john deere 4650 | 4850 tractor service manual · john deere model: 4650 & 4850 tractors volume...

John Deere

MODEL:

4650 & 4850 Tractors Volume 1 of 3

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

JD-S-TM13S4

http://www.jensales.com/products/john-deere-tractor-service-manual-4650-tractor-4850-tractor.html

4650 AND 4850 TRACTORS TECHNICAL MANUAL

TM-1354 (SEP-85)

CONTENTS-REPAIR SECTIONS

PUBLICATION NUMBER CHANGE

This technical manual was formerly TM-1258. The number was changed to TM-1354 when engine information was removed. Some pages still carry the old publication number. For engine information, refer to engine component technical manual CTM-1, 6466 Engines. This machine technical manual covers removal and installation of the engine components. The component manual covers basic repair of engine.

SECTION 10-GENERAL Group OO-Specifications Group 05-Predelivery, Delivery and After-Sale

Services Group 10-Tune-up Group 15-Lubrication

SECTION 15-SEPARATION Group 05-Front Axle Group 10-Front-End Group 15-Front-End and Engine Group 20-Engine Group 25-S0UND-GARD® body

and ROIl-Gard Protective Structure Group 30-Power Shift Clutch Housing Group 31-QUAD-RANGETM Clutch Housing Group 35-Transmission Group 40-Final Drives

SECTION 20-ENGINE Group 05-Acquire Access to Cylinder Head,

Valves and Camshaft Group 10-Acquire Access to Cylinder Block,

Liners, Pistons and Rods Group 15-Acquire Access to Crankshaft, Main

Bearings and Flywheel Group 20-Acquire Access to Lubrication System Group 25-Remove/lnstall Cooling System

SECTION 30-FUEL AND AIR SYSTEM Group 05-Acquire Access to Air Intake System Group .1 O-Acquire Access to Diesel Fuel System Group 15-Speed Control Linkage

SECTION 40-ELECTRICAL Group 05-Harness Replacement Group 06-Connector Repair Group 10-Remove/lnstall Delco-Remy Charging

Circuit Group 11-John Deere Charging Circuit Group 15-Starting Circuit Replacement Group 25-Lighting Circuit Repair Group 30-INVESTIGATOR IITM Warning System

And Digital Tachometer Repair Group 31-Gauge Cluster Instrumentation Repair Group 32-Analog Tachometer Repair Group 35-Accessories Circuits Repair

Continued on next page

All information, illustrations and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

UIO;OlOGEN AX4 240985

Litho in U.S.A. 01 TM-1354 (Sep-85) lUSiOl 220885


CONTENTS-CONTINUED

SECTION 50-POWER TRAIN-QUAD-RANGE TRANSMISSION

Group 05-Remove/lnstall Clutch Pressure Valve Housing

Group 10-Clutch Oil Pressure Regulating Valve Housing

Group 15-Clutch Operating Piston Housing Group 20-PERMA CLUTCHTM Group 30-QUAD-RANGETM Planetary Group 35-QUAD-RANGE Transmission & Charge

Pump Group 40-Shift Lever Assembly Group 55-PTO Gear Train Group 60-Adjust PTO Clutch Rod Group 65-Differential Group 70-Remove/lnstall Differential Lock

Valve and Adjust Lock Valve Release Bar

Group 75-Differential Lock Valve Group 80-Final Drive

SECTION 55-POWER TRAIN-POWER SHIFT TRANSMISSION

-Group 05-Remove/lnstall Traction Clutch Valve Housing

Group 10-Traction Clutch Valve Housing Group 15-Remove/lnstall Transmission Control

Valve Housing Group 20-Transmission Control Valves Group 25-Remove/lnstall Traction Clutch Group 30-Traction Clutch and Drive Shafts Group 35-lnput Planetary Group 40-Reduction Gear Train Group 45-0utput Planetary Group 50-Speed Selector Assembly Group 55-Charge Pump Assembly Group 60-PTO Gear Train with MFWD Group 61-PTO Gear Train without MFWD Group 65-Adjust PTO Clutch Rod Group 70-Differential Group 75-Remove/lnstall Differential Lock

Valve and Adjust Lock Valve Release Bar

Group 80-Differential Lock Valve Group 85-Final Drive Group 95-MFWD Gear Train

Litho in U.S.A. 02

Group 100-MFWD Clutch Group 1 05-MFWD Axle and Final Drive

SECTION 60-STEERING/BRAKES Group 05-Remove/lnstall Power Steering

Components Group 10-Steering Column Group 15-Metering Pump Group 20-Steering Valve Group 25-Steering Motor Group 30-Steering Assist Cylinders (MFWD) Group 35-Remove/lnstall Brake Valve and

Brake Accumulator Group 40-Brake Valve Group 45-Brake Accumulator Group 50-Bleeding Brakes and Testing Brake

Accumulator Group 55-Brake Pistons, Plates and Disks

SECTION 70-HYDRAULICS Group 05-Remove/lnstall Main Hydraulic Pump Group 10-Main Hydraulic Pump Group 15-0il Filter Relief Valve Housing (QRT) Group 20-Return Oil Filter Relief Valve Housing

(PST) Group 25-Remove/lnstall Attenuator Group 30-Hydraulic Attenuator Group 35-Remove/lnstall HYDRACUSHIONEDTM

Seat Valve Group 40-Repair Hydra-Cushioned Seat Valve

Assembly Group 45-Pressure Control Valve Group 50-Remove/Install Rockshaft Compo-

nents and Lift Assist Cylinders Group 55-Rockshaft Components Group 60-Lift Assist Cylinders Group 65-Draft Sensing Cylinders Group 70-Hitch Components Group 75-Remove/lnstall SCV Coupler and

Levers Group 80-SCV and ISO Coupler Group 85-Remote Cylinder Group 90-Hydraluic Oil Cooler and Thermal

Bypass Valve Group 95-Transmission-Hydraulic System Clean

up Procedure


UIO;OlOGEN BX4 090563

TM-1258 (May-83)


CONTENTS-CONTINUED

SECTION 80-MISCELLANEOUS Group 05-Rear Wheels Group 10-Front Axle

SECTION 90-0PERATOR STATION Group 05-Air Conditioning System Group 06-Air Conditioning System Service Group 10-Heating System Group 15-Seat Group 20-Miscellaneous Components

Litho in U.S.A. 03

SECTION 95-MISCELLANEOUS OPTIONS Group 40-Auxiliary Lighting and Electrical

Components Group 62-Auxiliary Trailer Brake Group 63-Secondary Brake Group 80-Minor Options

SECTION 99-SPECIAL TOOLS

U lO;OlOGEN CX4 090583

TM-1258 (May-83)


Section 10 GENERAL

CONTENTS

GROUP 00 - SPECIFICATIONS

General Tractor Specifications .......... 10-00-01 QUAD-RANGETM Ground Speeds ....... 10-00-04 Power-Shift Ground Speeds ............ 10-00-05

GROUP 05 - PREDELIVERY, DELIVERY AND AFTER-SALE SERVICES

Predelivery, Delivery, And After-Sale Service Specifications ............... 10-05-01

Lubrication Specifications .............. 10-05-02 English Torque Specifications. . . . . . . . . .. 10-05-03 Metric Torque Specifications . . . . . . . . . . .. 10-05-03 Dealer Predelivery Service ............. 10-05-04

Charge Battery(ies) (If Needed) ....... 10-05-04 Install ROLL-GARD As Per Instructions . . . . . . . . . . . . . . . . . . . . . . .. 1 0-05-05

If Equipped, Install Ether Aid Solenoid Wiring ................... 10-05-05

Tighten Air Intake Hose Clamps. . . . . .. 10-05-05 Adjust All Lamps .................... 10-05-06

Aim Head Lamps . . . . . . . . . . . . . . . . .. 10-05-06 Remove SMV Plastic Cover .......... 10-05-06 Check Tire Pressure ................. 10-05-07 Adjust Wheel Spacing ............... 10-05-08

Adjusting Front Fenders . . . . . . . . . . .. 10-05-08 Adjust Front Wheel Toe-In ........... 10-05-09 On FWD: (If Equipped), Set

Steering Stops .................... 10-05-09 Torque Wheel Hardware To

Specifications . . . . . . . . . . . . . . . . . . . .. 10-05-10 Lubricate All Grease Fittings.......... 10-05-10 Follow Break-In Procedure ........... 10-05-10

Verify Factory Services ................ 10-05-10 Is Engine Crankcase Oil Level Correct. 10-05-10 Is Fuel Injection Sealing Cover

(Or Pump Seals) Intact . . . . . . . . . . . .. 10-05-11 Is Air Cleaner Element(s) Installed

Correctly ......................... 10-05-11 Is Belt(s) Adjusted Correctly .......... 10-05-11 Is Engine Coolant Level Correct . . . . . .. 10-05-12 Is Transmission/Hydraulic System

Oil Level Correct .................. 10-05-12

Litho in U.S.A. 10-01

Are Shields, Handrails, And Steps I nstalled Correctly ................. 10-05-13

Is Clutch Pedal Adjusted Correctly ... " 10-05-13 Was Battery(ies) Charged As Received

From Factory ..................... 10-05-14 If Equipped, Does INVESTIGATORTM II

Warning System Operate Correctly .. 10-05-14 Are Instrument Panel Gauges And

Lights Operating Correctly .......... 10-05-14 Are All Lights Operating Correctly

In All Positions .................... 10-05-15 Is Neutral Start Switch Operating

Correctly ......................... 1 0-05-15 Is Engine Fast And Slow Idle

Adjusted Correctly . . . . . . . . . . . . . . . .. 10-05-15 Does Engine Stop Knob

Operate Correctly ................. 10-05-15 Are Brakes Operating Correctly

With Engine On/Off ............... 10-05-16 Does Transmission Operate Correctly

In All Gears (And In Park) .......... 10-05-16 Does Hydraulic System Operate

Properly . . . . . . . . . . . . . . . . . . . . . . .. .. 10-05-16 Does PTO Operate Correctly ......... 10-05-17 Are Coolant Lines Free Of Leaks ..... 10-05-17 Are Engine Oil Lines Free Of Leaks ... 10-05-17 Are Fuel Lines Free Of Leaks ........ 10-05-17 Are Hydraulic/Transmission Lines

Free Of Leaks .................... 10-05-18 Are Seat Belts Installed And

Operational, If Equipped ........... 10-05-18 Are Decals Smooth And Neat ........ 10-05-18 Is Paint Coverage Acceptable . . . . . . . .. 10-05-18 Is Overall Tractor Appearance

Acceptable ....................... 10-05-18 If Equipped, Does SGB Door Operate

Properly . . . . . . . . . . . . . . . . . . . . . . . . .. 1 0-05-18 If Equipped, Is SGB Upholstery Neat

In Appearance .................... 10-05-19 If Equipped, Is Interior of SGB

Clean ............................ 10-05-19

Continued on next page U10;010GEN MX4 100685

TM-1354 (Sep-85) lU8;1001 220885


General

CONTENTS-CONTINUED

GROUP 05 - PREDELIVERY, DELIVERY AND AFTER-SALE SERVICES - Cont.

