McCormick ZTX230 Service Manual

Table of Contents
ZTX Series Tractors

Service Manual SM 8-12602
Section Pub. No.
1 GENERAL
Safety Rules, General Information and Torque Specifications ............................1001
General Specifications and Torques ...................................................................1002
2 ENGINE
Engine How it Works .................................................................................................2
Fault Codes
3 FUEL
4 ELECTRICAL
Electrical How it Works ......................................................................................... ..4
Electrical Schematics.........................................................................................4001
Instrument Cluster Programming.......................................................................4002
Battery Servicing and Testing............................................................................4004
5 STEERING
Steering How it Works ...............................................................................................5
Steering Column and Steering Hand Pump Removal ........................................5001
Rexroth Steering Hand Pump.............................................................................5002
6 TRANSMISSION
Transmission How it Works ......................................................................................6
Splitting the Tractor .............................................................................................6003
Full Powershift Transmission ..............................................................................6006
MFD Clutch..........................................................................................................6017
Rear Axle.............................................................................................................6018
Power Take Off ...................................................................................................6019
MFD Front Axle - 20.49 Axle ...............................................................................6021
Front Suspended Axle - 20.49 Axle.....................................................................6022
7 BRAKES
Brakes How it Works .................................................................................................7
Parking Brake ......................................................................................................7001
8 HYDRAULICS
Hydraulics How it Works............................................................................................8
Hydraulic Troubleshooting and Schematic ..........................................................8001
Left Hand and Right Hand Hydraulic Covers........................................................8005
Hydraulic Priority Valve Blocks ............................................................................8006
Auxiliary/Remote Spool Valves............................................................................8008
9 CHASSIS AND MOUNTED EQUIPMENT

Climate Control How it Works.....................................................................................9
Pedal, Lever And Switch Adjustments .................................................................9001
10 CONTROLLER SYSTEMS
Electrical Controllers How it Works..........................................................................10
Auxiliary/Remote Valve Controller - Error Codes,
Troubleshooting and Schematics ..................................................................10001
Hitch Controller - Error Codes,
Front Suspended Axle Controller
Calibration, Error Codes, Troubleshooting and Schematics..........................10003
Transmission and Cab (MCC) Controller - Calibration, Error Codes,
Instrument Cluster Controller - Error Codes,
Controller Programming ................................................................................10010
Automatic Temperature Control.....................................................................10012
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND STANDARD TORQUE SPECIFICATIONS
© 2001 McCormick Tractors International Limited.

SM 8-10080 March 2001
2 SECTION 1001
TABLE OF CONTENTS
SAFETY ................................................................................................................................................................... 3
GENERAL INFORMATION
Cleaning ............................................................................................................................................................... 5
Inspection ............................................................................................................................................................. 5
Bearings ............................................................................................................................................................... 5
Needle Bearings .................................................................................................................................................. 5
Gears ................................................................................................................................................................... 5
Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5
Shafts ................................................................................................................................................................... 5
Service Parts ........................................................................................................................................................ 5
Lubrication ........................................................................................................................................................... 5
STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6
Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7
SM 8-10080 Issued 03-2001

SECTION 1001 3
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED. The message that follows the symbol contains
! important information about safety. Carefully read the message.
Make sure you fully understand the causes of possible injury or
death.
To prevent injury always follow the Warning,

Caution and Danger notes in this section and WARNING: Before starting engine, study
throughout the manual. Operator’s Manual safety messages.
Read all safety signs on machine. Clear
Put a warning tag as shown below on the key for the the area of other persons. Learn and
key switch when carrying out servicing or repairs to practice safe use of controls before
the tractor. Warning tags (publication number 2-1000) operating.
are available from your McCormick dealer. ! It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service, and to
REASON/RAISON
observe pertinent laws and regulations.
!
VERNUNFT/RAZON
Operator’s and Service Manuals may be

obtained from you McCormick dealer.
DO NOT OPERATE WARNING: If you wear clothing that is too

NE PAS UTILISER loose or do not use the correct safety
NICHT BETREIBEN equipment for your job, you can be
NO UTILIZAR
injured. Always wear clothing that will not
! catch on objects. Extra safety equipment
that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector
clothing.
2-1000
WARNING: When working in the area of

WARNING: Read the operators manual to the fan belt with the engine running, avoid
! familiarize yourself with the correct ! loose clothing if possible, and use
control functions. extreme caution.
WARNING: Operate the machine and WARNING: When doing checks and tests
equipment controls from the seat on the equipment hydraulics, follow the
! position only. Any other method could ! procedures as they are written. DO NOT
result in serious injury. change the procedure.
WARNING: This is one a man machine, no WARNING: When putting the hydraulic
! riders allowed . cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
WARNING: Use insulated gloves or

! mittens when working with hot parts.
SM 8-10080 Issued 03-2001

4 SECTION 1001
CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

ground or use stands to safely support the machine. Keep the shop floor and
! the attachments before you do any operator’s compartment and steps free of
maintenance or service. ! oil, water, grease, tools, etc. Use oil
absorbing material and or shop cloths as
required. Use safe practices at all times.
CAUTION: Pin sized and smaller streams
of hydraulic oil under pressure can
penetrate the skin and result in serious CAUTION: Some components of this
infection. If hydraulic oil under pressure machine are very heavy. Use suitable
does penetrate the skin, seek medical ! lifting equipment or additional help as
treatment immediately. Maintain all hoses instructed in this Service Manual.
! and tubes in good condition. Make sure
all connections are tight. Make a
replacement of any tube or hose that is DANGER: Engine exhaust fumes can
damaged or thought to be damaged. DO cause death. If it is necessary to start the
NOT use your hand to check for leaks, engine in a closed place, remove the
use a piece of cardboard or wood.
! exhaust fumes from the area with an
exhaust pipe extension. Open the doors
and get outside air into the area.
CAUTION: When removing hardened pins
such as a pivot pin, or a hardened shaft,
use a soft head (brass or bronze) hammer DANGER: When the battery electrolyte is
! or use a driver made from brass or bronze frozen, the battery can explode if (1), you
and a steel head hammer. try to charge the battery, or (2), you try to
jump start and run the engine. To prevent
! that battery electrolyte from freezing, try
CAUTION: When using a hammer to to keep the battery at full charge. If you do
remove and install pivot pins or separate not follow these instructions, you or
parts using compressed air or using a others in the area can be injured.
! grinder, wear eye protection that
completely encloses the eyes (approved
goggles or other approved eye DANGER: Batteries contain acid and
protectors). explosive gas. Explosions can result from
sparks, flames or wrong cable
connections. To connect the jumper
CAUTION: Use suitable floor (service) ! cables correctly to the battery of this
jacks or chain hoist to raise wheels or machine see the Operator’s Manual.
! tracks off the floor. Always block machine Failure to follow these instructions can
in place with suitable safety stands. cause serious injury or death.
SM 8-10080 Issued 03-2001

SECTION 1001 5
GENERAL INFORMATION
Cleaning Gears
Clean all metal parts except bearings, in mineral Check all gears for wear and damage. Replace
spirits or by steam cleaning. Do not use caustic gears that have wear or damage.
soda for steam cleaning. After cleaning dry and put
oil on all parts. Clean oil passages with compressed Oil Seals, O-Rings And Gaskets
air. Clean bearings in kerosene, dry the bearings
completely and put oil on the bearings. Always install new oil seals, o-rings and gaskets.
Put petroleum jelly on seals and o-rings.
Inspection
Shafts
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small Check all shafts that have wear or damage. Check
scoring or grooves can be removed with a hone or the bearing and oil seal surfaces of the shafts for
crocus cloth. Complete visual inspection for damage.
indications of wear, pitting and the replacement of
parts necessary will prevent early failures. Service Parts
Always install genuine McCormick service parts,
Bearings when ordering refer to the Parts Catalog for the
Check bearings for easy action. If bearings have a correct part number of the genuine McCormick
loose fit or rough action replace the bearing. Wash replacement items. Failures due to the use of other
bearings with a good solvent or kerosene and than genuine McCormick replacement parts are not
permit to air dry. DO NOT DRY BEARINGS WITH covered by warranty.
COMPRESSED AIR.
Lubrication
Needle Bearings Only use the oils and lubricants specified in the
Before you press needle bearings in a bore always Operators or Service Manual. Failures due to the
remove any metal protrusions in the bore or edge of use of non specified oils and lubricants are not
the bore. Before you press bearings into position covered by warranty.
put petroleum jelly on the inside and outside
diameter of the bearings.
SM 8-10080 Issued 03-2001

6 SECTION 1001
STANDARD TORQUE DATA FOR NUTS AND BOLTS

NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.
Chart 1 (Plain Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) lb ft Nm lb ft Nm lb ft Nm lb ft Nm
M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5
M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5
M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0
M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0
M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0
M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0
M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0
M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0
M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0
M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0
M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0
M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0
M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0
Chart 2 (Phosphate Coated Nuts/Bolts)

M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9
M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0
M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5
M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8
M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0
M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0
M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0
M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0
M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0
M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0
M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0
M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0
M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0
SM 8-10080 Issued 03-2001

SECTION 1001 7
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6
M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0
M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3
M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2
M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0
M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0
M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0
M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0
M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0
M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0
M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0
M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0
M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0
SM 8-10080 Issued 03-2001

Section
1002
1002
GENERAL SPECIFICATIONS AND TORQUES
ZTX Series Tractors

SM 8-12501 March 2004 (Revised June 2004)
2 SECTION 1002
TABLE OF CONTENTS
GENERAL SPECIFICATIONS
Lubricants and Capacities ....................................................................................................................................3
Engine ..................................................................................................................................................................3
Fuel ......................................................................................................................................................................3
Electrical ...............................................................................................................................................................3
Transmission ........................................................................................................................................................4
Hydraulics .............................................................................................................................................................4
Air Conditioning ....................................................................................................................................................5
SPECIAL TORQUES
Engine ..................................................................................................................................................................6
Transmission ........................................................................................................................................................6
Cab and Chassis ..................................................................................................................................................6
SM 8-12501 Issued 06-2004

SECTION 1002 3
GENERAL SPECIFICATIONS
Lubricants and Capacities

ENGINE
Oil Type....................................................................................................... McCormick Engine Oil, SAE 15W - 40
Capacity (With Filter Change).........................................................................................20 Litres (5.3 US gallons)
ENGINE COOLANT
Coolant Mix......................................................................................................... McCormick Universal Anti-freeze
Solution of 33% to 50% Ethylene Glycol
(depending on market requirements)
Capacity........................................................................................................................40 Litres (10.6 US gallons)
AIR CONDITIONER SYSTEM

Compressor Oil................................................................................................................. Sanden SP - 20 Pag Oil
Capacities ...................................................................................................................................... Refer to Page 5
TRANSMISSION
Oil Type...................................................................................................................................... McCormick UTTO
Capacity......................................................................................................................158 Litres (41.7 US gallons)
MFD AXLE
Oil Type........................................................................................................... McCormick Multi-Purpose Gear Oil
SAE 85W - 140 EP Gear Oil to API GL-5
or MIL-L-2105 Specification
Differential Oil .................................................................................................................10 Litres (2.6 US gallons)
Axle Planetaries (Each) .................................................................................................1.9 Litres (0.5 US gallons)
FUEL TANK
Fuel Capacity...............................................................................................................570 Litres (150 US gallons)
Engine
NOTE: For the Engine Specifications, refer to the your Engine Service Manual.
Fuel
NOTE: For the Fuel Specifications, refer to the your Engine Service Manual.
Electrical
System Type .................................................................................................................... 12 Volt Negative Ground
Batteries....................................................................................... Two 12 Volt, Low Maintenance Hybrid Batteries
Connected in Parallel, DIN Type 60527, Top Stud Terminals
BATTERY SAE (COLD CRANKING AMPERE RESERVE

IEC DIN
TYPE CAPACITY) HOURS CAPACITY
644 660 Amps 440 Amps 400 Amps 95 180 mins
Alternator ..................................................................................................................................... 12 Volt, 150 Amp

Starter Motor................................................................................................................................... 12 Volt, 4.2 kW
SM 8-12501 Issued 06-2004

4 SECTION 1002
Transmission
Pinion Shaft Bearing Preload ........................................................................................................0.05 to 0.15 mm
MFD Output Shaft End Play .................................................................................................................0 to 0.1 mm
MFD CLUTCH
Number of Clutch Plates
Friction Plates ...............................................................................................................................................8
Separator Plates ...........................................................................................................................................7
DIFFERENTIAL AND DIFFERENTIAL LOCK

Ring Gear and Pinion Backlash.....................................................................................................0.15 to 0.45 mm
Differential Lock Clutch
Number of Plates
Friction Plate ................................................................................................................................................ 8
Separator Plate............................................................................................................................................ 7
Hydraulics
HYDRAULIC PUMPS
Charge Pump
110 l/min ........................................................................................................................... 60 cm3 per revolution
150 l/min ........................................................................................................................... 80 cm3 per revolution
Variable Displacement Pump
110 l/min .................................................................................................................... 0 to 45 cm3 per revolution
150 l/min .................................................................................................................... 0 to 60 cm3 per revolution
SM 8-12501 Issued 06-2004

SECTION 1002 5
Air Conditioning
REFRIGERANT
Type ....................................................................................................................................................... HFC-134A
System Capacity............................................................................................................................................1.9 kg
Boiling Point at Atmospheric Pressure.......................................................................................................... -26° C
COMPRESSOR
Manufacturer............................................................................................................................................ SANDEN
Model .......................................................................................................................................... SD 7H15MD4609
Number of Cylinders ............................................................................................................................................. 7
Displacement Per Revolution........................................................................................................................155 cc
Clutch Voltage ............................................................................................................................................12 Volts
Clutch Ampage Draw at 12 Volts .............................................................................................. 3.6 to 4.2 Amperes
Front Clutch Plate Air Gap ................................................................................................................ 0.4 to 0.8 mm
COMPRESSOR AND SYSTEM LUBRICATION

Lubrication Type............................................................................................................... Sanden SP - 20 PAG Oil
HIGH PRESSURE SWITCH

Operation ................................................................................................... Closed by Excessive System Pressure
LOW PRESSURE SWITCH

Operation ............................................................................................................ Closed by Low System Pressure
SM 8-12501 Issued 06-2004

6 SECTION 1002
SPECIAL TORQUES
Engine
Engine to Transmission Retaining Bolts
Adapter Plate to Engine...........................................................114 to 128 Nm (84 to 94 lb ft)
Adapter Plate to Transmission .................................................555 to 620 Nm (409 to 457 lb ft)
Torque Dampener Retaining Bolts...............................................74 to 84 Nm (54 to 62 lb ft)
Front Bolster to Transmission Retaining Bolts .........................555 to 620 Nm (409 to 457 lb ft)
Flywheel ..................................................................................108 to 132 Nm (80 to 97 lb ft)
Transmission
DIFFERENTIAL AND DIFFERENTIAL LOCK
Ring Gear Retaining Bolts .......................................................240 to 340 Nm (177 to 251 lb ft)
Differential Lock Clutch Cage Retaining Bolts .........................110 to 130 Nm (81 to 96 lb ft)
Differential Bearing Carrier Retaining Bolts .............................100 to 130 Nm (74 to 96 lb ft)
REAR AXLES
Rear Axle Mounting Nuts.........................................................247 to 253 Nm (182 to 187 lb ft)
MFD DRIVE SHAFT

MFD Drive Shaft Centre Mounting Bolts.............................................570 Nm (420 lb ft)
PTO
PTO Housing Retaining Bolts ......................................................480 to 640 Nm (354 to 472 lb ft)
PTO Clutch Pack Retaining Bolt ..................................................25 to 34 Nm (18 to 25 lb ft)
PTO Clutch Assembly Retaining Bolt ..........................................50 to 70 Nm (37 to 52 lb ft)
Bearing Carrier Retaining Bolt.....................................................72 to 96 Nm (53 to 71 lb ft)
Cab and Chassis

CAB
Cab Mounting Bracket to Rear Axle Bolts ...............................190 to 244 Nm (140 to 180 lb ft)
Cab Mounting Bracket to Transmission Bolts Bolts .................205 to 260 Nm (151 to 192 lb ft)
Cab Mounting Bolt to Threaded Plate ........................................47 to 61 Nm (33 to 45 lb ft)
Cab Mounting Nut....................................................................190 to 244 Nm (140 to 180 lb ft)
WHEELS
Front Wheel to MFD Axle Nuts ................................................530 to 570 Nm (391 to 420 lb ft)
Wheel Hub to Tapered Bushing ...............................................500 to 600 Nm (369 to 443 lb ft)
Wheel to Wheel Hub................................................................640 to 680 Nm (472 to 502 lb ft)
SM 8-12501 Issued 06-2004

Section
2
2
ENGINE
How it Works
ZTX Series Tractors

DT50-50260 March 2004
SECTION!2
This!page!is!intentionally!blank
Page!2 !!!DT50-50260 McCormick!Service!Training

SECTION!2
Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !Page
Engine!Description! ................................................................................................4
Engine!electronic!Control!System! .........................................................................5
Engine!Control!Circuit! ...........................................................................................8
Fuel!Pump!Schematic! ...........................................................................................10
Fuel!Pump!Operation! ............................................................................................11
Caps!Fuel!System! .................................................................................................13
Troubleshooting! ....................................................................................................18
Distributor!Valve!Check!.........................................................................................19
Bleeding!the!Fuel!System! .....................................................................................20
!McCormick!Service!Training! DT50-50260 Page!3

SECTION!2
Engine!Description
The!ZTX,!models!ZTX230,!ZTX!260!and!ZTX!280,!are!fitted!with!the!Cummins!QSC
24!valve!8.3!Litre!Engine.!These!engines!have!full!authority!electronic!control.!A!vast
number! of! changes! have! been! implemented! when! compared! to! the! previous! C
series!8.3-liter!Cummins!engines.
These! engines! have! 24! valves,! 4! valves! per! cylinder,! to! ensure! optimum! airflow,
improved!fuel!economy!and!fully!emissions!compliant.!The!fuel!injector!is!located!in
the! center! of! the! cylinder! to! provide! a! more! centralized! injection! and! improved!fuel
burn!over!conventional!layouts.
The!fuel!system!itself!is!totally!electronically!controlled!and!uses!an!engine!mounted
ECM! (Engine! Control! Module)! to! process! all! relevant! information,! and! make
necessary!adjustments.

SECTION!2
Engine!Electronic!Control!System
Fuel!Pump
Engine!Control!Module
(View!left-hand!side!of!engine)

SECTION!2
Engine!Electronic!Control!System!(Cont'd)
The! electronic! control! system! for! the! QSC! Engine! uses! input! information! from! a
number!of!sensors!installed!on!the!engine!and!related!equipment.!This!information
is!used!to!monitor!the!current!engine!operating!conditions,!and! therefore! allow! the
ECM!to!determine!the!quantity!and!timing!of!the!fuel!delivery!to!the!engine.
The! engine! control! module! (ECM)! is! mounted! on! the! left-hand! side! of! the! engine,
just!to!the!rear!of!the!fuel!pump.!All!the!information!received,!and!all!corresponding
outputs!will!enter!and!exit!the!ECM!via!two!50-pin!connectors!located!on!the!body!of
the! controller.! All! inputs! and! outputs! use! the! rearmost! 50-pin! connector,! the! foot
throttle!is!the!only!circuit!that!makes!a!connection!through!the!front!50-pin!connector.
Should! there! be! a! requirement! to! download! software! into! the! ECM,! or! to! monitor
data! for! the! aid! of! diagnostics,! this! can! be! achieved! using! the! Cummins! EST
(Electronic!Service!Tool)!by!an!authorized!Cummins!agent.!Although!a!connection!is
provided!for!at!the!controller,!it!is!not!used!by!McCormick!Tractors!as!all!fault!code
retrieval;! data! monitoring! functions! can! be! carried! out! through! the! diagnostics
connector!found!in!the!operators!cab.

SECTION!2
Engine!Control!Circuits
Accumulator
Temperature!Sensor
Oil!Pressure!Sensor
Accumulator!Pressure
Sensor
Engine!Position
Sensor
Coolant!Temperature
Sensor
Engine!Speed
Sensor
Intake!Manifold
Temperature!Sensor
Intake!Manifold
Pressure!Sensor
Engine!Control!Module
Foot!Throttle
Injection
Lift!Pump Control!Valve
Data!Bus Rear!Pumping
Connection Control!Valve
Power!Supply Front!Pumping
Control!Valve

SECTION!2
Engine!Control!Circuits
The!components!that!send!information!to!the!ECM!are:!-
•! The! accumulator! fuel! pressure! and! temperature! sensors! are! located! at! the! top
rear!of!the!injection!pump!and!indicate!the!pressure!available!to!inject!fuel!to!the
engine! and! the! temperature! of! the! fuel! to! be! injected! respectively.! The
accumulator! pressure! sensor! has! a! working! range! between! 0! bar! (0! psi)! and
1655!bar!(24000!psi).
•! The!engine!speed!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing!and
indicates!the!speed!of!the!engine.!There!is!a!71-position!signal!indicator!ring!on
the!rear!of!the!cam!gear,!which!triggers!this!sensor.!At!top!dead!center,!the!signal
indent!is!removed!leaving!a!wide!blank.
•! The!engine!position!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing,
next! to! the! engine! speed! sensor,! and! indicates! the! position! of! the! crankshaft
camshaft!to!allow!for!precise!timing!of!fuel!injection.!There!is!a!71-position!signal
indicator!ring!on!the!rear!of!the!cam!gear!that!triggers!this!sensor.
•! The! intake! manifold! air! temperature! sensor! is! located! on! the! left! side! of! the
cylinder!head!and!indicates!the!temperature!of!the!intake!air.
•! The! intake! manifold! pressure! sensor! is! located! on! the! left! side! of! the! cylinder
head!and!indicates!the!manifold!boost!pressure.
•! The! coolant! temperature! sensor! is! located! on! the! right! side! of! the! engine,! just
behind!the!alternator,!and!indicates!the!operating!temperature!of!the!engine.
•! The! engine! oil! pressure! sensor! is! located! on! the! left! side! of! the! engine! block
behind! the! fuel! filter.! This! sensor! indicates! the! actual! engine! oil! pressure! and,
This!information!is!transmitted!to!the!to!the!instrument!cluster!via!the!data!bus.
•! The!foot!throttle!(accelerator!pedal)!is!located!in!the!cab!and!is!connected!to!the
engine!control!module!via!dedicated!wiring!through!the!front!50-pin!connector!on
the!ECM.

SECTION!2
Engine!Control!Circuits!(Cont'd)
The!outputs!from!the!ECM!that!are!used!to!control!the!operating!state!of!the!engine
are:!-
•! The!electrically!operated!lift!pump!is!located!at!the!left!rear!of!the!engine!and!is
controlled!by!the!engine!control!module.!The!lift!pump!only!runs!for!the!first!30!ñ
60! seconds! after! the! key! switch! is! turned! on.! It! draws! fuel! from! the! tank! and
supplies!pressurized!fuel!to!prime!the!filter!and!gear!pump.!If!additional!priming!is
required,!the!key!switch!can!be!cycled!to!the!off!position!and!then!returned!to!the
on! position.! The! gear! pump! provides! the! continuous! fuel! pressure! required! for
the!injection!pump.
•! The!Cummins!CAPS!fuel!system!has!two!high-pressure!pumps!to!pressurize!fuel
to!the!very!high!pressure!required!for!injection.!An!electrically!actuated!pumping
control! valve! individually! controls! each! pumping! element.! The! engine! control
module!controls!when!the!pumping!control!valve!closes!during!the!rotation!of!the
injection!pump!crankshaft.!At!light!load!and!idle,!the!pumping!control!valve!closes
later! during! the! pumping! cycle! so! that! less! fuel! is! delivered! to! the! accumulator.
When! the! engine! is! operating! under! heavy! load! and! additional! fuel! is! required,
the! pumping! control! valve! closes! earlier! to! deliver! more! pressurized! fuel! to! the
accumulator.
•! The! injection! control! valve! is! an! electrically! operated! valve! controlled! by! the
engine! control! module,! which! controls! the! delivery! of! fuel! to! each! cylinder.! The
opening!of!the!injection!control!valve!controls!the!timing!of!injection.!The!length!of
time! that! the! valve! as! well! as! the! fuel! pressure! stored! within! the! accumulator
controls!the!total!amount!of!fuel!delivered!which!in!turn!controls!the!power!output.
The! single! injection! control! valve! ports! fuel! to! each! injector! through! a! rotary
distributor!valve.! As! the! injection! pump! rotates,! the! rotary! distributor! valve! ports
fuel!to!the!correct!injector!based!on!crankshaft!rotation.

SECTION!2
Fuel!Pump!Schematic

SECTION!2
Fuel!Pump!Operation
When!the!key!switch!is!initially!actuated,!the!lift!pump!runs!for!30!-!60!seconds!and
draws!fuel!from!the!tank!to!prime!the!system.!The!lift!pump!pressurizes!the!system
to!approximately!6.5!bar!(95!psi).!The!lift!pump!also!incorporates!a!check!valve!to
allow!fuel!flow!when!it!is!not!running.!The!fuel!filter!is!located!between!the!lift!pump
and!gear!pump!on!the!left!side!of!the!engine.
The! gear! pump! is! part! of! the! injection! pump! assembly! and! is! driven! by! the! input
shaft.!Its!purpose!is!to!provide!fuel!flow!to!the!system!during!engine!operation.!This
fuel!flow!is!delivered!to!both!the!front!and!rear!pumping!control!valves!(PCV),!which
are!mounted!on!the!top!of!the!accumulator!housing.!A!pressure!regulator!valve!that
is! integral! to! the! gear! pump! housing! controls! the! output! pressure! from! the! gear
pump.! This! regulator! valve! is! set! to! a! pressure! of! 11.5! bar! (165! psi)! and! is
considered!non!adjustable.
The! two! pumping! control! valves! are! normally! open! solenoid! valves! and! will! close
when!commanded!to!do!so!by!the!ECM.!Closing!these!solenoid!valves!will!result!in
the!high!pressure!pumping!units!to!increasing!the!fuel!pressure!from!approximately
11.5! bar! (165! psi)! to! between! 345! 1035! bar! (5000! to! 15000! psi)! required! for
injection.! The! output! pressure! from! these! pumping! elements! is! determined! by! the
fuel!requirement!of!the!engine.
The!input!shaft!in!the!injection!pump!body!has!two!tri-lobe!cams!on!the!shaft,!which
actuate!the!high!pressure!pumping!units.!Each!high!pressure-pumping!unit!actuates
three!times!each!revolution!of!the!injection!pump!shaft.!The!duration!of!the!revolution
that! the! pumping! control! valve! is! closed! controls! the! quantity! of! high-pressure! fuel
that!is!delivered.!During!the!time!that!the!pumping!control!valve!is!open,!the!output!of
the! high! pressure-pumping! unit! returns! to! the! fuel! tank! via! the! pressure! regulator
valve.! When! the! pumping! control! valves! are! closed! the! high! pressure! pumping
elements! will! deliver! the! fuel! flow,! through! one! way! check! valves,! into! the
accumulator!housing.

SECTION!2
Fuel!Pump!Operation!!(Cont'd)
The!point!at!which!the!pumping!control!valves!are!commanded!on!can!be!monitored
using! the! Cummins! Electronic! Service! Tool! (EST).! The! parameter! that! should! be
viewed! is! the! Valve! Crank! Angle! (VCA)! and! relates! to! the! angle,! in! degrees! of
rotation,!before!top!dead!center!when!the!control!valves!are!energized.
The!accumulator!stores!pressurized!fuel,!typically!at!pressures!between!345!to!1035
bar!(5000!to!15000!psi),!ready!for!injection!event.!The!accumulator!is!also!connected
to!the,!normally!closed,!injection!control!valve!(ICV)!via!the!ìRate!Shape!Tubeî.!The
injection! control! valve! opens! at! the! required! time! to! control! the! injection! timing! to
each!cylinder.!The!length!of!time!that!the!injection!control!valve!is!open!controls!the
amount!of!fuel!delivery,!which!in!turn!controls!the!power!output.
The!output!of!the!injection!control!valve!is!connected!to!the!rotary!distributor!valve!at
the! lower! rear! of! the! injection! pump.! This! rotary! distributor! valve! is! driven! by! the
pump!drive!shaft!and!is!used!to!direct!the!fuel!to!the!required!injector.

SECTION!2
CAPS!Fuel!System
The!Cummins!Accumulator!Pump!System!(CAPS)!consists!of!six!basic!components,
components!are!separate!assemblies!and!will!be!discussed!individually.
The!fuel!pump!body!is!directly!connected!to!the!engine!timing!cover!and!includes!the
input!shaft!and!camshaft!lobes!that!actuate!the!high!pressure!pumping!units.
The! gear! pump! is! mounted! to! the! rear! of! the! fuel! pump! body! and! is! driven! by! the
input!shaft;!a!small!internal!coupling!connects!the!two!components.!The!gear!pump
will!take!fuel!from!the!fuel!tank!and!pass!it!through!the!fuel!filter.!It!will!then!make!it
available!to!the!inlet!of!the!high!pressure!pumping!units.!The!outlet!pressure!of!this
pump!is!regulated!to!approximately!11.5!bar!(165!psi).
The! accumulator! assembly! mounts! directly! to! the! top! of! the! fuel! pump! body! and
consists!of!the!following!components:!-
•! The! camshaft! in! the! fuel! pump! body! actuates! the! high-pressure! pumping! units.
These! units! take! fuel! delivered! by! the! gear! pump! and! increase! the! pressure! to
that! required! for! injection! into! the! combustion! chamber.! The! outlet! pressure! of
these! units! is! typically! regulated! between! 345! to! 1035! bar! (5000! to! 15000! psi).
Individual!pump!control!valves!control!the!outlet!flow!of!these!pumping!units.
•! Electrically! operated! pump! control! valves! are! located! on! the! top! of! the
accumulator! assembly.! The! timing! of! the! actuation! of! these! valves! controls! the
quantity! of! fuel! delivered! by! the! high! pressure! pumping! units! and! therefore! the
injection!pressure.!The!engine!control!module!controls!these!valves.!These!pump
control! valves! are! installed! and! calibrated! on! initial! assembly! and! cannot! be
adjusted.! Replacement! of! a! faulty! pumping! control! valve! would! require! a! new
accumulator!assembly
•! The! accumulator! portion! of! the! accumulator! assembly! consists! of! drilled
passages!within!the!accumulator!body.!The!accumulator!function!is!based!on!the
fact! that! diesel! fuel! is! approximately! 8%! compressible! at! 1035! bar! (15000! psi).
These! drilled! passages! are! sealed! with! plugs! that! have! seal! discs! under! them.
These!seal!discs!are!currently!not!available!as!separate!service!parts.

SECTION!2
CAPS!Fuel!System!(cont'd)
•! The! accumulator!fuel!pressure!and! temperature! sensor! is! located! at! the! rear! of
the!accumulator!assembly.!This!sensor!monitors!the!pressure!and!temperature!of
the!high-pressure!fuel!stored!in!the!accumulator.!This!sensor!sends!information!to
the!engine!control!module.
•! The!rate!shape!tube!is!located!at!the!top!rear!of!the!injection!pump!assembly!and
ports! the! high-pressure! fuel! from! the! accumulator! to! the! injection! control! valve.
The!length!of!this!tube!controls!the!shape!of!the!injection!line!pressure!rise!curve.
The! length! of! this! tube! affects! NOX! emissions.! Do! not! bend! this! tube! during! or
after!installation.

