVA 1
3. The system being calibrated will be shown on the

central display, ’CAL’ will be displayed for a few sec-
onds, then the transmission oil temperature will be
shown on the lower central display.
BAIL09APH209AVB 2
4. Go to step 7.
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HH Menu Entry
BAIL06CCM213AVA 3
6. Use the "h", "m" and "dimming" keys on the instru-

ment cluster to navigate the HH menu’s to H1 and
the transmission symbol on the DS controller.
The lower central display will show the transmission
oil temperature.
BAIL09APH266AVA 4
7. Set the engine speed to 1200 RPM The engine

speed must be stable, adjust the throttle slightly to
achieve a stable RPM.
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8. Place the shuttle lever into the forward position the

range lever in neutral and release the clutch pedal.
BAIL06CCM610AVA 5
Synchroniser Calibration
hold the upshift switch, SOC will be displayed.
BAIL09APH312AVA 6

through to 5 and then ’end’ when the synchronisers
are calibrated.
Release the upshift switch.
BSE3139A 7
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Clutch Calibration
11. Move the range lever to the "neutral" position, press
and hold the upshift switch again to commence cali-
bration of the C1 clutch.
BAIL09APH313AVA 8
12. When the calibration is complete the display will al-

ternate between the calibration value and C1 for as
long as the switch is held.
When the switch is released CAL will be displayed
followed by the oil temperature.
BAIL09APH314AVA 9
13. Press and hold the downshift switch to calibrate C2

clutch. The routine will then be same as for C1 clutch.
BAIL09APH315AVA 10
14. To calibrate clutches C3 and C4 shift the range lever

to ’Hi’.
Press and hold the upshift switch to calibrate the C3
clutch. The routine will be the same as for C1 clutch.
BAIL09APH316AVA 11
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BAIL09APH317AVA 12
16. For models with the 50 km/h transmission it is nec-

essary to calibrate the additional C5 clutch.
Shift the range lever to ’Lo’.
Press and hold the downshift switch. The routine will
be the same as clutches C1, C2, C3 and C4.
NOTE: Error code U47 will be displayed if C5 ( 50 Km/h)
clutch is not present. DO NOT KEY OFF.
Proceed to Flywheel Torque Sensor Calibrations step 17
once complete, "Key Off" to store both Clutch and Synchro-
niser Calibration and Flywheel Torque Sensor Calibrations.
BAIL09APH318AVA 13
Flywheel Torque Sensor Calibration

17. If the tractor has the Auto-Shift option the flywheel
torque sensor must be calibrated. Auto-Shift will not
be enabled if this calibration has not been completed.
Range lever to "Hi" position, shuttle lever in forward
position.
To calibrate the flywheel torque sensor, press the
Auto-trans switch once.
BSF4868A 14
18. Increase the engine speed to maximum press the

Auto-Shift switch once.
Press and hold the upshift switch, ’dt’ (damper
torque) will be displayed.
Keeping the upshift switch depressed, the calibration
will be completed and the calibration value, which
represents flywheel damper deflection, will alternate
with ’dt’ until the upshift switch is released.
Reduce the engine rev/min to low idle, return the
range lever to neutral and turn the key start off for
at least 5 second to store the calibration values.
NOTE: If during calibration the engine speed drops below
1200 RPM, calibration will stop. If this occurs increase the BAIL09APH319AVA 15
engine speed and restart the procedure.
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Manual Adjustment of the C3/C4 Clutch Calibrations

19. Install the diagnostic connector, 380000843 and start
the engine.
NOTE: The transmission oil temperature should be no
lower than 40 °C.
BAIL06CCM213AVA 16
20. Using the "h", "m" and "dimming" buttons on the in-
strument cluster navigate to H1 on the DS processor.
Press the "h" button while the shuttle lever is in neu-
tral to select the C3/C4 clutches manual adjustment
mode.
BAIL09APH209AVB 17
21. With the shuttle lever in neutral C3 or C4 is displayed,

depending on the gear selected. The gear can be
changed while the shuttle lever is in neutral and the
tractor can be driven in any gear but powershifts are
not possible.
BSE3752A 18
22. If the range lever is in neutral with the shuttle lever in

forward or reverse, the transmission oil temperature
will be displayed.
BSE3753A 19
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C.20.D / 95
23. With the range lever and shuttle lever engaged and
the clutch pedal fully released or fully engaged the
NOTE: With the range and shuttle levers engaged the trac-
tor will drive if the clutch pedal is released.
BSE3754A 20
the clutch pedal position between 3 - 98 %, the dis-
play will show the clutch pedal position in percent,
preceded by ’c’ if the clutch pedal switch is closed
and ’o’ if it is open.
BSE3147A 21
25. With the range lever and shuttle lever engaged the
calibration value for the appropriate clutch can be
adjusted using the upshift and downshift switches.
It is recommended that the clutches are adjusted to
optimise shuttle shifts in gears 7Lo and 8Lo at 1500
- 1800 RPM.
Select gear 7Lo, drive the tractor and shuttle shift,
using only the lever, not the clutch pedal, adjust the
calibration value until the smoothest shuttle shift is
obtained.
BSF4243A 22
26. Shift the shuttle lever to neutral and select gear 8Lo,
repeat the procedure described for gear 7Lo.
NOTE: It is possible to drive the tractor in other gears and
at other engine speeds but it is not recommended to make
adjustments while in the high range as the low range is
much more sensitive. A slightly harsh shift in high range
may be a severely jerky shift in low range.
BRE1465C 23
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TRANSMISSION Semi-Powershift - Calibrate 16x16 Transmission

NOTE: Prior to performing a clutch and synchroniser calibration the transmission oil must be at the correct tempera-
ture, this can be checked using the H9 menu.
The 16x16 transmission should be calibrated when the transmission oil temperature is between 60 - 105 °C.
NOTE: Make sure that the air conditioning (if equipped) is switched off and all electrical hydraulic applications are
deselected.
NOTE: If a four-digit number starting with "2" is displayed at any time during the calibration procedure, it is a standard
1. There are two methods of entering the calibration
mode:
With the operator in the seat:
• Quick entry - Depress the upshift switch and
downshift switch simultaneously while starting
the engine.
• HH menu entry - Using the diagnostic connec-
tor 380000843 and H1 calibrations in the HH
menu’s.
Quick Entry
2. Depress the upshift switch (1) and downshift switch
(2) simultaneously while starting the engine.
BAIL09HHP256AVC 1
3. The system being calibrated will be shown in the dis-

play, ’CAL’ will be displayed for a few seconds, then
the transmission oil temperature will be displayed.
BAIL09HHP103AVK 2
4. Go to step 8.
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HH Menu Entry
BAIL06CCM213AVA 3

navigate the HH menu’s to H1 and the transmission
symbol on the RV controller.
BAIL09HHP105FVB 4
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7. The system being calibrated will be shown in the dis-

play, ’CAL’ will be displayed for a few seconds, then
the transmission oil temperature will be displayed.
BAIL09HHP103AVK 5
8. Set the engine speed to 1200 RPM The engine

speed must be stable, adjust the throttle slightly to
achieve a stable RPM.
9. Place the shuttle lever into the forward position, the
range lever in neutral and release the clutch pedal.
BAIL09HHP237AVC 6
Synchroniser Calibration
hold the upshift switch, "Soc" will be displayed.
BAIL09HHP291AVA 7
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through to 5 and then ’end’ when the synchronisers
are calibrated.
Release the upshift switch.
BAIL09HHP210AVD 8
Clutch Calibration
12. Move the range lever to the "neutral" position, press
and hold the upshift switch again to commence cali-
bration of the C1 clutch.
BAIL09HHP289AVA 9
13. The display will show "C1".
BAIL09HHP103AVD 10
14. When the calibration is complete the display will al-

ternate between the calibration value and C1 for as
long as the switch is held.
When the switch is released CAL will be displayed
followed by the oil temperature.
BAIL09HHP290AVA 11
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BAIL09HHP292AVA 12
16. To calibrate clutches C3 and C4 shift the range lever

to ’Hi’.
Press and hold the upshift switch to calibrate the C3
clutch. The routine will be the same as for C1 clutch.
BAIL09HHP293AVA 13

BAIL09HHP294AVA 14
18. For models with the 50 km/h transmission or 40 km/h

Economy transmission it is necessary to calibrate the
additional C5 clutch.
Shift the range lever to ’Lo’.
Press and hold the upshift switch. The routine will be
the same as clutches C1, C2, C3 and C4.
NOTE: Error code U47 will be displayed if C5 ( 50 km/h)
clutch is not present. DO NOT KEY OFF.
Proceed to Flywheel and PTO Torque Sensor Calibrations
step 19 once complete, "Key Off" to store the Clutch and
Synchroniser Calibrations and the Flywheel and PTO
Torque Sensor Calibrations.
BAIL09HHP295AVA 15
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Flywheel and PTO Torque Sensor Calibration

19. If the tractor has the Auto-Shift option the flywheel
torque sensor must be calibrated. Auto-Shift will not
be enabled if this calibration has not been completed.
Move the range lever to the "Hi" position.
BAIL09HHP297AVA 16
20. To calibrate the flywheel torque sensor, press the

Field Auto switch (1) once.
BAIL09HHP288AVA 17
21. Press and hold the upshift switch. The display will
change to ’dt’ (damper torque) and the engine speed
will be set to approximately 2150 RPM. Keeping the
upshift switch depressed, the calibration will be com-
pleted and the calibration value, which represents fly-
wheel damper deflection, will alternate with ’dt’ until
the upshift switch is released.
BAIL09HHP298AVA 18
22. Press and hold the downshift switch. The display will
change to ’Pt’ (PTO torque) and the engine speed
will be set to approximately 1600 RPM. Keeping the
upshift switch depressed, the calibration will be com-
pleted and the calibration value will be displayed.
Reduce the engine speed to low idle, return the
range lever to neutral and turn the key start off for at
least 2 second to store the calibration values.
BAIL09HHP299AVA 19
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Manual Adjustment of the C3/C4 Clutch Calibrations

navigate the HH menu’s to H1 on the RV controller.
24. Press the "up" key while the shuttle lever is in neu-
tral to select the C3/C4 clutches manual adjustment
mode. C3 or C4 is displayed, depending on the gear
selected. The gear can be changed while the shuttle
lever is in neutral and the tractor can be driven in any
gear but powershifts are not possible.
BAIL09HHP306AVA 20
25. If the range lever is in neutral with the shuttle lever in

forward or reverse, the transmission oil temperature
will be displayed.
NOTE: When optimizing the calibration values, the trans-
mission oil temperature should be higher than 40 °C.
BAIL09HHP300AVC 21
the clutch pedal fully released or fully engaged the
NOTE: With the range and shuttle levers engaged the trac-
tor will drive if the clutch pedal is released.
BAIL09HHP301AVA 22
the clutch pedal position between 3 - 98 %, the dis-
play will show the clutch pedal position as a per-
centage, preceded by ’c’ if the clutch pedal switch
is closed and ’o’ if it is open.
BAIL09HHP302AVA 23
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28. With the range lever and shuttle lever engaged the
calibration value for the appropriate clutch can be
adjusted using the upshift and downshift switches.
It is recommended that the calibration values are ad-
justed to optimize shuttle shifts (made without using
the clutch pedal) in gears 7Lo and 8Lo at 1500 - 1800
RPM.
The inching point can also be evaluated by using the
display of the clutch pedal position.
BAIL09HHP303AVA 24
29. To adjust the calibration value, shift the range lever

to low range. With the shuttle lever in neutral, se-
lect gear L7 (indicated by the display of gears). The
transmission will not powershift while in this mode
and gear selection can only be done while the shut-
tle lever is in neutral.
BAIL09HHP304AVA 25
30. Shuttle shift using the shuttle lever but not using the
clutch pedal. Use the upshift and downshift switches
to increase or decrease the calibration value until the
smoothest shuttle shift is obtained.
BAIL09HHP305AVA 26
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Control valve - Remove

NOTE: The following procedure treats the transmission as removed from the tractor. It is possible to remove the
control valve assembly from the transmission without removing the transmission from the tractor. Removal of the
surrounding oil supply tubing, the accumulator and other peripheral hardware is necessary.
NOTE: It should be noted that unless contaminant is suspected to be within the control valve cover oil galleries or
there is a suspected fault within the lubrication control valve, it is not necessary to remove the valve cover to remove
any of the PWM solenoids.
NOTE: During removal of the control valve and the connecting hardware, it is essential that outside contaminant is
not permitted to enter the inside of the transmission. If necessary steam clean the outside of the control valve area
before proceeding to remove the valve assembly.
Control Valve Removal

1. Drain the transmission/rear axle oil into a suitable
container.
Remove the surrounding oil supply tubing, accumu-
lator and other peripheral hardware.
Remove the control valve cover retaining bolts (1).
BVE0761A 1
2. Using the separating holes (1) separate the transmis-

sion control valve from the transmission housing.
BVE0761B 2
3. Remove the Hi/Lo rail detent spring (1), detent ball

actuator (2) and the detent ball (3).
BVE0769A 3
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Next operation:
Control valve - Visual inspection (C.20.D).
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Control valve - Visual inspection

Prior operation:
Control valve - Remove (C.20.D).
NOTE: Note if any contamination is expelled when cleaning, which may have caused an oil blockage or a sticking
valve.
1. Clean the cover in a suitable cleaning solvent and
thoroughly dry.
2. Carefully examine the cover for hairline cracks or
other damage which may have caused oil leakage.
Replace the cover if any damage or cracks are found,
do not attempt a repair.
3. Clean the complete PWM valve assemblies, less the
solenoids, in a suitable cleaning solvent. It is not rec-
ommended to disassemble the PWM valves further
to clean. If the performance of the valve is suspect
and no contaminant is found during cleaning, but the
solenoid is within specification, the valve should be
replaced with a new one.
Next operation:
Control valve - Install (C.20.D).
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Control valve - Disassemble

Absolute cleanliness is essential during disassembly and reassembly of the control valve. Ensure the working area is
clean and not likely to be contaminated by other working operations being performed alongside. It is recommended
that only a clean, dust free environment is used for the overhaul.
Lubrication Valve Removal and Disassembly

1. Place the control valve face down on a clean surface
and remove the retaining bolts retaining the lubrica-
tion valve assembly to the side cover. Carefully lift
off the lubrication valve, noting the gasket between
the two castings.
Remove the end plugs and withdraw the spools and
springs as shown in Figure 2.
1b0o2004061011 1
1 Dowel 2 ‘O’ Ring

3 Dowel 4 High/Low Detent
5 Side Cover 6 Lubrication Control Valve
7 C3/C4 Supply Tubes
2. Clean the valve body in a suitable cleaning solvent
and use compressed air to dry.
NOTE: Note if any contamination is expelled when clean-
ing, which may have caused an oil blockage or a sticking
valve.
3. Examine the valves and bores for wear or damage,
replace parts as necessary.
4. Assembly is the reverse of the disassembly. Coat all
components with clean transmission oil NEW HOL-
LAND AMBRA MULTI G 134 AKCELA NEXPLORE
(MAT 3525) just prior to assembly.
5. Prior to assembling the lubrication valve to the cover,
ensure the mating faces are clean and fit a new gas-
ket. Do not use a liquid gasket sealant between
these surfaces.
Control Valve Cover Disassembly

6. Remove the four PWM solenoid valves and the oil
temperature sender.
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Lube_vlvDF01 2
Lubrication Valve Assembly
1 Lubrication Pressure Relief Valve 2 Lubrication Control Valve Spool

3 Lubrication Shuttle Valve Ball 4 Lubrication Valve Spool Spring ( 220 lb) and Plunger
84276322A 31/05/2010
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Control valve - Assemble

Assembly is the reverse of the disassembly. Ensure the ‘O’ rings of all the solenoid valve assemblies are in good
condition prior to installation. Coat the valve components with clean transmission oil NEW HOLLAND AMBRA MULTI
G 134 AKCELA NEXPLORE (MAT 3525) prior to assembly.
1. Tighten the retaining bolts to a torque value of 27 Nm

( 20 lbf.ft).
BVE0319A_236 1
Control Valve Assembly
1 Lubrication Supply Inlet Connector 2 Regulated/Pressure Supply Inlet Connector

3 Transmission Oil Temperature Sender 4 C1 PWM Solenoid and Valve Assembly
5 C2 PWM Solenoid and Valve Assembly 6 C3 PWM Solenoid and Valve Assembly
7 C4 PWM Solenoid and Valve Assembly
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Control valve - Install

Prior operation:
Control valve - Remove (C.20.D) Control valve - Visual inspection (C.20.D).
1. Install the Hi/Lo detent ball (3), detent ball actuator

(2) and the Hi/Lo rail detent spring (1).
BVE0769A 1

BSF4021A 2
3. Install the control valve cover and tighten the retain-

Install the surrounding oil supply tubing, accumulator
and other peripheral hardware.
Refill the transmission/rear axle with NEW HOL-
LAND AMBRA MULTI G 134 AKCELA NEXPLORE
(MAT 3525) oil.
BVE0761C 3
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Hydraulic line - Overhaul

Prior operation:
Control valve - Remove (C.20.D).
NOTE: Note if any contamination is expelled when cleaning, which may have caused an oil blockage or a sticking
valve.
1. Clean the cover in a suitable cleaning solvent and
thoroughly dry.
2. Carefully examine the cover for hairline cracks or
other damage which may have caused oil leakage.
Replace the cover if any damage or cracks are found,
do not attempt a repair.
3. Clean the complete PWM valve assemblies, less the
solenoids, in a suitable cleaning solvent. It is not rec-
ommended to disassemble the PWM valves further
to clean. If the performance of the valve is suspect
and no contaminant is found during cleaning, but the
solenoid is within specification, the valve should be
replaced with a new one.
Next operation:
Control valve - Install (C.20.D).
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Gear and synchroniser - Disassemble

Prior operation:
Gear and synchroniser - Remove (C.20.D).
BSF4043A_234 1
Drive Line Components
1 C2 clutch output gear 2 Reverse gear (33 teeth)

3 Forward gear (37 teeth) 4 Main range synchroniser (1-4/5-8)
5 Main range synchroniser support shaft 6 Main low gear (53 teeth)
7 Lower shaft 8 Forward/reverse synchroniser
9 Inner cover plate
84276322A 31/05/2010
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BSF3990A 2
Cross Sectional View
1 Support shaft 2 Snap ring

3 Roller bearing 4 Reverse gear (33 teeth)
5 Forward/reverse synchroniser 6 Forward/reverse synchroniser retaining circlip
7 Main range synchroniser (1-4/5-8) 8 Needle roller bearing
9 Roller bearing 10 Needle roller bearing
11 Needle roller bearing 12 Snap ring
13 Low main gear (53 teeth) 14 Needle roller bearing
15 Main range synchroniser (1-4/5-8) retaining circlip 16 Thrust washer
17 Needle roller bearing 18 Needle roller bearing
19 Thrust washer
Middle Section Disassembly

1. Using suitable circlip pliers, remove the reverse idler
gear circlip (1).
BSF4029A 3
84276322A 31/05/2010
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2. Remove the front bearing retaining plate.
BVE0660A 4
3. Using suitable snap ring pliers, remove the front

BVE0662A 5
4. Remove the forward/reverse synchroniser end float

adjustment shims (1).
BVE0661A 6
5. Remove the inner cover plate (1).

NOTE: Support the lower shaft, synchroniser assembly
and the reverse idler gear.
BVE0663A 7
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6. Remove the steel thrust washer (4), reverse idler

gear (3), needle roller bearing (2) and the steel thrust
washer (1).
Remove the support shaft if necessary.
BSF4028A 8
Forward/Reverse Synchroniser and Related Parts Disassembly
BSF4037A 9
7. Remove the needle roller bearing (1), forward gear

(2), circlip (5), needle roller bearing (3) and the syn-
chroniser gears (4).
BVE0655A 10
84276322A 31/05/2010
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8. Using suitable circlip pliers, remove the forward/re-

verse synchroniser retaining circlip (1).
BVE0656A 11
9. Remove the forward/reverse synchroniser (1).
BVE0657A 12
10. Remove the reverse gear (1), needle roller bearing

(2), ’D’ shaped washer (3) and the circlip (4).
Using a suitable hydraulic press, remove the roller
bearing (5) from the forward/reverse synchroniser
support shaft (6).
BVE0658A 13
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BVE0659A 14
Forward/Reverse synchroniser Exploded View

9 Detent guide
Forward/Reverse Synchroniser and Related Parts Assembly

11. Using a suitable hydraulic press, install the roller
bearing (5) onto the forward/reverse synchroniser
support shaft (6).
Install the circlip (4), ’D’ shaped washer (3), needle
roller bearing (2), and the reverse gear (1).
BVE0658A 15
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12. Install the forward/reverse synchroniser (1).
BVE0657A 16
13. Using suitable circlip pliers, install the forward/re-

verse synchroniser retaining circlip (1).
BVE0656A 17
14.
NOTICE: When assembling the synchroniser assemblies,
it is essential that the forward gear is installed correctly.
15. 1. Forward/Reverse synchroniser side
2. 1-4/5-8 synchroniser side
BVE0770A 18
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16. Install the synchroniser gears (4), needle roller bear-

ing (3), circlip (5), forward gear (2), and the needle
roller bearing (1).
BVE0655A 19
Main Range (1-4/5-8) Synchronizer and Related Parts Disassembly/Assembly
SHG21158 20
17. Remove the outer cone/coupling and friction cone

from the main range (1-4/5-8) synchroniser.
Using suitable circlip pliers, remove the main range
(1-4/5-8) synchroniser retaining circlip (1).
BVE0656A 21
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BSF4034A 22
Main Range (1-4/5-8) Synchroniser And Related Parts
1 Roller bearing 2 Circlip

3 Needle roller bearing retaining snap ring 4 Needle roller bearing
5 Main low gear (53 teeth) 6 Main range (1-4/5-8) synchroniser
7 Circlip 8 Needle roller bearing
9 Washer 10 Main range (1-4/5-8) synchroniser support shaft
BVE0659A 23
Main Range (1-4/5-8) Synchroniser
1 Outer cone/Coupling 2 Friction cone

9 Detent guide
84276322A 31/05/2010
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18. Using suitable circlip pliers, install the main range

(1-4/5-8) synchroniser retaining circlip (1).
19. Install the outer cone/coupling and friction cone to the
main range (1-4/5-8) synchroniser.
BVE0656A 24
Next operation:
Gear and synchroniser - Visual inspection (C.20.D).
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Gear and synchroniser - Assemble - Middle Section Assembly.

Prior operation:
Gear and synchroniser - Disassemble (C.20.D).
1. Install the support shaft if necessary.

Install the steel thrust washer (1), needle roller bear-
ing (2) reverse idler gear (3), and the steel thrust
washer (1).
NOTE: Do not install the circlip (5) at this stage.
BSF4028A 1
2. Install the inner cover plate (1).

NOTE: Support the lower shaft, synchroniser assembly
and the reverse idler gear.
BVE0663A 2
3. Install the forward/reverse synchroniser end float ad-

justment shims (1).
BVE0661A 3
84276322A 31/05/2010
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4. Using suitable circlip pliers, install the front bearing

retaining snap ring (1).
BVE0662A 4
5. Install the front bearing retaining plate and tighten the

BVE0660B 5
6. Using suitable circlip pliers, install the reverse idler

gear circlip (1).
BSF4029A 6
Next operation:
Gear and synchroniser - Clearance (C.20.D).
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Gear and synchroniser - Remove - Middle Section Removal.

Prior operation:
Clutch and gear Range clutch - Remove (C.20.D).
BSF4043A 1
1 C2 clutch output gear (37 teeth) 2 Reverse gear (33 teeth)

3 Forward gear (37 teeth) 4 Main range synchroniser (1-4/5-8)
5 Main range synchroniser support shaft 6 Main low gear (53 teeth)
7 Lower shaft 8 Lower shaft
9 Inner cover plate
1. Remove the inner cover plate retaining bolts.
BSF4026A 2
84276322A 31/05/2010
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2. Install two of the retaining bolts into the separating

holes.
NOTE: Do not tighten the bolts at this stage.
BSF4024A 3
3. Rotate the transmission to a horizontal position.

While tightening the separating bolts previously
installed in the separating holes, use a suitable lever
(1) to separate the forward/reverse synchroniser
from the forward gear.
BVE0650A 4
4. Remove the inner cover assembly (1) from the trans-

mission housing.
WARNING
Lift and handle all heavy components using lifting
equipment of appropriate lifting capacity. Make sure
that units or parts are supported by suitable slings
or hooks. Make sure that no-one is in the vicinity of
the load to be lifted. Failure to comply could result in
serious injury or death.
B012
BVE0652A 5

Using suitable snap ring pliers, expand the snap ring
(1) and remove the synchroniser and main low gear
assembly.
NOTE: Use a suitable lever to release the main low gear
assembly while expanding the snap ring.
BVE0653A 6
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Next operation:
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Gear and synchroniser - Visual inspection

Prior operation:
1. Inspect the main range and forward/reverse synchro-

niser components for wear and damage as follows:-
colouration, if excessive renew the synchroniser.
if the gap is less than that specified renew the syn-
chroniser.
MMG 21 447 1
Measuring Main Range synchroniser for Serviceable Life

3 Feeler blade
Minimum Gap
Main synchroniser mm inches
1-4, 5-8 0,5 0.020
Foward/Reverse synchroniser 0,8 0.0315
Hi/Lo synchroniser 0,85 0.0335
Next operation:
Gear and synchroniser - Clearance (C.20.D) Gear and synchroniser - Assemble (C.20.D).
84276322A 31/05/2010
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Gear and synchroniser - Clearance

Prior operation:
Gear and synchroniser - Disassemble (C.20.D) Gear and synchroniser - Visual inspection (C.20.D).
NOTE: It is necessary to adjust the running clearance of the components on the forward/reverse synchroniser support
shaft. The clearance is obtained by the placement of shim(s) behind the forward/reverse synchroniser support shaft
front bearing retaining snap ring.
NOTICE: The transmission must remain in the vertical position during this operation. The rear end components must
have been installed and the rear top shaft rear bearing retainer must be in position and fully secured.
1. Remove the forward/reverse synchroniser bearing
retaining plate.
BVE0660A_246 1
2. Using suitable snap ring pliers, remove the forward/

reverse synchroniser bearing retaining snap ring (1).
BVE0662A_247 2
3. Remove the forward/reverse synchroniser end float

adjustment shims (1).
BVE0661A_248 3
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4. Using suitable snap ring pliers, install the forward/

reverse synchroniser bearing retaining snap ring (1).
BVE0662A_247 4
5. Install the forward/reverse synchroniser bearing re-

taining plate and tighten the retaining bolts to the
NOTE: Using a suitable soft faced mallet, gently tap the
synchroniser support shaft downward to seat the compo-
nents. Be careful not to damage any components.
BVE0660B_249 5
6. Using a suitable dial gauge, measure the end-float of

the forward/reverse synchronizer.
BVE0670A 6
7. Do this by raising the forward/reverse synchroniser

at the positions indicated.
This measurement is H1
Determine the forward/reverse synchroniser
end-float adjustment shim(s) (S) as follows:
S = H1 - 0.5 mm
Where :
H1 = End-float of the forward/reverse synchroniser
0.5 mm = Average of the specified end-float 0.4 to
0.6
S = Forward/reverse synchroniser end-float adjust-
ment shim(s)
BVE0669A 7
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8. Install the calculated adjustment shim(s).

value.
BVE0660B_249 8
9. Install the needle roller bearing (2) and the steel

thrust washer (1).
BVE0649A_250 9
Next operation:
Gear and synchroniser - Assemble (C.20.D).
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Clutch and gear Range clutch - Remove - Front Section Removal.

Prior operation:
TRANSMISSION Semi-Powershift - Service instruction (C.20.D) TRANSMISSION Semi-Powershift - Disassem-
ble (C.20.D).
BSF4035A 1
1 C1/C2 clutch support shaft 2 ’O’ ring seal

3 Clutch annular sealing rings 4 Polyimide thrust washer
5 C1 clutch needle roller bearing 6 C1 clutch output gear (34 teeth)
7 C1/C2 clutch assembly 8 Support shaft roller bearing
9 Front bottom support shaft 10 Support shaft roller bearing
11 Lubrication oil baffle 12 Front cover plate
Remove the oil transfer tube retaining bracket (1) and
the lubrication oil supply tube (2).
BVE0704A 2
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2. Reposition the oil transfer tubes back into the front

cover distribution block.
MMG 21 403 3
3. Remove the front cover retaining bolts.
BVE0646B 4
4. Remove the C1/C2 clutch support manifold retaining

bolts (1).
Remove the C1/C2 clutch support manifold (4).
Install two bolts into the separating holes (3) and sep-
arate the front cover plate (2) from the transmission
housing.
MMG 21 404 5
5. Remove the front cover plate (1) and the O-rings (2).
BVE0705A 6
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6. Remove the baffle plate (1) and the front roller bear-
ing (4) from the front lower support shaft (3).
Remove the needle roller bearing (2).
NOTE: The front roller bearing (4) and the baffle plate (1)
may remain in the front cover plate.
MMG 21 407 7
7. Remove the C1/C2 clutch (3), output gear (2) and the
front lower support shaft (1).
BSF4023A 8
8. Remove the PTO/input shaft (1).
BVE0648A 9
9. Remove the steel thrust washer (1) and the PTO in-
put shaft needle roller bearing (2).
BVE0649A 10
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Next operation:
Clutch and gear Range clutch - Disassemble (C.20.D).
84276322A 31/05/2010
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Clutch and gear Range clutch - Disassemble - Front Section

Disassembly.
Prior operation:
Clutch and gear Range clutch - Remove (C.20.D).
BSF4038A 1
1 C1 clutch output gear (34 teeth) 2 Clutch C1

3 Clutch C2 4 Lower shaft bearing
5 Lower shaft 6 Lower shaft bearing
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BSF3989A 2
Cross Sectional View - Clutch C1/C2
1 Clutch support 2 Clutch C1

3 Clutch C2 4 C1 clutch output gear (34 teeth)
5 PTO/input shaft
C1 Clutch Disassembly
1. Remove the needle roller bearing (2) and the C1
clutch output gear (3) from the centre of the C1 clutch
(1).
MMG 21 513 3
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2. Remove the clutch hub (1) from the C1/C2 clutch

housing (2).
MMG 21 515 4
3. Remove the steel thrust washer (1).

NOTE: The inner face of the thrust washer is raised (2).
MMG 21 514 5
4. Using a suitable lever, remove the snap ring (1).
MMG 21 516 6
5. Remove the end plate (1).
BVE0665A 7
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6. Remove the four friction plates, the four separating

springs and the four steel plates (1).
Inspect the clutch friction and steel plates for exces-
Inspect the clutch separating springs for distortion
or discolouration. Compare each spring shape and
sary.
NOTE: It is not possible to remove the components (1) as
a complete assembly.
MMG 21 511 8
C2 Clutch Disassembly
7. Using a suitable lever, remove the snap ring (1).
BVE0664A 9
8. Remove the end plate (1), the clutch centre hub (2)
and the steel thrust washer (3).
BVE0666A 10
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9. Remove the four friction plates, the four separating

springs and the four steel plates (1).
Inspect the clutch friction and steel plates for exces-
Inspect the clutch separating springs for distortion
or discolouration. Compare each spring shape and
sary.
NOTE: It is not possible to remove the components (1) as

a complete assembly.
MMG 21 511 11
10. C1/C2 Clutch Housing Disassembly/Assembly

Using a suitable hydraulic press (2) and the spe-
cial tool 380001155 (1), compress the piston return
spring retainer assembly (4) to allow the removal of
the snap ring (3).
WARNING
Take care when compressing springs.
B032
MMG 21 508 12
11. Remove the piston return spring retainer snap ring.

Release the hydraulic press and remove the piston
return spring assembly.
Repeat steps 1 to 3 for the C2 clutch housing.
MMG 21 507 13
12. Remove the pistons by applying compressed air of

not more than 3 bar ( 50 lbf/in2) to the C2 clutch
piston oil feed port (1) and the C1 clutch piston oil
feed port (2).
NOTE: Temporarily install the C1/C2 support manifold (2)
to aid the application of compressed air.
BVE0730A 14
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SHG21153 15
1 Clutch housing 2 Piston

3 Belleville washer 4 Piston adaptor
5 Circlip 6 Return spring assembly
7 Piston oil seal
Next operation:
Clutch and gear Range clutch - Visual inspection (C.20.D).
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Clutch and gear Range clutch - Visual inspection

Prior operation:
Clutch and gear Range clutch - Disassemble (C.20.D).
NOTE: The belleville washer is concave. Note the position of the washer when removing.
1. Inspect the piston inner and outer components for
scoring or damage. Inspect the piston belleville
washer for distortion. Replace parts as necessary.
2. Inspect the clutch housing for scratches, scores, ex-
cessive wear and piston scuffing. Replace parts as
necessary.
3. Remove the piston outer oil seals from the clutch
pistons.
4. Remove the piston inner oil seals and oil seal ener-
gisers from the clutch housing.
5. Inspect the clutch driven hubs for wear or damage.
Replace parts as necessary.
6. Inspect the front lower shaft gears and gear teeth for
damage. Replace parts as necessary.
7. Inspect the clutch engagement spring assemblies for
cracked coils or distortion. Replace parts as neces-
sary.
8. Inspect the C1 and C2 clutch spring assembly loaded
height as shown, or compare with a new item. Re-
place the spring assembly as required.
MMG 21 453 1
1 Load Spreader (flat disc) 2 Weight (or load)

3 Piston Return Spring Assembly 4 Base Plate
Next operation:
Clutch and gear Master clutch - Assemble (C.20.D).
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Clutch and gear Master clutch - Assemble - C1/C2 Clutches.

Prior operation:
Clutch and gear Range clutch - Disassemble (C.20.D) Clutch and gear Range clutch - Visual inspection
(C.20.D).
NOTE: Make sure the lip of the oil seal is facing the inner or rear face of the piston (2).
1. Install the C1 clutch piston outer oil seal (1) onto the
piston. Repeat this step for the C2 clutch piston.
MMG 21 454 1
2. Install the C1 clutch piston inner oil seal energiser

into the groove on the clutch housing. Repeat this
step for the C2 clutch piston inner seal energiser.
NOTE: Make sure the oil seal is seated correctly and the
lip has not ’rolled’ in the groove.
MMG 21 529 2
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MMG 21 519 3
Installation and Re-sizing of the Inner Seals
1 Special tool 380001150 (tapered sleeve expander) 2 Special tool 380001148 (handle)
3 Special tool 380001154 (re-sizer) 4 C1/C2 clutch housing assembly
5 Seal positioned in groove on top of seal energiser 6 Seal positioned on expander
7 Seal groove with energiser already installed
3. Lubricate the piston inner oil seal and the special tool
380001150 (1) with petroleum jelly and position the
expander sleeve on the clutch housing centre (4) and
the oil seal (6) on the sleeve as shown.
NOTE: Perform the operation quickly so that the seal is not
subjected to the stretching action for too long.
4. Push the piston inner oil seal up the taper, dropping
the oil seal on top of the seal energiser, already in
position on the clutch housing (5).
5. Place the clutch housing with the inner oil seal
installed into a suitable cooling device for approxi-
mately 30 minutes.
NOTICE: As the tool is positioned over the oil seal, ensure
that the tool slides smoothly and squarely over the oil seal.
When the process is completed, inspect the oil seal to en-
sure that no damage has occurred.
6. Ensure the oil seal is lubricated. Assemble the
re-sizer special tool 380001154 (3) onto the handle
of special tool 380001148 (2), so that the smaller
diameter is at the opening. Lubricate the re-sizer
with petroleum jelly and using the handle, firmly
push the re-sizer over the oil seal to compress and
re-size the oil seal.
7. Place the clutch housing with the special tool still in
position into a suitable cooling device for approxi-
mately 30 minutes.
8. Repeat the installation and re-sizing process of the
second clutch piston inner seal.
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MMG 21 489 4
Installation of the Pistons into the C1/C2 Clutch Housing
1 Piston guide sleeve special tool 380001153 2 Piston

3 Piston pusher special tool 380001151 4 Piston outer seal
9. Lubricate the C1 piston inner oil seal inside the clutch
housing with petroleum jelly and check that the oil
seal is resized.
10. Position the piston guide sleeve special tool
380001153 (1), on top of the C1 clutch housing and
lubricate the inside of the special tool with petroleum
jelly.
NOTICE: Do not use more than hand pressure to install the
piston, or damage to the seal(s) may occur.
11. Position the piston (2), in the guide sleeve and us-
ing the piston pusher special tool 380001151 4 (3),
evenly and firmly, push the piston into the housing.
12. Remove the special tools 380001151 (3) and
380001153 (1).
13. Position the piston belleville washer on top of the
main piston making sure the outer edge of the
belleville is facing upwards and that the inner diam-
eter is resting on the piston. Install the outer part of
the piston, refer to Clutch and gear Range clutch
- Disassemble (C.20.D).
14. Repeat the piston installation process on the second
clutch piston.
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15. Assemble the clutch return spring assembly (4),

onto the clutch housing and using a suitable hy-
draulic press (2), and spring compressor special tool
380001155 (1), compress the spring assembly and
install the snap ring (3). Release the hydraulic press
and remove the special tool.
Repeat the above procedure for the second clutch.
MMG 21 479 5
16. Check the piston oil seals by applying compressed

air of not more than 3 bar ( 50 lbf/in2) to the C2
clutch piston oil feed port (1) and the C1 clutch piston
oil feed port (2). Make sure the pistons have no signs
of leakage.
NOTE: Temporarily install the C1/C2 support manifold (2)
to aid the application of compressed air.
Coat the pistons with transmission oil to indicate any leak-
age.
BVE0730A 6
C1/C2 Clutch Support Manifold Inspection and Assembly

17. Remove the valve spring retaining pin (2), valve re-
taining plug (4) and the proportional selector valve
(5).
Inspect the components for wear or damage, thor-
oughly clean and re-assemble using a new quad seal
(3) and ’O’ ring (6).
NOTE: The C1/C2 clutch assembly support shaft (1) con-
tains the lubrication proportional selector valve (5).
MMG 21 452 7
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18. The support shaft also contains rubber adaptors (1)

and (5), these adaptors join the C1/C2 clutch oil
transfer tubes and the front lower shaft lubrication
oil supply tube.
1. Rubber Adaptor x 1 (small)
2. Annular Seals
3. Support Shaft
4. ‘O’ Ring Seal
5. Rubber Adaptors x 4 (large)
MMG 21 451 8
19. The front cover (3), contains similar rubber adap-

tors and plugs to the C1/C2 clutch oil transfer tubes
and the front lower shaft lubrication oil supply tube.
These can be removed and new items installed by
removing the plug retaining pins (2) and plugs (1).
Install new quad seals as necessary.
Inspect all bearings for wear and damage, if neces-
sary remove the bearings from the front lower shaft
and install new components as necessary.
MMG 21 450 9
C1/C2 Clutch Support Manifold Inspection and Assembly

20. Remove the PTO input shaft oil seal (1) from the
C1/C2 clutch support manifold (2).
Install a new oil seal by gently pressing it into the
centre of the support shaft (ensure the oil seal lip is
facing inwards towards the transmission).
Remove and discard the four annular groove sealing
rings (3) and inspect the shaft for wear and damage.
Replace parts as necessary.
Install new annular groove sealing rings (3) to the
support manifold. Ensure the annular groove sealing
ring ends are correctly positioned.
MMG 21 456 10
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21. Inspect the PTO input shaft (1) for damage, evidence
of binding, pick-up etc. Replace parts as necessary.
Inspect the splined areas for damage. Replace parts
as necessary.
Make sure all of the oil galleries are thoroughly clean.
Renew the lubrication oil seal (2).
Inspect the steel washer (3), snap rings and their
grooves for distortion and damage. Replace parts
as necessary.
NOTE: It is important the lubrication oil seal (2) is held down
in its groove during re-assembly. If the oil seal is damaged,
lubrication oil will not be correctly distributed.
MMG 21 455 11
MMG 21 532 12
1 Snap ring 2 End plate

3 Friction plate x 4 4 Steel plate x 4
5 Snap ring 6 Outer piston half
7 Inner piston half 8 C1/C2 clutch housing
9 Piston outer seal 10 Belleville washer
11 Piston return spring assembly 12 Separating spring x 4
22. Install the steel plates (4), friction plates (3) and the
separating springs (12).
NOTE: Make sure the openings on the separator springs
are all aligned.
NOTE: Make sure the last separating spring does not be-
come hooked in the snap ring groove.
23. Install the end plate (2).
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24. Apply a small amount of pressure to the end plate

and install the retaining snap ring (1).
25. Repeat the above procedure for the second clutch.
BVE0647A 13
C1/C2 Clutch Hubs and Gears - Exploded View
1 Thrust washer 2 Needle roller bearing

3 C1 clutch output gear 4 C1 clutch hub
5 Circlip 6 C1 end plate
7 Steel washer (note: step on inner face) 8 C1/C2 clutch housing
9 Steel washer (note: step on inner face) 10 C2 clutch hub
11 C2 end plate 12 Circlip
26. Install the C2 clutch hub (10) into the C2 clutch hous-
ing (8).
27. Install the steel washer (9) (ensure the step on the
inner face is against the piston return spring assem-
bly of the C1 clutch).
28. Install the C1 clutch hub (4) into the C1 clutch hous-
ing.
Next operation:
TRANSMISSION Semi-Powershift - Service instruction (C.20.D).
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Clutch and gear Speed clutch - Remove - Rear Section Removal.

Prior operation:
BSF4033A 1
1 Clutch C3 2 Clutch C4
3 Clutch C4 output gear (41 or 37 teeth) 4 Clutch C3/C4 support assembly
5 Output shaft 6 Low range gear (65 teeth)
7 Hi/Lo synchroniser 8 Cluster gear
1. Rotate the transmission until the rear of the transmis-
sion is in a vertical position.
Using a suitable lever (5), raise the output shaft as-
sembly (1) to release the tension on the circlip (2).
Remove the circlip (2), ’D’ shaped washer (3) and the
roller bearing thrust washer (4).
MMG 21 486 2
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2. Remove the rear cover retaining bolts (1).
BSF4030A 3
3. Remove the rear cover assembly.
BSF4031A 4
4. Loosen the locknut (1) and remove the Hi/Lo selector

fork rail locking bolt (2).
Remove the Hi/Lo selector fork rail (3).
BVE0667A 5
5. Remove the output shaft, Hi/Lo synchroniser and

shift fork as a complete assembly.
MMG 21 428 6
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6. Remove the C3 clutch output shaft.
MMG 21 430 7
7. Remove the C3/C4 clutch and oil supply manifold

assembly.
BVE0721A 8
8. Loosen the clamping bolt (1) and remove the selector

actuator (5).
Remove the woodruff key (4), locking pin (2) and
remove the shaft (3).
Remove and inspect any bearings which may remain
in the transmission housing.
BVE0668A 9
Next operation:
Clutch and gear Speed clutch - Disassemble (C.20.D).
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Clutch and gear Speed clutch - Disassemble - Rear Section

Disassembly.
Prior operation:
Clutch and gear Speed clutch - Remove (C.20.D).
BSF4033A 1
Drive Line Components - Rear Section
1 Clutch C3 2 Clutch C4
3 Clutch C4 output gear (41 or 37 teeth) 4 Clutch C3/C4 support assembly
5 Output shaft 6 Low range gear (65 teeth)
7 Hi/Lo synchroniser 8 Cluster gear
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MMG 21 498 2
C4 Clutch Driven Gear, Gear Bearing, C3 Driven Gear Bearing and Polyimide Thrust Washer
1 Manifold 2 Polyimide thrust washer

3 C4 driven gear 4 C3/C4 clutch assembly
5 C4 driven gear front bearing 6 Support shaft
7 C3 driven gear to support shaft rear bearing 8 C4 driven gear rear bearing
9 Manifold retaining screws and washers
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BSF3984A 3
Cross Sectional View -C3/C4
1 Retaining ring screw 2 C3 piston

3 Piston outer oil seals 4 C4 piston
5 Steel washer 6 C4 end plate
7 C4 output gear needle roller bearing 8 C3 output gear needle roller bearing
9 Oil transfer manifold 10 Polyimide thrust washer
11 Needle roller bearing 12 Belleville washer snap ring retainer
13 Belleville washers 14 Inner piston oil seals
15 Snap ring 16 Snap ring
17 Clutch plate retaining ring 18 Snap ring
19 Support shaft annular sealing rings 20 Support shaft needle roller bearing
21 Roller bearing
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C3/C4 Clutches - Disassembly

1. Remove the two split pins (3).
Remove the four end plate (1) retaining ring screws
(2).
MMG 21 439 4
2. Apply hand pressure and rotate the locking ring (1)

until the outer teeth align with the stamped grooves
in the housing (2).
Remove the retaining ring (1).
MMG 21 524 5
BSF3987A 6
C3 Clutch Friction and Steel Plates - Assembly Order
1 C3/C4 clutch housing 2 Steel plates x 9

3 Friction plates x 9 4 End plate locking ring
5 Locking ring retaining screws and split pins 6 End plate
7 C3 clutch hub
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3. Remove the C3 clutch end plate (6), clutch hub (8),

friction plates (3) and the steel plates (2).
4. Remove the two Polyimide thrust washers (7) posi-
tioned either side of the hub.
NOTE: The support shaft inner front needle roller bearings
are an interference fit and will remain in the shaft.
5. Rotate the assembly 180 °.
6. Remove the four manifold retaining bolts (1) and the
washers (2).
Remove the manifold (3).
Remove the Polyimide thrust washer (4).
BVE0755A 7
7. Remove the C4 output gear (1) and the C4 output

gear rear needle roller bearings (2).
BVE0756A 8
8. Using suitable circlip pliers, remove the circlip (1).
BVE0757A 9
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BSF3986A 10
C4 Clutch Pressure Plate, Hub, Friction and Steel Plates - Exploded View
1 C3/C4 clutch housing 2 Steel washer

3 Friction plates x 9 4 Steel plates x 9
5 End plate 6 Circlip
7 Lubrication seal 8 Clutch hub
9. Remove the C3 clutch end plate (5), clutch hub (8),
friction plates (3) steel plates (4) and the steel washer
(2).
Remove the C4 output gear front needle roller bear-
ing (1), steel thrust washer (2) and the C4 clutch to
support shaft needle roller bearing (3), from the sup-
port shaft (4).
NOTE: A hub oil seal is positioned in the clutch hub, sealing
against the pressure plate.
BVE0758A 11
10. Remove the clutch support shaft front bearing (4) and
the retaining snap rings (2) and (3) from the C4 clutch
housing (1).
MMG 21 510 12
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11. Remove the support shaft (1) from the bearing by

removing from the C4 end of the housing.
NOTE: Removing the support shaft from the C4 end of the
housing will prevent damage occurring to the annular seal-
ing rings (2).
BVE0759A 13
12. Using a suitable hydraulic press (2) and the special

tool 380001155 (1), depress the clutch piston return
belleville washers and remove the retaining snap ring
(3).
Release the hydraulic press and collect the belleville
washers and the snap ring retainer.
Repeat the above procedure for the second clutch
piston return belleville washers.
NOTE: The retainer is shaped to provide a ‘lock’ for the
snap ring.
MMG 21 485 14
13. Remove the pistons by applying compressed air of

not more than 3 bar ( 50 lbf/in2) to the clutch piston
oil feed ports (2).
NOTE: Each piston is fed by two drillings. Apply com-
pressed air to one of these and plug the other (1).
BVE0760A 15
Next operation:
Clutch and gear Speed clutch - Visual inspection (C.20.D).
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Clutch and gear Speed clutch - Visual inspection

Prior operation:
Clutch and gear Speed clutch - Disassemble (C.20.D).
MMG 21 484 1
Piston Return Spring and Retainer - Exploded View
1 C3/C4 clutch body 2 Snap ring groove

3 Piston 4 Flat washer
5 Belleville washers 6 Snap ring
7 Snap ring retainer 8 Piston outer oil seal
1. Inspect each of the belleville spring washers for
cracks and deformation.
Assemble the belleville springs to form a stack (2).
Measure the height as shown (1). The height should
be approximately 24 mm. If the specified height is
incorrect, replace parts as necessary.
NOTE: Alternatively compare the measured height with
that of new items.
MMG 21 445 2
2. Check that the splined areas of the input hub and the
output gear are undamaged.
3. Inspect the clutch driven hubs for wear, damage or
pitting.
4. Install a new lubrication oil seal into the groove of the
C4 clutch hub, ensure that it is correctly seated.
5. Ensure all of the oil galleries are free and thoroughly
clean.
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6. Inspect all snap rings and their grooves for deforma-

tion and damage.
7. Check the clutch friction and steel plates for exces-
sive wear, the friction plate material should have a
out warping and there should not be excessive dis-
colouration.
8. Ensure all components are lubricated with trans-
mission oil NEW HOLLAND AMBRA MULTI G 134
AKCELA NEXPLORE (MAT 3525) prior to reassem-
bly.
9. Using a suitable punch, remove the retaining pins (1)
and (7).
Remove the plug (2), spring (3), lubrication propor-
tional valve (4), spring (5) and the plug (6).
BSF4032A 3
Next operation:
Clutch and gear Range clutch - Assemble (C.20.D).
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Clutch and gear Range clutch - Assemble - C3/C4 Clutches.