Delivery Service . . . . . . . . . . . . . . . . . . . . . .. 10·05-19 After Sale Inspection .................. 10-05-20

Inspect Engine. . . . . . . . . . . . . . . . . . . . .. 10·05-21 Are There Any Oil, Fuel Or

Coolant Leaks .................. 10-05-21 Is Fan Belt Tension Correct ........ 10-05-21 Are Engine Idle Speeds Correct . . . .. 10-05-22 Does Fuel Shut-Off

Operate Correctly ............... 10-05-22 Is Throttle Lever Friction Disk

Adjusted Correctly . . . . . . . . . . . . . .. 10-05-22 I nspect Electrical System . . . . . . . . . . . .. 10-05-22

Does Neutral Start Switch Operate Correctly ............... 10-05-22

Do All Lights Operate Correctly ..... 10-05-23 Does Air Conditioner Operate

Correctly ....................... 10-05-23 Is Battery At Full Charge ........... 10-05-23

Inspect Power Train ................. 10-05-24 Is Transmission Operating In

All Gears And I n Park . . . . . . . . . . .. 1 0-05-24 Is Differential Lock Operating

Correctly And Adjusted With Brake Pedal . . . . . . . . . . . . . . .. 10-05-24

Is PTO Operating Correctly And Are Shields In Place ............. 10-05-24

Inspect Hydraulic System ............ 10-05-25 Is Rockshaft Operating Correctly .... 10-05-25 Are There Any Visible Oil Leaks . . . .. 10-05-25

Inspect Steering And Brakes ......... 10-05-25 Do Brakes Operate Correctly

With Engine On And Off ......... 10-05-25 Does Steering Operate Correctly

Both Left And Right ............. 10-05-26 Inspect Operator Station ............. 10-05-26

Are SGB Or ROPS Mounting Tight And Properly Installed ...... 10-05-26

Is Seat Operating Correctly .. . . . . . .. 10-05-27 Are All Gauges And Indicator

Lights Operating Correctly .... . . .. 10-05-27 Are Following Fluid Levels Correct: .... 10-05-27

Engine Crankcase ................. 10-05-27 Engine Coolant ................... 10-05-28 Hydraulic System . . . . . . . . . . . . . . . . .. 10-05-28 Battery . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-05-28

Does Customer Understand Proper Operation And Maintenance Of Tractor ...... . . . . . . . . . . . . . . . . .. 10-05-28

GROUP 10 - TUNE-UP

Make Preliminary Engine Tests ......... 10-10-01 Service Air Cleaner . . . . . . . . . . . . . . . . . . .. 10-10-02 Tighten Air Intake Connections ......... 10-10-02 Clean Crankcase Breather Tube ........ 10-10-02 Clean Grille Screens. . . . . . . . . . . . . . . . . .. 10-10-02 Clean Radiator And Oil Cooler .......... 10-10-03 Test Radiator And Cap ................ 10-10-03 Check Alternator And

Compressor Belt .................... 10-10-03 Check And Adjust Injection

Pump Timing ....................... 10-10-03 Check And Adjust Idle Speeds . . . . . . . . .. 10-10-03 Replace Fuel Filters ................... 10-10-04 Bleed Fuel System .................... 10-10-04 Service Batteries ... . . . . . . . . . . . . . . . . . .. 1 0-1 0-04 Make Yearly Cooling System Flush ...... 10-10-05 Make Final Engine Test ................ 10-10-05

GROUP 15 - LUBRICATION

Lubricate Tractor Properly . . . . . . . . . . . . .. 10-15-01 Engine Oil ... . . . . . . . . . . . . . . . . . . . . . . . .. 10-15-01 Transmission - Hydraulic Oils .......... 10-15-02 Use Correct Hydraulic Filter Element .... 10-15-02 Grease .............................. 10-15-03 MFWD Gear Lubricant ................. 10-15-03 Use Approved Alternate Lubricants . . . . .. 10-15-04 Store Lubricants Correctly ..... . . . . . . . .. 10-15-04 Lubrication Specifications .............. 10-15-05 Check Engine Oil Level ................ 10-15-06 Change Engine Oil And Oil Filter . . . . . . .. 10-15-06 Clean Crankcase Vent Tube ............ 10-15-06 Check Transmission-Hydraulic

Oil Level ........................... 10-15-07 Replace Transmission Oil Filter ......... 10-15-07 Replace Hydraulic Oil Filter . . . . . . . . . . . .. 10-15-08 Change Transmission-Hydraulic Oil ...... 10-15-09 Lubricate Grease Fittings. . . . . . . . . . . . . .. 10-15-10 Lubricate Axle Bearings ................ 10-15-10 Lubricate Wide Swing Drawbar . . . . . . . . .. 10-15-10 Lubricate Lift Links .................... 10-15-10 Lubricate Front Wheel Bearings

On Tractors Without MFWD .......... 10-15-11 Lubricate Front Axles And Pivot Pins .... 10-15-11 Lubricate MFWD Equipped Tractors ..... 10-15-11 Lubricate MFWD Axle Differential

And Planetary Drive 10-15-12

UIO;OlOGEN NX4 051184

Litho in U.S.A. 10-02 TM-1258 (Nov-84) lU8;lQ02 051184


Section 20 ENGINE REPAIR

CONTENTS

REPAIR INFORMATION

For complete repair information on the 6466 John Deere engine, component technical manual CTM-1 is also required.

Use the component manual in conjunction with this machine manual.

See the component manual for instructions on the engine, fuel system, and engine accessory items:

Theory of operation Diagnostic and testing procedures Disassembly Inspection Repair Assembly

See this machine manual for removal and installation instructions.

GROUP 05 - ACQUIRE ACCESS TO CYLINDER HEAD, VALVES AND CAMSHAFT

About This Group ..................... 20-05-01 Remove Valve Cover .................. 20-05-01 Acquire Access to Cylinder Head ....... 20-05-01 Acquire Access to Camshaft . . . . . . . . . . .. 20-05-02

GROUP 10 - ACQUIRE ACCESS TO CYLINDER BLOCK, LINERS, PISTONS AND RODS

About This Group ..................... 20-10-01 Acquire Access to Cylinder Block, Liners,

Pistons and Rods ................... 20-10-01

GROUP 15 - ACQUIRE ACCESS TO CRANK~ SHAFT, MAIN BEARINGS AND FLY· WHEEL

About This Group ..................... 20-15-01 Acquire Access to Flywheel ............ 20-15-01 Acquire Access to Crankshaft

and Main Bearings .................. 20-15-02

GROUP 20 - ACQUIRE ACCESS TO LUBRICATION SYSTEM

About This Group ..................... 20-20-01 Acquire Access to Oil Pump ............ 20-20-01

GROUP 25 - ACQUIRE ACCESS TO COOLING SYSTEM

Special Tools and Specifications ........ 20-25-01 Test Radiator and Cap. . . . . . . . . . . . . . . .. 20-25-02 Test Coolant Overflow Valve ........... 20-25-03 Replace Belts ........................ 20-25-04 Adjust Belt Tension .................. " 20-25-05 Remove Radiator ..................... 20-25-06 Install Radiator. . . . . . . . . . . . . . . . . . . . . . .. 20-25-08 Remove and Install Fan and

Viscous Clutch ...................... 20-25-09 Remove and Repair Fan Idler Assembly . 20-25-10 Acquire Access to Water Pump ......... 20-25-11 Electric Coolant Heater ................ 20-25-12

U20;020CON AX4 240985

Litho in U.S.A. 20-01 TM-1354 (Sep-85) lU8;2001 300885


Section 30 FUEL AND AIR SYSTEMS REPAIR

CONTENTS

REPAIR INFORMATION

For complete repair information on the 6466 John Deere engine, component technical manual CTM-1 is also required.

Use the component manual in conjunction with this machine manual.

See the component manual for instructions on the engine, fuel system, and engine accessory items:

Theory of operation Diagnostic and testing procedures Disassembly Inspection Repair Assembly

See this machine manual for removal and installation instructions.

GROUP 05 - ACQUIRE ACCESS TO AIR INTAKE SYSTEM

About This Group ..................... 30-05-01 Removing Air Cleaner Elements . . . . . . . .. 30-05-01 Cleaning Element ..................... 30-05-02 Washing Element ..................... 30-05-03 Inspecting Element. . . . . . . . . . . . . . . . . . .. 30-05-03 Service Ether Starting Aid .............. 30-05-04

GROUP 10 - ACQUIRE ACCESS TO DIESEL FUEL SYSTEM

About This Group ..................... 30-10-01 Bleed Fuel System .................... 30-10-02 Remove Fuel Tank .................... 30-10-02 Install Fuel Tank ...................... 30-10-04

GROUP 15 - SPEED CONTROL LINKAGE

Remove and Install Control Linkage ..... 30-15-01

U30;030CON AX4 240985

Litho in U.S.A. 30-01 TM-1354 (Sep-85) lU4j3001 170985


Section 40 ELECTRICAL REPAIR

CONTENTS

REPAIR INFORMATION

Repair information for starters and Delco-Remy charging circuit is contained in component technical manual CTM-1, 6466 Engines.