SECTION!2
CAPS!Fuel!Pump!Components
Rate!Shape!Tube
Accumulator
Distributor!Housing
Gear!Pump
Assembly
Fuel!Pump
Body

SECTION!2
CAPS!Fuel!Pump
Pumping!Control
Valves
Accumulator
Housing
Injection
Control!Valve
Rate
Shape
High!Pressure
Pumping
Elements
Fuel!Pump Distributor
Body Valve
Drive
Gear Coupling
Tri-lobe Pump
Cams
Drive
Coupling

SECTION!2
CAPS!Fuel!System!(cont'd)
The! injection! control! valve! (ICV)! is! located! at! the! rear! of! the! injection! pump.! This
control! valve! is! an! electrically! operated! valve! commanded! by! the! engine! control
module! (ECM),! which! controls!the! delivery! of!fuel! to! each! cylinder.! The! opening! of
the!injection!control!valve!controls!the!timing!of!injection.!The!length!of!time!that!the
valve!is!open,!as!well!as!the!fuel!pressure!stored!within!the!accumulator!controls!the
total! amount! of! fuel! delivered,! which! in! turn! controls! the! power! output.! The! single
injection! control! valve! ports! fuel! to! individual! injectors! through! a! rotary! distributor
valve.
The!rotary!distributor!control!valve!is!located!at!the!lower!rear!of!the!injection!pump
and! is!driven! from!the! gear! pump! shaft;!a! small! internal! coupling! connects! the! two
components.!As!the!injection!pump!rotates,!the!distributor!will!control!which!injector
is!supplied!with!fuel,!based!on!the!rotation!of!the!crankshaft.
The! injectors! are! located! at! the! top!of! the! cylinder! head! centered! over! the! pistons.
The! injectors! inject! atomized! fuel! into! the! combustion! chamber! during! the! power
stroke!of!the!combustion!cycle.

SECTION!2
Engine!Troubleshooting
Retrieval! of! fault! code! information! from! the! Engine! Control! Module! can! be! done
through!the!instrument!cluster,!or!with!the!Cummins!Electronic!Service!Tool!and!the
McCormick!Diagnostic!Tool
Engine! troubleshooting! information! is! available! in!the! QSC! Engine! Troubleshooting

Manual!(available!from!Cummins).
If!QSC!engine!running!problems!are!encountered:!-
•! Inspect!the!fuel!level!in!the!tanks;
•! Check!for!air!leaks!and!restrictions!in!the!fuel!inlet!system;
•! Inspect!for!air!intake!problems;
•! Inspect!for!mechanical!problems;
•! Inspect!for!rotary!distributor!valve!problems;
•! Inspect!for!injector!problems;
•! Check!for!fault!codes!using!the!tractor!instrumentation!or!the!electronic
service!tool.

SECTION!2
Fuel!Pump!Distributor!Valve!Inspection
Remove!the!key!from!the!ignition!switch
to! prevent! any! attempt! at! starting! the
engine.
!Thoroughly! clean! the! area! around! the

fuel! pump.! Pay! particular! attention! to
the!rear!connections!area.
After! removing! the! front! access! cap,

rotate!the!engine!using!the!turn!over!tool
until! the! Timing! mark! on! the! pump! drive
gear! aligns! with! the! TDC! mark! on! the
timing!cover.
Remove!the!distributor!plug!(1).
Do! not! attempt! to! start! the! engine! with

the! distributor! plug! removed.! To! do! so
could! result! in! the! rotor! being! ejected
from! the! distributor,! causing! damage! to
the!rotor.
Check! the! position! of! the! notch! on! the

rotor.! It! should! line-up! with! the! alignment
mark!(A)!on!the!outside!of!the!distributor.!If
the! alignment! is! correct! the! rotor! is
properly!timed!to!the!engine.
If! the! alignment! is! incorrect! inspect! the

internal!drive!couplings.
Replace! distributor! plug! oíring! as

necessary.

SECTION!2
Recommendations!For!Bleeding!CAPS!Fuel!System
Crank!the!engine,!checking!for!exhaust!smoke!or!no!exhaust!smoke!and!follow!the
appropriate!troubleshooting!tree!of!the!lnsite!diagnostic!information.
If! the! engine! cranks! but! does! not! start! after! running! out! of! fuel,! and! there! is! no
smoke!from!the!exhaust,!carry!out!the!following!procedure:!-
•! Confirm!that!the!fuel!level!is!low!and!fill.
•! Check!instrumentation!for!engine!faults.
•! Confirm!the!electric!lift!pump!run!after!the!key!switch!is!activated.
•! Refer!to!the!relevant!sections!service!manual!as!required.
1.! Loosen!the!fitting!(1/18"!pipe!plug)!at!the!outlet!of!the!fuel!filter.
2.! Cycle!the!electric!lift!pump!with!the!key!switch!until!air!is!purged.
3.! If!air!cannot!be!purged!after!several!cycles!of!the!lift!pump,!an!air!leak
may!be!present.!Check!the!fuel!supply!system!from!the!fuel!tank!to!the
fuel!filter.
•! If!engine!does!not!start!after!purging!air,!check!for!battery!voltage.
•! Check!Engine!Control!Module!for!6.5!VDC!minimum!during!engine!cranking.
•! Recheck!for!exhaust!smoke!during!cranking!and!go!back!to!appropriate!fault
trouble!shooting!tree.

Cummins QSC 8.3 Litre Tier III
Extract from Cummins Product Announcement July 2006.

Not to be reproduced in hard copy or electronic form or used for any purpose without
the consent of Cummins Ltd.
McCormick Product Support January 2007

Introduction to the QSC 8.3 litre Tier III engine.
QSC Tier III Engine View.
The QSC8.3 with CM850 engine is designed to meet the Environmental

Protection Agency (EPA) Tier III levels.
Engine Configuration Numbers
The configuration numbers for the QSC engine is as follows.
Engine type Configuration Number

QSC D413055CX03

Design Features
Cylinder Block – Overview

The QSC8.3 with CM850 utilizes the same connecting rod bearing shell for
the upper and lower location. The construction is similar to previous product
bearings with the exception of a narrower base to accommodate the
crankshaft fillet radii changes. The QSC8.3 with CM850 engine is equipped
with J-jet directed piston cooling nozzles. The nozzle geometry is similar to
the ISL with CM554 with slight changes to the oil spray targeting for improved
cooling of the piston. A standard cap screw secures the piston cooling nozzle,
replacing a banjo style bolt for added strength and oil flow.
The primary speed indicator ring has been moved internally and mounted to
the crankshaft. The new indicator ring provides increased speed resolution for
the Cummins Common Rail Fuel System. To calculate the engine speed and
position, a sensor is mounted at the rear of the block on the intake side of the
engine.
The secondary (backup) indicator pick-ups are cast into the camshaft gear.
The secondary sensor is located in the backside of the gear housing.
Due to geometrical differences, the primary and secondary speed sensors are
not interchangeable and have different part numbers.

Rocker Levers – Overview
The crankcase breather system utilizes a baffle system that is mounted on the
valve cover. The breather contains two tubes. The larger tube is the
crankcase gas draft tube. The smaller tube is for draining oil that is
accumulated in the valve cover baffle. The oil is drained back to the oil pan
through a port on the lower intake-side of the cylinder block. There is no
maintenance required for any breather system components.
A rocker housing spacer is required on the QSC8.3 engine to accommodate a

pass-through location for the injector wiring harness. The rocker housing
utilizes a press-in-place gasket to form a seal with the cylinder head. The
valve cover is mounted to the rocker housing by cap screws, isolators, and a
press-in-place gasket.

Camshaft Followers/Tappets - Overview
The QSC8.3, with CM850 engine is equipped with new roller tappets. The
new design incorporates larger diameter rollers to reduce the load on the
camshaft and improve durability.
Fuel System – Overview

General Fuel System Notices
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment,
and switches out of the work area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when working on the fuel system.
CAUTION
To reduce the possibility of engine damage, always use the proper torque on
the high-pressure line nuts.
The Cummins Common Rail Fuel System is a high-pressure common rail

injection system. A fuel rail is used to store pressurized fuel for fuel injection.
There are four components that provide or receive input to the electronic
control module (ECM). The ECM powers the electric fuel lift pump (located
behind the ECM) for approximately 30 seconds at key-on to make sure the
fuel system is primed. The normally open fuel pump actuator receives a pulse
width modulated (PWM) signal from the ECM to open or close in response to
the signal from the fuel rail pressure sensor. The injectors have individual
solenoids. The ECM powers each injector individually to provide fueling to
each cylinder.

The high-pressure fuel pump can be divided into four distinct assemblies.
They are the fuel gear pump, fuel pump actuator housing, cam housing,
and high-pressure fuel pump head. Fuel flows through the gear pump to a
2-micron pressure-side filter.
After the pressure-side filter, fuel enters the fuel pump actuator housing. The
fuel pump actuator housing includes an air-bleed fitting and the fuel pump
actuator. Some fuel continuously returns to drain through the air-bleed orifice
fitting. Fuel that is metered through the fuel pump actuator enters the high-
pressure fuel pump head where it is pumped to fuel rail pressure and exits at
the high-pressure outlet fitting.
A lift pump is used for priming the gear pump at start-up. The lift pump runs
for approximately 30 seconds after key-on. Once the engine is started, the
gear pump is able to maintain prime without any assistance from the lift pump.
The ECM and ECM cooling plate must be removed to access the lift pump
and lift pump fuel lines. This is accomplished by disconnecting the engine
harnesses and the quick disconnect style fuel lines first. Removal of the ECM
cooling plate cap screws allows the ECM, cooling plate, lift pump and lift pump
plumbing to be removed as one assembly.

The gear pump output is routed to a 2-micron fuel filter. The filtered fuel
returns to the fuel pump actuator housing. The high-pressure pump is driven
by the engine camshaft. The gear pump is driven by the pump camshaft
through an internal coupling.
Each of the two pumping plungers is driven by a three lobed camshaft. The
camshaft is located in the cam housing module by tapered roller bearings.
The bearings that support the camshaft, as well as the tappets, rollers and
camshaft itself are lubricated with engine oil. These are the only components
in the pump lubricated with engine oil.
Engine oil to the high-pressure pump is supplied through a drilling in the
engine gear housing. The oil passes from the engine gear housing to the high-
pressure pump cam housing. A small o-ring in a recess on the back of the
engine gear housing seals this passage.

Pressurized fuel from the gear pump is supplied to the fuel pump actuator.
The fuel pump actuator is opened or closed by the ECM to maintain the
appropriate fuel rail pressure.
An air-bleed orifice fitting in the fuel pump actuator housing aids in purging air
from the fuel supply. Because of the air-bleed orifice fitting, some fuel that is
supplied by the gear pump will return to drain at all times.
Fuel that is metered past the fuel pump actuator enters the high-pressure fuel
pump inlet drilling, past the inlet check valve and fills the pumping chamber by
pressing the pumping plunger downward. When the camshaft pushes the
pumping plunger upward, fuel reaches rail pressure and causes the outlet
check valve to lift. Fuel then enters the outlet drilling of the fuel pump and
exits the high pressure fuel line to the fuel rail.

Injectors and Fuel Lines - Overview
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing
equipment, and switches out of the work area and areas sharing
ventilation to reduce the possibility of severe personal injury or death
when working on the fuel system.
High-pressure common rail fuel systems use solenoid-actuated injectors.
High-pressure fuel flows into the side of the injector. When the solenoid is
activated, an internal needle lifts and fuel is injected. The clearances in the
nozzle bore are extremely small and any dirt or contaminants will cause the
injector to stick. This is why it is important to clean around all fuel connections
before servicing the fuel system. Also, cap or cover any open fuel connections
before a fuel system repair is performed.
High-pressure fuel is supplied to the injector from the fuel rail by an injector
supply line and a fuel connector. The fuel connector pushes against the
injector body when the fuel connector nut is tightened. The injector supply line
is then connected to the fuel connector.
CAUTION
To reduce the possibility of engine damage, always use the proper
torque on the high-pressure line nuts.
The torque and sequence for this joint is critical. If the nut or line is under-
tightened, the surfaces will not seal and a high-pressure fuel leak will result. If
the nut is over-tightened, the connector and injector will deform and cause a
high-pressure fuel leak. This leak will be inside the head and will not be
visible. The result will be a fault code, low power, or no-start.
If the injector is not fully seated prior to the installation of the high-pressure
connector, the joint will not seal.

The fuel connector contains an edge filter that breaks up small contaminants
that enter the fuel system.
The edge filters are not a substitute for cleaning and covering all fuel system
connections during repair.
Be sure to cap or cover all fuel fittings and ports.
All injectors feed into a common return drilling contained within the cylinder
head. Any excess fuel is returned to the tank via this drilling and return line
attached to the rear of the cylinder head. A back-pressure valve is located on
the back of the cylinder head where the drain line attaches.
The electronic control module (ECM) controls the fueling and timing of the
engine by actuating the injector solenoids. An electronic pulse is sent to the
solenoids to lift the needle and start the injection event. By electronically
controlling the injectors, there is a more precise and accurate control of fueling
quantity and timing. Also, multiple injection events can be achieved by
electronically controlling the injectors.
Fuel Filters
The QSC8.3 with CM850 engine, requires original equipment manufacturers
(OEM's) to mount a 10-micron suction filter prior to the OEM fuel supply
connection at the rear of the engine block. The 10-micron filter performs water
stripping and includes a water-in-fuel sensor. The water-in-fuel sensor must
be installed. If not, a fault code warning lamp will be active.
The QSC8.3, with CM850 engine includes a 2-micron pressure-side fuel
filter. The pressure-side filter will be located downstream of the gear pump

before the high-pressure fuel pump inlet. If a water-in-fuel fault is
experienced, drain the water stripping filter and replace the pressure side
fuel filter.
Air Intake System - Overview
The QSC8.3 engines utilize a Holset® waste gated turbocharger. The waste
gate is pneumatically controlled by intake manifold pressure and factory
calibrated. The waste gates are not adjustable in the field.
Engine Data plate

The engine data plate provides important facts about the engine. The engine
serial number (ESN) and control parts list (CPL) provide information for
service and ordering parts. The engine data plate must not be changed
unless approved by Cummins Inc.
The data plate is located on the top side of the gear housing.
If the engine data plate (1) is not readable, the ESN (2) can be found on the
engine block on top of the lubricating oil cooler housing. Additional engine
information is on the electronic control module (ECM) data plate.

Fuel Injection Pump Data plate
The Cummins Common Rail Fuel System data plate is located on the side of
the high-pressure pump. The data plate contains the following information:
A. Cummins part number
B. Pump serial number

C. Factory code.
The ECM dataplate is located on the front of the ECM. The following
information is found on the ECM dataplate:
• ECM part number (PN)
• ECM serial number (SN)
• ECM date code (DC)
• Engine serial number (ESN)
• ECM Code (identifies the software in the ECM).
Flow Diagram, Fuel System

1. Fuel from supply tank
2. Fuel filter and water separator
3. OEM fuel supply connection
4. Fuel supply to ECM mounted fuel lift pump
5. ECM cooling plate
6. ECM mounted fuel lift pump
7. Fuel outlet from ECM mounted fuel lift pump
8. Fuel gear pump
9. Fuel from gear pump to fuel filter
10. Primary fuel filter
11. Fuel inlet to fuel pump actuator
12. High-pressure fuel pump
13. Fuel outlet from high-pressure pump
14. High-pressure pump drain flow connection
15. Fuel rail
16. High-pressure injector supply lines
17. High-pressure fuel connector
18. Fuel injector
19. Fuel pressure relief valve
20. Fuel injector drain flow line
21. Fuel return to supply tanks
Electronic Engine Controls – Overview

The electronic control module (ECM) controls all engine operations and is
fuel-cooled by a cooling plate. The CM850 module on the QSC8.3, engine
processes all sensor inputs and sends commands to, performs calculations
for, and monitors the following:
• Fueling and timing
• Turbocharger boost pressure
• Operator interface data communications
• Auxiliary systems control
• Market-specific features.
The CM850 utilizes a 50-pin connector for the OEM harness, a 60-pin
connector for the engine harness, and a 4-pin connector for the un-switched
power supply harness. The ECM power connector must be directly connected
to the vehicle batteries to meet the supply voltage requirements.

Several new sensors have been added to monitor and control the new fuel
system and turbocharger. The following is a list of sensors on the engine:
• Coolant temperature sensor
• Intake manifold temperature sensor
• Intake manifold pressure sensor
• Primary engine speed/position (crankshaft) sensor
• Secondary engine speed/position (camshaft) sensor
• Fuel pressure sensor
• Oil pressure sensor
• Water-in-fuel sensor
• Ambient air (barometric) pressure sensor

Application
Engineering
Bulletin
Subject This AEB is for the following applications:
Datalinks and Diagnostics
Automotive Industrial Power Generation
Date June 2001 Page 1 of 64 AEB Number 15.43
Engine Models included: QSB, QSC, QSL9, QSM11, QSX15, QSK19, QST30, QSK45, QSK60
Fuel Systems included:
Introduction
The Quantum Diagnostic and Serial Communication Technical Package was written to assist OEMs in integrating
Quantum engines into their equipment. This technical package includes the diagnostic codes supported by the
Quantum engines as well as the J1587 and J1939 messages supported.
Refer to the following other Industrial AEB’s:
AEB 15.40 – Electronic Features
AEB 15.42 – OEM Components and Interfaces
AEB 15.44 – Installation Recommendations
Authors: Scott Decker, Michael L. Hill, Brian Landes, Jeffrey Martin, Stewart Sullivan, Tiffany Walker
AEB15.43
Page 2 of 64
Table of Contents
Introduction ......................................................................................................................................... 1
Table of Contents................................................................................................................................. 2
Section I – Quantum Diagnostics...................................................................................................... 3-5

Advanced Diagnostics................................................................................................................... 3-5
Onboard Diagnostics .................................................................................................................... 3-4
Offboard Diagnostics ....................................................................................................................... 5
Section II ECM Serial Communications.................................................................................... 6-39

Quantum Serial Communications................................................................................................ 6-35
Introduction ..................................................................................................................................... 6
Applicable SAE Documents........................................................................................................... 6-7
Applicable Cummins Documents....................................................................................................... 7
J1939 Installation Information ........................................................................................................ 7-9
1. Mandatory EA (datalink) options for QSM11 and QSX15.......................................................... 7
2. J1939................................................................................................................................... 7
3. Cabling................................................................................................................................. 8
4. Connections.......................................................................................................................... 8
5. J1939 Cable and Connector Suppliers .................................................................................... 9
J1587 Installation Information ......................................................................................................... 12
1. Cabling............................................................................................................................... 12
2. Connections........................................................................................................................ 12
3. J1587 Cable and Connectors Supplier.................................................................................. 12
Messages Supported on Quantum Modules .................................................................................... 14
1. Messages Supported on J1939 ....................................................................................... 14-15
2. PIDS Supported on J1587 ................................................................................................... 32
Network Utilization..................................................................................................................... 36-39
J1939 Network Utilization.......................................................................................................... 36-39
Section III – Diagnostics Supported over Quantum Datalinks............................................................ 40

Supported Messages and Source Addresses for Clearing Faults................................................... 40
Frequently Asked Questions on Cummins Datalinks................................................................. 40-41
Figure 1 – Typical J1939 Topology for On-Highway Applications...................................................... 10
Figure 2 – Typical J1939 Topology for Construction/Agriculture Applications.................................. 11
Figure 3 – Example of J1587 Topology .............................................................................................. 13
Table 1 – Messages Supported on J1939...................................................................................... 16-29
Table 2 – Cummins Specific Information for PGN 65229 (DM4).......................................................... 31
Table 3 – PIDS Supported on J1587 .............................................................................................. 33-36
Table 4 – J1939 Messages Non-multiplexed – vs- Multiplexed.......................................................... 38
Table 5 – Fault Codes for Quantum Engines................................................................................. 42-64

AEB15.43
Page 3 of 64
Section I – Quantum Diagnostics
Advanced Diagnostics
Advanced diagnostics are included to make Quantum engines straightforward to repair and service. Diagnostic
examination of a fault or maintenance condition can occur through onboard or offboard systems.
Onboard Diagnostics
• Extensive fault detection fault capability within the ECM

• Flash out of fault codes
• Fault lamps located on the cab dash to indicate warning/stop
• Maintenance lamp
Offboard Diagnostics
• INSITE a windows-based PC service tool for Cummins Quantum engines. It is used to help troubleshoot and
repair the Quantum engines. This tool is capable of doing diagnostics and programming.
Onboard Diagnostics
1. Fault Detection
Faults are detected while the key switch is on, during the operation of the machine itself. If a fault becomes active
(currently detected) at this time, a fault is logged in memory and a snapshot of engine parameters is logged. In
addition, certain faults may illuminate the warning lamp (amber) or the stop lamp (red), the maintenance lamp or
WIF lamp depending on the severity of the active fault.
2. Flash Out of Fault Codes
Fault flash out mode can be entered through the use of a diagnostic switch or the accelerator pedal. To enter the
fault flash out the key switch must be on with the engine not running. When a diagnostic switch is used to enter
the mode, the ECM will automatically flash the first fault code after the switch is turned on. The diagnostic
increment/ decrement is used to sequence forward or backwards through the active faults. To enter fault flash out
mode using the accelerator pedal, the pedal must be cycled from 0 to 100% 3 times. Once in diagnostic mode,
cycling the accelerator pedal will sequence forward through the active faults. The diagram below depicts the
pattern of the fault code flash out scheme as indicated by the stop lamp.
Example Fault Code Sequences

Fault Code 244: P = Pause
WARNING WARNING WARNING WARNING WARNING
STOP P STOP P STOP P STOP P STOP

Maintenance Maintenance Maintenance Maintenance
Maintenance
1 Blink 2 Blinks 4 Blinks 4 Blinks 1 Blink

Fault Code 112:
WARNING WARNING WARNING WARNING WARNING
STOP STOP STOP STOP STOP

P P P P
Maintenance Maintenance Maintenance Maintenance Maintenance
1 Blink 1 Blink 1 Blink 2 Blinks 1 Blink

AEB15.43
Page 4 of 64
3. Fault Lamps
The Quantum systems use up to five indicator lamps with one of the lamps serving two functions: the stop lamp,
the warning lamp, the maintenance lamp/engine protection lamp (all engine families use one of these lamps, but
not both), wait-to-start lamp, and a water-in-fuel lamp. If the key switch is turned on but the diagnostic switch
remains off, the indicator lamps will illuminate for approximately two seconds and then go off, one after the other,
to verify they are working and wired correctly. See illustration below where they are all on and then go off one at
a time.
Fault Lamp Sequence
WARNING WARNING WARNING WARNING
STOP STOP STOP STOP

Maintenance Maintenance Maintenance Maintenance
Warning Lamp - All Quantum Engines - The warning lamp provides important operator messages. These
messages require timely operator attention. The warning lamp is also used to delineate diagnostics fault codes.
P = Pause
Stop Lamp - All Quantum Engines - The stop lamp provides critical operator messages. These messages
require immediate and decisive operator response. The stopP lamp is also used to flash out diagnostic fault codes.
Wait-to-Start Lamp - QSB/C/L, QSM11, QSX15, QST30 - The wait-to-start lamp indicates that the pre-start
intake manifold heater warm-up sequence is active. An OEM-supplied grid heater will automatically heat the
intake manifold when needed prior to engine starting. Intake manifold heating improves engine starting in cold
temperatures and reduces white smoke.
Water-in-Fuel (WIF) Lamp - QSB/C/L - The water-in-fuel lamp indicates there is water in the fuel. When the
lamp is illuminated the vehicle driver/operator should release the water from the fuel filter.
Maintenance Lamp - QSB/C/L, QSM11, QSX15 - Upon ECM power up the maintenance lamp will flash when it
is time to change the oil. It also will illuminate during engine operation when certain lower priority faults are
present.
Engine Protection Lamp - QSK19/45/60, QST30 - The engine protection lamp will illuminate when an engine
protection fault is present. It is possible, through OEM wiring, to configure the system to use the red/stop lamp for
engine protection faults. This is done through wiring the red lamp to both the red/stop lamp input and the engine
protection lamp input on the ECM. If the engine protection lamp signal is being used to control other functions
such as the vehicle propel circuit, a diode must be inserted in the circuit.
Optional - 2 Lamp Strategy - QSK19/45/60 - The Optional 2-lamp strategy will eliminate the Engine Protection
(white) Lamp. Therefore, the operator will only have a warning (yellow) and stop (red) lamp on the dashboard.
All of the faults that were mapped to the Engine protection lamp will become annunciated through the stop (red)
lamp. This change will only affect the wiring of the fault lamps and not the software or calibration. See wiring
below.
AEB15.43
Page 5 of 64
Engine ECU
Stop Lamp Drive
Warning Lamp
Drive
Engine Protection
Lamp Drive
Diagnostic
Switch To Vehicle
Propel Circuit
(when used)
To Ground
Power Connection
Optional 2-Lamp Strategy Wiring
Offboard Diagnostics
INSITE is the windows-based PC service/programming/diagnostic tool for Cummins Quantum engines. It is used
to help troubleshoot and repair the Quantum engines with extended fault diagnostics and processing power.
INSITE allows the user to view active and inactive faults and clear the inactive faults. It provides a monitor
function that allows the service technician to monitor measured parameters, actuator status and some calculated
values. It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift
pump as well as running diagnostic tests such as single cylinder cutout. Currently, Insite capability is different per
each Quantum engine. Therefore, the examples mentioned are only applicable to certain engine families.
AEB15.43
Page 6 of 64
Section II – ECM Serial Communications
Quantum Serial Communications
The intent of this document is to provide information pertaining to application of the Quantum controller’s serial
communications interface to machines. The contents of this document are divided into two broad categories.
The first category caters to OEMs who are involved in building machines; therefore installing datalinks is their
primary concern. This category provides information on cables, connectors and it lists datalink devices that have
been tested by Cummins as being compatible with Quantum controllers. The second category captures
information to be used by OEMs and component suppliers who design datalink devices that will interface with
Quantum controllers. This category has details pertaining to message support, parameter characteristics,
network utilization and diagnostics.
Introduction
Datalinks provide the means for electronic devices on the machine to interact with each other. Some typical
functions performed are sharing of sensor data, sharing of calculated information, allowing subsystems (e.g.
engine, transmission, etc.) to influence each others operation, communication of subsystem operation state.
Datalinks also provide a means for on and off board diagnostic work to be done.
The Quantum controllers have been designed with two independent serial communications ports. One port
provides access to SAE J1939 and is J1939-11 compatible, while the other is for SAE J1587 and is compatible
with J1708. There is no support for SAE J1922 on Quantum controllers.
SAE J1939 datalink is a high-speed network for machines that operate at 250K baud. It is capable of supporting
control, information sharing, diagnostics, multiplexing and proprietary communications. The J1939 (physical
layer) datalink uses a differential line driver circuit and allows a maximum bus length of 40 meters. The network
can have a maximum of 30 node connections at a given time.
SAE J1587 is a J1708 based network that operates at 9600 baud. It supports information sharing, diagnostics
and proprietary communications. The network can have a maximum of 20 node connections at a given time.
Both J1939/J1587 datalinks on Quantum controllers are active when the machine key-switch is turned on.
Applicable SAE Documents
This document, along with the SAE specifications listed below, contain the information required to apply the
Quantum datalink interfaces (both J1939 and J1587) to machine applications.
SAE 1939 Recommended Practice for a Serial Control and Communications Network (April
1997). Provides a list of all of the J1939-xx documents that are planned. It provides
a brief tutorial about the overall set of documents and basic operation of the network.
SAE J1939-11 Physical Layer (March 1997). Operates at 250K bits/sec, linear bus with shielded
twisted pair cable with a drain.
SAE J1939-12 Physical Layer (Working draft is ISO 11783 Part 2, May 1997). Operates at 250K
bits/sec, linear bus with twisted quad cable
SAE J1939-13 Off-board Diagnostic Connector (January 1997). Specifies 9-pin Deutsch that will
provide a connection to J1939, J1587, a second CAN network for implements,
unswitched power and ground.
SAE J1939-21 Data Link Layer (July 1998). Specifies CAN 2.0b as the message protocol to be
used. Also defines an interface to the application layer of J1939.
AEB15.43
Page 7 of 64
SAE J1939-71 Vehicle Application Layer (May 1996 plus 1/97 addendum). Defines transmitted
parameter value interpretation rules that allow receiving devices to determine if the
sending device is able to supply all parameters associated with the parameter group,
if any of the parameters has an error condition or if the signal is valid.
SAE J1939-73 Diagnostic Application Layer (October 1998)–Diagnostics. Defines capability

required to perform diagnostics on J1939 strategy to identify the least repairable
subsystem that failed, how it failed, read and clear diagnostics fault codes,
communication of diagnostic lamp status and providing a variety of parameters for
monitoring by the service tool.
SAE J1939-81 Network Management (November 1996)
SAE J1587 (March 1996 plus 1/97 addendum)–Joint SAE/TMC Electronic Data Interchange
Between Microcomputer Systems in Heavy Duty Machine Applications. Defines
format of messages and data and guidelines for the frequency and circumstances in
which messages are transmitted.
SAE J1708 Physical Layer (October 1993)–Serial Data Communications Between

Microcomputer Systems in Heavy Duty Machine Applications.
Applicable Cummins Documents
Additional information on the data links can be found in the following Cummins Engineering Standards and
documents:
Interface Specification: 1377-9804 - J1939 Multiplexing of Inputs and Outputs. Provides the signal processing
requirements for information that will be supplied to/from engine by the J1939 datalink rather than by discrete
wires (e.g. cruise control switch inputs, lamp outputs etc.).
AEB 15.44 Quantum Installation Recommendations document.
J1939 Installation Information
This section provides information required by those involved in installing J1939 datalinks on their machines.
Please refer to AEB 15.44 - Quantum Installation Recommendations for further details.
1. Mandatory EA (datalink) Options for QSM11 and QSX15
There are two required main types of EA options for QSM11 and QSX15 that must be ordered because the
datalink does not ship on either of these engines.
The first option consists of the datalink and backbone being supplied by the OEM as a part of the OEM harness;
therefore, the engine will ship without a 9-pin datalink connector. The other option consists of the datalink and
backbone being supplied by Cummins; therefore, it will ship with the datalink connection installed on the engine.
When using the second option the OEM will have a 47-pin Deutsch connector as the interface instead of
connecting directly to the 50-pin OEM connection on the ECM. This option will include a 9-pin connector, 3-pin
connector, a 50-pin connector and a 47 pin round connector. The 3-pin connector is setup as a termination with a
120 ohm terminating resistors supplied. Please refer to AEB 15.44 for wiring this option.
2. J1939
To install J1939 datalink on a machine, it is important to understand the requirements relating to cabling and
connectors. The following section provides details on both. It also provides information on some suppliers to
procure cabling and connectors.
AEB15.43
Page 8 of 64
3. Cabling
Backbone - It is a linear bus with a maximum length of 40 meters (approximately 131 feet). At a given time, the
maximum number of nodes (electronic controllers) that can be connected to the backbone is 30. Note that B and
B MATE (STYLE 2 Keying) is the backbone and termination connector keying, where B is the receptacle and B
MATE is the plug.
For J1939-11 compliance, the backbone is a twisted shielded pair with a drain and requires passive termination
resistors at each end of the network. The J1939-11 topology is typically used for automotive/ on highway
applications. Please refer to Figure 1.
For J1939-12 compliance, the backbone is a twisted quad and requires an active termination and bias circuit at
each end of the network. This physical layer eliminates the need for shield required in J1939-11. The physical
layer also uses a transceiver circuit design, which allows J1939-11 nodes to exist on the same network as the
J1939-12 nodes.
Stub - The connection from the backbone to each node (electronic controller) is called a stub and it can be a
maximum of 1-meter (approximately 3.3 feet) in length. Please refer to Figure 1.
Shield - Electrical connection to the shield is achieved by the drain wire at bus connection points for the nodes
(electronic controllers) and at the main bus interconnects. Also note that the shield should be grounded only at
one point with a connection to the battery negative. Although the shield does not provide coverage in the area
where connections are made to the linear bus or at the stub connector (read section below for details) locations, it
is connected electrically to the next segment of the shielded cable, and provides sufficient coverage to provide the
necessary electromagnetic compatibility (EMC) improvements.
4. Connections
Engine Connections - The Quantum controller may be connected to the backbone by a 3-pin unshielded
connector called a stub connector. This is illustrated by the manner in which ECU 1 is connected to the backbone
in Figure 1. The stub connector has a special keying (STYLE 1 Keying) and is shown in Figure 1 as A and A
MATE, where A MATE is the mating half. For a connection type as shown for ECU 1 in Figure 1, one of the three
pins will be used to pass the drain wire through to the mating half (A MATE) of the stub connector, in order to
allow the electrical continuity of the shield to be maintained. Two other alternatives for connecting electronic
controllers to the backbone as supported by SAE J1939 are shown in Figure X. It should be noted that the
connection of ECU 2 provides the best case EMC improvement (i.e. shortest possible stub).
Note: The OEM must supply a J1939 service connection on engine when creating a backbone harness.
Diagnostic Connections - The diagnostic connector is a 9-pin Deutsch and will provide a connection to J1939, a
second CAN network for implements (for Agriculture/Construction Application), unswitched power and ground.
The maximum allowed distance of the diagnostic connector from the backbone is two-thirds of 1 meter (0.67
meter). The remaining one-third of 1 meter (0.33 meter) is the maximum allowed distance between the diagnostic
connector and the interface circuitry of the tool that is connected to the diagnostic connector.
For the automotive/ truck industry the SAE preferred location of the connector is in the cab area on the operator’s
side and should be accessible from the ground on the operator’s side. For a 6-pin installation for J1587 the
Deutsch HD10-6-12P connector is recommended. A 9-pin installation for J1939 and J1587 is suggested to use
the Deutsch HD10-9-1939P connector - Please refer to AEB 15.10 section 4.0 for more details.
Bulkhead Connection - The J1939 datalink may be routed through the OEM bulkhead connector. To reduce the
chance of electrical noise affecting the datalink, it is recommended that the wires not be placed adjacent to
circuits with extremely high current loads or switching currents. It is recommended that the installer design
flyback diodes on all relays to prevent system noise issues.
AEB15.43
Page 9 of 64
5. J1939 Cable and Connector Suppliers
J1939 compatible connectors and cabling are now available through many local and national distributors. For
application information and to locate distributors in your area, contact the following companies:
Connectors
Deutsch Industrial Products Division Packard Electric
37140 Industrial Avenue P.O. Box 431
Hemet, CA 92543 Warren, OH 44486
Phone: (714) 929-1200 1-800-722-5273
(909) 765-2250
Fax (714) 652-9784
Deutsch Distributor
Ladd Industrial Sales
1-800-223-1236
Cabling
Belden Wire and Cable Company Champlain Cable Corporation
2200 U.S. Highway 27 South 12 Hercules Drive
P.O. Box 1980 Colchester, Vermont 05446
Richmond, IN 47345 Phone: 1-800-451-5162
Phone: 800-235-3361
Fax: (765) 983-5737
BICC Brand-Rex Ltd. Waytec Inc.