Prior operation:
Clutch and gear Speed clutch - Disassemble (C.20.D) Clutch and gear Speed clutch - Visual inspection
(C.20.D).
NOTE: Make sure the lip of the oil seal is facing the inner or rear face of the piston (2).
1. Install the C3 clutch piston outer oil seal (1) onto the
piston. Repeat this step for the C3 clutch piston.
MMG 21 446 1
2. Install the C3 clutch piston inner oil seal energiser

into the groove on the clutch housing. Repeat this
step for the C4 clutch piston inner seal energiser.
NOTE: Make sure the oil seal is seated correctly and the
lip has not ’rolled’ in the groove.
MMG 21 502 2
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BVE0810A 3
Installation and Re-sizing of the Inner Oil Seals
1 Special tool 380001149 (tapered sleeve expander) 2 Special tool 380001154 (re-sizer)
3 Special tool 380001148 (handle) 4 Piston inner oil seal in groove
5 C3/C4 clutch housing 6 Piston inner seal on tapered sleeve expander
7 Seal energizer in position in groove
3. Lubricate the piston inner oil seal and the special tool
380001149 (1) with petroleum jelly and position the
expander sleeve on the clutch housing centre and
the oil seal (6) on the sleeve as shown.
NOTE: Perform the operation quickly so that the oil seal is
not subjected to the stretching action for too long.
4. Push the piston inner oil seal up the taper, dropping
the seal on top of the oil seal energiser already in
position on the clutch housing.
5. Place the clutch housing with the inner oil seal
installed into a suitable cooling device for approxi-
mately 30 minutes.
NOTICE: As the tool is positioned over the oil seal, ensure
that the tool slides smoothly and squarely over the oil seal.
When the process is completed, inspect the oil seal to en-
sure that no damage has occurred.
6. Ensure the oil seal is fully lubricated. Assemble the
re-sizer special tool 380001154 (2) onto the handle
of special tool 380001148 (3) so that the larger di-
ameter is at the opening. Lubricate the re-sizer with
petroleum jelly and with the handle, firmly push the
re-sizer over the oil seal to compress and re-size the
oil seal.
7. Place the clutch housing with the special tool still in
position into a suitable cooling device for approxi-
mately 30 minutes.
8. Repeat the installation and re-sizing process on the
second clutch piston inner oil seal.
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MMG 21 488 4
Installing Pistons into C3/C4 Clutch Housing
1 Piston guide sleeve special tool 380001152 2 Piston

3 Piston pusher special tool 380001151 4 Piston oil seal
9. Lubricate the piston inner oil seal inside the clutch
housing with petroleum jelly and check that the oil
seal is resized.
10. Position the piston guide sleeve special tool
380001152 (1), on top of the clutch housing and
lubricate the inside of the special tool with petroleum
jelly.
11. Position the piston (2), in the guide sleeve and using
the piston pusher special tool 380001151 (3), evenly
and firmly, push the piston into the housing. Remove
the guide sleeve and the pusher.
NOTICE: Do not use more than hand pressure to install the
piston, or damage to the oil seal(s) may occur.
12. Repeat the piston installation process on the second
clutch piston.
C3/C4 Clutch Piston Movement Adjustment

13. Assemble the friction plates, steel plates, end plates
and the circlip/locking ring.
NOTICE: C3 and C4 must be adjusted to achieve optimum
piston movement or running clearance.
NOTE: Do not install the locking ring retaining screws or
the clutch hubs as this will interfere with the measurement.
14. Using a suitable dial gauge and a suitable air line,
supply compressed air through the piston oil supply
ports and measure the clutch pack C3 free move-
ment.
15. The free movement should be 2.40 - 4.10 mm.
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16. If the measurement is not within specification it will be

necessary to install one or more alternate sized sep-
arator plates to achieve the correct free movement.
These separator plates are available in two thick-
nesses 2.76 - 2.80 mm and 2.26 - 2.30 mm.
17. Repeat the above procedure on the second clutch.
18. Disassemble both the C3 and C4 clutches, removing
the end plates, steel plates and the friction plates.
Keep the C3 and C4 clutch components matched to
the respective clutches. Continue with the following
assembly procedure.
NOTE: Assemble the support shaft (1) through the clutch
assembly from the C4 end so as not to damage the annular
sealing rings (2).
19. Install the support shaft (1), with new annular sealing
rings (2).
BVE0759A 5
20. Install the clutch support shaft front bearing (4) and
the retaining snap rings (2) and (3) to the C4 clutch
housing (1).
MMG 21 510 6
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MMG 21 484 7
Piston Return Spring and Retainer - Exploded View
1 C3/C4 clutch body 2 Snap ring groove

3 Piston 4 Flat washer
5 Belleville washers 6 Snap ring
7 Snap ring retainer 8 Piston outer oil seal
21. Using a suitable hydraulic press (2) and special
tool 380001155 (1), depress the clutch piston return
belleville washers and install the retaining snap ring
(3).
Release the hydraulic press.
Repeat the process on the second clutch piston re-
turn belleville washers.
NOTE: The retainer is shaped to provide a ‘lock’ for the
snap ring.
MMG 21 485 8
22. Check the piston oil seals by applying compressed

air of not more than 3 bar ( 50 lbf/in2) to the C3/C4
clutch piston oil feed ports. Make sure the pistons
have no signs of leakage.
NOTE: Each piston is fed by two drillings (2) apply com-
pressed air to one of these and plug the other (1).
NOTE: Coat the pistons with transmission oil to indicate
any leakage.
BVE0760A 9
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BSF3987A 10
C3 Clutch Friction and Separator Plates - Assembly Order
1 C3/C4 clutch housing 2 Steel plates x 9

3 Friction plates x 9 4 End plate locking ring
5 Locking ring retaining screws and split pins 6 End plate
7 C3 clutch hub
23. Install the clutch hub (1) into the clutch housing (2).
Install the steel plates and friction plates in the order
as shown in Figure 10.
BVE 0799A 11
24. Install the retaining ring (1).

Apply hand pressure and rotate the locking ring (1)
until the locking ring screw holes line up with the end
plate (2).
MMG 21 524_235 12
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25. Install the four end plate (1) retaining ring screws (2).
Install the two split pins (3).
MMG 21 439 13

Install onto the support shaft (4) the C4 clutch to
support shaft needle roller bearing (3), steel thrust
washer (2) and the C4 output gear front needle roller
bearing (1).
BVE0758A 14
27. Install the C4 clutch hub (2) into C4 clutch housing

(3) over the support shaft (4),
NOTE: Ensure that the previously assembled lubrication
oil seal (1), is in place.
MMG 21 528 15
28. Assemble the C4 clutch steel plates, friction plates

and the end plate as shown below.
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BSF3986A 16
C4 Clutch Pressure Plate, Hub, Friction and Steel Plates - Exploded View
1 C3/C4 clutch housing 2 Steel washer

3 Friction plates x 9 4 Steel plates x 9
5 End plate 6 Snap ring
7 Lubrication oil seal 8 Clutch hub
29. Using suitable circlip pliers, install the circlip (1).
BVE0757A 17
30. Install the C4 output gear rear needle roller bearing

(2) and the C4 output gear (1).
BVE0756A 18
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31. Install the polyimide thrust washer (3).

Install the manifold (2).
Install the washers (1), four retaining bolts and
NOTE: Ensure the clutch assembly is free to rotate on its
support shaft without binding and that a small amount of
axial end float for the C4 driven gear is present.
BVE0755B 19
BSF4036A 20
Output Shaft and High/Low Range Synchroniser - Exploded View
84276322A 31/05/2010
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1 Low range output gear 2 Needle roller bearing

3 ‘D’ shaped steel washer 4 Circlip
5 Circlip 6 High/Low synchroniser
7 Output shaft 8 Needle roller bearing
9 Polyimide thrust washer 10 Two gear cluster
BVE0659A 21
Hi/Lo Range Synchroniser

9 Detent guide
Next operation:
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Fork and shift rail - Travel adjust

1. ADJUSTMENT OF FORWARD/REVERSE AND
MAIN (1-4/5-8) SYNCHRONISERS
To gain access to the synchroniser forks and rails it
is necessary to remove the cab mat and floor.
Remove the transmission cover plate to expose the
shift rails (1) and forks (2).
The adjustment procedure is the same for both syn-
chronisers.
BSF4019C 1
2. Remove the detent spring, plunger and ball from the

transmission cover.
BAIS09APH296AVA 2
3. Insert the special tool 380002598 into the plunger

bore and position the tip of the special tool into the
2mm bore hole in the selector rail, midway between
the forward and reverse detent positions. This will
centralize and lock the selector rail in the neutral po-
sition.
BAIS09APH297AVA 3
4. Remove the two locking screws fixing the selector

fork to the selector rail.
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5. Using a suitable lever, fully position the synchroniser

in the engaged position and measure the distance
(A).
BSF4019B 4
6. Now fully position the synchroniser in the opposite

fully engaged position and measure distance (B).
Replace the detent spring, plunger and ball. Set the
shift rail to neutral.
Adjust the fork to its neutral position.
Neutral N = (A + B)/2
Tighten the fork lock screws.
BSF4019A 5
HIGH/LOW RANGE CABLE ADJUSTMENT

7. Place the high/low synchroniser in the neutral posi-
tion.
Loosen clamp bolt (1).
Position the high/low selector lever in the cab cen-
trally.
Tighten clamp bolt (1).
Operate the high/low selector lever and ensure that
the synchroniser fully engages. If the lever travel
contacts the console slot, repeat the adjustment pro-
cedure.
BVE0220B 6
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BVE0671A 7
Centralising high/low range synchroniser selector fork
1 High/Low fork moved fully rearward 2 High/Low fork moved fully forward
3 High/Low fork in neutral and adjusting mid-point 4 High/Low selector actuator
5 Detent ball spring retainer (Note: hole to allow stem 6 Adjuster screw
of detent to protrude)
7 Adjuster screw locking nut
8. Position the high/low synchroniser fork rail in neutral
and install the rail detent ball, the ball actuator and
the spring.
9. Fabricate a simple plate from 3 mm ( 0.125 in) strip
steel so that the plate straddles the rail detent bore
and allows the stem of the detent ball actuator to
protrude (only the spring needs to be compressed).
Bolt the plate across the control valve retaining bolt
holes so that it compresses the detent spring and
holds the rail in neutral, Figure 7.
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10. Ensure the rail to fork set screw and locknut are
installed and tightened. Also ensure that the ad-
justable high/low fork adjusting screw is tightened.
11. Using an adjustable wrench to act on the high/low
range selector actuator (1), Figure 7, move the syn-
chroniser backward and forward to engage the high
and low ranges several times, in order to seat all the
components.
12. Using the selector actuator (1), move the fork and
synchroniser into the engaged low range position,
shown at (A) in Figure 7 and hold the lever fully hard
in this position (beyond the natural point of detent).
Establish a datum point and from that datum using a
vernier caliper, measure the distance to the selector
fork in the low range position. Record the measured
distance, (X) in Figure 7.
13. Again using the lever move the fork and synchroniser
into the fully engaged high range position, shown at
(B) in Figure 7 and hold hard in that position (again
possibly beyond the natural point of detent) and from
the previously established datum point, measure the
distance to the fork in the high range position. Ensure
that the point of measurement on the fork is exactly
the same as when the fork was measured in the low
range position. Record this distance, (Y) in Figure 7.
14. Neutral (mid-point) Z = (X + Y) / 2
15. This resultant measurement (Z), shown at (C) in Fig-
ure 7, is the neutral position for the high/low synchro-
niser.
16. Move the fork and rail so that the neutral detented
position is selected.
17. Loosen the adjustable fork adjusting screw locknut
and by rotating the screw, adjust the position of the
fork relative to the rail to achieve the previously calcu-
lated mid-point position. Tighten the adjuster locknut
to 58 - 80 Nm ( 43 - 59 lbf. ft).
18. Move the fork and synchroniser in and out of high
and low range several times and re-check the ad-
justment.
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Cover - Remove Transmission Top Cover.
WARNING
The top cover assembly is heavy. If necessary remove with the aid of another technician.
B036
1. Remove the cab mat and floor.

Disconnect the wiring harness to the forward, re-
verse, 1-4 and 5-8 PWM solenoids and the synchro-
niser position potentiometers.
Disconnect the hydraulic oil supply tube.
Remove the transmission top cover retaining bolts
(1).
Remove the transmission top cover.
BVE0624A 1
Next operation:
Cover - Disassemble (C.20.D).
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Cover - Disassemble - Transmission Top Cover.

Prior operation:
Cover - Remove (C.20.D).
1. Remove the two detent assemblies. Cover - Ex-

ploded view (C.20.D).
2. Remove the two synchronizer position potentiome-
ters, shaft housings and operating shafts.
3. Remove the four PWM solenoid valve assemblies.
4. Remove the 1-4/5-8 shift rail. Remove the circlip and
the end cap of the forward/reverse rail. Loosen the
shift fork retaining screws. Through the potentiome-
ter housing orifice carefully pry the 1-4/5-8 shift rail
from the top cover.
5. Remove the forward/reverse shift rail. Remove the
circlip and the end cap of the forward/reverse rail.
Loosen the shift fork retaining screws. Through the
potentiometer housing orifice carefully lever the for-
ward/reverse shift rail from the top cover.
Next operation:
Cover - Visual inspection (C.20.D).
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Cover - Visual inspection Transmission Top Cover.

Prior operation:
Cover - Disassemble (C.20.D).
1. Thoroughly clean the top cover, ensuring that the oil

galleries from the PWM valves to the shift rail pistons
are free from any obstructions.
2. Inspect the shift rails and forks. Replace if bent and in
the case of the forks, the fork tips appear excessively
worn.
3. Inspect all the ’O’ ring seals. It is advisable to re-
place all of the ’O’ rings as standard practice. If the
oil seals on the forward/reverse or 1-4/5-8 pistons ap-
pear in anyway damaged or suspect they should be
replaced.
Next operation:
Cover - Assemble (C.20.D).
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Cover - Assemble Transmission Top Cover.

Prior operation:
Cover - Visual inspection (C.20.D).
NOTE: Reassembly is the reverse of the disassembly, noting the following items:
1. Coat the piston oil seals with transmission oil prior to
assembly. NEW HOLLAND AMBRA MULTI G 134
AKCELA NEXPLORE (MAT 3525).
Next operation:
Adjust the fork positions on their rails (refer to Fork and shift rail - Travel adjust (C.20.D)) Cover - Install (C.20.D).
84276322A 31/05/2010
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Cover - Install
Prior operation:
Cover - Assemble (C.20.D).

BSF4018A 1
2. Install the transmission top cover and tighten the re-

taining bolts to the specified torque value.
Connect the hydraulic oil supply tube.
Connect the wiring harness to the forward, reverse,
1-4 and 5-8 PWM solenoids and the synchroniser
position potentiometers.
Install the cab floor and mat.
WARNING
The top cover assembly is heavy. If necessary remove
with the aid of another technician.
B036
BVE0624B 2
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TRANSMISSION Semi-Powershift - Testing - Tractor does not drive

in any gear
1 Condition Result Action
Key ON. Is the Instrument Cluster YES NO
providing ‘Normal’ Display? Action Go to test 3
Go to test 2
Install flow meter into remote, is flow YES NO
indicated when operated? Action Closed centre system fault. Re-
Go to test 4 fer to Hydraulic Pressure Testing
Hydraulic pump Variable dis-
placement pump - Pressure test
(A.10.A).
Are any fault codes displayed YES NO
Action Go to test 7
Refer to Fault Codes Control mod-
ule - Fault code index (A.50.A).
Charge pump warning light illumi- YES NO
nated Action Go to test 8
Go to test 5
Check pressure in low pressure cir- YES NO
cuit. Is pressure 17 - 19 bar (247 - Action Pressure reducing valve fault, or
276 psi)? Go to test 6 leak in low pressure circuit. Re-
fer to Hydraulic Pressure Testing
Hydraulic pump Variable dis-
placement pump - Pressure test
(A.10.A).
Pressure test the transmission YES NO
clutches. Are pressures okay? Action Suspect PWM valves. Clean or re-
Suspect a mechanical failure within place valves in circuits with incorrect
transmission. Seized clutches, syn- pressures
chronizers or broken gear in shaft. Go to test 10
Go to test 10
Are the connectors on the controller YES NO
okay? Action Remove refit/repair as required
Reset ’H8’ and re-calibrate the con- Go to test 10
troller. Recheck the operation. If still
no drive replace controller.
Go to test 10
Does the engine rev/min decrease or YES NO
the engine stalls? Action Go to test 9
Go to pressure testing clutches
Inspect operation of levers for cor- YES NO
rect preparation. Enter mode H5, is Action Inspect switch and wiring
Neutral/start inhibitor switch okay? Go to test 5 Go to test 10
Key OFF, Key ON, recheck.
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TRANSMISSION Semi-Powershift - Testing - Tractor drives in

ranges but has following fault:
NOTE: - Powershift function operates but the shift sequence is incorrect or gears missing
Are the PWM solenoid connectors YES NO
on the correct PWM valves Action Using the wiring diagram ensure the
Go to test 2 correct harness connector is on the
appropriate PWM solenoid.
Go to test 4
Establish the missing gears. From YES NO
the table below determine the af- Action Go to test 3
fected clutch. Pressure test the Suspect mechanical failure of
clutch. (Using the procedure de- clutches shafts or gears
tailed in pressure testing section.) Go to test 4
Is the pressure 17 - 19 bar (246.5 -
275.5 psi)?
Substitute the affected clutches YES NO
PWM valve and retest for pressure. Action Suspect internal leakage within the
Is pressure okay Install a new PWM valve to the af- transmission example, side plate
fected clutch gasket, Clutch pack housing, clutch
Go to test 4 supply tubes.
Go to test 4
BRF1852B 1
BVE0637A_233 2
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TRANSMISSION Semi-Powershift - Testing - The powershifts are

not smooth or the tractor loses drive between powershifts:
NOTE: In work tractor stops or could be jerky.
Perform complete transmission cali- YES NO
bration. Action Tractor okay
1) spring calibration Go to test 2 Go to test 7
2) fill time adjustment
is transmission still performing
poorly?
Is feathering performance poor? YES NO
Action Go to test 4
Go to test 3
Suspect PWM valves 3 or 4. Clean YES NO
or replace and repeat spring cali- Action Go to test 7
bration. Is powershift performance Go to test 4
poor?
Are only double swap shifts poor? YES NO
(i.e. 2 to 3 or 6 to 7 gear changes. Action Go to test 6
3 to 2 or 7 to 6 gear changes) Go to test 5
Suspect PWM valves 1 or 2. Clean YES NO
or replace. Repeat spring calibration Action Go to test 7
and fill time adjustment. Is power- Go to test 6
shift performance still poor?
Remove and test accumulator YES NO
Is accumulator okay? Action Repair/replace accumulator perform
Suspect damaged clutch plates. In- fill time adjustment
spect and replace as required. For Go to test 7
further information refer to Clutch
and gear Speed clutch - Visual in-
spection (C.20.D) Clutch and gear
Range clutch - Visual inspection
(C.20.D)) re-calibrate after assembly
Go to test 7
BRF1852B 1
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TRANSMISSION Semi-Powershift - Testing - The tractor drives in all

gears and ranges but has the following fault:
NOTE: - Transmission jumps out of gear, holds in gear or gears clash when shifting
Is the gear fully engaging? Inspect YES NO
and adjust shift lever linkage as re- Action Go to test 2
quired. Fault fixed? Go to test 5
Using the service diagnostic switch, YES NO
select mode H9 Channel 0, Clutch Action Check operation and inspect wiring
pedal display. Does display go to 26 Go to test 3 of clutch pedal switch and check op-
with the pedal depressed? eration of potentiometer..
Go to test 5
YES
Pressure test all clutches. Is pres- NO
sure dumped when the clutch pedal Action Go to test 4
is depressed? Suspect a mechanical fault within
the transmission, inspect the detents
in the shift cover, if no fault found
suspect either worn synchronizers
or excessive end float of transmis-
sion components
Go to test 5
Test affected clutch pack PWM with YES NO
the PWM valve coil removed from Action Disconnect, inspect and refit con-
the valve. Is pressure indicated? Swap the PWM with one of known troller connectors, if fault still exists
performance. If pressure still ex- replace controller.
ists suspect internal leakage or faulty Go to test 5
side plate gasket.
Go to test 5
TRANSMISSION Semi-Powershift - Testing The tractor drives in all

NOTE: - Clutches squeal/whine during inching
In 1st (5th) and 3rd (7th) gears only? YES NO
Action Go to test 3
Go to test 2
Pressure test C4 clutch. Is pressure YES NO
250 - 280 lbf.in2( 17 - 19 bar)? Action Suspect leaking clutch seals or leak
Suspect worn clutch plates in circuit to clutch
In 2nd (6th) and 4th (8th) gears only? YES
Action
Go to test 4
Pressure test C4 clutch. Is pressure YES NO
( 250 - 280 lbf.in2 ( 17 - 19 bar)? Action Suspect leaking clutch seals or leak
Suspect worn clutch plates in circuit to clutch
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TRANSMISSION Semi-Powershift - Testing The tractor drives in all

gears and in all ranges but has the following fault:
NOTE: - Transmission is noisy in operation
Is the transmission lube warning light YES NO
illuminated? Action Go to test 3
Go to test 2
Fault in the lube supply to transmis- YES
sion. Refer to Hydraulic Pressure Action
Testing Regulator and lubrication Go to test 3
valve - Pressure test (A.12.A). Is
the transmission noisy after lube sys-
tem repair?
Is the oil level correct? YES NO
Action Adjust as required and investigate
Go to test 4 reason for oil loss (leakage)
Is the correct grade of oil used? YES NO
Action Drain and refill with correct grade of
Suspect failure within transmission, oil
worn bearings, worn or failed parts
TRANSMISSION Semi-Powershift - Testing - Tractor drives in all

NOTE: - Transmission clunks during inching.
Perform Clutch spring calibration on YES NO
C1 and C2 Clutches. Does Trans- Action Tractor okay
mission still clunk? Go to test 2
Perform manual clutch fill time cali- YES NO
bration on C1 and C2 clutches. Does Action Tractor okay
transmission still clunk after fill time Go to test 3
calibration?
Perform clutch pressure test proce- YES NO
dure, observing the operation of the Action Suspect faulty or contaminated
C1 and C2 Clutches. Does the op- Suspect worn clutches. Examine PWM Valves, clean or replace as
eration compare with that described and replace as required required
in the pressure testing section?
- Pressure test (C.20.D).
84276322A 31/05/2010
C.20.D / 185
Index

Clutch and gear Master clutch - Assemble - C1/C2 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Clutch and gear Range clutch - Assemble - C3/C4 Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Clutch and gear Range clutch - Disassemble - Front Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Clutch and gear Range clutch - Remove - Front Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Clutch and gear Range clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Clutch and gear Speed clutch - Disassemble - Rear Section Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Clutch and gear Speed clutch - Remove - Rear Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Clutch and gear Speed clutch - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cover - Assemble Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Cover - Disassemble - Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cover - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Cover - Remove Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Cover - Visual inspection Transmission Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Fork and shift rail - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Gear and synchroniser - Assemble - Middle Section Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Gear and synchroniser - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Gear and synchroniser - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Gear and synchroniser - Remove - Middle Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Gear and synchroniser - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Hydraulic line - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TRANSMISSION Semi-Powershift - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TRANSMISSION Semi-Powershift - Calibrate 16x16 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
TRANSMISSION Semi-Powershift - Calibrate 16x16 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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TRANSMISSION Semi-Powershift - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
TRANSMISSION Semi-Powershift - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TRANSMISSION Semi-Powershift - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRANSMISSION Semi-Powershift - Hydraulic schema (Schematics 1st Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TRANSMISSION Semi-Powershift - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
TRANSMISSION Semi-Powershift - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
TRANSMISSION Semi-Powershift - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
TRANSMISSION Semi-Powershift - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TRANSMISSION Semi-Powershift - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION Semi-Powershift - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TRANSMISSION Semi-Powershift - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Semi-Powershift - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TRANSMISSION Semi-Powershift - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TRANSMISSION Semi-Powershift - Testing - The powershifts are not smooth or the tractor loses drive between
powershifts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
TRANSMISSION Semi-Powershift - Testing - The tractor drives in all gears and ranges but has the following fault:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
TRANSMISSION Semi-Powershift - Testing - Tractor does not drive in any gear . . . . . . . . . . . . . . . . . . . . . . . . . . 181
TRANSMISSION Semi-Powershift - Testing - Tractor drives in all gears and ranges but has the following fault: 185
TRANSMISSION Semi-Powershift - Testing - Tractor drives in ranges but has following fault: . . . . . . . . . . . . . . 181
TRANSMISSION Semi-Powershift - Testing The tractor drives in all gears and in all ranges but has the following
fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
TRANSMISSION Semi-Powershift - Testing The tractor drives in all gears and ranges but has the following fault:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
TRANSMISSION Semi-Powershift - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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ADDITIONAL REDUCERS Creeper - 30.C

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Contents
TECHNICAL DATA
ADDITIONAL REDUCERS Creeper
FUNCTIONAL DATA
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSTIC
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TRANSMISSION, DRIVE AND PTO OUT - ADDITIONAL REDUCERS Creeper
ADDITIONAL REDUCERS Creeper - General specification

Transmission 16x16 Electro-hydraulic actuation of a sliding coupler selector
Transmission 24x24 Electro-hydraulic actuation of a sliding coupler selector
Transmission 12x12 Mechanical actuation of a sliding coupler selector
Creeper Speeds
Transmission 16x16 m/hr 225
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ADDITIONAL REDUCERS Creeper - Sectional view
BVF0817A 1
Creeper Speed Drive

1 Creeper driven gear 2 Sliding engagement coupler (engaged position)
3 Creeper drive gear 4 Pinion shaft
5 Creeper driven gear bush 6 Creeper driven gear
7 Sliding engagement coupler (disengaged 8 Creeper drive gear
position)
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BVF0818A 2
Hydraulic Operated Creeper Selector

1 Selector shaft 2 O-ring
3 Piston retaining ring 4 Selector shaft piston
5 Piston retaining ring 6 Disengagement spring
7 Selector fork 8 Engagement stop sleeve
9 Oil seal 10 Creeper disengaged status switch
11 Creeper engaged status switch 12 Status switch plunger spring
13 Status switch plunger
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ADDITIONAL REDUCERS Creeper - Dynamic description
BVF0819A 1
Creeper Disengaged
1 Selector shaft 2 Creeper drive gear
3 Sliding engagement coupler 4 Pinion shaft
5 Creeper driven gear 6 Selector fork
7 Disengagement spring 8 Shift rail piston
9 Low pressure oil supply from creeper 10 Creeper disengaged status switch
engagement solenoid
11 Creeper engaged status switch
Figure Colour Key

A Return to reservoir
The creeper solenoid valve is de-energized. The disengagement spring (7) pushes against the shift rail piston (8),
which slides the sliding engagement coupler (3) out of the creeper driven gear (5). The creeper driven gear (5) will
rotate freely on the shaft.
Drive to the pinion shaft (4) is transferred from the transmission output shaft through the creeper drive gear shaft and
the engagement coupler (3) to the pinion shaft (4).
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BVF0819B 2
Creeper Engaged
1 Selector shaft 2 Creeper drive gear
3 Sliding engagement coupler 4 Pinion shaft
5 Creeper driven gear 6 Selector fork
7 Disengagement spring 8 Shift rail piston
9 Low pressure oil supply from creeper 10 Creeper disengaged status switch
engagement solenoid
11 Creeper engaged status switch
Figure Colour Key

A Low pressure circuit
The creeper solenoid valve is energized. This supplies low pressure circuit oil (9) to flow behind the shift rail piston
(8) pushing the sliding engagement coupler (3) onto the driven gear (5). Drive to the pinion shaft is is transferred
from the transmission output shaft through the creeper drive gear (2) and down to the driven gear (5) which drives
the pinion shaft (4).
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ADDITIONAL REDUCERS Creeper - Static description

MAXXUM 140
There are two types of creeper selection available which are installed into the rear axle housing, these are:
- Electro-hydraulic via a two position rocker switch in the cab (16x16 and 24x24 transmissions)
- Mechanical via a selector lever in the cab and a cable (12 x 12 transmission only)
The electro-hydraulic creeper is activated by the two position rocker switch (1) located in the cab on the right hand
control console.
A solenoid valve located on the low pressure distribution block is energized allowing low pressure circuit oil to flow to
a control piston which is connected to a shift rail and fork to engage the creeper.
BSE3691A 1
The mechanical creeper is selected using the selector lever in the cab.
The selector lever moves a shift rail and fork via a cable to engage the creeper.
BRF1818A 2
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ADDITIONAL REDUCERS Creeper - Static description

For tractors with Garu there is not a dedicated creeper switch. To select creeper gears, with the engine running, shift
down to 1st gear, depress the clutch and brake pedals and hold the downshift switch (1). The creeper icon will appear
on the transmission display flashing until the creeper gears are fully engaged when it will remain constantly lit. The
creeper engagement gear will always be 10th creeper.
SS09J056 1
To return to normal operation shift to 10th creeper gear, depress the clutch and brake pedals and hold the upshift
switch (2). Once the transmission has returned to normal gear range 1st, the creeper icon will disappear.
SS09J057 2
NOTE: The creeper gears offer very low ground speeds. Do not use the low gearing advantage to apply excessive
draft loads to the tractor.
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ADDITIONAL REDUCERS Creeper - Troubleshooting

NOTE: If the creeper is not functioning correctly, check for any electronic error codes which may be stored. These
are defined by the error code range of 2001 to 3000 - see Control module - Fault code index (A.50.A).
(A.50.A).
Creeper will not engage Tractor is not stationary. Make sure the tractor is not moving.
Creeper engagement switch faulty. Replace the creeper engagement switch.
Solenoid valve faulty. Replace the solenoid valve.
No or low oil pressure to the creeper shift Pressure test the creeper circuit - see Pri-
rail piston. ority valve - Pressure test (A.14.A).
Shift rail piston oil seals damaged. Replace the shift rail piston oil seals.
Shift rail piston loose on the shift rail. Repair or replace part(s) as necessary.
Worn selector fork. Replace the selector fork.
Selector fork loose on the shift rail. Tighten the selector fork retaining bolt.
Sliding engagement coupler is a tight fit on Clean the splines or replace the shaft and
the shaft splines. the sliding engagement coupler.
Worn sliding engagement coupler. Replace the sliding engagement coupler.
Engagement teeth worn on the driven gear. Replace the driven gear.
Creeper will not Creeper engagement switch faulty. Replace the creeper engagement switch.
disengage
Electrical circuit faulty. Repair or replace the electrical harness.
Solenoid valve faulty. Replace the solenoid valve.
Oil pressure still being supplied to the Pressure test the creeper circuit - see Pri-
creeper shift rail piston. ority valve - Pressure test (A.14.A).
Disengagement spring broken. Replace the disengagement spring.
Drive gear shaft engagement teeth worn. Replace the drive gear shaft.
Shift rail piston loose on the shift rail. Repair or replace part(s) as necessary.
Difficult to engage the Tractor is not stationary. Make sure the tractor is not moving.
creeper
Incorrect selector cable adjustment. Adjust the selector cable.
Damaged selector cable. Replace the selector cable.
Selector fork loose on the shift rail. Tighten the selector fork retaining bolt.
Engagement teeth worn on the driven gear. Replace the driven gear.
Creeper will not remain in Incorrect selector cable adjustment. Adjust the selector cable.
the engaged position.
Sliding engagement coupler loose on the Replace the sliding engagement coupler
shaft splines. and/or the shaft.
Creeper shaft support bearings worn. Replace the shaft support bearings.
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Index

ADDITIONAL REDUCERS Creeper - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADDITIONAL REDUCERS Creeper - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADDITIONAL REDUCERS Creeper - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADDITIONAL REDUCERS Creeper - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ADDITIONAL REDUCERS Creeper - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADDITIONAL REDUCERS Creeper - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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ADDITIONAL REDUCERS Overdrive - 30.D

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Contents
TECHNICAL DATA
ADDITIONAL REDUCERS Overdrive
Torque (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Sectional view (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dynamic description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Static description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Static description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE
Control valve
Remove (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch
Remove (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSTIC
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TRANSMISSION, DRIVE AND PTO OUT - ADDITIONAL REDUCERS Overdrive
ADDITIONAL REDUCERS Overdrive - Torque (17th Gear)
BVE0353B_371 1
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ADDITIONAL REDUCERS Overdrive - Special tools (17th Gear)
CAUTION
in this manual.
B008

previous No.
380000403 Rear axle support -
X 380000291 Tool for hydraulic clutch plunger springs 295021
ADDITIONAL REDUCERS Overdrive - General specification (17th

Gear)
Type Mulit-wet plate clutch
Electro-hydraulic engaged
Location Rear axle housing
Drive Direct drive from the engine flywheel via the PTO input driveshaft
Friction discs 4
Steel plates 4
Belleville washers 6
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ADDITIONAL REDUCERS Overdrive - Sectional view (17th Gear)
BSF4442A 1
Drive Line Sectional View

1 Main input shaft from the engine flywheel 2 17th gear clutch
damper
3 Power take-off (PTO) driveshaft
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BVF0989A 2
17th gear Drive Sectional View

1 PTO driveshaft from the engine flywheel 2 PTO driveshaft to the rear PTO
3 Lubrication oil supply 4 Oil supply manifold
5 Control piston 6 Friction and steel plates
7 Drive gear 8 Pinion shaft
9 Driven gear 10 Belleville washers
11 Clutch housing
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ADDITIONAL REDUCERS Overdrive - Dynamic description (17th

Gear)
BVF0992A 1
17th Gear Clutch Disengaged

1 Power take-off (PTO) driveshaft from the 2 PTO driveshaft to the rear PTO
engine flywheel
3 Lubrication oil supply 4 Control piston
5 Friction and steel plates 6 Drive gear
7 Pinion shaft 8 Driven gear
9 Belleville washers
Figure Colour Key

A Return to reservoir B Lubrication
The engagement PWM solenoid valve and the dump solenoid valve are both de-energized (the dump solenoid valve
is energized when in 16th gear in preparation to engage 17th gear). The belleville washers (9) apply a force to the
control piston (4), which releases the control piston (4) from the friction and steel plates (5).
The drive gear (6) can now rotate freely on the shaft without transmitting drive to the driven gear (8) mounted on the
pinion shaft (7).
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BVF0992B 2
17th Gear Clutch Engaged

1 Power take-off (PTO) driveshaft from the 2 PTO driveshaft to the rear PTO
engine flywheel
3 Lubrication oil supply 4 Control piston
5 Friction and steel plates 6 Drive gear
7 Pinion shaft 8 Driven gear
9 Belleville washers
Figure Colour Key

A Low pressure circuit B Lubrication
The engagement PWM solenoid valve and the dump solenoid valve are both energized, supplying oil from the low
pressure circuit to the face of the control piston (4).
The oil pressure applied to the face of the control piston (4), moves the control piston (4) against the force applied by
the belleville washers (9). This compresses the friction and steel plates (5). Drive is then transferred from the PTO
driveshaft (2) through the 17th gear clutch, drive gear (6) and to the driven gear (8) mounted on the rear axle pinion
shaft (7).
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ADDITIONAL REDUCERS Overdrive - Static description (17th Gear)

MAXXUM 140
The transmission (16x16) has an additional gear and clutch located in the rear axle housing.
When the extra gear (17th) is selected, no other clutches in the transmission are energized and drive is taken directly
from the engine flywheel, through the power take-off (PTO) input shaft and to the 17th gear clutch.
The advanced display of gears (ADOG) will indicate that 17th gear is selected by displaying the gear number (1) and
the gear span indicator (2).
BVF0990A 1
To engage the 17th gear clutch, low pressure circuit oil is directed from the engagement PWM solenoid valve (1),
through the dump solenoid valve (2) and to the 17th gear clutch.
As a safety feature the 17th gear clutch cannot be engaged unless both the dump solenoid valve (2) and the engage-
ment PWM solenoid valve (1) are energized.
The dump solenoid valve is energized in 16th gear in preparation to engage 17th gear.
Changing gear from 16th to 17th gear is only possible if the engine speed will be greater than 700 rev/min when 17th
gear is engaged.
BVF0991A 2
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ADDITIONAL REDUCERS Overdrive - Static description (17th Gear)

The transmission (16x16) has an additional gear and clutch located in the rear axle housing.
When the extra gear (17th) is selected, no other clutches in the transmission are energized and drive is taken directly
from the engine flywheel, through the power take-off (PTO) input shaft and to the 17th gear clutch.
The advanced display of gears (ICU3) will indicate that 17th gear is selected by displaying the gear number (1) and
the gear span indicator (2).
SS09J058 1
To engage the 17th gear clutch, low pressure circuit oil is directed from the engagement PWM solenoid valve (1),
through the dump solenoid valve (2) and to the 17th gear clutch.
As a safety feature the 17th gear clutch cannot be engaged unless both the dump solenoid valve (2) and the engage-
ment PWM solenoid valve (1) are energized.
The dump solenoid valve is energized in 16th gear in preparation to engage 17th gear.
Changing gear from 16th to 17th gear is only possible if the engine speed will be greater than 700 rev/min when 17th
gear is engaged.
BVF0991A 2
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Control valve - Remove (17th Gear)

Prior operation:
1. Disconnect the oil supply pipes (1) and remove the

oil supply pipe banjo bolt (2).
BVF1021A 1
2. Remove the oil supply pipe.
BVF1022A 2
3. Remove the 17th gear solenoid valve block retaining

bolts.
BVF1020A 3
Next operation:
Control valve - Disassemble (17th Gear) (C.30.D)
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Control valve - Disassemble (17th Gear)

Prior operation:
Control valve - Remove (17th Gear) (C.30.D)
1. Remove the 17th gear engage/drive PWM solenoid

valve (1) and the dump solenoid valve (2).
BVF1026A 1
2. Inspect all solenoid valve block components for wear

and damage and replace as necessary.
Next operation:
Control valve - Assemble (17th Gear) (C.30.D)
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Control valve - Assemble (17th Gear)

Prior operation:
Control valve - Disassemble (17th Gear) (C.30.D)
1. Install the 17th gear engage/drive PWM solenoid

valve (1) and the dump solenoid valve (2).
BVF1026A 1
2. Install the solenoid retaining bolts and tighten to the

BVF1024A 2
Next operation:
Control valve - Install (17th Gear) (C.30.D)
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Control valve - Install (17th Gear)

Prior operation:
Control valve - Assemble (17th Gear) (C.30.D)
1. Install the 17th gear solenoid valve block retaining

bolts and tighten to the specified torque value.
BVF1020B 1
2. Install the oil supply pipe.
BVF1022A 2
3. Connect the oil supply pipes (1) and install the oil
supply pipe banjo bolt (2).
BVF1021A 3
Next operation:
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Clutch - Remove (17th Gear)

Prior operation:
REAR AXLE - Remove (D.12.A)
Remove the PTO housing - see REAR PTO Hydraulic - Remove (C.40.C).
Remove both final drive cases - see Final drive Housing - Remove (D.12.A).
WARNING
B026
1. Remove the oil supply tube retaining bolt (1).
BVF0872A_372 1
2. Remove the rear axle bottom cover.
BVE0353A_373 2
3. Remove the four wheel drive clutch inner cover.
BVE0618A_374 3
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4. Remove the draft sensor protection plate.
BVE0354A_375 4
5. Remove the retaining bolts, slide out the draft sensor

with its mounting plate and remove the lower link.
BVE0355A_376 5
6. Remove the vertical tie rod pivot pin retaining bolt (1).
Remove the vertical tie rod pivot pin (2) and remove
the vertical tie rod.
BVE0356A_377 6
7. Remove the lower link support.
BVE0357A_378 7
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8. Support the rear axle on the tractor splitting kit spe-

cial tool 380000569 and position the support spe-
cial tool 380000403 underneath the rear axle center
housing.
BVE0358A_379 8
9. Remove the rear differential - see REAR AXLE - Dis-

assemble (D.12.A).
10. Remove the PTO torque sensor (1)
BVE0330A_380 9
11. Remove the PTO torque sensor pick up disc.

NOTE: Use a suitable bar to hold the PTO torque sensor
pick up disc.
BVE0331A_381 10
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12. Remove the 17th gear clutch supply pipe (1).
BVF0995A 11
13. Expand the retaining ring into the housing and re-
move the PTO driveshaft.
NOTE: The PTO driveshaft bearing retaining ring must seat
fully into the groove of the housing before the PTO drive-
shaft can be removed.
BVF0996A 12
14. Using a suitable slide hammer/puller, remove the

17th gear clutch support shaft.
BVF0997A 13
15. Remove the 17th gear clutch manifold retaining

bolts.
BVF0998A 14
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16. Using a suitable lever (1), reposition and support the

17th gear clutch to allow access to the pinion shaft
retaining nut.
BVF0999A 15

Remove the pinion shaft retaining nut (1)
BVF1000A 16
18. Remove the 17th gear driven gear (1) from the pinion
shaft.
BVF1001A 17
19. Remove the left hand side (1) and right hand side (2)
lubrication oil supply pipes.
BVF0993A 18
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20. Remove the rear hydraulic lift - see HITCH Rear

hitch - Remove (H.10.C).
21. Remove the lubrication oil supply pipe retaining bolt
(1).
BVF0994A 19
22. Using a universal puller (1), partially remove the pin-

ion shaft (2).
NOTE: Only move the pinion shaft enough to allow the
removal of the 17th gear clutch.
BVE1025A 20
23. Support the 17th gear clutch (1) and remove the lever
(2).
Remove the 17th gear clutch from the rear axle hous-
ing.
BVF1002A 21
Next operation:
Clutch - Disassemble (17th Gear) (C.30.D)
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Clutch - Disassemble (17th Gear)

Prior operation:
Clutch - Remove (17th Gear) (C.30.D)
1. Remove the 17th gear clutch supply manifold (1).
BVF1003A 1
2. Using suitable circlip pliers, remove the drive gear/

hub retaining circlip (1).
BVF1004A 2
3. Remove the drive gear/hub (1).
BVF1005A 3
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4. Remove the drive gear/hub bearings (1) and (2).
BVF1013A 4
5. Remove the clutch end plate retaining circlip (1).
BVF1006A 5
6. Remove the clutch end plate (1).
BVF1007A 6
7. Remove the four steel plates and the four friction

discs.
BVF1008A 7
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8. Using special tool 380000291 (1) and a suitable hy-

draulic press (2), compress the belleville washers
and remove the retaining circlip (3).
BVF1009A 8
9. Remove the circlip retainer (1).
BVF1010A 9
10. Remove the six belleville washers.
BVF1011A 10
11. Install the manifold (1) and the support shaft (2).
Supply compressed air into the manifold (3) to re-
move the piston.
BVF1012A 11
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12. Inspect all 17th gear clutch components for wear and
damage and replace as necessary.
Next operation:
Clutch - Assemble (17th Gear) (C.30.D)
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Clutch - Assemble (17th Gear)

Prior operation:
Clutch - Disassemble (17th Gear) (C.30.D)
1. Install new piston oil seals (1) and (2).
BVF1015A 1

hydraulic press (2), install the piston (3).
BVF1017A 2
3. Install the six belleville washers.
BVF1011A 3
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4. Install the circlip retainer (1).
BVF1010A 4

hydraulic press (2), compress the belleville washers
and install the retaining circlip (3).
BVF1009A 5
6. Install the four steel plates and the four friction discs.
BVF1008A 6
7. Install the clutch end plate (1).
BVF1007A 7
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8. Using suitable circlip pliers, install the clutch end

plate retaining circlip (1).
BVF1006A 8
9. Install the drive gear/hub bearings (1) and (2).
BVF1013A 9
10. Install the drive gear/hub (1).
BVF1005A 10
11. Using suitable circlip pliers, install the drive gear/hub

retaining circlip (1).
BVF1004A 11
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12. Install new annular sealing rings (1).
BVF1016A 12
13. Install the 17th gear clutch supply manifold (1).

NOTE: Make sure the machined face of the manifold is
facing away from the 17th gear clutch.
BVF1003A 13
Next operation:
Clutch - Install (17th Gear) (C.30.D)
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Clutch - Install (17th Gear)

Prior operation:
Clutch - Assemble (17th Gear) (C.30.D)
1. Install the 17th gear clutch into the rear axle housing
and support with a suitable lever (1).
BVF0999A 1
2. Install the bearing onto the pinion shaft.

in the installation of the bearing.
396 RA-50_382 2
3. Install the lubrication oil supply pipe and retaining bolt

(1).
BVF0994A 3
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4. Install the right hand side (2) and the left hand side
(1) lubrication oil supply pipe.
BVF0993A 4
5. Install the rear hydraulic lift - see HITCH Rear hitch

- Install (H.10.C).
6. Install the 17th gear driven gear (1) onto the pinion
shaft.
BVF1001A 5

Install the pinion shaft retaining nut and tighten to the
Stake the retaining nut in four places.
BVF1000B 6
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8. Remove the lever supporting the 17th gear clutch

and position the manifold retaining bolt holes in line
with the holes in the rear axle housing.
Install the 17th gear clutch manifold retaining bolts
and tighten to the specified torque value.
BVF0998B 7
9. Install new 17th gear support shaft O-rings (1).
BVF1014A 8
10. Install the 17th gear clutch support shaft (1).
BVF1019A 9
11. Expand the retaining ring into the housing and install
the PTO driveshaft.
fully into the groove of the bearing.
BVF0996B 10
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12. Install the 17th gear clutch supply pipe (1).
BVF0995A 11
13. Install the PTO torque sensor pick up disc.

pick up disc.
NOTE: Apply LOCTITE® 243 onto the retaining bolt threads.
BVE0331A_381 12
14. Install the PTO torque sensor (1).
BVE0330A_380 13
15. Install the lower link support to the rear axle housing
taking the following into consideration:
- Thoroughly clean and degrease the mating sur-
faces and apply a bead of liquid gasket of approxi-
mately 2 mm (0.079 in) in diameter to the rear axle
housing.
Install the lower link support. Tighten the retaining
BVE0357B_383 14
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16. Position the vertical tie rod. Install the vertical tie
rod pivot pin (2). Install the vertical tie rod pivot pin
retaining bolt (1).
BVE0356A_377 15
17. Position the lower link. Install the draft sensor with
its mounting plate and install the retaining bolts.
BVE0355A_376 16
18. Install the draft sensor protection plate (1).
BVE0354A_375 17
19. Install the four wheel drive clutch inner cover. Tighten
BVE0618B_384 18
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BVF0918A_385 19
21. Install the rear axle bottom cover. Tighten the retain-
BVE0353B_386 20
22. Install the oil supply tube retaining bolt (1).
BVF0872A_372 21
Next operation:
Install both final drive cases - see Final drive Housing - Install (D.12.A).
Install the PTO housing - see REAR PTO Hydraulic - Install (C.40.C).
REAR AXLE - Install (D.12.A)
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ADDITIONAL REDUCERS Overdrive - Troubleshooting

17th gear does not engage 40 Km/h maximum speed restriction set in Turn off the speed restriction in machine
machine configurations. configurations (refer to the diagnostic H
routines - see Control module - Config-
ure (A.50.A).
Engagement PWM solenoid valve faulty. Replace engagement PWM solenoid valve.
Dump solenoid valve faulty. Replace dump solenoid valve.
No or low oil pressure to the 17th gear Pressure test 17th gear circuit - see Prior-
clutch. ity valve - Pressure test (A.14.A).
Clutch slipping Low oil pressure to the 17th Gear clutch. Pressure test 17th Gear circuit - see Prior-
ity valve - Pressure test (A.14.A).
Clutch control piston oil seals damaged / Replace clutch control piston oil seals.
worn.
Worn clutch friction discs. Replace the clutch friction discs.
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Index

ADDITIONAL REDUCERS Overdrive - Dynamic description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADDITIONAL REDUCERS Overdrive - General specification (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADDITIONAL REDUCERS Overdrive - Sectional view (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADDITIONAL REDUCERS Overdrive - Special tools (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADDITIONAL REDUCERS Overdrive - Static description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADDITIONAL REDUCERS Overdrive - Static description (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADDITIONAL REDUCERS Overdrive - Torque (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADDITIONAL REDUCERS Overdrive - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Clutch - Assemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Clutch - Disassemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clutch - Install (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clutch - Remove (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control valve - Assemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control valve - Disassemble (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control valve - Install (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control valve - Remove (17th Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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REAR PTO Hydraulic - 40.C

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Contents
TECHNICAL DATA
REAR PTO Hydraulic
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
REAR PTO Hydraulic
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dynamic description Shiftable PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Dynamic description Ground Speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE
REAR PTO Hydraulic
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
PTO clutch
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electrical control
Electrical adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSTIC
REAR PTO Hydraulic
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TRANSMISSION, DRIVE AND PTO OUT - REAR PTO Hydraulic
REAR PTO Hydraulic - Torque
BVE0553A 1
540 / 750 / 1000 RPM PTO Sectional View and Torque Values
1 Clutch Plates and Separator Discs 2 Piston

3 1000 RPM Drive Gear 4 750 RPM Drive Gear
5 Shaft Seals 6 540 RPM Drive Gear
7 Clutch Housing Shaft 8 PTO Output Shaft
9 Retaining Ring 10 PTO Speed Sensor
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BSE3817A 2
540 / 1000 RPM PTO Sectional Views and Torque Values
1 Clutch Plates and Separator Discs 2 Piston

3 1000 RPM Drive Gear 4 Shaft Seals
5 540 RPM Drive Gear 6 Clutch Housing Shaft
7 Retaining Ring 8 PTO Output Shaft
9 Oil Seal 10 540 RPM Driven Gear
11 540 / 1000 RPM Coupler 12 1000 RPM Driven Gear
13 Driven Shaft 14 Washer
15 Bellville Springs 16 Clutch Hub
17 Brake Band 18 Brake Piston
REAR PTO Hydraulic - Special tools

The PTO can be overhauled using proprietary special tools purchased from a good tool retailer.
If required the belleville spring compressor tool 50063 can be manufactured to assist in disassembly but this is not
essential.
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24525 1
PTO hydraulic clutch bellville spring compressor
(Mark tool with no. 50063. Dimensions in mm.)
Fabricate tool using Fe42C material.
REAR PTO Hydraulic - General specification

Ground Speed PTO
Type Mechanical actuation of a sliding coupler
Drive selector
From the pinion shaft
PTO Shaft Revolutions Per Wheel Revolution:
Heavy Duty Rear Axle (All Models)
540 range engaged 9.93 : 1
540E range engaged 12.65 : 1
Light Duty Rear Axle (100 and 110 Models)
540E range engaged 11.24 : 1
REAR PTO Hydraulic - General specification

Type Fully independent 540/1000 base
ISO 1+1 shaft - Shiftable lever
Type Fully independant 540/1000 base
NASO 1 shaft - Reversible shaft
selection
Type Fully independant 540/540E/1000
Opz. ISO 1+1 shaft - Shiftable lever
Clutch type Wet multidisc
Number of plates 6
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Actuation Electrohydraulic
Selectable soft start yes
Fender mounted switch Optional
Number of splines for ISO 1-3/8 in 6 or 21 spline stub 2
shaft
for NASO 1-3/8 in 6 and 21 spline
stub 1 shaft
Number of shafts 1+1 for ISO 1-3/8 in
6 spline base -
Opz 21 spline
1 reversible for NASO base 1-3/8 in 6 and 21 spline
Engine speed at PTO 1969 RPM
speed: 1546 RPM
540 rpm 2120 RPM
540 economy rpm
1000 rpm
PTO speed at engine 603 RPM
rated speed: 768 RPM
540 rpm 1222 RPM
540 economy rpm
1000 rpm
Driven Gear Bush mm 47.910 to 47.966
OD ( (9), REAR mm 48.050 to 48.089
PTO Hydraulic - mm 0.084 to 0.179
Torque (C.40.C)
C.40.C-D.20.A.10)
Driven Gear ID (8)
Gears to Bushes Free
Play
Driven Shaft Diameter mm 39.975 to 40.000
( (11), REAR PTO mm 40.009 to 40.034
Hydraulic - Torque mm 0.009 to 0.059
(C.40.C)C.40.C-
D.20.A.10)
Bush ID (9)
Shaft to Bushes Free
Play
Number of Clutch Discs: n 6
Drive Disc Thickness: mm 1.60 to 1.70
Driven Disc Thickness mm 2.15 to 2.25
Number of Clutch mm 8
Engagement Springs n
Brake Hydraulically controlled brake band
acting on the clutch bell housing
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REAR PTO Hydraulic - Sectional view
BVF0815A 1
Ground Speed PTO Drive Sectional View
1 Ground speed PTO driven gear 2 Sliding engagement coupler (disengaged position)
3 Sliding engagement coupler (engaged position) 4 Ground speed PTO driveshaft
5 Ground speed PTO control clutch end plate 6 PTO output shaft
7 Pinion shaft 8 Ground speed PTO drive gear
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REAR PTO Hydraulic - Sectional view
BVE0541A 1
540 / 750 / 1000 RPM PTO Drive
1 Splined shaft from the engine flywheel 2 Splined shaft to the PTO clutch
3 PTO Clutch 4 PTO Output Shaft
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REAR PTO Hydraulic - Dynamic description Shiftable PTO

The PTO brake solenoid (1) and the PTO engagement solenoid (2), are housed in the low pressure distribution block
on the left hand side of the rear axle.
When the PTO is not in use the PTO brake solenoid is energised and the PTO engagement solenoid is de-energised.
BVE0552A 1
Oil behind the PTO clutch piston is open to reservoir through the lubrication control valve and de-energised PTO
engagement solenoid.
The lubrification valve is housed in the PTO housing support plate and comprises of the following components:
1. Circlip
2. Seat
3. Spool
4. Seat
5. Spring
6. Plug
7. Circlip
BVE0539A 2
The bellville springs force the piston into the piston housing and disengages drive through the clutch plates to the
output shaft .
When the piston is seated in the housing there is a small gap between the rear of the washer and the clutch piston
housing.
Lubrication oil flows from the lubrication circuit, through the lubrication valve into the centre of the clutch housing shaft
and through drillings in the shaft to the washer.
The small gap behind the washer allows lubricating oil at a restricted rate of 2-3 Litres/min to flow past the rear of
washer then through the chanels machined on the front of the piston to lubricate the clutch plates.
It should be noted that when the PTO clutch is disengaged the volume of oil required to lubricate the clutch plates is
less than during engagement as described in the next sequence. Consequently this method of restricting lubricating
oil to the clutch plates allows additional lubrication to be available for other hydraulic circuits operating on the tractor.
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BSE2355A 3
BVE0554A 4
PTO CONTROL CLUTCH-DISENGAGED
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Lubrication Circuit Oil Return to reservoir
Lubrication Oil
@ ReducedFlow
1 Clutch Plates 2 Washer

3 Piston 4 Lubrication Valve
5 PTO Output Shaft 6 Bellville Springs
PTO Engaged (initial engagement)
Engagement of the PTO is considered as a two phase operation.