GROUP 05 - HARNESS REPLACEMENT

Remove and Install Batteries ........... 40-05-01 Electrical Load Center Circuit Breakers .. 40-05-01 Remove and Install Electrical

Load Center ........................ 40-05-02 Replace Harnesses . . . . . . . . . . . . . . . . . . .. 40-05-02 Install Instrument Panel Harness ........ 40-05-13 Install SOUND-GARD Body Harness. . . .. 40-05-13

GROUP 06 - CONNECTOR REPAIR

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 40-06-01 CPCTM, Large MATE-N-LOKTM and

METRIMATETM Pin Type Connectors Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-06-01

CPC Blade Type Connectors Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-06-02

Small MATE-N-LOK Connectors Replace Socket Type ..... . . . . . . . . . .. 40-06-02 Replace Pin Type ................... 40-06-03

DEUTSCHTM Connector Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-06-03

WEATHER PACKTM Connector Replace . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-06-04

Remove Connector Body from Blade Termin~ ........................... 40-06-06

DEUTSCH Contact Install .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-06-06

WEATHER PACK Contact Install .............. . . . . . . . . . . . . . . .. 40-06-07

Group 10 - REMOVEIINSTALL DELCO-REMY CHARGING CIRCUIT

Special Tools ......................... 40-10-01 Specification . . . . . . . . . . . . . . . . . . . . . . . . .. 40-10-01 Remove Alternator .................... 40-10-01

Repair Alternator . . . . . . . . . . . . . . . . . . . . .. 40-10-02 I nstall Alternator ...................... 40-10-02 Adjust Alternator Belts ................. 40-10-03

GROUP 11 - JOHN DEERE CHARGING CIRCUIT REPAIR

Special Tools ......................... 40-11-01 Other Materials ....................... 40-11-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 40-11-01 Remove Alternator .................... 40-11-02 Disassemble Alternator ................ 40-11-02 Remove Pulley Nut .................... 40-11-03 Separate Housings .................... 40-11-03 Remove and Inspect Front Bearing . . . . .. 40-11-04 Install Front Bearing ................... 40-11-04 Remove Rotor and Rear Bearing . . . . . . .. 40-11-05 Inspect Rear Bearing .................. 40-11-05 Install Rear Bearing ................... 40-11-06 Remove Stator, Rectifier Bridge,

and Brush Assembly . . . . . . . . . . . . . . . .. 40-11-06 Test Rotor For Grounds ................ 40-11-07 Test Rotor For Opens

and Short Circuits ................... 40-11-07 Repair Slip Rings ..................... 40-11-07 Test Brush Assembly .................. 40-11-08 Install New Brushes ................... 40-11-08 I nspect Stator ........................ 40-11-09 Test Stator For Grounds ............... 40-11-09 Test Stator For Opens

Or Short Circuits .................... 40-11-09 Test Diode In Rectifier Bridge ........... 40-11-09 Test Diode For Open Or Short Circuits . .. 40-11-10 Test Diode/Resistor Trio ............... 40-11-10 Connect Stator Windings .......... . . . .. 40-11-11 Test Regulator . . . . . . . . . . . . . . . . . . . . . . .. 40-11-11 Assemble Alternator ................... 40-11-11 I nstall Regulator ...................... 40-11-12 Install Rotor and Front Housing ......... 40-11-12 Install Pulley Assembly ................. 40-11-12 Install Alternator ...................... 40-11-13 Adjust Alternator Belts ................. 40-11-13 Connect Alternator Wires .............. 40-11-14


U40;040CON AX4 230985



Contents

CONTENTS-Continued

GROUP 15 - STARTING CIRCUIT REPLACEMENT

Essential Tools ....................... 40-15-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 40-15-01 Remove and Install Starting Motor ...... 40-15-01 Repair Starter ........................ 40-15-02 Remove and Install Starter Circuit

Relay .............................. 40-15-03 Remove and I nstall Key Switch ......... 40-15-03 Remove Neutral Start Switch

(Power Shift Transmission) ........... 40-15-04 Remove Neutral Start Switch

(QUAD-RANGE Transmission) ........ 40-15-05 I nstall and Adjust Neutral Start Switch ... 40-15-05

GROUP 25 - LIGHTING CIRCUIT REPAIR

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 40-25-01 Remove and Install Light Switch ........ 40-25-01 Remove and Install Turn Signal

Controller .......................... 40-25-02 Remove and Install Turn Indicator

Lamps and Hi-Beam Indicator Lamp. .. 40-25-03 Remove and Install Dimmer Switch . . . . .. 40-25-03 Remove and Install Lighting Circuit

Relays ............................. 40-25-04 Remove and Install Gear

Indicator Lamp. . . . . . . . . . . . . . . . . . . . .. 40-25-04 Replace Console and Dome Lamp ...... 40-25-05 Remove and Install Dome

Lamp Door Switch . . . . . . . . . . . . . . . . . .. 40-25-05 Replace Headlamps and Flood Lamps ... 40-25-05 Adjust Headlamps ..................... 40-25-06 Replace Warning and Tail Lamps ....... 40-25-07 Replace Front Light Bar Bulb ........... 40-25-08 Replace Front Light Bar . . . . . . . . . . . . . . .. 40-25-08

U40;040CON BX4 230985



Electrical Repair

CONTENTS-Continued

GROUP 30 - INVESTIGATOR II WARNING SYSTEM AND DIGITAL TACHOMETER REPAIR

Specifications ........................ . Remove and Install Investigator II

Warning System Module ............ . Remove and Install Digital Tachometer .. Replacing Digital Tachometer Bulbs .... . Setting Tachometer Clock ............. . Setting Digital Tachometer

Ground Speeds .................... . 4650 Tractor Tire Size Switch Codes 4850 Tractor Tire Size Switch Codes .... Replace Stop Engine Lamp

and Service Alert Lamp ............. . Replace Investigator II Warning Horn ... . Replace Investigator II Warning System

Sensors ........................... . Fuel Level Sensor .................... . Engine Speed Sensor ................. . Engine Coolant Sensor ............... . Engine Cylinder Head

Temperature Sensor ................ . Air Filter Restriction Sensor ........... . Engine Oil Pressure Sensor ........... . Clutch Temperature Sensor ........... . Hydraulic Oil Temperature Sensor ...... . Transmission Control Pressure Sensor .. . Transmission Oil Filter Restriction

40-30-01

40-30-01 40-30-03 40-30-03 40-30-03

40-30-04 40-30-04 40-30-05

40-30-06 40-30-06

40-30-07 40-30-07 40-30-07 40-30-08

40-30-08 40-30-08 40-30-08 40-30-09 40-30-09 40-30-09

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-30-10 Ground Speed Sensor ................. 40-30-10 PTO Speed Sensor . . . . . . . . . . . . . . . . . . .. 40-30-10

GROUP 31 - GAUGE CLUSTER INSTRUMENTATION REPAIR

Introduction .......................... 40-31-01 Remove Gauge Cluster ................ 40-31-01 Gauge Removal . . . . . . . . . . . . . . . . . . . . . .. 40-31-03 Remove and Install Lamps ............. 40-31-04 Switches and Sensors ................. 40-31-05 Fuel Level Sensor ..................... 40-31-07 Engine Coolant Temperature Sensor .... 40-31-07 Engine Oil Pressure Sensor ............ 40-31-07 Voltage .............................. 40-31-07 Transmission Oil Sensors - aRT ........ 40-31-08 Transmission Oil Sensors - PST ........ 40-31-09

GROUP 32 - ANALOG TACHOMETER REPAIR

Introduction .......................... 40-32-01 Removal ............................. 40-32-01

GROUP 35 - ACCESSORIES CIRCUIT REPAIR

Remove and Install Horns and Horn Switch ........................ 40-35-01

Remove and Install Electric Starting Aid Solenoid and Switch ............. 40-35-02

Remove and Install MFWD Solenoid and Switch ......................... 40-35-02

Remove and Install Cigar Lighter. . . . . . .. 40-35-03 Remove and Install Clock .............. 40-35-03 Adjust Clock . . . . . . . . . . . . . . . . . . . . . . . . .. 40-35-04 Remove and Install Radio

and Antenna . . . . . . . . . . . . . . . . . . . . . . .. 40-35-04 Remove and Install Convenience

Outlet Socket ....................... 40-35-05 Remove and Install Electrical

Outlet Socket ....................... 40-35-05 Remove and Install Blower

Motor Assembly . . . . . . . . . . . . . . . . . . . .. 40-35-06 Replace Air Conditioning Warning Lamps

and Temperature Control Switch ...... 40-35-07 Replace Air Conditioning Timer Relay . . .. 40-35-08 Replace Air Conditioning Hi-and-Low-

Pressure Switches . . . . . . . . . . . . . . . . . .. 40-35-08 Remove and Install L.H. Wiper Motor. . .. 40-35-09 Remove and Install R.H. Wiper Motor

and Drive Gear Replacement ......... 40-35-09 Remove and Install Wiper Switches ..... 40-35-11

U40;040CON CX4 221084

Litho in U.S.A. 40-03 TM-1258 (Nov-84) lUBi4003 221084


Section 50 POWER TRAIN - QUAD-RANGE

TRANSMISSION

CONTENTS

GROUP 05 - REMOVE/INSTALL CLUTCH PRESSURE VALVE HOUSING

Other Materials ....................... 50-05-01 Specifications ......................... 50-05-01 Drain Auxiliary Reservoir and

Oil Cooler .......................... 50-05-01 Remove Clutch Pressure

Valve Housing ...................... 50-05-02 Install Clutch Pressure

Valve Housing ...................... 50-05-02

GROUP 10 - CLUTCH OIL PRESSURE REGULATING VALVE HOUSING

Specifications ......................... 50-1 0-01 Disassemble and Inspect Clutch

Valve Housing ...................... 50-10-02 Pressure Regulating Valve

Remove and Inspect ................ 50-10-09 Install .............................. 50-1 0-09

GROUP 15 - CLUTCH OPERATING PISTON HOUSING

Special Tools ......................... 50-15-01 Specifications ......................... 50-15-01 Piston Housing

Remove ............................ 50-15-03 Disassemble ........................ 50-15-03 Inspect ............................. 50-15-05 Assemble .......................... 50-15-1 0