Viewfield Industrial Estate P. O. Box 690
Glenrothes Chanhassen, MN 55317
Fife Phone: 800-328-2724
KY6 2RS Fax: 800-858-0319
Scotland Local: 952-949-0765
Phone: +44 (0) 1592 772124
Fax: +44 (0) 1592 775314
AEB15.43
Page 10 of 64
Figure 1 Typical J1939 Topology for On-Highway Applications
The points intended to be emphasized:
1). Backbone-twisted shielded pair with a drain wire and a maximum length of 40 meters (approx. 131 ft)
It has termination resistors at each end. The figure illustrates a linear topology.
2). Stub – maximum length of 1 meter (approx. 3.3 ft)
3). Four Types of Connectors:

i. A- Stub Connector (Receptacle
A MATE: Mating Half of Stub Connector (Plug) STYLE 1 Keying
ii. B: Backbone )through) Connector (Receptacle)

B MATE: Mating Half of Backbone Connector (Plug) STYLE 2 Keying
iii. Diagnostic Connector – Deutsch 9 pin
iv. J1939 backbone passing through the OEM bulkhead connector
4). Three possible ways of connecting ECUs to backbone:

i. ECU 1 is connected to backbone via a stub connector (A-A MATE)
ii. ECU 2 has the stub receptacle at the module
iii. ECU n has the stub cable wired directly to the OEM connector
AEB15.43
Page 11 of 64
Figure 2 Typical J1939 Topology for Construction/Agriculture Applications
1). Backbone-twisted quad with a maximum length of 40 m (approx. 131 ft). Both the tractor bus and implement
bus is examples of twisted quad backbone. The backbone is both cases have active termination resistors.
The figure illustrates a linear topology.
2). Stub – maximum length of 1 meter (approx. 3.3 ft)
3). Three Types of Connectors:

i. A and A MATE
ii. Diagnostic Connector
iii. Bulkhead connector
4). Two possible ways shown of connecting ECUs to back bone

i. ECU 1 (J1939/11 compatible) is connected to backbone via a stub connector (A-A MATE)
As can be seen J1939/11 compatible cable (3 leads) connects via stub connector to twisted quad.
Only the CAN_H and CAN_L wires connect. The power and ground are unterminated.
ii. ECU2 through ECU n are J1939/12 compatible nodes and their connections to backbone are show.
AEB15.43
Page 12 of 64
J1587 Installation Information
This section provides information on cabling and connectors for installing J1708/1587 datalink on a machine.
1. Cabling
Backbone - This terminology does not apply to J1708/J1587. The bus can have a maximum length of 40 meters
(approximately 131 feet). At a given time, the maximum number of nodes (electronic controllers) that can be
connected to the bus is 20. The bus is a twisted pair cable. Termination resistors are not needed.
Stub - Not Applicable to J1587
Shield - Not Applicable to J1587
2. Connections
Engine Connections - The J1587 connections to a Quantum module are shown in Figure 1. Please note that the
J1587 interconnect pins for Quantum must be gold. No stub connector is needed to connect an electronic
controller to the J1587 bus.
Diagnostic Connections - The diagnostic connector to be used is SAE 9-pin Deutsch.
Bulkhead Connection - The J1587 datalink may be routed through the OEM bulkhead connector.
3. J1587 Cable and Connector Supplier
J1587 compatible connectors and cabling are now available through many local and national distributors. For
application information and to locate distributors in your area, contact the following companies:
Connectors:
Deutsch Industrial Products Division Packard Electric
37140 Industrial Avenue P.O. Box 431
Hemet, CA 92543 Warren, OH 44486
Phone: (714) 929-1200 1-800-722-5273
(909) 765-2250
Fax (714) 652-9784
Deutsch Distributor
Ladd Industrial Sales
1-800-223-1236
Cabling
Belden Wire and Cable Company Champlain Cable Corporation
2200 U.S. Highway 27 South 12 Hercules Drive
P.O. Box 1980 Colchester, Vermont 05446
Richmond, IN 47345 Phone: 1-800-451-5162
Phone: 800-235-3361
Fax: (765) 983-5737
BICC Brand-Rex Ltd.

Viewfield Industrial Estate Waytec Inc.
Glenrothes - Fife P. O. Box 690
KY6 2RS Chanhassen, MN 55317
Scotland Phone: 800-328-2724
Phone: +44 (0) 1592 772124 Fax: 800-858-0319
Fax: +44 (0) 1592 775314 Local: 952-949-0765
AEB15.43
Page 13 of 64
ECU 2
ECU n
J 1708 bus
ECU 1
ECU
ECU n-1
Figure 3 Example of J1587 Topology
1). The J1708/J1587 network topology. As can be seen, it is a free topology vs. being a J1939 linear topology.
2). There are no stubs or a restriction on their length.

AEB15.43
Page 14 of 64
Messages Supported on Quantum Modules
This section details the J1939 and J1587 industry standard messages that are supported by the Quantum
controller. Parameter characteristics for messages sent on J1939 and J1587 are also listed.
1. Messages Supported on J1939
Cummins has identified six categories of J1939 capability. They are:
• Powertrain Control (PT) - The powertrain control category comprises of parameters exchanged between the
engine and devices such as transmission, ASR and ABS.
• Information Sharing (IS) - This category has parameters pertaining to general engine operation. These
parameters can be broadcast as well as be provided upon request from a remote system, e.g. engine coolant
temperature, engine oil pressure, etc.
• Diagnostics (DG) - This category comprises of parameters that are used to convey fault information, have
capability to command system tests, access test results, clear active and inactive diagnostic trouble codes
and access emissions related active diagnostic trouble codes separately from other diagnostic trouble codes
(DTCs).
• Multiplexing (MX) - What is Multiplexing - J1939 Multiplexing is sending or receiving of input and output
control commands using J1939 datalink instead of individual hard wires. The enables for multiplex
parameters are service trims and can be adjusted with VEPS. The source address from which the parameter
is multiplexed is also VEPS trimmable. Please refer to 1377 – 9804 – J1939 Multiplexing of Inputs and
Outputs (Interface Specification) for details. All parameters that help accomplish multiplexing fall in this
category.
• General (G) - All other nonproprietary J1939 requirements that are not covered in the other 5 categories are
grouped under General. For example: Acknowledgment (ACK/NACK), Transport Protocol.
• Service/Proprietary (SP) - This category comprises J1939 messages that can be used to convey proprietary
information, e.g. PGN for Proprietary A.
Table 1 lists all J1939 PGNs and parameters that are supported on all Quantum engine platforms. Please read
the following notes in order to understand the contents of the table.
AEB15.43
Page 15 of 64
Notes to Aid Understanding of Table 1:
Column 1 lists the SAE PGN number.
Column 2 lists the SAE defined PGN names.
Also, SA/DA refers to the Source Address/Destination Address and listing of SAE defined PGN numbers is given.
As an example, the combination of PGN 00000–TSC1 and Trans(3)/Engine(0) should be interpreted as TSC1 is
sourced from the Transmission (J1939 address 3) and received by Engine (J1939 address 0). Also note that any
PGN can be requested by any source with a J1939 address. Where this is not true, the specific addresses have
been listed.
Some PGNs are not completely defined in SAE J1939-71 and -73. They are denoted with a superscripted
asterisk “*”. Please refer to the notes at the end of the table for details.
Column 3 lists the update rate of the PGN in Quantum
Column 4 indicates which Cummins defined category the parameter falls in.
Please note that there are cases where the parameter may belong to more than one category. For example -
Parameter “engine Derate Switch” belongs to both IS/MX. Also read Note 6.
Column 5 lists the parameters within the PGN.
Columns 6-14 describes parameter support for Quantum engines.
TX means that the parameter is transmitted from the engine, RX means that the engine receives the parameter,
an entry no means that the parameter is not supported. Support of a J1939 parameter listed as both TX/RX,
means the following:
Under a non-multiplexed case, the parameter value is transmitted (TX) from engine.
Under a multiplexed case, the parameter value is received (RX) by engine.
The broadcast of certain J1939 Parameters shall be dependent upon the override trims for those parameters.
These trims can only be changed (enabled/disabled) prior to the powerup sequence. When the overrides have
been enabled, J1939 Parameters for those System Names shall be broadcast with N/ A (112 for switches & FF16
for analog values.)
Note: Multiplexing – if the hardwire is still attached to the ECM for that particular switch/sensor and the
parameter is set to be multiplexed, the ECU will ignore the hardwire input.
AEB15.43
Page 16 of 64
Table 1 Messages Supported on J1939
Message Name Update Parameters

PGN SA/DA Rate Use QSB QSC QSL9 QSM11 QSX15 QSK19 QST30 QSK45 QSK60
00000 Torque/Speed Control 0.01 s PT 1) Override control mode priority 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX
Message #1 – TSC1 PT 2) Desired speed control conditions 2) see 3- 2) see 3- 2) see 3- 2) see 3- 2) see 3- 2) see 2) see 2) see 2) see
B, C, D B, C, D B, C, D B, C, D B, C, D B,C,D B,C,D B,C,D B,C,D
Trans(3) / Engine(0) PT 3) Override control mode 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX
ABS(11) / Engine(0) A) Override disabled (00) A) RX A) RX A) RX A) RX A) RX
ASR(33) / Engine(0) B) Speed control (01) B) RX B) RX B) RX B) RX B) RX B) RX B) RX B) RX B) RX

a) desired speed a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX
b) desired speed control conditions b) RX b) RX b) RX b) RX b) RX b) no b) no b) no b) no
C) Torque control (10) C) RX C) RX C) RX C) RX C) RX C) RX C) RX C) RX C) RX

a) desired torque a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX
b) desired speed control conditions b) no b) no b) no b) no b) no b) no b) no b) no b) no
D) Speed/torque limit control (11) D) RX D) RX D) RX D) RX D) RX D) RX D) RX D) RX D) RX

a) speed and torque limit a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX a) RX
b) desired speed control conditions b) no b) no b) no b) no b) no b) no b) no b) no b) no
00000 Torque/Speed Control 0.05 s PT 1) Override control mode priority 1) RX 1) RX 1) RX 1) RX 1) RX
Message #2 – TSC1 PT 2) Desired speed control conditions 2) see 3- 2) see 3- 2) see 3- 2) see 3- 2) see 3-
B, C, D B, C, D B, C, D B, C, D B, C, D
Trans(3) / Retarder(41) PT 3) Override control mode 3) RX 3) RX 3) RX 3) RX 3) RX
ABS(11) / Retarder(41) A) Override disabled (00) A) no A) no A) no A) RX A) RX
ASR(33) / Retarder(41) B) Speed control (01) B) no B) no B) no B) no B) no

a) desired speed a) no a) no a) no a) no a) no
b) desired speed control conditions b) no b) no b) no b) no b) no
C) Torque control (10) C) RX C) RX C) RX C) RX C) RX

a) desired torque a) RX a) RX a) RX a) RX a) RX
b) desired speed control conditions b) no b) no b) no b) no b) no
D) Speed/torque limit control (11) D) RX D) RX D) RX D) RX D) RX

a) speed limit a) no a) no a) no a) no a) no
b) torque limit b) RX b) RX b) RX b) RX b) RX
c) desired speed control conditions c) no c) no c) no c) no c) no
AEB15.43
Page 17 of 64
PGN Message Name Update Use Parameters QSB QSC QSL9 QSM11 QSX15 QSK19 QST30 QSK45 QSK60
SA/DA Rate
57088 Stop Start Broadcast As
Needed
57344 Cab Message #1 1.0s 1) Requested Percent fan speed 1) RX 1) RX 1) RX 1) RX 1) no 1) RX 1) RX
Any / Engine(0)
59392 Acknowledgment As Acknowledgment Message
Message Needed
1) Control Byte (identifies ACK or 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) no 1) TX 1) TX
NACK)
Engine(0) / Any 2) Group Function 1) no 2) no 2) no 2) TX 2) no 2) TX 2) TX
3) PGN being acknowledged 2) TX 3) TX 3) TX 3) TX 3) TX

59904 Request PGN As Request PGN
Needed
1) PGN being requested 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX
Any / Engine(0)
AEB15.43
Page 18 of 64
SA/DA Rate
60160 Transport Protocol- On G Transport Protocol-Data Transfer
Data Transfer Request
2) Sequence Number 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX
Any/Engine (0) 3) Packeted Data 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX
Any/Retarder (41)
Engine (0)/Any
60416 Transport Protocol- As G Transport Protocol Connection Management
Connection Needed
1) Control Byte, identifies CM message type 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX 1) TX/RX
Management
2) Total Message Size, number of bytes
Any / Engine(0) 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX
3) Total Number of Packets
Any/Retarder (41) 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX
4) Parameter Group Number of Packeted
Engine (0)/Any message 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX 4) TX/RX
61184 Proprietary A As SP Proprietary A 1) TX 1) TX 1) TX 1) TX/RX 1) TX/RX 1) TX/RX

Engine (0)/ Needed
1) Proprietary information, manufacturer specific
Service Tool
(249,250)
Service Tool
(249,250) Engine (0)
61440 ERC 1 0.1S PT 1) TX 1) TX 1) TX 1) no 1) no 1) no
1) Retarder enable – shift assist switch
Retarder (41)/None PT 2) Retarder enable – brake assist switch 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
PT 3) Retarder torque mode 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX
PT 4) Actual Retarder – percent torque 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX

AEB15.43
Page 19 of 64
SA/DA Rate
61441 EBC1 0.1s 1) ABS Active 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no
2) ASR Brake Control Active 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
Engine(0) / None 3) ASR Engine Control Active 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no
4) Brake Pedal position 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no
5) ASR Hill Holder Switch 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no
6) ASR Offroad Switch 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no
7) ABS Offroad Switch 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no
IS/MX 8) Remote Accelerator Enable Switch 8) TX/RX 8) TX/RX 8) TX/RX 8) TX 8) TX 8) RX 8) no 8) RX 8) RX
9) Shutdown Switch 9) RX 9) RX 9) RX 9) 9) no 9) no 9) no
IS/MX 10) Switched Torque 10) no 10) no 10) no 10) 10) no 10) no 10) no
IS/MX 11) Multi Unit Sync On/Off Switch 11) TX/RX 11) TX/RX 11) TX/RX 9) no 11) no 11) no 11) no 11) no 11) no
IS/MX 12) Engine Retarder Selection 12) TX/RX 12) TX/RX 12) TX/RX 10) TX 12) TX 12) no 12) no
61442 Transmission 0.01s PT 1) Shift in process 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX 1) RX

Message #1 – ETC1
2) Torque converter lockup engaged 2) no 2) RX 2) RX 2) RX 2) RX 2) RX 2) no 2) no 2) no
(If converter lockup is sensed, Eng
Brakes will not engage. If transmission
is automated send a zero(0))
Trans(3)/Engine(0) 3) Driveline engaged

3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) RX 3) Rx
PT 4) Output shaft speed
4) RX 4) RX 4) RX 4) RX 4) RX 4) RX 4) no 4) no 4) no
5) Percent clutch slip
5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no
6) Progressive shift disable
PT
6) RX 6) RX 6) RX 6) RX 6) RX 6) RX 6) RX 6) no 6) no
7) Momentary engine overspeed enable
PT 7) RX 7) RX 7) RX 7) RX 7) RX 7) RX 7) RX 7) RX 7) RX
8) Input shaft speed
8) no 8) no 8) no 8) no 8) No 8) no 8) no 8) no 8) no
9) Source address of Controlling Device
9) no 9) no
AEB15.43
Page 20 of 64
SA/DA Rate
61443 EEC2 - Electronic 0.05 s PT 1) AP kick down switch 1) TX 1) TX 1) TX 1) TX 1) TX 1) no 1) TX 1) no 1) no
Engine Controller #2
PT/MX 2) AP low idle switch 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX/RX 2) TX 2) TX 2) TX 2) TX
PT/MX 3) Accelerator pedal position 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX/RX 3) TX 3) TX 3) TX 3) TX
Engine(0) / None
PT
4) Percent load at current speed 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
PT/MX
5) Remote Accelerator 5) TX/RX 5) TX/RX 5) TX/RX 5) TX/RX 5) TX/RX 5) no
61444 EEC1 - Electronic 0.02 s PT 1) Engine torque mode 1) TX 1) TX 1) TX 1) TX (1) 1) TX (1) 1) TX 1) TX 1) TX 1) TX

Engine Controller #1
PT 2) Drivers demand engine-percent torque 2) TX 2) TX 2) TX 2) TX/RX 2) TX/RX 2) TX 2) TX 2) TX 2) TX
PT 3) Actual engine - percent torque 3) TX 3) TX 3) TX 3) TX/RX 3) TX/RX 3) TX 3) TX 3) TX 3) TX

Engine(0) / None
PT 4) Engine speed 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
5) Source Address of Controlling Device 5) no 5) no 5) no 5) no 5) no 5) no
65213 Fan Drive 1.0 s IS 1) Estimated Percent Fan Speed 1) TX 1) TX 1) TX 1) no 1) no 1) TX 1) no 1) TX 1) TX
IS 2) Fan Drive State 2) TX 2) TX 2) TX 2) no 2) no 2) TX 2) no 2) TX 2) TX
Engine(0) / None
DM1 1.0 s Active Diagnostic Trouble Codes

65226
Active Diagnostic DG(MX) 1) Malfunction indicator lamp status 1) no 1) no 1) no 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
Trouble Codes
DG(MX) 2) Red Stop Lamp status 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
DG(MX) 3) Amber Warning Lamp status 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

Engine(0) / None
DG(MX) 4) Protect lamp status 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
DG(MX) 5) Diagnostic Trouble Code (s) 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX
(1) not all modes specified by SAE are supported

AEB15.43
Page 21 of 64
SA/DA Rate
65227 On Previously Active Diagnostic Trouble
DM2
Request Codes
DG 1) Malfunction indicator lamp status

Any / Engine(0) 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
DG 2) Red Stop Lamp status
2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
DG 3) Amber Warning Lamp status
DG 4) Protect lamp status
DG 5) Diagnostic Trouble Code (s)
65228 DM3 On DG Diagnostic Data Clear/Reset of RX RX RX RX RX RX RX RX RX

Request Previously Active DTCs
Any / Engine(0)
Freeze Frame Parameters
65229 DM4 On
* Request 1) Freeze Frame Length
1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
2) Diagnostic Trouble Code
2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
Engine(0) / None
3) Engine Torque Mode
3) no 3) no 3) no 3) no 3) no 3) no
4) Boost 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
5) Engine Speed
5) TX 5) TX 5) TX 5) TX 5) TX 5) TX
6) Engine Percent Load
6) TX 6) TX 6) TX 6) TX 6) TX 6) TX
7) Engine Coolant Temperature 7) TX 7) TX 7) TX 7) TX 7) TX 7) TX
Vehicle Speed 8) TX 8) TX 8) TX 8) TX 8) TX 8) no
9) Manufacturer Specific Information 9) no 9) no 9) no 9) TX 9) TX 9) TX
* See page 30 – Notes on superscripted PGN

AEB15.43
Page 22 of 64
SA/DA Rate
65230 DM5 On Diagnostic Readiness
Request
DG 1) Active Trouble Codes 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
Engine(0) / None DG 2) Previously Active Diagnostic Trouble 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX

Codes
3) OBD Compliance
DG 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
4) Continuously Monitored Systems
DG Status 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX
DG 5) Non-Continuously Monitored Systems

Support 6) TX 6) TX 6) TX 6) TX 6) TX 6) TX 6) TX 6) TX 6) TX
6) Non-Continuously Monitored Systems

DG
Status
65232 DM8 On Test Results for Non-Continuously

Request Monitored Systems
DG 1) Test Identifier 1) TX 1) TX 1) TX 1) TX
Engine(0) / None
2) Test Type / Component Identifier 2) no 2) no 2) no 2) no
3) Test Value 3) TX 3) TX 3) TX 3) TX
4) Test Limit Maximum 4) no 4) no 4) no 4) no
5) Test Limit Minimum 5) no 5) no 5) no 5) no
65234 DM10 On Non-Continuously Monitored Systems

Request Test ID Support
DG 1) Test ID 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
Engine(0) / None
65243 Engine Fluid 0.5 IS 1) Injection control pressure 1) no 1) no 1) no 1) no 1) no 1) no 1) no

Level/Pressure #2
IS 2) Injector rail metering pressure 2) no 2) no 2) no 2) TX 2) no 2) TX 2) TX
Engine(0) / None
65244 Idle Operation On IS 1) Total idle fuel used 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Request
IS 2) Total idle hours 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
Engine(0) / None
AEB15.43
Page 23 of 64
SA/DA Rate
65247 EEC3 0.25 s PT 1) Nominal friction - percent torque 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
PT 2) Engine's desired operating speed 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
Engine(0) / None PT 3)Engine's operating speed asymmetry 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

adjustment
65248 Vehicle Distance On IS 1) Trip distance 1) TX 1) TX 1) TX 1) no 1) no 1) TX

Request
IS 2) Total vehicle distance 2) TX 2) TX 2) TX 2) no 2) no 2) TX
Engine(0) / None
PGN
65249 Retarder 5.0 s PT 1) Retarder location 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Configuration
PT 2) Retarder type 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
PT 3) Retarder control method 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

Retarder(41) / None
PT 4) Retarder speed at idle, point 1 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
PT 5) Percent torque at idle, point 1 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX
PT 6) Maximum retarder speed, point 2 6) TX 6) TX 6) TX 6) TX 6) TX 6) TX
PT 7) Percent torque at max speed, 7) TX 7) TX 7) TX 7) TX 7) TX 7) TX

point 2
PT 8) Retarder speed at point 3 8) TX 8) TX 8) TX 8) TX 8) TX 8) TX
PT 9) Percent torque at point 3 9) TX 9) TX 9) TX 9) TX 9) TX 9) TX
PT 10) Retarder speed at point 4 10) TX 10) TX 10) TX 10) TX 10) TX 10) TX
PT 11) Percent torque at point 4 11) TX 11) TX 11) TX 11) TX 11) TX 11) TX
PT 12) Retarder speed at peak torque, point 5 12) TX 12) TX 12) TX 13) TX 12) TX 12) TX
PT
13) Reference retarder torque 13) TX 13) TX 13) TX 13) TX 13) TX 13) TX
PT 14) Percent torque at peak torque, point 5 14) no 14) no 14) no 14) TX 14) TX 14) no
AEB15.43
Page 24 of 64
SA/DA Rate
65251 Engine Configuration 5.0 PT 1) Engine speed at idle, point 1 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
s/10%
chg PT 2) Percent torque at idle, point 1 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
Engine(0) / None PT 3) Engine speed at point 2 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX
PT 4) Percent torque at point 2 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX
PT 5) Engine speed at point 3 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX
PT 11) Engine speed at high idle, point 6 11) TX 11) TX 11) TX 11) TX 11) TX 11) TX 11) TX 11) TX 11) TX
PT 12) Gain (KP) of endspeed governor 12) no 12) no 12) no 12) no 12) no 12) no 12) no 12) no 12) no
PT 13) Reference engine torque 13) TX 13) TX 13) TX 13) TX 13) TX 13) TX 13) TX 13) TX 13) TX
PT 14) Maximum momentary engine 14) TX 14) TX 14) TX 14) TX 14) TX 14) TX 14) TX 14) TX 14) TX
override speed, point 7
PT 15) Maximum momentary engine 15) TX 15) TX 15) TX 15) TX 15) TX 15) TX 15) TX 15) TX 15) TX
override time limit
PT 16) Requested speed control range lower 16) TX 16) TX 16) TX 16) TX 16) TX 16) TX 16) TX 16) TX 16) TX
limit
PT 17) Requested speed control range 17) TX 17) TX 17) TX 17) TX 17) TX 17) TX 17) TX 17) TX 17) TX
upper limit
PT 18) Requested torque control range 18) TX 18) TX 18) TX 18) TX 18) TX 18) TX 18) TX 18) TX 18) TX
lower limit
PT 19) Requested torque control range 19) TX 19) TX 19) TX 19) TX 19) TX 19) TX 19) TX 19) TX 19) TX
upper limit
AEB15.43
Page 25 of 64
SA/DA Rate
65252 Idle Shutdown 1.0 s IS 1) Idle shutdown timer state 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
IS 2) Idle shutdown timer override 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) no 2) TX 2) TX
Engine(0) / None IS 3) Driver alert mode 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) no 3) TX 3) TX
IS 4) Engine has shutdown by system 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) no 4) TX 4) TX
IS 5) Idle shutdown timer function 5) TX 5) TX 5) TX 5) TX 5) TX 5) TX 5) no 5) TX 5) TX
6) Refrigerant high pressure switch 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no
7) Refrigerant low pressure switch 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no
IS/MX 8) A/C high pressure fan switch 8) TX 8) TX 8) TX 8) TX/RX 8) TX/RX 8) no 8) no 8) no 8) no
9) Wait to start lamp 9) TX 9) TX 9) TX 9) no 9) no 9) no 9) no 9) no 9) no
10) Engine protection shutdown timer 10) no 10) no 10) no 10) TX 10) TX 10) TX 10) no 10) TX 10) TX
state
11) no 11) no 11) no 11) no 11) no 11) TX 11) no 11) TX 11) TX
11) Engine protection shutdown override
12) Engine shutdown approaching 12) no 12) no 12) no 12) TX 12) TX 12) TX 12) no 12) TX 12) TX
13) Engine has shutdown by protection

13) no 13) no 13) no 13) TX 13) TX 13) TX 13) no 13) TX 13) TX
system
14) Engine protection timer system 14) no 14) no 14) no 14) TX 14) TX 14) TX 14) no 14) TX 14) TX
configuration
65253 Engine Hours, On IS 1) Total engine hours 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Revolutions Request
IS 2) Total engine revolutions 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
Engine(0) / None
65254 Time/Date On IS 1) Seconds 1) TX 1) TX 1) TX 1) no 1) no 1) no

Request
IS 2) Minutes 2) TX 2) TX 2) TX 2) no 2) no 2) no
Engine(0) / None IS 3) Hours 3) TX 3) TX 3) TX 3) no 3) no 3) no
IS 4) Day 4) TX 4) TX 4) TX 4) no 4) no 4) no
IS 5) Month 5) TX 5) TX 5) TX 5) no 5) no 5) no
IS 6) Year 6) TX 6) TX 6) TX 6) no 6) no 6) no
AEB15.43
Page 26 of 64
SA/DA Rate
65255 Vehicle Hours On IS 1) Total vehicle hours 1) no 1) no 1) no 1) no 1) no 1) no
Request
IS 2) Total power takeoff hours 2) TX 2) TX 2) TX 2) TX 2) TX 2) no
Engine(0) / None
65257 Fuel Consumption On IS 1) Trip fuel 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Request
IS 2) Total fuel used 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
Engine(0) / None
65259 Component On IS 1) Make 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Identification Request
IS 2) Model 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
*
IS 3) Serial Number 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX
Engine(0) / None
IS 4) Unit Number 4) TX 4) TX 4) TX 4) TX 4) TX 4) TX 4) no 4) TX 4) TX
65260 Vehicle Identification On IS 1) VIN 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX

Request
*
PGN
65261 Cruise On IS 1) Maximum vehicle speed limit 1) TX 1) TX 1) TX 1) no

Control/Vehicle Request
Speed Setup IS 2) Cruise control high set limit speed 2) TX 2) TX 2) TX 2) no
IS 3) Cruise control low set limit speed 3) TX 3) TX 3) TX 3) no
Engine(0) / None
65262 Engine Temperature 1.0 s IS 1) Engine coolant temperature 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
2) Fuel temperature 2) TX 2) TX 2) TX 2) TX 2) no 2) TX 2) no 2) TX 2) TX
Engine(0) / None 3) Engine oil temperature 3) no 3) no 3) no 3) TX 3) TX 3) no 3) TX 3) no 3) no
4) Turbo oil temperature 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no
5) Engine intercooler temperature 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no
* See page 30 – Notes on superscripted PGN

AEB15.43
Page 27 of 64
SA/DA Rate
65263 Engine Fluid 0.5 s 1) Fuel delivery pressure 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no
Level/Pressure
2) Engine oil level 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
IS 3) Engine oil pressure 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

Engine(0) / None
4) Crankcase pressure 4) no 4) no 4) no 4) no 4) no 4) TX 4) TX 4) TX 4) TX
5) Coolant pressure 5) no 5) no 5) no 5) no 5) no 5) TX 5) TX 5) TX 5) TX
6) Coolant level 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no
65264 PTO - Power 0.1 s 1) Power Takeoff Oil Temperature 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no

Takeoff Information
2) Power Takeoff Speed 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
IS 3) Power Takeoff Set Speed 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

Engine(0) / None
4) Remote PTO variable speed control 4) no 4) no 4) no 4) TX 4) TX 4) no 4) no 4) no 4) no
switch
IS/MX 5) AUX Governor On/Off Switch 5) no 5) no 5) no 5) no 5) no 5) TX/RX 5) no 5) TX/RX 5) TX/RX
6) PTO enable switch 6) TX/RX 6) TX/RX 6) TX/RX 6) TX 6) TX 6) no 6) no 6) no 6) no
IS/MX 7) PTO accelerate switch 7) no 7) no 7) no 7) TX 7) TX 7) no 7) no 7) no 7) no
8) PTO resume switch 8) TX/RX 8) TX/RX 8) TX/RX 8) TX 8) TX 8) TX/RX 8) no 8) TX/RX 8) TX/RX
IS/MX 9) PTO coast/decelerate switch 9) no 9) no 9) no 9) no 9) no 9) no 9) no 9) no 9) no
IS/MX 10) PTO set switch 10)TX/RX 10)TX/RX 10)TX/RX 10)TX 10)TX 10)TX/RX 10)no 10)TX/RX 10)TX/RX
AEB15.43
Page 28 of 64
SA/DA Rate
65265 Cruise 0.1 s 1) Parking Brake Switch 1) no 1) no 1) no 1) no 1) no 1) no
Control/Vehicle
Speed 2) ISC 1 Switch 2) no 2) no 2) no 2) no 2) no 2) no
IS 3) Wheel Base Vehicle Speed 3) TX 3) TX 3) TX 3) no 3) no 3) no
Engine(0) / None IS/MX 4) Clutch Switch 4) TX/RX 4) TX/RX 4) TX/RX 4) no 4) no 4) no
IS/MX 5) Brake Switch 5) TX/RX 5) TX/RX 5) TX/RX 5) no 5) no 5) no
IS/MX 6) Cruise Control Enable Switch 6) TX/RX 6) TX/RX 6) TX/RX 6) no 6) no 6) no
IS 7) Cruise Control Active 7) TX 7) TX 7) TX 7) no 7) no 7) no
IS 8) Cruise Control Accelerate Switch 8) TX 8) TX 8) TX 8) no 8) no 8) no
IS/MX 9) Cruise Control Resume Switch 9) TX/RX 9) TX/RX 9) TX/RX 9) no 9) no 9) no
IS 10) Cruise Control Coast Switch 10) TX 10) TX 10) TX 10) no 10) no 10) no
IS/MX 11) Cruise Control Set Switch 11)TX/RX 11)TX/RX 11)TX/RX 11)no 11)no 11)no
IS 12) Cruise Control Set Speed 12) TX 12) TX 12) TX 12) no 12) no 12) no
IS 13) Cruise Control State 13) TX 13) TX 13) TX 13) no 13) no 13) no
IS 14) PTO State 14) TX 14) TX 14) TX 14) TX 14) TX 14) no
IS/MX 15) Engine Test Mode Switch 15)TX/RX 15)TX/RX 15)TX/RX 15) TX 15) TX 15) no
IS/MX 16) Idle Decrement Switch 16)TX/RX 16)TX/RX 16)TX/RX 16) TX 16) TX 16) no
IS/MX 17) Idle Increment Switch 17)TX/RX 17)TX/RX 17)TX/RX 17) TX 17) TX 17) no
65266 Fuel Economy 0.1 s IS 1) Fuel Rate 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
IS 2) Instantaneous fuel economy 2) TX 2) TX 2) TX 2) no 2) no 2) TX 2) TX 2) TX 2) TX
Engine(0) / None IS 3) Average fuel economy 3) TX 3) TX 3) TX 3) no 3) no 3) no 3) TX 3) no 3) no
65269 Ambient Conditions 1.0 s 1) Barometric pressure 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX 1) TX
2) Cab interior temperature 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
Engine(0) / None 3) Ambient air temperature 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no
4) Air inlet temperature 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no
5) Road surface temperature 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no