When the PTO is operated the engagement solenoid is energised and the brake solenoid disengaged.
Low pressure hydraulic circuit oil flows from the solenoid and past the end of the lubrication valve to the rear of the
clutch piston. As pressure increases the PTO clutch piston moves forward against the washer (2) and bellville springs
(6) to compress the clutch plates (1). The action of the piston moving forward increases the gap between the rear
of the washer and the clutch piston housing allowing an increased flow of lubricating oil to the clutch plates. This
increased flow of up to 15 Litres/min ensures the clutch plates are adequately lubricated during the initial stages of
engagement.
PTO Soft Start
The automatic PTO clutch softstart system ensures the load applied to the PTO is controlled in a predictable manner
without putting undue stresses on the tractor engine, the PTO shaft and the connecting implement. The soft start
feedback system senses engine deceleration and PTO shaft acceleration. Limits for these two parameters are set in
the controller and if the system detects that either parameter is going above the set threshold limits, the rise in PTO
clutch pressure is held untill they return within the preset limit at which time the clutch pressure again increases to
continue engaging the PTO. If the soft start parameters are again exceeded the pressure held process is repeated
untill full engagement is achieved. If engagement is not achieved after 5 seconds the clutch pressure is released
and the PTO system is turned off.
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BVE0555A 5
PTO CONTROL CLUTCH-INITIAL ENGAGEMENT
Low Pressure Clutch Lubrication Oil

EngagementOil < 14 bar @ HighFlow

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BVE0556A 6
PTO CONTROL CLUTCH-FINAL ENGAGEMENT
Low Pressure Clutch Lubrication Oil at Low Flow

EngagementOil > 14 bar
Lubrication Circuit Oil

PTO Engaged (final engagement)
When the pressure applied to the piston approaches 14 bar the pressure applied to the end face of the lubrication
valve moves the valve against the spring and reduces the flow of lubricating oil across the valve to the clutch plates
to 2 - 3 Litres/min.
Less lubrication of the clutch plates is necessary after the initial stage of engagement and this process limits the
demand of the PTO on the lubrication circuit oil which is also used for other circuits on the tractor. The pressure
84276322A 31/05/2010
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applied to the rear of the piston will now continue to increases towards 18 bar in order to maintain adequate clutch
plate clamping pressure and drive through the clutch to the PTO output shaft.
BSE2359A 7
Low Pressure Circuit Oil
1 PTO Clutch Housing 2 PTO brake Band

3 Lever 4 Return Spring
5 Piston
PTO CLUTCH BRAKE
The band type clutch brake operates automatically. It applies when the PTO clutch is being disengaged (braking start)
and stops braking when the clutch is completely engaged.
When working with high inertia implements it is possible to keep the brake disengaged by pressing the switch located
on the right hand console near the PTO control handle. When the PTO clutch is engaged, the brake control oil is
returned to reservoir as the solenoid valve is in the discharge position (de-energized) and consequently there is no
operation of the actuation piston (5) onto the band operating lever (2), the piston (5) being returned by the spring (4).
When the PTO control clutch is being disengaged, the solenoid valve is energised and opens, diverting oil from the
low pressure circuit onto the piston (5). The piston contacts the lever (3) and band (2) is tightened against the housing
(1) to brake the assembly.
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REAR PTO Hydraulic - Static description

The power take-off (PTO) transfers engine power directly to mounted, semi-mounted or trailed equipment via a splined
shaft at the rear of the tractor.
The PTO drive shaft runs through the transmission upper shafts. The PTO drive shaft front end is directly splined to
the engine flywheel damper, the rear end is connected to the PTO control clutch.
The rear PTO is controlled by the controller located behind the operators seat.
The controller receives inputs from the PTO ON/OFF switches, (in cab and fender), PTO speed sensor, brake, soft
start and the engine controller. These signals are then used to provide the output signals to the PTO clutch engage-
ment solenoid, P.T.O brake solenoid and the PTO ON/OFF overspeed warning lamp.
If the correct conditions are met, ie, speed parameters and switch engagements then the PTO is allowed to start.
BAIL09CCM091AVA 1
The PTO speed sensor (1) is located below the PTO output shaft.
BVE0284A 2
The P.T.O. is engaged and disengaged by means of a knob (1) on the right-hand console. The adjacent warning light
(2) will illuminate when the P.T.O. is engaged.
BRE1810C 3
With shiftable P.T.O., a range lever is provided. The lever is used to select one of two or three P.T.O. speed ranges to
provide power or economy. The range lever (1), is located at the rear of the right-hand console.
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Ground drive P.T.O. is available, in conjunction with 3-speed, shiftable P.T.O., on all models. As suggested by the
name, ground drive P.T.O. speed is directly related to rotation of the rear wheels rather than engine speed. When
ground drive P.T.O. is installed, a second lever (2) is provided.
BRE1745C 5
Ground speed PTO

NOTE: To aid smooth engagement of the ground speed PTO, depress and hold both brake pedals while moving the
cab selector lever.
When ground speed PTO is engaged, a Controller Area Network (CAN) message is sent to the instrument cluster and
“GPto" is displayed instead of the rear PTO speed.
If ground speed PTO is disengaged then the CAN message is updated and the instrument cluster display will change
to display the rear PTO speed.
NOTE: Selecting ground drive with the engine PTO function engaged will automatically disable engine PTO drive. To
re-enable engine PTO drive, move the selector lever to the engine drive position, disengage and then re-engage the
main PTO switch.
BRE1742A 7
NOTICE: An automatic PTO brake is installed to stop shaft rotation quickly when the PTO is disengaged. To avoid
overstressing the PTO brake, slow down the implement by reducing engine speed before disengaging the PTO. This
is particularly important with implements having a high inertia. Such implements should, ideally, be fitted with an
overrun clutch. To avoid damage to the brake when operating high inertia implements, hold down the switch (1), to
disengage the brake and allow the implement to come to rest naturally.
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DANGER
To avoid inadvertent movement of the implement, disengage the PTO after each use. Failure to comply could
result in death or serious injury.
B014
BRF1738B 9
External PTO Controls

(except N. America)
An optional, fender-mounted PTO switch (1), may be installed on the outer surface of both rear fenders to aid align-
ment of the P.T.O shaft splines with equipment and facilitate stationary PTO operations.
With the engine running, touch the switch momentarily to cause the PTO shaft to index round to align the shaft splines.
If the switch is pressed for less than 5 seconds, the shaft will stop turning when the switch is released.
Press and hold in the switch for more than 5 seconds and the PTO will operate continuously. Press the switch again
to stop the PTO Alternatively, the PTO may be stopped by means of the in-cab controls, as previously described.
NOTE: The warning light, on the PTO control panel, will illuminate when the PTO is engaged, momentarily or perma-
nently.
NOTE: The PTO may be engaged or disengaged from the fender switch, whether the in-cab control is in the on or off
position.
NOTE: The soft start function will operate irrespective of whether the P.T.O. is engaged from inside the cab or from a
fender switch.
BRE1483C 11
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CAUTION
Before leaving the vehicle to operate the external PTO switches:- Move the gearshift levers to neutral.- Dis-
engage the PTO- Apply the parking brake. With the engine running, move the hand throttle lever to the low
idle position (fully rearwards).
B001
The operator must only activate the external Power Take Off switches (1) while standing to the side of the tractor
(outboard of the rear tyres). To aviod damage to implement or tractor, operation of the in cab and external PTO
switches should not be carried out simultaneously.
NOTE: Before using the external Power Take Off switches, ensure that no person or object is in the area of the
implement, 3-point linkage or PTO shaft.
Never operate the external switches while standing:
· Directly behind the tractor or tyres.
· Between the lower links.
· On or near the implement.
· Never extend arms, legs, any part of the body or any object into the area near the 3-point linkage, PTO shaft or
implement while operating the external switch.
· Never have an assistant working the opposite set of controls.
· When moving to the opposite set of controls, move around the tractor or implement. · Do not cross between the
implement and tractor.
BRE1727B 12
Auto PTO Function (if fitted)
The Auto P.T.O. function provides automatic engagement or disengagement of the rear P.T.O. drive when using the
electronic draft control raise/lower switch (1). Operating the electronic draft control switch to raise the implement will
automatically disengage P.T.O. drive. Lowering the implement with the electronic draft control switch will re-engage
P.T.O. drive.
BRE1468B 13
To activate the Auto function, engage the P.T.O. and then depress and hold the switch (1) for more than one second.
The Auto P.T.O. lamp on the instrument panel will illuminate to confirm engagement.
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With the 3 point hitch in the lowered position and the P.T.O. engaged, the Auto lamp will remain on. Raising the
implement will cause the Auto lamp to flash until the implement is lowered and P.T.O. drive is re-engaged.
NOTE: The Auto P.T.O. function will be de-activated every time the key start is switched off.
The Auto P.T.O. function will automatically de-activate if one or more of the following situations occurs.
• The tractor speed is above 0.5 Km/h (0.3 MPH) with the 3 point hitch in the raised position for more than 2 minutes.
• With the 3 point hitch raised, the tractor speed falls below 0.5 Km/h (0.3 MPH), or the tractor is stationary for more
than 10 seconds.
• If one of the external switches for P.T.O. or 3 point hitch are operated.
• The P.T.O. is switched off using the internal or external switches.
• Operating both internal and external P.T.O. switches simultaneously.
• Ground drive P.T.O. is selected.
• The operator leaves the seat for more than 2 minutes with Auto P.T.O. activated and the 3 point hitch in the raised
position.
BRF1811B 15
Engine Power Management
Tractors with common rail fuel injection are equipped with an Engine Power Management (EPM) system that monitors
and boosts engine power during Power Take Off operations.
NOTE: The indicator light (1) on the instrument panel will illuminate when Engine Power Management is activated.
With the tractor moving and the engine running above 1300 r.p.m., engaging the rear P.T.O. will activate Engine Power
Management in the standby mode. When the torque applied through the P.T.O. exceeds a pre-set level, EPM will
increase the available engine horsepower. The full level of additional power will be made available providing the
combined power requirement for both P.T.O. and driving wheels does not exceed the specified rated power of the
tractor.
BRE1495B 17
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The ‘soft start’ facility provides easy start up of heavy, high inertia, PTO driven equipment. Soft start is a fully automatic
system controlled by hall effect speed sensors on the engine and within the PTO driveline.
Soft start ‘feathers’ the PTO clutch engagement to provide a slower, gradual take up of the drive over the first 5
seconds.
BVE0547A 19
PTO Torque Sensor (Engine Power Management)
A PTO under load B PTO without load

1 Engine flywheel torque sensor 2 PTO torque sensor
3 PTO clutch 4 PTO torque sensor tone wheel
5 PTO input shaft 6 Engine flywheel damper
The PTO power management system records the amount of torque being transmitted through the PTO shaft (5) using
two hall effect sensors (1) and (2). One hall effect sensor is located at the engine flywheel damper (6) and the other
is located at the PTO torque sensor tone wheel (4).
The PTO shaft is engineered from high torsional steel and is designed to twist when a load is applied. Under no load
(B) there is no difference (x) between the two sensor positions. Under load (A) the PTO management system detects
the amount of twist by comparing the difference (x) between the two sensor positions. The PTO management system
knows the torque required to twist the PTO shaft a given amount and uses the difference (x) to calculate the torque
produced at the PTO shaft. The PTO management system can then detect an increase in torque and electronically
modify the power curves of the engine management system to provide an increase of up to 25 additional horsepower
to maintain the PTO performance.
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REAR PTO Hydraulic - Dynamic description Ground Speed PTO

When ground speed PTO is selected, the rear axle selector fork will move the sliding engagement coupler (2) to
the engaged position (3). This will transfer drive from the drive gear (8) splined to the pinion shaft (7), to the PTO
control clutch end plate via the driven gear (1) and the driveshaft (4). The drive by-passes the PTO control clutch and
depending on the speed selected by the operator to the output shaft (6).
BVF0816A 1
PTO Clutch Oil Supply Cut Off Valve Operation - Ground Speed PTO Engaged
1 Oil supply to the PTO control clutch 2 Selector lever

3 Oil supply from the low pressure distribution block 4 PTO oil supply cut-off valve
5 Oil supply to the PTO brake
A Oil supply gallery to PTO control clutch B Oil supply gallery from the low pressure distribution
block
C Oil gallery to the oil reservoir (rear axle)
Figure Colour Key
A. Return to reservoir
When ground speed PTO is engaged, the PTO brake solenoid is automatically disengaged by the controller. The PTO
clutch oil supply cut-off valve (4) is moved by the selector lever (2) to block the flow of oil from gallery ’A’ to gallery ’B’.
This will stop the engagement of the PTO clutch as an additional safety feature.
Any residual pressure behind the PTO clutch piston will be open to the oil reservoir through the PTO oil supply cut-off
valve (4) and galley ’C’.
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BVF0816B 2
PTO Clutch Oil Supply Cut Off Valve Operation - Ground Speed PTO Disengaged and PTO Clutch Engaged
1 Oil supply to the PTO control clutch 2 Selector lever

3 Oil supply from the low pressure distribution block 4 PTO oil supply cut-off valve
5 Oil supply to the PTO brake
A Oil supply gallery to PTO control clutch B Oil supply gallery from the low pressure distribution
block
C Oil gallery to the oil reservoir (rear axle)
Figure Colour Key
B. Low pressure circuit
When ground speed PTO is disengaged, the PTO oil supply cut off valve (4) is moved by the selector lever (2) and
the PTO brake solenoid is automatically engaged by the controller.
When the PTO clutch is engaged, the PTO brake is disengaged by the controller and oil can flow from gallery ’B’ to
gallery ’A’ through the PTO oil supply cut-off valve (4).
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REAR PTO Hydraulic - Remove
WARNING
B026
1. Remove the battery cover and disconnect the battery

negative cable (1).
BVE0207A_388 1
2. Remove the drain plug (1) and drain the oil into a
suitable container.
Install the drain plug after the oil has drained
BSE2927A_389 2
3. Remove the PTO guard.
BVE0274A 3
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4. Remove the pick up hitch lower retaining bolts (if fit-

ted).
BVE0272A 4
5. Remove the pick up hitch upper retaining bolts and

remove the pick up hitch (if fitted).
NOTE: Using a suitable trolley jack support the pick up
hitch.
BVE0273A 5
6. Remove the PTO speed sensor retaining bolt (1) and

detach the PTO speed sensor.
BVE0284A_390 6
7. Using a suitable chain or sling, attach the PTO hous-

ing to a hoist. Remove the PTO housing retaining
bolts and remove the PTO assembly from the rear
axle.
BVE0285A 7
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REAR PTO Hydraulic - Install
WARNING
B026
1. Install the PTO assembly to the rear axle housing

- Thoroughly clean and degrease the mating sur-
faces and apply a bead of liquid gasket of approxi-
mately 2 mm in diameter to the rear axle casing fol-
lowing the pattern shown.
BVE0530B 1
2. Using a suitable chain or sling, attach the PTO hous-

ing to a hoist and install the PTO assembly to the rear
axle. Install the PTO housing retaining bolts. Tighten
BVE0285B 2
3. Attach the PTO speed sensor and install the PTO

speed sensor retaining bolt (1).
BVE0284A_390 3
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4. Install the pick up hitch and install the pick up hitch

upper retaining bolts. Tighten to the specified torque
value (if fitted).
NOTE: Using a suitable trolley jack support the pick up
hitch
BVE0273B 4
5. Install the pick up hitch lower retaining bolts. Tighten

to the specified torque value (if fitted).
BVE0272B 5
6. Install the PTO guard.
BVE0274A 6
7. Refill the driveline with the correct specification oil.

Connect the battery negative cable (1) and install the
battery cover.
BVE0207A_388 7
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REAR PTO Hydraulic - Disassemble

Prior operation:
REAR PTO Hydraulic - Remove (C.40.C)
WARNING
B026
1. Place the PTO assembly on a suitable clean working

surface or stand if available.
2. Remove the brake band and the brake piston hous-
ing.
BVE0412A 1
3. Remove the PTO clutch housing PTO end plate cir-

clip (1).
BVE0413A 2
PTO Assemblies with Ground Speed PTO

4. Remove the PTO clutch housing ground speed PTO
end plate (1).
BVE0415A 3
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PTO Assemblies Without Ground Speed PTO

5. Remove the clutch housing PTO end plate (1).
BVE0527A 4
All PTO Assemblies

6. Remove the clutch hub (1) and the clutch drive and
driven discs (2).
BVE0414A 5
7. If the clutch piston is to be serviced and it is not

necessary that further repairs to the clutch hub are
required, compress and remove the clutch bellville
springs as follows:
Install the PTO clutch housing end plate circlip and
install a suitable puller and locally fabricated tool
50063 (1). Compress the bellville springs and re-
move the retaining ring. Slowly and carefully release
the pressure.
Remove the PTO clutch housing end plate circlip.
BVE0482A 6
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8. Remove the bellville springs.
BVE0416A 7
9. Use compressed air in the inlet port to remove the

piston from the clutch plate housing.
BVE0481A 8
10. Examine the piston seals and replace if damaged
BSE2355A_391 9
11. Remove the roll pin (1) from the selector rod and
remove the selector.
BVE0417A 10
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12. Remove the PTO selector fork roll pin (1).
BVE0418A 11
13. Remove the PTO selector fork pin (1) and remove
the 1000 RPM selector fork assembly (2).
BVE0419A 12
14. Using a suitable bar (1) to lock the PTO output shaft.
Unstake and remove the PTO output shaft retaining
nut.
BVE0420A 13
15. Remove the support plate retaining bolts.
BVE0421A 14
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16. Remove the support plate and remove the 1000 RPM
driven gear (1).
BVE0422A 15
17. Remove the bush (1), thrust washer (2), bearing (3),
thrust washer (4), 750 RPM driven gear (5), bush (7),
and the 540/750 RPM sliding coupler gear (6).
BVE0423A 16
18. Remove the 540/750 RPM selector fork and the slid-
ing coupler.
BVE0424A 17
19. Remove the 540 RPM driven gear from the output
shaft.
BVE0425A 18
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20. Remove the PTO output shaft circlip (1)
BVE0426A 19
21. Remove the PTO output shaft.
BVE0427A 20
22. Remove the circlip (1) bearing (2) and the seal (3).
BSD2323A 21
23. Remove the roll pin (1), remove selector lever (2) and
remove the selector gate (3).
BVE0431A 22
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24. Remove the bearing (5) circlip (4), washer (3) sleeve
(2) and the 750 RPM drive gear (1).
BVE0432A 23
25. Expand the circlip (1) into the housing and remove
the clutch hub assembly.
BVE0433A 24
26. Remove the sealing rings from the clutch hub shaft.
BVE0434A 25
27. Remove the circlip (1).
BVE0435A 26
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28. Remove the washer (1), 750 RPM drive gear (2),
bearing (3) and 1000 RPM drive gear (4).
BVE0436A 27
Next operation:
REAR PTO Hydraulic - Assemble (C.40.C)
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REAR PTO Hydraulic - Assemble

Prior operation:
REAR PTO Hydraulic - Disassemble (C.40.C)
WARNING
B026
1. Install the 1000 RPM drive gear (4), bearing (3), 750
RPM drive gear (2), and the washer (1).
NOTE: Install new O-ring seals and sealing washers as
required.
BVE0436A 1
2. Install the circlip (1).
BVE0435A 2
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3. Install the sealing rings to the clutch hub shaft.
BVE0434A 3
4. Expand the circlip (1) into the housing and install the
clutch hub assembly.
BVE0433A 4
5. Install the 750 RPM drive gear (1), sleeve (2), washer
(3), circlip (4) and the bearing (5).
BVE0432A 5
6. Install the selector gate (3), selector lever (2) and the
roll pin (1).
BVE0431A 6
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7. Install the seal (3), bearing (2) and the circlip (1).
BSD2323A 7
8. Install the PTO output shaft.
BVE0427B 8
9. Install the PTO output shaft circlip (1).
BVE0426A 9
10. Install the 540 RPM driven gear to the output shaft.
BVE0425A 10
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11. Install the selector fork and the sliding coupler.
BVE0424A 11
12. Install the 540/750 RPM sliding coupler gear (6),

bush (7), 750 RPM driven gear (5), thrust washer
(4), bearing (3) thrust washer (2) and the bush (1).
BVE0423A 12
13. Install the 1000 RPM driven gear (1) and the support
plate.
BVE0422A 13
14. Install the support plate retaining bolts. Tighten to

BVE0421B 14
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15. Using a suitable bar (1) to lock the PTO output shaft.
Install a new PTO output shaft gear retaining nut.
Tighten to the specified torque value and stake the
retaining nut.
BVE0420B 15
16. Install the PTO selector fork and sliding coupler (2)
and install the selector fork pin (1).
BVE0419B 16
17. Install the PTO selector fork roll pin (1).
BVE0418B 17
18. Install the selector and install the roll pin (1) to the
selector rod.
BVE0417B 18
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19. Install the piston to the clutch housing.

Install the bellville springs.
BVE0416A_392 19
20. Install the PTO clutch housing end plate circlip and
install a suitable puller and locally fabricated tool
50063 (1). Compress the bellville springs and install
the retaining ring. Slowly and carefully release the
pressure.
Remove the PTO clutch housing end plate circlip
BVE0482A 20
21. Install the clutch drive and driven discs (2) and the
clutch hub (1).
BVE0414A 21
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PTO Assemblies with Ground Speed PTO

22. Install the ground speed PTO end plate (1).
BVE0415A 22
PTO Assemblies Without Ground Speed PTO

23. Install the clutch housing PTO end plate (1).
BVE0527A 23
All PTO Assemblies

24. Install the PTO end plate circlip (1).
BVE0413A 24
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25. Install the brake band and the brake piston housing.
BVE0412A 25
PTO Brake Band Adjustment

26. Loosen locknut (1). Torque screw (2) to 1-1,2 Nm,
in order to close brake band. Loosen screw two and
one half turns and retighten locknut. Check brake
band for concentricity. Adjust as required and repeat
adjustment procedure.
BCG0005A 26
2 Speed Shaft Change PTO - Initial PTO Shaft Set Up (21 Spline)
27. Position the PTO shaft (1) into the assembly, with the
21 teeth splines to the outside of the assembly. Se-
cure the PTO output shaft retaining ring (2). Loosen
locknut (5) and tighten screw (4) until it touches the
rod. Tighten screw (4) one more turn 360 °, tighten
the locknut (5)to secure. This should now provide a
clearance of 0,5-1,5 mm between the sliding sleeve
and 1000 RPM gear (3).
NOTE: This set up is for tractors with Driveline Serial Num-
ber UP TO 009017242 ONLY.
NOTE: The following set up procedure is required to be
carried out to 2 Speed PTO units for both 540 and 1000
RPM shafts, after a overhaul or strip down of the PTO as-
sembly and prior to the refit into the tractor.
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BCG0007A 27
28.
NOTE: After installing the PTO output shaft retaining ring
into the seat, rotate the ring to ensure that it is positioned
opposite the flat surface on the PTO output shaft, as per
28.
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BCG0010A 28

29. Position the PTO shaft (1) into the assembly, with
the 6 teeth splines to the outside of the assembly.
Secure PTO shaft into place using the PTO output
shaft retaining ring (2). Pull lever (4), in the direction
of the arrow and check for the clearance between the
actuating pin (3) of 1-3 mm.
ber UP TO 009017242 ONLY.
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BCG0006A 29
30.
28.
84276322A 31/05/2010
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31. Position the PTO shaft (1) into the assembly, with the
21 teeth splines to the outside of the assembly. Se-
cure PTO shaft into place using the PTO output shaft
retaining ring (2). Loosen locknut (5) and tighten
screw (4) until it touches the rod. Tighten the screw
(4) half to one more turn ( 180/360 °), tighten the lock-
nut (5) to secure. This should now provide a clear-
ance of 0,2-0,6 mm between the sliding sleeve and
1000 RPM gear (3). Refer to 27.
ber FROM 009017243 ONLY.
32.
28.

33. Position the PTO shaft (1) into the assembly, with
the 6 teeth splines to the outside of the assembly.
Secure PTO shaft into place using the PTO output
shaft retaining ring (2). Pull lever (4), in the direction
of the arrow and check for the clearance between the
actuating pin (3) of 0,4-1,2 mm. Refer to 29.
ber FROM 009017243 ONLY.
34.
28.
Next operation:
REAR PTO Hydraulic - Install (C.40.C)
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PTO clutch - Travel adjust

1. Disengage the ground speed PTO.
Make sure the oil supply cut off valve (3) is level +/-
0.2 mm (H) with the valve body (1)
Adjustment is obtained by the adjustment bolt (2).
BVF0908A 1
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Electrical control - Electrical adjust

1. Disengage the ground speed PTO.
Make sure the switch plunger (1) is depressed be-
tween 2.5 - 4.5 mm
Adjustment is obtained by loosening the locknut (3)
and turning the adjustment bolt (2).
BVF0814A 1
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REAR PTO Hydraulic - Troubleshooting

Difficult to engage ground Tractor is not stationary. Apply parking brake and foot brake pedals
speed PTO before selecting ground speed PTO.
Incorrect selector cable adjustment. Adjust the selector cable.
Damaged selector cable. Replace the selector cable.
Selector shaft lever spring broken. Replace the selector shaft lever spring.
Engagement teeth worn on the ground Replace the ground speed PTO driveshaft.
speed PTO driveshaft.
Shift rail seized in the axle housing. Remove the shift rail and repair or replace
as necessary.
Rear PTO output shaft rotating.. PTO brake not being applied, repair or re-
place as necessary
PTO clutch oil supply cut off valve. Replace PTO clutch oil supply cut off valve.
Ground speed PTO will Incorrect selector cable adjustment. Adjust the selector cable.
not remain in the engaged
position
Selector shaft lever spring broken. Replace the selector shaft lever spring.
Sliding engagement coupler loose on the Replace the sliding engagement coupler
shaft splines. and/or the shaft.
Ground speed PTO shaft support bearings Replace the shaft support bearings.
worn.
Ground speed PTO (Gpto) Cab selector lever switch open circuit. Replace the cab selector lever switch.
is displayed on the
instrument cluster when
ground speed PTO is
disengeged or not fitted
and engine driven rear
PTO is engaged
Cab selector lever switch electrical circuit Repair or replace the electrical harness.
faulty.
Incorrect ground speed PTO switch adjust- Adjust the ground speed PTO switch.
ment.
Link wire electrical connector faulty. Repair or replace the link wire electrical
connector.
REAR PTO Hydraulic - Troubleshooting

NOTE: The table below details some possible mechanical/hydraulic faults. The controller will also generate error
codes related to the PTO system. The error codes are prefixed with the number (5) and displayed on the instrument
cluster.
The PTO does not operate Low transmission oil level. Reset correct level.
Blocked oil filter. Replace filter.
Faulty hydraulic pump. Repair or replace pump.
Faulty PTO engagement switch Replace switch.
Lack of power supply to the solenoid valve: Reset electrical connections and replace
detached or damaged connectors, faulty faulty parts.
remote switch.
PTO control solenoid valve stuck open. Repair or replace solenoid valve.
Oil leakage through the seals with conse- Replace damaged seals.
quent pressure drop: manifold or control
plunger seals
The PTO remains Faulty PTO engagement switch. Replace switch.
engaged.
84276322A 31/05/2010
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detached or damaged connectors or faulty faulty parts.
remote switch.
PTO control valve stuck open Repair or replace solenoid valve.
The PTO control clutch Faulty brake engagement switch Replace switch.
drags.
detached or damaged connectors or faulty faulty parts.
remote switch.
Brake control valve stuck closed. Repair or replace solenoid valve.
Worn PTO brake Replace brake.
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Index

Electrical control - Electrical adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
PTO clutch - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REAR PTO Hydraulic - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR PTO Hydraulic - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REAR PTO Hydraulic - Dynamic description Ground Speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR PTO Hydraulic - Dynamic description Shiftable PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR PTO Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR PTO Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR PTO Hydraulic - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR PTO Hydraulic - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REAR PTO Hydraulic - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR PTO Hydraulic - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REAR PTO Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR PTO Hydraulic - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR PTO Hydraulic - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR PTO Hydraulic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REAR PTO Hydraulic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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FRONT PTO Hydraulic - 42.C

84276322A 31/05/2010
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Contents
TECHNICAL DATA
FRONT PTO Hydraulic
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
FRONT PTO Hydraulic
SERVICE
Gearbox
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSTIC
FRONT PTO Hydraulic
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TRANSMISSION, DRIVE AND PTO OUT - FRONT PTO Hydraulic
FRONT PTO Hydraulic - Torque
BVF0910B 1
BVF0924B 2
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FRONT PTO Hydraulic - Special tools
CAUTION
in this manual.
B008
List of special tools necessary to carry out the different operations described in this section:
380001158 Control Piston Spanner.
FRONT PTO Hydraulic - General specification

Front PTO
Type Fully independent 1000 rev/min.
Electro-hydraulic engagement.
Spring disengagement
Clutch type Multi-dry plate
Drive From the engine front crankshaft pulley
Multi-dry plate clutch discs
Friction discs 3
Steel discs 3
Engine speed at 1000 rev/min PTO speed 2120 rev/min
Maximum PTO capacity Hp 110
Reduction gearbox oil specification AKCELA NEXPLORE (MAT 3525)
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FRONT PTO Hydraulic - Dynamic description
BSF4297A 1
Front PTO Operation - Front PTO Disengaged
1 Friction discs and steel plates 2 Clutch release bearing

3 Piston spring 4 Piston
5 Diaphragm spring
Figure Colour Key
When the front PTO is disengaged, power to the solenoid valve is switched off allowing the oil to return to the reservoir.
With no oil pressure acting against the piston (4), the spring (3) pushes the piston (4) out of the housing and pushes
the clutch release bearing (2) into contact with the PTO clutch diaphragm spring (5). When pressure is applied to the
diaphragm spring (5) it releases the force acting on the clutch pressure plate. This allows the springs in between the
friction discs and steel plates (1) to expand, allowing the clutch hub to rotate freely within the clutch housing.
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BSF4297B 2
Front PTO Operation - Front PTO Engaged
1 Friction discs and steel plates 2 Clutch release bearing

3 Spring 4 Piston
5 Diaphragm spring
Figure Colour Key
A. Low pressure circuit
When the front PTO is engaged, the solenoid valve is energized, allowing oil pressure to be applied to the piston (4).
The oil pressure acting against the piston (4), overcomes the piston spring (3), which allows the piston (4) to retract
into the housing, releasing the clutch release bearing (2) from the force of the diaphragm spring (5). When pressure
is released from the diaphragm spring (5), it increases the force acting on the clutch pressure plate. This compresses
the springs in between the friction discs and steel plates (1), clamping the friction discs and steel plates (1) together,
locking the clutch hub and the clutch housing together.
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FRONT PTO Hydraulic - Static description
BSF4302A 1
Front PTO
1 PTO multi-dry plate clutch 2 PTO control housing

3 PTO input shaft 4 Engine crankshaft pulley coupler
5 PTO reduction gearbox
The front PTO is engaged/disengaged by the piston control housing (2). The PTO is driven directly from the engine
crankshaft. The engine crankshaft pulley coupler (4) transfers drive through the PTO input shaft (3) and into the
multi-dry plate clutch (1). When the PTO is engaged the drive is transferred through the multi-dry plate clutch (1) into
the PTO reduction gearbox (5) to the PTO reduction gearbox output shaft.
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Gearbox - Disassemble
Prior operation:
Remove the front PTO reduction gearbox (refer to Gearbox - Remove (C.42.C)).
WARNING
B026
1. Remove the PTO reduction gearbox front cover re-

taining bolts.
BVF0944A 1
2. Remove the PTO reduction gearbox front cover (1).
BVF0945A 2
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BVF0946A 3
Front PTO Reduction Gearbox Exploded View
1 Bearing 2 Bearing
3 PTO driven gear assembly 4 Bearing
5 Bearing 6 PTO drive gear
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Gearbox - Assemble
Prior operation:
Gearbox - Disassemble (C.42.C)
WARNING
B026

BVF0947A 1
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BVF0946A 2
Front PTO Reduction Gearbox Exploded View
1 Bearing 2 Bearing
3 PTO driven gear assembly 4 Bearing
5 Bearing 6 PTO drive gear
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2. Install the PTO reduction gearbox front cover.
BVF0945A 3
3. Install the PTO reduction gearbox front cover retain-

ing bolts. Tighten to the specified torque value.
BVF0944B 4
Next operation:
Gearbox - Install (C.42.C)
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Gearbox - Remove
Prior operation:
Remove the PTO clutch (refer to Clutch - Remove (C.42.C)).
WARNING
B026
suitable container.
Install the drain plug (1) after the oil has drained.
BVF0948A 1
2. Disconnect the PTO speed sensor electrical connec-

tor.
BVF0843A 2
3. Remove the PTO speed sensor (1).
BVF0948C 3
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4. Remove the front PTO reduction gearbox rear retain-

ing bolt (1).
BVF0927A 4
5. Remove the front PTO reduction gearbox.
BVF0928A 5
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Gearbox - Install
WARNING
B026
1. Install the PTO reduction gearbox and the retaining

bolts. Tighten the retaining bolts to the specified
torque value.
BVF0928B 1
2. Install the PTO rear retaining bolt. Tighten to the

BVF0927B 2
3. Install the PTO speed sensor (1).
BVF0948C 3
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4. Connect the PTO speed sensor electrical connector

(1).
BVF0843A 4
5. Remove the refill/level plug (1).
BVF0948B 5
6. Fill the PTO reduction gearbox with the correct spec-

ification oil, NEW HOLLAND AMBRA MULTI G 134
AKCELA NEXPLORE (MAT 3525)until the oil can be
seen level with the refill/level plug hole.
Install the refill/level plug (1).
BVF0948B 6
Next operation:
Install the front PTO clutch (refer to Clutch - Install (C.42.C)).
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Clutch - Disassemble
WARNING
B026
1. Remove and discard the front PTO clutch shaft

O-ring seal (1).
Remove the retaining bolts (2) and remove the front
PTO clutch shaft (3).
BVF0937A 1
2. Remove the PTO clutch pressure plate.
BVF0938A 2
3. Remove the PTO clutch top plate (1).

Remove the washers (2).
BVF0940A 3
4. Remove the friction discs and steel plates from the

PTO clutch.
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BVF0941A 4
5. Using suitable circlip pliers, remove the clutch hub

circlip (1).
BVF0942A 5
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BVF0943A 6
PTO Clutch Assembly Exploded View
1 Circlip 2 PTO clutch plate housing

3 Bearing 4 Circlip
5 Clutch hub
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Clutch - Assemble
WARNING
B026
BVF0943A 1
PTO Clutch Assembly Exploded View
1 Circlip 2 PTO clutch plate housing

3 Bearing 4 Circlip
5 Clutch hub
1. Using suitable circlip pliers, install the clutch hub cir-
clip (1).
BVF0942A 2
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2.
NOTE: Make sure that the steel plates are installed alter-
nately as indicated.
BVF0939A 3
3. Install the friction discs and steel plates into the PTO
clutch.
BVF0941A 4
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4. Install the washers (2).

Install the PTO clutch top plate (1).
BVF0940A 5
5. Install the PTO clutch pressure plate. Tighten the

retaining nuts to the specified torque value.
BVF0938B 6
6. Install the PTO clutch shaft. Tighten the retaining

Install a new front PTO clutch shaft O-ring seal (1).
BVF0937C 7
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Clutch - Remove
Prior operation:
Remove the PTO control housing (refer to Housing - Remove (C.42.C)).
WARNING
B026
1. Using suitable circlip pliers, remove the PTO clutch

shaft circlip (1).
BVF0925A 1
2. Remove the PTO clutch (1).
BVF0926A 2
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Clutch - Install
WARNING
B026
1. Install the PTO clutch (1).
BVF0926B 1
2. Using suitable circlip pliers, install the PTO clutch

shaft circlip (1).
BVF0925A 2
Next operation:
Install the PTO control housing (refer to Housing - Install (C.42.C)).
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Housing - Disassemble
Prior operation:
Housing - Remove (C.42.C)
WARNING
B026
BVF0933A 1
PTO Control Housing Exploded View
1 Bearing cover 2 Bearing

3 Dust ring 4 Piston oil seal
5 PTO control housing 6 Piston
7 Piston seal 8 Spring
9 Spring cover 10 Circlip
11 Solenoid valve
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1. Remove the clutch release bearing cover (1) and the

clutch release bearing (2).
BVF0929A 2
2. Rotate the PTO control housing 180 °.

Using suitable circlip pliers, compress the circlip.
BVF0930A 3
3. Remove the piston and spring assembly (1) from the

PTO control housing.
BVF0931A 4
4. Remove the solenoid from the PTO control housing.
BVF0932A 5
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5. Remove and discard the PTO control housing dust

ring (1) and piston oil seal (2).
BVF0934A 6
6. Using a suitable vice, clamp the head of the piston

spring compression bolt (M36 x 4 x 140 mm). Using
the 380001158 Control Piston Spanner release the
spring tension and remove the piston (1).
Remove and discard the piston oil seal (2).
BVF0935A 7
7. Remove the spring (1) and cover (2)
BVF0936A 8
Next operation:
Housing - Assemble (C.42.C)
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Housing - Assemble
Prior operation:
Housing - Disassemble (C.42.C)
WARNING
B026
BVF0933A 1
PTO Control Housing Exploded View
1 Bearing cover 2 Bearing

3 Dust ring 4 Piston oil seal
5 PTO control housing 6 Piston
7 Piston seal 8 Spring
9 Spring cover 10 Circlip
11 Solenoid valve
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1. Install the spring (1) and cover (2)
BVF0936A 2
2. Install a new piston oil seal (2).

Install the piston (1).
Using 380001158 Control Piston Spanner, tighten
the piston to fully compress the spring.
BVF0935A 3
3. Install a new dust ring (1) and a new piston oil seal
(2) into the PTO control housing.
BVF0934A 4
4. Install the solenoid valve into the PTO control hous-

ing.
BVF0932A 5
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5. Partially install the piston and spring assembly (1)

into the PTO control housing.
BVF0931A 6
6. Using suitable circlip pliers, compress the circlip and

fully install the piston into the PTO control housing.
BVF0930A 7
7. Install the clutch release bearing (2) and the clutch

release bearing cover (1).
BVF0929A 8
Next operation:
Housing - Install (C.42.C)
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Housing - Remove
WARNING
B026
1. Lower the front hydraulic lift arms.

Remove the battery cover and disconnect the battery
negative cable (1).
BVE0207A_424 1
2. Remove the PTO output shaft cover (1).
BSE3811A 2
3. Remove the retaining bolts (1) and remove the PTO

guard.
BVF0900A 3
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4. Remove the intercooler (1).
BVF0963A_426 4
5. Remove the front axle support cover plates (1).
BVF0857A_427 5
6. Remove the PTO input shaft cover (1).
BVF0910A 6
7. Using suitable circlip pliers, remove the PTO input

shaft plug circlip (1).
BVF0911A 7
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8. Using a suitable slide hammer and a M12 x 1.75 mm

adaptor, remove the PTO input shaft plug (1).
BVF0912A 8
9. Using a suitable slide hammer and a M12 x 1.50 mm

adaptor, remove the PTO input shaft (1).
BVF0914A 9
If the PTO cannot be engaged

10. Remove the front PTO return pipe (1) and the front
PTO feed pipe (2).
Disconnect the control housing solenoid valve elec-
trical connector (3).
BVF0951A 10
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11. Remove the piston spring compression bolt (M36 x

4 x 140 mm), supplied with the tractor and located in
the front support cover plates.
BVF0919A 11
12. Install the piston spring compression bolt into the

PTO control housing. Using 380001158 Control Pis-
ton Spanner (1), stop the piston from turning. Using
a 50 mm spanner (2). Tighten the piston spring com-
pression bolt to withdraw the piston.
BVF0921A 12
13. If the front PTO can be engaged

Remove the piston spring compression bolt (M36 x
4 x 140 mm), supplied with the tractor and located in
the front support cover plates.
BVF0919A 13
14. Install the piston spring compression bolt (1) into the
PTO control housing and tighten finger tight.
BVF0920A 14
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15. Start the engine and engage the front PTO.

Tighten the piston spring compression bolt (1) into
the PTO control housing.
BVF0922A 15
16. Disengage the PTO and turn off the engine.

Remove the front PTO return pipe (1) and the front
PTO supply pipe (2).
Disconnect the control housing solenoid valve elec-
trical connector (3).
BVF0951A 16
17. Remove the PTO control housing.
BVF0924A 17
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Housing - Install
WARNING
B026
1. Install the PTO control housing. Tighten the retaining

BVF0924B_428 1
2. Install the front PTO return pipe (1) and the front PTO
supply pipe (2).
Connect the control housing solenoid valve electrical
connector (3).
BVF0951A 2
3. Start the engine and engage the front PTO.