, Install .............................. 50-1 5-14

GROUP 20 - PERMA-CLUTCH

Special Tools ......................... 50-20-01 Specifications ......................... 50-20-01 PERMA-CLUTCH

Remove ............................ 50-20-02 Disassemble and Inspect ............. 50-20-02 Assemble .......................... 50-20-05

Install .............................. 50-20-07 Adjust ............................. 50-20-07

GROUP 30 - QUAD-RANGE PLANETARY

Special Tools ......................... 50-30-01 Service Parts Kits ..................... 50-30-01 Specifications ......................... 50-30-02 QUAD-RANGE Planetary

Remove ............................ 50-30-05 Disassemble ........................ 50-30-06 Inspect ............................. 50-30-09

Control and Shift Valve Disassemble ........................ 50-30-15 Inspect ............................. 50-30-16 Assemble .......................... 50-30-17

Assemble Planetary ................... 50-30-18 Test Planetary Clutch and 8rake ........ 50-30-21 Install QUAD-RANGE Planetary ......... 50-30-22

GROUP 35 - QUAD-RANGE TRANSMISSION AND CHARGE PUMP

Special Tools ......................... 50-35-01 Other Materials ....................... 50-35-02 Specifications ......................... 50-35-03 Shifter Shaft Supports

Remove ............................ 50-35-09 Inspect, Disassemble and Assemble ... 50-35-09 Install and Check Shaft End Play ...... 50-35-10

Upper Shifter Cam Remove ............................ 50-35-11 Inspect and Install ................... 50-35-13

Lower Shifter Cam Remove ........................... 50-35-138 Inspect ............................. 50-35-14 Install .............................. 50-35-15

Upper Shifter Assembly Remove ............................ 50-35-16


U50;050CON AX4 180283

Litho in U.S.A. 50-01 TM-1258 (Dec-83) lU8i5001 221183


Power Train - QUAD-RANGE Transmission

CONTENTS-Continued

GROUP 35 - QUAD-RANGE TRANSMISSION AND CHARGE PUMP (Continued)

Inspect ............................ 50-35-18 Disassemble .. . . . . . . . . . . . . . . . . . . . . .. 50-35-18 Assemble .......................... 50-35-19

Adjust Reverse Shifter Stop Screw ...... 50-35-21 Lower Shifter Assembly

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-22 Inspect ............................ 50-35-23 Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 50-35-24 Assemble .......................... 50-35-24 Install .............................. 50-35-25

Transmission Oil Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-26 Disassemble, Inspect and Assemble . .. 50-35-29 Install .,;";,........................... 50-35-32

TransmissiOn Drive Shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-34 Disassemble .. . . . . . . . . . . . . . . . . . . . . .. 50-35-35 Inspect ............................ 50-35-38 Assemble .......................... 50-35-41 Install .............................. 50-35-46 Adjust End Play and Front Assembly .. 50-35-47

Differential Drive Shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-48 Inspect ............................ 50-35-51 Adjust Cone Point ................... 50-35-53 Adjust End Play ..................... 50-35-55 Check Rolling Drag Torque. . . . . . . . . .. 50-35-58 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-59

Countershaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-35-63 Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 50-35-64 Inspect ............................ 50-35-66 Assemble .......................... 50-35-67 Install .............................. 50-35-69 Adjust End Play ..................... 50-35-70 Final Assembly ..................... 50-35-71

GROUP 40 - SHIFT LEVER ASSEMBLY

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 50-40-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 50-40-01 Shift Lever Assembly

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-40-02 Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 50-40-04 Inspect and Repair .................. 50-40-06 Assemble .......................... 50-40-07 Install .............................. 50-40-10

Adjust Shift Linkage ................... 50-40-12

GROUP 55 - PTO GEAR TRAIN

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 50-55-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 50-55-01 PTO Shaft

Remove and Disassemble . . . . . . . . . . .. 50-55-02 Inspect and Assemble ............... 50-55-04 Adjust Bearing End Play ............. 50-55-07 Assemble and Install ................ 50-55-07

PTO Drive Gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-55-10 Inspect ............................ 50-55-1 0 Assemble and Install ................ 50-55-12

GROUP 60 - ADJUST PTO CLUTCH ROD

Adjust Clutch Rod ..................... 50-60-01

GROUP 65 - DIFFERENTIAL

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 50-65-01 Other Materials ....................... 50-65-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 50-65-02 Differential

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50-65-03 Ring Gear From Housing

Inspect and Remove ................ 50-65-05 Assemble .......................... 50-65-05

Differential Housing Disassemble ... . . . . . . . . . . . . . . . . . . . .. 50-65-06 Inspect ............................ 50-65-08 Assemble .......................... 50-65-12

Install Differential. . . . . . . . . . . . . . . . . . . . .. 50-65-16 Adjust Preload of Differential

Housing ............................ 50-65-17 Adjust Backlash of Differential

Housing ............................ 50-65-18 Final Assembly of Differential

Housing ............................ 50-65-18

GROUP 70 - REMOVE/INSTALL DIFFERENTIAL LOCK VALVE AND ADJUST LOCK VALVE RELEASE BAR

Remove Differential Lock Valve. . . . . . . .. 50-70-01 Adjust Lock Valve Release Bar ......... 50-70-02


U50;050CON BX4 120784

Litho in U.S.A. 50-02 TM-1258 (Aug-84) lU8;5002 130784


Power Train - QUAD-RANGE Transmission

CONTENTS-Continued

GROUP 75 • DIFFERENTIAL LOCK VALVE GROUP 80 - FINAL DRIVE

Specifications ......................... 50-75-01 Special Tools ......................... 50-80-01 Differential Lock Valve Other Materials ....................... 50-80-01

Disassemble ........................ 50-75-01 Service Parts Kits ..................... 50-80-02 Inspect ............................. 50-75-02 Specifications ......................... 50-80-03 Assemble .......................... 50-75-03 Planet Pinion Carrier

Disassemble from Axle Shaft ......... 50-80-04 Disassemble ........................ 50-80-05 Inspect ............................. 50-80-06 Assemble .......................... 50-80-07

Axle Housing Remove from Axle Shaft ............. 50-80-08 Inspect and Disassemble ............. 50-80-09 Assemble .......................... 50-80-1 0

Axle Shaft Inspect and Disassemble ............. 50-80-11 Assemble .......................... 50-80-12 Install Axle Housing ................. 50-80-13 Adjust Axle Bearing End Play ......... 50-80-13

Install Planet Pinion Carrier Assembly and Check Rolling Drag Torque ....... 50-80-16

I nstall Final Drive to Tractor ............ 50-80-19

U50;OSOCON CX4 180283

Litho in U.S.A. 50-03 TM-1258 (Dec-83) lUB;5003 221183


QUAD-RANGE Transmission and Charge Pump

12. Install front shifter gear (A), (snap ring recess rearward) and shifter collar (B) on arbor.

NOTE: The front shifter gear has part number stamped on rear side and the front shifter gear has internal splines that are complete where a portion of the internal splines of the rear shifter gear is removed. Do not interchange with rear shifter gear.

13. Install thinnest snap ring with retainer (A), and thrust washer (B).

NOTE: The front and rear shifter gear thrust washers are interchangeable.

14. Install B-range gear (A) with shifter splines facing forward, captive thrust washer (B) with flat side faCing B-range gear. Install second thinnest snap ring with retainer (C), and thrust washer (D).

IMPORTANT: Captive thrust washer must be installed so flat side faces B-range gear to allow future disassembly.

A-B-Range Gear B-Captive Thrust Washer

C-5econd Thinnest Snap Ring With Retainer

D-Thrust Washer

15. Install D-range gear (A) (helical section to front with shifter splines facing rearward) and second thickest snap ring with retainer (B).

Litho in U.S.A. 50-35-61

AU6;R35744 R50;OS004Q OVXI 310881

AU6;R35745 R50;050040 DWXl 310881

, t

AU6;R35746 R50;050040 EAX1 120784

AU6;R35747 R50;050040 EBXl 310881

TM-1258 (Aug-84) lU8;50.3561 130784


Section 55 POWER TRAIN - POWER SHIFT

TRANSMISSION

CONTENTS

GROUP 05 - REMOVE/INSTALL TRACTION CLUTCH VALVE HOUSING

Traction Clutch Valve Housing Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-05-01 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-05-02

GROUP 10 - TRACTION CLUTCH VALVE HOUSING

Special Tools ......................... 55-10-01 Other Materials ....................... 55-10-01 Service Parts Kits ..................... 55-1 0-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-10-02 PTO Clutch Valve

Remove/Inspect PTO Lock Piston

55-10-03

Remove/Inspect .................... 55-10-04 Install ...... . . . . . . . . . . . . . . . . . . . . . . .. 55-10-04

PTO Clutch Valve Install .............................. 55-1 0-04

Traction Clutch Valve Remove/Install ..................... 55-10-05 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-10-07

PTO Modulating Valves Remove, Inspect and Install .......... 55-10-09

Filter Relief Valve Remove, Inspect and Install

Pressure Regulating Valve Remove, Inspect and Install

PTO Brake Check Valve Remove, Inspect and Install

55-10-10

55-10-11

55-10-11

GROUP 15 - REMOVE/INSTALL TRANSMISSION CONTROL VALVE HOUSING

Transmission Control Valve Housing Remove ............................ 55-15-01 Install ............................. , 55-15-02

Modulating Valve Housing .............. 55-15-03

GROUP 20 - TRANSMISSION CONTROL VALVES AND ACCUMULATORS

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-20-01 Transmission Control Valve Cover

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-20-02 Speed Selector Assembly

Disassemble and Inspect. . . . . . . . . . . .. 55-20-03 Forward-Reverse Valve Assembly

Disassemble and Inspect. . . . . . . . . . . .. 55-20-05 Shift Valve Housing

Remove/Inspect .................... 55-20-07 Remove/Inspect Remaining Control

Valves ........................... 55-20-10 I nstall Control Valves ................ 55-20-11 Assemble and Install ................ 55-20-13

Assemble Forward-Reverse Valve Assembly .......................... 55-20-15

Speed Selector Assembly Assemble .......................... 55-20-16

Modulating Valve Housing Disassemble/Inspect ................ 55-20-19

Accumulator C3 Gas-Type Operational Check ...... 55-20-20 System Operational Check ........... 55-20-20 Checking and Recharging ............ 55-20-21

GROUP 25 - REMOVE/INSTALL TRACTION CLUTCH

Remove/Install Traction Clutches ....... 55-25-01

GROUP 30 - TRACTION CLUTCH AND DRIVE SHAFTS

Special Tools ........................ . Specifications ........................ . Remove/Inspect Shafts ............... . Traction Clutch

Disassemble/Inspect ............... . Assemble ......................... .