AEB15.43
Page 29 of 64
SA/DA Rate
65270 Inlet/Exhaust 0.5 s 1) Particulate trap inlet pressure 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no
Conditions
IS 2) Boost pressure 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX 2) TX
IS 3) Intake manifold temperature 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX 3) TX

Engine(0) / None
4) Air inlet pressure 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no 4) no
5) Air filter differential pressure 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no 5) no
6) Exhaust gas temperature 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no 6) no
7) Coolant filter differential 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no 7) no
65271 Vehicle Electrical 1.0 s 1) Net battery current 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no 1) no

Power
2) Alternator current 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no 2) no
3) Alternator potential (voltage) 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no 3) no

Engine(0) / None
IS 4) Electrical potential (voltage) 4) TX 4) TX 4) TX 4) TX (2) 4) TX (2) 4) TX 4) no 4) TX 4) TX
5) Battery potential (voltage), switched 5) no 5) no 5) no 5) no 5) no 5) no 5) TX 5) no 5) no
65279 Water in Fuel 10.0 s IS 1) Water in fuel indicator 1) TX 1) TX 1) TX 1) no 1) no 1) no

Indicator
Engine(0) / None
(2) Available by request only

AEB15.43
Page 30 of 64
*
Notes on Superscripted PGN used in Table 1:
1. The SAE J1939 specification does not contain all the information on PGNs 65229, 65259 and 65260.
2. Only able to reset the Engine Oil.
3. Nonconforming to J1939/21 SAE Specification.
4. Nonconforming to J1939/71 SAE Specification.
5. The Request PGN is actually received with the DM3 PGN in the data field.
6. When cruise control/PTO set or resume switches are used to activate coast or accelerate switches, the set
or resume switches will no longer activate during a broadcast while the resume or accelerate switches are
active.
Cummins has provided the following detailed definitions:
PGN 65229 - Diagnostic Message DM4
A freeze frame is defined as the list of recorded parameters at the time a diagnostic trouble code was captured.
The freeze frame record for each diagnostic trouble code contains the SAE defined required parameters first
and then any manufacturer-specific information.
Byte 1: Freeze Frame Length

Bytes 2-5: Diagnostic Trouble Code (4 bytes)
Byte 6: Engine Torque Mode set to FF16 - not available
Byte 7: Boost
Bytes 8-9: Engine Speed
Byte 10: Engine % Load
Byte 11: Engine Coolant Temperature
Bytes 12-13: Vehicle Speed
Bytes 14-74: Manufacturer Specific Information - Please refer to Table 2
Note: The following illustrates the message format for when there is more than one freeze frame.
Given: a = freeze frame length

b = required parameters
c = manufacturer specific freeze frame information
Message form will be as follows: a,b,c,a,b,c,a,b,c,.etc. The transport protocol of J1939-21 will have to be used
to send freeze frames because they are more than 8 data bytes. The maximum message size limit is 1785
bytes.
AEB15.43
Page 31 of 64
Table 2 Cummins Specific Information for PGN 65229 (DM4)
Cummins Internal Length Information is

Description
Parameter (bytes) transmitted as:
ECM_Run_Time The ECM time that a fault occurred in 4

seconds
Fault_index Index for service fault information 2
Road_Speed The speed of the vehicle 2
Filtered_Engine_Speed The speed of the engine 2
J1587_Percent_Load Fuel as a percentile 2
Commanded_Throttle Throttle position as a percentile 2
Engine_State Defined state of engine operation 2
Fueling_Control_State Indicator of which algorithm is in control of 2
final fueling
Final_Fueling Fueling value commanded to Fuel System 2
Final_Timing_State Indicator of which algorithm is in control of 2
final timing
Final_Timing Calculated timing value as start of injection 2
Boost_Pressure Boost pressure in psig 2
Coolant_Temperature Coolant temperature in degrees Fahrenheit 2
Intake_Manifold Intake Manifold temperature in degrees 2
_Temperature Fahrenheit
Oil_Temperature Oil temperature in degrees Fahrenheit 2 FFFF
Oil_Pressure Oil pressure in psig 2
System_Switch_Status Sensor and switch status indicators 2
System_Switch_Status_2 Sensor and switch status indicators 2
Engine_Run_Time Engine time that fault occurred in seconds. 4
This does not include any base time set for a
new ECM
Battery_Voltage Battery voltage in volts 2
Injected_Fueling Fueling value delivered by Fuel System 2 FFFF
Fuel_Rail_Pressure Measured fuel pressure in psia 2 FFFF
Coolant_Pressure Coolant pressure in psia 2 FFFF
Fuel_Error_Front_Metered Calculated fueling error of the front bank in 4 FFFF
_Fuel_ Error units of mm3/stk
Fuel_Error_Rear_Metered Calculated fueling error of the rear bank in 4 FFFF
_Fuel_ Error units of mm3/stk
AEB15.43
Page 32 of 64
PGN 65259 — Component Identification
Data length Variable (transport layer used)
The following parameters are mapped to this message:

Engine Make 5 bytes
Asterisk (*) 1 byte
Engine Model 34 bytes
Asterisk (*) 1 byte
Engine SN 8bytes
Asterisk (*) 1 byte
Unit Number 20 bytes
Asterisk (*) 1 byte
Note: Each parameter shall be followed by an ASCII asterisk (*). That is, the engine Make is the first element
of this message and the asterisk following Unit Number is the last. If a build does not support one of these
parameters, the following asterisk will still be used.
PGN 65260 — Vehicle Identification (VIN)
Data length Variable (transport layer used)

Byte 1-n VIN
Byte n+1 Asterisk (ascii “*”)
Note: The actual data length of this message shall be determined by the number of characters in the VIN
(represented by “n” in this example).
2. PIDS Supported on J1587
J1587 datalink supports information sharing, diagnostics and proprietary communications on Quantum. The
messages used to accomplish that are listed below in table. Please read the following notes in order to
understand the contents of the table.
Column 1 lists the SAE defined Parameter Identification (PID) numbers
Column 2 lists the SAE defined PID names.
Column 3 lists the Update rate for the PID on Quantum. As Needed refers to the message being used
whenever the desire is to use it. For example, PID 000 (Request Parameter) will be used by a tool only when it
wishes to request some information from the Quantum. Some update rates have the number (5) written after
them. Please refer to the notes at the end of the table for details.
Columns 4-12 lists support of the PIDs on the Quantum engine platforms. Some PIDs have numbers (1)–(5)
written after them. Please refer to the notes at the end of the table for details.
AEB15.43
Page 33 of 64
Table 3 PIDS Supported on J1587

PID J1587 Message Name Update Rate QSB QSC QSL9 QSM11 QSX15 QSK19 QST30 QSK45 QSK60
000 Request Parameter As Needed RX RX RX RX RX RX RX RX RX
002 Status Word 1 1.0 s TX (1) TX (1) TX (1) TX (1) TX (1) TX (1) TX (1) TX (1) TX (1)
003 Diagnostic Status As Needed no no no TX (1) TX (1) TX (1) TX (1) TX (1) TX (1)
029 Percent Accelerator Position #2 0.1 s TX TX TX
030 Crankcase Blowby Pressure (when available) 1.0 s TX TX TX
044 Attention/Warning Indicator Lamps Status 1.0 s TX TX TX TX TX

051 Throttle Position (Rack Position) 0.2 s TX
071 Idle Shutdown Timer Status 1.0 s TX TX TX TX TX
074 Maximum Road Speed On Request TX TX TX

083 Road Speed Limit Status On Request TX TX TX
084 Road Speed 0.1 s TX TX TX
085 Cruise Control Status 0.2 s TX TX TX
086 Cruise Control Set Speed 10.0 s TX TX TX

087 Cruise Control High Set Limit Speed On Request TX TX TX
088 Cruise Control Low Set Limit Speed On Request TX TX TX
089 Power Takeoff Status 1.0 s TX TX TX TX TX TX TX TX TX
091 Percent Accelerator Pedal Position 0.1 s TX TX TX TX TX TX TX TX TX

092 Percent Engine Load 0.1 s TX TX TX TX TX TX TX TX TX
097 Water In Fuel Indicator 10.0 s TX TX
100 Engine Oil Pressure 1.0 s TX TX TX TX TX TX TX TX TX
101 Crankcase Pressure (when available) 1.0 s TX

102 Boost Pressure 1.0 s TX TX TX TX TX TX TX TX TX
105 Intake Manifold Temperature 1.0 s TX TX TX TX TX TX TX TX TX
108 Barometric Pressure 1.0 s TX TX TX TX TX TX

109 Coolant Pressure 10 s TX TX TX TX
110 Engine Coolant Temperature 1.0 s TX TX TX TX TX TX TX TX TX
111 Coolant Level 10.0 s TX
121 Engine Retarder Status 0.2 s no no no TX TX

AEB15.43
Page 34 of 64

128 Component Specific Parameter Request As Needed RX RX RX RX RX RX RX RX
133 Average Fuel Rate 0.2 s TX TX TX

135 Electronic Fuel Pump Pressure 1.0 s TX TX TX
156 Injector Timing Rail Pressure On Request TX TX TX
157 Injector Metering Rail Pressure On Request TX TX TX
166 Rated Engine Power On Request TX TX TX TX TX TX

168 Volts (Battery) 1.0 s TX TX TX TX TX TX TX TX TX
174 Fuel Temperature On Request no TX TX
175 Engine Oil Temperature 1.0 s TX TX TX
182 Trip Fuel 10.0 s TX TX TX TX TX

183 Fuel Rate 0.2 s TX TX TX TX TX TX TX TX
184 Instantaneous MPG 0.2 s TX TX TX
185 Average MPG 10.0 s TX TX TX
187 Power Takeoff (ISC) Set Speed On Request TX TX TX TX TX TX TX TX TX

188 Idle Engine Speed On Request TX TX TX TX TX TX TX TX TX
189 Maximum Engine Speed On Request TX TX TX TX TX TX TX TX TX
190 Engine Speed 0.1 s TX TX TX TX TX TX TX TX TX

191 Transmission Output Shaft Speed 0.1 s TX TX TX
192 Multisection Parameter As Needed TX TX TX TX TX TX TX TX TX
193 Transmitter System Diagnostic Table On Request TX (1,3) TX (1,3) TX (1,3) TX (1,3) TX (1,3) TX (1,3) TX (1,3) TX (1,3) TX (1,3)
194 Transmitter System Diagnostic Code and 1.0 s TX (2,4) TX (2,4) TX (2,4) TX (2,4) TX (2,4) TX (2,4) TX (2,4) TX (2,4) TX (2,4)
Occurrence Count Table
195 Diagnostic Data Request/Clear Count As Needed RX RX RX RX RX RX RX RX RX
196 Diagnostic Data Request/Clear Count Response As Needed TX TX TX TX TX TX TX TX TX
234 Software Identification On Request TX (5) TX (5) TX (5) TX (5) TX (5)

235 Total Idle Hours On Request TX TX TX TX
236 Total Idle Fuel Used On Request TX TX TX
237 Vehicle Identification Number On Request TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5)
243 Component Identification Parameter On Request TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5) TX (5)
AEB15.43
Page 35 of 64

244 Trip Distance 10.0 s TX TX TX
245 Total Vehicle Distance 10.0 s TX TX TX

247 Total Engine Hours On Request TX TX TX TX TX TX (*) TX TX TX
248 Total PTO Hours On Request TX TX TX TX TX TX
250 Total Fuel Used On Request TX TX TX TX TX
251 Clock On Request no no no TX TX

252 Date On Request no no no TX TX
254 Escape On Request no no no TX/RX TX/RX
(*) Not in software phase 2.7
Notes on numbers (1) – (5) used in Table:
1. These PIDs are specified as broadcast PIDs in SAE J1587 but due to limitation in the number of broadcast PIDs that can be supported in the
Quantum calibration, they are instead available On Request
2. Cummins PID 194 messages include occurrence count when requested. When PID 194 is broadcast, the fault count information is not included.
3. PID 194 should be used for new products. Refer to Table 7-1 for system fault codes.
4. Active faults are broadcast at the rates specified in the SAE J1587 specification (7/96). Inactive faults are only available on request.
5. The SAE J1587 specification does not contain all the information on PIDs 234, 237 and 243. Cummins has provided the following detailed definitions:
PID 234 - Software Identification
Format: PID Data

234 n a a a a * b b b b * c c c c c c c c c c c c*dddd*ee*ff
n- Number of parameter data characters following this byte
a- Module Part Number, 8 bytes, ASCII
b- Module Serial Number, 8 bytes, ASCII
c- Engine Calibration Date and Time Stamp, 12 bytes, ASCII
(format = mmddyyhhmmss)
d- Phase Designation (describes software version number), 4 bytes, ASCII
e- Module Identifier, 2 bytes, ASCII
f- Application Identifier, 2 bytes, ASCII
AEB15.43
Page 36 of 64
PID 237 — Vehicle Identification
Format: PID Data

na aaaaaaa aaaaaaaa aaaa
n - Number of parameter data characters (20)
a - VIN (alphanumeric)
Note: The stored Vehicle Identification Number is a twenty-byte value.
PID 243 - Component Identification
Format: PID Data

43 n b c c c c c * d d d d d d d d d d d d d d d d d* e e e e
n- Number of parameter data characters following this byte
b- MID of component being identified (Cummins uses MID 128)
c- Engine Make, 5 bytes, ASCII (Cummins stores and transmits “CMMNS”)
d- Engine Model, 17 bytes, ASCII
e- Engine Serial Number, 8 bytes, ASCII
Network Utilization
Network utilization is a limited resource, as the network can become saturated by excessive use. The
following sections detail network utilization computations for J1939 and J1587 datalinks on Quantum
controllers.
J1939 Network Utilization
The engine module’s contribution to percent bus utilization may be calculated for J1939 broadcast data
by dividing the network transmission time by the repetition frame time. Computation of Bus Utilization has
been done both for Nonmultiplexed and Multiplexed cases. When computing J1939 traffic over a time
slice for Nonmultiplexed case, only the Quantum broadcast messages are taken in consideration. There
may be message traffic from other J1939 devices that the engine module receives but the engine would
continue to function with no degradation if it were not to receive these messages. Therefore the
contribution of the engine module towards bus loading is because of the messages it broadcasts.
In a multiplexed case though, the engine module depends on receiving parameters from the Cab
Electronic Control Unit (ECU). Therefore, bus loading is not only due to messages that the engine
module broadcasts but also the traffic contributed by the multiplexed messages from Cab ECU.
Following assumptions have been made for doing the calculation:
• The engine configuration has not changed over time of calculation.

• No active system faults are present.
• No collisions take place.
• Calculated over 2-second time slice

AEB15.43
Page 37 of 64
The equation for calculating bus utilization for J1939 per 2 seconds is provided below:
U = bus utilization = (B*N)/2...................................... (A)
where:
B = number of J1939 messages
N = number of microseconds to send a single J1939 message frame = (128 bits per message) * (4
microseconds per bit) = 512 microsecond per message
Table below details the message traffic on J1939 datalink contributed by Quantum for the two possible
cases - nonmultiplexed and multiplexed. Please read the notes below to understand the contents of the
table.
Column 1 lists the SAE defined Parameter Group Number (PGN)

Column 2 lists the periodic rate at which the PGN is updated on Quantum
Column 3 lists the # of PGN frames Quantum broadcasts in a Nonmultiplexed case
Column 4 lists the # of PGN frames Quantum either broadcasts or receives in a multiplexed case.
Please refer to the write- up in Section 0 of J1939 Network Utilization to understand why the message
frame calculations are done differently for nonmultiplexed vs. multiplexed cases.
AEB15.43
Page 38 of 64
Table 4 J1939 Messages Non-multiplexed -vs- Multiplexed

PGN Update Rate Non-multiplexed Multiplexed
57344 - Cab Message #1 1.0 s 0 2
61440 - ERC1 0.1 s 20 20
61441 - EBC1 0.1 s 20 40
61443 - EEC2 0.05 s 40 80
61444 - EEC1 0.02 s 100 100
65213 - Fan Drive 1.0 s 2 2
65247 - EEC3 0.25 s 8 8
65249 - Retarder Configuration 5.0 s 1.6 1.6
65251 - Engine Configuration 5.0 s 2 2
65252 - Idle Shutdown 1.0 s 2 4
65262 - Engine Temperature 1.0 s 2 2
65263 - Engine Fluid Level/Pressure 0.5 s 4 4
65264 - Power Takeoff Information 0.1 s 20 40
65265 - Cruise Control/Vehicle Speed 0.1 s 20 40
65266 - Fuel Economy 0.1 s 20 20
65269 - Ambient Conditions 1.0 s 2 2
65270 - Inlet/Exhaust Conditions 0.5 s 4 4
65271 - Vehicle Electrical Power 1.0 s 2 2
65279 - Water In Fuel Indicator 10.0 s 0.2 0.2
B = TOTAL # of messages in 2 sec 269.8 373.8
Therefore Network Utilization for Nonmultiplexed Messages in 2 seconds, per equation (A):
U NonMUX = 269.8 frames * 512 microseconds * sec * 100
6
2 sec frame 10 microseconds
U NonMUX = 6.90%
and Network Utilization for Multiplexed Messages in 2 seconds, per equation (A):
UMUX = 373.8 frames * 512 microseconds * sec * 100
6
2 sec frame 10 microseconds
UMUX = 9.56%
J1587 Network Utilization

For the J1587 ECM broadcast, the network utilization is calculated as follows:
U = bus utilization = B/N

AEB15.43
Page 39 of 64
where:
N = baud rate/number of bits per character

= 9600/10 = 960
RA = access bytes + MID byte = 3.0 (assumes two tries, winning half the time)
C# = number of collisions.
This number is dependent on the number of units on the bus with equal priority, the size of the message
and the total number of messages to be transmitted on the bus.
Ct = collision bytes = re-access bytes * number of collisions = RA * C#

B = number of bytes broadcasted per second
= B1 + B2 + B3 + Ct
B1 = bytes for access *maximum broadcast rate
= 2 * 10
Note: 20 bits (two transmission bytes) are approximately equal to the access time plus the priority time.
This assumes only one packet per broadcast.
B2 = bytes for overhead of each packet * maximum broadcast rate

= 2 * 10 (overhead is the MID and checksum)
B3 = total number of bytes broadcasted (byte count * update frequency * number of PIDs rate)
Therefore, Network Utilization for J1587 broadcast data is as follows:
B3 = number of message bits (assume one active fault)

B3 = 2*10*3 + 3*10*1 + 2*5*2 + 3*5*1 + 2*1*9 + 3*1*3 + 5*1*1 + 2*0.1*3 + 3*0.1*3 + 5*0.1*2 +
3*5*1 + 2*10*1
= 60 + 30 + 20 + 15 + 18 + 9 + 5 +.6 +.9 + 1 + 15 + 20
= 194.5
B2 = packet overhead
= 2*10 + 2*1 = normal packet frequency + 2nd packet frequency
= 22
B1 = access overhead
= 1.7*10 = 17
Ct = collision bytes
= 3 (assuming one collision per second)
Network Utilization = (B1 + B2 + B3 + Ct)/960
= (194.5 + 22 + 17 + 3)/960
= 236.5/960 = 0.246
Network Utilization = 24.6%

AEB15.43
Page 40 of 64
Section III - Diagnostics Supported over Quantum Datalinks

The intent of this section is to discuss Quantum diagnostics that can be performed using standard
messages on J1939 and J1587 datalinks.
Supported Messages and Source Addresses for Clearing Faults

This section describes the J1939/J1587 messages that will be used by datalink devices to clear faults on
Quantum controllers. The intent is to allow clearing of faults on Quantum only by authorized source
addresses.
To clear faults on Quantum via J1939, the PGN 65,228 — Diagnostics Message #3 (DM3 - Diagnostic
Data Clear/Reset of Previously Active DTCs) can be used by a device making the request. Currently
there is no source address restriction from which this PGN will be accepted. This will change in future
revisions of Quantum product. All diagnostic information pertaining to previously active DTCs will be
erased when this PGN is received by Quantum controllers. Upon completion of this operation, a Positive
Acknowledgment will be sent using J1939-21 PGN 59392. If the operation is not completed, a Negative
Acknowledgment using PGN 59392 will be sent.
When clearing faults on Quantum via J1587, PID 195 — Diagnostic Data Request/Clear Count can be
used. For a list of authorized MIDs please refer to Error! Reference source not found.. When the bits
8-7 of diagnostic code character (please refer to J1587 specification for details of PID 195) are set to 00,
then the CUMMINS 3 digit fault code representing the PID or SID will be sent as a 3 digit ASCII character
in PID 196 format. If the requested PID/SID does not exist as an active/inactive fault, Quantum will
respond with number of parameter data characters “n” in PID 196 (please refer to J1587 specification for
details of PID 196) set to zero. For bits 8-7, the functions of states 01 and 11 as defined by SAE
Recommended Practice are not supported. When bits 8-7 are set to 10, then only the inactive faults will
be cleared. The Quantum acknowledges an authorized PID 195 request with a PID 196.
J1939/J1587 Messages for Clearing Faults

Authorized
PGN PID Parameter Description
Addresses/ MIDs
J1939 65,228 NA DM3 - Diagnostic Data Clear/Reset Any except those used
of Previously Active DTCs by Quantum
J1587 NA 195 Diagnostic Data/Request Clear 141,154, 172, 180, 182
Count
Quantum Diagnostic Information
Please refer to page 42 for a tabulation of all faults logged on Quantum engine platforms - The
corresponding Cummins service description, applicable SPN/FMI and/ or PIDs/SIDs/FMI information is
captured. The associated lamp action for the fault is also given. The Quantum diagnostics for both
J1939 and J1587 datalinks is also included.
Frequently Asked Questions on Cummins Datalinks
Question # 1 What is the impact on Quantum controllers of not receiving parameters it supports?
Answer: Cummins datalink message support can be divided in two categories to discuss the
possible impact on Quantum controllers of not receiving parameters it supports from other source
addresses - i). Powertrain messages and ii). Multiplexed Messages. The details are discussed below:
AEB15.43
Page 41 of 64
i). Impact of not receiving Powertrain Messages - In such a scenario the Quantum controller will function
by reverting to safe defaults and respond only to the operator requested torque and speed values.
ii). Impact of not receiving Multiplexed Messages - If the Quantum has been configured to receive
multiplexed messages and it does not receive them, then a configuration error will be logged in Quantum
and calibrated safe defaults values for such messages will be used by Quantum.
Question #2 How to Ensure Cummins Compatibility with New Datalink Devices?
Answer: Cummins is constantly working with OEMs and datalink device suppliers to ensure full
compatibility of all devices with our engines. When developing a new device that will interact with our
engine via the J1587 or J1939 datalinks, it is strongly recommended that you contact either your OEM
application engineer.
Note: Contacting Customer Engineering early in the design process provides a greater chance
for success in integrating a new device with Quantum controllers in the machine system.
Areas where Quantum Differs from Intent of SAE Recommended Practice
The implementation of the some PGNs/PIDs on Quantum differs from the intent of J1939/J1587. Where
needed, the difference will be removed in future revisions of the product. The list of specific PGNs/ PIDs
and their shift from J1939/J1587 intent is captured below:
• PGN 57344 (Cab Message #1) — Quantum does not broadcast this message currently. It is ONLY
received from other source addresses.
• The Request-PGN 59904 is NOT supported by Engine Retarder.
• In PGN 65247 (EEC3), the two parameters: i). Engine’s desired operating speed; and ii). Engines
operating speed asymmetry adjustment are calibrated (static) values.
• A request for PGN with data bytes greater than 8 causes a BAM and not RTS/CTS sequence as
specified by J1939-21.
• Progressive Shift Algorithm is not supported on Quantum, therefore enabling/disabling parameter -

Progressive Shift Disable in message ETC1, will have NO effect.
• PIDs 4, 97 and 187 are supported as On Request on Quantum controllers, whereas the SAE J1587
specification specifies their update rates to be periodic.
Note: Please be advised that if the PGN is a regular broadcast then the request for it may not be
honored because of ECM memory limitations. Please further be advised that SAE recommended
practices say do not ask for something that is regularly broadcast.
AEB15.43
Page 42 of 64
Table 5 – Fault Codes for Quantum Engines (* Denotes Cense Fault codes)
FAULT SID(S) SPN