Loosen the piston spring compression bolt (M36 x 4
x 140 mm) (1) from the PTO control housing until the
piston spring compression bolt comes into contact
with the pipe.
Disengage the front PTO and turn off the engine.
NOTE: The bolt cannot be removed at this stage.
BVF0922A 3
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4. Remove the piston spring compression bolt (M36 x

4 x 140 mm) (1) from the PTO control housing.
BVF0920A 4
5. Install the PTO input shaft (1).
BVF0915A 5
6. Install the PTO input shaft plug (1).
BVF0913A 6
7. Using suitable circlip pliers, install the PTO input

shaft plug circlip (1).
BVF0911A 7
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8. Install the PTO input shaft cover. Tighten to the spec-

ified torque value.
BVF0910B_429 8
9. Install the PTO guard (1).
BVF0900A 9
10. Install the front axle support cover plates (1).
BVF0857A_427 10
11. install the Intercooler (1).
BVF0963A_426 11
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12. Connect the battery negative cable (1) and install the
battery cover.
BVE0207A_424 12
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FRONT PTO Hydraulic - Troubleshooting

Front PTO not engaging Front PTO is not turned on in machine con- Turn the front PTO on in machine configu-
figurations. rations (refer to Control module - Config-
ure (A.50.A)).
Front PTO solenoid valve not energizing. Check the electrical circuit.
Solenoid valve sticking. Replace the solenoid valve.
Front PTO permanently Piston spring broken. Replace the piston spring.
engaged
Solenoid valve sticking. Replace the solenoid valve.
Low power from the front Fault in the low pressure circuit. Pressure test the low pressure circuit.
PTO output shaft
Front PTO piston oil seals leaking. Overhaul the front PTO control housing.
Front PTO multi-dry plate clutch plates Overhaul the front PTO multi-dry plate
worn. clutch.
Front PTO output shaft oil Worn oil seal. Replace the oil seal and check the level of
seal leak oil in the reduction gearbox.
Excessive oil level in the front PTO reduc- Check the oil level.
tion gearbox.
Front PTO bearings Lack of oil in front PTO reduction gearbox. Check the oil level. If low examine the front
overheated/worn PTO reduction gearbox for leaks.
Incorrect specification oil or old oil in the Replace with the correct specification of oil.
front PTO reduction gearbox.
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Index

Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT PTO Hydraulic - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT PTO Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT PTO Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT PTO Hydraulic - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT PTO Hydraulic - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT PTO Hydraulic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gearbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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PRINTED IN FRANCE
84276322A 31/05/2010
SERVICE MANUAL
AXLES, BRAKES AND STEERING

84276322A 31/05/2010
D
Contents
AXLES, BRAKES AND STEERING - D
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.10.A

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.12.A

2WD-4WD SYSTEM Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.14.C

STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C

SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C

PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

BRAKE CONNECTION Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.34.C

SUSPENSION Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.40.C

WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C

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FRONT AXLE - 10.A

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Contents
FRONT AXLE - 10.A
TECHNICAL DATA
FRONT AXLE
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUNCTIONAL DATA
FRONT AXLE
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bevel gear
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential lock
Hub
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE
FRONT AXLE
Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Remove (Suspended Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install (Suspended axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Axle shaft
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Differential
Overhaul (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Clearance (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Backlash (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Assemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Disassemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Bevel gear
Preload (Standard Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Backlash (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Overhaul (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Preload (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Preload (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Install (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Differential lock
Assemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Assemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Disassemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Disassemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Housing
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Hub
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Install Four Wheel Drive Axle With Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Overhaul Four Wheel Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Remove Four Wheel Drive Axle With Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Support
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Sensing system
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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AXLES, BRAKES AND STEERING - FRONT AXLE
FRONT AXLE - General specification

SPECIFICATIONS (Class 3+ Axle)
Type steering, stress-supporting, centrally pivoted

Pinion and Crown Wheel - Differential
Pinion to crown wheel reduction ratio 10/34 = 1:3.4
Pinion to crown wheel backlash mm 0.18 - 0.23
Cone point adjustment shims mm 2.5 - 2.6 - 2.7 - 2.8 - 2.9 - 3.0 - 3.1 - 3.2 - 3.3 -
3.4 - 3.5 - 3.6 - 3.7
Pinion bearing adjustment shims mm 2.50 - 2.55 - 2.60 - 2.65 - 2.70 - 2.75 - 2.80 - 2.85
- 2.90 - 2.95 - 3.00 - 3.05 - 3.10 - 3.15 - 3.20 -
3.25 - 3.30 - 3.35 - 3.40 - 3.45 - 3.50 - 3.55 - 3.60
- 3.65 - 3.70 - 3.75 - 3.80 - 3.85 - 3.90 - 3.95 -
4.00 - 4.05 - 4.10 - 4.15 - 4.20 - 4.25 - 4.30 - 4.35
- 4.40 - 4.45 - 4.50 - 4.55 - 4.60 - 4.65 - 4.70 -
4.75 - 4.80
Crown wheel point adjustment shims mm 0.9 - 1.0 - 1.1 - 1.2 - 1.3 - 1.4 - 1.5 - 1.6 - 1.7 -
1.8 - 1.9 - 2.0
Side gear to differential gear backlash mm 0.15
Differential gear thrust washer thickness mm 1.470 - 1.530
Side gear thrust washer thickness mm 1.4 - 1.5 - 1.6 - 1.7 - 1.8 - 1.9 - 2.0 - 2.1 - 2.2
Differential gear pin diameter mm 23.939 - 23.960
Pin bore diameter on differential gears mm 24.040 - 24.061
Pins to seats mounting clearance mm 0.080 - 0.122
Side gear hub diameter mm 43.961 - 44.000
Hub bore diameter on differential casing mm 44.019 - 44.080
Side gears to seats mounting clearance mm 0.019 - 0.119
Differential Lock Assembly (Dog
Clutch)
Free spring length mm approximately. 87
Compressed spring length, under a load of 1888 - mm approximately. 48
2035 N (424.4 - 457.5 lb)
Differential Lock Assembly (Multi-Wet
Plate Clutch)
Drive discs mm 1.75 - 1.855
Drive discs quantity 5
Driven discs mm 2.35 - 2.45
Driven discs quantity 6
Axle-Shafts and Swivel Assemblies
Outer axle-shaft diameter at the bushings mm 41.975 - 42.000
Press-fit bushing inner diameter mm 42.100 - 42.175 (final dimension without reaming)
Axle-shafts to bushings mounting clearance mm 0.100 - 0.200
Bushings to seats fitting interference mm 0.064 - 0.129
Swivel pin bearing adjust shims mm 0.10 - 0.15 - 0.20 - 0.25 - 0.30
Planetary Reduction Hubs
Reduction ratio 16:(16+68) = 1:5.25
Planet gear thrust washer thickness mm 0.77 - 0.83
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Auto 4WD/Difflock
Auto 4WD will disengage if: Wheel speed > 20 km/h.
When speed, 10 km/h and steering angle
exceeds selected value.
When the speed is between 10 - 20 km/h and
the steering angle exceeds the selected value.
Auto Difflock will disengage if: Wheel speed > 15 km/h.
Wheel speed < 10 km/h and steering angle
exceeds the selected value.
Rear hitch switch is pressed (1 second delay).
One brake pedal is pressed (will re-engage when
pedal is released).
Inputs required: Wheel speed sensor/radar.
Steering angle sensor.
Rear hitch fast raise/lower switch.
Brake pedal switches.
Auto 4WD or difflock switch.
SPECIFICATIONS (Class 3.5 Axle)
Type steering, stress-supporting, centrally pivoted

Pinion to crown wheel reduction ratio 10/34 = 1:3.4
Pinion to crown wheel backlash mm 0.10 - 0.50
Cone point adjustment shims mm 2.5 - 2.6 - 2.7 - 2.8 - 2.9 - 3.0 - 3.1 - 3.2 - 3.3 -
3.4 - 3.5 - 3.6 - 3.7
Pinion bearing adjustment shims mm 2.50 - 2.55 - 2.60 - 2.65 - 2.70 - 2.75 - 2.80 - 2.85
- 2.90 - 2.95 - 3.00 - 3.05 - 3.10 - 3.15 - 3.20 -
3.25 - 3.30 - 3.35 - 3.40 - 3.45 - 3.50 - 3.55 - 3.60
- 3.65 - 3.70 - 3.75 - 3.80 - 3.85 - 3.90 - 3.95 -
4.00 - 4.05 - 4.10 - 4.15 - 4.20 - 4.25 - 4.30 - 4.35
- 4.40 - 4.45 - 4.50 - 4.55 - 4.60 - 4.65 - 4.70 -
4.75 - 4.80
Crown wheel point adjustment shims mm 0.9 - 1.0 - 1.1 - 1.2 - 1.3 - 1.4 - 1.5 - 1.6 - 1.7 -
1.8 - 1.9 - 2.0
Side gear to differential gear backlash mm 0.15
Differential gear thrust washer thickness mm 1.470 - 1.530
Side gear thrust washer thickness mm 1.4 - 1.5 - 1.6 - 1.7 - 1.8 - 1.9 - 2.0 - 2.1 - 2.2
Differential gear pin diameter mm 23.939 - 23.960
Pin bore diameter on differential gears mm 24.040 - 24.061
Pins to seats mounting clearance mm 0.080 - 0.122
Side gear hub diameter mm 43.961 - 44.000
Hub bore diameter on differential casing mm 44.019 - 44.080
Side gears to seats mounting clearance mm 0.019 - 0.119
Differential Lock Assembly (Multi-Wet
Plate Clutch)
Drive discs mm 1.75 - 1.855
Drive discs quantity 5
Driven discs mm 2.35 - 2.45
Driven discs quantity 6
Axle-Shafts and Swivel Assemblies
Outer axle-shaft diameter at the bushings mm 41.975 - 42.000
Press-fit bushing inner diameter mm 42.100 - 42.175 (final dimension without reaming)
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Axle-shafts to bushings mounting clearance mm 0.100 - 0.200

Bushings to seats fitting interference mm 0.064 - 0.129
Swivel pin bearing adjust shims mm 0.10 - 0.15 - 0.20 - 0.25 - 0.30
Planetary Reduction Hubs
Reduction ratio 16:(16+68) = 1:5.25
Planet gear thrust washer thickness mm 0.77 - 0.83
Auto 4WD/Difflock
Auto 4WD will disengage if: Wheel speed > 20 km/h.
When speed, 10 km/h and steering angle
exceeds selected value.
Auto Difflock will disengage if: Wheel speed > 15 km/h.
Wheel speed < 10 km/h and steering angle
exceeds the selected value.
Rear hitch switch is pressed (1 second delay).
One brake pedal is pressed (will re-engage when
pedal is released).
Inputs required: Wheel speed sensor/radar.
Steering angle sensor.
Rear hitch fast raise/lower switch.
Brake pedal switches.
Auto 4WD or difflock switch.
FRONT AXLE - Special tools
CAUTION
in this manual.
B008
List of special tools necessary to carry out the different operations described in this Section.
380000251 Front axle overhaul stand

X 380000227 Front differential casing removal - installation hook
380000255 Front axle differential casing overhaul fixture
X 380000268 Front axle drive pinion nut spanner
X 380000248 Pinion Bearing Preload adjusting tool
X 380000463 Drive pinion bearing adjustment tool
380001000 Front axle drive pinion retaining tool
X 380000249 Front axle drive pinion cone point adjustment gauge
380000270 Front axle hub bearing pulling aids (two)
380000548 Front axle planetary reduction hub alignment pins (M12 x 1.25)
380000265 Front axle swivel pin puller
380000234 Front axle swivel pin bearing outer race puller
380000235 Front axle bearing rolling torque test tool
380001143 Front axle-shaft to swivel housing mounting guide (Class 3+)
380000240 Front axle differential engagement oil pressure test kit
X 380000600 Front axle drive pinion shimming measurement tool
X 380000269 Front wheel hub bearing ring nut spanner (Class 3+)
X 380000253 Front axle differential casing bearing ring nut spanner
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X 380001115 Suspended axle differential pinion bearing spacer (use with 293391 )
X 380200041 Pinion seal protector installer
X 380200042 Pinion seal installer
LOCALLY FABRICATED TOOLS
•
•
•
• Suspended axle differential casting guide bolts (2 x M16 x 1.5 bolts)
• Suspended axle pinion flange holding tool
• Multi wet-plate differential lock depth gauge adaptor plate
BSB0214A 1
Differential Casting Guide Bolts (Suspended Axles)
BSB0215A 2
Differential Pinion Bearing Setting Spacer (Suspended Axles). Also available as a Special Tool 380001115.
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BVE0544A 3
Pinion Flange Holding Tool (Suspended Axle)
BVE0564A 4
Depth Gauge Adaptor Plate (Multi Wet-Plate Differential Lock)
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FRONT AXLE - Torque
BVE0625A 1
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BAIL09APH181FVA 2
Suspended Front Axle
BVE0626B 3
Dog Clutch Differential Lock
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BVE0551B 4
Multi-Wet Plate Differential Lock
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FRONT AXLE - Static description

The tractors are fitted with a centrally pivoted front axle with support pillars and prop shaft parallel to the tractor centre
line.
The differential assembly includes two planet gears. Drive is transferred to the epicyclic reduction gear hubs by means
of maintenance-free universal joints.
The four wheel drive is actuated by a rocker switch on the right hand console (1). The drive for the axle is provided
via a clutch unit from the rear axle which is activated by oil from the low pressure circuit. When the four wheel drive
is engaged, a solenoid is activated to prevent oil flow to the clutch unit which is then free to engage under spring
pressure. When the four wheel drive is disengaged, low pressure circuit oil is used to release the clutch pack. Refer
to 2WD-4WD SYSTEM Hydraulic - Static description (D.14.C) for more detail.
BRI4019C 1
The axle is equipped with a wet multi-plate clutch differential lock controlled by a rocker switch (1) on the right hand
console When the switch is activated low pressure oil is diverted, via a solenoid valve, to the front and rear axles
and locks all four wheels together for conditions where wheel slip may occur. Refer to Differential lock - Dynamic
description (D.10.A) for more detail.
BRI4019C 2
The four wheel drive and differential lock engagement can be operated in manual mode or auto mode. The auto mode
will automatically engage and disengage the systems depending on operating conditions, such as, wheel speed,
steering angles and hydraulic lift operations (differential lock). The auto mode parameters are set up in the H3 H-Menu
of the RB or RD module, refer to Control module - Configure (A.50.A).
BAIL06CCM239AVC 3
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APH06 and APH07 can be built with any option of 3+ or 3.5 front axle, apart from the Puma 155, which takes the 3.5.
(Documented in PAL/Support Pro as APH Class 4). The class 3+ has 290 mmdiameter cylindrical hubs. The class
3.5 has 362 mm diameter tapered hubs.
BAIL09APH207AVB 4
Class 3+ hub is 290 mm diameter and hub casing is cylindrical.
Class 3+
Axle Type Pinion Shaft Crown Wheel Pinion Nut Torque
Adjustment/Preload
Standard axle with limited Step in pinion shaft 2 x adjusters, preload and Pinion nut 392 N·m (289 lb
slip differential lock backlash ft)
Standard axle with hydraulic Step in pinion shaft Adjusters on RHS shim Pinion nut 392 N·m (289 lb
differential lock (DOG LHS preload and backlash ft)
clutch)
Suspended axle with Spacer on pinion shaft Adjuster on LHS shim RHS 441 N·m (325 lb ft)
hydraulic differential lock preload and backlash
(DOG clutch)
BAIL09APH206AVB 5
Class 3.5 hub is 362 mm diameter and hub casing is tapered.
Class 3.5
Axle Type Pinion Shaft Crown Wheel Pinion Nut Torque
Adjustment/Preload
Standard axle with hydraulic Step in pinion shaft Adjuster on LHS for preload Pinion nut 392 N·m (289 lb
differential lock (wet clutch) only ft)
Suspended axle with Spacer on pinion shaft Adjuster on LHS preload 441 N·m (325 lb ft)
hydraulic differential lock only
(DOG clutch)
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FRONT AXLE - Sectional view
BAIL09APH185GVA 1
Suspended Class 3+ Front Axle Cross Section with Dog Clutch
1. Crown wheel 13. Spring

2. Bearing 14. Thrust washer
3. Differential casing 15. Circlip
4. Bearing 16. Thrust washer
5. Spacer 17. Dog clutch
6. Bearing 18. Piston
7. Pinion nut 19. Bell housing
8. Pinion flange 20. Locking ring
9. Dust cover 21. Dog clutch
10. Pinion seal 22. Circlip
11. Pinion 23. Shim
12. Shim 24. Bearing
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BAIL09APH182GVA 2
Standard Class 3+ Front Axle Cross Section with Limited Slip Differential
1. Crown wheel 9. Circlip

2. Bearing 10. Pinion nut
3. Differential casing 11. Bearing
4. Bearing 12. Shim
5. Pinion 13. Clutch pack
6. Bearing 14. Adjuster ring
7. Pinion seal 15. Bearing
8. Dust cover
84276322A 31/05/2010
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BAIL09APH183GVA 3
Standard Class 3+ Front Axle Cross Section with Dog Clutch
1. Crown wheel 13. Thrust washer

2. Bearing 14. Circlip
3. Differential casing 15. Thrust washer
4. Bearing 16. Dog clutch
5. Pinion 17. Piston
6. Bearing 18. Bell housing
7. Pinion seal 19. Locking ring
8. Dust cover 20. Dog clutch
9. Circlip 21. Circlip
10. Pinion nut 22. Shim
11. Shim 23. Bearing
12. Spring
84276322A 31/05/2010
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BAIL08APH170GVA 4
Suspended Class 3.5 Front Axle Cross Section
1. Crown wheel 9. Dust cover

2. Bearing 10. Pinion seal
3. Differential casing 11. Pinion
4. Bearing 12. Shim
5. Spacer 13. Clutch pack
7. Pinion nut 15. Bearing
8. Pinion flange
84276322A 31/05/2010
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BAIL08APH169GVA 5
Standard Class 3.5 Front Axle Cross Section
1. Crown wheel 9. Circlip

2. Bearing 10. Pinion nut
3. Differential casing 11. Bearing
4. Bearing 12. Shim
5. Pinion 13. Clutch pack
7. Pinion seal 15. Bearing
8. Dust cover
84276322A 31/05/2010
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25814 6
Support Pillars and Planetary Reduction Hub Cross-Sections
1. Front support pillar 6. Rear thrust washer

2. Front support pillar bush 7. Outer axle-shafts
3. Front thrust washer 8. Bushings
4. Rear bush (press-fit into support pillar) 9. Driven gear thrust washers
5. Rear bush (press-fit into pinion support) 10. Swivel pin adjustment shims
84276322A 31/05/2010
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Bevel gear - Exploded view
BVF0841A 1
Suspended Front Axle Pinion (Class 3+ Axle) Components
1 Pinion 2 Pinion depth shim

3 Bearing 4 Spacer
5 Shim 6 O-ring seal
7 Differential casing 8 Pinion nut
9 Pinion flange 10 Dust cover
11 Pinion seal 12 O-ring seal
13 O-ring seal carrier 14 Bearing
84276322A 31/05/2010
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BAIL08APH173GVA 2
Suspended Front Axle Pinion (Class 3.5 Axle) Components
1. Pinion 7. Pinion nut

3. Spacer 9. Dust cover
4. Differential casing 10. Pinion flange
5. Shim 11. Pinion flange bolt
6. Bearing
84276322A 31/05/2010
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BAIL08APH167GVB 3
Standard Front Axle (Class 3.5 Axle) Components
1. Pinion 6. Pinion nut

3. Differential casing 8. Dust cover
4. Shim 9. Circlip
5. Bearing 10. Coupling
84276322A 31/05/2010
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Differential lock - Dynamic description
BVE0442A 1
Front differential lock engaged
Trapped oil
Pressure oil
When the differential lock is disengaged, the solenoid valve is in the discharge position (not energised) and the oil (1)
is free to return to the sump.
84276322A 31/05/2010
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Under these conditions, the clutch piston (2) and the drive and driven discs remain separated and the differential lock
is disengaged.
When the differential lock switch is activated, the solenoid valve opens and directs oil from the low pressure circuit
into the clutch piston (3) locking the differential plates (4).
84276322A 31/05/2010
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Differential lock - Dynamic description
BTB0127B 1
Front differential lock disengaged
Trapped oil
Pressure oil
When the differential lock is disengaged, the solenoid valve is in the discharge position (not energised) and therefore
the oil is free to return to sump.
84276322A 31/05/2010
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Under these conditions, the helix spring (2) keeps the differential lock dog clutch teeth apart.
into the drive piston (1), where it creates a pressure greater than the spring (2) force and moves the piston, locking
the differential.
84276322A 31/05/2010
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Hub - Exploded view
BAIL07APH670GVA 1
1 Spacer 2 Cassette seal

3 Bushing 4 Hub carrier
5 Circlip 6 Bleed nipple
7 Drive gear 8 Sleeve
9 Plate 10 Seals
11 Piston 12 Drive gear
13 Plate 14 Brake disc
15 Drive gear 16 Circlip
17 Carrier
84276322A 31/05/2010
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FRONT AXLE - Remove (Standard axle)
DANGER
B012
NOTE: The front axle assembly can be removed from the tractor with either the propshaft removed from or installed in
the tractor. The following operations detail how to remove the front axle assembly with the propshaft still in the tractor.
1. If front weights are fitted to the front of the tractor re-
move using a suitable hoist with adequate safe work-
ing load.
BSB0181A_344 1

3. Position the splitting kit (1) 380000569 underneath
the tractor.
Use the supports (2) in the splitting kit to support the
engine on the splitting stand.
BVE0314A_345 2
4. Lock the front axle relative to the engine using

wooden wedges. Remove the front wheels.
23699 3
84276322A 31/05/2010
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5. Disconnect the steering cylinder oil supply and oil

return pipes (1).
Disconnect the differential lock oil supply pipe (2) (if
fitted).
BVE0375A 4
6. Disconnect the steering sensor electrical connector

(1) (if fitted).
BVE0289A_346 5
7. Using suitable slings (1), attach the axle to a move-

able overhead hoist.
Remove the front (2) and rear support pillar retaining
bolts and remove the front axle.
BVE0469A 6
Next operation:
FRONT AXLE - Install (Standard axle) (D.10.A)
84276322A 31/05/2010
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FRONT AXLE - Install (Standard axle)

Prior operation:
FRONT AXLE - Remove (Standard axle) (D.10.A)
DANGER
B012
WARNING
B020
1. Using suitable slings (1), attach the axle to a move-

able overhead hoist.
Install the front (2) and rear support pillar retaining
bolts and tighten to the specified torque value.
BVE0469A 1
2. Connect the steering sensor electrical connector (1)

(if fitted).
BVE0289A_346 2
84276322A 31/05/2010
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3. Connect the steering cylinder oil supply and oil return

pipes (1).
Connect the differential lock oil supply pipe (2) (if fit-
ted).
BVE0375A 3
4. Install the front wheels and tighten the retaining bolts

to the specified torque value. Remove the wooden
wedges.
For the tighten torque - see Front wheel - Torque
(D.50.C).
23699 4
5. Remove the supports (2) and the splitting kit (1).
BVE0314A_345 5

84276322A 31/05/2010
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7. If front weights are fitted to the front of the tractor in-

stall using a suitable hoist with adequate safe work-
ing load.
BSB0181A_344 6
84276322A 31/05/2010
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FRONT AXLE - Remove (Suspended Axle)

Prior operation:
DANGER
B012
1. Using suitable lifting equipment support the front

weights.
Disconnect and remove the front weights from the
weight carrier.
BAIL07APH062AVA 1
2. Raise and support the front of the vehicle.

Remove both front wheels.
BAIL07APH064AVA 2
3. Remove both dynamic front fenders (if equipped).
BAIL07APH065AVA 3
84276322A 31/05/2010
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4. Depressurise the suspension system. Locate the

screw (1) of the load sense unload valve, on the
valve block and rotate clockwise, allow the tractor to
lower completely onto the stops then rotate the screw
anti-clockwise to return to normal operation.
BSF4010B 4
5. Support the front of the vehicle and front axle on axle

stands.
BAIL07APH067AVA 5
6. Disconnect the steering supply and return hoses and

the differential lock hose.
BAIL07APH068AVA 6
7. Disconnect the brake hose from the front axle.
BAIL07APH070AVA 7
84276322A 31/05/2010
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8. Disconnect the steering angle sensor and front axle

potentiometer electrical connectors.
BAIL07APH071AVA 8
9. Remove the front axle potentiometer cover.
BAIL07APH072AVA 9
10. Disconnect the front axle potentiometer quick re-

lease clip (1).
Remove the potentiometer retaining bolts (2).
Feed the wiring loom through the tombstone and re-
move the potentiometer.
BAIL07APH073AVA 10
11. Remove the left-hand pivot pin retaining plate (1) and
remove the pin (2).
BAIL07APH074AVA 11
84276322A 31/05/2010
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12. Remove the right-hand pivot pin retaining plate (1)

and remove the pin (2).
BAIL07APH075AVA 12
13. Remove the hydraulic pipe clamp bracket.
BAIL07APH078AVA 13
14. Support the front axle using a suitable hoist and re-
move the axle stands from below the front axle.
BAIL07APH079AVB 14
15. Remove the drive shaft cover plate.
BAIL07APH076AVA 15
84276322A 31/05/2010
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16. Remove the drive shaft bearing carrier.
BAIL07APH077AVA 16
17. Release the circlip (1) and drift the sleeve (2) back-
wards.
BAIL07APH081AVA 17
18. Lower the front axle, while supporting the drive shaft
and suspension arm.
BAIL07APH080AVA 18
19. Remove the front axle from below the vehicle.
BAIL07APH082AVA 19
Next operation:
FRONT AXLE - Install (Suspended axle) (D.10.A)
84276322A 31/05/2010
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FRONT AXLE - Install (Suspended axle)
Prior operation:
FRONT AXLE - Remove (Suspended Axle) (D.10.A)
DANGER
B012
WARNING
B020
1. Locate the front axle while supporting the drive shaft

and suspension arm.
BAIL07APH080AVB 1
2. Support the front axle with axle stands.
BAIL07APH079AVC 2
3. Drift the sleeve back onto the drive shaft (1) and in-
stall the circlip (2) .
BAIL07APH081AVB 3
84276322A 31/05/2010
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4. Install the drive shaft bearing carrier.
BAIL07APH077AVA 4
5. Install the drive shaft cover plate.
BAIL07APH076AVA 5
6. Support the front axle on axle stands and remove the

overhead hoist.
BAIL07APH079AVB 6
7. Install the hydraulic pipe clamp bracket.
BAIL07APH078AVA 7
84276322A 31/05/2010
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8. Install the right-hand pivot pin (1) and install the re-
taining plate (2).
BAIL07APH075AVB 8
9. Install the left-hand pivot pin (1) and install the retain-
ing plate (2).
BAIL07APH074AVB 9
10. Connect the front axle potentiometer quick release

clip (1).
Install the potentiometer retaining bolts (2).
Feed the wiring loom through the tombstone.
BAIL07APH073AVA 10
11. Install the front axle potentiometer cover.
BAIL07APH072AVA 11
84276322A 31/05/2010
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12. Connect the steering angle sensor and front axle po-
tentiometer electrical connectors.
BAIL07APH071AVA 12
13. Connect the brake hose from the front axle.
BAIL07APH070AVA 13
14. Remove the clamp from the brake reservoir hose.
BAIL07APH069AVA 14
15. Connect the steering supply and return hoses and

the differential lock hose.
BAIL07APH068AVA 15
84276322A 31/05/2010
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16. Remove the axle stands from under the axle.
BAIL07APH067AVA 16
NOTE: The screw (1) must be rotate anti-clockwise, gently,

until resting against the internal circlip, to return to normal
operation.
SS09G059 17
17. Install both dynamic front fenders (if equipped).
BAIL07APH065AVA 18
18. Install both front wheels.

Tighten to the specified torque - see Front wheel -
Torque (D.50.C).
BAIL07APH064AVA 19
84276322A 31/05/2010
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19. Using suitable lifting equipment install the front

weights onto the weight carrier.
Secure the front weights to the weight carrier.
BAIL07APH062AVA 20
20. Connect the battery cable - see Battery - Connect

(A.30.A).
84276322A 31/05/2010
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FRONT AXLE - Calibrate

MAXXUM 140
Steering Angle Sensor

BAIL06CCM213AVA 1
NOTE: The illustrations in this procedure depict the DS module (16x16 transmission), and DT module (16x16 trans-
mission with multicontroller), controllers for other transmission variants (DR) will be displayed as appropriate, the
actual steps remain the same as below.
2. Use the "h", "m" and "dimming" keys on the instru-
ment cluster to navigate the HH menu’s to H1 and
the Difflock symbol on the DR (24x24 transmission)
or DS (16x16 transmission) or DT (16x16 transmis-
sion with multicontroller) controller.
The lower central display will show "CAL".
84276322A 31/05/2010
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BAIL09APH266AVA 2
Vehicles with Multicontroller
BAIL09APH267AVA 3
84276322A 31/05/2010
D.10.A / 45
3. Depress the Auto Difflock switch three times.
BAIL06CCM624AVA 4
4. The lower central display will display "ScP" followed

by the current steering sensor reading.
NOTE: If the display shows "-1" then the steering sensor
option needs to be enabled using the H3 menu before the
steering sensor can be calibrated.
5. Turn the steering wheel so that the front wheels are
in line with the drive line.
6. Depress the Auto Difflock switch three times.
BAIL06CCM624AVA 5
7. The top section of the display will display the cali-

brated steering sensor reading and then "End" to in-
dicate the calibration procedure has been completed.
NOTE: If an error occurs during calibration a "U" code will
be displayed and the procedure will need to be repeated.
84276322A 31/05/2010
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FRONT AXLE - Calibrate

Steering Angle Sensor

ment of the tractor, firmly apply the parking brake and block the rear wheels. Check that the Ground speed display is
Zero before commencing.
NOTE: If the vehicle is fitted with AFS AccuGuide™ make sure that the steering angle sensor is connected to the
main engine wiring harness rather than the AutoGuidance wiring harness during the calibration procedure. When
calibration is complete the steering angle sensor should be reconnected to the AutoGuidance harness.
BAIL06CCM213AVA 1
2. Use the "up", "down" and "menu" keys on the ICU3

to navigate the HH menu’s to H1 and the Difflock
symbol on the RV module.
BAIL06CCM225FVH 2
84276322A 31/05/2010
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3. The top section of the display will show "CAL".
BAIL09HHP308AVA 3
4. Press and hold the Auto Difflock switch for 2 sec-

onds.
BAIL08CVT319AVB 4
5. The top section of the display will display "ScP" fol-

lowed by the current steering sensor reading.
NOTE: If the display shows "-1" then the steering sensor
option needs to be enabled using the H3 menu of configure
Instrument Cluster Unit before the steering sensor can be
calibrated. For further information, refer to Control mod-
ule - Configure Instrument Cluster (A.50.A)
If the display shows "-2", this indicates an error with the
steering angle sensor input to the instrument cluster. Re-
view the associated instrument cluster error codes to de-
termine the cause, for further information refer to Control
module - Fault code index (A.50.A).
BAIL09HHP266AVB 5
6. Turn the steering wheel so that the front wheels are

in line with the drive line.
84276322A 31/05/2010
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7. Press and hold the Auto Difflock switch for 2 seconds

to confirm the steering angle position.
BAIL08CVT319AVB 6
8. The top section of the display will show the calibrated

steering sensor value and then "End" to indicate the
calibration procedure has been completed.
BAIL09HHP267AVB 7

NOTE: There are no ’U’ codes available for this calibration
procedure.
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Axle shaft - Install

1. Install the axle shaft into the axle housing.
BAIL07APH580AVA 1
Next operation:
Install the hub, for further information refer to Hub - Install (D.10.A)
84276322A 31/05/2010
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Axle shaft - Remove

Prior operation:
Remove the hub, for further information refer to Hub - Remove (D.10.A)
1. Remove the axle shaft from the axle housing.
BAIL07APH580AVA 1
84276322A 31/05/2010
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Differential - Overhaul (Class 3+ Axle)
WARNING
B026
Pinion Bearing Preload Shimming

1. Remove the pinion bearing from the pinion.
2. Clamp the special tool 380000248 (1) in the vice, fit
the inner races of the bearings (2) and (4) and the
bearing spacer (3) and secure the nut on the tool.
1b0o2004061029 1
3. Using a depth micrometer, measure distance (H1)

between the upper surface of the tool and the cen-
tral threaded pin of the special tool 380000248/
380000463 (1).
Disassemble the above parts, lubricate the bearings
with oil and then re-assemble the parts, excluding the
bearing spacer, in the differential housing. Hold the
differential housing in the vice using the special tool
380000255.
40-25-26 SHG 2
4. Tighten the nut of special tool 380000248/

380000463 (1), while turning the tool to ensure that
the bearings are seated correctly.
Using a depth micrometer, measure distance (H2).
The thickness of the adjustment shim required is cal-
culated by:
Shim S1 = H2 - H1 + 0.05 mm
If necessary, round the value obtained up to the near-
est 0.05 mm.
Leave the special tool in the differential housing for
pinion depth measurement.
40-25-34 SHG 3
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Pinion To Crown Wheel Shimming Procedure

5. The pinion to crown wheel shimming procedure cal-
culates the thickness of shims S2, positioned be-
neath the shoulder of the pinion gear to ensure that
the theoretical conical point of the pinion aligns with
the centre of the differential crown wheel.
Pinion Shimming Dimensions

6. H4 Dimension from Pinion Bearing to Centre line of
Differential Casing
H3 115 mm Manufacturers Pinion Dimension ±C
(Correction Factor)
S2 Shim Thickness
The dimension H4 in the calculation of the shim thick-
ness can be determined by using either the pinion
adjustment special tool 380000249.
Both procedures are explained as follows.
40-25-42 SHG 4
Pinion Shimming using Pinion Adjustment Special Tool 380000249.

7. Install the pinion bearings in differential support
housing and clamp in position using the special tool
380000248/ 380000463 as used when determining
thickness of shims for bearing preload.
1. Pinion Measuring Gauge special tool 380000249

2. Pinion Bearing Clamp. Use special tool
380000248/ 380000463
3. Pinion Bearings
4. Micrometer (Part of special tool 380000249)
17212 5
8. Install the Pinion Setting special tool 380000249

complete with bearing cup and adjusting rings.
Tighten bearing caps to 113 Nm ( 83 lbf).
Adjust the cones of the tool so that the depth microm-
eter tip touches the inner race of the bearing and
measure the dimension (H4).
40-25-39 SHG 6
84276322A 31/05/2010
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9. Determine the thickness of shims to be installed be-

neath the pinion gear as follows:
Shim thickness S2 = H4 - H3
Where:-
H4 = Dimension measured using pinion micrometer
tool
H3 = 115 mm ±C
115 mm is the nominal manufacturing dimension
from rear face of pinion gear to conical point of
pinion.
C = Manufacturing correction factor stamped on face
of pinion.
Example
H4 = 118.27
C = + 0.1 mm 1b0o2004061030 7
H3 = 115 + 0.1 = 115.1 mm
S2 = H4 - H3 = 118.27 - 115.1
Shim Thickness S2 = 3.17 mm.
Pinion Shimming Using Special Tool 380000600.

10. Install bearing caps (less bearing cup) and tighten to
a torque of 113 Nm ( 83 lbf).
Measure internal dimension of bearing bore and call
this dimension A.
1b0o2004061031 8
11. Install pinion bearings in the differential support

housing and clamp in position using the special tool
380000600.
Locate the bar gauge, part of special tool 380000600,
across bearing bore and measure dimension B.
1. Depth Gauge
2. Bar Gauge - Part Of Special Tool 380000600
3. Pinion Shaft Bearings
4. Pinion Setting Gauge - Special Tool 380000600
5. Differential Support Casing
NOTE: Tighten the clamp so that the bearing cones can
just be turned by hand.
1b0o2004061032 9
12. Calculate Dimension H4 using the formula H4 = B -

25* + (A/2)
84276322A 31/05/2010
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13. Determine the thickness of shims S2 to be installed

beneath the pinion gear as follows:
S2 = H4- H3
Where:-
H4 = Dimension calculated in Step 5 above.
H3 = 115 mm ±C
115 mm is the nominal manufacturing dimension
from the rear face of the pinion gear to the conical
point of the pinion.
C = Manufacturing correction factor stamped on the
face of the pinion.
Example
A = 95 mm
B = 95.77 mm
H4 = B - 25* + (A/2)
H4 = 95.77 - 25* + (95/2)
H4 = 118.27
C = 0.1 mm
H3 = 15 + 0.1 = 115.1
Shim Thickness S2 = 118.27 - 115.1 = 3.17 mm.
Pinion Shim and Bearing Installation
40-25-17 SHG 10
Standard Front Axle Pinion Components
1 Pinion Depth Shim 2 Bearing

3 Bearing Cup 4 Differential Housing
5 Nut 6 Dust Cap
7 Seal 8 Ball Bearing
9 Sleeve 10 Bearing
11 Bearing Cup 12 Shim
13 Shim 14 Spacer
15 ‘O’ Ring 16 Pinion
84276322A 31/05/2010
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14. Install the pinion depth shim selected in pinion to

crown wheel shimming procedure in this chapter, be-
tween the pinion head and the bearing. Ensure the
chamfer on the shim faces towards the pinion head.
40-25-9 SHG 11
15. Install the pinion bearing onto the pinion.
1b0o2004061033 12
16.
NOTE: The use of a electronic induction heater will assist in
the installation of the bearings without the need for a press.
396 RA-50 13
84276322A 31/05/2010
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Pinion Bearing Preload Rolling Torque

17. The pinion bearing preload is measured as the
torque or force required to rotate the pinion. The
shim selected in the Pinion Bearing preload shim-
ming procedure on instruction 1 ensures that the
correct preload is achieved when the pinion nut is
tightened to a torque of 294 Nm ( 217 lbf. ft).
Install the inner pinion bearing onto the pinion and
locate the pinion into the differential carrier. Hold the
pinion in position with a universal puller.
NOTE: If the special tool required to determine the thick-
ness of preload shim is not available install the same shim
as removed during disassembly.
19094 14
18. Install the spacer and shims onto the pinion shaft.
Lubricate and install the pinion outer bearing.
19095 15
19. Install the sleeve, ball bearing and the pinion nut. Do
not install the O-ring seal, oil seal and dust shield at
this stage.
Tighten the pinion nut to the specified torque value
of 294 Nm ( 217 lbf. ft).
19097 16
84276322A 31/05/2010
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20. Screw an M12 bolt into end of the pinion shaft or

use the locally fabricated pinion holding tool. Using a
suitable low value torque meter measure the rolling
torque of the pinion A1.
The rolling torque should be 0.5 - 1.0 Nm ( 4.5 - 8.5
lbf in) excluding breakaway torque.
If the values recorded during the adjustment proce-
dure are outside the specification adjust the thick-
ness of shim and recheck bearing preload.
40-25-31 SHG 17
21. When the correct shim thickness has been estab-

lished remove the pinion nut, sleeve and ball and in-
stall the ‘O’ ring and pinion oil seal.
22. Carefully reinstall the sleeve, ball and pinion nut.
NOTE: Attempting to fit the oil seal with the sleeve installed
may damage the oil seal lip.
23. Tighten the pinion nut to a torque value of 294 Nm (
217 lbf. ft) and bend the locking tab.
Measure and record the pinion and seals rolling
torque A1.
84276322A 31/05/2010
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Differential - Install
Prior operation:
Assemble the differential, for further information refer to Differential - Assemble (D.10.A)
1. Clean and degrease the mating surfaces and apply

a bead of gasket sealer approximately 2 mm wide
along the mating surface as indicated.
NOTE: It is advisable that new seals are installed to avoid
any leakages after assembly.
BAIL07APH488AVA 1
2. Install a suitable lifting eye bolt (1) to the pinion shaft.

Attach suitable lifting equipment (2) to the lifting eye
bolt.
BAIL07APH489AVB 2
3. Install the differential into the axle housing, making

sure that the 2 locating dowels are located correctly.
BAIL07APH479AVA 3
84276322A 31/05/2010
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4. Install the differential housing securing bolts and

tighten to 137 Nm (101 lb ft).
BAIL07APH477AVA 4
5. Using suitable lifting equipment, reposition the front

axle on the axle stands.
BAIL07APH491AVA 5
Next operation:
Install the axle shafts, for further information refer to Axle shaft - Install (D.10.A)
84276322A 31/05/2010
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Differential - Clearance (Class 3+ Axle)

1. The end float required between the sun and planet
gears is 0.25 mm. To calculate the size of thrust
washer required, carry out the following:
2. Using a depth gauge and the locally fabricated depth
gauge adaptor plate, measure against the front of the
sun gear. Do this measurement in two opposite po-
sitions and take a mean calculation of the two read-
ings. This measurement is H1.
BVE0574A 1
3. Carry out the same measurement again but using

only one thrust washer as a test shim. This mea-
surement is H2
4. Determine the thickness of the shim to be installed
as follows:
Remove the thrust washer and measure the thick-
ness. This measurement is S1.
Thrust washer size = (H2 - H1) + S1 - 0.25 mm.
5. Install the new calculated thrust washer (1) and the
sun gear (2) into the differential cage (3).
BVE0570A 2
6. Install the crown wheel onto the differential cage.

value.
BVE0590A 3
84276322A 31/05/2010
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7. Install two thrust washers (1) and the sun gear (2)
into the differential cage (3).
NOTE: Two thrust washers are required to lock the sun
gear against the planet gears. These can be the original
thrust washer and a new thrust washer or two new thrust
washers.
BVE0576A 4
8. Hand tighten the clutch pack cover retaining bolts.

NOTE: Make sure the clutch pack cover is fitted evenly.
BVE0577A 5

BVE0578A 6

surement is H2.
as follows:
84276322A 31/05/2010
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BVE0575A 7
84276322A 31/05/2010
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Differential - Backlash (Class 3+ Axle)

NOTE: In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the planet
pinions and side gears. Proceed as follows:
1. Thoroughly clean the components of the differential
to remove any traces of oil which would otherwise
prevent accurate backlash measurement.
Install the two side gears without thrust washers.
Fit the planet gears complete with thrust washers and
pins and screw the pin retaining bolts in by a few
turns to hold the pins in place.
Position a dial gauge on the differential housing.
Move the left-hand side gear to bring it into full con-
tact with the planet pinion and then push it up against
the differential housing, reading the end float (Gs) on
the dial gauge.
1b0o2004061023 1
2. Repeat the above operations to measure the end

float on the right-hand side gear (Gd).
Therefore the shims to be inserted in the differential
housing are given by:
S (L.H). = Gs - 0.25 mm for the left-hand side gear;
S (L.H). = Gd - 0.25 mm for the right-hand side gear.
Install shims as near as possible to the calculated
value, and, using a dial gauge and following the pro-
cedure described above, check that the end float of
the left and right-hand side gears is approximately
0.25 mm.
1b0o2004061024 2
Next operation:
Bevel gear - Remove (D.10.A).
84276322A 31/05/2010
D.10.A / 64
Differential - Remove
Prior operation:
Remove the front axle, for further information refer to FRONT AXLE - Remove (D.10.A) (suspended axle), , FRONT
AXLE - Remove (D.10.A) (standard axle).
Prior operation:
Remove the axle shafts, for further information refer to Axle shaft - Remove (D.10.A).
DANGER
B012
1. Using suitable lifting equipment turn the front axle so

that the differential housing is facing upwards.
BAIL07APH584AVA 1
2. Remove the differential housing bolts.
BAIL07APH477AVA 2
3. Install a suitable lifting eye bolt (1) to the pinion shaft

.
Attach suitable lifting equipment (2) to the lifting eye
bolt.
BAIL07APH478AVA 3
84276322A 31/05/2010
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4. Remove the differential.
BAIL07APH479AVA 4
Next operation:
Differential lock - Disassemble (D.10.A).
84276322A 31/05/2010
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Differential - Assemble (Class 3.5 Axle)
DANGER
B012
WARNING
B026
BVE0583A 1
Illustration showing the differential cage and planet gear assembly layout.
1. Thrust washer 5. Planet gear

2. Planet gear 6. Thrust washer
3. Planet gear shaft locking pin 7. Differential cage
4. Planet gear shaft
1. Install the planet gear shaft, planet gears and thrust
washers.
BAIL07APH571AVB 2
84276322A 31/05/2010
D.10.A / 67
2. Install the planet gear shaft locating pin through the

bolt hole within the differential cage.
BAIL07APH572AVA 3
3. Install the sun gear.
BAIL07APH597AVA 4
4. Install the thrust washer.
BAIL07APH596AVA 5
5. Install the crown wheel (1) and bearing (2).
BAIL07APH595AVA 6
84276322A 31/05/2010
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6. Install the crown wheel retaining bolts and tighten to

136 Nm (100 lb ft).
BAIL07APH594AVA 7
7. Install the spacer (1) and the bearing cup (2).
BAIL07APH593AVA 8
8. Install the differential assembly into the housing.
BAIL07APH592AVA 9
9. Install the support caps.

Note the locating pin (1) and groove (2) into which it
locates.
BAIL07APH575AVA 10
84276322A 31/05/2010
D.10.A / 69
10. Install the support cap retaining bolts finger tight.
BAIL07APH573AVB 11
11. Using special tool 293665 or 380000253, install the

adjuster ring.
BAIL07APH574AVA 12
12. Tighten the support cap retaining bolts to 130 Nm (96

lb ft).
BAIL07APH573AVB 13
13. Adjust the backlash.

For further information refer to Bevel gear - Back-
lash (D.10.A).
14. Tighten the adjuster ring locking grub screw.
BAIL07APH604AVA 14
84276322A 31/05/2010
D.10.A / 70
Next operation:
Refer to Differential - Install (D.10.A)
84276322A 31/05/2010
D.10.A / 71
Differential - Disassemble (Class 3+ Axle)

Prior operation:
Disassemble the multi-plate differential lock clutch, for further information refer to Differential lock - Disassemble
(D.10.A).
WARNING
B026
1. Using a suitable puller, remove the clutch pack cover

bearing.
BVE0584A 1
2. Remove the thrust washer (1) and sun gear (2) from
the differential cage (3).
BVE0575A 2
3. Remove the crown wheel from the differential cage.
BVE0580A 3
84276322A 31/05/2010
D.10.A / 72
4. Using a suitable puller, remove the crown wheel

bearing.
BVE0587A 4
5. Remove the thrust washer (1) and sun gear (2) from
the differential casing (3).
BVE0570A 5
6. Using a suitable drift, remove the planet gear shaft

locking pin (1) from the differential cage.
BVE0582A 6
84276322A 31/05/2010
D.10.A / 73
BVE0583A 7
1. Thrust washer 5. Planet gear

2. Planet gear 6. Thrust washer
3. Planet gear shaft locking pin 7. Differential cage
4. Planet gear shaft
Next operation:
Differential - Assemble (D.10.A).
84276322A 31/05/2010
D.10.A / 74
Differential - Disassemble (Class 3.5 Axle)

Prior operation:
Differential - Remove (D.10.A)
DANGER
B012
WARNING
B026
1. Place the differential assembly on a suitable work-

bench.
Loosen the adjuster ring locking grub screw (1).
Loosen the support caps retaining bolts (2).
BAIL07APH573AVA 1
2. Using special tool 293665 or 380000253, remove the

adjuster ring.
BAIL07APH574AVA 2
3. Remove the retaining bolts and remove the support

caps.
BAIL07APH573AVB 3
84276322A 31/05/2010
D.10.A / 75
4. Remove the differential assembly from the differen-

tial housing.
BAIL07APH592AVA 4
5. Remove the spacer (1) and the bearing cup (2).
BAIL07APH593AVA 5
6. Using a suitable vice fitted with soft jaws, secure the

differential assembly.
BAIL07APH576AVA 6
7. Remove the crown wheel retaining bolts.
BAIL07APH594AVA 7
84276322A 31/05/2010
D.10.A / 76
8. Using a suitable puller, remove the bearing (1).

Remove the crown wheel (2).
BAIL07APH595AVA 8
9. Remove the thrust washer.
BAIL07APH596AVA 9
10. Remove the sun gear.
BAIL07APH597AVA 10
11. Remove the planet gear shaft locating pin.
BAIL07APH572AVA 11
84276322A 31/05/2010
D.10.A / 77
12. Remove the planet gear shaft, planet gears and

thrust washers.
BAIL07APH571AVB 12
BVE0583A 13
Illustration of the differential cage and planet gear assembly layout.
1 Thrust washer 2 Planet gear

3 Planet gear shaft locking pin 4 Planet gear shaft
5 Planet gear 6 Thrust washer
7 Differential cage
Next operation:
Differential - Backlash (D.10.A).
84276322A 31/05/2010
D.10.A / 78
Bevel gear - Preload (Standard Class 3.5 Axle)
WARNING
B026
1. Install the inner bearing (1) onto the pinion shaft.
BAIL09APH213AVG 1
2. Using a suitable depth gauge micrometer, measure

the distance from the top of the pinion shaft to the
shoulder to obtain measurement (L).
BAIL08APH161AVA 2
3. Using a suitable micrometer, measure the thickness

of the pinion nut to obtain measurement (G).
BAIL08APH164AVA 3
84276322A 31/05/2010
D.10.A / 79

of pinion outer bearing to obtain the measurement
(C).
NOTE: Take the measurement of the inner race only.
BAIL08APH165AVA 4
5. Install the pinion shaft complete with bearings and

pinion nut into the differential housing.
NOTE: Do not install the preload adjustment shim at this
stage.
BAIL09APH213AVE 5
6. Slowly tighten the pinion nut until the rolling torque

of the pinion shaft bearings is between 0.49 N·m
(0.3614 lb ft) and 0.98 N·m (0.7228 lb ft).
NOTE: Make sure that the bearings are seated correctly
by turning the pinion shaft during tightening. If the rolling
torque figure is lower than the specified value, tighten the
pinion nut. If the rolling torque figure is higher than the
specified value, loosen the pinion nut.
BAIL08APH162AVA 6
7. Measure the distance between the top of the pinion

shaft and the flat edge of the pinion nut to obtain
measurement (L1).
NOTE: As shown in instruction 5.
BAIL08APH163AVA 7
84276322A 31/05/2010
D.10.A / 80
8. Using the previously recorded measurements calcu-

late the required thickness of the bearing preload ad-
justment shim to obtain measurement (S).
The bearing preload adjustment shim (1) will be cal-
culated as follows:
(S) = L- L1-C-G +0.05mm.
For information on available shims refer to FRONT
AXLE - General specification (D.10.A).
BAIL09APH213FVB 8
9. Remove the pinion shaft from the differential hous-

ing. Install the correct thickness preload adjustment
shim (1) and reassemble the pinion shaft into the dif-
ferential housing.
Lubricate the bearings.
Apply LOCTITE® 243 to the threads of the pinion nut.
BAIL09APH213AVF 9
84276322A 31/05/2010
D.10.A / 81
10. Using special tool 380000268 (1) to hold the pinion

nut and special tool 380000257 (2) to rotate the pin-
ion counter clockwise, slowly tighten the pinion to
392 N·m (289 lb ft).
BAIL08APH166AVA 10
11. Using a suitable torque wrench, check that the rolling

torque of the pinion shaft bearings is between 0.49
N·m (0.3614 lb ft) and 0.98 N·m (0.7228 lb ft).
BAIL08APH162AVA 11
12. Stake the pinion nut.

13. Using special tool 380200042 (1), install the pinion
shaft seal (2).
BAIL08APH175AVA 12
14. Using special tool 380200041 (1), install the pinion

shaft seal protector (2).
BAIL08APH176AVA 13
84276322A 31/05/2010
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Bevel gear - Backlash (Class 3.5 Axle)

1. Using special tool 293876, lock the pinion to prevent
it from rotating.
2. Measure the backlash between the pinion and crown
wheel using a dial gauge (1) perpendicular to the
outer edge of a tooth on the crown wheel.
Repeat the measurement in a further two positions
120 ° apart and compare the average of the three
values with the backlash specification: 0.10 - 0.50
mm.
Using special tool 293665 (2), adjust the locking ring
until the backlash is between 0.10 mm - 0.50 mm.
Rotate the crown wheel 360 ° and repeat the mea-
surement.
BAIL08APH172AVA 1
84276322A 31/05/2010
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Bevel gear - Overhaul (Class 3+ Axle)

Prior operation:
Differential - Disassemble (D.10.A)

BVE0574A 1

surement is H2
as follows:
BVE0570A 2
84276322A 31/05/2010
D.10.A / 84
6. Install the crown wheel onto the differential cage.

Tighten the retaining bolts to 136 Nm (100 lb ft).
BAIL07APH594AVA 3
7. Install two thrust washers (1) and the sun gear (2)
into the differential cage (3).
NOTE: Two thrust washers are required to lock the sun
gear against the planet gears. These can be the original
thrust washer and a new thrust washer or two new thrust
washers.
BVE0576A 4
8. Hand tighten the clutch pack cover retaining bolts.

NOTE: Make sure the clutch pack cover is fitted evenly.
BVE0577A 5

84276322A 31/05/2010
D.10.A / 85

BVE0578A 6

surement is H2.
as follows:
BVE0575A 7
Next operation:
. Differential - Assemble (D.10.A)
84276322A 31/05/2010
D.10.A / 86
Bevel gear - Preload (Class 3+ Axle)

Dog Clutch Differential Lock
1. The differential bearing preload is checked by mea-
suring the combined rolling torque of the crown wheel
and pinion assembly and comparing it to the pinion
and seals rolling torque value A1 ( Bevel gear - In-
stall (D.10.A)).
Attach a torque meter to the pinion shaft and mea-
sure the rolling torque to rotate the pinion and crown
wheel A2.
19109 1
2. Subtract from the rolling torque reading A2 described

above, the pinion only rolling torque A1.
The difference between the two values should be 1 -
15 Nm, ( 9 - 13 lbf in).
If the rolling torque of the pinion and differential as-
sembly is not to specification adjust the ring ‘oppo-
site’ the crown wheel to increase or reduce differen-
tial bearing preload. Recheck the rolling torque as
detailed above.
Refit the lock tabs to secure the adjusting ring(s).
1b0o2004061036 2
3. EXAMPLE
Rolling torque of Pinion and Differential
A2 = 2.1 Nm ( 19 lbf in)
Rolling torque of Pinion
A1 = 0.7 Nm ( 6 lbf in)
Calculated Rolling Torque of Differential
= 2.1 - 0.7 Nm ( 19 - 6 lbf in)
= 1.4 Nm ( 13 lbf in)
Next operation:
Housing - Assemble (D.10.A).
84276322A 31/05/2010
D.10.A / 87
Bevel gear - Preload (Class 3+ Axle)

Multi Wet-Plate Differential Lock
1. The differential bearing preload is checked by mea-
suring the combined rolling torque of the crown wheel
and pinion assembly and comparing it to the pinion
and seals rolling torque value A1 ( Bevel gear - In-
stall (D.10.A)).
Attach a torque meter to the pinion shaft and mea-
sure the rolling torque to rotate the pinion and crown
wheel A2.
19109 1
2. Subtract from the rolling torque reading A2, the pin-

ion and seals rolling torque A1. The difference be-
tween the two values should be 1 - 1.5 Nm ( 9 - 13
lbf in).
3. Adjust the right-hand locking ring until the rolling
torque is within the specification quoted in the pre-
vious step.
4. Rotate the crown wheel and pinion through 360 °.
5. Recheck the backlash, adjust as necessary.
6. Rotate the crown wheel and pinion through 360 °.
7. Recheck the differential bearing preload, adjust as
necessary.
8. Tighten the differential assembly side cap retaining
BVE0588A 2
84276322A 31/05/2010
D.10.A / 88
9. Install the locking ring lock tabs.