Assemble/Install Drive Shaft

55-30-01 55-30-02 55-30-03

55-30-05 55-30-11 55-30-16


U50;055CON AX4 111183

Litho in U.S.A. 55-01 TM-1258 (Aug-84) 1U8;5001 130784


Power Train - Power Shift Transmission

CONTENTS-Continued

GROUP 35 - INPUT PLANETARY

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-35-01 Other Materials ....................... 55-30-01 Service Parts Kits ..................... 55-35-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-35-02 Input Planetary

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-35-03 Remove Lube Manifold .............. 55-35-04 Disassemble/Inspect ................ 55-35-05 Disassemble/Inspect Lube Manifold ... 55-35-07 Disassemble/Inspect Hi-Lo ........... 55-35-08 Assemble Input Planetary ............ 55-35-13 Assemble Hi-Lo ..................... 55-35-15

Lube Manifold Assemble .......................... 55-35-20 Install .............................. 55-35-21

Assemble/Install Input Planetary ........ 55-35-22

GROUP 40 - REDUCTION GEAR TRAIN

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-40-01 Other Materials ....................... 55-40-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-40-02 Reduction Gear Shaft

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-40-04 Disassemble and Inspect. . . . . . . . . . . .. 55-40-05 Assemble and Install ................ 55-40-08 Adjust End Play ..................... 55-40-10 Final Assembly ..................... 55-40-12

Tow Disconnect Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-40-13 Inspect ............................ 55-40-15 Install and Adjust .................... 55-40-16 Final Assembly ..................... 55-40-18

Park Pawl Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-40-19 Inspect ............................ 55-40-20 Install .............................. 55-40-21

Differential Drive Shaft Remove and Disassemble . . . . . . . . . . .. 55-40-22 Inspect ............................ 55-40-25 Adjust Cone Point ................... 55-40-26 Assemble Check Rolling Drag Torque . 55-40-26 Final Assembly ..................... 55-40-31

GROUP 45 - OUTPUT PLANETARY

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-45-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-45-02 Remove Output Planetary .............. 55-45-03

Brake Pack Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 55-45-04 Inspect ............................ 55-45-08

Clutch Pack Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 55-45-09 Inspect ............................ 55-45-1 0

Disassemble and Inspect Planetary . . . . .. 55-45-11 Assemble Planetary ................... 55-45-13 Assemble Clutch Pack ................. 55-45-18 Assemble Brake Pack ................. 55-45-20 Checking Piston Return Plate Clearance . 55-45-24 Install Output Planetary ................ 55-45-26

GROUP 50 - SPEED SELECTOR ASSEMBLY

Upper Control Assembly ............... 55-50-01 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-50-02 Disassemble and Repair ............. 55-50-03 Assemble and Install ................ 55-50-09

Center Control Assembly Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-50-10 Disassemble and Repair ............. 55-50-10 Assemble and Install ................ 55-50-12

Adjust Speed Selector Assembly ........ 55-50-13

GROUP 55 - CHARGE PUMP ASSEMBLY

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-55-01 Other Materials ....................... 55-55-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 55-55-01 Charge Pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-55-02 Disassemble and Inspect. . . . . . . . . . . .. 55-55-02 Assemble .......................... 55-55-04 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-55-07

GROUP 60 - PTO GEAR TRAIN WITH MFWD

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-60-01 Other Materials ....................... 55-60-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-60-02 PTa Clutch

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-60-04 Disassemble ... . . . . . . . . . . . . . . . . . . . .. 55-60-07 Inspect and Assemble ............... 55-60-09 Install and Adjust End Play and Continue Inspect and Assemble .............. 55-60-13

PTa Brake Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-60-19 Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 55-60-21 Inspect and Assemble ............... 55-60-22 Install .............................. 55-60-25

USO;OSSCON BX4 120784

Litho in U.S.A. 55-02 TM-1258 (Aug-84) 1U8i5502 130784



CONTENTS-Continued

GROUP 60 - PTO GEAR TRAIN WITH MFWD (Continued)

PTO Shaft Remove and Disassemble . . . . . . . . . . .. 55-60-26 Inspect and Assemble ............... 55-60-28 Adjust Bearing End Play ............. 55-60-31 Assemble and Install ................ 55-60-31

GROUP 61 - PTO GEAR TRAIN WITHOUT MFWD

Special Tools ......................... 55-61-01 Other Materials ....................... 55-61-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-61-02 PTO Clutch

Remove ............................ 55-61-04 Disassemble PTO Clutch

and Drive Gear ................... 55-61-08 I nspect and Assemble ............... 55-61-1 0 Install and Adjust End Play and Continue Inspect and Assemble .............. 55-61-13

PTO Brake Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-61-22 Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 55-61-25 Inspect and Assemble Components ... 55-61-26 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-61-29

PTO Shaft Remove and Disassemble. . . . . . . . . . .. 55-61-34 Inspect and Assemble ............... 55-61-36 Adjust Bearing End Play ............. 55-61-39 Assemble and Install ................ 55-61-39

GROUP 65 - ADJUST PTO CLUTCH ROD

Adjust PTO Clutch Rod ................ 55-65-01

GROUP 70 - DIFFERENTIAL

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 55-70-01 Other Materials ....................... 55-70-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-70-02 Differential

Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-70-04 Inspect and Remove Ring Gear from

Housing. . . . . . . . . . . . . . . . . . . . . . . . .. 55-70-06 Assemble Ring Gear to Housing ...... 55-70-07

Differential Housing Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 55-70-07 Inspect ............................ 55-70-09 Assemble .......................... 55-70-10 Install .............................. 55-70-18

Adjustments Preload of Differential Housing .. . . . . .. 55-70-19 Backlash of Differential Housing ...... 55-70-20

Final Assembly of Differential ........... 55-70-21

GROUP 75 - REMOVE/INSTALL DIFFERENTIAL BLOCK VALVE

Differential Lock Valve Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-75-01 Adjust Release Bar. . . . . . . . . . . . . . . . .. 55-75-02

GROUP 80 - DIFFERENTIAL LOCK VALVE

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-80-01 Differential Lock Valve

Disassemble. . . . . . . . . . . . . . . . . . . . . . .. 55-80-01 Inspect ............................ 55-80-02 Assemble .......................... 55-80-03

GROUP 85 - FINAL DRIVE

Special Tools ......................... 55-85-01 Other Materials ....................... 55-85-02 Service Parts Kits ..................... 55-85-02 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-85-03 Planet Pinion Carrier

Disassemble From Axle Shaft. . . . . . . .. 55-85-04 Disassemble .. . . . . . . . . . . . . . . . . . . . . .. 55-85-05 Inspect 4650 Components. . . . . . . . . . .. 55-85-06 Inspect 4850 Components. . . . . . . . . . .. 55-85-07 Assemble .......................... 55-85-08

Axle Housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-85-09 I nspect and Disassemble . . . . . . . . . . . .. 55-85-10 Assemble .......................... 55-85-11

Axle Shaft I nspect and Disassemble . . . . . . . . . . . .. 55-85-12 Assemble .......................... 55-85-13 Install Axle Housing to Axle Shaft ..... 55-85-14 Adjust Axle Bearing End Play ......... 55-85-14

Install Planet Pinion Carrier Assembly and Check Rolling Drag Torque ..... " 55-85-17

Install Final Drive to Tractor ............ 55-85-20

U50;055CON CX4 120784

Litho in U.S.A. 55-03 TM-1258 (Aug-84) lU8;5503 130784



CONTENTS-Continued

GROUP 95 a MFWD GEAR TRAIN

Special Tools ...... " . . . . . . . . . . . . . . . . .. 55-95-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 55-95-02 Clutch Idler Shaft

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-95-03 Inspect ............................ 55-95-04 Assemble ....... ".................. 55-95-05 Install .............................. 55-95-06 Check End Play . . . . . . . . . . . . . . . . . . . .. 55-95-07 Remove Idler Gear ..... " ... "........ 55-95-07 Disassemble, Inspect and Assemble ... 55-95-09 Install Idler Gear .................... 55-95-09

Drive Shaft Remove Front Gear and Quill . . . . . . . .. 55-95-11 Inspect and Disassemble Driver Gear

and Quill ......................... 55-95-12 Drive Shaft and Components ........... 55-95-11

Inspect and Disassemble ............. 55-95-13 Install .............................. 55-95-15 Inspect Rear Gear. . . . . . . . . . . . . . . . . .. 55-95-17 Install Rear Gear .................... 55-95-19

GROUP 100 - MFWD CLUTCH

Special Tools ........................ 55-100-01 Specifications. . . . . . . . . . . . . . . . . . . . . . .. 55-100-01 Service Parts Kits .................... 55-100-02 Remove Mechanical Front-Wheel Drive

Clutch Quill ........................ 55-100-02 Inspect and Replace Oil Seal

and a-Ring Packing ................ 55-100-03 Install Quill and Check Clutch Shaft

End Play ......................... 55-100-03B Mechanical Front-Wheel Drive Clutch

Remove . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-100-04 Disassemble, Inspect and Assemble Clutch

Cover . . .. .. .. .. .. .. .. . . . . . .. .. .. 55-100-05 Disassemble and Inspect . . . . . . . . . . .. 55-100-06 Assemble ......................... 55-100-10 Install ............................. 55-100-14

Solenoid Remove, Disassemble and Inspect ... 55-100-15 Assemble and Install Solenoid ....... 55-100-17

Inlet Check Ball Assembly Remove and Inspect ............... 55-100-18 Install ............................. 55-100-19