CODE/ PID(P) FMI DESCRIPTION
QSK60
QSM11
QSK19
QSK45
LAMP FMI
QSX15
QST30
QSL9
QSB
QSC
111 S254 629 Engine Control Module – Critical X X X X X X X X X
internal failure
Red 12 12
112 S020 635 Engine Timing Actuator is not X X X
responding to ECM commands
Red 7 7
113 S020 635 Engine Timing Actuator Circuit - X X X X
shorted high
Yellow 3 3
114 S020 635 Engine Timing Actuator Circuit - X
shorted low
Yellow 4 4
115 P190 190 Engine Speed/Position Sensor Circuit - X X X X X X X X X
lost both of two signals from the
Red 2 2 magnetic pickup sensor
116 P156 156 Fuel Timing Pressure Sensor Circuit - X X X X X
shorted high
Red 3 3
117 P156 156 Fuel Timing Pressure Sensor Circuit - X X X X X
shorted low
Red 4 4
118 P135 135 Fuel Pump Delivery Pressure Sensor X X X X X
Circuit - shorted high
Yellow 3 3
119 P135 135 Fuel Pump Delivery Pressure Sensor X X X X X
Circuit - shorted low
Yellow 4 4
121 P190 190 Engine Speed/Position Sensor Circuit - X X X X X X X X
lost one of two signals from the
Yellow 10 10 magnetic pickup sensor
122 P102 102 Intake Manifold Pressure Sensor #1 X X X X X X X X X
Yellow 3 3
123 P102 102 Intake Manifold Pressure Sensor #1 X X X X X X X X X
Yellow 4 4
124* 102 High Intake Manifold Pressure Left X X X
Bank
Yellow 16
125* 102 Low Intake Manifold Pressure Left X X X
Bank
None 18
126* 1129 High Intake Manifold Pressure Right X X X
Bank
Yellow 16
127* 1129 Low Intake Manifold Pressure Right X X X
Bank
None 18
AEB15.43
Page 43 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
128* 1129 Right Bank Intake Manifold Pressure X X X
Sensor Circuit Failed High
None 3
129* 1129 Right Bank Intake Manifold Pressure X X X
Sensor Circuit Failed Low
None 4
131 P091 091 Accelerator Pedal Position Sensor X X X X X X X X X
Red 3 3
Red 4 4
133 P029 974 Remote Accelerator Pedal Position X X X X X X
Sensor Circuit - shorted high
Red 3 3
133 P029 29 Remote Accelerator Pedal Position X X X
Red 3 3
134 P029 974 Remote Accelerator Pedal Position X X X X X X
Sensor Circuit - shorted low
Red 4 4
134 P029 29 Remote Accelerator Pedal Position X X X
Red 4 4
135 P100 100 Engine Oil Pressure Sensor Circuit - X X X X X X X X X
shorted high
Yellow 3 3
136* 1208 Pre Filter Oil Pressure Sensor Circuit X X X
Failed High
None 3
137* 1208 Pre Filter Oil Pressure Sensor Circuit X X X
Failed Low
None 4
141 P100 100 Engine Oil Pressure Sensor Circuit - X X X X X X X X X
shorted low
Yellow 4 4
143 P100 100 Engine Oil Pressure Low - Warning X X X X X X
Yellow 1 18
143 P100 100 Engine Oil Pressure Low - Warning X X X
White 1 1
144 P110 110 Engine Coolant Temperature Sensor X X X X X X X X X
Yellow 3 3
145 P110 110 Engine Coolant Temperature Sensor X X X X X X X X X
Yellow 4 4
146 P110 110 Engine Coolant Temperature High - X X X
Warning
Yellow 0 16
AEB15.43
Page 44 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
Circuit - low frequency
Red 8 8
Circuit - high frequency
Red 8 8
151 P110 110 Engine Coolant Temperature High – X X X X X X
Critical
Red 0 0
151 P110 110 Engine Coolant Temperature High – X X X
Critical
White 0 0
153 P105 105 Intake Manifold Temperature Sensor X X X X X X X X X
#1 Circuit - shorted high
Yellow 3 3
154 P105 105 Intake Manifold Temperature Sensor X X X X X X X X X
#1 Circuit - shorted low
Yellow 4 4
155 P105 105 Intake Manifold Temperature #1 High - X X X X X X
Critical
Red 0 0
155 P105 105 Intake Manifold Temperature #1 High - X X X
Critical
White 0 0
156* 1131 Left Bank Rear Intake Manifold X X
Temperature Sensor Circuit Failed
Yellow 3 High
157* 1131 Left Bank Rear Intake Manifold X X
Temperature Sensor Circuit Failed Low
Yellow 4
158* 1131 High Intake Manifold Temperature - X X
Left Bank Rear
White 0
159* 1132 Right Bank Front Intake Manifold X X
Yellow 3 High
161* 1132 Right Bank Front Intake Manifold X X
Yellow 4
Right Bank Front
White 0
163* 1133 Right Bank Rear Intake Manifold X X
Yellow 3 High
164* 1133 Right Bank Rear Intake Manifold X X
Yellow 4
Right Bank Rear
White 0
AEB15.43
Page 45 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
166 S024 733 Rack Position Sensor #1 Circuit - X
shorted high
Yellow 3 3
172 S023 638 Rack Actuator Position #1 Circuit - X
grounded circuit
Red 6 6
173 S023 638 Rack Actuator - mechanically stuck X
open
Yellow 7 7
184 S233 609 Engine Control Module Identification X X X X
Input State Error
Yellow 2 2
185 S231 639 Engine Control Module Network X
Communication Error
Yellow 2 2
187 S232 620 Sensor Supply Voltage #2 Circuit - X X
shorted low
Yellow 4 4
211 S216 1484 Additional OEM/Vehicle Diagnostic X X
Codes have been logged. Check other
None 11 31 ECM's for DTC's.
211* 613 OEM Component Failure X X X
None 14
212 P175 175 Engine Oil Temperature Sensor Circuit X X X
- shorted high
Yellow 3 3
212* 175 Engine Oil Temperature Sensor Circuit X X
- shorted high
Yellow 3
213 P175 175 Engine Oil Temperature Sensor Circuit X X X
- shorted low
Yellow 4 4
213* 175 Engine Oil Temperature Sensor Circuit X X
- shorted low
Yellow 4
214 P175 175 Engine Oil Temperature High - Critical X X
Red 0 0
214* 175 Engine Oil Temperature High - Critical X X
White 0
219 P17 1380 Low Oil Level in the Centinel makeup X X
oil tank
Maint. 1 17
219 P17 1380 Low Oil Level in the Centinel makeup X X X
oil tank
White 1 1
221 P108 108 Ambient Air Pressure Sensor Circuit – X X X X X X X X
shorted high
Yellow 3 3
AEB15.43
Page 46 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
222 P108 108 Ambient Air Pressure Sensor Circuit – X X X X X X X X
shorted low
Yellow 4 4
223 S085 1265 Engine Oil Burn Valve Solenoid Circuit X X X X X
– shorted low
Yellow 4 4
225 S086 1266 Engine Oil Replacement Valve X X X
Solenoid Circuit - shorted low
Yellow 4 4
227 S232 620 Sensor Supply Voltage #2 Circuit - X X
shorted high
Yellow 3 3
231 P109 109 Engine Coolant Pressure Sensor X X X X
Yellow 3 3
232 P109 109 Engine Coolant Pressure Sensor X X X X
Yellow 4 4
233 P109 109 Engine Coolant Pressure Low - X
Warning
Yellow 1 18
233 P109 109 Engine Coolant Pressure Low - X X X
Warning
White 1 1
234 P190 190 Engine Speed High - Cricital X X X X X X X X X
Red 0 0
235 P111 111 Engine Coolant Level Low - Critical X X X X X X
Red 1 1
235 P111 111 Engine Coolant Level Low - Critical X X X
White 1 1
237 S030 644 External Speed Input (Multiple Unit X X X X
Sychronization) - data incorrect
Yellow 2 2
241 P084 084 Vehicle Speed Sensor Circuit - data X X X X X
incorrect
Yellow 2 2
242 P084 084 Vehicle Speed Sensor Circuit - X X X X X
tampering has been detected
Yellow 10 10
243 P121 513 Engine Brake Driver #1 Circuit - X X X
shorted low
Yellow 4 4
245 S033 647 Fan Clutch Circuit - shorted low X X X X X
Yellow 4 4
252 P098 098 Engine Oil Level #1 Sensor Circuit - X X X
data incorrect
Yellow 2 2
AEB15.43
Page 47 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
253 P098 098 Engine Oil Level #1 Low - Critical X X X
White 1 1
254 S017 632 Fuel Shutoff Valve Circuit - shorted low X X X
Red 4 4
254 S017 632 Fuel Shutoff Valve Circuit - shorted low X X X
None 4 4
255 S017 632 Fuel Shutoff Valve Circuit - shorted X X
high
Yellow 3 3
259 S017 632 Fuel Shutoff Valve - stuck open X X X X X
Red 7 7
261 P174 174 Fuel Temperature High - Warning X
Yellow 0 16
261 P174 174 Fuel Temperature High - Warning X X X
White 0 0
263 P174 174 Fuel Temperature Sensor Circuit - X X X X X
shorted high
Yellow 3 3
264 P174 174 Fuel Temperature Sensor Circuit - data X
out-of-range
Yellow 11 11
265 P174 174 Fuel Temperature Sensor Circuit - X X X X X
shorted low
Yellow 4 4
268 P094 94 Fuel Pressure Sensor Circuit - data X X
incorrect
Yellow 2 2
271 S126 1347 High Fuel Pressure Solenoid Valve #1 X X
Yellow 4 4
Yellow 3 3
Yellow 4 4
Yellow 3 3
275 S126 1347 Fuel Pumping Element #1 (Front) - X X
mechanically stuck
Yellow 7 7
276 S018 633 Fuel Injection Control Valve Circuit - X X
shorted high
Yellow 3 3
AEB15.43
Page 48 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
277 S018 633 Fuel Injection Control Valve - X X
mechanically stuck
Yellow 7 7
278 P073 1075 Fuel Priming Pump Control Circuit - X X X
shorted high/low
Yellow 11 11
279 S018 633 Fuel Injection Control Valve Circuit - X X
shorted low
Yellow 4 4
- mechanically stuck
Yellow 7 7
- mechanically stuck
Yellow 7 7
283 S221 1043 Engine Speed/Position Sensor #1 X X X
(Crankshaft) Supply Voltage Circuit -
Yellow 3 3 shorted high
284 S221 1043 Engine Speed/Position Sensor #1 X X X X
(Crankshaft) Supply Voltage Circuit -
Yellow 4 4 shorted low
285 S231 639 SAE J1939 Multiplexing PGN Timeout X X X X X
Error
Yellow 9 9
286 S231 639 SAE J1939 Multiplexing Configuration X X X X X
Error
Yellow 13 13
287 P091 91 SAE J1939 Multiplexing Accelerator X X X X X
Pedal Sensor System Error
Red 2 19
288 P029 974 SAE J1939 Multiplexing Remote X X X X X
Throttle Data Error
Red 2 19
292 P223 1083 Auxiliary Temperature Sensor Input # 1 X X X
Engine Protection - Critical
White 14 14
293 S441 441 Auxiliary Temperature Sensor Input # 1
Circuit – shorted high
Yellow 3 3
Yellow 3 3
293 S154 1083 Auxiliary Temperature Sensor Input # 1 X X
Yellow 3 3
294 S441 441 Auxiliary Temperature Sensor Input # 1
Circuit – shorted low
Yellow 4 4
Yellow 4 4
AEB15.43
Page 49 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
294 S154 1083 Auxiliary Temperature Sensor Input # 1 X X
Yellow 4 4
295 P108 108 Ambient Air Pressure Sensor Circuit - X X
data incorrect
Yellow 2 2
296 P223 1387 Auxiliary Pressure Sensor Input # 2 X X X
Red 14 14
White 14 14
Yellow 3 3
297 P223 1084 Auxiliary Pressure Sensor Input # 2 X X X X X
Yellow 3 3
Yellow 4 4
298 P223 1084 Auxiliary Pressure Sensor Input # 2 X X X X X
Yellow 4 4
299 S117 1384 Engine Shutdown Commanded by X X X
J1939
None 14 31
299 S117 1384 Engine Shutdown Commanded by X X
J1939
Yellow 11 31
311 S001 651 Injector Solenoid Valve Cylinder #1 X X
Circuit – grounded circuit
Yellow 6 6
Yellow 6 6
Yellow 6 6
Circuit - grounded circuit
Yellow 6 6
Yellow 6 6
316 S078 931 Fuel Supply Pump Actuator Circuit - X X X
shorted high
Yellow 3 3
318 S078 931 Fuel Supply Pump Actuator – X X X
mechanically stuck
Yellow 7 7
AEB15.43
Page 50 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
319 P251 251 Real Time Clock - Power Interrupt X X X X X
Maint. 2 2
321 S004 654 Injector Solenoid Valve Cylinder #4 X
Circuit - grounded circuit
Yellow 6 6
Circuit - open circuit
Yellow 5 5
Circuit – open circuit
Yellow 5 5
Yellow 5 5
Yellow 5 5
328 S152 1348 Fuel Pumping Element #2 (Rear) - X X
mechanically stuck
Yellow 7 7
329 S233 1077 Fuel System Leakage error X X
Yellow 14 14
Yellow 5 5
Yellow 5 5
341 S253 630 Engine Control Module – data lost X X
Yellow 2 2
342 S253 630 Engine Control Module – out of X
calibration
Red 13 13
343 S254 629 Engine Control Module - Warning X X X X X X
internal hardware failure
Yellow 12 12
346 S253 630 Engine Control Module - Warning X X X X X X
Software error
Yellow 12 12
349 P191 191 Transmission Output Shaft (Tailshaft) X X X X X
Speed High – Warning
Yellow 0 16
349 P191 191 Transmission Output Shaft (Tailshaft) X X X
Speed High – Warning
Yellow 0 0
352 S232 1079 Sensor Supply Voltage #1 Circuit - X X X X X
shorted low
Yellow 4 4
AEB15.43
Page 51 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
361 S251 1076 Fuel Pump Control Module, Fuel X
Control Valve Circuit - shorted high
Red 3 3
Control Valve Circuit - shorted low
Yellow 4 4
Control Valve - mechanically stuck
Yellow 7 7
364 S233 1077 Fuel Pump Control Module, CAN X
Communication Error - abnormal
Yellow 9 9 update rate
365 S233 1077 Fuel Pump Control Module, Supply X
Voltage Circuit - shorted low
Yellow 4 4
366 S233 1077 Fuel Pump Control Module, Supply X
Voltage Circuit - data incorrect
Yellow 2 2
367 P190 1078 Fuel Pump Control Module, Increment X
Angle Time Sensor Error
Yellow 11 11
368 S254 1078 Fuel Pump Control Module, Timing X
Error
Yellow 8 8
369 P190 1078 Fuel Pump Control Module, Engine X
Synchronization Error
Yellow 2 2
372 S233 1077 Fuel Pump Control Module, Idle X
Validation Error
Yellow 11 11
Shutoff Error
Red 3 3
374 S233 1077 Fuel Pump Control Module, Self-Test X
Error
Yellow 12 12
375 S254 629 Fuel Pump Control Module, Electronic X
Yellow Calibration Code Error
2 2
376 S233 1077 Fuel Pump Control Module, Fueling or X
Engine Speed Mismatch
Yellow 13 13
377 S233 1077 Fuel Pump Control Module, Stuck X
Relay Error
Yellow 7 7
378 S018 633 Fueling Actuator #1 Circuit - open X
circuit
Yellow 5 5
379 S018 633 Fueling Actuator #1 Circuit - grounded X
circuit
Yellow 6 6
AEB15.43
Page 52 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
381 S237 626 Intake Air Heater (Relay Enable) #1 X X X
Circuit - data incorrect
Yellow 11 11
382 S237 626 Intake Air Heater (Relay Enable) #2 X X X
Yellow 11 11
384 S237 626 Start Assist Device Control Circuit X X X
Error (Ether Injection)
Yellow 11 11
385 S232 620 OEM Sensor Supply Voltage Circuit - X X X
shorted high
Yellow 3 3
386 S232 1079 Sensor Supply Voltage #1 Circuit - X X X X X
shorted high
Yellow 3 3
387 S221 1043 Accelerator Pedal Position Sensor X X X X X
Supply Voltage Circuit - shorted high
Yellow 3 3
389 S033 647 Fan Clutch Circuit Error X X X
Yellow 11 11
391 S017 632 Fuel Shutoff Valve Supply Voltage X
error
Yellow 11 11
394 S020 635 Timing Actuator #1 Circuit - open X
circuit
Yellow 5 5
395 S020 635 Timing Actuator #1 Circuit - grounded X
circuit
Yellow 6 6
396 S083 1244 Fueling Actuator #2 Circuit - open X
circuit
Yellow 5 5
397 S083 1244 Fueling Actuator #2 Circuit - grounded X
circuit
Yellow 6 6
398 S084 1245 Timing Actuator #2 Circuit - open X
circuit
Yellow 5 5
399 S084 1245 Timing Actuator #2 Circuit - grounded X
circuit
Yellow 6 6
414* S250 608 Data Communication error over the X
J1587 data link Circuit
Yellow 9 9
415 P100 100 Engine Oil Pressure Low – Critical X X X X X X
Red 1 1
415 P100 100 Engine Oil Pressure Low – Critical X X X
White 1 1
AEB15.43
Page 53 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
418 P097 097 Water in Fuel Indicator High – X X X X X X
Maintenance
WIF / 0 15
Maint.
419 1319 Intake Manifold Boost Pressure X
Imbalance
Yellow 2
422 P111 111 Engine Coolant Level Sensor Circuit - X X X X X X X X X
data incorrect
Yellow 2 2
423 P156 156 Fuel Timing Pressure or Timing X X X X
Actuator Stuck
Yellow 2 2
426 S231 639 SAE J1939 datalink - cannot transmit X X
None 2 2
426 S231 639 SAE J1939 datalink - cannot transmit X X X
Yellow 2 2
426* 639 SAE J1939 datalink - cannot transmit X X X
None 2
427 S231 639 SAE J1939 not fast enough X X X
None 9
428 P097 97 Water in Fuel Sensor Circuit - shorted X X X
high
Yellow 3 3
429 P097 097 Water in Fuel Sensor Circuit - shorted X X X X X X
low
Yellow 4 4
431 S230 558 Accelerator Pedal Idle Validation X X X X X X
Yellow 2 2
431 P091 91 Accelerator Pedal Idle Validation X X X
Yellow 2 2
Circuit - out of calibration
Red 13 13
Circuit - out of calibration
Red 13 13
433 P102 102 Intake Manifold Pressure Sensor X X X X X
Yellow 2 2
434 S251 627 Power Lost without Ignition Off X X X X X
Yellow 2 2
435 P100 100 Engine Oil Pressure Sensor Circuit - X X
data incorrect
Yellow 2 2
AEB15.43
Page 54 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
441 P168 168 Battery #1 Voltage Low - Warning X X X X X X
Yellow 1 18
441 P168 168 Battery #1 Voltage Low - Warning X X X
None 1 1
442 P168 168 Battery #1 Voltage High - Warning X X X X X X
Yellow 0 16
442 P168 168 Battery #1 Voltage High - Warning X X X
Yellow 0 0
443 S221 1043 Accelerator Pedal Position Sensor X X X X X
Supply Voltage Circuit - shorted low
Yellow 4 4
444 S232 620 OEM Sensor Supply Voltage Low - X X X
Warning
Yellow 1 18
446* N/A GSP Communication Failure X X X
None
447* N/A RPC Number Not Supported X X X
None
448* N/A RPC Argument Mismatch X X X
None
449 P094 094 Fuel Pressure High - Warning X X X
Yellow 0 16
451 P157 157 Injector Metering Rail #1 Pressure X X X
Yellow 3 3
Red 3 3
Yellow 4 4
Red 4 4
455 S018 633 Fuel Control Valve Circuit - shorted X X X
high
Red 3 3
466 S032 1188 Turbocharger #1 Wastegate Control X
Yellow 4 4
467 S020 635 Timing Rail Actuator Circuit - data X X X
incorrect
Yellow 2 2
AEB15.43
Page 55 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
468 S018 633 Fuel Rail Actuator Circuit - data X X X
incorrect
Yellow 2 2
471 P098 98 Engine Oil Level Low - Maintenance
Maint. 1 17
471 P098 98 Engine Oil Level Low - Maintenance X X X
Maint. 1 1
472 P017 1380 Engine Oil Level #2 Low – X X X
Maintenance
Maint. 2 2
473 P017 1380 Engine Oil Level #2 Low – Warning X X X
Yellow 2 2
479* 1318 Exhaust Port Temperature Bank X
Imbalance
None 9
482 P094 094 Fuel Pressure Low - Warning X
Yellow 1 18
483 P129 1349 Injector Metering Rail #2 Pressure X
Yellow 3 3
Yellow 4 4
High - Warning
Yellow 0 16
486 P129 1349 Injector Metering Rail #2 Pressure Low X
- Warning
Yellow 1 18
487 S237 626 Start Assist Device - Canister Empty X X X
(Ether Injection)
None 1 1
488 P105 105 Intake Manifold Temperature High – X X X
Warningl
Yellow 0 16
489 P191 191 Transmission Output Shaft (Tailshaft) X X X X X
Speed Low – Warning
Yellow 1 18
489 P191 191 Transmission Output Shaft (Tailshaft) X X X
Speed Low – Warning
Yellow 1 1
493 S018 1076 Fuel Pump Calibration Trim Circuit X X
Error
13 13
496 S221 1043 Engine Speed/Position Sensor #2 X
(Camshaft) Supply Voltage
Yellow 11 11
AEB15.43
Page 56 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
497 S114 1377 Multiple Unit Synchronization Switch X X X X X X
Yellow 2 2
514 S018 633 Fuel Control Valve - mechanically X X X
stuck
Red 7 7
515 P091 091 Accelerator Pedal Frequency Position X X X
Sensor Supply Circuit - shorted high
Yellow 3 3
516 P091 091 Accelerator Pedal Frequency Position X X X
Sensor Supply Circuit - shorted low
Yellow 4 4
517 S251 1076 Fuel Metering Solenoid - bad device X
Yellow 12 12
524 P113 113 OEM Alternate Droop Switch X X X X
Validation - data incorrect
Yellow 2 2
527 P154 702 Auxiliary Input/Output #2 Circuit - X X X X X X
Yellow shorted high
3 3
527 S040 702 Auxiliary Input/Output #2 Circuit - X X X
Yellow shorted high
3 3
528 P093 093 OEM Alternate torque validation switch X X X X X X
- data incorrect
Yellow 2 2
529 S051 703 Auxiliary Input/Output #3 Circuit - X X X X X X X X X
shorted high
Yellow 3 3
539 S018 633 Injector Control Valve Electronic Filter X X
(Transorb) Error
Yellow 11 11
546 P094 94 Fuel Delivery Pressure Sensor Circuit - X
shorted high
Yellow 3 3
547 P094 94 Fuel Delivery Pressure Sensor Circuit- X
shorted low
Yellow 4 4
Yellow 4 4
Red 4 4
High - warning level
Yellow 0 16
Red 0 0
AEB15.43
Page 57 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
54 P157 157 Fuel Pressure Sensor Error X X X
Yellow 2 2
555 P022 1264 Engine Blowby - Warning Level X
Yellow 0 16
555 P022 1264 Engine Blowby - Warning Level X X X
White 0 0
581 P015 1381 Fuel Supply Pump Inlet Pressure X X
Yellow 3 3
582 P015 1381 Fuel Supply Pump Inlet Pressure X X
Sensor Circuit – shorted low
Yellow 4 4
583 P015 1381 Fuel Supply Pump Inlet Pressure Low - X X
warning level
Yellow 1 18
595 P103 103 Turbocharger #1 Speed High - warning X
level
Yellow 0 16
596 P167 167 Electrical Charging System Voltage X X
Yellow 0 16
Low - Warning Level
Yellow 1 18
Low - Critical Level
Red 1 1
599 S025 640 OEM Commanded Dual Output X X X
Shutdown
Red 14 14
611 S151 1383 Engine Hot Shutdown X X X X X
None 11 31
611 S151 1383 Engine Hot Shutdown X X X X
None 14 31
612* 99 High Lubricating Oil Filter Restriction X X X
Red 1
616* 1173 High Turbo Compressor Inlet Temp RB X X
None 16
617* 1172 High Turbo Compressor Inlet Temp LB X
None 0
621* 1137 Low #1 LB Cylinder Power X X X
Yellow 18
AEB15.43
Page 58 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
Yellow 18
Yellow 18
Yellow 18
Yellow 18
Yellow 18
627* 1143 Low #7 LB Cylinder Power X
Yellow 18
628* 1144 Low #8 LB Cylinder Power X
Yellow 18
631* 1143 (45) Low #1 RB Cylinder Power X X
1145 (60)
Yellow
18
631* 1329 Low #1 RB Cylinder Power X
Yellow 1
1146 (60)
Yellow
18
Yellow 1
1147 (60)
Yellow
18
Yellow 1
1148 (60)
Yellow
18
Yellow 1
AEB15.43
Page 59 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
1149 (60)
Yellow
18
Yellow 1
1150 (60)
Yellow
18
Yellow 1
Yellow 18
Yellow 18
641* 1137 High #1 LB Cylinder Exhaust X X X
Temperature
Red 0
Temperature
Red 0
Temperature
Red 0
Temperature
Red 0
Temperature
Red 0
Temperature
Red 0
647* 1143 High #7 LB Cylinder Exhaust X
Temperature
Red 0
648* 1144 High #8 LB Cylinder Exhaust X
Temperature
Red 0
649 S115 1378 Change Lubricating Oil and Filter X X X
None 0 0
AEB15.43
Page 60 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
QSX15
LAMP FMI
QST30
QSL9
QSB
QSC
649* Change Lubricating Oil and Filter X X X
None
651* 1143 (30,45) High #1 RB Cylinder Exhaust X X X
1145 (60) Temperature
Red
0
Red
0
Red
0
654* 1146 (30,45) High #4 RB Cylinder Exhaust X X
Red
0
Red
0
Red
0
657* 1150 High #7 RB Cylinder Exhaust X
Temperature
Red 0
658* 1151 High #8 RB Cylinder Exhaust X
Temperature
Red 0
659* Change fuel filter X X X
None
661* 1137 High #1 LB Cylinder Power X X
Yellow 16
661* 1323 High #1 LB Cylinder Power X
Yellow 0
Yellow 16
Yellow 0
Yellow 16
AEB15.43
Page 61 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
LAMP FMI
QSX15
QST30
QSL9
QSB
QSC
Yellow 0
Yellow 16
Yellow 0
Yellow 16
Yellow 0
Yellow 16
Yellow 0
Yellow 16
Yellow 16
669* Change coolant filter X X X
None
671* 1137 Cyl #1 LB Exhaust Temp Sens Failed X X X
Low
None 4
Low
None 4
Low
None 4
Low
None 4
Low
None 4
Low
None 4
677* 1143 Cyl #7 LB Exhaust Temp Sens Failed X
Low
None 4
678* 1144 Cyl #8 LB Exhaust Temp Sens Failed X
Low
None 4
AEB15.43
Page 62 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
LAMP FMI
QSX15
QST30
QSL9
QSB
QSC
679* Change Coolant X X X
None
691* 1172 LBF Turbo Comp Inlet Temp Sens X
Failed High
None 3
692* 1172 LBR Turbo Comp Inlet Temp Sens X
Failed Low
None 4
694* 1173 RBF Turbo Comp Inlet Temp Sens X X
Failed High
None 3
695* 1174 RBR Turbo Comp Inlet Temp Sens X X
Failed Low
None 4
711* 1143 (45) High #1 RB Cylinder Power X X
1145 (60
Yellow
16
711* 1329 High #1 RB Cylinder Power X
Yellow 0
1146 (60)
Yellow
16
Yellow 0
1147 (60)
Yellow
16
Yellow 0
1148 (60)
Yellow
16
Yellow 0
Yellow 1148 (60)
16
Yellow 0
Yellow 1149 (60)
16
AEB15.43
Page 63 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
LAMP FMI
QSX15
QST30
QSL9
QSB
QSC
Yellow 0
Yellow 0
Yellow 0
719 P022 1264 Crankcase Blowby Pressure Sensor X X X X
Yellow 3 3
721* 1143 (30,45) Cyl #1 RB Exhaust Temp Sens Failed X X X
1145 (60) Low
None
4
1146 (60) Low
None
4
1147 (60) Low
None
4
1148 (60) Low
None
4
Low
None 1149 (60)
4
Low
None 1150 (60)
4
727* 1151 Cyl #7 RB Exhaust Temp Sens Failed X
Low
None 4
728* 1152 Cyl #8 RB Exhaust Temp Sens Failed X
Low
None 4
729 P022 1264 Crankcase Blowby Pressure Sensor X X X X
Yellow 4 4
747* Trend Data Memory Nearly Full X X X
None
748* Trend Data Memory Full X X X
None
749* Fault Log Snapshot Data Nearly Full X X X
None
AEB15.43
Page 64 of 64
FAULT SID(S) SPN
QSK60
QSM11
QSK19
QSK45
LAMP FMI
QSX15
QST30
QSL9
QSB
QSC
753 S064 723 Engine Speed/Position #2 - Cam sync X X X X
error
None 2 2
754* Fault Log Snapshot Data Full X X X
None
Malfunction
Yellow 7 7
756* Change Lubricating Oil Filters X X X
None
757* Catastrophic Power Loss - ECM Data X X X
Lost
None
Malfunction
Yellow 7 7
768 S009 923 Output Device Driver (VGT or X X X
Transmission shift PWM signal)
Yellow 11 11
777 P173 1180 Turbocharger #1 Turbine Inlet X X X
Temperature High - warning level
Yellow 0 0
779 S051 703 Auxiliary Equipment Sensor Input # 3 X X X
(OEM Switch)
Yellow 11 11
951 P166 166 Cylinder Power Imbalance between X X
cylinders
None 2 2
1000* Vehicle Controller initiated fault log X
None
2154* 611 Post-Filter Oil Pressure Sensor Circuit- X X X
Shorted high
None 3
2155* 611 Post-Filter Oil Pressure Sensor Circuit- X X X
Shorted Low
None 4
2194 P223 1387 Auxiliary Equipment Sensor Input # 2 X X X
(OEM Pressure Sensor) Engine
Yellow 11 11 Protection – Warning
2195 S051 703 Auxiliary Equipment Sensor Input # 3 X X X
(OEM Switch) Engine Protection -
Red 14 14 Critical
Section
4
ELECTRICAL
4
How it Works
ZTX Series Tractors

DT50-50270 March 2004
SECTION!4

SECTION!4
Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !Page
Introduction ............................................................................................................4
What!!is!CAN!BUS .................................................................................................4
Diagram!of!CAN!BUS!layout ..................................................................................5
Description!of!control!modules ...............................................................................5
Control!module!location..........................................................................................6
Description!of!new!instrument!cluster!....................................................................9
Instrument!panel!functions .....................................................................................10
Operating!the!Instrument!panel..............................................................................10
Fault!codes!!...........................................................................................................11
McCormick!Diagnostic!tool!!...................................................................................12

SECTION!4
Introduction
The!electrical!system!used!on!ZTX!is!a!CAN!BUS!system.!Using!this!system!has
allowed!McCormick!tractors!to!fully!integrate!all!the!different!areas!of!the!tractor!and
bring!them!together!to!work!as!one.
It! has! also! allowed! the! total! number! of! wires! running! around! the! tractor! to! be! cut
down!for!maximum!reliability!and!the!time!it!takes!for!messages!to!be!passed!from
component!to!component!has!been!vastly!reduced!and!therefore!smoother!operation
and!greater!productivity!can!be!achieved.
What!is!CAN!BUS
CAN!BUS!is!the!name!that!is!given!to!the!method!of!data!transfer,!on!many!types!of
machinery!now.!Its!name!comes!from!the!computer!industry,!and!stands!for;
Computer!Area!Network
This!term!simply!means!the!networking!of!components!and!controllers!and!within
this!network!the!exchange!of!data!between!components!via!a!data!bus!system.
CAN!BUS!in!very!basic!terms!is!a!pair!of!insulated!wires!twisted!together!that!run
around!the!tractor!between!each!control!module!and!some!components,!and!are
joined!at!each!end!by!a!terminal!resistor.!These!wires!therefore!are!the
communication!link!for!the!whole!of!the!tractor.!The!engineering!name!for!these
wires!is!CAN!High!and!CAN!Low.!These!wires!are!very!often!green!and!yellow
colours.
This!means!that!ultimately!each!component!that!is!controlled!by!a CAN!BUS!link
only!needs!4!wires!to!it.!These!are!CAN!High,!CAN!Low,!B+!(power)!and!Ground
(earth).
Electrical!messages!are!then!sent!out!around!the!can!bus!system!as!digital!pulses,
and!are!seen!by!all!the!components!linked!to!the!CAN!BUS.
Depending!on!the!type!of!messages!sent!on!the!CAN!BUS!the!number!of!messages
seen!at!any!one!time!can!be!between!781!messages!per!second!and!1851
messages!per!second.
Although!all!components!see!all!the!messages!they!will!only!act!on!the!messages
that!are!relevant!at!the!time!to!themselves.!This!is!because!each!message!has!an
identifier!(address)!attached!to!it
This!means!that!all!the!control!modules!are!constantly!linked!and!as!soon!as!one
sends!out!a!signal!that!all!other!modules!need!to!act!on,!they!can!do!so!immediately.
There!is!however!a!priority!system!in!place!that!will!allow!more!important!messages
to!be!transferred!before!non!important!ones.
Because!of!this!most!of!the!wires!found!on!the!tractor!will!actually!be!connecting
sensors,!switches,!solenoids,!potentiometers!and!lights!to!the!control!modules.

SECTION!4
Line!drawing!of!ZTX!CAN!BUS
Climate
Diagnostic Instrument
Control Hitch
Socket Cluster
Module Control
Module
Terminal Terminal
Resister Resister
Engine Transmission
McCormick Auxiliary!Valve
Control Controller
Tractors Control!Module
Module
Cab!Controller
Control!Modules!(Controllers)
There! are! 7! separate! control! modules! located! around! the! tractor! to! control! its
functions!these!are!as!follows.
•! McCormick!Cab!Controller!Module
•! McCormick!Instrument!Cluster
•! Hitch!Controller
•! Auxiliary!Valve!Control!Module
•! Engine!Control!Module.
•! Transmission!Control!Module
•! Climate!Control!Module,!(Not!linked!on!the!CAN.)
These! modules! above! fit! into! two! different! categories,! they! are! either! intelligent
modules!that!can!analyse!data!and!act!on!it!or!they!are!dumb!modules!that!control
what!they!are!told!to!do.

SECTION!4
Controller!locations
Engine
Controller
Transmission
Controller

SECTION!4
The!following!controllers!are!mounted!underneath!the!rear!cab
trim!panel.
McCormick!Cab
Auxiliary/Remote Controller
Hitch!(Bosch)
Valve!Controller
Controller

SECTION!4
The!climate!control!module!is!located!within!the!climate!control
unit
The!instrument!cluster!is!also!a!controller

SECTION!4
Description!of!new!instrument!cluster
The!new!instrument!cluster!can!be!split!into!4!main!sections!these!are:!Warning
lamps,!analogue!type!gauges,!touch!sensitive!buttons,!and!the!main!digital!display.
The!main!digital!display!is!made!up!using!a!conventional!lead!crystal!display!and
uses!LED`s!(Light!emitting!diodes)!to!show!the!symbols!and!digits!on!its!display
screen.!This!feature!allows!the!Instrument!panel!contrast!to!be!changed!and!means
that!the!all!functions!can!also!be!clearly!seen!and!read!regardless!of!light!conditions.
The!2!rows!of!touch!sensitive!buttons!allow!the!operator!to!programme!the
Instrument!functions,!calibrate!speed!and!area!functions!and!carry!out!further
calibrations!of!the!tractor!and!also!extract!stored!information.
The!analogue!gauges!are!for!fuel!level,!water!temperature,!and!air!trailer!brake
system!pressure!(if!fitted),!-!(These!gauges!are!all!stepper!motor!type!gauges).
Touch!senitive Analogue
buttosns gauges
Digital
display
Indicator
lamps

SECTION!4
Instrument!cluster!functions
The!Instrument!cluster!functions!can!be!split!into!3!main!areas!these!are,!tractor
function!information,!tractor!performance!information,!and!the!programming!modes.
The!tractor!function!information!is!constantly!visible!on!all!the!lights!and!gauges.
The!tractor!performance!information!mode,!allows!the!operator!to!set!calibrations!for
functions!such!as!wheel!slip,!hitch!position!indicator!display,!forward!speed,!fuel
remaining!timer,!and!area!meter,!and!trip!and!total!distance.
The!programming!mode!allows!the!operator!to!set!the!tractors!calibrations!for
variations!in!things!such!as!metric!or!imperial!speed!functions,!different!tyre!sizes,
service!interval!lengths,!implement!widths,!PTO!constants,!and!true!ground!speed
(radar)!constants.
Should!the!Instrument!cluster!have!to!be!replaced!at!any!time,!it!is!tamper!proof!,
and!the!old!machine!hours!cannot!be!put!onto!the!new!Instrument!to!run
consecutively,!however!the!old!hours!can!be!stored!to!allow!the!total!recorded!hours
to!be!kept!!within!the!Instrument!cluster.
Operating!the!Instrument!cluster
The!Instrument!cluster!is!operated!by!turning!the!key!switch!to!either!the!ignition!on
stage,!for!the!tractor!performance!info!mode,!(called!universal!data!display!in
operators!manual)!or!turning!the!key!backwards!into!the!accessory!position!for!the
programming!mode.!Then!by!pressing!the!correct!combination!of!touch!sensitive
buttons!(that!are!situated!on!top!of!the!two!blocks!of!warning!lights!on!either!side!of
the!panel)!you!can!enter!and!view!or!edit!specific!information.
For!most!functions!it!is!first!necessary!to!enter!the!programming!mode,!once!in!this
mode,!by!using!the!arrow!keys!to!scroll!up!and!down!the!main!menu!functions.!From
this!certain!menus!have!subsequent!sub!menus,!where!by!pressing!the!menu!button
you!can!enter!the!sub!menu!to!either!view!or!edit!specific!information.