Using a lifting hoist, remove the differential support
from the tool and remove the special tool 380000255
from the vice on the work bench.
BVE0559B 3
Next operation:
Bevel gear - Backlash (D.10.A).
84276322A 31/05/2010
D.10.A / 89
Bevel gear - Backlash (Class 3+ Axle)

Adjustment of the crown wheel bearings and the backlash between the pinion and crown wheel.
1. Install the differential assembly complete with crown

wheel and inner crown wheel bearing rings in the
differential housing.
24112 1
2. Insert the outer bearing rings in the differential hous-

ing, fit the differential support caps (4), ensuring cor-
rect orientation of the threaded adjustment ring (3),
smooth edge facing outwards.
TAG25017_348 2
3. Tighten the retaining bolt to the specified torque

value of 59 Nm, then slacken the retaining bolts and
re-tighten to a torque of 20 Nm.
1b0o2004061034 3
84276322A 31/05/2010
D.10.A / 90
4. Measure the thickness Sp of the adjustment shim

(2) which was previously removed during the axle
overhaul procedure. Refit the shim and circlip (3).
TAG25019_349 4
5. With the bearings lubricated, rotate the crown wheel

and at the same time tighten the threaded adjustment
ring using the special tool 380000253 (1) to the spec-
ified torque value of 39 - 59 Nm to take up the axial
play between the components.
1b0o2004061035 5
6. Measure the backlash between pinion and crown

wheel, using a dial gauge perpendicular to the outer
edge of a tooth on the crown wheel.
7. Repeat the measurement in a further two positions
values (Gm) with the specification backlash: 0.15 -
0.20 mm, with an average of 0.18 mm.
If the measured backlash exceeds the specified
value, fit a thinner adjustment shim (2).
The thickness of the adjustment shim to be fitted in
the differential housing is given by:
Shim S = Sp - {(Gm - 0.18 ) x 1.35}
where:
Sp = thickness of test shim installed in the differential
housing. i.e. original shim used as a test shim.
Gm = average backlash measured between the pin-
ion and crown wheel
If the backlash measured is less than the prescribed TAG25019_349 6
value, fit a thicker adjustment shim (2), the value be-
ing given by:
Shim S = Sp + {( 0.18 - Gm) x 1.35}
Recheck the backlash and adjust shim if necessary.
Next operation:
Bevel gear - Preload (D.10.A).
84276322A 31/05/2010
D.10.A / 91
Bevel gear - Backlash (Class 3+ Axle)

Adjustment of the crown wheel bearings and the backlash between the pinion and crown wheel.
1. Using the locally fabricated flange holding tool, lock

the pinion flange to prevent it from rotating.
2. Measure the backlash between the pinion and crown
wheel using a dial gauge perpendicular to the outer
edge of a tooth on the crown wheel.
Repeat the measurement in a further two positions
values (Gm) with the specification backlash: 0.15 -
0.20 mm.
BVE0567A 1
3. Adjust the left-hand locking ring until the backlash

is between 0.15 mm - 0.20 mm. Rotate the crown
wheel 360 ° between each reading.
BVE0563A 2
84276322A 31/05/2010
D.10.A / 92
Bevel gear - Install (Class 3+ Axle)
WARNING
B026
Pinion Bearing Preload Shimming

1. Remove the pinion bearing from the pinion.
2. Clamp the special tool 380000248 (1) in the vice, fit
the inner races of the bearings (2) and (4)and the
bearing spacer (3) and secure the nut on the special
tool.
1b0o2004061029 1
3.
NOTE: The pinion of all the Suspended front axles is
shorter and special tool 380000248 and 380000463 re-
quires a spacer, special tool No. 380001115 to be inserted
under the lower bearing (4). The spacer can be manufac-
tured locally using the dimensions shown in FRONT AXLE
- Special tools (D.10.A)
BSB0223A 2
4. Using a depth micrometer, measure the distance

(H1) between the upper surface of the special tool
and the central threaded pin of the special tool
380000248/ 380000463 (1).
Disassemble the above parts, lubricate the bearings
with oil and then re-assemble the parts, excluding the
bearing spacer, in the differential housing.
40-25-26 SHG 3
84276322A 31/05/2010
D.10.A / 93
5. Tighten the nut of the special tool 380000248/

380000463 (1), while turning the special tool to
ensure that the bearings are seated correctly.
Install spacer for Suspended front axle.
Using a depth micrometer, measure distance (H2).
The thickness of the adjustment shim required is cal-
culated by:
Shim S1 = H2 - H1 + 0.05 mm
If necessary, round the value obtained up to the near-
est 0.05 mm.
Leave the special tool in the differential housing for
the pinion depth measurement.
40-25-34 SHG 4
Pinion To Crown Wheel Shimming Procedure

6. The pinion to crown wheel shimming procedure cal-
culates the thickness of shims S2, positioned be-
neath the shoulder of the pinion gear to ensure that
the theoretical conical point of the pinion aligns with
the centre of the differential crown wheel.
Pinion Shimming Dimensions

7. H4 Dimension from Pinion Bearing to Centre line of
Differential Casing
H3 115 mm Manufacturers Pinion Dimension ±C
(Correction Factor) or 122.5 mm ±C for class IV
axles
S2 Shim Thickness
The dimension H4 in the calculation of the shim thick-
ness can be determined using the pinion adjustment
special tool 380000249
Both procedures are explained as follows.
40-25-42 SHG 5
Pinion Shimming using Pinion Adjustment Tool 380000249.

8. Install pinion bearings in differential support housing
and clamp in position using special tool 380000248/
380000463 as used when determining thickness of
shims for bearing preload.
1. Pinion Measuring Gauge special tool 380000249

2. Pinion Bearing Clamp. Use special tool
380000248/ 380000463
3. Pinion Bearings
4. Micrometer (Part of special tool 380000249 )
17212 6
84276322A 31/05/2010
D.10.A / 94
9. Install the Pinion Setting special tool 380000249

complete with bearing cup and adjusting rings.
Tighten the bearing caps retaining bolts to the spec-
ified torque value of 113 Nm ( 83 lbf).
Adjust the cones of the special tool so that the depth
micrometer tip touches the inner race of the bearing
and measure the dimension (H4).
BVE0566A 7
10. Determine the thickness of shims to be installed be-

neath the pinion gear as follows:
Shim thickness S2 = H4- H3
Where:-
H4 = Dimension measured using pinion micrometer
tool
H3 = 115 Nm ±C
115 Nm is the nominal manufacturing dimension
from rear face of pinion gear to conical point of
pinion.
C = Manufacturing correction factor stamped on face
of pinion.
Example
H4= 118.27
C = +0.1 mm 1b0o2004061030 8
H3 = 115 + 0.1 = 115.1 mm
S2 = H4 - H3 = 118.27 - 115.1
Shim Thickness S2 = 3.17 mm.
11. Refer to Bevel gear - Exploded view (D.10.A).
12. Install the pinion depth shim selected in pinion to
crown wheel shimming procedure in this chapter, be-
tween the pinion head and the bearing. Ensure the
chamfer on the shim faces towards the pinion head.
40-25-9 SHG 9
84276322A 31/05/2010
D.10.A / 95
13. Install the pinion bearing onto the pinion.
1b0o2004061033 10
14.
NOTE: The use of a electronic induction heater will assist in
the installation of the bearings without the need for a press.
396 RA-50 11
Pinion Bearing Preload Rolling Torque

15. The pinion bearing preload is measured as the
torque or force required to rotate the pinion. The
shim selected in the Pinion Bearing preload shim-
ming procedure on instruction 1 ensures that the
correct preload is achieved when the pinion nut is
tightened to a torque of 294 Nm ( 217 lbf. ft).
Install the inner pinion bearing onto the pinion and
locate the pinion into the differential carrier. Hold the
pinion in position with a universal puller.
NOTE: If the special tool required to determine the thick-
ness of preload shim is not available install the same shim
as removed during disassembly.
19094 12
84276322A 31/05/2010
D.10.A / 96
16. Install the spacer and shims onto the pinion shaft.
Lubricate and install the pinion outer bearing.
NOTE: Do not install the pinion seal and dust cover.
19095 13
17. Install the pinion flange and retaining nut.

Using the locally fabricated pinion flange holding tool.
Tighten the retaining nut to the specified torque value
of 294 Nm ( 217 lbf. ft).
BVE0591A 14
18. Using a suitable low value torque meter measure the

rolling torque of the pinion A1.
The rolling torque should be 0.5 - 1.0 Nm ( 4.5 - 8.5
lbf in) excluding breakaway torque.
19. If the values recorded during the adjustment proce-
dure are outside the specification adjust the thick-
ness of shim and recheck bearing preload.
20. When the correct shim thickness has been estab-
lished, remove the pinion flange retaining nut and the
pinion flange.
Install the dust cover (1), pinion seal (2) and pinion
bearing (3) to the differential casing.
BVE0593A 15
84276322A 31/05/2010
D.10.A / 97
21. Install the pinion flange and retaining nut.

Using the locally fabricated pinion flange holding tool.
Tighten the retaining nut to the specified torque value
of 294 Nm ( 217 lbf. ft).
Measure and record the pinion and seals rolling
torque A1.
BVE0591A 16
Next operation:
Bevel gear - Backlash (D.10.A).
84276322A 31/05/2010
D.10.A / 98
Bevel gear - Remove

suspended axle
1. Using a locally fabricated pinion flange holding tool,
remove the pinion retaining nut and pinion flange.
BVE0591A 1
2. Remove the dust cover (1), pinion seal (2) and pinion
bearing (3) from the differential casing.
BVE0593A 2
3. Withdraw the pinion shaft (1) from the rear of the

differential casing and remove the spacer.
BVE0592A 3
Next operation:
Bevel gear - Install (D.10.A).
84276322A 31/05/2010
D.10.A / 99
Differential lock - Assemble (Class 3+ Axle)

Prior operation:
Differential lock - Disassemble (D.10.A)
1. 1. Differential assembly
2. Shim (Backlash)
3. Circlip
4. Dog clutch
5. Lock ring
TAG25019 1
2. 1. Dog clutch
2. Thrust washer
3. Return spring
4. Piston O-ring seal 2
5. Hub
6. Lock ring
7. Circlip
TAG25016 2
Next operation:
Differential - Assemble (D.10.A)
84276322A 31/05/2010
D.10.A / 100
Differential lock - Assemble (Class 3.5 Axle)

Prior operation:
Differential lock - Disassemble (D.10.A)
WARNING
B026
BAIL07APH603AVA 1
2. Install the clutch discs (1) into the differential cage.
BVE0581A 2
3. Install the thrust washer.
BAIL07APH602AVA 3
84276322A 31/05/2010
D.10.A / 101
4. Apply transmission oil to the O-ring seals.

Install the clutch piston (1) to the clutch pack cover
(2).
NOTE: Install new O-ring seals as required.
BVE0585A 4
5. Install the clutch pack cover and bearing onto the

differential cage.
BAIL07APH601AVA 5
6. Install the clutch pack cover retaining bolts finger

tight.
BAIL07APH600AVA 6
7. Tighten the crown wheel retaining bolts to 136 Nm

(100 lb ft).
BAIL07APH600AVA 7
84276322A 31/05/2010
D.10.A / 102
BAIL07APH599AVA 8
BAIL07APH593AVA 9
10. Install the differential assembly into the housing.
BAIL07APH592AVA 10
11. Install the support caps.

Note the locating pin (1) and groove (2) into which it
locates.
BAIL07APH575AVA 11
84276322A 31/05/2010
D.10.A / 103
12. Install the support cap retaining bolts finger tight.
BAIL07APH573AVB 12
13. Using special tool 293665 or 380000253, install the

adjuster ring.
BAIL07APH574AVA 13
14. Tighten the support cap retaining bolts to 130 Nm (96

lb ft).
BAIL07APH573AVB 14
15. Adjust the backlash.

For further information refer to Bevel gear - Back-
lash (D.10.A).
16. Tighten the adjuster ring locking grub screw.
BAIL07APH604AVA 15
84276322A 31/05/2010
D.10.A / 104
17. Exploded view of components
BAIL08APH168FVA 16
1. Bearing cup 7. Oil seal

2. Bearing 8. Oil manifold
3. Differential housing 9. Oil seal
4. Bearing 10. Shim
5. Bearing cup 11. Locking ring
6. Dust cover 12. O-ring seal
Next operation:
Refer to Differential - Install (D.10.A)
84276322A 31/05/2010
D.10.A / 105
Differential lock - Disassemble (Class 3+ Axle)

Prior operation:
Differential - Remove (D.10.A)
1. Remove the two bolts securing the external bell

housing (1) of the differential lock, and fit in their
place two bolts with minimum length 70 mm. Grad-
ually remove the four remaining bolts from the
external bell housing of the differential lock so as to
allow the differential lock release spring to gradually
extend.
NOTE: It is necessary to fit two bolts because the nor-
mal bell housing bolts are not sufficiently long to allow the
spring to extend to its full free length.
TAG21017 1
2. Remove the last two 70 mm bolts. Remove the bell

housing (1), the helical spring (2) and the differential
lock piston.
25609 2
3. Remove circlip (2) and remove the differential lock

sleeve.
25610 3
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4. Remove the circlip securing the differential lock pis-

ton, and retrieve the sliding sleeve with the two thrust
washers.
1b0o2004061021 4
5. Using a suitable drift gently tap the piston out of the

clutch bell housing.
1b0o2004061022 5
6. 1. Differential assembly
2. Shim (Backlash)
3. Circlip
4. Dog clutch
5. Locking ring
TAG25019 6
7. 1. Dog clutch
2. Thrust washer
3. Return spring
4. Piston O-ring seals 2
5. Hub
6. Locking ring
7. Circlip
TAG25016 7
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Next operation:
Differential - Disassemble (D.10.A).
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Differential lock - Disassemble (Class 3.5 Axle)

Prior operation:
Differential - Remove (D.10.A).
WARNING
B026
1. Place the differential assembly on a suitable work-

bench.
Loosen the adjuster ring locking grub screw (1).
Loosen the support caps retaining bolts (2).
BAIL07APH573AVA 1
2. Using special tool 293665 or 380000253, remove the

adjuster ring.
BAIL07APH574AVA 2
3. Remove the retaining bolts and remove the support

caps.
BAIL07APH573AVB 3
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4. Remove the differential assembly from the housing.
BAIL07APH592AVA 4
BAIL07APH593AVA 5
BAIL07APH599AVA 6
7. Using a suitable vice fitted with soft jaws, secure the

differential assembly.
Remove the clutch pack cover retaining bolts.
BAIL07APH600AVA 7
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8. Remove the clutch pack cover from the differential

cage.
BAIL07APH601AVA 8
9. Remove the clutch piston (1) from the clutch pack

cover (2).
BVE0585A 9
10. Remove the thrust washer.
BAIL07APH602AVA 10
11. Remove the clutch discs (1) from the differential

cage.
BVE0581A 11
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BAIL07APH603AVA 12
Next operation:
Differential - Disassemble (D.10.A).
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Housing - Assemble
1. Using a suitable tool, install the brass lubricating
bushing into the axle housing.
BAIL07APH667AVA 1
2. Using a suitable tool, install the cassette seal.
BAIL07APH666AVA 2
3. Using a suitable tool, install the brass protection

washer.
BAIL07APH668AVA 3
Next operation:
Install the differential, for further information refer to Differential - Install (D.10.A).
Next operation:
Install the steering cylinders, for further information refer to Steering cylinder - Install (D.20.C).
84276322A 31/05/2010
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Housing - Disassemble
Prior operation:
Remove the steering cylinders, for further information refer to Steering cylinder - Remove (D.20.C).
Prior operation:
Remove the differential, for further information refer to Differential - Remove (D.10.A).
1. Remove the brass protection washer from the hub

carrier.
BAIL07APH668AVA 1
2. Remove the cassette seal.
BAIL07APH666AVA 2
3. Remove the brass lubricating bushing.
BAIL07APH667AVA 3
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Hub - Assemble
DANGER
B012
All vehicles
1. Using a suitable tool, install the brass lubricating
bushing into hub carrier.
BAIL07APH667AVA 1
2. Using a suitable tool, install the cassette seal.
BAIL07APH666AVA 2
3. Using a suitable tool, install the brass protection

washer.
BAIL07APH665AVA 3
84276322A 31/05/2010
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4. Using suitable lifting equipment, support the hub car-

rier.
Install the hub carrier assembly.
BAIL07APH581AVA 4
NOTE: When installing the right-hand side upper swivel pin

assembly, take care to avoid damaging the steering sensor
located within the housing.
BAIL07APH475AVA 5
5. Install the upper swivel pin.

Install the upper swivel pin retaining bolts.
BAIL07APH472AVA 6
6. Install the lower swivel pin (1) and the shims (2) as
removed.
BAIL07APH587AVA 7
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7. Install the lower swivel pin retaining bolts.
BAIL07APH607AVA 8
NOTE: This step is for the right-hand side only.

8. Install the potentiometer (2).
Install the potentiometer cover plate (1).
BRH3254B 9
9. Connect the track rod end to the hub.

Tighten to 113 Nm (83 lb ft).
BAIL07APH470AVA 10
10. Install the steering cylinder pivot pin, making sure

that the spacers (1) are installed as removed.
Install the steering cylinder pivot pin retaining bolt (2).
Install the circlip (3).
BAIL07APH480AVC 11
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11. Tighten the upper (1) and lower (2) swivel pin retain-
ing bolts to 130 Nm (96 lb ft).
BAIL07APH450AVA 12
Vehicles with front brakes

12. Position the new cassette oil seal onto the special
tool 380200020.
NOTE: Make sure that the oil seal is positioned onto the
special tool with the spiral ring visible.
BSB0232A 13
13. Position the special tool 380202719 around the hub

centre. With the cassette seal on the special tool
380200020, slide the assembly forward over the
splines until the oil seal locates in the housing.
BSB0231A 14
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14. Using a suitable soft faced hammer and special tool

380200020, install the oil seal into the housing.
BSB0230A 15
15. Install the oil seal (1).

Using a suitable tool, install the bearing assembly (2).
BAIL07APH577AVA 16
16. Using suitable lifting equipment, support the hub.

Install the hub.
BAIL07APH672AVA 17
17. Install the brake piston (1) into the brake carrier (2)
with new seals.
Install the snap ring (3).
BAIL07APH671AVA 18
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18. Install the brake carrier.
BAIL07APH502AVA 19

Install the retaining bolts into the inner hub (2).
BAIL07APH503AVA 20
Vehicles without front brakes

20. Place the hub on a suitable surface. Clean the seat
of the seal thoroughly and position the seal inside the
circumference of the hub. Using special tool number
380200135 install the seal until the top edge of the
tool meets the top surface of the hub.
MDM873A 21
21. Install the hub onto the axle.
BAIL07APH672AVA 22
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22. Install the hub nut.
MDM851A 23
23. Using the special tool 380000269 tighten the hub to

392 N·m (289.1 lb ft) while rotating the hub to make
sure that the bearings are correctly seated.
MDM852A 24
All vehicles
24. Install the drive gear onto the drive shaft pushing it
fully back.
With the drive gear fully back, ease the drive shaft
out 10 mm to reveal the groove for the collets.
BAIL07APH504AVA 25
25. Install the collets. (1).

Push the drive shaft back so that the drive gear (2)
retains the collets.
BAIL07APH158AVA 26
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Vehicles with front brakes

26. Install the inboard steel brake disc.
BAIL07APH179AVA 27
27. Install the friction disc.
BAIL07APH156AVA 28
28. Install the outboard steel brake disc.
BAIL07APH155AVA 29
29. Install the snap ring.
BAIL07APH154AVA 30
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All vehicles
30. Install the O-ring seal.
BAIL07APH501AVA 31
31. Prior to installation of the planetary cover, thoroughly

clean and degrease the mating surfaces and apply a
2 mm bead of flexible sealing gasket.
BAIL07APH507AVA 32
32. Install the hub end plate and the planetary gears as-
sembly.
BAIL07APH487AVA 33
33. Rotate the hub so that the filler/level plug is in the

horizontal position.
Remove the plug and refill the hub to the level with
oil to the correct specification.
Reinstall the filler-level plug and tighten to 74 Nm (55
lb ft).
BAIL07APH510AVA 34
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34. Install the dynamic front fender (if equipped).
BAIL07APH065AVA 35
35. Install the front wheel.

Tighten the wheel nuts to the specified torque, for
further information refer to Front wheel - Torque
(D.50.C).
BAIL07APH064AVA 36
36. Using suitable lifting equipment, install the front

weights.
BAIL07APH062AVA 37
37. Install the retaining bolts to the front weights.
BAIL07APH063AVA 38
Next operation:
Hub - Overhaul (D.10.A).
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Hub - Disassemble
DANGER
B012
1. Using suitable lifting equipment, support the front

weights.
BAIL07APH062AVA 1
2. Disconnect and remove the front weights from the

weight carrier.
BAIL07APH063AVA 2
3. Raise the front of the vehicle and support with suit-

able axle stands under the front weight carrier.
Remove the front wheel.
BAIL07APH064AVA 3
84276322A 31/05/2010
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4. Remove the dynamic front fender (if equipped).
BAIL07APH065AVA 4
5. Rotate the hub until the drain plug is at the lowest

point. Remove the axle hub drain plug and drain the
hub oil into a suitable container.
Reinstall the drain plug and tighten to 75 Nm (55 lb
ft).
BAIL07APH159AVA 5
6. Remove the hub end plate and the planetary gears

assembly.
BAIL07APH487AVA 6
7. Remove the O-ring seal.
BAIL07APH501AVA 7
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8. Remove the snap ring.
BAIL07APH154AVA 8
9. Remove the outboard steel brake disc.
BAIL07APH155AVA 9
10. Remove the friction disc.
BAIL07APH156AVA 10
11. Remove the inboard steel brake disc.
BAIL07APH179AVA 11
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12. Using a suitable lever, gently ease forward the drive

gear (1) and drive shaft (3) by 10 mm.
Then push back the drive gear leaving the drive shaft
forward to reveal the collets (2).
BAIL07APH178AVA 12
13. Remove the collets (1).

Remove the drive gear from the shaft (2).
BAIL07APH158AVA 13
14. Remove the retaining bolts (2) from the inner hub.
Remove the retaining ring (1).
BAIL07APH503AVA 14
15. Install 2 bolts, 12 mm x 1.5 x 50 mm long into the

threaded holes in the back plate.
Tighten the bolts and remove the brake carrier.
BAIL07APH448AVA 15
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16. Remove the snap ring (1).

Remove the brake piston (2) from the brake disc car-
rier (3).
BAIL07APH671AVA 16
17. Remove the oil seal (1).

Remove the bearing assembly (2).
BAIL07APH577AVA 17

Using a suitable puller, remove the hub.
BAIL07APH585AVA 18
BAIL07APH579AVA 19
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20. Using a suitable puller, remove the bearing.
BAIL07APH586AVA 20
21. Loosen the upper (1) and lower (2) swivel pin retain-
ing bolts.
BAIL07APH450AVA 21

Remove the steering cylinder pivot pin retaining bolt
(2).
Support the steering cylinder.
Remove the pivot pin and retrieve the spacers (3).
BAIL07APH480AVA 22
23. Disconnect the track rod from the hub carrier.
BAIL07APH470AVA 23
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24. Using suitable lifting equipment support the hub car-

rier.
BAIL07APH581AVA 24
25. Remove the lower swivel pin retaining bolts.
BAIL07APH471AVA 25
26. Remove the lower swivel pin (1).

NOTE: Note the number of shims removed (2).
BAIL07APH587AVA 26

27. Remove the potentiometer cover plate (1).
Remove the potentiometer (2).
BRH3254B 27
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28. Remove the upper swivel pin retaining bolts.

Remove the upper swivel pin.
BAIL07APH472AVA 28
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29. When removing the offside upper swivel pin assem-
bly take care to avoid damaging the steering sensor
located in this housing.
BAIL07APH475AVA 29
30. Remove the hub carrier assembly.
BAIL07APH581AVA 30
31. Remove the brass protection washer from the hub

carrier.
BAIL07APH665AVA 31
BAIL07APH666AVA 32
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33. Remove the brass lubricating bushing.
BAIL07APH667AVA 33
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Hub - Install Four Wheel Drive Axle With Brakes
DANGER
B012
1. Using suitable lifting equipment support the hub.
BAIL07APH512AVA 1
2. Install the hub (1).

Install the upper swivel pin (2).
BAIL07APH605AVA 2
3. Install the upper swivel pin retaining bolts.
BAIL07APH606AVA 3
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NOTE: When installing the right-hand side upper swivel pin

assembly, take care to avoid damaging the steering sensor
located within the housing.
BAIL07APH475AVA 4
4. Install the lower swivel pin (1) and the shims (2) as
removed.
BAIL07APH587AVA 5
5. Install the lower swivel pin retaining bolts.
BAIL07APH607AVA 6
6. Connect the track rod end to the hub.

Tighten to 113 Nm (83 lb ft).
BAIL07APH470AVA 7
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7. Install the steering cylinder pivot pin, making sure

that the spacers (1) are installed as removed.
Install the steering cylinder pivot pin retaining bolt (2).
Install the circlip (3).
BAIL07APH480AVC 8
8. Tighten the upper and lower swivel pin retaining bolts

to 130 Nm (96 lb ft).
BAIL07APH450AVA 9
9. Remove the lifting equipment.
BAIL07APH512AVA 10

10. Install the potentiometer (2).
Install the potentiometer cover plate (1).
BRH3254B 11
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11. Install the drive gear onto the drive shaft pushing it
fully back.
With the drive gear fully back ease the drive shaft out
10 mm to reveal the groove for the collets.
BAIL07APH504AVA 12
12. Install the collets (1).

Push the drive shaft back so that the drive gear (2)
holds the collets in place.
BAIL07APH158AVA 13
13. Install the inboard steel brake disc.
BAIL07APH179AVA 14
BAIL07APH156AVA 15
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15. Install the outboard steel brake disc.
BAIL07APH155AVA 16
16. Install the snap ring.
BAIL07APH154AVA 17
17. Install the O-ring seal.
BAIL07APH501AVA 18
18. Prior to installation of the planetary cover, thoroughly

clean and degrease the mating surfaces and apply a
2 mm bead of flexible sealing gasket.
BAIL07APH507AVA 19
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19. Install the hub end plate and the planetary gears as-
sembly.
BAIL07APH487AVA 20
20. Rotate the hub so that the filler/level plug is in the

horizontal position.
Remove the plug and refill the hub to the level with
oil to the correct specification.
Reinstall the filler/level plug and tighten to 74 Nm (55
lb ft).
BAIL07APH510AVA 21
21. Install the dynamic front fender (if equipped).
BAIL07APH065AVA 22
22. Install the front wheel.

Tighten the wheel nuts to the specified torque, for
further information refer to Front wheel - Torque
(D.50.C).
BAIL07APH064AVA 23
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23. Using suitable lifting equipment install the front

weights.
BAIL07APH062AVA 24
24. Install the retaining bolts to the front weights.
BAIL07APH063AVA 25
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Hub - Preload
WARNING
B026
1. Apply grease CASE AKCELA MOLY GREASE

on the outer races of the bearings and fit the up-
per cover, without the shims, and with special tool
380000235 (2) attached. Torque the retaining bolts
to the specified torque value of 130 Nm.
NOTE: To aid installation of the swivel pin, is is recommend
that guide 380001143 (1) is installed on the axle shaft.
1b0o2004061039 1
2. Fit the lower cover without shims, lubricate the three

retaining bolts with engine oil.
Gradually, tighten the lower cover bolts equally while
rotating the casing to allow the excess grease to es-
cape.
1b0o2004061040 2
3. Using a torque wrench and special tool 380000235

(1), check that the torque required to rotate the cas-
ing is 15 - 20 Nm. Adjust the three lower bolts until
the correct torque is achieved.
Measure the gap (H) created between the lower
cover and the casing in three places.
1b0o2004061041 3
4. Calculate the average of the three values measured.

The total thickness of the adjustment shims to be
fitted under the lower cover is Shim S3= H - 0.20 mm
.
If necessary, round up the value to the next 0.05 mm.
84276322A 31/05/2010
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5. Insert shims under lower swivel cover. Tighten the

retaining bolts to the specified torque value of 113
Nm.
6. After having rotated the casing a few times to allow
the components to bed down, check that the torque
necessary to rotate the casing is 118 - 147 Nm.
If the torque value measured is greater than the spec-
ified value, increase the thickness of the shims, if it
is less than the specified value, reduce the thickness
of the shims.
Remove the special tool 380000235 , fit the grease
nipples in the upper and lower covers and grease the
assembly.
1b0o2004061042 4
Next operation:
Tie rod - Toe in adjust (D.20.C)
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Hub - Overhaul Four Wheel Drive Axle

STEERING SWIVEL PINS AND BEARINGS - Less Steering Angle Potentiometer
Replacement
Prior operation:
Hub - Remove (D.10.A).
1. In the event that the steering swivel pins prove diffi-

cult to remove, proceed as follows.
Remove the grease nipples and the steering swivel
pin retaining bolts.
Fit the bolts (1) of the special tool 380000265 .
Fit the plate (2) of the tool and fix it to the three bolts
with nuts (5).
Fit the central tie bolt (4) screwing it fully into the
grease nipple bore on the pin (6).
Screw in the nut (3) to drive the pin out of its bore.
24596 1
2. Using the extractor special tool 380000234 (1) re-

move the steering swivel bearings.
Re-install the steering swivel bearings using a suit-
able drift.
1b0o2004061038 2
Steering Swivel Pins and Bearings - With steering angle potentiometer

3. Remove the steering angle potentiometer, refer to
Sensing system - Replace (D.10.A).
84276322A 31/05/2010
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4. In the event that the steering swivel pins prove diffi-

cult to remove, remove the 3 steering swivel retaining
bolts. Using suitable pry bars located in the swivel
housing casting slots, carefully lever the swivel pin
from the housing.
BRH3250A 3
5. Remove the swivel housing, refer to Hub - Remove

(D.10.A).
6. Remove the steering angle potentiometer shaft from
the axle housing. Refer to Sensing system - Re-
place (D.10.A).
7. Using the bearing puller attachment of extrac-
tor, special tool No. 380000234 (3) with adaptor
tool, 380002489 (2) couple these to special tool
380000265 (1) and remove the steering swivel bear-
ings.
BRH3404BB 4
8. Install the new steering swivel bearings using a suit-

able drift.
NOTE: Take care when installing the bearings not to dam-
age the special bearing coating.
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Hub - Remove Four Wheel Drive Axle With Brakes
DANGER
B012
1. Using suitable lifting equipment support the front

weights.
BAIL07APH062AVA 1
2. Disconnect and remove the front weights from the

weight carrier.
BAIL07APH063AVA 2
3. Raise the front of the vehicle and support with suit-

able axle stands under the front weight carrier.
Remove the front wheel.
BAIL07APH064AVA 3
84276322A 31/05/2010
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4. Remove the dynamic front fender (if equipped).
BAIL07APH065AVA 4
5. Rotate the hub until the drain plug is at the lowest

point. Remove the axle hub drain plug and drain the
hub oil into a suitable container.
Reinstall the drain plug and tighten to 75 Nm (55 lb
ft).
BAIL07APH159AVA 5
6. Remove the hub end plate and the planetary gears

assembly.
BAIL07APH487AVA 6
7. Remove the O-ring seal.
BAIL07APH501AVA 7
84276322A 31/05/2010
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8. Remove the snap ring.
BAIL07APH154AVA 8
9. Remove the outboard steel brake disc.
BAIL07APH155AVA 9
10. Remove the friction disc.
BAIL07APH156AVA 10
11. Remove the inboard steel brake disc.
BAIL07APH179AVA 11
84276322A 31/05/2010
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12. Using a suitable lever, gently ease forward the drive

gear (1) and drive shaft (3) by 10 mm.
Then push back the drive gear leaving the drive shaft
forward to reveal the collets. (2).
BAIL07APH178AVA 12
13. Remove the collets. (1)

Remove the drive gear from the shaft. (2).
BAIL07APH158AVA 13
BAIL07APH512AVA 14
15. Loosen the upper and lower swivel pin retaining

bolts.
BAIL07APH450AVA 15
84276322A 31/05/2010
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Remove the steering cylinder pivot pin retaining bolt
(2).
Support the steering cylinder.
Remove the pivot pin and retrieve the spacers (3).
BAIL07APH480AVA 16
17. Disconnect the track rod end from the hub.
BAIL07APH470AVA 17
18. Remove the lower swivel pin retaining bolts.
BAIL07APH471AVA 18
19. Remove the lower swivel pin.

NOTE: Note the number of shims removed.
BAIL07APH587AVA 19
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20. Remove the potentiometer cover plate (1).

Remove the potentiometer (2).
BRH3254B 20
21. Remove the upper swivel pin.
BAIL07APH472AVA 21
NOTE: When removing the right-hand side upper swivel

pin assembly, take care to avoid damaging the steering
sensor located within the housing.
BAIL07APH475AVA 22
22. Remove the hub assembly .
BAIL07APH591AVA 23
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Support - Preload
SUPERSTEER AXLE
BSB0181A_353 1
2. Remove the front weight carrier.
BVE0312A 2
3. Attach the locally fabricated tool (1) to the front of the

axle using M24 x 2.0 x 75 mm bolts.
BVE0316A 3
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4. Detach the steering arm from the stub axle housing

and reposition. Repeat for the right hand side.
BVE0439A 4
5. Remove the retaining nut. Withdraw the steering

cylinder pin from the stub axle housing and recover
the spacers. Repeat for the right hand side.
BVE0440A 5
6. Using a suitable torque wrench, rotate the axle as-

sembly on the nut of the locally fabricated tool. The
correct force to rotate the axle on the swivel, after ini-
tial breakaway, should be between 35 - 38 Kgm.
BVE0317A 6
7. If the force required is incorrect adjust the shims to

obtain the correct value.
Increasing the shim thickness will decrease the force
required to rotate the axle assembly.
NOTE: If the correct value cannot be obtained with equal
size shims on each side, it is acceptable to raise or lower
one side by one shim increment to obtain the correct value.
BVE0318A 7
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8. When the correct value is obtained remove the lo-

cally fabricated tool (1).
BVE0316A 8
9. Tighten the SuperSteer swivel lower plate retaining

BVE0318B 9
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Sensing system - Replace

1. To replace the potentiometer sensor unit only, re-
move the potentiometer retaining plate (1) and with-
draw the potentiometer (2) from the axle swivel hous-
ing.
BRH3254B 1
2. Refit the potentiometer ensuring that the ’D’ drive of

the shaft and potentiometer are correctly aligned.
3. Check the sealing ring of the retaining plate is in good
condition and refit the retaining plate
NOTE: Calibration of the steering angle sensor must then be carried out. Refer to FRONT AXLE - Calibrate (D.10.A).
Potentiometer shaft and wiring replacement

4. With the swivel housing and axle shaft removed, re-
fer to Hub - Remove (D.10.A), carefully remove the
electrical connector from the potentiometer wiring.
Remove the wire retaining plate (1) and pull the po-
tentiometer shaft and wiring up through the top of the
axle housing.
BRH3253B 2
5. Install the new potentiometer shaft (1) and wiring

through the axle hole and locate as shown in Figure
3. Refit the wire retaining plate and ensure the rub-
ber grommet for the wiring is correctly installed into
the housing. Reconnect the wiring to the connector.
BRH3252B 3
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6. Fit the swivel housing, the adjustment shims, the up-

per and lower pivot pins, ensuring that the upper pin
flange is correctly positioned as shown in Figure 4,
refer to Hub - Remove (D.10.A).
NOTE: Calibration of the steering angle sensor must
then be carried out. Refer to FRONT AXLE - Calibrate
(D.10.A).
BRH3251B 4
84276322A 31/05/2010
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Index
FRONT AXLE - 10.A

Axle shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Axle shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bevel gear - Backlash (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Bevel gear - Backlash (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Bevel gear - Backlash (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Bevel gear - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bevel gear - Install (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Bevel gear - Overhaul (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Bevel gear - Preload (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Bevel gear - Preload (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Bevel gear - Preload (Standard Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bevel gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Differential - Assemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Differential - Backlash (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Differential - Clearance (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Differential - Disassemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Differential - Disassemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Differential - Overhaul (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Differential lock - Assemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Differential lock - Assemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Differential lock - Disassemble (Class 3+ Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Differential lock - Disassemble (Class 3.5 Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Differential lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Differential lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FRONT AXLE - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FRONT AXLE - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
FRONT AXLE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT AXLE - Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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FRONT AXLE - Install (Suspended axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT AXLE - Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT AXLE - Remove (Suspended Axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT AXLE - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT AXLE - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT AXLE - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT AXLE - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Hub - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hub - Install Four Wheel Drive Axle With Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Hub - Overhaul Four Wheel Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Hub - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Hub - Remove Four Wheel Drive Axle With Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Sensing system - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Support - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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REAR AXLE - 12.A

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Contents
REAR AXLE - 12.A
TECHNICAL DATA
REAR AXLE
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Final drive
FUNCTIONAL DATA
REAR AXLE
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential lock
Multi plate clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SERVICE
REAR AXLE
Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Final drive
Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reducer, spur gear - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reducer, spur gear - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shaft - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Differential
Disassemble (Multi plate clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assemble (Multi plate clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Bevel gear
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Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Differential lock
Multi plate clutch - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
DIAGNOSTIC
Final drive
Bevel gear
Differential lock
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AXLES, BRAKES AND STEERING - REAR AXLE
REAR AXLE - Torque
BVE0627C 1
Rear Axle Cross-Section - Multi-Wet Plate Clutch
BVE0548C 2
Rear Axle Cross-Section - Dog Clutch
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BSE3840C 3
Rear Axle Longitudinal Cross-Sectional View
BVE0599A_49 4
Rear Axle - Transmission Flange
REAR AXLE - General specification

Pinion and crown wheel ratio 9/47 = 1:5.22
Pinion to crown wheel backlash 0.20 - 0.30 mm (0.0079 - 0.0118 in)
Differential: Light version 2-planet gears

Differential: Heavy version 4-planet gears
Differential lock control:

Dog type clutch Acting through front-meshing, hydraulically operated
gears
Multi-wet plate clutch Acting through a hydraulically controlled multi-pack
clutch in an oil bath
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Differential Lock Assembly (Multi-Wet Plate Clutch)

Driven discs Quantity 6
Drive discs Quantity 6
Driven disc thickness (each) 2.85 - 2.95 mm (0.1122 - 0.1161 in)

Drive disc thickness (each) 1.75 - 1.85 mm (0.0689 - 0.0728 in)
Differential pinion bore diameter 28.04 - 28.061 mm (1.1039 - 1.1048 in)
Differential pinion journal diameter 27.939 - 27.960 mm (1.1000 - 1.1008 in)
Differential pinion running clearance 0.080 - 0.122 mm (0.0031 - 0.0048 in)
Sun gear hub seat in differential

Cage diameter 80.5 - 82.6 mm (3.17 - 3.25 in)
Sun gear hub diameter 79 mm (3.11 in)
Pinion shaft position shimming: 1.40; 1.45; 1.50; 1.55; 1.60;

Dog type clutch differential lock mm 1.65; 1.70; 1.75; 1.80; 1.85;
Multi-wet plate clutch differential lock 1.90; 1.95; 2.00; 2.05; 2.10;
2.15; 2.20; 2.25; 2.30; 2.35;
2.40; 2.45; 2.50
Pinion bearing shimming mm 4.40; 4.50; 4.60; 4.70; 4.80; 4.85;
4.90; 4.95; 5.00; 5.05; 5.10; 5.15
5.20; 5.25; 5.30; 5.35; 5.40; 5.45;
5.50; 5.55; 5.60; 5.65; 5.70;5.75;
5.80; 5.85; 5.90; 5.95; 6.00; 6.05;
6.10; 6.15; 6.20; 6.30; 6.40; 6.50; 6.60
Crown wheel bearing position shimming 0.15 mm (0.006 in); 0.20 mm (0.008 in); 0.50 mm
(0.020 in)
Differential sun gear and planet gear 0.20 mm (0.0079 in)
backlash
Differential sun gear thrust washer mm 2.70; 2.75; 2.80; 2.85; 2.90;
thickness 2.95; 3.00; 3.05; 3.10; 3.15;
3.20; 3.25; 3.30; 3.35; 3.40;
3.45; 3.50
Differential gear end play (each) 0.20 - 0.45 mm (0.008 - 0.018 in)
REAR AXLE - Special tools
CAUTION
in this manual.
B008

previous No.
380000301 Rotary stand 290090
380000236 Tractor separation stand 292320
X 380000227 Rear axle housing lifting hook 291517
380000272 Front bracket for rear axle overhaul (to be used with 380000301) 293972
380000273 Rear bracket for rear axle overhaul (to be used with 380000301) 293973
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previous No.
X 380000249 Universal pinion installer 293400
X 380001144 Crown wheel-differential lifting hook 293994
380000240 Universal differential lock pressure test kit 292870
X 380000237 Rear wheel lifting hook 292400
380000462 Differential overhaul stand 291221
380000549 Slide hammer 292927
380000403 Rear axle support -
380001113 Final drive case, removal and installation tool -
380001114 Crown wheel backlash and differential support bearing adjustment -
tool
BVE0615A 1
Hydraulic Pump Idler Gear Rolling Torque Measurement Tool
BVE0545A 2
Pinion Shaft Position Adjustment Tool
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REAR AXLE - Sealing
BVE0677A 1
Patterns for application of liquid gasket
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Final drive - General specification

Type Epicyclic, with planetary spur
gears
Reduction ratios:
Light version 1:6
Heavy version 1:6.75
Thickness of planetary gear thrust washers 1 mm (0.0394 in)
Thickness of planetary gear roller bearing spacer:

Light version 3.95 - 4.00 mm (0.1555 - 0.1575 in)
Heavy version 10.95 - 11.00 mm (0.4311 - 0.4331 in)
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REAR AXLE - Sectional view
BSE3840B 1
Rear Axle Longitudinal Cross-Sectional View
1 Pinion shaft 2 Tapered roller bearing

3 Parking brake discs 4 Roller bearing
5 PTO drive shaft 6 PTO clutch
7 Crown wheel 8 Planet gear shafts
9 Planet gears 10 Pinion shaft position adjustment shim
11 Four wheel drive clutch 12 Pinion shaft retaining nut
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BVE0627B 2
Rear Axle Cross-Section - Multi-Wet Plate Clutch
1 Differential output half-shaft 2 Differential Support

3 Sun gears 4 Differential cage
5 Planet gears 6 Differential support
7 Thrust washer 8 Planetary gear bearing spacer
9 Thrust washer 10 Planetary final reduction gears
11 Wheel axle shaft 12 Oil seal
13 Oil seal 14 Planetary carrier
15 Differential output half-shaft 16 Drive discs
17 Driven discs 18 Differential lock control piston
19 Sun gear end play adjuster rings
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BVE0548B 3
Rear Axle Cross-Section - Dog Clutch
1 Dog clutch piston 2 Dog clutch sliding coupler

3 Dog clutch fixed gear 4 Differential cage
5 Planet gears 6 Differential support
7 Thrust washer 8 Planetary gear bearing spacer
9 Thrust washer 10 Planetary final reduction gears
11 Wheel axle shaft 12 Oil seal
13 Oil seal 14 Planetary carrier
15 Differential output half-shaft 16 Sun gears
17 Helix spring
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REAR AXLE - Static description

The rear axle assembly transfers drive from the transmission to the epicyclic final drives through a bevel pinion and
crown wheel coupling. The bevel gears are spiral type and are supported by tapered roller bearings.
The differential is fitted with four planetary gears and a hydraulic differential lock. The differential lock being of a
multi-plate type.
Refer to index for the locations of descriptions and operations of differential lock.
The epicyclic final reduction gear sets are controlled by the bevel pinion and crown wheel output half-shafts, which
also control the brakes.
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Differential lock Multi plate clutch - Dynamic description
SS09D217 1
A - Trapped oil (Rear differential lock disengaged)
B - Pressure oil (Rear differential lock engaged)
When the differential lock is disengaged, the solenoid valve is in the discharge position (not engergised) and the oil
(1) is free to return to the sump. Under these conditions, the clutch piston (2) and the drive and driven discs remain
separated and the differential lock is disengaged. When the differential lock switch is activated, the solenoid valve
opens and directs oil from the low pressure circuit into the clutch piston (3) locking the differential plates (4).
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Differential lock Dog clutch - Dynamic description

SS09D218 1
A - Trapped oil (Rear differential lock disengaged)
B - Pressure oil (Rear differential lock engaged)
When the differential lock is disengaged, the solenoid valve is in the discharge position (not engergised) and the oil
(1) is free to return to the sump. Under these conditions, the helix spring (2) Keeps the lock dog clutch teeth apart.
into the drive piston (3), where it creates a pressure greater than the spring (4) force and moves the piston, locking
the differential.
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REAR AXLE - Drain fluid
WARNING
Avoid direct contact of hot oil with your skin. Hot oil will cause injury.
M929
1. Remove the drain plug (1) and drain oil into a suitable
container.
BSE2927A 1
2. Install the drain plug after the oil has drained.
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REAR AXLE - Remove

Prior operation:
DANGER
B012

the separation of the rear axle from the transmission.
BSB0181A_20 1

4. Detach the brake tubes from the support bracket.
BVE0324A 2
84276322A 31/05/2010
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Tractors with 16 x 16 Transmission

5. Disconnect the transmission oil supply pipe (1).
BVE0325A 3
6. Disconnect the oil supply pipes (1) and (2) from the
hydraulic pump.
BVE0326A 4
7. Disconnect the oil supply pipes from the low pressure

distribution block.
BVE0327A 5
84276322A 31/05/2010
D.12.A / 18
All Tractors
8. Position wooden wedges (1) between the front axle
and the front support. These prevent articulation of
the front axle.
BVE0410A_25 6
BVE0328A 7
9. Position the splitting kit (3) 380000569 underneath

the tractor.
10. Use the support (2), in the splitting kit to support the
11. Use the support (1), in the splitting kit to support the
transmission on the wheeled splitting trolley.
84276322A 31/05/2010
D.12.A / 19
12. Check that all necessary hoses tubes and electrical

connectors have been disconnected. It may be nec-
essary to disconnect additional items due to other op-
tional equipment that has been installed on the trac-
tor.
WARNING
B019

Remove the rear axle from the transmission and en-
gine.
BVE0520A 8
Next operation:
REAR AXLE - Disassemble (D.12.A)
84276322A 31/05/2010
D.12.A / 20
REAR AXLE - Disassemble

Prior operation:
REAR AXLE - Remove (D.12.A)
Remove both of the final drive cases - see Final drive Housing - Remove (D.12.A).
WARNING
B026
BVE0353A_365 1
BVE0618A_366 2
3. Remove the draft sensor protection plate.
BVE0354A 3
84276322A 31/05/2010
D.12.A / 21
4. Remove the retaining bolts, slide out the draft sensor

with its mounting plate and remove the lower link.
BVE0355A 4
5. Remove the vertical tie rod pivot pin retaining bolt (1).
Remove the vertical tie rod pivot pin (2) and remove
the vertical tie rod.
BVE0356A 5
6. Remove the lower link support.
BVE0357A 6
7. Support the rear axle on the tractor splitting kit spe-

cial tool 380000569 and position the support spe-
cial tool 380000403 underneath the rear axle centre
housing.
NOTE: Ensure that the tractor splitting kit support does not
obstruct the removal of the four wheel drive hydraulic clutch
from underneath the rear axle.
BVE0358A 7
84276322A 31/05/2010
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8. Remove the PTO torque sensor (1) (if fitted).
BVE0330A 8
9. Remove the PTO torque sensor pick up disc (if fitted).

pick up disc.
BVE0331A 9
10. Release the PTO driveshaft bearing from the housing

by expanding the exposed ends of the retaining ring
(1) into the groove in the housing and at the same
time remove the PTO driveshaft.
shaft can be removed.
BVE0332A 10
11. Remove the hydraulic pump idler gear locking plate

(1).
BVE0333A 11
84276322A 31/05/2010
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12. Remove the hydraulic pump idler gear retaining bolt

(1), remove the pin and remove the gear, bearings
and the adjustment spacer.
BVE0334A 12
13. Using suitable circlip pliers, remove the four wheel

drive clutch driveshaft circlip (1).
BVE0337A 13
14. Using the slide hammer special tool (1) 380000549

and the locally fabricated adaptor M8 x 1.25 (2), re-
move the transfer clutch driveshaft (3).
NOTE: With the aid of another technician, support the four
wheel drive clutch assembly.
BVE0340A 14
15. Remove the four wheel drive clutch assembly from

the underneath the rear axle.
BVE0341A 15
84276322A 31/05/2010
D.12.A / 24
16. Remove the creeper status switches and the switch

plungers.
BVE0359A 16
17. Remove the creeper oil supply pipe (1).
BVE0360A 17
18. Remove the creeper gear selector fork retaining bolt

(1).
BVE0361A 18
19. Remove the creeper shaft and the bearing support

bracket.
BVE0362A 19
84276322A 31/05/2010
D.12.A / 25
20. Loosely install two M8 x 1.25 x 50 bolts (1) to support

the creeper gear.
NOTE: Make sure the creeper gear is in the correct position
so the exposed ends of the retaining ring can be seen.
BVE0363A 20
21. Using suitable circlip pliers, release the creeper shaft

from the casing by expanding the exposed ends of
the retaining ring (2) into the groove in the housing
and at the same time using a slide hammer special
tool (1) 380000549 and a locally fabricated adaptor,
remove the creeper shaft.
BVE0364A 21
22. Remove the creeper gear retaining bolts (1) and re-
move the creeper gear (2).
BVE0356A_367 22
23. Using suitable snap ring pliers, remove the snap ring
from the pinion shaft (1) and remove the creeper cou-
pler assembly (2) (if fitted).
BVE0366A 23
84276322A 31/05/2010
D.12.A / 26
24. Using a suitable socket and bar (1), remove the

crushed nut.
BVE0368A 24
25. Remove the creeper gear (if fitted).
BVE0369A 25
26. Remove the left hand differential support and the ad-
justment shims.
BVE0394A 26
27. Remove the right hand differential support and re-

move the differential from the rear axle housing.
WARNING
B012
BVE0395A 27
84276322A 31/05/2010
D.12.A / 27
28. Remove the parking brake housing - see Brake -

Remove (D.32.B).
BVE0370A 28
29. Using a universal puller (1), partially remove the pin-

ion shaft.
BVE0371A 29
30. Remove the universal puller and remove the front

bearing (1) from the pinion shaft.
24384 30
31. Remove the pinion shaft and remove the inner parts
through the parking brake housing.
BSE2461A 31
84276322A 31/05/2010
D.12.A / 28
32. Remove the bearing (1) from pinion shaft using a

hydraulic press.
24386 32
33. Remove the retaining clip (1) and remove the pin (2)
from the PTO clutch oil supply cut off valve.
BVE0386A 33
34. Remove the PTO ground drive selector fork retaining

bolt (1), disengage the PTO ground drive selector
fork from the PTO ground drive sliding coupler (2).
BVE0387A 34
35. Using suitable circlip pliers, remove the PTO ground

drive shaft circlip (1).
BVE0388A 35
84276322A 31/05/2010
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36. Partially remove the PTO ground drive shaft and re-
move the circlips (1).
BVE0389A 36
37. While supporting the PTO ground drive gear, remove

the PTO ground drive shaft.
BVE0390A 37
38. Remove the PTO ground drive selector shaft retain-

ing bolts.
BVE0391A 38
39. Remove the PTO ground drive selector shaft and re-
move the selector fork from the rear axle housing.
Remove the detent plunger and spring (1).
BVE0392A 39
84276322A 31/05/2010
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40. Remove the internal PTO clutch oil supply cut off
valve (1).
BVE0393A 40
Next operation:
REAR AXLE - Assemble (D.12.A)
84276322A 31/05/2010
D.12.A / 31
REAR AXLE - Assemble

Prior operation:
REAR AXLE - Disassemble (D.12.A)
WARNING
B026
1. Install the internal PTO clutch oil supply cut off valve
(1).
BVE0393A 1
2. Install the detent plunger and spring (1).