GROUP 105 - MFWD AXLE AND FINAL DRIVE

Essential Tools ...................... 55-105-01 Other Materials ...................... 55-105-01 Specifications . . . . . . . . . . . . . . . . . . . . . . .. 55-105-03 MFWD Components .................. 55-105-04 Remove and Repair Planetary Carrier . .. 55-105-05 Assemble Planetary Carrier . . . . . . . . . . .. 55-105-07 Remove and Inspect Sun Gear, Ring Gear,

Hub and Spindle Bearings . . . . . . . . . .. 55-105-08 Install Wheel Hub Bearing Cup, Cone

and Seal .......................... 55-105-10 Remove, Inspect, and Repair Wheel

Spindle ........................... 55-105-12 Remove and Inspect Axle Shaft and

Replace U-Joint . . . . . . . . . . . . . . . . . . .. 55-105-14 Install Drive Axle Universal Joint ....... 55-105-15 Replace Inner Axle Seals and

Bushings .......................... 55-105-16 Remove and Inspect Steering

Knuckle ........................... 55-105-18 Assemble Steering Knuckles .......... 55-105-20 Install Axle and Wheel Spindle ......... 55-105-21 Adjust Steering Knuckle Rolling Drag

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-105-22 Adjust U-Joint Shaft End Play . . . . . . . . .. 55-105-23 Install Planetary Carrier ............... 55-105-25 Remove and Disassemble Pivot Housing

Differential Assembly ............... 55-105-26 Inspect Differential Housings and Spiral

Bevel Drive Pinion . . . . . . . . . . . . . . . . .. 55-105-28 Assemble Pivot Housing Differential

Assembly ......................... 55-105-30 Disassemble Differential Drive Shaft .... 55-105-32 Adjust Differential Drive Shaft Cone

Point ............................. 55-105-34 Assemble Differential Drive Shaft ...... 55-105-36 Determining Differential Drive Shaft Rolling

Drag Torque Shim Thickness ........ 55-105-38 Install Ring Gear Assembly and Adjust

Backlash .......................... 55-105-39 Check Drive Pinion-to-Ring Gear Contact

Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55-105-41 Install Differential Assembly into Axle

Housing ........................... 55-105-41 Changing Differential Drive Shaft

Seal .............................. 55-105-43

U50;055CON DX4 230985



PTO Gear Train With MFWD

ADJUST PTO SHAFT BEARING END PLAY

1. With PTa shaft in vise, install dial indicator as shown.

2. Rotate bearing quill several times in each direction to seat roller bearings.

3. Pull bearing quill rearward and zero the dial indicator.

4. Push quill forward and note indicator reading.

5. Add or remove enough shims to provide 0.03 to 0.13 mm (0.001 to 0.005 in.) end play.

NOTE: Shims are available in nominal thicknesses of 0.08, 0.15,0.30 mm (0.0030.006, and 0.012 in.). Measure shims individually to assure accurate measurement.

6. Repeat Steps 1-5 until proper end play is obtained.

7. Remove dial indicator and tighten retaining plate-to-quill cap screws to 68 N·m (50 Ib-ft).

ASSEMBLE AND INSTALL PTO SHAFT

NOTE: 1. PTO shaft bearing end play adjustment must be made before proceeding with final assembly and installa tion.

2. Disregard references to magnetic disk, pin, and snap rings, if tractor is not equipped with INVESTIGA TOR" Warning System.

1. Install rear magnetic pick-up disk snap ring (A) with the gap in line with pin hole in shaft.

NOTE: Later model tractors have a 6.4 mm (0.250 in.) solid pin instead of a spring pin. Pin must be in hole in shaft to keep magnetic pick-up disk from turning on PTO shaft.

2. Install pin in shaft so that it protrudes 6.00 mm (0.236 in.) from 0.0. of shaft.

2A. Install magnetic pick-up disk (A) with slot (8) over pin in PTa shaft.

Litho in U.S.A. 55-60-31

AZ7;R36557 R50;50100 90 120784

AZ7;R36558 R50;50100 91 120784

AZ7;R36559 R50;50100 92 120784

TM-1258 (Aug-84) 1U8;556031 130784


Section 60 STEERING AND BRAKES

CONTENTS

GROUP 05 - REMOVE/INSTALL POWER STEERING COMPONENTS

Special Tools ......................... 60-05-01 Specifications ......................... 60-05-01 Steering Column

Remove ............................ 60-05-02 Install .............................. 60-05-04

Metering Pump Remove and Install .................. 60-05-04

Steering Valve Remove ............................ 60-05-05 Install .............................. 60-05-05

Steering Motor Remove ............................ 60-05-06 Install .............................. 60-05-11

GROUP 10 - STEERING COLUMN

Special Tools ......................... 60-10-01 Specifications ......................... 60-10-01 Steering Shaft

Remove ............................ 60-10-01 I nspect and Repair .................. 60-10-02

Replace Steering Column Bushing ...... 60-10-03 Assemble and Install Steering Column 60-10-04

GROUP 15 - METERING PUMP

Special Tools ......................... 60-15-01 Specifications ......................... 60-15-01 Metering Pump

Test for Leakage .................... 60-15-02 Disassemble ........................ 60-15-03 Assemble .......................... 60-15-03 Test for Leakage .................... 60-15-05

GROUP 20 - STEERING VALVE

Specifications ......................... 60-20-01 Steering Valve

Disassemble and Inspect ............. 60-20-01 Assemble .......................... 60-20-04

GROUP 25 - STEERING MOTOR

Special Tools ......................... 60-25-01 Specifications ......................... 60-25-02 Steering Motor

Disassemble ........................ 60-25-03 Inspect Parts ....................... 60-25-06 Assemble .......................... 60-25-08

GROUP 30 - STEERING ASSIST CYLINDERS (MFWD)

Special Tools ......................... 60-30-01 Specifications ......................... 60-30-01 Other Materials ....................... 60-30-01 MFWD Steering Assist Cylinder

Remove ............................ 60-30-02 Disassemble and Inspect ............. 60-30-03 Assemble .......................... 60-30-04 Install .............................. 60-30-05

GROUP 35 - REMOVE/INSTALL BRAKE VALVE AND BRAKE ACCUMULATOR

Brake Valve Remove ............................ 60-35-01 Install .............................. 60-35-03

Brake Accumulator Remove/Install ..................... 60-35-04

GROUP 40 - BRAKE VALVE

Service Parts Kit ...................... 60-40-01 Specifications ......................... 60-40-01 Brake Valve

Disassemble ........................ 60-40-02 Inspect ............................. 60-40-05 Assemble .......................... 60-40-06


U60;060CON AX3 190483

Litho in U.S.A. 60-01 TM-1258 (May-83)


Steering and Brakes

CONTENTS-Continued

GROUP 45 - BRAKE ACCUMULATOR

Special Tools ......................... 60-45-01 Other Materials ....................... 60-45-01 Specifications ......................... 60-45-01 Brake Accumulator

Disassemble and Inspect ............. 60-45-02 Assemble .......................... 60-45-04 Pre-Charge ......................... 60-45-06

GROUP 50 - BLEEDING BRAKES AND TESTING BRAKE ACCUMULATOR

Bleed Brakes ......................... 60-50-01 Adjust Brake Valve .................... 60-50-01 Test Brake Accumulator ............... 60-50-03

GROUP 55 - BRAKE PISTONS, PLATES AND DISKS

Specifications ......................... 60-55-01 Brake Pistons, Plates and Disks


U60;060CON BX3 060483

Litho in U.S.A. 60-02 TM-1258 (May-83)


Section 70 HYDRAULICS

CONTENTS

GROUP 05 - REMOVE/INSTALL MAIN HYDRAULIC PUMP

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-05-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-05-01 Main Hydraulic Pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-02 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-06

Pump Drive Shaft and Couplings Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-07 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-05-06

Repair Main Pump Shaft Oil Seal ....... 70-05-07

GROUP 10 - MAIN HYDRAULIC PUMP

Special Tools ......................... 70-10-01 Speci"fications . . . . . . . . . . . . . . . . . . . . . . . .. 70-10-02 Hydraulic Pump


Stroke Control Valve Disassemble and Inspect . . . . . . . . . . . .. 70-10-16 Assemble .......................... 70-10-20

GROUP 15 - OIL FILTER RELIEF VALVE HOUSING (QRT)

Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-15-01 Return Oil Filter Relief Valve Housing

Disassemble and Inspect. . . . . . . . . . . .. 70-15-01 Assemble .......................... 70-15-03

Return Oil Manifold Disassemble, I nspect and Assemble . .. 70-15-04

GROUP 20 - RETURN OIL FILTER RELIEF VALVE HOUSING (PST)

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 70-20-01 Return Oil Filter Relief Valve


Return Oil Manifold Disassemble, Inspect and Assemble ... 70-20-03

GROUP 25 - REMOVE/INSTALL ATTENUATOR

Remove and Install Attenuator . . . . . . . . .. 70-25-01

GROUP 30 - HYDRAULIC ATTENUATOR

Disassemble, Repair and Assemble Hydraulic Attenuator ................. 70-30-01

GROUP 35 - REMOVE/INSTALL HYDRACUSHIONED SEAT VALVE

Special Tools ......................... 70-35-01 Other Materials ....................... 70-35-01 Spedfications . . . . . . . . . . . . . . . . . . . . . . . .. 70-35-01 Hydracushioned Seat Valve

Remove and Install ... . . . . . . . . . . . . . .. 70-35-02 Seat Accumulator

Remove and Install. . . . . . . . . . . . . . . . .. 70-35-03 Checking Pre-Charge ................ 70-35-03

GROUP 40 - HYDRA-CUSHIONED SEAT VALVE ASSEMBLY

Special Tools ......................... 70-40-01 Other Materials ....................... 70-40-01 Specifications .... . . . . . . . . . . . . . . . . . . . .. 70-40-01 Seat Valve


Accumulator Check Pre-Charge . . . . . . . . . . . . . . . . . .. 70-40-06 Pre-Charge ......................... 70-40-07

GROUP 45 - PRESSURE CONTROL VALVE

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 70-45-01 Pressure Control Valve