SECTION!4
Fault!codes
The!tractor!has!the!ability!to!display!active!error!codes!on!via!the!instrument!cluster.
These!codes!are!split!into!different!categories!and!different!levels!of!severity,
according!to!the!level!of!damage!that!could!occur!if!the!tractor!was!operated!with!a
fault.!These!codes!can!be!used!to!help!diagnose!and!repair!problems!with!the
tractor.
There!are!2!ways!that!error!codes!can!be!read!these!are!:-
•! Directly!from!the!Instrument!panel.!(Active!codes!only)
•! Using!the!McCormick!diagnostic!tool.
It!should!be!noted!that!not!all!the!error!codes!can!be!read!from!the!instrument
cluster,!and!that!the!only!way!to!retrieve!ALL!error!codes!is!via!the!McCormick
diagnostic!tool.
Instrument!board!displayed!codes
-
The!codes!that!are!displayed!on!the!Instrument!are!shown!on!the!left!hand!side!of
the!display!as!indicated.!There!will!be!an!exclamation!mark!shown!on!the!display!to
indicate!that!there!is!a!code,!and!by!pressing!the!menu!key!on!the!panel!the!Failure
mode!identifier!(FMI)!or!Suspect!parameter!number!(SPN),!or!both!will!be!shown
with!the!error!code.!This!code!can!then!be!diagnosed!from!the!table!in!the!service
manual.
Error!codes!are
shown!here

SECTION!4
McCormick!Diagnostic!tool
A!laptop!based!service!tool!is!available!to!carry!out!several!procedures!on!the
tractor.
•! The!down!loading!of!control!modules!with!new!software.
•! The!setting!up!of!the!tractors!functions.
•! The!setting!of!some!default!values.
•! The!set!up!of!extra!or!replacement!auxiliary!valves.
•! The!retrieval,!and!erasing!of!error!codes.
In!order!to!connect!the!laptop!to!the!tractor!you!must!use!an!AVG!interface!between
the!laptop!and!the!tractor,!!this!basically!allows!the!J1939!CAN!messages!from!the
tractor!to!be!converted!into!hexi-decimal!computer!messages!and!the!computer
messages!back!to!J1939.
The!part!number!of!the!AVG!is!1014T1.
The!laptop!then!plugs!into!the!AVG!via!its!USB!port!(a!USB!A!to!B!connector!lead
will!also!be!required!-!This!is!the!type!of!lead!commonly!used!to!connect!a!PC!to!a
printer!via!its!USB!port)!and!the!AVG!interface!box!plugs!into!the!diagnostic!socket
located!under!the!right!hand!side!of!the!instrument!panel.

4001
Section
4001
Electrical Schematics
ZTX Series Tractors

SM 8-12540 September 2004
2 SECTION 4001
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 4
CIRCUIT TESTING
General Information.............................................................................................................................................. 5
FUSE LOCATION AND IDENTIFICATION

(European Specification Tractors) ............................................................................................................................ 8

(American Specification Tractors)........................................................................................................................... 10
COMPONENT IDENTIFICATION
Hood Components ............................................................................................................................................. 12
Engine Components ........................................................................................................................................... 13
Instrument Panel Component............................................................................................................................. 14
Right Hand Console Harness Components ....................................................................................................... 15
Armrest Components ......................................................................................................................................... 16
Rear Fender Components .................................................................................................................................. 17
Cab Components ............................................................................................................................................... 18
Cab Roof Panel Components............................................................................................................................. 19
NEUTRAL START, COLD START, KEY SWITCH, CAB POWER,

WATER IN FUEL AND THROTTLE
Starter Circuit .................................................................................................................................................20
Cold Start Circuit ............................................................................................................................................20
Hand Throttle Circuit ......................................................................................................................................21
Foot Throttle Circuit ........................................................................................................................................21
Accessory Power Relay .................................................................................................................................21
Cab Power Relay ...........................................................................................................................................21
Schematic Circuit ........................................................................................................................................... 22
IMPLEMENT INTERFACE CONNECTOR, AUXILIARY POWER

CONNECTORS AND BEACON LIGHT
Implement Interface Connector Circuit ...........................................................................................................24
Front and Rear 3 Pin Auxiliary Power Connector Circuit ...............................................................................24
Switched Fender Auxiliary Power Connector Circuit ......................................................................................24
Beacon Light ..................................................................................................................................................24
HORN, CIGAR LIGHTER AND SEAT

Horn Circuit ....................................................................................................................................................26
Cigar Lighter Circuit. ......................................................................................................................................26
Electric Air Seat Circuit ..................................................................................................................................26
RADIO AND INTERIOR LIGHT

Radio Circuit ...................................................................................................................................................28
Interior Light Circuit ........................................................................................................................................28
BRAKE LIGHTS AND AIR TRAILER BRAKE

(European Specification Tractors Only)
Brake Light Circuit ..........................................................................................................................................34
Air Trailer Brake Solenoid Circuit ...................................................................................................................34
SM 8-12540 Issued 09-2004

SECTION 4001 3
SIDE/TAIL LIGHTS, NUMBER PLATE LIGHTS, RIGHT HAND CONSOLE LIGHT,TURN SIGNAL AND HAZARD
WARNING LIGHTS
Side/Tail Light, Number Plate Light and
Right Hand Console Light Circuits .............................................................................................................37
Turn Signal and Hazard Warning Light Circuits .............................................................................................37
TURN SIGNAL/WARNING LIGHTS

(American Specification Tractors Only)
Turn Signal and Warning Light Circuits .........................................................................................................41
GRILLE HEADLIGHTS, CAB MOUNTED HEADLIGHTS

AND REAR FOG LIGHTS
Grille Headlights Circuit .................................................................................................................................44
Cab Mounted Headlights Circuit ....................................................................................................................45
Rear Fog Lights Circuit ..................................................................................................................................46
TAIL LIGHTS, RIGHT HAND CONSOLE LIGHT AND HEADLIGHTS

Tail Light Circuit .............................................................................................................................................49
Right Hand Console Light Circuit ...................................................................................................................49
Headlights Circuit ...........................................................................................................................................49
WORK LIGHTS
Rear Work Light Circuit ..................................................................................................................................53
Front Work Light Circuit .................................................................................................................................54
WORK LIGHTS
Rear Work Light Circuit ..................................................................................................................................57
Front Work Light Circuit .................................................................................................................................58
MAIN CONNECTORS ............................................................................................................................................ 60
AUXILIARY/REMOTE VALVE CONTROLLER ...................................................................... Refer to Section 10001
HITCH CONTROLLER ........................................................................................................... Refer to Section 10002
FRONT SUSPENDED AXLE ................................................................................................. Refer to Section 10003
TRANSMISSION AND CAB (MCC) CONTROLLERS ........................................................... Refer to Section 10006
INSTRUMENT CLUSTER CONTROLLER ............................................................................ Refer to Section 10009
AUTOMATIC TEMPERATURE CONTROL ........................................................................... Refer to Section 10012
SM 8-12540 Issued 09-2004

4 SECTION 4001
SPECIAL TOOLS
DD98H120 DD97E383
MC2616 MULTIMETER KIT includes: MC31000 HARNESS REPAIR KIT

MC2616-1 MULTIMETER ONLY
MC2616-2 TEST LEADS
MC2616-3 TEMPERATURE PROBE
DI97K101
MC2530 and MC2531 CAB ROOF TILT TOOLS

DD99A051
MC2656 TEST PROBE KIT
SM 8-12540 Issued 09-2004

SECTION 4001 5
CIRCUIT TESTING
General Information
WARNING: Never operate the engine in a closed building. Proper

! ventilation is required under all circumstances.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with park
brake engaged, the F/N/R/P lever in Neutral and the engine OFF, unless otherwise stated.
IMPORTANT: Put blocks in front of and behind the rear wheels.
IMPORTANT: The batter y must be at full charge and all connections must be clean and tight before
testing. Only use a HIGH IMPEDANCE multimeter for the tests. Do not use a test lamp or damage to the
switches may occur.
IMPORTANT: Use MC2656 test probe kit when making electrical checks at connectors to avoid the risk
of shorting between the connector pins or terminals.
IMPORTANT: Replace the controller if the fault remains only after all necessar y checks have been
made.
IMPORTANT: When disconnecting harness connectors, always check the connector pins and terminals
for damage and alignment.
NOTE: When measuring resistance values, always measure the resistance of the multimeter leads
before testing components. Subtract the resistance of the multimeter leads from the component
resistance to obtain a true resistance value.
NOTE: When testing diodes and diode modules use the multimeter diode test function.
NOTE: All components, wires and connectors disconnected during any electrical checks must be
connected when the checks are completed
SM 8-12540 Issued 09-2004

6 SECTION 4001
Schematic Symbols
ACTUATORS
LEVER HAND FOOT TEMPERATURE
LIQUID LEVEL FLOAT PRESSURE COIL DIODE
CONTACTS
MOMENTARY
MAINTAINED
VARIABLE RESISTOR RESISTOR MAGNETIC
HOUSINGS
V P T M
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LIGHT
SWITCH CONTACT CONFIGURATION
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.

(SINGLE POLE SINGLE (SINGLE POLE DOUBLE (DOUBLE POLE SINGLE (DOUBLE POLE DOUBLE
THROW) THROW) THROW) THROW)
MISCELLANEOUS SYMBOLS
FUSE CIRCUIT BREAKER
NOTE: Schematic symbols shown with tractor parked and power OFF.
SM 8-12540 Issued 09-2004

SECTION 4001 7
Schematic Legend
123 Y 1.0 CIRCUIT TAG IF REQUIRED
CIRCUIT NUMBER WIRE SIZE mm2

COLOUR
CONNECTOR TERMINAL
00 INDICATES INLINE CONNECTION WITH

00 TERMINALS
CONNECTOR IDENTIFICATION
INDICATES CIRCUIT CONNECTION TO

BATTERY POWER OR SWITCHED POWER STUD
INDICATES CIRCUIT SPLICE CONNECTION
INDICATES CIRCUIT CAB MAIN SPLICE

CONNECTION
INDICATES CIRCUIT CROSSING NOT

CONNECTED
INTERNAL INDICATES CHASSIS GROUND CONNECTIONS
EXTERNAL
GROUND
Wire Colour Code

R................................................................................ RED
T ................................................................................. TAN
W........................................................................... WHITE
Y........................................................................ YELLOW
B ........................................................................... BLACK
G ............................................................................ GREY
O ....................................................................... ORANGE
P............................................................................... PINK
V......................................................... VIOLET (PURPLE)
BR ...................................................................... BROWN
DB ................................................................ DARK BLUE
DG............................................................. DARK GREEN
LB ............................................................... LIGHT BLUE
LG ............................................................. LIGHT GREEN
SM 8-12540 Issued 09-2004
8 SECTION 4001

(European Specification Tractors)
MI03G058
To gain access to the fuses remove the instrument

panel left hand side cover.
41 42 43 44
37 38 39 40
33 34 35 36
29 30 31 32
22 23 24 25 26 27 28
15 16 17 18 19 20 21
8 9 10 11 12 13 14
1 2 3 4 5 6 7
NOTE: Locations 3, 9, 10, 12, 32 and 44 are mini circuit breakers, which will reset automatically.
Fuse No Circuit Amps

HORN 15
1
# SEAT, HORN 15
2 FRONT LOWER CAB AND FRONT GRILLE WORK LIGHTS 25
3 LEFT HAND REAR CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
4 REAR FENDER WORK LIGHTS 15
5 FORWARD/NEUTRAL/REVERSE/PARK SWITCH 5
6 LEFT HAND SIDE/TAIL LIGHTS 10
7 RIGHT HAND SIDE/TAIL LIGHTS 10
SEAT, LOADER CONTROL 15

8
# LOADER CONTROLS 15
9 RIGHT HAND REAR CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
10 GRILLE HEADLIGHTS - LOW BEAM (CIRCUIT BREAKER) 10
11 REAR FOG LIGHT 15
12 LEFT HAND FRONT CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
13 GRILLE HEADLIGHTS - HIGH BEAM 10

SM 8-12540 Issued 09-2004
SECTION 4001 9

14 ENGINE CONTROLLER (BATTERY B+ 1) 7.5
15 CAB MOUNTED HEADLIGHTS 15
16 IMPLEMENT INTERFACE CONNECTOR UNSWITCHED B+ 10
18 HAZARD WARNING LIGHT SWITCH 15
20 AUXILIARY/REMOTE VALVE CONTROLLER B+ (UNSWITCHED) 7.5
21 TURN SIGNAL LIGHTS 15
22 BEACON LIGHT 15
23 ENGINE CONTROLLER (VP44) 20
24 BRAKE LIGHTS 20
25 INSTRUMENT CLUSTER SWITCHED B+, ENGINE CONTROLLER SWITCHED B+ 7.5
26 MFD, DIFF LOCK 30
27 CAB CONTROLLER (MCC), HITCH CONTROLLER SWITCHED B+ 7.5
28 FRONT SUSPENDED AXLE CONTROLLER SWITCHED B+ 10
29 REAR FENDER AUXILIARY POWER CONNECTOR, 30

AIR TRAILER BRAKE (IF EQUIPPED)
FRONT AND REAR AUXILIARY POWER CONNECTOR SWITCHED B+ 30

30
# INTERIOR LIGHT, RADIO CLOCK POWER, INSTRUMENT CLUSTER CLOCK 7.5
POWER, FRONT SUSPENDED AXLE CONTROLLER UNSWITCHED B+)
31 REAR WINDSCREEN WIPER/WASHER 15
32 FRONT WINDSCREEN WIPER/WASHER, ELECTRIC MIRRORS (CIRCUIT BREAKER) 15
PTO CONTROLLER UNSWITCHED B+ 7.5

33
# HITCH CONTROLLER, UNSWITCHED B+ 7.5
34 TRANSMISSION CONTROLLER SWITCHED B+ 7.5
35 ARMREST, AUXILIARY/REMOTE VALVE CONTROLLER, SWITCHED B+ (VF IN, VP IN) 7.5
36 FRONT PTO 10
INTERIOR LIGHT, RADIO CLOCK POWER, INSTRUMENT CLUSTER CLOCK POWER, 7.5
37 FRONT SUSPENDED AXLE CONTROLLER UNSWITCHED B+
# PTO CONTROLLER UNSWITCHED B+ 7.5
38 CAB CONTROLLER (MCC) UNSWITCHED B+ 7.5
39 CIGAR LIGHTER, DIAGNOSTIC CONNECTOR B+ 10
40 ACCESSORY, INSTRUMENT CLUSTER, RADIO 7.5
41 REAR AUXILIARY POWER CONNECTOR, UNSWITCHED B+ 30
42 FRONT AUXILIARY POWER CONNECTOR, UNSWITCHED B+ 30
HITCH CONTROLLER, UNSWITCHED B+ 7.5

43
# FRONT AND REAR AUXILIARY POWER CONNECTOR SWITCHED B+ 30
44 RIGHT HAND FRONT CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
# NOTE: Early production tractors only.
SM 8-12540 Issued 09-2004

10 SECTION 4001

(American Specification Tractors)
MI03G058
To gain access to the fuses remove the instrument

panel left hand side cover.
41 42 43 44
37 38 39 40
33 34 35 36
29 30 31 32
22 23 24 25 26 27 28
15 16 17 18 19 20 21
8 9 10 11 12 13 14
1 2 3 4 5 6 7
NOTE: Locations 3, 9, 10, 12, 32 and 44 are mini circuit breakers, which will reset automatically.

HORN 15
1
# SEAT, HORN 15
2 FRONT LOWER CAB AND FRONT GRILLE WORK LIGHTS 25
3 LEFT HAND REAR CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
4 REAR FENDER WORK LIGHTS 15
5 FORWARD/NEUTRAL/REVERSE/PARK SWITCH 5
6 TAIL LIGHTS 5
7 WARNING LIGHTS 5
SEAT, LOADER CONTROL 15

8
# LOADER CONTROLS 15
9 RIGHT HAND REAR CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
10 HEADLIGHTS - LOW BEAM (CIRCUIT BREAKER) 10
OPEN -------
11
# WARNING LIGHTS 5
SM 8-12540 Issued 09-2004

SECTION 4001 11

12 LEFT HAND FRONT CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
13 HEADLIGHTS HIGH BEAM 10
15 CAB MOUNTED HEADLIGHTS (NOT USED) 15
16 IMPLEMENT INTERFACE CONNECTOR UNSWITCHED B+ 10
20 AUXILIARY/REMOTE VALVE CONTROLLER B+ (UNSWITCHED) 7.5
22 BEACON LIGHT 15
23 ENGINE CONTROLLER (VP44) 20
24 BRAKE LIGHTS (NOT USED) 20
25 INSTRUMENT CLUSTER SWITCHED B+, ENGINE CONTROLLER SWITCHED B+ 7.5
26 MFD, DIFF LOCK 30
27 CAB CONTROLLER (MCC), HITCH CONTROLLER SWITCHED B+ 7.5
28 FRONT SUSPENDED AXLE CONTROLLER SWITCHED B+ 10
29 7 POLE CONNECTOR AUXILIARY POWER B+ 30
30 INTERIOR LIGHT, RADIO CLOCK POWER, INSTRUMENT CLUSTER CLOCK POWER, 7.5
FRONT SUSPENDED AXLE CONTROLLER UNSWITCHED B+)
31 REAR WINDSCREEN WIPER/WASHER 15
32 FRONT WINDSCREEN WIPER/WASHER, ELECTRIC MIRRORS (CIRCUIT BREAKER) 15
PTO CONTROLLER UNSWITCHED B+ 7.5

33
# HITCH CONTROLLER, UNSWITCHED B+ 7.5
34 TRANSMISSION CONTROLLER SWITCHED B+ 7.5
35 ARMREST, AUXILIARY/REMOTE VALVE CONTROLLER, SWITCHED B+, VF IN, VP IN 7.5
36 FRONT PTO 10
HITCH CONTROLLER UNSWITCHED B+ 7.5

37
# PTO CONTROLLER UNSWITCHED B+ 7.5
38 CAB CONTROLLER (MCC) UNSWITCHED B+ 7.5
39 CIGAR LIGHTER, DIAGNOSTIC CONNECTOR B+ 10
40 ACCESSORY, INSTRUMENT CLUSTER, RADIO 7.5
41 REAR AUXILIARY POWER CONNECTOR, UNSWITCHED B+ 30
42 FRONT AUXILIARY POWER CONNECTOR, UNSWITCHED B+ 30
43 FRONT AND REAR AUXILIARY POWER CONNECTOR SWITCHED B+ 30
44 RIGHT HAND FRONT CAB ROOF WORK LIGHTS (CIRCUIT BREAKER) 25
# NOTE: Early production tractors only.
SM 8-12540 Issued 09-2004

12 SECTION 4001
Hood Components
4
2 3
MI04J001
1. CONNECTOR 67 (ENGINE HARNESS) 4. LEFT HAND HEADLIGHT

2. RIGHT HAND FRONT GRILLE WORK LIGHT 5. LEFT HAND FRONT GRILLE WORK LIGHT
3. RIGHT HAND HEADLIGHT 6. HORN
SM 8-12540 Issued 09-2004

SECTION 4001 13
Engine Component Identification
4 8
1
7 11
3 10
6 9
2
17 21
15 16
12 18
19
22
20
14
13
1. COOLANT LEVEL SENDER 7. STARTER RELAY 13. WATER IN FUEL SENSOR 19. MASTER DISCONNECT SWITCH (IF EQUIPPED)
2. AIR CONDITIONING COMPRESSOR CLUTCH DIODE 8. COLD START RELAYS 14. ENGINE CONTROLLER CAN BUS CONNECTOR 20. JUMP START STUD (IF EQUIPPED)
3. AIR CONDITIONING COMPRESSOR CLUTCH 9. COLD START FUSES 1 AND 2 (125 AMP) 15. CONNECTOR 61 (ENGINE CONTROLLER) 21. STARTER MOTOR
4. CONNECTOR 10 TO (INSTRUMENT PANEL HARNESS) 10. GRID HEATERS 16. CONNECTOR 62 (ENGINE CONTROLLER) 22. ALTERNATOR
5. CONNECTOR 67 (TO HOOD HARNESS) 11. AIR FILTER RESTRICTION SWITCH 17. CAN BUS TERMINATION RESISTOR
6. RADAR HARNESS CONNECTOR 12. AIR CONDITIONING HIGH PRESSURE SWITCH 18. CONNECTOR 60 (ENGINE CONTROLLER HARNESS)
SM 8-12540 Issued 09-2004
14 SECTION 4001
Instrument Panel Component Identification
2 3 4 5 6 7 8 9 10 11 12 13 14
16
17
1 18
15 19
20
35 36
21
22 25 26
34 23
24
28
33
29
31
30 27
32 G1
MI04D011
1. FUSE BOX 20. FLASHER RELAY

2. FRONT WORK LIGHT SWITCH 21. CIRCUIT BREAKER
3. REAR WORK LIGHT SWITCH 22. CAB POWER RELAY
4. REAR FOG LIGHT SWITCH (IF EQUIPPED) 23. LEFT HAND BRAKE SWITCH
5. INSTRUMENT CLUSTER CONNECTOR C2 24. RIGHT HAND BRAKE SWITCH
6. HEAD LIGHT LOW BEAM RELAY 25. KEY SWITCH
7. HEAD LIGHT HIGH BEAM RELAY 26. PROGRAMMING CONNECTOR
8. SWITCHED POWER STUD 27. AUXILIARY POWER CONNECTOR
9. FRONT LOWER CAB AND GRILLE WORK LIGHT RELAY 28. BATTERY POWER STUD (UNSWITCHED)
10. LEFT HAND REAR CAB WORK LIGHT RELAY 29. CONNECTOR 33 (STALK SWITCH)
11. ACCESSORY POWER RELAY 30. CONNECTOR 32 (STALK SWITCH)
12. LEFT HAND FRONT CAB WORK LIGHT RELAY 31. TURN SIGNAL SELF CANCELLING MODULE
13. RIGHT HAND FRONT CAB WORK LIGHT RELAY CONNECTOR
14. RIGHT HAND REAR CAB WORK LIGHT RELAY 32. CONNECTOR 1 (CAB HARNESS)
15. INSTRUMENT CLUSTER CONNECTOR C1 33. INCHING PEDAL POSITION POTENTIOMETER
16. * HAZARD WARNING LIGHT SWITCH 34. INCHING PEDAL SWITCH (TOP OF PEDAL)
17. BEACON LIGHT SWITCH (IF EQUIPPED) 35. INCHING PEDAL SWITCH (BOTTOM OF PEDAL)
18. * UPPER/LOWER HEADLIGHT SWITCH 36. MAIN LIGHT SWITCH
19. CAN DIAGNOSTIC CONNECTOR
G1. CHASSIS GROUND CONNECTION G1
* EUROPEAN SPECIFICATION TRACTORS ONLY
SM 8-12540 Issued 09-2004

SECTION 4001 15
Right Hand Console Harness Components
7 9
5 8 10
6
4
3
2 11
14
15
16
1
12
17
13
18
20
G2 19
22 21
23
25
24
26
MI04J041
1. HITCH MAIN SETTING LEVER (HEIGHT/DEPTH) 15. HITCH DIAGNOSTIC LIGHT

2. AUTO PTO SWITCH 16. HITCH UPPER LIMIT CONTROL
3. FRONT PTO SWITCH (IF EQUIPPED) 17. HITCH DROP SPEED CONTROL
4. REAR PTO INDICATOR LIGHT 18. AUDIBLE ALARM
5. REAR PTO SWITCH 19. SEAT CONNECTOR
6. RIDE CONTROL SWITCH 20. CONNECTOR 52 (FENDER HARNESS)
7. SLIP CONTROL SWITCH 21. CONNECTOR 53 (FENDER HARNESS)
8. DIFFERENTIAL LOCK SWITCH 22. CONNECTOR 51 (FENDER HARNESS)
9. MFD SWITCH 23. CONNECTOR 26 (INSTRUMENT PANEL HARNESS)
10. SUSPENDED FRONT AXLE ON/OFF SWITCH 24. CONNECTOR 27 (INSTRUMENT PANEL HARNESS)
11. CIGAR LIGHTER 25. CONNECTOR 28 (INSTRUMENT PANEL HARNESS)
12. AUXILIARY POWER SOCKET 26. CONNECTOR 29 (INSTRUMENT PANEL HARNESS)
13. AUXILIARY POWER SOCKET
14. HITCH MODE CONTROL (INTERMIX) G2. CHASSIS GROUND CONNECTION G2
SM 8-12540 Issued 09-2004

16 SECTION 4001
Armrest Components
5 6
4
3
8 9
10
14
13 15 16
12
11
MI02F149A
17 18 19 20
MI02F151A
1. THROTTLE CONTROL 10. AUXILIARY/REMOTE VALVE

2. AUXILIARY/REMOTE VALVE EMERGENCY STOP JOYSTICK 2 (VALVES 3 AND 4)
BUTTON 11. AUXILIARY/REMOTE VALVE 1 FLOW CONTROL
3. GEAR DOWN SHIFT CONTROL 12. AUXILIARY/REMOTE VALVE 1 TIMER CONTROL
4. GEAR UP SHIFT CONTROL 13. AUXILIARY/REMOTE VALVE 2 FLOW CONTROL
5. AUXILIARY/REMOTE VALVE 5 LOWER CONTROL 14. AUXILIARY/REMOTE VALVE 2 TIMER CONTROL
6. AUXILIARY/REMOTE VALVE 5 RAISE CONTROL 15. AUXILIARY/REMOTE VALVE 3 FLOW CONTROL
7. HITCH UP/DOWN SWITCH 16. AUXILIARY/REMOTE VALVE 3 TIMER CONTROL
8. AUXILIARY/REMOTE VALVE ENABLE SWITCH AND 17. AUXILIARY/REMOTE VALVE 4 FLOW CONTROL
INDICATOR LIGHT 18. AUXILIARY/REMOTE VALVE 4 TIMER CONTROL
9. AUXILIARY/REMOTE VALVE 19. AUXILIARY/REMOTE VALVE 5 FLOW CONTROL
JOYSTICK 1 (VALVES 1 AND 2) 20. AUXILIARY/REMOTE VALVE 5 TIMER CONTROL
SM 8-12540 Issued 09-2004

SECTION 4001 17
Rear Fender Components
8
5
9
4 11
10
12
2
1 13
27 26
25
14 17
18
16 23
15
24
19 22
G5 21
20 MI04J002
1. LEFT HAND HITCH REMOTE SWITCH 15. 7 PIN TRAILER CONNECTOR

2. * LEFT HAND REMOTE PTO SWITCH 16. TRAILED IMPLEMENT UP/DOWN SWITCH CONNECTOR
3. * LEFT HAND STOP LIGHT 17. CONNECTOR 50 (ARMREST HARNESS)
4. LEFT HAND REAR SIDE/TAIL LIGHT 18. RIGHT HAND REAR FENDER WORK LIGHT
5. LEFT HAND REAR TURN SIGNAL LIGHT 19. RIGHT HAND HITCH REMOTE SWITCH
6. LEFT HAND EXTREMITY LIGHTS (OPTIONAL) 20. * RIGHT HAND REMOTE PTO SWITCH
7. RIGHT HAND EXTREMITY LIGHTS (OPTIONAL) 21. CONNECTOR 52 (RIGHT HAND CONSOLE HARNESS)
8. AUXILIARY/REMOTE VALVE CONTROLLER 22. CONNECTOR 53 (RIGHT HAND CONSOLE HARNESS)
9. HITCH CONTROLLER 23. CONNECTOR 51 (RIGHT HAND CONSOLE HARNESS)
10. CAB (MCC) CONTROLLER 24. CONNECTOR 40 (TRANSMISSION HARNESS)
11. FRONT WINDSHIELD WASHER MOTOR 25. * RIGHT HAND REAR TURN SIGNAL LIGHT
12. REAR WINDSHIELD WASHER MOTOR 26. RIGHT HAND REAR SIDE/TAIL LIGHT
13. LEFT HAND REAR FENDER WORK LIGHT 27. RIGHT HAND STOP LIGHT
14. AUXILIARY POWER CONNECTOR
* EUROPEAN SPECIFICATION TRACTORS ONLY.
SM 8-12540 Issued 09-2004

18 SECTION 4001
Cab Components
13
12
11
14
7
6 10 19
16
9 18
17
5
15
G4
4 20
21
3 22
8 23 2
1
MI04J003
1. CONNECTOR 1 (INSTRUMENT PANEL HARNESS) 13. * LEFT HAND FRONT CAB HEADLIGHT
2. CIRCUIT BREAKER 14. LEFT HAND MIRROR CONNECTOR
3. MIRROR CONTROL SWITCH 15. FRONT WINDSHIELD WIPER SWITCH
4. HEATED MIRROR SWITCH 16. FRONT WINDSHIELD WIPER MOTOR
5. INTERIOR LIGHT DOOR SWITCH 17. RIGHT HAND CAB LOWER FRONT WORK LIGHT
6. BEACON LIGHT 18. * RIGHT HAND FRONT SIDE/TURN LIGHT CLUSTER
7. CONNECTOR 2 (CAB ROOF HARNESS) 19. * RIGHT HAND FRONT CAB HEADLIGHT
8. REAR WINDSHIELD WIPER MOTOR 20. LEFT HAND MIRROR CONNECTOR
9. LEFT HAND SPEAKER 21. RIGHT HAND CONSOLE LIGHT
10. INTERIOR LIGHT 22. RIGHT HAND SPEAKER
11. LEFT HAND CAB LOWER FRONT WORK LIGHT 23. RADIO CONNECTORS
12. * LEFT HAND FRONT SIDE/TURN LIGHT CLUSTER
* EUROPEAN SPECIFICATION TRACTORS ONLY.
NOTE: For Automatic Temperature Control components, refer to Section 10012.
SM 8-12540 Issued 09-2004

SECTION 4001 19
Cab Roof Panel Components

EUROPEAN SPECIFICATION TRACTORS
2 3 4
5 6 7
11
10
13
12 MI04J004
9
8
1. CONNECTOR 2 (CAB HARNESS) 7. RIGHT HAND FRONT OUTER WORK LIGHT

2. LEFT HAND FRONT OUTER WORK LIGHT 8. RIGHT HAND REAR OUTER WORK LIGHT
3. LEFT HAND FRONT MIDDLE WORK LIGHT 9. RIGHT HAND REAR INNER WORK LIGHT
4. LEFT HAND FRONT INNER WORK LIGHT 10. LEFT HAND REAR INNER WORK LIGHT
5. RIGHT HAND FRONT INNER WORK LIGHT 11. LEFT HAND REAR OUTER WORK LIGHT
6. RIGHT HAND FRONT MIDDLE WORK LIGHT 12. RIGHT HAND REAR NUMBER PLATE LIGHT
13. LEFT HAND REAR NUMBER PLATE LIGHT
AMERICAN SPECIFICATION TRACTORS
2 3 4
5 6 7
13
12
11
10
9
8 MI04J005
1. CONNECTOR 2 (CAB HARNESS) 10. RIGHT HAND REAR INNER WORK LIGHT
2. LEFT HAND FRONT TURN SIGNAL LIGHT 11. LEFT HAND REAR INNER WORK LIGHT
3. LEFT HAND FRONT OUTER WORK LIGHT 12. LEFT HAND REAR OUTER WORK LIGHT
4. LEFT HAND FRONT INNER WORK LIGHT 13. LEFT HAND REAR TURN SIGNAL LIGHT
5. RIGHT HAND FRONT INNER WORK LIGHT
6. RIGHT HAND FRONT OUTER WORK LIGHT
7. RIGHT HAND FRONT TURN SIGNAL LIGHT
8. RIGHT HAND REAR TURN SIGNAL LIGHT
9. RIGHT HAND REAR OUTER WORK LIGHT
SM 8-12540 Issued 09-2004

20 SECTION 4001
NEUTRAL START, COLD START, KEY SWITCH, CAB POWER,

WATER IN FUEL AND THROTTLE
Starter Circuit
NOTE: If the inlet manifold temperature is too low the wait to star t symbol will appear on the instrument
cluster. With the key in the ON position the grid heaters will switch ON. When the wait to start symbol
goes out the engine can be star ted.
The starter solenoid will only operate when the Forward/Neutral/Reverse/Park lever is in the PARK position.
With the key switch in the START position, battery power at terminal 1 of the key switch flows to terminal 2 then
to the Forward/Neutral/Reverse/Park switch at terminal 4. With the Forward/Neutral/Reverse switch in the PARK
position, power flows through the F/N/R/P switch from terminal 4 to terminal 5 then to the starter relay at
terminal 86. Power flows through the relay windings to terminal 85 and to ground (battery negative terminal),
energizing the relay.
With the starter relay energised, battery power flows from terminal 30 of the starter relay to terminal 87 and to
the starter solenoid at terminal S. Power then flows to ground (internally through the starter motor), energising
the starter solenoid.
With the starter solenoid energised, battery power flows from the battery to the starter motor (through an
optional jumper stud or battery master disconnect switch) and to ground (internally through the motor),
operating the motor.
NOTE: For tractors equipped with a master disconnect switch, when the switch is in the OFF position all
battery power is disconnected to the tractor except for power for the instrument cluster clock, interior
light, radio and independent front suspension axle controller (if equipped).
Cold Start Circuit