Install the PTO ground drive selector shaft and se-
lector fork into the rear axle housing.
BVE0392B 2
3. Install the PTO ground drive selector shaft retaining

bolts.
BVE0391A 3
84276322A 31/05/2010
D.12.A / 32
4. Install the PTO ground drive, drive shaft and PTO

ground drive gear into the rear axle housing.
BVE0390A 4
5. Install the PTO ground drive gear and install the cir-
clips (1).
Install the PTO ground drive shaft.
BVE0389B 5
6. Using suitable circlip pliers, install the PTO ground

drive shaft circlip (1).
BVE0388A 6
7. Engage the PTO ground drive selector fork into the

PTO ground drive sliding coupler (2).
Install the PTO ground drive selector fork retaining
bolt (1).
BVE0387A 7
84276322A 31/05/2010
D.12.A / 33
8. Install the pin (1) and install the retaining clip (2) to
the PTO clutch oil supply cut off valve.
BVE0386A 8
9. Install the bearing onto the pinion shaft.

draulic press.
396 RA-50_368 9
10. Rear Pinion and Crown Wheel Adjustments - see

Bevel gear - Adjust (D.12.A).
11. Install the creeper coupler assembly (2) and install
the snap ring to the pinion shaft (1) (if fitted).
BVE0366A 10
84276322A 31/05/2010
D.12.A / 34
12. Position the creeper gear (2).

Loosely install two M8 x 1.25 x 50 bolts (1) to support
the creeper gear (2).
NOTE: Make sure the creeper gear is in the correct position
so the exposed ends of the retaining ring can be seen.
BVE0356A_367 11
13. Using suitable circlip pliers, install the creeper shaft

into the housing by expanding the exposed ends of
the retaining ring (2) into the groove in the housing
and at the same time install the creeper shaft.
BVE0364B 12
14. Remove the creeper gear support bolts.
BVE0363A 13
15. Install the creeper shaft and bearing support bracket.
BVE0362A 14
84276322A 31/05/2010
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16. Install the creeper gear selector fork retaining bolt

(1).
BVE0361A 15
17. Install the creeper oil supply pipe (1).
BVE0360A 16
18. Install the switch plungers and the creeper status

switches.
BVE0359A 17
19. With the aid of another technician, install the clutch

assembly into the rear axle housing and support.
BVE0341A 18
84276322A 31/05/2010
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20. Using suitable circlip pliers, install the four wheel

drive clutch driveshaft and circlip (1).
BVE0337A 19
Hydraulic Pump Idler Gear Bearing Adjustment

21. When installing new bearings it will be necessary to
calculate the thickness of the spacer (4), (refer to
figure 22) to obtain the correct bearing pre-load. The
spacer is available in various thickness of 11.80 - 2.6
mm (0.46 - 0.10 in) in steps of 0.025 mm (0.001 in).
Measure the thickness of each bearing and record
the measurement as (B1) and (B2).
NOTE: If new hydraulic pump idler gear or bearings are
installed this adjustment must be carried out.
BTB0095B 20
22. Install the bearings into the idler gear and measure
dimension (A).
Calculate thickness of spacer as follows.
Shim Thickness = A-(B1+B2) - 0.15 mm (0.006 in)
Example:
B1 = 19.47 mm (0.767 in)
B2 = 19.47 mm (0.767 in)
A = 55.88 mm (2.2 in)
Spacer Thickness
= 55.88-(19.47+19.47)-0.15
= 44.45-31.9-0.15
= 16.79 mm (0.661 in).
BVE0336A 21
23. Install the hydraulic pump idler gear assembly with

the calculated spacer.
84276322A 31/05/2010
D.12.A / 37
BVE0335A 22

3 Hydraulic pump idler gear 4 Spacer
5 Shim 6 Taper roller bearing
7 Locking tab retaining bolt 8 Washer
9 Locking tab 10 Hydraulic pump idler gear shaft retaining bolt
11 Washer 12 Hydraulic pump idler gear shaft
24. Install the hydraulic pump idler gear retaining bolt

and tighten to the specified torque value.
BVE0334B 23
84276322A 31/05/2010
D.12.A / 38
25. Install the locally fabricated hydraulic pump idler gear

rolling torque measurement tool (1).
Wrap a piece of cord around the locally fabricated
tool and using a spring balance check if the pull re-
quired to turn the idler gear is 0.8 - 1.4 kg (1.764 -
3.086 lb). If the pull is not within specification, recal-
culate the thickness of the spacer required.
BVE0694A 24
26. Install the hydraulic pump idler gear locking plate (1).
BVE0333A 25
27. Install the PTO driveshaft bearing into the housing by

expanding the exposed ends of the retaining ring (1)
into the groove in the housing and at the same time
pushing the PTO driveshaft.
shaft can be installed.
BVE0332B 26
28. Install the PTO torque sensor pick up disc (if fitted).
pick up disc.
BVE0331A 27
84276322A 31/05/2010
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29. Install the PTO torque sensor (1) (if fitted).
BVE0330A 28
30. Install the lower link support to the rear axle housing
Throughly clean and degrease the mating surfaces
mm (0.079 in) in diameter to the rear axle casing -
see REAR AXLE - Sealing (D.12.A).
Install the lower link support. Tighten the retaining
BVE0357B 29
31. Position the vertical tie rod. Install the vertical tie
rod pivot pin (2). Install the vertical tie rod pivot pin
retaining bolt (1).
BVE0356A 30
32. Position the lower link. Install the draft sensor with
its mounting plate and install the retaining bolts.
BVE0355A 31
84276322A 31/05/2010
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33. Install the draft sensor protection plate (1).
BVE0354A 32
34. Install the four wheel drive clutch inner cover.
BVE0618A_366 33
35. Install the rear axle bottom cover.
BVE0353A_365 34
Next operation:
Install both final drive cases - see Final drive Housing - Install (D.12.A).
Install the rear axle - see REAR AXLE - Install (D.12.A).
84276322A 31/05/2010
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REAR AXLE - Install

Prior operation:
REAR AXLE - Assemble (D.12.A)
DANGER
B012
WARNING
B018

BVE0599A_26 1
Tractors with 16 x 16 Transmission

2. Connect the oil supply pipes to the low pressure dis-
tribution block.
BVE0327A 2
84276322A 31/05/2010
D.12.A / 42
3. Connect the oil supply pipes (1) and (2) to the hy-
draulic pump.
BVE0326A 3
4. Connect the transmission oil supply pipe (1).
BVE0325A 4
All Tractors
5. Attach the brake tubes to the support bracket.
BVE0324A 5

84276322A 31/05/2010
D.12.A / 43

hoist and install the front weights (if fitted).
BSB0181A_20 6
8. Connect or Install the wiring harness.
Next operation:
84276322A 31/05/2010
D.12.A / 44
Final drive Housing - Remove

Prior operation:
WARNING
B012
1. Remove the drain plug (1) and drain oil into a suitable
container.
Install the drain plug after the oil has drained (1).
BSE2927A 1
2. Jack up the tractor and place a stationary stand un-

der the rear axle housing.
Using a suitable sling (1), connect the rear wheel to
a hoist and remove the rear wheel.
BTB0282A_370 2
3. Remove the cab support from the final drive case.
BVE0345A 3
84276322A 31/05/2010
D.12.A / 45
4. Remove the damper/spring (1) (if fitted).
BVE0346A 4
5. Disconnect the lift arm potentiometer link.
BVE0347A 5
6. Disconnect the assistor ram oil supply pipe (1). Re-

move the circlip (2). Remove the lift assistor ram
lower retaining bracket nuts (3) and remove the lift
assistor ram.
BVE0348A 6
7. Install Special tool 380001113 and connect it to a

hoist. Remove the final drive case to rear axle hous-
ing retaining nuts and remove the final drive assem-
bly together with the half-shaft.
BVE0349A 7
84276322A 31/05/2010
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8. Remove the outer ring gear (1), steel plate (2) and
friction disc (3).
BVE0350A 8
Next operation:
Final drive - Disassemble (D.12.A)
84276322A 31/05/2010
D.12.A / 47
Final drive - Disassemble

Prior operation:
Final drive Housing - Remove (D.12.A)
WARNING
B026
1. Position the final drive case (1) on a rotary stand.
24608 1
2. If necessary, remove the locking plate (1) by slightly

turning it
24609 2
3. Loosen the screw attaching the planetary carrier (1)

to the drive shaft.
24610 3
84276322A 31/05/2010
D.12.A / 48
4. Slide out the planetary carrier (1).
24611 4
5. Recover the thrust washer (1).
24612 5
6. Using a suitable puller, remove the drive shaft (1).
1b0o2004061045 6
7. Remove the seal (1) and recover the bearing inner

cup from the wheel side.
24614 7
84276322A 31/05/2010
D.12.A / 49
8. Using an expansion puller and a slide hammer, re-

move the bearing outer cup from the wheel side.
1b0o2004061046 8
9. Using an expansion puller and a slide hammer, re-

move the bearing outer cup (1) from the final drive
side.
24616 9
10. Remove the seal (1).
WARNING
Always use suitable tools to align holes. DO NOT USE
HAND OR FINGERS.
B020
24617 10
Next operation:
Final drive - Assemble (D.12.A)
84276322A 31/05/2010
D.12.A / 50
Final drive - Assemble

Prior operation:
Final drive - Disassemble (D.12.A)
1. The reassembly follows the disassembly procedure

in reverse, from step 10 back to step 1 - see Final
drive - Disassemble (D.12.A).
Install the outer bearing cups and seals on the hous-
ing using suitable drifts.
2. Disassemble the final drive reducer - see Final drive
Reducer, spur gear - Disassemble (D.12.A).
Next operation:
After installing all components on the final drive case, adjust the drive wheel taper bearings - see Final drive Shaft
- Adjust (D.12.A).
84276322A 31/05/2010
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Final drive Reducer, spur gear - Disassemble

Prior operation:
Final drive - Assemble (D.12.A)
WARNING
B026
1. Remove retaining ring (1).

Slide out the pivot pins and recover the gears com-
plete with the needle bearings. Remove the thrust
washer.
1b0o2004061047 1
Next operation:
Final drive Reducer, spur gear - Assemble (D.12.A)
84276322A 31/05/2010
D.12.A / 52
Final drive Reducer, spur gear - Assemble

Prior operation:
Final drive Reducer, spur gear - Disassemble (D.12.A)
1. Insert the thrust washer first on the driven gear

holder.
The reassembly follows the disassembly procedure
in reverse.
1b0o2004061047 1
Next operation:
Final drive Shaft - Adjust (D.12.A)
84276322A 31/05/2010
D.12.A / 53
Final drive Shaft - Adjust

Prior operation:
Final drive Reducer, spur gear - Assemble (D.12.A)
1. Drive wheel taper bearing adjustment
Tighten the axle shaft screw to 196 Nm (144.6 lb ft)

while turning the shaft to settle the assembly.
24610 1
2. Loosen the axle shaft screw then tighten it again to

88 Nm (64.9 lb ft) while turning the shaft to settle the
bearings properly.
3. Insert the safety plate and lock it screwing in or out
the screw until reaching the next notch.
NOTE: Screw in or out to a max. angular variation of 15 °.
4. Turn the shaft by hand and check if it turns freely,
with no end float, nor excess resistance.
Using the grease nipple, fill the inner recess with
grease AKCELA MOLY GREASE (several grease
gun strokes are needed).
NOTE: If a plug is fitted instead of the grease nipple, re-
move plug and replace with a grease nipple.
TI-72 2
Next operation:
Final drive Housing - Install (D.12.A)
84276322A 31/05/2010
D.12.A / 54
Final drive Housing - Install

Prior operation:
Final drive Shaft - Adjust (D.12.A)
WARNING
B012
1. Install the friction disc (3), steel plate (2) and the outer
ring gear (1).
BVE0350A 1
2. Install Special tool 380001113 and install the final

drive assembly together with the half-shaft.
BVE0349A 2
3. Install the lift assistor ram, lower retaining bracket

and the retaining nuts. Tighten the retaining nuts to
the specified torque value. Install the circlip (2) and
connect the lift assistor ram oil supply pipe (1).
BVE0488B 3
84276322A 31/05/2010
D.12.A / 55
4. Connect the lift arm potentiometer link (1).
BVE0347A 4
5. Install the damper/spring (1) (if fitted).
BVE0346A 5
6. Install the cab support onto the final drive case.
BVE0345A 6
7. Using a suitable sling (1), connect the rear wheel to

a hoist and install the rear wheel.
Jack up the tractor and remove the stationary stand
from under the rear axle housing.
For the tighten torque - see Rear wheel - Torque
(D.50.C).
BTB0282A_370 7
84276322A 31/05/2010
D.12.A / 56
Next operation:
84276322A 31/05/2010
D.12.A / 57
Differential - Disassemble (Multi plate clutch)

Prior operation:
Remove the differential as described in REAR AXLE - Disassemble (D.12.A).
WARNING
B026
1. Remove the multi-wet plate clutch cover (1) from the

differential cage.
BVE0378A 1
2. Remove the multi-wet plate clutch drive and driven

discs from the differential cage.
BVE0379A 2
3. Remove the thrust washer / shim (1) from the differ-

ential cage.
BVE0497A 3
84276322A 31/05/2010
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4. Remove the sun gear (1) from the differential cage.
BVE0380A 4
5. Remove the crown wheel from the differential cage

using a suitable soft faced hammer.
BVE0381A 5
6. Remove the piston from the differential cage.
BVE0382A 6
7. Remove the grub screw from the differential cage.
BVE0383A 7
84276322A 31/05/2010
D.12.A / 59
8. Remove the planet gear shaft locking pin from the

differential cage.
BVE0384A 8
84276322A 31/05/2010
D.12.A / 60
9. Disassemble the differential cage assembly.
BVE0385A 9
1 Thrust washer 2 Planet gear

3 Planet gear shaft 4 Sun gear
5 Thrust washer / shim 6 Differential cage
NOTE: It is advisable to keep the planet gear shafts and planet gears matched as they are removed.
Next operation:
Differential - Assemble (Multi plate clutch) (D.12.A)
84276322A 31/05/2010
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Differential - Assemble (Multi plate clutch)

Prior operation:
Differential - Disassemble (Multi plate clutch) (D.12.A)
WARNING
B026
1. The end float required between the sun gear and

planet gears is 0.20 - 0.45 mm (0.0079 - 0.0177 in).
2. Install a test thrust washer / shim (S1).
3. Assemble the differential cage assembly as de-
scribed in step 9 Differential - Disassemble (Multi
plate clutch) (D.12.A).
4. Using a depth gauge, take two measurements 180 °
apart, between the sun gear and the differential cage.
Calculate the average of the two measurements.
This measurement is (H1).
BVE0493A 1
5. Raise the sun gear so it comes into contact with the

differential cage. Using a depth gauge, take two
measurements 180 ° apart, between the sun gear
and the differential cage. Calculate the average of
the two measurements.
BVE0494A 2
6. Remove the test thrust washer/shim and measure

the thickness.
This measurement is (S1).
84276322A 31/05/2010
D.12.A / 62
7. Determine the thickness of the thrust washer / shim

to be installed as follows:
Thrust washer/shim = (H1-H2) + S1 - 0.30 mm
Where:
0.30 mm = the average calculation of 0.20 - 0.45 mm
(0.0079 - 0.0177 in) rounded down to the nearest
available shim size.
Example:
H1 = Average sun gear measurement using the
depth gauge = 75.35 mm.
H2 = Average lifted sun gear measurement using the
depth gauge = 74.80 mm.
S1 = Test thrust washer / shim = 2.70 mm.
0.30 mm = Specified sun gear end play.
75.35 - 74.80 = 0.55
0.55 + 2.70 = 3.25
3.25 - 0.30 = 2.95
2.95 = Thrust washer/shim.
8. Assemble the differential cage assembly as de-
scribed in step 9 Differential - Disassemble (Multi
plate clutch) (D.12.A).
9. Install the planet gear shaft locking pin.
BVE0384B 3
10. Install the grub screw to the differential cage.

NOTE: Apply LOCTITE® 243 to the grub screw.
BVE0383A 4
84276322A 31/05/2010
D.12.A / 63
11. Install the piston to the differential cage.
BVE0382A 5
12. Install the ring gear from the differential cage.

13. The end float required between the sun gear and
planet gears is 0.20 - 0.45 mm (0.0079 - 0.0177 in).
14. Install the sun gear (1) to the differential cage.
BVE0380A 6
15. Install a test thrust washer / shim (S1).
BVE0497A 7
84276322A 31/05/2010
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16. Install the multi-wet plate clutch cover (1) to the dif-
ferential cage. Tighten to the specified torque value.
BVE0378B 8
17. Using a depth gauge, take two measurements 180 °

apart, between the sun gear and the differential cage.
Calculate the average of the two measurements.
BVE0495A 9
18. Lift up the sun gear so it comes into contact with

the differential cage. Using a depth gauge, take two
measurements 180 ° apart, between the sun gear
and the differential cage. Calculate the average of
the two measurements.
BVE0496A 10
19. Remove the multi-wet plated clutch cover (1) from

the differential cage.
BVE0378A 11
84276322A 31/05/2010
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20. Remove the test thrust washer / shim (1) and mea-
sure the thickness.
This measurement is (S1).
BVE0497A 12
21. Determine the thickness of the thrust washer / shim

to be installed as follows:
Thrust washer/shim = (H1-H2) + S1 - 0.30 mm
Where:
0.30 mm = the average calculation of 0.20 - 0.45 mm
(0.0079 - 0.0177 in) rounded down to the nearest
available shim size.
22. Install the new calculated thrust washer / shim (1).
BVE0497A 13
23. Install the clutch drive and driven discs from the dif-
ferential cage.
BVE0379A 14
84276322A 31/05/2010
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24. Install the multi-wet plated clutch cover (1) to the dif-
ferential cage. Tighten to the specified torque value.
BVE0378B 15
Next operation:
Install the differential as described in REAR AXLE - Assemble (D.12.A).
84276322A 31/05/2010
D.12.A / 67
Bevel gear - Adjust

NOTE: If ground drive PTO option and/or the 17th gear clutch option are pre-assembled into the rear axle housing,
then the rolling torque (Rp) measured from the pinion shaft has to be increased by the rotational torque of the option
installed.
BVE0693A 1
1 Pinion shaft bearing pre-load adjustment shim 2 Pinion shaft position adjustment shim (Sp) -
(Sr) - Adjusts the pre-load on the pinion shaft Adjusts the position of the pinion shaft gear relative
bearings and components. to the crown wheel.
3 Crown wheel backlash and differential support 4 Right hand side differential sun gear adjustment
bearing pre-load adjustment nut - Adjusts the shims - Adjusts the (pre-load) on the differential
(pre-load) on the differential support bearings. gear assembly.
5 Left hand side differential sun gear adjustment 6 Crown wheel backlash adjustment shims - Adjusts
shims. the radial play (backlash) between the crown
wheel and pinion shaft gear.
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Determining the thickness of the pinion shaft position adjustment shim

1. Install the pinion shaft rear bearing outer cone (1)
without the pinion shaft position adjustment shim.
Using the locally fabricated pinion shaft position ad-
justment tool (2), hold the tapper roller bearing into
the outer bearing cone (1).
BVE0616A 2
2. Install the left and right hand side differential supports

into the rear axle housing.
Install the special tool 380000249, (1) into the dif-
ferential supports and install the micrometer and the
depth rod.
Move the depth rod to make contact with the tapper
roller bearing and measure the dimension. This mea-
surement is (H1).
BVE0617A 3
3. Determine the correct nominal dimension (H2) be-

tween the crown wheel centre line and the pinion
shaft larger base as follows:
H2 = H3 +/- C
Where:
H3 = 180 mm (7.1 in)

Nominal manufacturing dimension between the
crown wheel centre line and the rear face of the
pinion shaft gear
C = Manufacturing correction factor (1) stamped on

the face of the pinion shaft gear expressed in mm 1b0o2004061044 4
and prefixed by a + or -, to be added or subtracted
from the nominal dimension (H3)
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4. Determine the pinion shaft position adjustment shim

(Sp) as follows:
Sp = H1-H2
Where :
H1 = Depth gauge reading
H2 = Correct nominal dimension between the
crown wheel centre line and the rear face of the
pinion shaft gear
Example
- Depth gauge reading:
H1 = 181.85 mm (7.159 in)
- Nominal dimension between the crown wheel cen-
tre line and the rear face of the pinion shaft gear:
H3 = 180 mm (7.087 in)
- Correction factor: C = -0.18 mm (-0.007 in)
- Correct nominal dimension:
H2 = 180 - 0.18 = 179.82 mm (7.080 in)
- Shim thickness:
Sp = 181.85 - 179.82 = 2.03 mm (0.080 in).
NOTE: If required, increase (Sp) to the nearest available
shim size.
5. Remove the special tool 380000249 and the locally
fabricated pinion shaft position adjustment tool from
the rear axle housing.
6. Remove the left and right hand side differential sup-
ports from the rear axle housing.
7. Install the pinion shaft rear bearing outer cone with
the newly calculated position adjustment shim.
8. Position the inner parts through the parking brake
compartment and install the pinion shaft.
BSE2461A 5
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Determining the thickness of the pinion shaft position adjustment shim

9. Measure the thickness of the test shim(s) to be in-
stalled. This measurement is (St).
NOTE: Install a temporary pinion shaft bearings pre-load
adjustment test shim(s) (item 1, figure 1) to determine the
required pinion shaft bearings pre-load adjustment shim
thickness.
10. Install the front bearing to the pinion shaft.
draulic press.
396 RA-50_368 6
11. Install the creeper gear (if fitted).
BVE0369A 7
12. Install the parking brake housing - see Brake - Install

(D.32.B).
BVE0370A 8
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13. Using a suitable adjustable spanner, apply and hold

the parking brake.
BVE0367A 9
14. Install the pinion shaft retaining nut and tighten to the
BVE0368B 10
15. Using a suitable dial gauge (1) and a suitable lever

(2), measure the pinion shaft assembly end-float.
Determine the pinion shaft pre-load bearing adjust-
ment shim (Sr) as follows:
Sr = (St - H4) - 0.20 mm (0.008 in)
Where:
St = Thickness of the test shim installed to obtain
end-float in the pinion shaft assembly.
H4 = End-float measurement of the pinion shaft
assembly
0.20 mm (0.008 in) = Decrease necessary to achieve
the required bearing pre-load BVE0610A 11
Example
- Thickness of the test shim:
St = 7.8 mm (0.31 in)
- End-float measurement:
H4 = 2.03 mm (0.08 in)
- Decrease necessary to achieve the required bear-
ing pre-load = 0.20 mm (0.008 in)
- Shim thickness:
Sr = (7.8 - 2.03) - 0.20 = 5.6 mm (0.22 in).
NOTE: If required, decrease (Sr) to the nearest available
shim size.
16. Remove the test shim and install the calculated pin-
ion shaft bearings pre-load shim.
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17. Using a suitable adjustable spanner, apply and hold

the parking brake.
BVE0367A 12
18. Install the pinion shaft retaining nut and tighten to the
NOTE: Rotate the pinion shaft while tightening the pinion
shaft retaining nut to seat the bearing rollers.
BVE0368B 13
19. Using a suitable low value torque wrench (1), check

the rotational torque of the pinion shaft assembly.
This measurement is (Rp).
The rotational torque should be 1 - 2 Nm (0.74 - 1.48
lb ft) excluding breakaway torque.
If the values recorded during the adjustment pro-
cedure are outside the specification. Adjust the
thickness of the pinion shaft adjustment shim and
re-check.
NOTE: If ground drive PTO option and/or the 17th gear
clutch option are pre-assembled into the rear axle housing,
then the rolling toque (Rp) measured from the pinion shaft
has to be increased by the rotational torque of the option
installed.
BVE0613A 14
20. Secure the pinion shaft retaining nut in four places.
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21. Install the differential into the rear axle housing.

Install the right hand differential support. Tighten the
WARNING
B012
BVE0395B 15
Determining the thickness of the crown wheel backlash and differential support bearing
adjustment shims.
22. Using Special tool 380001114 (crown wheel back-
lash and differential support bearing adjustment
tool), (1), loosen the adjustment nut.
BVE0612A 16
23. Install the left hand differential support with a 0.7 mm

(0.028 in) test shim (A). Tighten the retaining bolts to
BVE0394B 17
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24. Using Special Tool 380001114 (crown wheel back-

lash and differential support bearing adjustment
tool), (1), tighten the adjustment nut.
NOTE: Only tighten the adjustment nut until the bearing
free play is removed.
BVE0612A 18
25. Using a suitable dial gauge (1), measure the radial

movement (backlash) between the pinion and crown
wheel perpendicular to the outer edge of a tooth on
the crown wheel (2).
Repeat the measurement in two further positions 120
° apart and calculate the average of the three values.
This measurement is (Gm).
BVE0611A 19
26. Refer to table A (above) for the relationship between

the measured average radial movement (backlash)
(Gm) and the thickness of the adjustment shim(s) to
be added to the test shim (A).
NOTE: If required, decrease (A) to the nearest available
shim size.
Table A
Ratio 9/47
Measured average radial movement Adjustment shim to be added
(backlash) (Gm) to the test shim (A)
0.05 mm (0.0020 in) -0.25 mm (-0.0098 in)
0.10 mm (0.0039 in) -0.19 mm (-0.0075 in)
0.15 mm (0.0059 in) -0.12 mm (-0.0047 in)
0.20 mm (0.0079 in) -0.05 mm (-0.0020 in)
0.25 mm (0.0098 in) 0.01 mm (0.0004 in)
0.30 mm (0.0118 in) 0.08 mm (0.0031 in)
0.35 mm (0.0138 in) 0.15 mm (0.0059 in)
0.40 mm (0.0157 in) 0.21 mm (0.0083 in)
0.45 mm (0.0177 in) 0.28 mm (0.0110 in)
0.50 mm (0.0197 in) 0.35 mm (0.0138 in)
0.55 mm (0.0217 in) 0.41 mm (0.0161 in)
0.60 mm (0.0236 in) 0.48 mm (0.0189 in)
0.65 mm (0.0256 in) 0.55 mm (0.0217 in)
0.70 mm (0.0276 in) 0.61 mm (0.0240 in)
0.75 mm (0.0295 in) 0.68 mm (0.0268 in)
0.80 mm (0.0315 in) 0.74 mm (0.0291 in)
0.85 mm (0.0335 in) 0.84 mm (0.0331 in)
84276322A 31/05/2010
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0.90 mm (0.0354 in) 0.88 mm (0.0346 in)

0.95 mm (0.0374 in) 0.95 mm (0.0374 in)
1 mm (0.039 in) 1.01 mm (0.040 in)
Example
- Thickness of the test shim: A = 0.7 mm (0.028 in)
- Average measured radial movement (backlash):
Gm = 0.94 mm (0.0370 in)
- Required average radial movement (backlash) = 0.24 mm
(0.0094 in)
- Shim thickness to be added to the 0.7 mm (0.028 in) shim
using table A = 0.88 mm (0.0346 in).
NOTE: If required, decrease (A) to the nearest available
shim size.
NOTE: If required, decrease (Gm) to the nearest measured
average radial movement (backlash).
NOTE: The adjustment shim to be added to the test shim
in table A is calculated using the following formula:
Z = (Gm - 0.24) x 1.33
NOTE: If required, decrease (Z) to the nearest available
calculated axial displacement (backlash) reading.
Where:
Z = The adjustment shim to be added to the test shim
0.24 = required average radial play (backlash)
1.33 = Ratio between the radial movement (backlash) and
the horizontal movement of the differential assembly
27. Install the calculated adjustment shim(s) to be added
to the test shim (A). Tighten the retaining bolts to the
NOTE: Apply liquid gasket to the first adjustment shim be-
fore installing the calculated adjustment shim(s).
BVE0394B 20
28. Using crown wheel backlash and differential support

bearing adjustment tool 380001114 (1), tighten the
adjustment nut while checking the rolling torque at
the pinion shaft.
NOTE: Rotate the differential assembly while tightening the
adjustment nut to seat the bearing rollers on their track.
BVE0612A 21
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29. Using a suitable low value torque wrench (1), check

the total rotational torque of the pinion shaft and the
differential assembly. This measurement is R tot.
The total rotational torque should be within the fol-
lowing range excluding breakaway torque:
R tot = Rp + ( 0.29 - 0.78 Nm)
R tot = Rp + ( 0.214 - 0.575 lb ft)
Where :
Rp = Rotational torque of the pinion shaft assembly
only.
Example BVE0613A 22
- Rotational torque of the pinion shaft assembly only:
Rp = 1.2 Nm (0.89 lb ft)
- Total rotational torque:
R tot = 1.7 Nm (1.25 lb ft)
- The differential assembly only rotational torque =
1.7 - 1.2 = 0.5 Nm (0.369 lb ft).
NOTE: If ground drive PTO option and/or the17th gear
clutch option are pre-assembled into the rear axle hous-
ing, then the rolling toque (Rp) measured from the pinion
shaft has to be increased by the rotational torque of the op-
tion installed.
30. Lock the adjustment nut in position with the locking
ring and tighten the retaining bolts to the specified
torque value.
BVE0395C 23
31. Using a suitable dial gauge (1), measure the radial

movement (backlash) between the pinion and crown
wheel perpendicular to the outer edge of a tooth on
the crown wheel (2).
Repeat the measurement in two further positions 120
° apart and calculate the average of the three values.
This measurement is (Gm).
Gm = 0.20 - 0.30 mm (0.0079 - 0.0118 in)
If the values recorded during the adjustment proce-
dure are outside the specification, adjust the thick-
ness of the crown wheel backlash adjustment shims
and re-check
BVE0611A 24
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Differential lock Multi plate clutch - Measure
WARNING
B026
With the crown wheel / differential assembly on the bench,

proceed as follows:
Using suitable feeler gauges, check the clearence between
the multi-wet plate clutch drive and driven discs. If the
clearence is not between 1.35 - 3.1 mm (0.053 - 0.122 in),
replace the multi-wet plate clutch drive and driven discs.
BVE0498A 1
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Final drive - Troubleshooting

Noisy final drives when Wheel axle shaft bearing incorrectly ad- Remove final drive case and adjust bear-
the tractor is moving and justed ings
also with transmission in
neutral
Faulty or defective internal component. Remove final drive case and replace dam-
aged parts.
Excess wheel axle shaft to final drive spline Remove final drive case and replace dam-
backlash aged parts.
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Bevel gear - Troubleshooting

Noisy rear axle when the Pinion and/or crown wheel bearing misad- Remove rear axle housing and adjust pin-
tractor is moving, and justment ion and crown wheel bearings correctly
also with transmission in
neutral (not originating
from final drives)
Worn or incorrectly adjusted sun and plan- Remove rear axle housing, replace worn
etary gears parts and adjust the differential gear back-
lash
Excess differential side gears to half-shaft Remove rear axle housing and replace
spline backlash damaged parts
Noisy rear axle with Excess bevel pinion to crown wheel back- Remove rear axle housing and adjust pin-
tractor under load and lash ion and crown wheel bearings correctly
upon release
Faulty or defective inner component Remove rear axle housing, replace worn
parts and adjust differential gear backlash
correctly
Noisy rear axle and Insufficient pinion and/or crown wheel Remove rear axle housing and adjust pin-
over-heating bearing backlash ion and crown wheel bearings correctly
Insufficient bevel pinion to crown wheel Remove rear axle housing and adjust
tooth backlash crown wheel bearings correctly
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Differential lock - Troubleshooting

Differential lock not Low rear axle oil level Top up to the correct oil level
engaging
Blocked oil filter Replace the oil filter
Faulty hydraulic pump Overhaul or replace pump
Faulty differential lock switch Replace the differential lock switch
Power supply not reaching solenoid valve: Restore electrical connection and replace
detached or damaged electrical connec- faulty parts. Overhaul or replace solenoid
tors, faulty remote switch valve
Differential lock control solenoid valve Overhaul or replace solenoid valve
stuck on discharge
Oil leaks through the seals with consequent Replace faulty seals
pressure drop: cylinder piston oil supply
line seals
Differential lock not Faulty differential lock-unlock switch Replace switch
disengaging
Power supply not reaching solenoid valve: Repair electrical connection and replace
detached or damaged connectors, faulty faulty parts
remote switch
Differential lock control solenoid valve Overhaul or replace solenoid valve
stuck on delivery
Oil leaks through the seals with consequent Replace faulty seals
pressure drop: cylinder piston or supply
line seals
With differential lock Faulty differential lock switch (connected to
Replace the differential lock switch
engaged and control the Fast Raise switch)
switch on automatic
mode, the differential lock
does not disengage when
raising lift arms using the
Fast Raise switch
With differential lock Faulty differential lock switch (connected Replace the differential lock switch
engaged, the differential to the brake pressure switches/foot pedal
lock does not disengage switches)
when brake pedals are
pressed
84276322A 31/05/2010
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Index
REAR AXLE - 12.A

Bevel gear - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Bevel gear - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Differential - Assemble (Multi plate clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Differential - Disassemble (Multi plate clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Differential lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Differential lock Multi plate clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential lock Multi plate clutch - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Final drive - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Final drive - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Final drive - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Final drive - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Final drive Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Final drive Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Final drive Reducer, spur gear - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Final drive Reducer, spur gear - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Final drive Shaft - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
REAR AXLE - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR AXLE - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REAR AXLE - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR AXLE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR AXLE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR AXLE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REAR AXLE - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR AXLE - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REAR AXLE - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR AXLE - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REAR AXLE - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2WD-4WD SYSTEM Hydraulic - 14.C

84276322A 31/05/2010
D.14.C / 1
Contents
TECHNICAL DATA
2WD-4WD SYSTEM Hydraulic
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shaft
Clutch
FUNCTIONAL DATA
Clutch
Dog clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Multi plate clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Multi plate clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Dog clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE
Hydraulic line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shaft
Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clutch
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Multi plate clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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D.14.C / 2
Multi plate clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dog clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dog clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSTIC
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AXLES, BRAKES AND STEERING - 2WD-4WD SYSTEM Hydraulic
2WD-4WD SYSTEM Hydraulic - Special tools
CAUTION
in this manual.
B008

previous No.
X 380000291 Tool for hydraulic clutch plunger springs 295021
X 380000984 Clutch spring compressor and pin spanner -
BVF0917A 1
Four wheel driveshaft slide hammer
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2WD-4WD SYSTEM Hydraulic - Torque
BVE0353B_333 1
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Shaft - General specification

1 mm; 1.2 mm; 1.5 mm; 1.8 mm;
Front Sleeve Positioning Adjust Ring Shims 2 mm; 2.2 mm; 2.5 mm; 3 mm;
3.3 mm; 3.7 mm; 4 mm; 4.3 mm
Front Sleeve End-Play 1.2 - 1.7 mm (0.047 - 0.067 in)
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Clutch - General specification

Four Wheel Drive
Mechanically engaged,
Mulit-wet plate clutch
electro-hydraulic disengaged
Mechanically engaged,
Dog clutch
electro-hydraulic disengaged
Dog clutch Mechanically engaged,

(only 12x12 transmission) mechanically disengaged
Drive From the pinion shaft
Multi Wet plate clutch discs

Friction Discs 8 pieces
Steel Plates 7 pieces
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2WD-4WD SYSTEM Hydraulic - Static description

MAXXUM 140
There are two types of four wheel drive transfer systems installed in the bottom of the rear axle housing, these are:
• Four wheel drive multi-wet plate clutch (16x16 transmission) - see Clutch Multi plate clutch - Sectional view
(D.14.C).
• Four wheel drive dog clutch (24x24 and 12x12 transmission) - see Clutch Dog clutch - Sectional view (D.14.C).
The four wheel drive is activated by the three position rocker switch (1) located in the cab on the right hand control
console.
BSE2812B 1
Manual Four Wheel Drive

When the rocker switch is in the manual four wheel drive position, four wheel drive is always engaged, regardless of
the steering angle and tractor speed.
Automatic Four Wheel Drive

When the rocker switch is in the automatic four wheel drive position, four wheel drive will engage and disengage
depending on the steering angle and tractor speed.
The disengagement steering angle and speed values can be changed using the diagnostic H routines, menu H3 -
refer to Control module - Configure (A.50.A).
Four Wheel Drive Off

NOTE: When the parking brake is applied, four wheel drive is engaged.
When the rocker switch is in the off position, four wheel drive is disengaged and will be engaged when both brake
pedal are depressed, to provide four wheel braking.
The four wheel braking engagement speed can be changed using the diagnostic H routines, menu H3 - refer to Con-
trol module - Configure (A.50.A).
NOTE: When four wheel drive is engaged and the key start is turned off, four wheel drive will be engaged when the
key start is turned on again.
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When four wheel drive is engaged, the four wheel drive solenoid is de-energized. This will close the pressure switch
located on the low pressure distribution block and will illuminate the symbol (1) on the instrument cluster.
BRE1525B 2
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2WD-4WD SYSTEM Hydraulic - Static description

Four wheel drive multi-wet plate clutch - see Clutch Multi plate clutch - Sectional view (D.14.C).
The four wheel drive is activated by two buttons (1) and (2) located on the switch panel (GARU).
SS09J074 1
Manual Four Wheel Drive

When the button manual four wheel drive (1) is switched, four wheel drive is always engaged, regardless of the steer-
ing angle and tractor speed.
Automatic Four Wheel Drive

When the button automatic four wheel drive (2) is switched, four wheel drive will engage and disengage depending
on the steering angle and tractor speed.
The disengagement steering angle and speed values can be changed using the diagnostic H routines, menu H3 -
refer to Control module - Configure (A.50.A).
Four Wheel Drive Off

NOTE: When the parking brake is applied, four wheel drive is engaged.
When the 4WD is switched off, four wheel drive is disengaged and will be engaged when both brake pedal are de-
pressed, to provide four wheel braking.
The four wheel braking engagement speed can be changed using the diagnostic H routines, menu H3 - refer to Con-
trol module - Configure (A.50.A).
NOTE: When four wheel drive is engaged and the key start is turned off, four wheel drive will be engaged when the
key start is turned on again.
When four wheel drive is engaged, the four wheel drive solenoid is de-energized. This information get the instrument
cluster from the transmission controller by CAN message and switch on the four wheel drive lamp (3).
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SS09J075 2
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Clutch Dog clutch - Exploded view

BVF0880A 1
Dog Clutch Four Wheel Drive
1 Circlip 2 Spring pack retaining washer

3 Spring pack 4 Washer
5 Control piston with engaging dog teeth 6 Control piston shaft
7 Driven gear with engaging dog teeth 8 Splined washer
9 O-ring 10 O-ring
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Clutch Multi plate clutch - Dynamic description
BVF0905A 1
Four Wheel Drive Multi-Wet Plate Clutch (Engaged)

1 Belleville washer 2 Control piston
3 Drive gear 4 Driven gear
5 Friction and steel plates 6 Driveshaft
Figure Colour Key

A Return to reservoir B Lubrication
The four wheel drive clutch solenoid is de-energized and the belleville washer (1) applies a force to the control piston
(2) which compresses the friction and steel plates (5). Drive is transferred from the drive gear (3) mounted on the rear
axle pinion to the driven gear (4) and through the clutch to the front axle via the driveshaft (6).
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BVF0905B 2
Four Wheel Drive Multi-Wet Plate Clutch (Disengaged)

1 Belleville washer 2 Control piston
3 Drive gear 4 Driven gear
5 Friction and steel plates 6 Driveshaft
Figure Colour Key

A Lubrication B Low pressure circuit
The four wheel drive clutch solenoid is energized, supplying oil from the low pressure circuit to the face of the control
piston (2).
The oil pressure applied to the face of the control piston (2) moves the control piston (2) against the force applied
from the belleville washer (1). This releases the force applied by the belleville washer (1) from the friction and steel
plates (5).
The driven gear (4) can now rotate freely without transferring the drive through the clutch to the driveshaft (6). Lubri-
cation oil will be supplied through the friction and steel plates (5).
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Clutch Dog clutch - Dynamic description

BVF0907A 1
Four Wheel Drive Dog Clutch (Engaged)

1 Spring pack 2 Control piston
3 Control piston dog teeth 4 Drive gear
5 Driven gear 6 Driven gear dog teeth
7 Driveshaft
Figure Colour Key

A Lubrication B Return to reservoir
The four wheel drive clutch solenoid is de-energized and the spring pack (1) applies a force to the control piston (2),
which moves the control piston dog teeth (3) into the driven gear dog teeth (6). Drive is transferred from the drive gear
(4), mounted on the rear axle pinion to the driven gear (5) and through the clutch to the front axle via the driveshaft (7).
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BVF0907B 2
Four Wheel Drive Dog Clutch (Disengaged)

1 Spring pack 2 Control piston
3 Control piston dog teeth 4 Drive gear
5 Driven gear 6 Driven gear dog teeth
7 Driveshaft
Figure Colour Key

A Lubrication B Low pressure circuit
The four wheel drive clutch solenoid is energized, supplying oil from the low pressure circuit to the face of the control
piston (2).
The oil pressure applied to the face of the control piston (2) moves the control piston (2) against the force applied by
the spring pack (1). This releases the control piston dog teeth (3) from the driven gear dog teeth (6).
The driven gear (5) can now rotate freely without transferring the drive through the clutch to the driveshaft (7).
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Clutch Multi plate clutch - Sectional view
BVF0811A 1
Four Wheel Drive Multi Plate Clutch
1 Retaining nut 2 Belleville washer

5 Annular sealing rings 6 Oil supply manifold
7 Oil supply manifold retaining pin 8 Driven gear
9 Friction and steel plates 10 Control piston
11 Driveshaft
H = 0.8 - 1.1 mm (0.031 - 0.043 in) release travel
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Clutch Dog clutch - Sectional view

BVF0812A 1
Four Wheel Drive Dog Clutch
1 Spring pack retaining washer 2 Spring pack

3 Control piston 4 Control piston dog teeth
7 Annular sealing rings 8 Oil supply manifold
9 Oil supply manifold retaining pin 10 Driven gear
11 Driven gear dog teeth 12 Driveshaft
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Hydraulic line - Remove

Prior operation:
Remove the four wheel drive clutch - see Clutch - Remove (D.14.C).
Remove the power take-off housing - see REAR PTO Hydraulic - Remove (C.40.C).
1. Remove the O-ring (2) and the oil supply manifold

retaining pin (1).
BVF0886A 1
2. Using a suitable punch, remove the oil supply mani-

fold (1) and the bearing (2).
BVF0887A 2
Next operation:
Hydraulic line - Install (D.14.C)
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Hydraulic line - Install

Prior operation:
Hydraulic line - Remove (D.14.C)
1. Install new O-rings (1) onto the oil supply manifold.
BVF0891A 1
2. Install the oil supply manifold (2) and the bearing (1)
into the rear axle housing.
NOTE: Make sure the hole (4) in the oil supply manifold is
aligned with the hole (3) in the rear axle housing.
BVF0888A 2
3. Install the oil supply manifold retaining pin (1) and a

new O-ring (2).
BVF0886A 3
Next operation:
Install the power take-off housing - see REAR PTO Hydraulic - Install (C.40.C).
Install the four wheel drive clutch - see Clutch - Install (D.14.C).
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Shaft - Remove (Standard axle)

Prior operation:
WARNING
B026
1. Remove the four wheel driveshaft guard (1).
BVE0871A 1
2. Expand the circlip (1) and slide the circlip (1) and
sleeve (2) along the four wheel drive shaft.
BVE0468A_335 2
3. Remove the four wheel driveshaft and the central

support.
BVE0486A_336 3
Next operation:
Shaft - Install (Standard axle) (D.14.C)
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Shaft - Install (Standard axle)

Prior operation:
Shaft - Remove (Standard axle) (D.14.C)
WARNING
B026
1. Install the four wheel driveshaft and the central sup-

port.
BVE0486A_336 1
2. Expand the circlip (1) and slide the circlip (1) and
sleeve (2) along the four wheel driveshaft.
BVE0468B_337 2
3. Install the four wheel driveshaft guard (1).
BVE0871A 3
Next operation:
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Clutch - Remove
Prior operation:
Remove the four wheel driveshaft - see Shaft - Remove (Standard axle) (D.14.C).
WARNING
B026
suitable container.
Install the drain plug after the oil has drained.
BVE0443A 1
2. Remove the oil supply tube retaining bolt (1).
BVF0872A 2
BVE0353A 3
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BVE0618A 4
5. Using suitable circlip pliers, remove the four wheel

driveshaft oil seal carrier retaining circlip (1).
BVF0873A 5
6. Using a suitable lever, remove the four wheel drive-

shaft coupler (1) and the oil seal carrier.
BVF0874A 6
7. Using suitable circlip pliers, remove the bearing re-

taining circlip (1).
BVF0876A 7
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8. Using the locally fabricated slide hammer (1), re-

move the four wheel driveshaft (2).
Remove the four wheel drive clutch assembly from
underneath the rear axle.
NOTE: Using a suitable hydraulic jack, support the four
The four wheel driveshaft cannot be fully removed from the
rear axle housing. To remove the driveshaft from the rear
axle housing, separate the transmission from the rear axle.
BVE0877A 8
Next operation:
Clutch Multi plate clutch - Disassemble (D.14.C) or
Clutch Dog clutch - Disassemble (D.14.C)
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Clutch Multi plate clutch - Disassemble

Prior operation:
Remove the clutch - see Clutch - Remove (D.14.C).
1. Unstake the retaining nut (1).
BVF0965A 1

draulic press, compress the Belleville washer. Using
special tool 380000984 (2), remove the retaining nut
(3).
NOTE: Make sure the retaining nut is fully unstaked or
damage to the threads may occur.
BVF0966A 2
3. Remove the special tools and the belleville washer

(1).
BVF0967A 3
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4. Rotate the clutch assembly 180 °.

Using suitable circlip pliers, remove the circlip (1).
BVF0968A 4
5. Remove the ’D’ washer (1) and the driven gear (2).
BVF0969A 5
6. Using suitable circlip pliers, remove the circlip (1).
BVF0970A 6
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7. Remove the end plate (1) and the friction and steel
plates (2).
BVF0971A 7
8. Remove the pressure plate (1).
BVF0972A 8
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9. Remove the piston (1) from the oil seal carrier (2).
NOTE: Apply pressure evenly to the piston.
BVF0973A 9
10. Using a suitable hydraulic press, remove the shaft

(1) from the oil seal carrier (2).
BVF0974A 10
Next operation:
Clutch Multi plate clutch - Assemble (D.14.C)
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Clutch Multi plate clutch - Assemble

Prior operation:
Clutch Multi plate clutch - Disassemble (D.14.C)

draulic press, install the oil seal carrier (2) onto the
shaft.
BVF0976A 1
2. Install new oil seals (1) and apply the correct speci-
fied driveline oil to the oil seals.
BVF0975A 2
3. Install the piston (1) onto the oil seal carrier (2).
NOTE: Apply pressure evenly to the piston to avoid dam-
age to the oil seals.
BVF0977A 3
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Install the pressure plate (1).
BVF0972A 4
5. Install the friction and steel plates (2) and the end
plate (1).
BVF0971A 5
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BVF0970A 6
7. Install the driven gear (2) and the ’D’ washer (1).
BVF0969A 7
BVF0968A 8

Install the belleville washer (1).
BVF0967A 9
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10. Loosely install the retaining nut (1).
BVF0965A 10
11. Using special tool 380000984. (1) and a suitable

hydraulic press, compress the belleville washer with
a force of 2000 - 2200 kg (4409.2 - 4850.2 lb). Using
special tool 380000984 (2), tighten the retaining nut
(3) to the specified torque value of 15 - 25 Nm (11.06
- 18.44 lb ft).
BVF0966A 11
12. Remove the special tools.

Make a reference mark (1) on the shaft opposite the
cut out (A).
Make an alignment mark (2) on the retaining nut
which is 210 ° (3.5 flats) clockwise from the refer-
ence mark (1) midway between the cut outs (D) and
(E).
BVF0978A 12
13. Using special tool 380000984 and a suitable hy-

draulic press, compress the belleville washer with a
force of 2000 - 2200 kg (4409.2 - 4850.2 lb).
Using special tool 380000984, rotate the retaining
nut anti-clockwise until the alignment mark (2) is
aligned with the reference mark (1).
BVF0979A 13
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14. Stake the retaining nut (1).
BVF0965A 14
Next operation:
Install the clutch - see Clutch - Install (D.14.C).
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Clutch Dog clutch - Disassemble

Clutch Dog clutch - Exploded view (D.14.C)
Prior operation:
Remove the clutch - see Clutch - Remove (D.14.C).
1. Remove the splined washer (1) and the four wheel

drive clutch driven gear (2).
BVF0878A 1

draulic press, compress the spring pack and remove
the circlip (2).
BVF0879A 2
Next operation:
Clutch Dog clutch - Assemble (D.14.C)
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Clutch Dog clutch - Assemble

Clutch Dog clutch - Exploded view (D.14.C)
Prior operation:
Clutch Dog clutch - Disassemble (D.14.C)
1. Install new O-rings, items (9) and (10).