U70;070CON AX4 260784

Litho in U.S.A. 70-01 TM-1258 (Dec-83) lU8;7001 161183


CONTENTS-Continued

GROUP 50 - REMOVE/INSTALL ROCKSHAFT COMPONENTS AND LIFT ASSIST CYLINDERS - Continued

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-50-01 Other Materials ....................... 70-50-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-50-01 Rockshaft Control Valve

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-50-02 Install .............................. 70-50-03

Rockshaft Adjustments Rockshaft Control Linkage ........... 70-50-04 Rockshaft Drop Rate ................ 70-50-04 Lift Rate ........................... 70-50-04 Rockshaft Valve Clearance ........... 70-50-05

Rockshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-50-06 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-50-11

Lift Assist Cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-50-12 Install .............................. 70-50-12

Remove and Install Draft Sensing Cylinder .................... 70-50-13

GROUP 55 - ROCKSHAFT COMPONENTS

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-55-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-55-01 Rockshaft Piston Cover

Remove and Repair ................. 70-55-03 Install .............................. 70-55-05

Rockshaft Piston Remove and Inspect ................ 70-55-06

Rockshaft Housing Disassemble and Inspect. . . . . . . . . . . .. 70-55-07 Assemble .......................... 70-55-09

Rockshaft Control Valve Housing Disassemble and Repair ............. 70-55-10 Inspect Linkage ..................... 70-55-14

Assemble Rockshaft Control Valve ...... 70-55-15 Load Control Valve

Disassemble and Inspect. . . . . . . . . . . .. 70-55-18 Load Control Valve

Assemble and Install ................ 70-55-19 Remove and Inspect Inline Check

Valve and Filter ..................... 70-55-19

GROUP 60 - LIFT ASSIST CYLINDERS

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-60-01 Lift Assist Cylinders

Disassemble and Repair ............. 70-60-01 Assemble .......................... 70-60-02

GROUP 65 - DRAFT SENSING COMPONENTS

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-65-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-65-01 Draft Sensing Cylinder

Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 70-65-02 Assemble .......................... 70-65-03

GROUP 70 - HITCH COMPONENTS

Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-70-01 3-Point Hitch

Repair ............................. 70-70-01 Remove and Install. . . . . . . . . . . . . . . . .. 70-70-02

GROUP 75 - REMOVE/INSTALL SCV COUPLER AND LEVERS

Selective Control Valve Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-75-01 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-75-01 Remove and Repair Linkage. . . . . . . . .. 70-75-02

Adjust Selective Control Valve Linkage .. 70-75-03

GROUP 80 - SCV AND ISO COUPLER

Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 70-80-01 Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-80-01 Breakaway (ISO) Coupler

Remove and Install. . . . . . . . . . . . . . . . .. 70-80-02 Disassemble Serviceable Coupler ...... 70-80-02A Assemble Serviceable Coupler ........ " 70-80-03 Install Non-Serviceable Coupler ........ 70-80-03A Install Serviceable Coupler ............ 70-80-03B Selective Control Valve

Disassemble . . . . . . . . . . . . . . . . . . . . . . .. 70-80-05 Assemble .......................... 70-80-09 Adjust ............................. 70-80-13

GROUP 85 - REMOTE CYLINDER

Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 70-85-01 Remote Cylinder


Continued on next page U70;070CON BX4 300885

Litho in U.S.A 70-02 TM-1354 (Sep-85) lU8;7001 300885


Hydraulics

CONTENTS-Continued

GROUP 90 - HYDRAULIC OIL COOLER AND THERMAL BYPASS VALVE

Hydraulic Oil Cooler Clean .............................. 70-90-01 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-90-01 Inspect ............................ 70-90-02 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-90-02

Thermal Bypass Valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-90-03 Inspect ............................ 70-90-04

GROUP 95 - TRANSMISSION-HYDRAULIC SYSTEM CLEAN-UP PROCEDURE

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 70-95-01 Other Materials ....................... 70-95-01 Oil Cleanup and Flushing

Transmission Case .................. 70-95-02 Monitoring System Oil Cleanup ......... 70-95-03 Cleanup Preparation ................... 70-95-03 System Cleanup ...................... 70-95-05 Returning Tractor to Field .............. 70-95-06

ACCUMULATORS

Service information on Accumulators can be found in Section 55, Group 20.

U70;070CON CX4 141284

Litho in U.S.A. 70-03 TM-1258 (Nov-84) lUS;7003 141284


Section 80 MISCELLANEOUS

CONTENTS

GROUP 05 - REAR WHEELS

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 80-0S-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 80-0S-01 Remove Rear Wheel .................. 80-0S-01 Install Rear Wheel .................... 80-0S-03 Remove Rear Wheel

Weights ............................ 80-0S-04 Install Rear Wheel Weights ............. 80-0S-0S Observe Rear Wheel Tread

Width Limitations .................... 80-0S-06 Check Implement-to-Tire Clearance ..... 80-0S-06 Using Radial-Ply Tires ................. 80-0S-07 Choosing Rear Tread Width ............ 80-0S-07 Rear Tread Ranges ................... 80-0S-07 Change Rim Position on

Wheel ............................. 80-0S-09 Reverse Wheels on Axles .............. 80-0S-10 Dual Wheels . . . . . . . . . . . . . . . . . . . . . . . . .. 80-0S-11 Determining Maximum Rear

Ballast ............................. 80-0S-11 Using Liquid Weight In

Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . .. 80-0S-12

GROUP - 10 FRONT AXLE

Special Tools ......................... 80-10-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 80-10-01

Check Front Axle Pivot Wear ........... 80-10-02 Replace Front Axle Pivot Bushing ....... 80-10-02 Replace Front Axle Pivot Pin ........... 80-10-03 Replace Front Axle Pivot

Pin (MFWD) ........................ 80-10-04 Replace Knee Bushing . . . . . . . . . . . . . . .. 80-10-04B Replace Wheel Bearings ............... 80-1 0-07 Adjustable Front Axle Size

Identification ........................ 80-10-08 Standard Front Axle Tread Settings ..... 80-10-09 Adjusting Standard Front Axle .......... 80-10-09 Check Toe-In (Adjustable Axle) ......... 80-10-10 Adjust Toe-In (Adjustable Axle) ......... 80-10-10 Check and Adjust Toe-In (MFWD) ....... 80-10-11 Mechanical Front Wheel Drive

Tread Settings ...................... 80-10-13 Set Steering Stops .................... 80-10-1S Adjust Steering Stop Screw ............ 80-10-16 Steering Stop Positions Charts . . . . . . . . .. 80-10-17 Install and Adjust Front Fenders ........ 80-10-19 Use Correct Tire Combinations ......... 80-1 0-23 Selecting Front Tire Rolling Direction .... 80-10-24 Selecting Front Ballast .............. . .. 80-10-24 Determining Maximum Front Ballast ..... 80-10-2S Installing Front Weights ................ 80-10-2S Using Liquid Weight In Front Tires ...... 80-10-26

USO;OSOCON AX4 1309S5

Litho in U.S.A. 80-01 TM-13S4 (Sep-8S) lU8;8001 300885


Section 90 OPERATOR STATION REPAIR

CONTENTS

GROUP 05 " AIR CONDITIONING SYSTEM

Special Tools o. 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 0 . 0 90-05-01 Other Materials 0 0 0 0 0 . 0 0 . 0 . 0 . 0 0 0 0 0 0 0 0 0 0 90-05-01 Service Parts Kits For Compressor 0 0 0 0 0 0 90-05-01 Compressor Specifications 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-02 Hose and Tubing Flare Connection

Torques o' 0 0 0 0 0 0 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 , 0 0 0 90-05-02 Hose and Tubing a-ring Connection

Torques 0'" 0 0 0 0 . 0 0 . 0 . 0 0 0 0 0 0 , . , 0 0 0 . 0 90-05-03 Cap Screw Torque Chart 0 0 0 0 . 0 0 0 . 0 0 0 0 0 0 90-05-03 Servicing Refrigerant Couplings 0 0 0 0 0 0 0 0 0 90-05-04 Discharge the System 0 0 0 0 0 0 0 . 0 . 0 0 . 0 0 0 0 90-05-05 Compressor

Remove 0 0 0 . 0 . , 0 0 0 0 0 . 0 0 0 0 0 0 0 , . 0 0 0 0 0 0 90-05-05 Dissemble and Inspect 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 90-05-08 Replace Clutch Pulley Bearing 0", 0 0 0 0 90-05-12 Replace Shaft Seal Seat 0 0 0 0 0 0 0 0 0 0 . 0 0 90-05-13 Assemble 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-14 Servicing Manifolds 0 0 0 0 0 0 0 0 0 0 0 0 0' 0 0 0 0 90-09-16 I nstall Compressor 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 90-05-16

Tests Volumetric Efficiency 0 0 0 0 0 0 0 0 0 0 0 0 . 0 o. 90-05-06 Shaft Seal Leak ,0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-07

Condenser Remove 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o. 90-05-18 Leak Test 0.00000000.0000' 0 0 0 0 0 0 0 0 0 0 90-05-19 Install 0 0 0 . 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 90-05-20

Receiver Dryer Replace 0' 0 0 0 0 0 0 0 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 90-05-20

Evaporator IHeater Core Remove '0000000000000' 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-21 Test and Install 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0' 90-05-22

Servicing Expansion Valve 0 0 0 0 0 0 0 0 0 0 0 '0 90-05-24 Air Conditoning Timer Relay

Replace 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-26 ServiCing Temperature Control

Switch 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-27 Compressor Relief Valve

Service 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 90-05-28 Air Filters

Remove 0 0 0 0 0 0 0 0 0 , , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-05-28 Clean and Install o. 0 0 0 0 0 0 0 00' 0 0 0 0 0 0 0 0 90-05-28

GROUP 06 - AIR CONDITONING SYSTEM SERVICE

Special Tools 0 0 0 0 0 0 , 0 0 0 , 0 0 0 0 0 0 0 , 0 0 0 0 '0 90-06-01 Other Materials 0 0 0 . 0 0 , , 0 0 0 0 0 . , 0 0 0 . 0 , 0 0 90-06-01 Specifications 0 0 0 . 0 0 0 0 0 , 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 90-06-02 Servicing 0' 0 . 0 0 . 0 . 0 0 0 0 0 0 0 . 0 . 0 0 , 0 0 0 0 0 0 0 90-06-03 Determining Refrigerant Oil Charge 0 0 0 0 0' 90-06-04 Adding Refrigerant Oil 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-06-05 Flushing the System 0 0 . 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 90-06-09 Purging the System 0 0 . 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 90-06-09 Evacuating the System 0000.00' o. 00' o. o. 90-06-10 Charging the System 00000000000.000000 90-06-11