When the engine controller detects that the inlet manifold air temperature is too low prior to starting the engine
the controller will direct power to terminal A of both the cold start relays. Power will flow through both relays to
terminal B and to ground (battery negative terminal), energising the relays.
With the cold start relay 1 energised, battery power from the starter motor terminal B will flow through the cold
start fuse 1 (125 amp) to the cold start relay 1. Power then flows through the cold start relay 1 to the cold start
grid heater 1 and to ground (though the grid heater body), heating the grid heater element.
With the cold start relay 2 energised, battery power from the starter motor terminal B will flow through the cold
start fuse 2 (125 amp) to the cold start relay 2. Power then flows through the cold start relay 2 to the cold start
grid heater 2 and to ground (though the grid heater body), heating the grid heater element.
NOTE: If engine controller detects a drop in the inlet manifold air temperature to a level which is too
low, the wait to start symbol will appear on the instrument cluster and the grid heaters will turn on.
When the inlet manifold temperature rises to the correct temperature the wait to start symbol will go out
the grid heaters will switch off.
SM 8-12540 Issued 09-2004

SECTION 4001 21
Hand Throttle Circuit

The engine controller directs power (5V reference voltage) from pin 10 of connector 61 to the hand throttle
potentiometer terminal 1. Power flows through the coil of the potentiometer to terminal 4 and to the engine
controller connector 61 pin 20. Power also flows to the engine controller connector 61 pin 45 (hand throttle
present signal).
Depending on the position of the hand throttle a signal voltage (between 0V and 5V will flow from the hand
throttle potentiometer terminal 2 to the engine controller connector 61 pin 9. The engine controller will measure
the signal voltage and automatically adjust the fuel delivery to the engine to give the requested engine speed.
NOTE: The engine controller will only respond to the greater throttle signal. Full hand throttle control
can only be made if the foot throttle is released.
Foot Throttle Circuit

The foot throttle assembly incorporates a throttle position potentiometer and a Idle Validation switch.
With the foot throttle released (low idle position) the engine controller directs power (5V reference voltage) from
pin 26 of connector 61 to the foot throttle Idle Validation switch terminal G. Power flows through the Idle
Validation switch to terminal J and to the engine controller connector 61 pin 20. The engine controller will detect
the signal voltage and automatically adjust the fuel delivery to the engine.
With the foot throttle depressed (off low idle position) the engine controller directs power (5V reference voltage)
from pin 25 of connector 61 to the foot throttle Idle Validation switch terminal H. Power flows through the Idle
Validation switch to terminal J and to the engine controller connector 61 pin 20. The engine controller will detect
the signal voltage and automatically adjust the fuel delivery to the engine.
The engine controller also directs power (5V reference voltage) from pin 29 of connector 61 to the foot throttle
potentiometer terminal D. Power flows through the coil of the potentiometer to terminal K and to the engine
controller connector 61 pin 20.
Depending on the position of the foot throttle a signal voltage (between 0V and 5V will flow from the foot throttle
potentiometer terminal E to the engine controller connector 61 pin 30. The engine controller will measure the
signal voltage and automatically adjust the fuel delivery to the engine to give the requested engine speed.
NOTE: The engine controller will only respond to the greater throttle signal. Full foot throttle control can
only be made if the hand throttle is in the low idle position.
Accessory Power Relay

With the key switch in the ON or ACCESSORY position battery power at terminal 1 of the key switch flows
through the switch to terminal 6. Power then flows to the accessory power relay terminal 1, through the relay
windings to terminal 2 and to ground at G1 energising the relay.
Cab Power Relay

With the key switch in the ON position, battery power at terminal 1 of the key switch flows through the switch to
terminal 3. Power then flows to the cab power relay terminal 86, through the relay windings to terminal 85 and
then to the accessory power relay terminal 3 (30). With the accessory power relay energised (see above) power
flows through the accessory power relay to terminal 5 (87) and to ground at G1 energising the cab power relay.
With the cab power relay energised battery power at terminal 30 flows through the relay to terminal 87 and is
available at the switched power stud and supplies most fuses.
When the key switch is moved to the START position the accessory relay is de-energised. This will prevent
power flow to ground from the cab power relay, which becomes de-energised.
SM 8-12540 Issued 09-2004

22 SECTION 4001
BATTERIES STARTER MOTOR, STARTER RELAY, NEUTRAL START KEY SWITCH, CAB POWER, ACCESSORY POWER, COLD START HAND THROTTLE
4
5
F
J
10 13 14 15 16
3
11
17
12
18
7
A
D C
G 19 21
B
8 E
9
H
20 22 23
MI04G007
Key
1. BATTERIES 10. FUSE 5 (5 AMP) 19. COLD START RELAY 1 A. TO INSTRUMENT CLUSTER (REFER TO SECTION 10009) J. TO RADIO, INTERIOR LIGHT
2. JUMP START STUD (IF EQUIPPED) 11. KEY SWITCH 20. COLD START GRID HEATER 1 B. TO ALTERNATOR (REFER TO SECTION 10009) K. TO INSTRUMENT CLUSTER REFER TO SECTION 10009)
3. MASTER DISCONNECT SWITCH (IF EQUIPPED) 12. F/N/R/P SWITCH 21. COLD START RELAY 2 C. FROM FRONT GRILLE WORK LIGHTS L. TO CAN BUS CIRCUIT
4. BATTERY POWER STUD 13. FUSE 25 (7.5 AMP) 22. COLD START GRID HEATER 1 D. FROM HEADLIGHTS M. FROM BLOWER MOTOR PWM CONTROL MODULE
5. SWITCHED POWER STUD 14. FUSE 19 (7.5 AMP) 23. HAND THROTTLE POTENTIOMETER E. FROM SPLICE 5 - AIR CONDITIONING DIODE, AIR FILTER N. FROM ENGINE SENSORS
6. STARTER RELAY 15. FUSE 17 (7.5 AMP) 24. FUSE 23 (20 AMP) RESTRICTION SWITCH, COOLANT LEVEL SENDER P. FROM FUEL LIFT PUMP
7. STARTER MOTOR 16. FUSE 14 (7.5 AMP) 25. WATER IN-FUEL SENSOR F. TO INCHING PEDAL SWITCHES (REFER TO SECTION 10006)
8. COLD START FUSE 1 (125A) 17. CAB POWER RELAY 26. FOOT THROTTLE POTENTIOMETER/IDLE G. TO IMPLEMENT INTERFACE CONNECTOR
9. COLD START FUSE 2 (125A) 18. ACCESSORY POWER RELAY VALIDATION SWITCH H. TO TRANSMISSION CONTROLLER (REFER TO SECTION 10006)
NOTE 1: Only use a HIGH IMPEDANCE multimeter to test the switches and circuits. Do not use a test lamp or damage to the switches may occur.
SM 8-12540 Issued 09-2004
SECTION 4001 23
WATER IN FUEL SENSOR, FOOT THROTTLE POTENTIOMETER, ENGINE CONTROLLER
24
M
25
26
MI04G008
ENGINE CONTROLLER PIN IDENTIFICATION

CONNECTOR 61 (50 Pin) CONNECTOR 62 (50 Pin)
1 TO 8 NOT USED 31 COLD START RELAY 2 SIGNAL 1 NOT USED 14 CAN LOW 27 COOLANT LEVEL HIGH SIGNAL 40 UNSWITCHED BATTERY POWER 2
9 HAND THROTTLE SIGNAL 32 TO 39 NOT USED 2 CAN HIGH 15 REAR PUMPING CONTROL SOLENOID (-) 28 CLEAN GROUND 41 FAN CLUTCH DRIVER (NOT USED)
10 HAND THROTTLE 5V POWER 40 WATER IN FUEL SIGNAL 3 NOT USED 16 NOT USED 29 CLEAN GROUND 42 NOT USED
11 TO 18 NOT USED 41 COLD START RELAY 1 SIGNAL 4 NOT USED 17 ENGINE SPEED SENSOR SIGNAL 30 CLEAN GROUND 43 NOT USED
19 FOOT THROTTLE RETURN 42 TO 44 NOT USED 5 SWITCHED POWER 18 ENGINE SPEED SENSOR RETURN 31 FRONT PUMPING CONTROL SOLENOID (+) 44 CAN GROUND (NOT USED)
20 HAND THROTTLE 0V 45 HAND THROTTLE PRESENT 6 INJECTION CONTROL SOLENOID (+) 19 ENGINE POSITION INPUT RETURN 32 AMBIENT AIR PRESSURE SIGNAL 45 BOOST PRESSURE SIGNAL
21 TO 24 NOT USED 46 NOT USED 7 INJECTION CONTROL SOLENOID (-) 20 CLEAN GROUND 33 OIL PRESSURE SIGNAL 46 ACCUMULATOR FUEL PRESS SIGNAL
25 OFF IDLE SIGNAL 47 NOT USED 8 ENGINE SPEED SENSOR (+5V) 21 FRONT PUMPING CONTROL SOLENOID (-) 34 INTAKE MANIFOLD AIR TEMP SIGNAL 47 NOT USED
26 ON IDLE SIGNAL 48 NOT USED 9 ENGINE POSITION INPUT SIGNAL 22 LIFT PUMP (PRIME PUMP) 35 ACCUMULATOR FUEL TEMP SIGNAL 48 NOT USED
27 NOT USED 49 NOT USED 10 ENGINE POSITION INPUT (+5V) 23 COOLANT TEMPERATURE SIGNAL 36 INJECTION CONTROL VALVE ID (+) 49 COOLANT LEVEL (+5V)
28 NOT USED 50 NOT USED 11 LIFT PUMP (PRIME PUMP) 24 NOT USED 37 COOLANT LEVEL LOW SIGNAL 50 UNSWITCHED BATTERY POWER 3
29 FOOT THROTTLE 5V POWER 12 CAN LOW 25 REAR PUMPING CONTROL SOLENOID (+) 38 UNSWITCHED BATTERY POWER (VP44)
30 FOOT THROTTLE SIGNAL 13 NOT USED 26 NOT USED 39 UNSWITCHED BATTERY POWER 1
SM 8-12540 Issued 09-2004

24 SECTION 4001
IMPLEMENT INTERFACE CONNECTOR, AUXILIARY POWER

CONNECTORS AND BEACON LIGHT
Implement Interface Connector Circuit

The Implement Interface Connector allows the implement systems to be connected to the tractor electrical system
to power the unit and enable the unit to monitor wheel speed and ground speed.
Front and Rear 3 Pin Auxiliary Power Connector Circuit

Battery power flows through fuse 42 to the front 3 pin auxiliary connector pin 2 (15/30 American specification
tractors) and through fuse 41 to the rear 3 pin auxiliary connectors pin 2 (15/30 American specification).
Switched Power flows through fuses 30 or 43 (see schematic circuit) to both the front and rear 3 pin auxiliary
connector pins 1 (82 American specification tractors). Pin 3 (31 American specification tractors) on both front
and rear 3 pin auxiliary connectors are connected to chassis ground at G1 for the front connector and G2 for
the rear connector.
Switched Fender Auxiliary Power Connector Circuit

Switched power flows through fuse 29 to the switched fender auxiliary power connector. For American
specification tractors, switched power also flows to the 7 pole trailer connector pins 4 and 7.
Beacon Light
Switched power flows through fuse 22 to the rotary beacon switch. With the switch ON power flows through the
switch internal warning lamp to ground at G1 illuminating the warning lamp. Power also flows to rotary beacon
light unit to ground at G4 (through the main cab splice 12) operating the rotary beacon motor and illuminating
the light.
For European specification tractors power also flows to the trailer connector.
SM 8-12540 Issued 09-2004

SECTION 4001 25
IMPLEMENT INTERFACE CONNECTOR FRONT AND REAR 3 PIN AUXILIARY POWER SOCKETS, TRAILER AUXILIARY POWER CONNECTOR ROTARY BEACON
IMPLEMENT INTERFACE
CONNECTOR PIN IDENTIFICATION
1 UNSWITCHED BATTERY POWER 1 3 6 12
5 9
2 KEY SENSING
3 CLEAN GROUND
4 WHEEL SPEED
5 RADAR SIGNAL
6 RADAR PRESENT
7 SWITCHED BATTERY POWER
8 CHASSIS GROUND
A
13
F G
H
2
B
J
C
10
B
K
14
D
15
E
B
D
10 11 16
L
4 7 8
MI04G015
Key
1. FUSE 16 (10A) 13. BEACON LIGHT SWITCH H. FROM DIFF LOCK SWITCH (REFER TO SECTION 10006)
2. IMPLEMENT INTERFACE CONNECTOR 14. BEACON LIGHT J. TO AUTO PTO SWITCH (REFER TO SECTION 10006)
3. FUSE 30 (30 AMP) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS 15. REAR TRAILER SOCKET - EUROPEAN SPECIFICATION TRACTORS ONLY K. TO AUXILIARY/REMOTE VALVE CONTROLLER CIRCUIT (REFER TO SECTION 10001)
FUSE 43 (30 AMP) - EARLY PRODUCTION EUROPEAN SPECIFICATION TRACTORS 16. MAIN CAB CHASSIS GROUND SPLICE 12 L. TO SUSPENDED AXLE CONTROLLER (REFER TO SECTION 10003)
FUSE 43 (30 AMP) - AMERICAN SPECIFICATION TRACTORS
4. FRONT 3 PIN AUXILIARY POWER SOCKET A. FROM ACCESSORY POWER RELAY
5. FUSE 42 (30 AMP) B. TO HITCH CONTROLLER (REFER TO SECTION 10002)
6. FUSE 41 (30 AMP) C. TO WHEEL SPEED SENSOR (REFER TO SECTION 10002)
7. REAR UPPER 3 PIN AUXILIARY POWER SOCKET D. TO INSTRUMENT CLUSTER (REFER TO SECTION 10009) (*) - EUROPEAN SPECIFICATION TRACTORS ONLY
8. REAR LOWER 3 PIN AUXILIARY POWER SOCKET E. FROM RADAR (REFER TO SECTION 10009) (**) - AMERICAN SPECIFICATION TRACTORS ONLY
9. FUSE 29 (30 AMP) F. FROM SUSPENDED AXLE SWITCH (REFER TO SECTION 10003) (#) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS
10. TRAILER AUXILIARY POWER CONNECTOR G. FROM MFD LOCK SWITCH (REFER TO SECTION 10006) (##) - AMERICAN SPECIFICATION TRACTORS AND EARLY PRODUCTION
11. 7 POLE TRAILER SOCKET - AMERICAN SPECIFICATION TRACTORS ONLY EUROPEAN SPECIFICATION TRACTORS
12. FUSE 22 (15 AMP)
SM 8-12540 Issued 09-2004
26 SECTION 4001
HORN, CIGAR LIGHTER AND SEAT
Horn Circuit
Battery power flows from fuse 1 to the horn through the horn windings to terminal 31b of to the stalk switch.
With the horn switch pressed ON (spring release to OFF) power flows through the switch to terminal 31 then to
ground at G1 operating the horn.
Cigar Lighter Circuit

Battery power flows through fuse 39 to the cigar lighter unit. When the cigar element is pushed IN power flows
through the cigar lighter element to ground at G2 heating the element. When the element reaches the required
temperature the element will partially eject and disconnect the power supply to the element.
Electric Air Seat Circuit

Switched power flows through fuse 8 to the seat connector terminal A. From terminal A of the seat connector
power flows to the seat switch raise/lower switch, seat heater switch and to the seat lumber control unit.
With the raise/lower switch held in the raise position (spring release to OFF) power flows through the raise/lower
switch to the electric seat motor, through the motor to terminal B of the seat connector. Power then flows to
ground at G2 energising the motor.
With the seat heater switch in the ON position power flows through the heater switch to the seat cushion
heater element, through the element to seat back rest heater element. Power then flows through the back rest
heater element to terminal B of the seat connector and to ground at G2 heating the both the cosine and back
rest elements. Power also flows through the heater switch warning light (LED) to terminal B of the seat
connector and to ground at G2 illuminating the light (LED).
SM 8-12540 Issued 09-2004

SECTION 4001 27
HORN CIGAR LIGHTER LOADER CONNECTORS AND SEAT
1 2 3
9
10
10f
C
10a
4
10c
7
10g
10b
10d 10e
MI04G016
Key
1. FUSE 1 (15 AMP) 10. SEAT ASSEMBLY A. TO TURN SIGNAL LIGHTS
2. FUSE 39 (10 AMP) 10a. RAISE/LOWER SWITCH B. TO HEADLIGHTS
3. FUSE 8 (30 AMP) 10b. AIR COMPRESSOR MOTOR C. FROM INSTRUMENT CLUSTER PROGRAMMING
4. STALK SWITCH (TURN/HORN/HIGH-LOW BEAM) 10c. HEATER SWITCH CONNECTOR (REFER TO SECTION 10009)
5. TURN SIGNAL SWITCH SELF CANCELLING MODULE 10d. CUSHION HEATER ELEMENT
6. HORN 10e. BACK REST HEATER ELEMENT
7. CIGAR LIGHTER 10f. LUMBER CONTROL UNIT
8. LOADER CONTROL SWITCH CONNECTOR 10g. LUMBER CONTROL SWITCH (*) - EUROPEAN SPECIFICATION TRACTORS ONLY
9. LOADER CONTROL SOLENOID HARNESS CONNECTOR (**) - AMERICAN SPECIFICATION TRACTORS ONLY
SM 8-12540 Issued 09-2004

28 SECTION 4001
RADIO AND INTERIOR LIGHT
Radio Circuit
NOTE: The radio can be connected directly to the tractor harness or connected using an adaptor
harness. Adapter harnesses available are as follows:
Type 1 - Twin European ISO connectors to single Yazaki connector.

Type 2 - Twin European ISO connectors to Twin American ISO connectors.
Power from the key switch in ACC and ON positions only, flows through fuse 40 (general radio supply) to the
tractor harness radio connector terminal 7 (type 1 adapter harness connector 74 terminal 4, type 2 adapter
harness connector 76 terminal D).
Battery power flows through fuse 30 (supply for radio memory and clock) to the radio connector 72 terminal 4,
(type 1 adapter harness connector 74 terminal 7, type 2 adapter harness connector 76 terminal K).
The radio is connected to ground at G4 (through the main cab splice 11) from connector 72 terminal 8 (type 1
adapter harness connector 75 terminal 8, type 2 adapter harness connector 76 terminal I).
The radio speaker ground terminals are connected to the radio through connector 73 terminals 4 and 6 (type 1
adapter harness connector 75 terminal 4 and 6, type 2 adapter harness connector 76 terminal L and M).
The radio speaker signal terminals are connected to the radio through connector 73 terminals 3 and 5 (type 1
adapter harness connector 75 terminal 3 and 5, type 2 adapter harness connector 76 terminal E and F).
Interior Light Circuit

Battery power flows directly from the battery positive terminal, through fuse 30 to the interior lamp unit terminal
B. Power flows through the lamp to the internal switch.
With the switch in the OFF position there is no circuit to ground at G4 (through main cab splice 11) and the lamp
will not illuminate.
With the switch moved to ON power flows through the switch to terminal A to ground at G4 (through the main
cab splice 11) illuminating the lamp.
With the switch moved to AUTO power flows through the switch to terminal C and to the door switch. With the
door open the switch contacts will close allowing power to flow through the switch to ground and the lamp will
illuminate.
SM 8-12540 Issued 09-2004

SECTION 4001 29
RADIO INTERIOR LIGHT
F G
6 13
2 B
E
1
H
E
C
8
D
J
K
9 14
L
4 5
3
B
E
11
7
D
10
12
15
MI04G017
Key
1. MAIN LIGHT SWITCH - AMERICAN SPECIFICATION TRACTORS 11. MAIN CAB CHASSIS GROUND SPLICE 11 A. TO TURN SIGNAL LIGHTS
2. FUSE 7 (5 AMP) 12. MAIN CAB CHASSIS GROUND SPLICE 12 B. TO RIGHT HAND TAIL LIGHT
3. MAIN LIGHT SWITCH - EUROPEAN SPECIFICATION TRACTORS 13. FUSE 37 (7.5 AMP) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS C. TO WORK LIGHTS
4. FUSE 6 (10 AMP) FUSE 30 (7.5 AMP) - EARLY PRODUCTION EUROPEAN SPECIFICATION TRACTORS D. TO HEADLIGHTS
5. FUSE 7 (10 AMP) FUSE 30 (7.5 AMP) - AMERICAN SPECIFICATION TRACTORS E. TO INSTRUMENT CLUSTER (REFER TO SECTION 10009)
6. FUSE 40 (7.5 AMP) 14. INTERIOR LIGHT F. FROM KEY SWITCH TERMINAL 6
7. RADIO 15. INTERIOR LIGHT DOOR SWITCH G. FROM BATTERY POSITIVE TERMINAL
8. RIGHT HAND SPEAKER H. TO SUSPENDED FRONT AXLE (REFER TO SECTION 10003)
9. LEFT HAND SPEAKER J. TO RIGHT HAND CONSOLE LIGHT
10. AERIAL K. TO REAR CAB No PLATE LIGHTS
L. TO RIGHT HAND FRONT SIDE/POSITION LIGHT - EUROPEAN SPECIFICATION TRACTORS ONLY
(*) - EUROPEAN SPECIFICATION TRACTORS ONLY
(**) - AMERICAN SPECIFICATION TRACTORS ONLY
SM 8-12540 Issued 09-2004

30 SECTION 4001
ELECTRIC MIRRORS AND WINDSHIELD WIPER/WASHERS
Electric Mirror Circuit

Switched power flows through circuit breaker 32 to the mirror control switch terminal 9, with the switch in the OFF
(centre) position no power can flow through the switch.
Left Hand Mirror - Up

With the mirror control switch in the left hand mirror position and the switch lever moved to the UP position,
switched power flows through the switch from terminals 9 to 8. Power flows from terminal 8 to one side of the left
hand mirror Up/down motor. Power then flows through the motor to terminal 7 of the mirror control switch, through
the switch to terminal 3 and to ground, energising the motor and moving the mirror up.
Left Hand Mirror - Down

With the mirror control switch in the left hand mirror position and the switch lever moved to the DOWN position
hand mirror Up/down motor. Power then flows through the motor to terminal 8 of the mirror control switch, through
the switch to terminal 3 and to ground, energising the motor and moving the mirror down.
Left Hand Mirror - In

With the mirror control switch in the left hand mirror position and the switch lever moved to the IN position switched
power flows through the switch from terminals 9 to 7. Power flows from terminal 7 to one side of the left hand mirror
In/Out motor. Power then flows through the motor to terminal 4 of the mirror control switch, through the switch to
terminal 3 and to ground, energising the motor and moving the mirror in.
Left Hand Mirror - Out

With the mirror control switch in the left hand mirror position and the switch lever moved to the OUT position
hand mirror In/Out motor. Power then flows through the motor to terminal 7 of the mirror control switch, through the
switch to terminal 3 and to ground, energising the motor and moving the mirror out.
Right Hand Mirror - Up

With the mirror control switch in the right hand mirror position and the switch lever moved to the UP position
switched power flows through the switch from terminals 9 to 10. Power flows from terminal 10 to one side of the
right hand mirror Up/Down motor. Power then flows through the motor to terminal 7 of the mirror control switch,
through the switch to terminal 3 and to ground, energising the motor and moving the mirror up.
Right Hand Mirror - Down

With the mirror control switch in the right hand mirror position and the switch lever moved to the DOWN position
hand mirror Up/Down motor. Power then flows through the motor to terminal 10 of the mirror control switch, through
the switch to terminal 3 and to ground, energising the motor and moving the mirror down.
Right Hand Mirror - In

With the mirror control switch in the right hand mirror position and the switch lever moved to the IN position
switch to terminal 3 and to ground, energising the motor and moving the mirror in.
SM 8-12540 Issued 09-2004

SECTION 4001 31
Right Hand Mirror - Out

With the mirror control switch in the right hand mirror position and the switch lever moved to the OUT position
switch to terminal 3 and to ground, energising the motor and moving the mirror out
Front Windscreen Wiper/Washer Circuit

Switched power flows through a circuit breaker located in fuse socket 32 to the front wiper/washer switch terminal E
and to the wiper motor at terminal C.
Intermittent Speed
The intermittent speed position is the range between the OFF and low speed positions. When the switch is near the
OFF position there will be a long interval between each sweep of the wiper. When the switch is near the low speed
position there will be only a short interval between each sweep of the wiper.
With the switch in the intermittent position power at terminal E flows to the internal electronic timer of the switch.
The timer will open and close an internal switch (not shown) intermittently according to the exact position of the
wiper switch.
With the internal switch closed power flows through the wiper switch to terminal B and to the wiper motor at
terminal B. Power flows through the wiper motor to ground at G4 (through main cab splice 11) operating the motor
at low speed.
Low Speed
With the switch in LOW speed position power at terminal E flows through the switch to terminal B and to the wiper
motor at terminal B. Power flows through the motor to ground at G4 (through main cab splice 11) operating the
motor at low speed.
When the wiper motor is operating the wiper motor internal switch closes and power flows from terminals C to D of
the wiper motor. Power then flows to terminal F of the wiper switch.
High Speed
With the switch in HIGH speed position power at terminal E flows through the switch to terminal A and to the wiper
motor at terminal A. Power flows through the motor to ground at G4 (through main cab splice 11) operating the
motor at high speed.
When the wiper motor is operating the wiper motor internal switch closes and power flows from terminals C to D of
the wiper motor. Power then flows to terminal F of the wiper switch.
Park Position
When the wiper switch is turned OFF, power at terminal F of the wiper switch (flowing through the wiper motor
internal switch) flows through the wiper switch to terminal B and to the motor at terminal A. Power flows through the
motor to ground at G4 (through main cab splice 11) operating the motor at low speed.
When the wiper mechanism reaches PARK position the motor internal switch opens disconnecting the power
supply from terminal C of the motor causing the motor to stop immediately.
Windscreen Washer
With the washer switch pressed ON (spring return to OFF) power available at the wiper/washer switch terminal E
flows through the switch to terminal C then to the washer motor. Power flows through the motor to ground at G5 and
the motor operates.
SM 8-12540 Issued 09-2004

32 SECTION 4001
Rear Windscreen Wiper/Washer Circuit

Switched power flows through fuse 31 to the rear wiper/washer switch terminal 3 and to the rear wiper motor
through terminal B of the wiper motor assembly connector.
Wiper ON
With the rear wiper switch in the ON position power at terminal 3 of the switch flows through the switch to terminal
4 to the wiper motor. Power flows through the motor to terminal C of the rear wiper assembly connector and to
ground at G4 (through main cab splice 11) operating the motor.
Park Position
Power at the motor from terminal B of the rear wiper assembly connector flows to an internal switch in the motor
which is open when the wiper mechanism is in the PARK position but closed in all other position. With the internal
motor switch closed power flows through the switch to terminal 1 of the wiper motor switch. With the wiper switch
OFF power flows through the switch to terminal 4 then to the motor. Power flows through the motor to terminal C of
the rear wiper assembly connector and to ground at G4 (through cab splice 11) operating the motor.
When the wiper mechanism reaches park position the motor internal switch will open. This will disconnect the
power supply from the switch connector terminal 3. The current flowing in the circuit is disconnected causing the
motor to stop immediately.
Windscreen Washer
With the washer switch pressed ON (spring return to OFF) power available at the wiper/washer switch terminal 3
flows through the switch to terminal 2 then to the washer motor. Power flows through the motor to ground at G5 and
the motor operates.
SM 8-12540 Issued 09-2004

SECTION 4001 33
ELECTRIC MIRRORS FRONT WINDSHIELD WIPER/WASHER REAR WINDSHIELD WIPER/WASHER
1 2
3
12
10
4 12b
12a
11 13
5 6
MI04G018
Key
1. CIRCUIT BREAKER - FUSE LOCATION 32 (15 AMP) 9. FRONT WIPER/WASHER SWITCH
2. FUSE 31 (15 AMP) 10. FRONT WIPER MOTOR
3. MIRROR CONTROL SWITCH 11. FRONT WINDSHIED WASHER MOTOR
4. MIRROR HEATER SWITCH 12. REAR WIPER MOTOR ASSEMBLY
5. LEFT HAND MIRROR 12a. REAR WIPER MOTOR
6. RIGHT HAND MIRROR 12b. REAR WIPER/WASHER SWITCH
7. MAIN CAB CHASSIS GROUND SPLICE 13 13. REAR WINDSHIED WASHER MOTOR
8. MAIN CAB CHASSIS GROUND SPLICE 11
SM 8-12540 Issued 09-2004

34 SECTION 4001
BRAKE LIGHTS AND AIR TRAILER BRAKE

Brake Light Circuit

Switched power flows through fuse 24 to terminal 3 of both brake relays.
Switched power flows through fuse 26 to terminal A of both brake pedal switches.
With the left hand brake pedal depressed, power flows from terminal B of the switch to terminal 1 of the left
hand brake relay. Power then flows through the relay windings to terminal 2 and to ground at G2 energizing the
relay.
With the right hand brake pedal depressed, power flows from terminal B of the switch to terminal 1 of the right
hand brake relay. Power then flows through the relay windings to terminal 2 and to ground at G2 energizing the
relay.
With the left hand brake relays or the right hand brake relays energised, power flows through the relay(s) from
terminals 3 to 5. Power then flows from terminal 5 to both the left and right hand brake lights, through the brake
lights to ground at G5 illuminating the lights. Power also flows and to terminal 6 of the 7 pole trailer socket.
Air Trailer Brake Solenoid Circuit

Switched power flows through fuse 29 to the air trailer brake relay terminals 86 and 30.
With the either or both brake pedals depressed, power flows from brake pedal switch(es) to terminal 1 of the
brake relay(s). Power then flows through the relay windings to terminal 2 and to ground at G2 energizing the
relay(s).
Power flows through the relay(s) from terminals 3 to 5, power then flows from terminal 5 of the relay to the air
trailer brake ‘inshot solenoid’. Power then flows through the solenoid to ground, energising the solenoid (priming
the air brake lines with low pressure air).
With the park brake engaged power flows from terminal 86 of the air trailer brake relay, through the relay
windings to terminal 85. Power then flows from terminal 85 of the relay through the park brake switch to ground,
energizing the relay. With the relay energised power will not flow through the relay to the air trailer brake
solenoid (solenoid OFF).
With the park brake disengaged power will not flow from terminal 85 of the relay to ground, de-energizing the
relay. With the relay de-energised power flows through the relay from terminal 30 to terminals 87a and to the
air trailer brake solenoid to ground, energizing the solenoid.
SM 8-12540 Issued 09-2004

SECTION 4001 35
STOP LIGHTS AIR TRAILER BRAKE
12
11
1 2
3 4
13
5 6
B 14
10
15
8 9
7
MI04G019
Key
1. FUSE 24 (20 AMP) 10. AIR TRAILER BRAKE INSHOT SOLENOID (IF EQUIPPED) A. TO MFD SWITCH, DIFFERENTIAL LOCK SWITCH, INCHING PEDAL RELAY
2. FUSE 26 (30 AMP) 11. FUSE 29 (30 AMP) (REFER TO SECTION 10006)
3. LEFT HAND BRAKE PEDAL SWITCH 12. TRAILER AUXILIARY POWER CONNECTOR B. TO CAB CONTROLLER (REFER TO SECTION 10006)
4. RIGHT HAND BRAKE PEDAL SWITCH 13. AIR TRAILER BRAKE RELAY (IF EQUIPPED) C. TO INSTRUMENT CLUSTER (REFER TO SECTION 10009)
5. LEFT HAND BRAKE RELAY 14. AIR TRAILER BRAKE SOLENOID (IF EQUIPPED)
6. RIGHT HAND BRAKE RELAY 15. PARK BRAKE SWITCH
7. TRAILER CONNECTOR
8. LEFT HAND STOP LIGHT
9. RIGHT HAND STOP LIGHT
SM 8-12540 Issued 09-2004
36 SECTION 4001
This Page Has been Left Blank
SM 8-12540 Issued 09-2004