NOTE: Apply the specified driveline oil onto the O-rings.
draulic press, compress the spring pack and install
the circlip (2).
BVF0879A 1
3. Install the four wheel drive clutch driven gear (2) and
the splined washer (1).
BVF0878A 2
Next operation:
Install the clutch - see Clutch - Install (D.14.C).
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Clutch - Install
Prior operation:
Assemble the clutch - see Clutch Multi plate clutch - Assemble (D.14.C) or
Clutch Dog clutch - Assemble (D.14.C).
WARNING
B026
1. Install a new O-ring (1) onto the driveshaft.
BVF0882A 1
2. Install new O-rings (1) and annular sealing rings (2)

onto the driveshaft.
Apply the specified driveline oil onto the O-rings and
the annular sealing rings.
BVF0881A 2
3. Install the four wheel drive clutch assembly into the

rear axle housing.
Install the driveshaft (1).
NOTE: Using a suitable hydraulic jack, support the four
BVF0884A 3
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4. Using suitable circlip pliers, install the bearing retain-

ing circlip (1).
BVF0876A 4
5. Install a new oil seal carrier O-ring (1).
BVF0883A 5
6. Install a new oil seal (2) into the oil seal carrier (1).
BVF0889A 6
7. Install the four wheel drive coupler (1), oil seal carrier
(2), and the oil seal carrier retaining circlip (3).
BVF0875A 7
84276322A 31/05/2010
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8. Install the four wheel drive clutch inner cover. Tighten

BVE0618B 8

BVF0918A 9
10. Install the rear axle bottom cover. Tighten the retain-
BVE0353B_342 10
11. Install the oil supply tube retaining bolt (1).
BVF0872A 11
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Next operation:
Install the four wheel driveshaft - see Shaft - Install (Standard axle) (D.14.C).
Refill the driveline with the correct specified oil - see Consumables Lubrications and Coolants.
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2WD-4WD SYSTEM Hydraulic - Troubleshooting

NOTE: If the front wheel drive is not functioning correctly, check for any electronic error codes which may be stored.
These are defined by the error code range of 6001 to 7000 - see Control module - Fault code index (A.50.A).
(A.50.A).
Four wheel drive does not Four wheel drive engagement switch faulty. Replace the four wheel drive engagement
engage switch.
Four wheel drive control solenoid valve Repair or replace solenoid valve.
stuck open.
Worn clutch discs. Replace the clutch discs.
Incorrectly set multi-wet plate clutch re- Adjust the release travel.
lease travel.
With the four wheel drive Incorrectly adjusted brake pedal switches. Adjust the brake pedal switches.
clutch disengaged, the
four wheel drive does not
engage when the brake
pedals are depressed
Faulty brake pedal switch. Replace the brake pedal switch.
Four wheel drive does not Low transmission oil. Refill to the correct oil level.
disengage
Faulty low pressure circuit. Pressure test the low pressure circuit - see
Priority valve - Pressure test (A.14.A).
Faulty four wheel drive engagement circuit. Check the circuit.
Four wheel drive control solenoid valve Repair or replace the solenoid valve.
stuck closed.
Oil leaks through the oil seals with con- Replace faulty oil seals.
sequent pressure drop: hub, piston, and
transfer box shaft oil seals.
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Index

2WD-4WD SYSTEM Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2WD-4WD SYSTEM Hydraulic - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2WD-4WD SYSTEM Hydraulic - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2WD-4WD SYSTEM Hydraulic - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2WD-4WD SYSTEM Hydraulic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch Dog clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Clutch Dog clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Clutch Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch Dog clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Dog clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Clutch Multi plate clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Clutch Multi plate clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clutch Multi plate clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch Multi plate clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Shaft - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shaft - Install (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shaft - Remove (Standard axle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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STEERING Hydraulic - 20.C

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Contents
TECHNICAL DATA
STEERING Hydraulic
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fast steer system
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTIONAL DATA
STEERING Hydraulic
Control valve
Exploded view (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering cylinder
Exploded view (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded view (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fast steer system

Control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SERVICE
STEERING Hydraulic
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control valve
Remove (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Relief valve
Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering cylinder
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Remove (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overhaul (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Remove (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overhaul (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fast steer system
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Tie rod
Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIAGNOSTIC
STEERING Hydraulic
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
STEERING Hydraulic - Special tools
CAUTION
in this manual.
B008

previous No.
380000281 Roto-glyd seal installer 294056
Pressure Test Tools

previous No.
X 380000545 Hose 292246
380000570 Tee adaptor, 1/4 ORFS (Internal) x 1/4 ORFS (External) x 7/16 297600
BSP (Internal)
380000599 Blanking Cap 11/16 ORFS -
STEERING Hydraulic - Torque
BSE3556B 1
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Steering Wheel Retaining Nut 23 Nm (17 lb ft)

Front Wheel Nut (2WD) 314 Nm (232 lb ft)
Front Wheel Nut (4WD) 211 Nm (156 lb ft)
Motor End Cover 23 Nm (17 lb ft)
Cylinder, Rod End Nut (2WD) 270 Nm (199 lb ft)
Cylinder, Tube End Nut (2WD) 360 Nm (266 lb ft)
Cylinder, Tube End Pin Retaining Bolt (4WD) 23 Nm (17 lb ft)
Column to Frame Bolt 23 Nm (17 lb ft)
BSE3555B 2
STEERING Hydraulic - General specification

PUMP SPECIFICATIONS
2WD 4WD
Minimum Pump Output 40 l (8.8 UK gal)
100 cm³/rev (6.10 in³/rev) with Std
Axle
Steering Motor Displacement 160 cm³/rev (9.76 in³/rev)
125 cm³/rev (7.63 in³/rev) with HD
Axle
Relief Valve Maximum Differential 145 bar (2103 psi) with Std Axle
170 bar (2465 psi)
Pressure Setting 170 bar (2465 psi) with HD Axle
161 bar (2335 psi) with Std Axle
Absolute Gauge Pressure 186 bar (2697 psi)
186 bar (2697 psi) with HD Axle
TWO WHEEL DRIVE AXLE

Maximum Steering angle 55 °
Steering Wheel Turns (Lock to Lock) 3,3
Cylinder 1 off Double Acting
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Turning Radius with Brakes 3.28 m (10.76 ft)

Turning Radius less Brakes 3.66 m (12.01 ft)
Toe-out 0 - 13 mm (0 - 0.51 in)
FOUR WHEEL DRIVE AXLE

4 cyl. 6 cyl.
Maximum Steering angle 55 °
Steering Wheel Turns
3,9
(Lock to Lock)
Cylinder 2 off double acting
Turning Radius with Brakes
3.51 m (11.52 ft) 3.745 m (12.29 ft)
(4WD disengaged)
Turning Radius less Brakes
4.04 m (13.25 ft) 4.355 m (14.29 ft)
(4WD disengaged)
Toe-In 0 - 3 mm (0 - 0.12 in)
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Fast steer system - Torque
BAIL06CCM069FSA 1
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STEERING Hydraulic - Dynamic description
BSE3600A 1
Steering Operation Schematic - Neutral Position
Return Oil
Pump Oil
(Restricted by Cooling and Lubrication)
Trapped Oil Suction Oil
1 Metering Unit 2 Check Valve

3 Non Return Valve 4 Pump and Flow Control Valve
5 Filter 6 Return via Cooling and Lubrication
7 Pressure Relief Valve 8 Control Valve Sleeve
9 Control Valve Spool 10 Suction Valves (2WD Only)
11 Bias Valve (2WD Only) 12 Steering Cylinder/s
The steering motor incorporates a metering unit which regulates the volume of oil supplied to the cylinder so that it is
proportional to the angular movement of the steering wheel. The metering unit in combination with the check valve
also allows the steering to be operated MANUALLY without pressurised oil being supplied from the pump.
Suction valves (10) Figure 1, only used on two wheel drive models, prevent cavitation in the steering cylinder as oil is
transferred from a small area to a large area when the steering motor is in the neutral position.
The system is fully hydrostatic and as such there is no mechanical connection between the steering column and the
steering wheels.
Neutral Position
With the steering wheel held still, the leaf springs in the steering motor return and hold the spool and sleeve in the
neutral position. This ensures no more oil is supplied to the steering cylinder, Figure 1. The trapped oil is, however,
allowed to transfer between the left and right turn sides of the cylinder/s, on less Supersteer models, with reactive
steering motors, allowing the wheels to react to the ground conditions to provide feedback for the driver. On Super-
steer models there is no feedback to the driver when in the neutral position, the non-reactive type steering motor has
shock valves installed to relieve excessive pressure in the case of a large object being hit which may otherwise cause
damage to the system.
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BSE3601A 2
Oil Flow Schematic
Return Oil
Pressure Supply
(Restricted by Cooling and Lubrication)
Metered Oil to Steering Cylinder Suction Oil
Right Hand Turn (A)

When the steering wheel is turned the movement of the control valve spool in its sleeve forms a series of passages.
During right turns the oil flows through the sleeve along a groove in the valve spool and into a passage in the steering
motor housing which leads to the metering unit, Figure 2. The metering unit is turned by the drive shaft and directs
oil along another set of passages in the spool and sleeve and into the steering cylinder. Return oil from the other side
of the cylinder is directed through the valve spool and sleeve to a return passage in the housing.
Left Hand Turn (B)

When turning the wheel to the left oil flows along the sleeve and operates in a similar manner as described in right
hand turn, Figure 2.
Manual Turning (no Power Assistance)

In the event of a power steering pump failure or loss of oil pressure, the power steering system can be operated
manually. Turning the steering wheel rotates the metering unit rotor and forces oil into the power steering cylinder
(2WD) or cylinders (4WD).
On the suction side of the metering unit, return oil flows from the cylinder and is drawn through the check valve to
feed the metering unit.
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STEERING Hydraulic - Static description
BSE3556A 1
Hydrostatic Steering System Component Layout (Right Hand Side)
1 Steering Motor 2 Right Hand Turn Hose

3 Left Hand Turn Hose 4 Steering Return Line
5 Switch 6 Steering Pump
7 Pump Output Line
All models have fitted as standard, hydrostatic steering systems that are powered when the engine is running, by a
fixed displacement hydraulic pump mounted on the rear axle.
Both open and closed centre hydraulic systems share the main intake filter of that system.
The pump, driven by a gear straight from the P.T.O. shaft, pressurises the steering column operated steering motor.
The pressurised oil from the steering motor drives the axle mounted double acting steering cylinder (2WD), or twin
cylinders (4WD).
A low pressure warning switch is fitted to the pump outlet port and should the pressure in the steering pump system
drop below 0.7 bar (10 psi) a light will illuminate on the instrument cluster.
The steering motor is similar across the vehicle range and is bolted to a bracket within the steering console and
connected to the steering column by a splined shaft.
All models, use a reactive type steering motor.
The steering column is adjustable for varying angles of tilt on all models.
On two wheel drive units the steering cylinder is fixed at one end to the front axle beam and at the other to an eye on
the spindle steering arm.
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On four wheel drive units two steering cylinders are used, one for each wheel. The cylinders are fixed at one end to
the axle casing and the piston end to steering arms from the swivel housings.
The pressure relief valve for the system is contained within the steering motor itself.
BSE3555A 2
Hydrostatic Steering System Component Layout (Left Hand Side)
1 Steering Motor 2 Right Hand Turn Hose

3 Left Hand Turn Hose 4 Steering Cylinder
OPERATION
Oil is drawn from the rear axle and into the pump through a filter, pressurised by the rotation of the gears, and expelled
through the pump outlet port to the steering motor.
The pressurised oil, when received at the steering motor, is directed to the steering actuating cylinder when the steer-
ing wheel is turned.
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Control valve - Exploded view (Steering Motor)
60-41-001 1
Steering Motor (2WD and 4WD)
1 Pin 2 Centering Springs

3 Retaining Bolts 4 Dowel Pin Bolt
5 O’ Ring Seal (Kit) 6 End Plate
7 Rotor and Stator Assembly 8 Manifold Plate
9 Drive Shaft 10 Retainer
11 Ball 12 Relief Valve Seat
13 Relief Valve (Kit items) 14 Spring
15 Complete Assembly 16 Ball (2WD only)
17 Pin (2WD only) 18 Thrust Bearing and Washers
19 Spacer
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Steering cylinder - Exploded view (4WD)
1b0o2004061085 1
Steering Cylinder Assembly - Four Wheel Drive
1 Cylinder 2 Wiper Seal

3 Retaining Ring 4 Gland Nut
5 Cylinder Rod 6 Gland and Seal Assembly
7 Piston 8 Nut
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Steering cylinder - Exploded view (2WD)

1b0o2004061084 1
Steering Cylinder Assembly - Two Wheel Drive
1 Cylinder 2 Lockring
3 Bearing 4 Gland
5 O’ Ring 6 Seal
7 Wiper Seal 8 Gland Lockring
9 Cylinder Rod 10 Retaining Ring
11 Piston 12 Seal
13 Seal
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Fast steer system - Dynamic description
1. Steering Cylinders 2. Steering Motor

3. Steering Motor Relief Valve 4. Split Valve/LVDT Valve (Linear Variable Differential
Transformer)
5. Shock Valve (SDS)(225-245) 6. Shock Valve (SDS)(225-245)
7. Distributor Spool 8. Compensator Valve
9. LSD Valve (40-180 Bar) 10. Change Valve (Pilot Valve)
11. Solenoid 12. Steering pump
13. Steering Low Pressure Warning Switch 14. Main Hydraulic Pump
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BAIL06CCM241JSA 1
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Turn Assist Hydraulic Operation

Hydraulic oil is fed from the steering pump (12) to the change or pilot valve (10) . When the system is enabled by
activating the Turn Assist switch, the solenoid (11) moves against the spring pressure to allow oil to activate the
change or pilot valve (10). The change valve spool overcomes the spring pressure and allows the oil to reach the
distributor spool (7) this directs the oil flow from the steering motor directly to the distributor spool and split valve. If
the steering wheel is rotated left for example, the pilot pressure is exerted on the distributor spool thus enabling oil to
flow to the Split valve (4) which in turn allows the increased oil flow to activate the steering cylinder (1).
Operating and Monitoring System

The electrical and hydraulic systems allow safe operation and monitoring of system in the following manner: When
the system is enabled by using the Turn Assist switch, the electronics perform a functional and status check. The
split valve spool is checked to ensure that it is not stuck in such a manner that would allow the Turn Assist system to
be active or operate in a dangerous way which may cause loss of control of the tractor. Should such a state exist the
system activates the critical stop audible and visual alarms to the operator. If there is an invalid state that does not
endanger the operator, only the visual alarm is activated. If the split valve is stuck at the midpoint of travel, then the
system is in between these two modes and will be unable to determine exactly which mode the tractor is in and the
critical stop alarms are activated. If the distributor spool becomes stuck it will be forced back into place by hydraulic
pressure and the system will revert to normal steering mode.
When the system has determined that the hydraulic components are functioning correctly the system then checks the
operator inputs and verifies that the operator controls are working correctly. The solenoids, sensors, and switches are
checked for correct operational voltage and current levels and any failure will cause the system to go into a fail-safe
mode. If there is any problems with any of these components the system deactivates itself and prevents any electrical
engagement of the system. If there are no problems with the components then the system goes into standby mode
awaiting operator inputs. The system constantly monitors itself checking for failures and illegal logic combinations
during fast steer operation and notifies the operator via the visual and audible alarms in the event of a system error
or component failure.
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Fast steer system - Hydraulic schema

Turn Assist Hydraulic Operation - For operation description refer to : Fast steer system - Dynamic
description (D.20.C)
1. Steering Cylinders 2. Steering Motor

3. Steering Motor Relief Valve 4. Split Valve/LVDT Valve (Linear Variable Differential
Transformer)
5. Shock Valve (SDS)(225-245) 6. Shock Valve (SDS)(225-245)
7. Distributor Spool 8. Compensator Valve
9. LSD Valve (40-180 Bar) 10. Change Valve (Pilot Valve)
11. Solenoid 12. Steering pump
13. Steering Low Pressure Warning Switch 14. Main Hydraulic Pump
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BAIL06CCM241JSA 1
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Turn Assist Hydraulic Operation

Refer to: Fast steer system - Hydraulic schema (D.20.C)
Hydraulic oil is fed from the steering pump (12) to the change or pilot valve (10) . When the system is enabled by
activating the Turn Assist switch, the solenoid (11) moves against the spring pressure to allow oil to activate the
change or pilot valve (10). The change valve spool overcomes the spring pressure and allows the oil to reach the
distributor spool (7) this directs the oil flow from the steering motor directly to the distributor spool and split valve. If
the steering wheel is rotated left for example, the pilot pressure is exerted on the distributor spool thus enabling oil to
flow to the Split valve (4) which in turn allows the increased oil flow to activate the steering cylinder (1).
Operating and Monitoring System

The electrical and hydraulic systems allow safe operation and monitoring of system in the following manner: When
the system is enabled by using the Turn Assist switch, the electronics perform a functional and status check. The
split valve spool is checked to ensure that it is not stuck in such a manner that would allow the Turn Assist system to
be active or operate in a dangerous way which may cause loss of control of the tractor. Should such a state exist the
system activates the critical stop audible and visual alarms to the operator. If there is an invalid state that does not
endanger the operator, only the visual alarm is activated. If the split valve is stuck at the midpoint of travel, then the
system is in between these two modes and will be unable to determine exactly which mode the tractor is in and the
critical stop alarms are activated. If the distributor spool becomes stuck it will be forced back into place by hydraulic
pressure and the system will revert to normal steering mode.
When the system has determined that the hydraulic components are functioning correctly the system then checks the
operator inputs and verifies that the operator controls are working correctly. The solenoids, sensors, and switches are
checked for correct operational voltage and current levels and any failure will cause the system to go into a fail-safe
mode. If there is any problems with any of these components the system deactivates itself and prevents any electrical
engagement of the system. If there are no problems with the components then the system goes into standby mode
awaiting operator inputs. The system constantly monitors itself checking for failures and illegal logic combinations
during fast steer operation and notifies the operator via the visual and audible alarms in the event of a system error
or component failure.
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Fast steer system - Static description

The optional Turn Assist system is designed to provide fast steering response when required i.e. when operating with
a front loader.
From the straight ahead position, Turn Assist will provide full right or left hand steering lock with plus or minus 8 °
movement of the steering wheel.
To activate Turn Assist, depress the isolator switch, Figure 1.
The green warning light (3), Figure 3 or 4 on the instrument panel will illuminate indicating that the system is active.
BRJ4978I 1
NOTE: For Turn Assist function the tractor speed must not exceed 10 km/h ( 6.2 mph).
To operate Turn Assist, depress and hold the centre ring (1), Figure 2 on the steering wheel, to disengage, release
the ring.
BAIL06CCM072ASA 2
With the Turn Assist centre ring depressed, the yellow warning light (2), Figure 3 4 will illuminate on the instrument
panel. It will extinguish when the centre ring is released.
BAIL06CCM078ASA 3
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BAIL09HHP335AVB 4
Turn Assist will only function if all the following conditions are met:
• The isolator switch is in the ON position
• The speed of the tractor does not exceed 10 km/h ( 6.2 mph)
• The centre ring (1), Figure 2 is held down.
• The warning light (3), Figure 3 4 on the instrument panel is illuminated
Turn Assist will automatically disengage if a fault occurs or one of the above conditions are not applied. Should Turn
Assist automatically disengage, an audible warning will sound and an error code will be appear in the Dot Matrix
Display.
To re-activate the Turn Assist function, turn off the isolator switch, Figure 1, ensure the tractor speed is below 10 km/h
( 6.2 mph), and turn the switch on again.
NOTICE: To promote safe operation of Turn Assist, it is advised that the operator become familiar with the system
before operating in the field.
NOTE: In cold oil temperature conditions it is advisable to turn steering from lock to lock before engaging the Turn
Assist System.
The Turn Assist controller is located on the right hand side underneath the instrument console. The module (1), Figure
5 is connected to the Turn Assist valve via a harness.
BAIL06CCM123ASA 5
A proximity sensor (1) is located on the steering column. This senses the magnetic field strength change as the metal
in the plate of the inner steering wheel ring moves away or closer to the sensor.
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BAIL06CCM075ASA 6
Turn Assist valve (1) is coupled to the steering motor (2)
BAIL07APH352ASA 7
The Turn Assist valve is connected electronically to the controller by a harness . When the system is enabled the
controller powers a pilot valve solenoid (1). The position of the split valve spool is checked by the sensor (LVDT) (2)
to verify that the spool is not stuck in such a manner that would allow the Fast steer to be active or operate in an
unsafe condition.
The construction of the LVDT consists of three coils which make up the static transformer and a movable inner iron
core. One of the coils is the primary coil and the other two are secondary coils. When the iron core slides through
the transformer, a certain number of coils are affected by the proximity of the sliding core and thus generate a unique
output to the controller.
BAIL06CCM076ASA 8
After the operator has enabled Turn Assist operation and the diagnostic program has not encountered any faults, the
Turn Assist controller powers a pilot valve solenoid (1) attached to a change valve (2) on the Turn Assist valve. this
directs the oil flow from the steering motor directly to the distributor spool and split valve. When the steering wheel is
turned the trapped oil in the steering motor now acts as pilot pressure to move the distributor valve, connecting the
pump directly to the steering cylinders. The increased flow of oil to the steering cylinders provides an accelerated
steering action. When the steering ring is released the Turn Assist controller disengages the solenoid and the oil flow
reverts to the conventional steering motor operation.
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Fast steer system Control valve - Exploded view
BAIL06CCM079FSA 1
Turn Assist Valve Components
1. LVDT Valve (Linear variable differential transformer) 2. Plug M18 X 1.5

(Linear Position Transducer)
3. LSD Valve (40-180 Bar) 4. Solenoid
5. Plug 6. Bushing
7. Bushing 8. Change Valve Spool
9. Change Valve Spring 10. ’O’ Ring
11. ’O’Ring 12. Split Valve Spring
13. Distributor Spool 14. Distributor Spool
15. Plug M12 X 1.5 16. Valve Body
17. SDS Valve 18. SDS Valve
19. Screw 20. Plug
21. Plug M12 X 1.5 22. Plug M18 X 1.5
23. Compensator Spring 24. Compensator Spool
25. Bushing 26. Spring
27. Bushing 28. Distributor Pin
29. ’O’Ring
84276322A 31/05/2010
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STEERING Hydraulic - Pressure test

There is no pressure relief valve in the steering hydraulic pump. The following practical test will determine if the
steering hydraulic pump output is sufficient to allow satisfactory operation of the steering system.
Steering Test
2. Quickly turn the steering from lock to lock.
If the steering is operating correctly the reaction
should be immediate with no time delay between
turning the steering wheel and the movement of the
wheels.
3. At full lock the relief valve in the steering motor
should be heard to blow and the engine speed drop
to approximately 970 RPM.
If on the 12x12 / 24x24 with fixed displacement pump
the transmission / steering low pressure warning
symbol is displayed when the steering is held on full
lock, this is an indication that the hydraulic pump has
developed an internal leak. Check the torque of the
hydraulic pump mounting bolts and if tight, examine
the hydraulic pump for leaking seals or wear.
BVE0400A 1
Steering Circuit Pressure Test

4. Install the T-adaptor 380000570 (1) and the quick
release fitting 380000492 (3), into the hydraulic hose
to the steering cylinder.
380000543 and the hose 380000545.
BVE0160A_497 2
5. Set the engine speed to 1500 RPM to observe the

6. Turn the steering wheel to full lock and hold in this
position.
7. The pressure reading should be 186 bar (2697 psi).
Steering Relief Valve Pressure Test

NOTICE: There is no pressure relief valve in the steering / low pressure hydraulic pump and the following pressure
test must only be performed as specified below. Failure to observe this precaution may result in severe damage to
the hydraulic pump.
84276322A 31/05/2010
D.20.C / 28
8. Turn the steering onto full right hand lock.

Disconnect the right hand turn feed hose.
Install the T-adaptor 380000570 (1) and the quick
release fitting 380000492 (4), into the solid tube. Cap
the bottom of the Tee-piece with the blanking cap,
380000599 or a standard No 6 cap (11/16 inch ORFS
female thread cap purchased locally (3).
380000543 and the hose 380000545.
BVE0161A_498 3
9. Set the engine speed to 1500 RPM to observe the

10. Turn the steering wheel to the left with a pull of ap-
proximately 22 N (4.9 lb) and observe the pressure
reading.
NOTE: The use of a force greater than 22 N (4.9 lb) at
the rim of the steering wheel may lead to slightly inaccu-
rate readings due to the pumping action of the hydrostatic
steering motor.
The pressure reading should be:
186 bar (2697 psi) for all models.
If the steering test was satisfactory but the pressure read-
ings are out of specification the pressure relief valve in the
steering motor must be adjusted.
If the system pressure is not to specification proceed to
Relief Valve Adjustment.
Differential Pressure
Differential pressure is the difference in pressure between
the supply and sump ports on the steering motor. Mea-
sured (gauge) pressure is equal to the relief valve setting
plus system back pressure.
System back pressure should be approximately 16 bar
(232 psi) for all models.
The flow of oil on leaving the steering motor returns to the
pump body for distribution to the low pressure and/or lubri-
cation circuits. The pressure of oil returning from the steer-
ing motor is regulated at a pressure of 16 bar (232 psi),
by the low pressure regulating valve, at 2100 RPM. As the
pressure is regulated, excess oil in the low pressure circuit
flows through the regulating valve, into an adjacent lubri-
cation circuit relief valve which limits the pressure of oil in
the lubrication circuit to 7 bar (101.5 psi).
84276322A 31/05/2010
D.20.C / 29
Control valve - Remove (Steering Motor)

1. Position the tractor on a hard level surface and apply
the parking brake.
2. Raise the engine hood.
3. Remove the steering column console.
4. Disconnect the four supply/return tubes and ‘O’ ring
seals from the steering motor and cap the ends of the
tubes.
5. Remove the four bolts at the base of the steering
column and slide the steering motor from the upper
section of the steering column.
BSE3551B 1
6. Remove the steering motor from the front of the cab

through the engine compartment.
Next operation:
Control valve - Disassemble (Steering Motor) (D.20.C)
84276322A 31/05/2010
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Control valve - Disassemble (Steering Motor)

Prior operation:
Control valve - Remove (Steering Motor) (D.20.C)
1. With the steering motor connectors removed note

position of the non return valve.
Hold the steering motor securely in a vice using a
tube connector as shown in, Figure 1.
Remove the end plate bolts, end plate and ‘O’ ring.
NOTE: The position of the pin bolt must remain the same
on re-assembly.
60-41-002 1
2. Remove metering unit, valve plate and ‘O’ ring seals,

note mating surfaces for correct re-assembly.
60-41-003 2
3. Lift out rotor drive-shaft.
60-41-004 3
84276322A 31/05/2010
D.20.C / 31
4. Unscrew the check valve retainer and shake out the

check and suction valves (2WD only).
60-41-005 4
5. Remove the relief valve assembly.

NOTICE: The relief valve must be set to the correct pres-
sure setting on re-assembly.
60-41-006 5
6. Remove the inner and outer valve sleeves, bearings

and thrust washer.
NOTE: When removing spool and sleeve ensure drive pin
is in a horizontal position so that it cannot fall into an internal
gallery and make removal difficult.
60-41-007 6
7. Once spool is disassembled from the body ensure oil

seal is removed.
60-41-008 7
84276322A 31/05/2010
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8. Remove the control valve spool and sleeve.

NOTICE: Upon re-assembly ensure washer (1) is installed
with chamfer towards the valve sleeve.
60-41-009 8
9. Remove centering springs.

Remove drive pin.
Push inner sleeve from outer sleeve.
Remove ‘O’ ring and back-up ring.
NOTE: Arrangement of the leaves must remain the same
upon re-assembly.
60-41-010 9
Next operation:
Control valve - Visual inspection (D.20.C)
Control valve - Assemble (Steering Motor) (D.20.C)
84276322A 31/05/2010
D.20.C / 33
Control valve - Visual inspection

1. Wash all parts in a suitable solvent to remove any
foreign particles and dry with a clean lint free cloth or
compressed air.
2. Inspect valve sleeves for, damage or wear. Minor
burrs or scratches can be removed with a fine abra-
sive. Ensure all parts are thoroughly cleaned prior to
re-assembly.
3. Check leaf springs for damage. Replace if neces-
sary.
4. Discard all ‘O’ ring seals and replace with new seals
on re-assembly.
84276322A 31/05/2010
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Control valve - Assemble (Steering Motor)

Prior operation:
Control valve - Disassemble (Steering Motor) (D.20.C)
1. Assemble inner and outer sleeves so that the leaf

spring slots align.
Install the drive pin.
60-41-010 1
2. Install the leaf springs and push fully into position.
60-41-012 2
3. Install leaf spring retainer, and bearing.

NOTE: The inner bearing race must be positioned with the
chamfer side facing the spool.
60-41-009_499 3
84276322A 31/05/2010
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4. Apply a light coating of hydraulic oil onto the sleeve

and insert into the steering motor body.
Coat the ‘O’ ring and back-up ring, with hydraulic fluid
and position them onto the seal installer guide.
NOTE: Use special tool No. 380000281 to install oil seal
type roto-glyd.
60-41-013 4
5. Position the seal guide tool into the sleeve and push
down with a twisting action.
Remove tools once the seal has seated.
60-41-014 5
6. With the seal installed in the motor body refit control

valve.
NOTE: Ensure that the Drive is in a horizontal position to
aid re-assembly.
60-41-015 6
7. Once the control valve is seated correctly refit the

check and suction valves (2WD only).
Screw the check valve down to just below the surface
of the housing.
60-41-005_500 7
84276322A 31/05/2010
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8. Refit the ‘O’ Ring and place the end plate in position.
60-41-016 8
Metering Unit Reassembly

9. To aid reassembly install the control valve into the
housing so that the drive pin is perpendicular to the
front face of the housing.
Install drive link into the steering motor body, ensur-
ing that the link engages correctly over the drive pin.
60-41-004_501 9
10. Assemble the metering unit rotor and stator and in-
stall new lightly greased ‘O’ rings to either side of the
stator.
Assemble the rotor and stator onto the drive link.
60-41-003_502 10
84276322A 31/05/2010
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11. Install the end plate and bolts, ensure the pin bolt (1)
is fitted in position ‘7’. Tighten the bolts in two steps,
first to 10.8 Nm (8.0 lb ft) and then to 28.4 Nm (20.9
lb ft) in sequence as shown.
1b0o2004061083 11
12. Install the relief valve assembly, items (1), (2) and
(3), leaving the plug, item (4) out until after the relief
valve has been adjusted.
Check to ensure the motor turns freely without bind-
ing.
NOTICE: The relief valve must be set to the correct pres-
sure setting after the motor has been re-assembled. Follow
the correct procedure as Relief valve - Pressure setting
(D.20.C).
60-41-006_503 12
Next operation:
Control valve - Install (Steering Motor) (D.20.C)
84276322A 31/05/2010
D.20.C / 38
Control valve - Install (Steering Motor)

Prior operation:
Relief valve - Pressure setting (D.20.C)
1. After the relief valve has been correctly set re-install

the steering motor onto the mounting bracket and
tighten the securing bolts to a torque value of 13 -
20 Nm (9.6 - 14.8 lb ft).
BSE3551B 1
2. Reconnect the steering hoses, tighten to a torque

value of 13 - 20 Nm (9.6 - 14.8 lb ft).
3. Purge the air from the system by operating the steer-
ing system from lock to lock until the system functions
correctly.
Next operation:
Refill the driveline with the correct specified oil - see Consumables Lubrications and Coolants.
84276322A 31/05/2010
D.20.C / 39
Relief valve - Pressure setting
1b0o2004061082 1
Steering Motor Relief Valve Adjustment
1 Plug 2 Steering Shaft

3 Relief Valve 4 Fabricated Steering Motor Output Hose
5 Tractor Tubes to Steering Cylinder 6 Fabricated Hose for Pump Supply to Steering
Motor
7 Pressure Gauge 0 - 350 bar (0 - 5075 psi) 8 Size 8 ORS Swivel Running Tee
9 Size 10 ORS Swivel Running Tee 10 Pressure Gauge 0 - 35 bar (0 - 508 psi)
11 Size 6 ORS Blanking Cap 12 Spring
13 Adjuster
84276322A 31/05/2010
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Relief Valve Adjustment - All Models

1. Disconnect the steering motor from the steering
bracket, as detailed previously in Control valve -
Remove (Steering Motor) (D.20.C) and remove
from the tractor.
NOTE: To adjust the steering system relief valve it is
necessary to remove the steering motor from the steering
bracket, to gain access to the hexagon headed adjusting
screw.
2. Fabricate suitable test hoses to connect from the
tractor pressure and return tubes. Connect the hoses
into locally procured tee pieces and install pressure
gauges. Start the engine and idle between 1450
- 1500 RPM. Run the tractor until the transmission
oil reaches normal working temperature of approxi-
mately 68 °C (154.4 °F).
3. With the engine running, turn the steering motor shaft
to obtain full lock. The pressure gauge reading at
point ’A’ should read 186 bar (2697 psi). The gauge
pressure at point ’B’ should be in the region of 16 bar
(232 psi).
4. To establish actual (differential) pressure subtract
gauge ’B’ reading from the gauge ’A’ reading. The
differential pressure should be to the specification
of: Gauge ’A’ 186 bar (2697 psi) minus Gauge ’B’
16 bar (232 psi) = 170 bar (2465 psi) on all models.
5. If the pressure readings are not correct, reset the
adjuster (13), Figure 1, using an 8 mm (0.31 in)
hexagon key. Half a turn on the adjuster equates to
approximately 13.8 bar (200 psi).
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Steering cylinder - Remove (2WD)

60-41-029 1
Steering Cylinder Installation - Two Wheel Drive (Standard Duty)
1 Nut 2 Washer
3 Nut 4 Washer
5 Cylinder Mounting Bracket 6 Spacer
7 Bolt
1. Stand the unit on a hard level surface and position

the front wheel in the straight ahead position.
2. Disconnect flexible pipes, cap the open pipe ends
and remove hose clamps.
3. Remove the nut securing the cylinder rod ball joint to
the steering arm and separate the joint, Figure 1.
4. Remove the steering cylinder to axle pivot pin and
remove the steering cylinder from the vehicle.
Next operation:
Steering cylinder - Overhaul (2WD) (D.20.C)
84276322A 31/05/2010
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Steering cylinder - Overhaul (2WD)

Steering cylinder - Exploded view (2WD) (D.20.C)
Prior operation:
Steering cylinder - Remove (2WD) (D.20.C)
1. Using appropriate circlip pliers, remove the gland

lockring.
60-41-030 1
2. Using a punch, push the steering cylinder gland into

the cylinder and remove the wire locking ring.
40-25-25 SHG 2
3. Pull the rod and gland assembly from the cylinder.

4. Remove the nut from the cylinder rod and disassem-
ble to replace seals.
5. Inspect the bore of the cylinder and replace if scored.
6. Reassemble the cylinder in the reverse to disassem-
bly, lubricating all components as assembled. Re-
place all seals supplied in the service seal kit.
NOTE: The seal located in the centre of the gland is re-
placeable.
Next operation:
Steering cylinder - Install (2WD) (D.20.C)
84276322A 31/05/2010
D.20.C / 43
Steering cylinder - Install (2WD)

Prior operation:
60-41-029 1
Steering Cylinder Installation - Two Wheel Drive (Standard Duty)
1 Nut 2 Washer
3 Nut 4 Washer
5 Cylinder Mounting Bracket 6 Spacer
7 Bolt
1. Install the steering cylinder on the vehicle and install

the steering cylinder to axle pivot pin.
2. Common the joint and install the nut securing the
cylinder rod ball joint to the steering arm, Figure 1.
3. Open the pipe ends and connect the flexible pipes.
4. Position of flexible pipes and orientation of connec-
tors.
Install the hose clamps.
84276322A 31/05/2010
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Steering cylinder - Remove (4WD)
40-25-38 SHG 1
Steering Cylinder Installation - Four Wheel Drive
1 Pivot Pin 2 Pivot Pin

3 Shaped Washer 4 Spacer
5 Spacer 6 Circlip
7 Spacer
1. Stand the unit on a hard level surface and position

the front wheel in the straight ahead position.
2. Disconnect flexible pipes, cap the open pipe ends
and remove hose clamps.
NOTE: Position of flexible pipes and orientation of connectors must be the same upon re-assembly.
3. Remove the snap ring (6) retaining the steering arm
to the cylinder piston pivot pin and remove the pivot
pin (2).
4. Remove the steering cylinder fixed end pivot pin re-
taining bolt and withdraw the pivot pin (1). Remove
the cylinder from the vehicle.
Next operation:
84276322A 31/05/2010
D.20.C / 45
Steering cylinder - Overhaul (4WD)

Steering cylinder - Exploded view (4WD) (D.20.C)
Prior operation:
Steering cylinder - Remove (4WD) (D.20.C)
1. Using appropriate ‘C’ spanner, unscrew and remove

the gland nut.
Using a punch, push the steering cylinder gland into
the cylinder and remove the wire locking ring.
Pull the rod and gland assembly from the cylinder.
Remove the nut from the cylinder rod and disassem-
ble to replace seals.
40-25-28 SHG 1
2. Inspect the bore of the cylinder and replace if scored.

Reassemble the cylinder in the reverse to disassem-
bly, lubricating all components as assembled. Re-
place all seals supplied in the service seal kit.
NOTE: The seal located in the centre of the gland is re-
placeable.
40-25-25 SHG 2
Next operation:
Steering cylinder - Install (4WD) (D.20.C)
84276322A 31/05/2010
D.20.C / 46
Steering cylinder - Install (4WD)

Prior operation:
40-25-38 SHG 1
Steering Cylinder Installation - Four Wheel Drive
1 Pivot Pin 2 Pivot Pin

3 Shaped Washer 4 Spacer
5 Spacer 6 Circlip
7 Spacer
1. Install the steering cylinder, fit the pivot pin’s (1) and
(2). Install the retaining bolt.
2. Install the snap ring (6) retaining the steering arm to
the cylinder piston.
3. Open the pipe ends and connect the flexible pipes.
4. Position the flexible pipes. Install the hose clamps.
Steering Stop Adjustment

5. Turn the wheels to full lock and adjust steering stop
to ensure tyres or mudguards do not touch the side
of the tractor and that the steering cylinders have not
reached the end of their travel.
40-25-37 SHG 2
84276322A 31/05/2010
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Fast steer system - Calibrate

MAXXUM 140
BAIL06CCM213AVA 1
2. Use the "h" and "m" and "dimming" buttons on the

instrument cluster to navigate the HH menu’s to H1
and the fast steer symbol on the KA controller.
BAIL06CCM601FVA 2
84276322A 31/05/2010
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3. Scroll through the available options using the "h" and

"m" button.
The three options are:
• "Pro" - proximity sensor
• "Lvdt" - LVDT sensor
• "deF" - adopt the default values

5. Select the "Pro" option by depressing the "dimming"
button.
BAIL06CCM638AVA 3
6. The lower central display will display "O _ _ _" for the
steering wheel in the disengaged position.
BAIL06CCM639AVA 4
7. Depress and hold the "m" button. When the signal

has been stable for 2 seconds an audible beep will
be heard and the display will change to "O xxx".
"xxx" is the digital reading of the sensor voltage when
the steering wheel is in the disengaged position.
BAIL06CCM640AVA 5
84276322A 31/05/2010
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8. The lower central display will display "C _ _ _" for the
steering wheel in the engaged position.
BAIL06CCM641AVA 6
9. Depress and hold the "m" button while the steering

wheel is in the engage position. When the signal has
been stable for 2 seconds an audible beep will be
heard and the display will change to "C xxx".
the steering wheel is in the engaged position.
BAIL06CCM642AVA 7
10. After a short delay the display will return to the "H1"
menu display.
Linear Variable Differential Transformer (LVDT) Sensor Calibration

11. Select the "Lvdt" option by depressing the "dimming"
button.
BAIL06CCM643AVA 8
12. Press the dimming button again to activate. The

system will then automatically pilot the solenoid and
measure the LVDT values in both positions and over-
write the default values.
84276322A 31/05/2010
D.20.C / 50
13. The lower central display will show a countdown

from "5" as the calibration is being performed. When
the calibration is complete the display will change to
"donE".
BAIL06CCM652AVA 9
Adopting the Default Values

14. Select the "deF" option by depressing the "dimming"
button.
BAIL06CCM644AVA 10
15. Depress and hold the "m" button. After a short delay
an audible beep will be heard to indicate that the
calibration values have reset to their default values.
The lower central display will then show "donE".
BAIL06CCM651AVA 11
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Fast steer system Control valve - Disassemble

Prior operation:
Fast steer system Control valve - Remove (D.20.C)
1. Remove the solenoid retaining screws and remove

the solenoid (4).
2. Carefully remove the four hexagon headed socket
screws which hold the change valve flange in place.
Remove the flange ,’O’ ring, spring and spool (8) .
3. Remove the five hexagon headed socket screws and
remove the flange which gives access to the split
valve spool and the distributor spool. Remove the
spools (13) & (14) , spring and ‘O’ rings.
4. On the opposite side of the valve remove the screws
and flange which hold the distributor pin in position.
Remove the pin (28), bush, spring and ‘O’ rings.
5. Remove the plug, spring and compensator spool (24)
.
6. Remove the two SDS valves (17) and (18),.
7. Remove the LVDT sensor (1) .
8. Remove the LSD valve (3)
BAIL06CCM079FSA 1
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Fast steer system Control valve - Remove

1. Position the tractor on a hard level surface and apply
the parking brake.
2. To gain access to the Turn Assist valve
Disconnect the negative cable from the battery and
insulate. Refer to: Battery - Disconnect (A.30.A)
Raise the engine hood
Remove the steering column console. Refer to
Steering column - Remove (D.20.C)
3. Move the processor harness out of the way
4. Undo the brake reservoir and move to one side. (Do
not disconnect hose)
5. Disconnect the four supply/return tubes and ‘O’ ring
seals from the control valve (1) and cap the ends of
the tubes.
BAIL09APH214AVB 1
6. Disconnect the wiring to the solenoid (1) and the

LVDT (2) sensor.
BAIL06CCM076ASA 2
7. Remove the two hexagon headed socket bolts on the

control valve with an 8 mm allen key.
BAIL06CCM081ASA 3
84276322A 31/05/2010
D.20.C / 53
8. Remove the control valve assembly from the front of

the cab through the engine compartment.
WARNING
B012
84276322A 31/05/2010
D.20.C / 54
Fast steer system Control valve - Install
WARNING
B012
1. Install the control valve assembly.

2. Install the two hexagon head socket bolts into the
control valve with an 8 mm allen key.
BAIL06CCM081ASA 1
3. Connect the wiring to the solenoid (1) and the LVDT

(2) sensor.
BAIL06CCM076ASA 2
4. Install ‘O’ ring seals to the control valve. Connect the

four supply/return hoses.
BAIL09APH214AVB 3
5. Reposition and attach the brake fluid reservoir.

6. Reposition the processor harness.
Next operation:
Install the steering column, for further information refer to Steering column - Install (D.20.C)
84276322A 31/05/2010
D.20.C / 55
Next operation:
84276322A 31/05/2010
D.20.C / 56
Fast steer system Control valve - Assemble

1. Install the LSD valve (3).
2. Install the LVDT sensor (1).
3. Install the two SDS valves (17) and (18).
4. Install the compensator spool, spring and plug (24).
5. On the opposite side of the valve Install the pin (28),
bush, spring and ‘O’ rings. Install the flange and
flange retaining screws.
6. Install the spools (13) and (14), spring and ‘O’ rings.
Install the flange and five hexagon head socket re-
taining screws.
7. Install the spool (8), spring (9) and,’O’ ring (10). In-
stall the flange and four hexagon head socket retain-
ing screws.
8. Install the solenoid (4) and solenoid retaining screws.
BAIL06CCM079FSA 1
Next operation:
Fast steer system Control valve - Install (D.20.C)
84276322A 31/05/2010
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Fast steer system - Calibrate

ment of the tractor, firmly apply the parking brake and block the wheels, front and rear. Check that the Ground speed
display is Zero before commencing.
diagnostic socket (1) and start the engine.
BAIL06CCM213AVA 1
2. Use the "up", "down" and "menu" keys on the ICU3

to navigate the HH menu’s to H1 and the fast steer
symbol on the KA controller.
BAIL06CCM746AVA 2
84276322A 31/05/2010
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3. Scroll through the available options using the "up"

and "down" keys.
The three options are:
• "Pro" - proximity sensor
• "Lvdt" - LVDT sensor
• "dEF" - adopt the default values
BAIL06CCM747AVA 3

5. Select the "Pro" option by depressing the "menu" key.
BAIL09HHP312AVA 4
6. The top section of the display will display "O _ _ _"

for the steering wheel in the disengaged position.
BAIL09HHP313AVA 5
7. Depress and hold the "down" key. When the signal

has been stable for 2 seconds an audible beep will
be heard and the display will change to "O xxx".
the steering wheel is in the disengaged position.
BAIL09HHP314AVA 6
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8. The top section of the display will display "C _ _ _"

for the steering wheel in the engaged position.
BAIL09HHP315AVA 7
9. Depress and hold the "down" key while the steering

wheel is in the engage position. When the signal has
been stable for 2 seconds an audible beep will be
heard and the display will change to "C xxx".
the steering wheel is in the engaged position.
BAIL09HHP316AVA 8
10. After a short delay the display will return to the "H1"
menu display.
Linear Variable Differential Transformer (LVDT) Sensor Calibration

11. Select the "Lvdt" option by depressing the "menu"
key.
BAIL09HHP317AVA 9
12. Press the "menu" key again to activate. The system

will then automatically pilot the solenoid and mea-
sure the LVDT values in both positions and overwrite
the default values.
84276322A 31/05/2010
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13. The top section of the display will show a countdown

from "5" as the calibration is being performed. When
the calibration is complete the display will change to
"donE".
BAIL06CCM754AVA 10
Adopting the Default Values

14. Select the "dEF" option by depressing the "menu"
key.
BAIL09HHP318AVA 11
15. Depress and hold the "down" key. After a short delay
an audible beep will be heard to indicate that the
calibration values have reset to their default values.
The top section of the display will then show "donE".
BAIL09HHP319AVA 12
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Steering column - Remove

Prior operation:
Remove the steering wheel.
1. Remove the instrument cluster upper retaining

screw. Repeat step for the right-hand side.
Detach the enhanced keypad panel.
BAIL07APH455AVB 1
2. Disconnect the enhanced keypad electrical connec-

tor.
Remove the enhanced keypad panel.
BAIL07APH456AVA 2
3. Detach the instrument cluster.
BAIL07APH455AVC 3
84276322A 31/05/2010
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4. Disconnect the instrument cluster electrical connec-

tors and remove the instrument cluster.
BAIL07APH457AVA 4
5. Remove the steering column lower shroud retaining

bolts.
BAIL07APH458AVA 5
6. Remove the steering column lower shroud.
BAIL07APH459AVA 6
7. Remove the steering column shroud left-hand retain-

ing screws.
BAIL07APH460AVA 7
84276322A 31/05/2010
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8. Remove the steering column shroud right-hand re-

taining screws and ignition switch retaining nut.
BAIL07APH461AVA 8
9. Remove the steering column shrouds.
BAIL07APH462AVA 9
Vehicles with Turn Assist

10. Disconnect the six electrical connectors.
BAIL07APH520AVA 10
Vehicles without Turn Assist

11. Disconnect the four electrical connectors.
BAIL07APH463AVA 11
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12. Remove the steering column to frame retaining bolts.

Repeat step for the right-hand side.
BAIL07APH464AVA 12
13. Remove the lower steering column retaining bolts.

Remove the steering column.
BAIL07APH466AVB 13
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Steering column - Install

1. Locate the steering column and install the lower
steering column retaining bolts.
BAIL07APH466AVB 1
2. Install the steering column to frame retaining bolts.

Tighten to 23 Nm (17 lb ft)
BAIL07APH464AVA 2
Vehicles with Turn Assist

3. Connect the six electrical connectors.
BAIL07APH520AVA 3
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Vehicles without Turn Assist

4. Connect the four electrical connectors.
BAIL07APH463AVA 4
5. Install the steering column shrouds.
BAIL07APH462AVA 5
6. Install the steering column shroud right-hand retain-

ing screws and ignition switch retaining nut.
BAIL07APH461AVA 6
7. Install the steering column shroud left-hand retaining

screws.
BAIL07APH460AVA 7
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8. Install the steering column lower shroud.
BAIL07APH459AVA 8
9. Install the steering column lower shroud retaining

bolts.
BAIL07APH458AVA 9
10. Connect the instrument cluster electrical connectors

and install the instrument cluster.
BAIL07APH457AVA 10
11. Install the instrument cluster lower retaining screw.
BAIL07APH455AVC 11
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12. Connect the enhanced keypad electrical connector.
BAIL07APH456AVA 12
13. Install the instrument cluster upper retaining screw.

BAIL07APH455AVB 13
Next operation:
Install the steering wheel.
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Steering column - Visual inspection

1. Inspect the steering shaft universal joint and lower
rubber coupling. Replace if any free play is evident.
2. Inspect the column assembly, if damaged or the
bushes are worn a new assembly will be required.
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Tie rod - Toe in adjust

When travelling forward in a straight path, the wheels of four-wheel drive tractors must be parallel to the longitudinal
axis of the tractor, alternatively a slight toe-in of the front wheels is permissible up to a maximum of 3 mm as measured
at the edges of the wheel rims.
To check the exact value of the toe-in setting of four-wheel drive tractors, proceed as follows.
1. Inflate the front tyres to the specified pressure.