GROUP 10 - HEATING SYSTEM

Replace Heater Control Valve 0 0 0 0 0 0 0 0 0 0 90-10-01 Replace Heater Hoses 00000000000000000 90-10-02

GROUP 15 - SEAT

Specifications 0 0 0 0 0 , 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-15-01 OtherTools 000000000000000000000000'090-15-01 Remove Hydracushioned Seat 00000000. 0 90-15-01 Remove Vertical Suspension

Assembly 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 90-15-02 Disassemble, Inspect, and Repair

Vertical Suspension Assembly 0 0 0 0 0 0 0 0 90-15-02 Assemble Vertical Suspension

Assembly 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 90-15-05 Remove Horizontal Suspension

Assembly 0' 0 0 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-15-06 Disassemble, Inspect, and Repair

Horizontal Suspension Assembly 0 0 0 0 ,0 90-15-07 Assemble Horizontal Suspension

Assembly '0 0 0 0 0 0 0 0 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 . 0 90-15-10 Install Seat and Vertical

Suspension 0 0 0 . 0 0 0 0 0 , 0 0 . 0 0 0 0 0 0 0 0 0 0 0 0 90-15-10 Remove, Repair and Install

Del uxe Seat 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 , 0 0 0 90-15-11 Disassemble and Inspect Deluxe

Seat Support Assembly 0 0 0 0 0 0 0 0 0 0 0 0 0 0 90-15-12 Assemble Deluxe Seat

Support Assembly 0 0 0 0 . 0 0 0 0 . 0 0 0 0 0 0 0 0 0 90-15-14

U90;090CON AX3 030383

Litho in UoS.A 90-01 TM-1258 (May-83)


--~

Section 95 MISCELLANEOUS OPTIONS

CONTENTS

ABOUT THIS SECTION

Miscellaneous options have been adopted to meet certain legal requirements. Included in these options is Auxiliary Lighting and Electrical Components, Auxiliary Trailer Brakes, Minor Options, and Secondary Brake.

The following groups in this section will cover minor comonents and major component theory, diagnosis, and repair.

GROUP 40 • AUXILIARY LIGHTING AND ELECTRICAL COMPONENTS

Special Tools. . . . . . . . . . . . . . . . . . . . . . . .. 95-40-01 Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 95-40-01 Safety Precautions .................... 95-40-01 Diagnosing Malfunctions ............... 95-40-02 Light Switch Operation and Diagnosis ... 95-40-03 Hazard Warning Switch ................ 95-40-03 Parking Brake Indicator ................ 95-40-04 Headlamps

Remove and Install Bulbs ............ 95-40-05 Front Turn Signal and Clearance

Lamps ............................. 95-40-07 Rear License Plate Lamp .............. 95-40-08 Tail, Stop, and Turn Lamps. . . . . . . . . . . .. 95-40-08 Electrical Outlet Socket ................ 95-40-10 Brake Light Switch Operation and

Diagnosis .......................... 95-40-11 Steering Pressure Sensor

Operation .......................... 95-4-0-12 Remove and Test ................... 95-40-13 Install .............................. 95-40-14

Other Electrical Components ........... 95-40-14 Using Wiring Schematics .. . . . . . . . . . . . .. 95-40-15 Wire Color Abbreviation Chart .......... 95-40-15 Lighting System Circuits. . . . . . . . . . . . . . .. 95-40-16 Lighting System Schematics ............ 95-40-17

GROUP 62 . AUXILIARY TRAILER BRAKE

Specifications. . . . . . . . . . . . . . . . . . . . . . . .. 95-62-01 System of Operation . . . . . . . . . . . . . . . . . .. 95-62-02 Trailer Brake Valve

Test ............................... 95-62-03 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .. 95-62-04 Disassemble ... . . . . . . . . . . . . . . . . . . . .. 95-62-04-Assemble .......................... 95-62-05

GROUP 63 - SECONDARY BRAKE

Special Tools ......................... 95-63-01 Specifications . . . . . . . . . . . . . . . . . . . . . . . .. 95-63-02 Secondary Brake

Operation .......................... 95-63-03 Remove Components . . . . . . . . . . . . . . .. 95-63-05 Inspect Components. . . . . . . . . . . . . . . .. 95-63-07 Install Components .................. 95-63-12

GROUP 80 - MINOR OPTIONS

Reflectors ............................ 95-80-01 License Plate (Mounting Support) ....... 95-80-01 Rear View Mirrors ..................... 95-80-02 Traffic Horn .......................... 95-80-02 Engine Coolant Heater

(220 Volt) ........................... 95··80-02 Auxiliary Steps ........................ 95-80-03 Auxiliary Grab Bar . . . . . . . . . . . . . . . . . . . .. 95-80-03 Fan Guards .......................... 95-80-03 Toolbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 95-80-04 SOUND-GARD Body Latches. . . . . . . . . .. 95-80-04 Foot Speed Control ................... 95-80-04

GROUP 85 . AUXILIARY STEERING

System Operation ..................... 95-85-01 Checking System Operation ............ 95-85-02 Check Accumulator Pressure ........... 95-85-02 System Reservoir ..................... 95-85-06

U95;095CON A1X3 141284

Litho in U.S.A. 95-01 TM-1258 (Nov-84) lU8;9501 171084


Section 99 SPECIAL TOOLS

CONTENTS

NOTE: Order tools from your SERVICE GARD Catalog, unless otherwise indicated.

PURCHASED TOOLS 2364 .................. 99-01 JOE-7 . ................ CS-2428 JOE-35 0-01003AA JOE-37A 0-01045AA ............ 99-02 JOE-55 0-01049AA JOE-66 ................ 0-01061AA JOE-78-1 0-01062AA ............ 99-03 JOE-78-2 0-01109AA ............ 99-04 JOE-78-5 0-01110AA JOE-79 ................ 0-01114AA JOE-80 0-01168AA JOE-81-1 0-01173AA ............ 99-05 JOE-81-4 0-01206AA JOE-90 ................ 0-01219AA ............ 99-06 JOE-92 0-05007ST JOE-93 0-05029ST ............ 99-07 JOE-96 0-05058ST JOE-99 ................ 0-05103ST ............ 99-08 JOE-105 0-05104ST JOE-106A 0-05124ST JOE-41296 ............. 0-05155ST ............ 99-09 JOF-29 0-05267ST JOF-33 ................ 0-05314ST JOG-10-2 0-15001NU ............ 99-10 JOG-15 0-15038NU JOG-16A 0-15041 NU .......... 99-10A JOG-17 ................ 0-17004BR JOG-18 0-17011 BR JOG-19 0-17015BR JOG-23 0-17024BR .......... 99-10B JOG-24 ................ 0-17030BR JOG-74-1 0-17501C1 JOG-127 0-17515C1 ............ 99-11 JOG-138 0-17525C1 JOG-138-2 ............. 0-17526C1 JOG215 0-18009KO JOG236 0-18019KO ........... . 99-12 JOG239 ............... 0-19001TI ........... 99-12A JOG246 0-20002W1 ......... . 99-12B JOG247 J0306-A JOG249 JOE-3 JOG266 ............... JOE-6 JOG268

Litho in U.S.A. 99-1

99-13

99-14

99-15

99-16

99-17

99-18

99-19

99-20

99-21

99-22

99-23

99-24

JOG287 JOG289 JOG290 JOG292 . .............. 99-25 JOG293 JOG295 JOG298 . .............. 99-26 JOG299 JOG302 JOG303 JOG304 ............... 99-27 JOG305 JOG306 JOG307 JOG308 ............... 99-28 JOG311 JOG312 JOG313 JOG315 ............... 99-29 JOG317 JOG337 JOG400-7 JOG523 ............... 99-30 JOG524 JOH-15C JOH-28 ................ 99-31 JOH-31A JOH-35A JOH-42-1 JOH-42-2 JOH-52 ................ 99-32 JOH-57 JOST-29 JOT-1 JOT-3A ................ 99-33 JOT-10 JOT-23 JOT-24A JOT-26 ................ 99-34 JOT-30 JOT-31 JOT-32

Continued on next page 99U;099CON 130985

TM-1354 (Sep-85) lU8;991 210885


PURCHASED TOOLS-Continued JDT-38 .................. 99-35 JDT-42 JDT-46 JT01463 ................ 99-36 JT01633 JT05470 JT27701 ................ 99-37 JT27702 JT27706 JT27707 ................ 99-38 OTC 33858 TY1481 TY-3315 ................ 99-39

Litho in U.S.A.

Special Tools

CONTENTS-Continued

FABRICATED TOOLS Adapter, Housing . . . . . . . .. 99-39 Compressor, Shock Absorber

Spring ................ 99-40 Starting Motor Commutator

Bushing Tool .......... 99-41 Extension, Rockshaft, Arm.. 99-42 Holding Fixture, Cylinder

Liner . . . . . . . . . . . . . . . . .. 99-43 Holding Fixture, Turbocharger

Turbine ............... 99-44 Holding Tool, DDS Holding Tool, Yoke ....... 99-45 Hook, Planetary Jacking Tool, Axle ........ 99-46 Lifting Tool, Differential ... 99-47

99-2

Lift Tool, Planetary ....... 99-48 Lift Tool, Rockshaft ....... 99-49 Puller, Tube and Sleeve . .. 99-50 Removal Tool, Trans. Input Shaft Set, Modified D-05001ST .. 99-51 Spanner ................. 99-52 Stop, Pivot Wrench, Spanner . . . . . . . .. 99-53 Removal/Tool, Final Drive

Gear .................. 99-54 Shaft, PTO Gear End Play

Adjusting .............. 99-54 Fitting, MFWD Pivot Pin

Adatper ............... 99-55 Holding Tool, SCV

Coupler ............... 99-56

99U;099CON A 270784

TM-1354 (Aug-84) lU8;992 210885


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