2. Position the steering at half-lock with a straight-edge
along the longitudinal axis of the tractor.
3. Check that the wheels are parallel to the longitudinal
axis of the tractor.
4. Measure the distance (1) between the front inside
edges of the wheel rims, at the height of the wheel
hub centers.
5. Turn both front wheels through 180 ° then measure,
again at the height of the wheel hub centers, the dis-
tance (2) between the rear inside edges of the wheel
rims, checking that this new measurement is equal
to or greater than the distance (1) by a maximum of
± 3 mm. The rotation of the wheels through 180 °
is necessary to eliminate the effect on the measure-
ment of any wear of the rims.
1b0o2004061043 1
6. If it is necessary to correct the wheel alignment, re-

move nut (2) and pull the track rod end (1) out of its
housing. Slacken off locknut (3) and screw the track
rod end (1) in or out to increase or decrease the dis-
tance (2, fig. 1).
Install the track rod end (1) in its housing and
re-check alignment as described in points 4 and 5.
After having adjusted the alignment to within the
prescribed limits, tighten locknut (3) to the specified
torque value of 180 Nm ( 183 kgm) and nut (2) to
100 Nm ( 10.2 kgm).
NOTE: Self-locking nut (2) must be renewed each time it
is removed or partially unscrewed.
24667 2
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STEERING Hydraulic - Troubleshooting

Low steering pressure Faulty pump Pressure test system, repair/replace pump
warning light illuminates as required.
Fault in return to tank (back pressure) side Check low pressure system (fixed displace-
ment main hydraulic pump) or check lubri-
cation system (variable displacement main
hydraulic pump systems).
Leak in system Inspect feed and return lines to the pump.
Replace damaged hoses as required.
No steering or excessive Air in system Check for loose connections or damaged
effort to steer tubing. Purge system of air.
Steering system relief valve sticking/faulty Check system pressure.
Worn pump Inspect and repair.
Leaking steering cylinder Inspect and repair.
Broken or damaged steering column cou- Inspect and replace as required.
pling
Damaged or worn metering unit Inspect and replace as required.
Steering wanders Excessive play in steering linkage joints Inspect and replace as required.
Leaking steering cylinder Inspect and repair.
Damaged or worn metering unit Inspect and replace as required.
Drift to Left (2WD only) Bias valve faulty Replace or repair
Front wheels surge when Leaking steering cylinder Inspect and repair.
steering
Damaged or worn metering unit Inspect and replace as required
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Index

Control valve - Assemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control valve - Disassemble (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control valve - Exploded view (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control valve - Install (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control valve - Remove (Steering Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control valve - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fast steer system - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fast steer system - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fast steer system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fast steer system - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fast steer system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fast steer system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fast steer system Control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fast steer system Control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fast steer system Control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fast steer system Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fast steer system Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Relief valve - Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Steering column - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Steering cylinder - Exploded view (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering cylinder - Exploded view (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering cylinder - Install (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Steering cylinder - Install (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Steering cylinder - Overhaul (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Steering cylinder - Overhaul (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering cylinder - Remove (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Steering cylinder - Remove (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
STEERING Hydraulic - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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STEERING Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING Hydraulic - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
STEERING Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING Hydraulic - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING Hydraulic - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING Hydraulic - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Tie rod - Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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SERVICE BRAKE Hydraulic - 30.C

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Contents
SERVICE
SERVICE BRAKE Hydraulic
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Command
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Master cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake light system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
SERVICE BRAKE Hydraulic - Bleed
WARNING
Air bleeding must be carried out any time the brake hydraulic system has been opened.
B016
NOTE: When bleeding the complete brake system, refer to 7 for the complete brake system air bleeding sequence.
NOTE: Make sure the vehicle is on a level surface.
General Brake System Air Bleeding

1. Thoroughly clean around all bleed screws and the
brake fluid reservoir cap (1).
Install one end of a suitable bleed tube to the bleed
screw, and the other end into a bleed jar containing
a small quantity of brake fluid.
Open the bleed screw.
Operate the brake pedal(s) fully, and allow the brake
pedal to return to the rest position.
NOTE: The brake fluid reservoir fluid level must remain
above the ’MIN’ line (3) at all times during brake system
air bleeding.
BSE2762A 1
2. Continue operating the brake pedal(s) until air-free

fluid is seen entering into the bleed jar.
3. Fully depress the brake pedal(s) and tighten the
brake bleed screw.
4. Operate the brake pedals fully several times to pres-
surize the brake system.
5. Refill the brake fluid reservoir to the ’MAX’ line (2)
(figure 1).
NOTE: Make sure the bleed screw cap(s) are installed af-
ter brake system air bleeding. This will prevent corrosion
and dirt ingress to the bleed screw. Failure to follow this in-
struction may cause the bleed screw(s) to become seized.
Rear Service Brake and Trailer Brake Bleeding

6. Open the corresponding bleed screw by one-half turn
in the sequence below on the trailer brake valve logic
head. Bleed the air from the brake system at each
bleed screw (refer to general brake system air bleed-
ing in this chapter).
1. Left brake pedal to bleed air from the system.
3. Right brake pedal to bleed air from the system.
4. Both brake pedals must be latched together to
bleed air from the system.
2. Both brake pedals must be latched together to
BVF0902A 2
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Pneumatic Brakes Air Bleeding (If Fitted)

7. Open the bleed screw (1) by one-half turn on the
pneumatic trailer brake valve.
Bleed the air from the brake system (refer to "General
Brake System Air Bleeding" ).
NOTE: Both brake pedals must be latched together to
BVF0840A 3
Front Axle Brakes Air Bleeding (If Fitted)

8. Open the bleed screw (1) one-half turn on the front
brake valve.
BVF0836A 4
9. Rotate the hubs to position the plug (1) in the verti-

cal position. Remove the plug and ensure the bleed
screw is aligned with the hole.
NOTE: Depending on wheel options it may be necessary
to bleed the brakes with the wheels removed.
26457 5
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10. Start the tractor and allow to idle.

Open the bleed screw (1) by one-half turn.
Install the axle hub plug.
NOTE: The front axle brakes are supplied from the low
pressure hydraulic oil circuit.
WARNING
Make sure the parking brake is applied and the trans-
mission range levers are in neutral.
26583 6
B029
BVF0916B 7
Complete Brake System Air Bleeding Sequence
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11. Follow the numbered step sequence indicated above

when bleeding the air from the brake system.
NOTE: Both brake pedals must be depressed when bleed-
ing the brakes in steps (3), (4), and (5).
NOTE: Brake fluid is not supplied to steps (6) and (7) from
the brake fluid reservoir, these are supplied from the low
pressure hydraulic oil circuit
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Command - Travel adjust

1. Adjust the clevis by loosening the locknut. The dis-
tance from the bulkhead to the centre of the clevis
hole should be 137 mm ( 5.4 in.). Repeat this step
for the left hand side brake pedal linkage.
BSE3073A 1
2. Make sure the brake pedal latch (1) engages prop-

erly. Adjust the brake pedal linkage as necessary.
BSE2691A 2
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Control valve - Remove
WARNING
B026
1. Open and raise the engine hood.

negative cable (1).
BVE0207A_396 1
3. Remove the intercooler (1).
BVF0963A 2
4. Remove the front axle support cover plates (1).
BVF0857A 3
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5. Remove the front PTO oil return pipe (1) and the oil
supply pipe (2) (if fitted).
BVF0844A 4
6. Disconnect the oil return pipe (1) and the oil supply
pipe (2).
BVF0845A 5
7. Disconnect the brake oil supply lines (1) and (2).
BVF0846A 6
8. Remove the front service brake valve.
BVF0847A 7
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Control valve - Install
WARNING
B026
1. Install the front service brake valve.
BVF0847A 1
2. Connect the brake oil supply lines (1) and (2).
BVF0846A 2
3. Connect the oil return pipe (1) and the oil supply pipe
(2).
BVF0845A 3
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4. Install the front PTO oil supply pipe (2) and the oil
return pipe (1) (if fitted).
BVF0844A 4
5. Install the front axle support cover plates (1).
BVF0857A 5
6. Install the intercooler (1).
BVF0963A 6

battery cover.
BVE0207A_396 7
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Next operation:
Bleed the hydraulic brake system (refer to SERVICE BRAKE Hydraulic - Bleed (D.30.C)).
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Master cylinder - Remove
WARNING
B026
WARNING
The master cylinder is not a serviceable item. If it is showing signs of leakage, damage or suspected of
malfunctioning, the complete unit must be replaced. DO NOT attempt to disassemble and reassemble as
seal damage will occur, rendering the unit inoperative with a resultant loss of brake performance.
B034

negative cable (1).
BVE0207A_396 1
3. Using a suitable hose clamp (1), clamp the brake

hose from the reservoir to the master cylinders.
BVF0831A 2
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4. Disconnect the brake hose (1).

Remove the brake line retaining bolts (2) and detach
the brake lines.
BVF0834A 3
5. Remove the retaining pin (1) and the retaining bolts

(2). Repeat this step for the right hand side master
cylinder.
Remove the master cylinders from the engine side of
the tractor
BVF0835A 4
6. Disconnect the brake supply hose from the master

cylinders.
BVF0862A 5
7. Remove the balance tube retaining bolts (1), balance

tube (2) and the retaining plate (3).
BVF0863A 6
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Master cylinder - Install
WARNING
B026
1. Install the retaining plate (2), balance tube (1) and the
balance tube retaining bolts. Tighten the retaining
BVF0863B 1
2. Connect the brake supply hose to the master cylin-

ders.
BVF0862A 2
3. Install the master cylinders from the engine side of

the tractor.
Install the retaining bolts (2) and the retaining pin
(1). Repeat this step for the right hand side master
cylinder.
BVF0835A 3
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4. Connect the brake hose (1).

Attach the brake lines and install the retaining bolts.
value.
BVF0834B 4

battery cover.
BVE0207A_396 5
6. Remove the hose clamp (1) from the brake hose.
BVF0831A 6
Next operation:
Adjust the brake pedal linkage (refer to Command - Travel adjust (D.30.C)).
Next operation:
Adjust the brake pedal switch(es) (refer to Brake light system - Travel adjust (D.30.C)).
Next operation:
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Hydraulic line - Remove
WARNING
Before removing any air system component make sure that there is no air pressure in the system. This can
be achieved by depressing and releasing the brake pedal several times with the engine off and draining the
air reservoirs. Also make sure that the wheels of the vehicle are chocked.
B022
Logic Head Valve Assembly - Figure 1.

1. Disconnect the two tubes from the braking system
and if fitted the tube to the front brakes. Cap the ends
of the tubes to prevent dirt ingress.
Remove the two (2) allen headed retaining bolts (1),
Figure 1 and lift away from the tractor.
Reassembly is the reversal of removal, noting the
following point:
a- Bleed the braking system of air as described SER-
VICE BRAKE Hydraulic - Bleed (D.30.C).
BSE3571B 1
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Brake - Install
Rear Service Brake Piston Installation.
1. Remove the self adjusting collets (1) from the brake
piston (2).
BSG7039A 1
2. Install the collets (2) and retaining bolts (1) into the
rear axle housing and tighten to 25 - 35 N·m (18 - 26
lb ft).
Measure the clearance between the bolt head, and
the collet.
BSG7038A 2
ATTENTION: This measurement must be between 0.35 - 0.45 mm. Mix and match the combination of collets and
bolts or replace until all meet the specified clearance.
3. When the specified clearance has been achieved
with all self adjusters, remove the retaining bolts and
collets and retain as matched pairs.
4. Measure the protrusion of the anti-rotation dowels
from the rear axle housing (X), which must not ex-
ceed 11 mm.
NOTICE: If the dowel protrudes in excess of 11 mm the pis-
ton will not install correctly, causing excessive brake wear
and overheating.
BAIL09APH222AVA 3
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5. Reinstall the collets into the brake piston.

NOTE: Make sure the collets are flush with the brake pis-
ton.
BVF0833A 4
6. Install a new brake piston oil seal (1) onto the brake
piston.
BVF0832A 5
7. Install a new brake piston oil seal (1) into the rear
axle housing.
BVF0909A 6
8. Lubricate the piston seals with transmission oil.

Install the brake piston (1).
BVF0821A 7
84276322A 31/05/2010
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NOTE: Release the bleed nipple before installing the piston.

NOTE: Apply pressure evenly to the brake piston to avoid damage to the seals.
9. Install the brake piston retaining bolts and tighten to
25 - 35 N·m (18 - 26 lb ft).
10. Measure the distance between the outer face of the
piston and the mating surface of the rear axle hous-
ing (P).
NOTICE: If measurement (P) is less than 11 mm the piston
has not seated correctly.
BAIL09APH225AVA 8
Next operation:
Install the final drive case (refer to Final drive Housing - Install (D.12.A)).
Next operation:
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Brake - Disassemble
WARNING
B026
1. Park the tractor on a level surface. Block the wheels

to prevent the tractor moving.
negative cable (1).
BVE0207A_396 1
4. Raise the front of the tractor, support the front axle

and remove the road wheel.
Rotate the hub until the drain plug is at the lowest
point and drain the oil from the hub.
BSB0234A_397 2
5. Remove planetary carrier retaining bolts.
24063 3
84276322A 31/05/2010
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6. Install special tool 380000548 (2).

Using a suitable slide hammer installed into the oil
drain plug hole, remove the planetary carrier (1) from
the casing.
25594_398 4
7. Using suitable circlip pliers, remove the sun gear re-

taining circlip.
BRB0155A 5
BRB0156A 6
9. Using suitable circlip pliers, remove the rear sun gear

retaining circlip.
BRB0157A 7
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10. Using suitable circlip pliers, remove the snap ring

retaining the outer brake disc.
BRB0158A 8
11. Remove the outer brake disc from the ring gear.
BRB0159A 9
12. Remove the friction disc from the friction disc drive
plate.
BRB0160A 10
13. Remove the friction disc drive plate from the drive-
shaft.
BRB0161A 11
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14. Remove the inner brake disc from the ring gear.
BRB0162A 12
15. Remove the piston from the backplate. Apply the foot
brakes if necessary to aid removal.
NOTE: There are three, 6 mm threaded bolt holes located
in the piston. Bolts may be installed and used as a lever
point to aid piston removal.
BRB0163A 13
16. Remove the ring gear retaining bolts.
BVF0894A 14
17. Install two M12x 1.5 mm bolts into the separating

holes.
Tighten the bolts (1) and remove the ring gear (2).
BVF0895A 15
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18. Using suitable circlip pliers, compress the circlip (1)

and remove the piston carrier plate (2) from the ring
gear.
BVF0896A 16
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Brake - Assemble
WARNING
B026
1. Remove the inner and outer piston oil seals from the
piston carrier plate. Ensure the carrier is free from
any debris and carefully install the new oil seals, al-
low the oil seals to relax for a few minutes prior to
installing the piston.
BRB0166A 1
2. Remove the oil transfer tube from the rear of the car-
rier and replace the O-rings.
BRB0167A 2
3. Lubricate the piston with the specified brake oil and

install the piston into the carrier.
BRB0168A 3
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4. Using suitable circlip pliers, compress the circlip (1)

and install the piston carrier plate (2) into the ring
gear.
BVF0896A 4
5. Install the ring gear.
BRB0164A 5
6. Install the retaining bolts and tighten to the specified

torque value.
BVF0894B 6
7. Install the inner brake disc into the ring gear.
BRB0162A 7
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8. Install the friction disc drive plate onto the driveshaft.
BRB0161A 8
BRB0160A 9
10. Install the outer brake disc into the ring gear.
BRB0159A 10
11. Using suitable circlip pliers, install the circlip retaining

the outer brake disc.
BRB0158A 11
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12. Using suitable circlip pliers, install the rear sun gear
retaining circlip.
BRB0157A 12
BRB0156A 13
14. Using suitable circlip pliers, install the sun gear re-
taining circlip.
BRB0155A 14

BVF0897A 15
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16. Install special tool 380000548 (2).

Install the planetary carrier (1) to the casing.
Remove the special tool (2).
25594_398 16
17. Install the retaining bolts and tighten to the specified

torque value.
BVF0893A 17
18. Refill the hub with the correct specified oil.

Connect the battery negative cable (1) and install the
battery cover.
BVE0207A_396 18
Next operation:
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Brake - Remove
Prior operation:
Remove the final drive case (refer to Final drive Housing - Remove (D.12.A)).
WARNING
B026
Rear Service Brake Piston Removal.

1. Remove the brake piston retaining bolts.
BVF0820A 1
2. Remove the brake piston (1).

NOTE: Slowly apply the foot brake to aid removal.
BVF0821A 2
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Brake - Visual inspection

Rear Service Brake Inspection.
1. Inspect the brake piston (1) and the rear axle housing
(2), for any signs of corrosion or damage which may
cause the piston to seize in the rear axle housing.
Repair or replace parts as necessary.
Check if the brake piston self adjusters (3) have be-
come loose in the brake piston. Replace parts as
necessary.
Inspect the inner and outer brake discs, if badly
scored, worn or cracked replace as necessary.
BVF0821B 1
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Brake - Visual inspection

of the brake friction disc at three points 120 °apart
and take an average of the three readings..
Replace the brake friction disc if the thickness is less
than 3.6 mm.
Inspect the inner and outer brake discs, if badly
scored, worn or cracked replace as necessary.
bvf0838a 1
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Brake - Measure
of the brake friction disc at three points 120 °apart
and take an average of the three readings.
Replace the brake friction disc if the thickness is less
than 3.6 mm.
BVF0838A 1
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Brake light system - Remove

Brake Pedal Switch Removal.

1. Remove the instrument cluster retaining screws (1).
Repeat this step for the right hand side retaining
screws.
Detach the instrument cluster panel to obtain access
to the instrument cluster electrical connectors.
BVF0865A 1
2. Disconnect the instrument cluster electrical connec-

tors (1) and remove the instrument panel (2).
BVF0866A 2
3. Remove the air ducting panel.
BVF0867A 3
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4. Remove the brake pedal switch support retaining bolt

(1). Repeat this step for the right hand side retaining
bolt.
BVF0869A 4
5. Position the brake pedal switch support to gain ac-

cess to the brake pedal switch retaining screws (2).
Disconnect the electrical connector (1) and remove
the brake pedal switch retaining screws (2).
Remove the brake pedal switch.
BVF0870A 5
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Brake light system - Install

MAXXUM 140
Brake Pedal Switch Installation.

1. Install the brake pedal switch.
Install the brake pedal switch retaining screws (2)
and connect the electrical connector (1).
BVF0870A 1
2. Position the brake pedal switch support.

Install the brake switch support retaining bolt (1). Re-
peat this step for the right hand side retaining bolt.
BVF0869A 2
3. Install the air ducting panel.
BVF0867B 3
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4. Install the instrument panel (2) and connect the in-

strument cluster electrical connectors (1).
BVF0866A 4
5. Install the instrument cluster panel.

Install the instrument cluster panel retaining screws
(1). Repeat this step for the right hand side retaining
screws.
BVF0865B 5
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Brake light system - Travel adjust

Brake Pedal Switch Adjustment.
1. Adjust the brake pedal adjustment bolt (1) to achieve
switch operation (an audible click will be heard) when
the brake pedal free play is removed and brake pedal
resistance is observed.
Ensure both the brake pedal switches operate simul-
taneously.
NOTE: Brake pedal linkage adjustment must be carried out
before brake pedal switch adjustment is attempted. Com-
mand - Travel adjust (D.30.C).
BVF0864A 1
84276322A 31/05/2010
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Index

Brake - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Brake - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brake - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Brake - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brake light system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Brake light system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Brake light system - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Command - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Master cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Master cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE BRAKE Hydraulic - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PARKING BRAKE Mechanical - 32.B

84276322A 31/05/2010
D.32.B / 1
Contents
TECHNICAL DATA
PARKING BRAKE Mechanical
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
SERVICE
Mechanical linkage
Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSTIC
84276322A 31/05/2010
D.32.B / 2
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
PARKING BRAKE Mechanical - Special tools

previous No.
380000982 Parking Brake Alignment tool -
PARKING BRAKE Mechanical - General specification

Type Wet discs acting on pinion gear shaft
Controls Mechanical through a hand lever
Parking Brake Disc Material Steel
Parking Brake Friction Pad Material Sintered or organic conglomerate
Disc Thickness
Friction Pad (New) (Single Friction Side) 3.4 mm (0.134 in)
Friction Pad (Minimum) (Single Friction Side) 3.1 mm (0.122 in)
Friction Pad (New) (Double Friction Side) 4.5 mm (0.177 in)
Friction Pad (Minimum) (Double Friction Side) 4.2 mm (0.165 in)
Steel Disc 4.45 - 4.55 mm (0.1752 - 0.1791 in)
PARKING BRAKE Mechanical - Torque
BVF0949B_399 1
BVF0823B 2
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D.32.B / 3
PARKING BRAKE Mechanical - Static description

The parking brake is controlled mechanically. It acts on the rear pinion gear shaft and is controlled through a hand
lever located to the left of the operators seat.
When the parking brake control lever is raised, the cable acts on the actuator forcing the pads against the brake discs
which are splined to the tractor rear pinion shaft.
84276322A 31/05/2010
D.32.B / 4
Mechanical linkage - Travel adjust

Prior operation:
Brake - Install (D.32.B)
NOTE: Adjustment of the parking brake control lever travel should be performed each time the parking brake is ser-
viced or repaired and when the idle travel of the lever is excessive.
Proceed as follows:
1. Block the front wheels using a suitable means.
2. Raise the rear of the tractor using a suitable means
until the wheels are slightly off the ground.
3. Raise the parking brake control lever to the third
notch on the quadrant.
4. Release the locknut (1) and screw in the adjustment
screw (2) until the wheels lock.
BVF0837A 1
5. Lower the parking brake control lever and ensure that

the wheels can rotate freely.
6. Apply the parking brake several times to check that
the assembly does not get blocked or operate abnor-
mally.
7. Tighten the locknut (1) and lower the tractor.
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Brake - Remove
Prior operation:
WARNING
B026
1. Remove the split pin (1) and the cotter pin (2) from
the parking brake lever.
BVE0950A 1
2. Remove the parking brake housing.
BVF0949A 2
Next operation:
Brake - Disassemble (D.32.B)
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D.32.B / 6
Brake - Disassemble
Prior operation:
Brake - Remove (D.32.B)
1. Install the parking brake housing into a suitable vice.

Release the retaining bolt locking tabs (1) and re-
move the retaining bolts (2).
BVF0823A 1
2. Remove the friction and steel plates (1).
BVF0824A 2
3. Rotate the parking brake housing 180 °.

Using suitable circlip pliers, remove the circlip (1).
BVF0825A 3
84276322A 31/05/2010
D.32.B / 7
4. Remove the parking brake lever and spring (1) .
BVF0826A 4
5. Remove the parking brake lever shaft (1).
BVF0827A 5
6. Remove the spacer (2) and the O-ring (1).
BVF0828A 6
Next operation:
Brake - Assemble (D.32.B)
84276322A 31/05/2010
D.32.B / 8
Brake - Assemble
Prior operation:
Brake - Disassemble (D.32.B)
1. Install the parking brake lever shaft (1).
BVF0827B 1
2. Install the O-ring (1) and the spacer (2).
BVF0829A 2
3. Install the parking brake lever and spring (1).

NOTE: The paint must be removed to see the aligning
marks.
NOTICE: When installing the parking brake lever, the lever
must be aligned to the shaft using the aligning marks.
BVF0830A 3
84276322A 31/05/2010
D.32.B / 9
BVF0825A 4
5. Rotate the parking brake housing 180 °.

Install the fiction and steel plates (1).
BVF0824A 5
6. Install the locking tabs (1) and the retaining bolts.

value.
Secure the retaining bolts with the locking tabs (1).
BVF0823B 6
Next operation:
Brake - Install (D.32.B)
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D.32.B / 10
Brake - Install
Prior operation:
Brake - Assemble (D.32.B)
WARNING
B026

mm (0.079 in) in diameter to the rear axle housing.
BVF0952A 1
2. Using special tool 380000982 (2), align the brake

discs (1) on the pinion shaft.
BVF0986A 2
3. Install the special tool 380000982 (1) between the

brake pads (2).
BVF0987A 3
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D.32.B / 11
4. Position the parking brake assembly complete with

the special tool 380000982 (1) between the brake
discs on the pinion shaft. Remove the special tool
(1) while installing the parking brake assembly.
BVF0988A 4

value.
BVF0949B_399 5

7. Install the cotter pin (2) and the split pin (1) into the
parking brake lever.
BVE0950A 6
Next operation:
Adjust the parking brake cable - see Mechanical linkage - Travel adjust (D.32.B).
84276322A 31/05/2010
D.32.B / 12
PARKING BRAKE Mechanical - Troubleshooting

Parking brake does not Parking brake cable incorrectly adjusted. Adjust the parking brake cable.
operate correctly
Worn brake pads. Replace brake pads.
Parking brake will not Restricted parking brake lever travel. Repair as necessary.
release
Seized brake pads on the brake discs. Replace damaged parts.
84276322A 31/05/2010
D.32.B / 13
Index

Brake - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brake - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mechanical linkage - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PARKING BRAKE Mechanical - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE Mechanical - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE Mechanical - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE Mechanical - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE Mechanical - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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BRAKE CONNECTION Hydraulic - 34.C

84276322A 31/05/2010
D.34.C / 1
Contents
TECHNICAL DATA
BRAKE CONNECTION Hydraulic
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
BRAKE CONNECTION Hydraulic
Dynamic description (Italian Trailer Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Trailer brake valve
Static description (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exploded view (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE
Trailer brake valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remove (Solenoid valve block Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install (Solenoid valve block Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSTIC
Trailer brake valve
Troubleshooting (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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AXLES, BRAKES AND STEERING - BRAKE CONNECTION Hydraulic
BRAKE CONNECTION Hydraulic - General specification

Maximum Trailer Brake Pressure 150 bar (2175.0 psi)
Italian Trailer Brakes 10 - 12 bar (145.00 - 174.00 psi)
Trailer Brake Disengagement Pressure
NOTE: The brake oil specification is described in Consumables Lubrications and Coolants.
BRAKE CONNECTION Hydraulic - Torque
BVE0557A 1
BRAKE CONNECTION Hydraulic - Special tools
CAUTION
in this manual.
B008
Pressure Test Tools

previous No.
X 380000545 Hose 292246
380000550 Pressure gauge connection -
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BRAKE CONNECTION Hydraulic - Dynamic description (Italian

Trailer Brake)
Engine Running - Brakes Not Applied
To release the trailer braking mechanism a pressure of 11 - 12 bar (159.50 - 174.00 psi) is required at the trailer brake
coupling whenever the handbrake is released while the engine is running and the footbrake is not being applied.
This pressure is controlled by the oil discharge valve (6) which is attached to the trailer brake return to reservoir port
(R).
Oil from the implement pump flows to the trailer brake valve (7) port (P). When the brakes are not applied a small flow
of oil returns to reservoir through port (R) with the remaining flow passing from port (P) to the implement valves and
hydraulic lift through port (N).
The 11 - 12 bar (159.50 - 174.00 psi) pressure created by the oil discharge valve flows from the trailer brake line (B),
through the solenoid valves (4 and 5) to the trailer brake coupler (12).
This pressure is sufficient to overcome spring (13) of the Italian brake actuating mechanism. As the spring is com-
pressed, spring (14) retracts the actuating pin to disengage the braking mechanism on the trailer.
NOTE: At engine start-up the trailer brake indicator light (16) will remain illuminated until the 11 bar (159.50 psi)
pressure necessary to disengage the braking mechanism has been created. To reduce the time necessary to reach
trailer brake release pressure depress the brake pedal with the parking brake lever in the off position.
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BTB0232A 1
Italian Trailer Brake Valve Schematic- Engine Running and Brakes Not Applied
Pump Pressure Brake Pedal Pressure
Trailer Brake Release Pressure Return to Reservoir

11 bar (159.50 psi)
1 Parking Brake 2 Parking Brake Switch

3 Relay 4 Discharge Solenoid
5 Delivery Solenoid 6 11 bar (159.50 psi) Pressure Regulating Valve
7 Trailer Brake Valve 8 Low Pressure Switch
9 Hydraulic Pump 10 Brake Pedal and Master Cylinder
11 Implement Valves and Hydraulic Lift 12 Trailer Brake Coupler
13 Spring 14 Spring
15 Trailer Brake Engaged Warning Lamp Switch 16 Trailer Brake Engaged Warning Lamp
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Engine Running - Brakes Applied

When the tractor brake pedal is depressed the control of oil flow through the trailer brake valve (7) is the same as
described for tractors with the standard trailer brake system in Trailer brake valve - Dynamic description (D.34.C).
The outlet pressure through port (B) will be 12 - 150 bar (174.00 - 2175.0 psi) depending on the pressure applied to
the brake pedal.
The delivery solenoid (5) is open and the discharge solenoid (4) is closed. Oil exiting port (B) flows through the ‘Open’
delivery solenoid valve (5) to the trailer brake coupler (12).
When a trailer is connected to the coupler the pressure passing through the coupling to the trailer braking mechanism
overcomes the spring force (13) and (14) and moves the actuating pin forward to apply the brakes on the trailer.
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BTB0233A 2
Italian Trailer Brake Valve Schematic- Engine Running and Brakes Applied
Pump Pressure Brake Pedal Pressure
Trailer Braking Pressure Return to Reservoir

11 bar (159.50 psi)

13 Spring 14 Spring
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Engine Stopped or Running but with Low Hydraulic Pump Flow

When the engine has stopped or the output from the hydraulic implement pump is very low the pressure switch (8)
closes. With the switch closed the current energizes the relay (3). The relay closes and current reaches and energizes
the solenoid valves (4) and (5). The delivery solenoid (5) is now closed and discharge solenoid (4) is open. In this
condition the oil in the trailer brake line discharges to reservoir through solenoid (4). Their is now insufficient pressure
to overcome the spring (13) and therefore the actuating pin moves forward to apply the brakes. Low pressure in the
trailer brake line causes the switch (15) to close and illuminate the warning lamp (16).
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BTB0230A 3
Italian Trailer Brake Valve Schematic- Engine Stopped or Running With Low Hydraulic Pump Flow

(Less than 10 bar (145.00 psi))
Brake Pedal Pressure

13 Spring 14 Spring
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Engine Running - Parking Brake Applied

When the parking brake is applied the switch (2) is closed. With the switch closed the current energizes the relay (3).
The relay closes and current reaches and energizes the solenoid valves (4) and (5).
The delivery solenoid valve (5) is now closed and discharge solenoid valve (4) is open. The 11 bar (159.50 psi)
pressure oil at port (B) is blocked by delivery solenoid valve (5) and the pressure in the trailer brake coupler line is
discharged to reservoir through discharge solenoid valve (4).
Because there is insufficient pressure to overcome spring (13) the actuating pin is pushed forward to apply the brakes.
The low pressure in the trailer brake coupler line causes the trailer brake warning lamp switch (15) to close and the
in cab warning lamp will illuminate.
NOTE: After applying the parking brake, wait approximately 10 seconds before stopping the engine. This will allow
complete discharge of the oil pressure in the trailer brake line to obtain full application of the trailer brakes.
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BTB0231A 4
Italian Trailer Brake Valve Schematic- Engine Running and Parking Brake Applied
Pump Pressure Zero Brake Pedal Pressure
Release Pressure Return to Reservoir

11 bar (159.50 psi)

13 Spring 14 Spring
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Trailer brake valve - Dynamic description
BTB0415A 1
Trailer Brake Valve Operation - Tractor Brakes Not Applied
Zero Brake Pedal Pressure
1 Control Valve and Spool 2 Pressure Relief Element

3 Piston 4 Pilot Head
5 Spring 6 Throttling Orifice
7 Flow Regulating Valve 8 Restrictor
9 Check Valve
A Load Sensing Gallery to Implement Pump B To Trailer Brakes

N Outlet Port to Implement Valves P Inlet Ort from Hydraulic Pump
R Return to Reservoir X Pressure from Tractor Brake Pedal Application
Tractor Brakes Not Applied

When the tractor brakes are not applied there is no hydraulic pressure in the circuit from the tractor brake pedal master
cylinder to ports (X) of the pilot head (4).
The piston (3) is not under pressure and the control valve (1) assumes the neutral position.
The trailer brake line (B) is relieved to reservoir through the control valve and port (R).
Their is a small controlled flow of oil from the implement pump through port (P) of approximately 0.6 l/min (0.16 US
gpm) which passes to the reservoir through restrictor (8), throttling orifice (6) control valve (1) and port (R). The pres-
sure drop at the throttling orifice (6) holds the flow regulating valve (7) in the open flow position allowing all remaining
flow to pass from port (P) through port (N) to the implement valves and other hydraulic circuits.
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BTB0418A 2
Trailer Brake Valve Operation - Brakes Being Applied
Pump Pressure Reduced Flow
Brake Pedal Pressure Return to Reservoir

9 Check Valve
A Load Sensing Gallery To Implement Pump B To Trailer Brakes

N Outlet Port to Hydraulic Circuit P Inlet Port from Hydraulic Pump
Tractor Brakes Being Applied-Initial application

When the tractor brake pedal is being depressed the pilot piston (3) is pressurised through ports (X) and moves
forward pushing against the pressure relief element (2). As the pressure relief element moves to the left the control
valve spool (1) similarly moves to the left.
As the control spool moves to the left the flow of oil to reservoir through port (R) is prevented in two stages. First the
connection between the trailer brake line (B) and return to reservoir port (R) is closed. Secondly oil passing through
the centre of the flow regulating valve is prevented from returning to reservoir through the control valve and port (R).
As oil from the hydraulic implement pump continues to pass through the flow regulating valve, the combination of
rising oil pressure on the spring side of the valve and the spring pressure moves the regulating valve to the left.
A constant flow of oil from the implement pump passes from port (P) to the trailer brake through restrictor (8), and
check valve (9). The residual flow by-passes the flow regulating valve (7) and passes to the tractor implement valves
and other hydraulic circuits through port (N).
The pressure in the trailer brake line (B) builds up and acts on the end of the control valve spool in opposition to the
pressure on the piston (3).
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BTB0417A 3
Trailer Brake Valve Operation - Brakes Held
Pump Pressure Trapped Oil (Pressurised)

9 Check Valve

Tractor Brakes Being Applied- Brakes Held

If the tractor brake pedal is kept depressed the brake line (B) remains blocked from the return to reservoir port (R).
The pressure in the trailer brake line (B) increases until it matches the tractor braking pressure and acts on the end
surface of the control valve spool (1) moving the spool to the right against the pressure being applied by the brake
pedals.
The oil trapped at the spring end of the flow regulating valve (7) is now open to reservoir through port (R) and the
valve moves to the right preventing any further pump pressure oil flowing past the check valve (9) and into the trailer
brake circuit (B). All pump flow with the exception of a small controlled flow returning to reservoir through the throttling
orifice (6) is now directed to port (N) and the tractor implement valves and other hydraulic circuits.
The oil in the trailer brakes is now trapped and maintained at a constant pressure until the pressure applied to the
brake pedal is changed.
When the brake pedal pressure is decreased the control spool moves to the right allowing the trapped oil in the trailer
brake circuit to return to reservoir through port (R) as shown in Figure 1. Oil in circuit (B) is allowed to escape to
reservoir until the pressure in the trailer brake circuit once again matches the pressure applied to the tractor brake
pedal.
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BTB0416A 4
Trailer Brake Valve Operation - Brakes Applied With Maximum Brake Pedal Pressure
Pump Pressure Trapped Oil (Pressurised)

9 Check Valve

Brakes Applied With Maximum Brake Pedal Pressure

If at any time the maximum permissible trailer braking pressure of 150 bar (2175.0 psi) is reached, for example by
pressing excessively on the tractor brake pedal or due to any other external forces an increase in braking pressure is
prevented by the pressure relief element (2).
As pressure in the trailer braking circuit increases to the maximum permissible limit, the trailer brake circuit pressure
forces the control spool (1) against the springs in the pressure relief element (2). The springs which are preset to the
maximum permissible braking pressure are compressed and the control spool (1) moves to the right allowing the oil
trapped behind the flow regulating valve to return to reservoir through port (R). The flow regulating valve now moves
to the right and prevents any further pump system pressure being directed over the check valve to the trailer brake
circuit.
If the excess pressure is as a result of external factors in the trailer brake system the pressure in gallery (B) is similarly
applied to the end face of the control valve which momentarily moves further to the right opening gallery (B) to reservoir
through port (R). This allows the excess pressure in the trailer brake circuit to be vented to reservoir avoiding further
increase of the braking pressure.
Although the trailer brake circuit has priority over the implement valve hydraulic circuits the tractor hydraulics can be
used and pressurised as desired through all operating situations of the trailer brakes without any adverse effect.
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Trailer brake valve - Static description

Tractors may be fitted with a hydraulically operated trailer brake valve which operates the trailer brakes whenever the
brake system is activated by depressing the footbrake.
Installation of the trailer brake valves varies according to model however the principal of operation remains the same.
BSE3571A 1
Trailer brake installation
1 Low Pressure Switch connection 2 Feed To Trailer Brake Coupling

3 Pressure Line to Tractor Brakes 4 Retaining Screws
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Trailer brake valve - Static description (Italian Trailer brake)

The unique braking mechanism on Italian trailers automatically applies the trailer brakes whenever the tractor engine
is stopped, output from the hydraulic pump is very low or the tractor is disconnected from the trailer.
NOTE: The Italian trailer braking system will only function on trailers specifically designed to the Italian trailer braking
specification. Do NOT attach trailers which are not to the Italian specification to tractors installed with the Italian trailer
brake option. Failure to observe this requirement may result in continual partial engagement of the brakes on the
trailer and consequential overheating.
The internal components of the Italian trailer brake valve are the same as the standard trailer braking system, however
an additional manifold (3) is attached to the (P) and (B) ports. This manifold contains two solenoids (1) and (2) and
internal galleries which direct oil to and from the trailer brake circuit in accordance with the trailer braking requirements
of this system.
An oil discharge valve located in the return port (R) of the valve creates a back pressure of 10 - 12 bar (145 - 174
psi) in the system whenever the engine is running but the foot brakes are not applied.
BSE3599A_471 1
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Trailer brake valve - Exploded view (Italian Trailer brake)
BSE3749A 1
Italian Trailer Brake Components
1 Low Pressure Switch 2 Trailer Brake Valve

Pressure Regulating Valve
3 Manifold Bolt 4
10 - 12 bar (145 - 174 psi)
5 Manifold 6 Solenoid
7 Solenoid
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Trailer brake valve - Hydraulic schema
BSF4011A 1
Trailer Brake Circuit
1 Trailer Brake Valve 2 Braking Pressure

3 Load Sense Line 4 Variable Displacement Hydraulic Pump
5 Remote Valves 6 Trailer Brakes
Oil flows from the hydraulic pump (4) and into the trailer brake valve (1) via the power beyond slice before flowing
onto the remote valves and other high pressure hydraulic circuits.
The position of the trailer brake valve in the circuit ensures that the trailer brake circuit has priority flow over the remote
valves (5) and other hydraulic high pressure circuits.
Trailer braking is proportional to the effort on the tractor brake pedal. Feedback is provided by the trailer brake valve
to give a sense of feel to the operator which aids precise braking.
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Trailer brake valve - External view
BSE3658A 1
Trailer Brake Layout
1 Remote Valves 2 Trailer Brake Valve

3 Bleed Nipple 4 Pressure Line to Tractor Left Hand Brakes
5 Trailer Brake engaged warning lamp switch 6 Feed to Trailer Brake Coupling
(Italian Trailer Brake)
7 Feed to solenoid block 8 Delivery Solenoid (Italian Trailer Brake)
9 Discharge Solenoid (Italian Trailer Brake) 10 Pressure Line to Right Hand Brakes
11 Low Pressure Switch 10 bar (145 psi) 12 Supply Feed From Pump
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Trailer brake valve - Remove

1. Disconnect the trailer brake valve electrical connec-
tors and reposition the wiring harness.
Disconnect the trailer brake valve oil supply pipe (1).
BVE0455A 1
2. Disconnect the brake pipes (1) and (2) from the trailer
brake valve.
BVE0456A 2
3. Remove the trailer brake valve retaining bolt.
BVE0457A_472 3
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4. Remove the remaining trailer brake valve retaining

bolts and remove the trailer brake valve.
BVE0458A_473 4
Next operation:
Trailer brake valve - Install (D.34.C)
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Trailer brake valve - Install

Prior operation:
Trailer brake valve - Remove (D.34.C)
NOTE: Install new O-ring seals as required.

1. Install the trailer brake valve and the trailer brake
valve retaining bolts.
BVE0458A_473 1
2. Install the remaining trailer brake valve retaining bolt.
BVE0457A_472 2
3. Connect the brake pipes (1) and (2) to the trailer

brake valve.
BVE0456A_474 3
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4. Connect the trailer brake valve oil supply pipe (1).

Connect the trailer brake valve electrical connectors.
BVE0455A 4
Next operation:
Bleed the brake system - see SERVICE BRAKE Hydraulic - Bleed (D.30.C).
Refill the driveline with correct the specification oil - see Consumables Lubrications and Coolants.
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Trailer brake valve - Remove (Solenoid valve block Italian Trailer

brake)
1. Disconnect the trailer brake solenoid valve block
electrical connectors.
2. Disconnect the trailer brake valve oil supply pipe (1).
BVE0455A 1
3. Disconnect the oil supply pipe (1) from the quick re-
lease coupling and remove the banjo retaining bolt
(2) from the Italian trailer brake solenoid valve block.
BVE0459A 2
4. Remove the Italian trailer brake solenoid valve block

with the oil supply pipes attached.
5. Remove the oil supply pipes from the Italian trailer
brake solenoid valve block.
Next operation:
Trailer brake valve - Install (Solenoid valve block Italian Trailer brake) (D.34.C)
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Trailer brake valve - Install (Solenoid valve block Italian Trailer

brake)
Prior operation:
Trailer brake valve - Remove (Solenoid valve block Italian Trailer brake) (D.34.C)
NOTE: Install new sealing washers as required.

1. Install the oil supply pipes to the Italian trailer brake
solenoid valve block.
2. Install the Italian trailer brake solenoid valve block
with the oil supply pipes attached.
3. Install the banjo retaining bolt (2) to the Italian trailer
brake solenoid valve block and connect the oil supply
pipe (1) to the quick release coupling.
BVE0459A 1
4. Connect the trailer brake valve oil supply pipe (1).
BVE0455A 2
5. Connect the Italian trailer brake solenoid valve elec-

trical connectors.
Next operation:
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Trailer brake valve - Pressure test

Oil temperature 40 - 50 °C (104 - 122 °F).
Engine speed 1000 RPM.
Electrical system powered.
Parking brake disengaged.
TRAILER BRAKING SYSTEM PRESSURE TEST

1. Insert fitting 380000550 (1) in trailer brake coupler
and connect it to a 0 - 250 bar (0 - 3625 psi) pressure
380000543 and the hose 380000545.
BVE0169A 1
2. Couple both brake pedals together and with engine

and oil in the conditions described at the beginning,
apply the foot brake.
The pressure gauge reading should increase de-
pending on pedal effort up to 135 - 145 bar (1958 -
2103 psi).
3. If the pressure is not 135 - 145 bar (1958 - 2103
psi) check the system as described in Trailer brake
valve - Troubleshooting (D.34.C).
4. Engage parking brake, disconnect pressure gauge
and fitting 380000550 (1).
TRAILER BRAKE SYSTEM LEAK TEST

380000543 and the hose 380000545.
BVE0169A 2
6. Couple both brake pedals together and with engine

and oil in the conditions described at the beginning,
apply the foot brakes for a minimum of 10 seconds.
The pressure gauge reading should increase up to
135 - 145 bar (1958 - 2103 psi) and remain constant.
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7. If the pressure is not 135 - 145 bar (1958 - 2103

psi) check the system as described in Trailer brake
valve - Troubleshooting (D.34.C).
and fitting 380000550 (1).
TRAILER BRAKE DISENGAGEMENT PRESSURE TEST (ITALIAN TRAILER BRAKES ONLY)

380000543 and the hose 380000545.
BVE0169A 3
10. With engine and oil as detailed above, pressure

should be 11 - 12 bar (160 - 174 psi).
11. Make sure that light indicator is off.
12. If the pressure is not 11 - 12 bar (160 - 174 psi) check
the system as described in Trailer brake valve -
Troubleshooting (Italian Trailer brake) (D.34.C).
and fitting 380000550 (1).
PARKING BRAKE ENGAGEMENT TEST (ITALIAN TRAILER BRAKES ONLY)

380000543 and the hose 380000545.
BVE0169A 4
15. With engine and oil in the conditions described at the

beginning of this chapter, fully raise parking brake
control lever.
16. Check if pressure is 0 bar (0 psi) and light indicator
is on.
17. If the pressure is not 0 bar (0 psi) check the system
as described in Trailer brake valve - Troubleshoot-
ing (Italian Trailer brake) (D.34.C).
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18. With the parking brake engaged disconnect pressure

gauge and fitting 380000550 (1).
TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST (ITALIAN TRAILER BRAKES ONLY)
380000543 and the hose 380000545.
BVE0169A 5
20. With the parking brake OFF and tractor brakes not
applied, operate and hold the remote control valve
lever and allow the system pressure relief valve to
operate.
Keep this position for a few seconds and quickly re-
lease the control lever.
21. Check if parking brake disengagement pressure re-
mains at the specified value between 11 - 12 bar (160
- 174 psi).
22. If the pressure is not 11 - 12 bar (160 - 174 psi) check
the system as described in Trailer brake valve -
Troubleshooting (Italian Trailer brake) (D.34.C).
and fitting 380000550 (1).
HYDRAULIC TRAILER BRAKE CHECK (ITALIAN OPTION)

Foot Brake Hand Brake Warning Light Gauge Pressure at Coupler
(Trailer Brake)
Key ’ON’ OFF OFF ON 0 bar (0 psi)
Engine Running ( 800 - 1000
OFF OFF OFF* 10 bar (145 psi)
RPM)*
OFF ON ON 0 bar (0 psi)
RPM)*
OFF OFF OFF 10 bar (145 psi)
RPM)*
Engine Running ( 800 - 1000 10 bar (145 psi) - 120 bar
Apply foot brake
RPM)* OFF OFF (1740 psi)/ 150 bar (2175
progressively
psi)
ON ON ON 0 bar (0 psi)
RPM)*
Engine Running ( 800 - 1000 120 bar (1740 psi)/ 150 bar
ON OFF OFF
RPM)* (2175 psi)
Engine Running ( 800 - 1000 Release
120 bar (1740 psi)/ 150 bar
RPM)* foot brake OFF OFF
(2175 psi) - 10 bar (145 psi)
progressively
OFF ON ON 0 bar (0 psi)
RPM)*
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Foot Brake Hand Brake Warning Light Gauge Pressure at Coupler

(Trailer Brake)
OFF OFF OFF 10 bar (145 psi)
RPM)*
Key ’OFF’ OFF OFF OFF 0 bar (0 psi)
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Trailer brake valve - Troubleshooting

Pressure higher or lower Faulty trailer brake pressure regulating Replace trailer brake valve.
than specified. valve.
Faulty hydraulic pump. Test Pump and identify concern.
Excess pressure peaks Oil leaks from hydraulic system. Locate leaks and repair.
are observed when
applying the brake pedals
for 10 seconds.
Solenoid valve leak. Replace solenoid valve.
Trailer brake auxiliary valve leaks. Replace trailer brake auxiliary valve.
Trailer brake valve - Troubleshooting (Italian Trailer brake)

Trailer brake Trailer brake disengagement pressure Replace valve.
disengagement pressure valve incorrectly adjusted.
= 0 - 10 bar (0 - 145.0 psi)
Trailer brake Faulty warning lamp. Replace lamp.
disengagement pressure
not correct but warning
light is off.
Faulty trailer brake engaged warning lamp Replace switch.
switch.
Correct trailer brake Faulty trailer brake engaged indicator Replace switch.
disengagement pressure switch.
but light indicator is on.
Trailer brake Faulty indicator lamp. Replace lamp.
not correct but light
indicator is off.
Faulty trailer brake engaged indicator Replace switch.
switch.
Trailer brake Faulty parking brake engaged switch. Replace switch.
does not zero when
parking brake is applied.
Faulty parking brake indicator circuit relay. Replace relay.
Discharge solenoid valve faulty or stuck Repair or replace solenoid valve.
closed.
Trailer brake Trailer brake circuit safety switch adjust- Replace switch.
disengagement pressure ment exceeding rated value 2.5 - 3.5 bar
is permanently zeroed (36.3 - 50.8 psi).
when operating the
levers.
Switches reversed in the specified po- Move switches to correct positions or re-
sitions or with exchanged power supply verse power supply cables.
cables.
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Index

BRAKE CONNECTION Hydraulic - Dynamic description (Italian Trailer Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BRAKE CONNECTION Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE CONNECTION Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BRAKE CONNECTION Hydraulic - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trailer brake valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trailer brake valve - Exploded view (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Trailer brake valve - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Trailer brake valve - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Trailer brake valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Trailer brake valve - Install (Solenoid valve block Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Trailer brake valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Trailer brake valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Trailer brake valve - Remove (Solenoid valve block Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Trailer brake valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trailer brake valve - Static description (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Trailer brake valve - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Trailer brake valve - Troubleshooting (Italian Trailer brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
84276322A 31/05/2010
D.34.C / 32
SUSPENSION Hydraulic - 40.C

84276322A 31/05/2010
D.40.C / 1
Contents
SUSPENSION Hydraulic - 40.C
TECHNICAL DATA
SUSPENSION Hydraulic
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Control valve
84276322A 31/05/2010
D.40.C / 2
Overview (Valve block assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overview (Valve block assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Sectional view (Valve block assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SERVICE
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SERVICE MANUAL

MAXXUM 100 , MAXXUM 110 Multicontroller , MAXXUM 110 , MAXXUM 115

SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A

ENGINE AND PTO IN .................................................................... B

TRANSMISSION, DRIVE AND PTO OUT .........................................C

ADDITIONAL REDUCERS Overdrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.30.D

FRONT PTO Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.42.C

AXLES, BRAKES AND STEERING..................................................D

STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C

SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C

PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

SUSPENSION Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.40.C

WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C

FRAME AND CAB ......................................................................... E

HITCH AND WORKING TOOL ........................................................H

That information could be:

How to Use this Manual

Each Chapter is divided into four Information types:

SECTION B, POWER PRODUCTION

SECTION C, POWER TRAIN

SECTION E, BODY AND STRUCTURE

SECTION G, TOOL POSITIONING

SECTION K, CROP PROCESSING

ENGINE - Dynamic description (B.10.A - C.30.A.10)

Information Units and Information Search

example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)

Page Header and Footer

The page footer will contain the following references:

NOTES FOR EQUIPMENT

PAY ATTENTION TO THIS SYMBOL

WHEELS AND TYRES

REMOVAL AND INSTALLATION

HEALTH AND SAFETY

FUELS - see Fire, Legal Aspects, Chemicals - General, Solvents.. . . . . . . . . . . . . . . . 8

HEALTH AND SAFETY PRECAUTIONS

ACIDS AND ALKALIS

ADHESIVES AND SEALERS

Solvent based Adhesives/Sealers

Water based Adhesives/Sealers

Resin based Adhesives/Sealers

Anaerobic, Cyanoacrylate and other Acrylic Adhesives

Isocyanate (Polyurethane) Adhesives/ Sealers

BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols)

CHEMICAL MATERIALS - GENERAL

Clutch Linings and Pads

CORROSION PROTECTION MATERIALS

Gasolene (Petrol) Engine

Gas-Oil (Diesel Fuel)

Gas Shielded Welding

GENERAL WORKSHOP TOOLS AND EQUIPMENT

LUBRICANTS AND GREASES

Noise Insulation Materials

ECOLOGY AND THE ENVIRONMENT

The following are recommendations which may be of assistance:

Identification - Hexagonal nuts and locknuts classes 05 onwards

Identification - Cap screws and carriage bolts

Locknuts - grade identification

Locknuts - grade identification

Locknuts - grade identification

Consumables Lubrications and Coolants

Biodegradable Transmission and Hydraulic Oil

Sulphur Content % Oil Change Period

Total Hardness Chloride Sulphate

Using Plain water