SECTION 4001 37
SIDE/TAIL LIGHTS, NUMBER PLATE LIGHTS, RIGHT HAND CONSOLE

LIGHT, TURN SIGNAL AND HAZARD WARNING LIGHTS
Side/Tail Light, Number Plate Light and

Right Hand Console Light Circuits
Battery power is connected to the main light switch terminal 4. With the switch in position 2 or 3 power flows through
the switch to terminal 6 then to fuses 6 and 7. Power also flows to the instrument cluster terminal CN1-24 through
the position warning light to terminal CN2-14 (refer to Section 10009). Power then flows to ground at the battery
negative terminal, illuminating the warning light.
Side/Tail Lights
Power flows from fuse 6 to the left hand front position light, through the light to ground at G4 (through the main
cab splice 11), illuminating the light. Power also from fuse 6 to the 7 pin trailer socket terminal 7, fender number
plate light (if equipped) and to the left hand rear position light. Power flows through the left hand rear position
light and fender number plate light (if equipped) to ground at G5 illuminating the lights.
Power flows from fuse 7 to the right hand front position light through the light to ground at G4 (through the main
cab splice 11), illuminating the light. Power also from fuse 7 to the 7 pin trailer socket terminal 5 and right hand
rear position light. Power flows through the right hand rear position light to ground at G5 illuminating the light.
Right Hand Console Light

Power flows from fuse 6 to the right hand console light, power then flows through the light to ground at G4
(through the main cab splice 11), illuminating the light.
Number Plate Lights

Power flows from fuse 6 to the right hand and left hand number plate lights, power then flows through the lights
to ground at G4 (through the main cab splice 11), illuminating the lights.
Turn Signal and Hazard Warning Light Circuits
Turn Signal
Switched power flows through fuse 21 to the hazard switch terminal 8 and to the turn signal self cancelling
module. With the switch OFF power flows through the switch to terminal 6 then to the flasher relay terminal 49,
through the relay to the stalk switch at terminal 49A.
With the stalk switch in right turn position, power flows through the switch to terminal L through the self
cancelling module to the right hand front turn signal light and to the instrument cluster terminal CN1-22. Power
flows through the right hand front turn signal light to ground at G4 (through the main cab splice 11), illuminating
(flashing) the light.
Power also flows to the right hand rear turn signal light and the 7 pin trailer socket terminal 4, power then flows
through the right hand rear turn signal light to ground at G5, illuminating (flashing) the light.
With the stalk switch in left turn position, power flows through the switch to terminal R through the self cancelling
module to the left hand front turn signal light and to the instrument cluster terminal CN1-29. Power flows through
the left hand front turn signal light to ground at G4 (through the main cab splice 11), illuminating (flashing) the
light.
Power also flows to the left hand rear turn signal light terminal 4 and the 7 pin trailer socket terminal 1, power
then flows through the left hand rear turn signal light to ground at G5.
Power flows through the instrument cluster turn signal warning lamps to terminal CN1-14 (refer to Section 10009).
Power then flows to ground at the battery negative terminal, illuminating (flashing) the warning lamp.
SM 8-12540 Issued 09-2004

38 SECTION 4001
Hazard Warning Light

Battery power flows through fuse 18 to the hazard switch terminal 2. With the switch ON power flows through
the switch to terminal 6 then to the flasher relay terminal 49 and through the relay to terminal 49A. Power flows
from terminal 49a to the hazard switch terminal 5, through the switch to terminals 1 and 3 and through the
internal warning light to terminal 10 and to chassis ground at G1, illuminating (flashing) the warning light.
The power at terminal 1 flows to the 7 pin trailer socket terminal 4 and through the right hand front and rear
lights to chassis ground illuminating the lights (See Turn Signal on Page 37).
The power at terminal 3 flows to the 7 pin trailer socket terminal 1 and through the left hand front and rear lights
to chassis ground illuminating the lights (See Turn Signal on Page 37).
SM 8-12540 Issued 09-2004

SECTION 4001 39
FRONT SIDE/POSITION LIGHTS, TAIL LIGHTS, No PLATE LIGHTS TURN SIGNAL SWITCH, FLASHER RELAY REAR TURN SIGNAL LIGHTS HAZARD WARNING LIGHT SWITCH, FRONT TURN SIGNAL LIGHTS
4 5
13
14 15
1 18 C
2
C
3 17
16
B
25 26
6 A
19
20
10 11
21 22 23 24
7 8 12
12 6
MI04G026
Key
1. FUSE 7 (10 AMP) 13. MAIN LIGHT SWITCH A. TO RADIO
2. FUSE 6 (10 AMP) 14. FUSE 18 (15 AMP) B. TO HORN
3. FENDER NUMBER PLATE LIGHT (IF EQUIPPED) 15. FUSE 21 (15 AMP) C. TO HEADLIGHTS
4. LEFT HAND FRONT SIDE/POSITION LIGHT 16. HAZARD WARNING LIGHT SWITCH
5. RIGHT HAND FRONT SIDE/POSITION LIGHT 17. STALK SWITCH (TURN/HORN/HIGH-LOW BEAM)
6. TRAILER CONNECTOR 18. TURN SIGNAL SWITCH SELF CANCELLING MODULE
7. LEFT HAND REAR TAIL LIGHT 19. INSTRUMENT CLUSTER
8. RIGHT HAND REAR TAIL LIGHT 20. FLASHER RELAY
9. RIGHT HAND CONSOLE LIGHT 21. LEFT HAND FENDER TURN SIGNAL LIGHT
10. LEFT HAND CAB No PLATE LIGHT 22. OPTIONAL LEFT HAND TURN SIGNAL EXTREMITY LIGHT
11. RIGHT HAND CAB No PLATE LIGHT 23. RIGHT HAND FENDER TURN SIGNAL LIGHT
12. MAIN CAB CHASSIS GROUND SPLICE 11 24. OPTIONAL RIGHT HAND TURN SIGNAL EXTREMITY LIGHT
25. LEFT HAND FRONT TURN SIGNAL LIGHT
26. RIGHT HAND FRONT TURN SIGNAL LIGHT
SM 8-12540 Issued 09-2004
40 SECTION 4001
SM 8-12540 Issued 09-2004

SECTION 4001 41
TURN SIGNAL/WARNING LIGHTS

Turn Signal and Warning Light Circuits
Warning Light Circuits

Battery power flows through fuse 7 to the main light switch terminal 4. With the main light switch in position 2
or 3, power flows through the switch to terminal 6 then to the flasher relay terminal 1. Power then flows from
terminal 4 of the flasher relay to ground at G1 activating the relay.
With the flasher relay activated, battery power flows through fuse 21 to the flasher relay terminal 2, through the
relay to terminals 7, 5, 3, and 6.
From terminal 7 power flows to the 7 pin trailer socket terminal 5, the right hand rear fender turn signal light
and the right hand front and rear cab mounted turn signal lights. Power flows through the turn signal lights
to ground illuminating (flashing) the lights. The fender turn signal light is connected to ground at G5 and the
cab turn signal lights are connected to ground at G4 (through the main cab splice 12).
From terminal 5 power flows to the 7 pin trailer socket terminal 3, the left hand rear fender turn signal light
and the left hand front and rear cab mounted turn signal lights. Power flows through the turn signal lights to
ground illuminating (flashing) the lights. The fender turn signal light is connected to ground at G5 and the
cab turn signal lights are connected to ground at G4 (through the main cab splice 12).
From terminal 3, power flows to the instrument cluster terminal CN1-22 then to the right hand warning light.
From terminal 6, power flows to the instrument cluster terminal CN1-29 then to the left hand warning light.
Power flows through the instrument cluster turn signal warning lamps to terminal CN1-14 (refer to Section 10009).
Power then flows to ground at the battery negative terminal, illuminating (flashing) the warning lamp.
Turn Signal Light Circuits

Battery power flows through fuse 21 to terminal 2 of the flasher relay and to turn signal self cancelling module.
Battery power also flows through fuse 18 to the stalk switch terminal 49A.
Right Turn
With the stalk switch in right turn position, power flows through the switch to terminal L then through the self
cancelling module (if equipped) to the flasher relay terminal 5, to the 7 pin trailer socket terminal 3 and to the
left hand rear fender turn signal light. Power also flows to the left hand front and rear cab mounted lights. Power
flows through the turn signal lights to ground illuminating (not flashing) the lights. The fender turn signal light is
connected to ground at G5 and the cab turn signal lights are connected to ground at G4 (through the main cab
splice 12).
Power at the flasher relay terminal 5 signals the relay which directs power available at terminal 2 through the
relay to terminal 7 then to the right hand rear fender turn signal light. Power also flows to the right hand front
and rear cab mounted lights. Power flows through the turn signal lights to ground illuminating (flashing) the
lights. The fender turn signal light is connected to ground at G5 and the cab turn signal lights are connected to
ground at G4 (through the main cab splice 12).
SM 8-12540 Issued 09-2004

42 SECTION 4001
Left Turn
With the stalk switch in left turn position, power flows through the switch to terminal R then through the self
cancelling module (if equipped) to the flasher relay terminal 7, to the 7 pin trailer socket terminal 5 and to the
right hand rear fender turn signal light. Power also flows to the right hand front and rear cab mounted lights.
Power flows through the turn signal lights to ground illuminating (not flashing) the lights. The fender turn signal
light is connected to ground at G5 and the cab turn signal lights are connected to ground at G4 (through the
main cab splice 12).
Power at the flasher relay terminal 7 signals the relay which directs power available at terminal 2 through the
relay to terminal 5 then to the left hand rear fender turn signal light. Power also flows to the left hand front and
rear cab mounted lights. Power flows through the turn signal lights to ground illuminating (flashing) the lights.
The fender turn signal light is connected to ground at G5 and the cab turn signal lights are connected to ground
at G4 (through the main cab splice 12).
SM 8-12540 Issued 09-2004

SECTION 4001 43
TURN SIGNAL SWITCH, FLASHER RELAY REAR FENDER TURN SIGNAL LIGHTS CAB TURN SIGNAL LIGHTS
14 15
1 5
7
B
C
D
D
8 16 17
18
4 E
11
9 10 12 13
MI04G027
Key
1. FUSE 18 (15 AMP) 13. OPTIONAL RIGHT HAND TURN SIGNAL EXTREMITY LIGHT A. TO TAIL LIGHTS
2. MAIN LIGHT SWITCH 14. LEFT HAND REAR CAB TURN SIGNAL LIGHT B. TO WORK LIGHTS
1. FUSE 7 (5 AMP) 15. LEFT HAND FRONT CAB TURN SIGNAL LIGHT C. TO RIGHT HAND CONSOLE LIGHTS AND RADIO
4. STALK SWITCH (TURN/HORN/HIGH-LOW BEAM) 16. LEFT HAND REAR CAB TURN SIGNAL LIGHT D. TO HEADLIGHTS
5. TURN SIGNAL SWITCH SELF CANCELLING MODULE 17. LEFT HAND FRONT CAB TURN SIGNAL LIGHT D. TO HORN
5. FUSE 21 (15 AMP) 18. MAIN CAB CHASSIS GROUND SPLICE 12
7. INSTRUMENT CLUSTER
8. FLASHER RELAY
9. LEFT HAND FENDER TURN SIGNAL LIGHT
10. OPTIONAL LEFT HAND TURN SIGNAL EXTREMITY LIGHT
11. 7 POLE TRAILER CONNECTOR
12. RIGHT HAND FENDER TURN SIGNAL LIGHT
SM 8-12540 Issued 09-2004

44 SECTION 4001
GRILLE HEADLIGHTS, CAB MOUNTED HEADLIGHTS

AND REAR FOG LIGHTS
Grille Headlights Circuit

NOTE: On tractors not equipped with cab mounted headlights, two jumper leads are installed into the
upper/lower headlight switch connector instead of the switch.
Grille Headlight Low Beam

Battery power is connected to the main light switch at terminal 1.With the main light switch in position 3 power
flows through the switch from terminal 1 to terminal 3, then to terminal 1 of the headlight low beam relay.
With the Turn/Horn/High/Low Beam switch in the Low Beam position power flows through the headlight low
beam relay windings to terminal 56b of the Turn/Horn/High/Low Beam switch. Power then flows through the
Turn/Horn/High/Low Beam from terminal 56b to terminal 56 then to ground at G1, energizing the headlight low
beam relay.
With the low beam relay energised battery power flows from terminal 3 terminal 5 of the relay then to terminal
5 of the upper/lower headlight switch terminal block. Power flows from terminal 5 to terminal 7 of the upper/
lower headlight switch terminal block through a jumper lead to the circuit breaker 10. Power flows from the
circuit breaker 10 to both the left hand and right hand low beam lights. Power then flows through the headlights
to the battery negative terminal, illuminating both the low beam lights.
Grille Headlight High Beam

When the key switch is tuned to the ON position, switched power flows to the headlight high beam relay terminal
1. With the Turn/Horn/High/Low Beam switch in the High Beam position, power flows through the headlight high
beam relay windings to terminal 56a of the Turn/Horn/High/Low Beam switch. Power then flows through the
Turn/Horn/High/Low Beam from terminal 56a to terminal 56 then to ground at G1, energizing the headlight high
beam relay.
With the high beam relay energised battery power flows from terminal 3 terminal 5 of the relay then to terminal
lower headlight switch terminal block through a jumper lead to fuse 13 and to terminal CN1-24 of the instrument
cluster. Power flows from fuse 13 to both the left hand and right hand high beam lights. Power then flows through
the headlights to the battery negative terminal, illuminating both the high beam lights.
Power also flows through the instrument cluster headlight high beam warning lamp to terminal CN1-14 (refer to
Section 10009). Power then flows to ground at the battery negative terminal, illuminating the warning lamp.
SM 8-12540 Issued 09-2004

SECTION 4001 45
Grille Headlight High Beam Flash

1. With the Turn/Horn/High/Low Beam switch held in the High Beam Flash position, power flows through the
headlight high beam relay windings to terminal 56a of the Turn/Horn/High/Low Beam switch. Power then flows
through the Turn/Horn/High/Low Beam from terminal 56a to terminal 56d then to ground at G1, energizing the
headlight high beam relay.
lower headlight switch terminal block through a jumper lead to fuse 13 and to terminal CN1-24 of the instrument
cluster. Power flows from fuse 13 to both the left hand and right hand high beam lights. Power then flows through
the headlights to the battery negative terminal, illuminating both the high beam lights.
Cab Mounted Headlights Circuit

Upper/Lower Switch OFF
With the upper/lower headlight switch OFF (grille position) the headlight circuit operates the same as the grille
headlight circuit, except that the jumper leads are replaced with the upper/lower headlight switch.
Upper/Lower Switch ON
beam relay.
5 of the upper/lower headlight switch. Power flows from terminal 5 to terminal 1 of the upper/lower headlight
switch to fuse 15. Power also flows to terminal 1 to terminal 9 of the upper/lower headlight switch, through the
warning light to ground at G1, illuminating the warning light.
With the Turn/Horn/High/Low Beam switch in the High Beam position power flows through the headlight high
beam relay.
Power flows from fuse 15 to both the left hand and right hand cab low beam lights. Power then flows through
the cab headlights and to ground at G4 (through cab splice 11), illuminating both the cab low beam lights.
SM 8-12540 Issued 09-2004

46 SECTION 4001
Cab Headlight Flash

Power flows from fuse 15 to both the left hand and right hand cab low beam lights. Power then flows through
the cab headlights and to ground at G4 (through cab splice 11), illuminating both the cab low beam lights.
Rear Fog Lights Circuit

The rear fog light will only function when the main light switch is at position 3, dipped beam is selected and the
upper/lower switch is OFF (grille) position.
beam relay.
5 of the upper/lower headlight switch terminal block or upper/lower headlight switch.
For tractors not equipped with cab mounted headlights power flows from terminal 5 to terminal 7 of the upper/
lower headlight switch terminal block through a jumper lead to fuse 11. Power flows from fuse 11 to terminal 5
of the rear fog light switch.
For tractors equipped with cab mounted headlights power flows from terminal 5 to terminal 7 of the upper/lower
headlight switch to fuse 11 (switch in the grille headlight position). Power flows from fuse 11 to terminal 5 of the
rear fog light switch.
With the rear fog light in the On position power flows from terminal 5 to terminal 1 of the rear work light switch
to the rear fog light, through the light to ground at G5 illuminating the light.
Power also flows from terminal 1 to terminal 10 of the rear fog light switch, trough the warning light to ground
at G1, illuminating the warning light.
SM 8-12540 Issued 09-2004

SECTION 4001 47
REAR FOG LIGHT FRONT GRILLE HEADLIGHTS CAB MOUNTED HEADLIGHTS
A
B
17
4 5
6
C
9 10 11 12
18
E F
2 D
13 14
8 G 15 16
MI04G025
Key
1. MAIN LIGHT SWITCH 11. FUSE 13 (10 AMP) A. TO INSTRUMENT CLUSTER
2. STALK SWITCH (TURN/HORN/HIGH-LOW BEAM) 12. FUSE 15 (15 AMP) B. TO SIDE/TAIL LIGHTS
3. TURN SIGNAL SWITCH SELF CANCELLING MODULE 13. LEFT HAND GRILLE HEADLIGHT C. TO TURN SIGNAL LIGHTS
4. HEADLIGHT LOW BEAM RELAY 14. RIGHT HAND GRILLE HEADLIGHT D. TO HORN
5. HEADLIGHT HIGH BEAM RELAY 15. LEFT HAND CAB MOUNTED HEADLIGHT (IF EQUIPPED) E. FROM FRONT GRILLE WORK LIGHTS
6. UPPER/LOWER HEADLIGHT SWITCH (IF EQUIPPED) - SEE NOTE 2 16. RIGHT HAND CAB MOUNTED HEADLIGHT (IF EQUIPPED) F. FROM STARTER RELAY
7. FOG LIGHT SWITCH (IF EQUIPPED) 17. INSTRUMENT CLUSTER G. FROM SPLICE E-SP5 - AIR CONDITIONING DIODE, AIR FILTER RESTRICTION
8. REAR FOG LIGHT (IF EQUIPPED) 18. MAIN CAB CHASSIS GROUND SPLICE 11 SWITCH, COOLANT LEVEL SENDER
9. FUSE 11 (15 AMP)
10. CIRCUIT BREAKER FUSE LOCATION 10 (10 AMP)
NOTE 2: For tractors not equipped with cab mounted headlights jumper leads are installed between the open terminals of the
switch terminal block as shown.
SM 8-12540 Issued 09-2004
48 SECTION 4001
SM 8-12540 Issued 09-2004

SECTION 4001 49
TAIL LIGHTS, RIGHT HAND CONSOLE LIGHT AND HEADLIGHTS

Tail Light Circuit

Battery power is connected to the main light switch terminal 1. With the main light switch in position 3 power flows
through the switch from terminal 1 to terminal 3, then to fuse 6.
Power flows through fuse 6 to terminal CN1-24 of the instrument cluster, rear tail lights, number plate light (if
equipped and terminal 2 of the 7 pin trailer connector. Power then flows through the rear tail lights to ground at
G5 illuminating the rear tail lights.
Power also flows through the instrument cluster rear fender work light warning lamp to terminal CN1-14 (refer to
Right Hand Console Light Circuit

Battery power is connected to the main light switch terminal 1. With the main light switch in position 3 or 4 power
flows through the switch from terminal 1 to terminal 5 to the right hand console light. Power then flows through
the light to ground at G5 through the main cab splice 11, illuminating the right hand console light.
Headlights Circuit
Headlight Low Beam

beam relay.
With the low beam relay energised battery power flows from terminal 3 terminal 5 of the relay then to the circuit
breaker 10. Power flows from the circuit breaker 10 to both the left hand and right hand low beam lights. Power
then flows through the headlights to the battery negative terminal, illuminating both the low beam lights.
Headlight High Beam

1. With the Turn/Horn/High/Low Beam switch in the High Beam position, power flows through the headlight high
beam relay.
With the high beam relay energised battery power flows from terminal 3 terminal 5 of the relay then to the fuse
13 and to terminal CN1-24 of the instrument cluster. Power flows from fuse 13 to both the left hand and right
hand high beam lights. Power then flows through the headlights to the battery negative terminal, illuminating
both the high beam lights.
SM 8-12540 Issued 09-2004

50 SECTION 4001
Headlight High Beam Flash

With the high beam relay energised battery power flows from terminal 3 terminal 5 then to the fuse 13 and to
terminal CN1-24 of the instrument cluster. Power flows from fuse 13 to both the left hand and right hand high
beam lights. Power then flows through the headlights to the battery negative terminal, illuminating both the high
beam lights.
SM 8-12540 Issued 09-2004

SECTION 4001 51
REAR TAIL LIGHT, OPTIONAL No PLATE LIGHT AND RIGHT HAND CONSOLE LIGHT HEADLIGHTS
1 2
C
15
13 14
3
D
A
12
A B
16 17
11
F G
6
18 19
10 E
4 5 7
H
MI04G028
Key
1. FUSE 6 (5 AMP) 12. INSTRUMENT CLUSTER A. TO FRONT POSITION LIGHT
2. FUSE 7 (5 AMP) 13. HEADLIGHT LOW BEAM RELAY B. TO RADIO
3. MAIN LIGHT SWITCH 14. HEADLIGHT HIGH BEAM RELAY C. TO TURN SIGNAL LIGHTS
4. OPTIONAL No PLATE LIGHT 15. SWITCH TERMINAL BLOCK D. TO WORK LIGHTS
5. LEFT HAND TAIL LIGHT 16. CIRCUIT BREAKER FUSE LOCATION 10 (10 AMP) E. TO HORN
6. 7 POLE TRAILER CONNECTOR 17. FUSE 13 (10 AMP) F. FROM FRONT GRILLE WORK LIGHTS
7. RIGHT HAND TAIL LIGHT 18. LEFT HAND GRILLE HEADLIGHT G. FROM STARTER RELAY
8. RIGHT HAND CONSOLE LIGHT 19. RIGHT HAND GRILLE HEADLIGHT H. FROM SPLICE E-SP5 - AIR CONDITIONING DIODE, AIR FILTER RESTRICTION
9. MAIN CAB CHASSIS GROUND SPLICE 11 SWITCH, COOLANT LEVEL SENDER
10. STALK SWITCH (TURN/HORN/HIGH-LOW BEAM)
11. TURN SIGNAL SWITCH SELF CANCELLING MODULE
SM 8-12540 Issued 09-2004

52 SECTION 4001
SM 8-12540 Issued 09-2004

SECTION 4001 53
WORK LIGHTS
Rear Work Light Circuit

The rear work lights are controlled by one three position switch located at the left side of the front console.
Position 1 - All rear work lights are OFF.

Position 2 - Rear fenders work lights.
Position 3 - Rear fender work lights and rear cab work lights.
Battery power is available at terminal 3 (through circuit breaker 3) and terminal 6 (through fuse 4) of the rear
work light switch.
Rear Fender Work Lights - Switch Position 2

With the rear work light switch in position 2 power flows through the switch from terminal 6 to terminal 2. Power
flows to the rear fender work lights and terminal CN2-25 of the instrument cluster. Power then flows through the
rear fender work lights to ground at G5 illuminating the rear fender work lights.
Power also flows through the instrument cluster rear fender work light warning lamp to terminal CN1-14 (refer
to Section 10009). Power then flows to ground at the battery negative terminal, illuminating the warning lamp.
Rear Cab Work Lights - Switch Position 3
With the rear work light switch in position 3 power flows through the switch from terminal 3 to terminal 1 and to
terminals 1 of both the left hand and right hand rear work light relays. Power flows through the relay windings
to ground at G1, energising the relays. Power also flows from terminal 1 to terminal 9 of the switch, through the
switch warning lamp to ground at G1, illuminating the warning lamp.
With the left hand rear cab work light relay energised power flows through circuit breaker 3 to terminal 3 of the
relay. Power flows through the relay to terminal 5 and to the left hand rear cab work lights. Power then flows
through the work lights to ground at G4 through the main cab chassis ground splice 12, illuminating the lights.
With the right hand rear cab work light relay energised power flows through circuit breaker 9 to terminal 3 of
the relay. Power flows through the relay to terminal 5 and to the left hand rear cab work lights. Power then flows
SM 8-12540 Issued 09-2004

54 SECTION 4001
Front Work Light Circuit

The front work lights are controlled by one three position switch located at the left side of the front console.

Position 2 - Grille and lower front cab work lights.
Position 3 - Grille, lower front cab work lights and front cab work lights.
Battery power is available at terminal 3 (through circuit breaker 12) and terminal 6 (through circuit breaker 43)
of the front work light switch.
Grille and Front Lower Cab Work Lights - Switch Position 2

With the front work light switch in position 2 power flows through the switch from terminal 6 to terminal 2 and
to terminals 1 of the grille work light relay. Power flows through the relay windings to ground at G1, energising
the relays.
With the grille work light relay energised power flows through fuse 2 to terminal 3 of the relay. Power flows
through the relay to terminal 5 and to the left hand rear cab work lights. Power flows through the relay to terminal
5 and to the grille work lights and the front lower cab work lights. Power then flows through the grille work lights
to ground at the battery negative terminal and through the front lower cab work lights to ground at G4 through
the main cab chassis ground splice 11, illuminating the lights.
Power also flows from terminal 5 of the grille work light relay to terminal CN2-24, through the instrument cluster
grille work light warning lamp to terminal CN1-14 (refer to Section 10009). Power then flows to ground at the
battery negative terminal, illuminating the warning lamp.
Front Cab Work Lights - Switch Position 3

to terminals 1 of both the left hand and right hand front work light relays. Power flows through the relay windings
With the left hand front cab work light relay energised power flows through circuit breaker 12 to terminal 3 of
the relay. Power flows through the relay to terminal 5 and to the left hand front cab work lights. Power then flows
With the right hand front cab work light relay energised power flows through circuit breaker 43 to terminal 3 of
SM 8-12540 Issued 09-2004

SECTION 4001 55
REAR FENDER WORK LIGHTS, AND REAR CAB WORK LIGHTS GRILLE WORK LIGHTS FRONT CAB LOWER WORK LIGHTS FRONT CAB WORK LIGHTS
19
20
1 5 6 7
3 4 21 22 23
2 18
14
A
10 11 12 13
25 26
16 17
15
24
B 27 28 29 30 31 32
8 9
MI04G030
Key
1. FUSE 4 (15 AMP) 15. MAIN CAB CHASSIS GROUND SPLICE 12 25. LEFT HAND FRONT LOWER CAB LOWER WORK LIGHT
2. REAR WORK LIGHT SWITCH 16. LEFT HAND GRILLE WORK LIGHT 26. RIGHT HAND FRONT LOWER CAB LOWER WORK LIGHT A. FROM HEADLIGHTS
3. LEFT HAND REAR WORK LIGHT RELAY 17. RIGHT HAND GRILLE WORK LIGHT 27. LEFT HAND FRONT CAB OUTER WORK LIGHT B. FROM STARTER RELAY
4. RIGHT HAND REAR WORK LIGHT RELAY 18. FRONT WORK LIGHT SWITCH 28. LEFT HAND FRONT CAB MIDDLE WORK LIGHT C. TO SPLICE E-SP5 - AIR CONDITIONING DIODE,
5. CIRCUIT BREAKER FUSE LOCATION 9 (25 AMP) 19. CIRCUIT BREAKER FUSE LOCATION 12 (25 AMP) 29. LEFT HAND FRONT CAB INNER WORK LIGHT AIR FILTER RESTRICTION SWITCH, COOLANT
6. CIRCUIT BREAKER FUSE LOCATION 3 (25 AMP) 20. CIRCUIT BREAKER FUSE LOCATION 44 (25 AMP) 30. RIGHT HAND FRONT CAB INNER WORK LIGHT LEVEL SENDER
7. FUSE 2 (25 AMP) 21. GRILLE AND FRONT LOWER CAB WORK LIGHT RELAY 31. RIGHT HAND FRONT CAB MIDDLE WORK LIGHT
8. LEFT HAND REAR FENDER WORK LIGHT 22. LEFT HAND FRONT CAB WORK LIGHT RELAY 32. RIGHT HAND FRONT CAB OUTER WORK LIGHT
9. RIGHT HAND REAR FENDER WORK LIGHT 23. RIGHT HAND FRONT CAB WORK LIGHT RELAY
10. LEFT HAND REAR CAB OUTER WORK LIGHT 24. MAIN CAB CHASSIS GROUND SPLICE 11
11. LEFT HAND REAR CAB INNER WORK LIGHT
12. RIGHT HAND REAR CAB INNER WORK LIGHT
13. RIGHT HAND REAR CAB OUTER WORK LIGHT
14. INSTRUMENT CLUSTER
SM 8-12540 Issued 09-2004
56 SECTION 4001
SM 8-12540 Issued 09-2004

SECTION 4001 57
WORK LIGHTS
Rear Work Light Circuit

The rear work lights are controlled by one three position switch located at the left side of the front console.

Position 2 - Rear fenders work lights.
Position 3 - Rear fender work lights and rear cab work lights.
NOTE: The work lights can only be operated with the main light switch in position 4.
Battery power is available at terminal 1 of the main light switch. With the main light switch in position 4, power flows
through the switch to terminal 2 and to terminals 6 and 3 of the rear work light switch.
Rear Fender Work Lights - Switch Position 2

With the rear work light switch in position 2 power flows through the switch from terminal 6 to terminal 2, then
to fuse 4. Power flows through fuse 4 to the rear fender work lights, terminal CN2-25 of the instrument cluster
and terminal 2 of the 7 pin trailer connector. Power then flows through the rear fender work lights to ground at
G5 illuminating the rear fender work lights.
Power also flows through the instrument cluster rear fender work light warning lamp to terminal CN1-14 (refer to
Rear Cab Work Lights - Switch Position 3
With the rear work light switch in position 3 power flows through the switch from terminal 3 to terminal 1 and to
terminals 1 of both the left hand and right hand rear work light relays. Power flows through the relay windings
With the left hand rear cab work light relay energised power flows through circuit breaker 3 to terminal 3 of the
relay. Power flows through the relay to terminal 5 and to the left hand rear cab work lights. Power then flows
With the right hand rear cab work light relay energised power flows through circuit breaker 9 to terminal 3 of
the relay. Power flows through the relay to terminal 5 and to the left hand rear cab work lights. Power then flows
SM 8-12540 Issued 09-2004

58 SECTION 4001
Front Work Light Circuit

The front work lights are controlled by one three position switch located at the left side of the front console.

Position 2 - Grille and lower front cab work lights.
Position 3 - Grille, lower front cab work lights and front cab work lights.
NOTE: The work lights can only be operated with the rotary light switch in position 4.
Battery power is available at terminal 1 of the light switch. With the light switch in position 4, power flows through
the switch to terminal 2 and to terminals 6 and 3 of the front work light switch.
Grille and Front Lower Cab Work Lights - Switch Position 2

to terminals 1 of the grille work light relay. Power flows through the relay windings to ground at G1, energising
the relays.
With the grille work light relay energised power flows through fuse 2 to terminal 3 of the relay. Power flows
through the relay to terminal 5 and to the left hand rear cab work lights. Power flows through the relay to terminal
5 and to the grille work lights and the front lower cab work lights. Power then flows through the grille work lights
to ground at the battery negative terminal and through the front lower cab work lights to ground at G4 through
the main cab chassis ground splice 11, illuminating the lights.
Power also flows from terminal 5 of the grille work light relay to terminal CN2-24, through the instrument cluster grille
work light warning lamp to terminal CN1-14 (refer to Section 10009). Power then flows to ground at the battery
negative terminal, illuminating the warning lamp.
Front Cab Work Lights - Switch Position 3
to terminals 1 of both the left hand and right hand front work light relays. Power flows through the relay windings
With the left hand front cab work light relay energised power flows through circuit breaker 12 to terminal 3 of
With the right hand front cab work light relay energised power flows through circuit breaker 43 to terminal 3 of
SM 8-12540 Issued 09-2004

SECTION 4001 59
REAR FENDER WORK LIGHTS, AND REAR CAB WORK LIGHTS GRILLE WORK LIGHTS FRONT CAB LOWER WORK LIGHTS FRONT CAB WORK LIGHTS
1 22
A 2
23
7 8 9
B
5 6 24 25 26
3 21
C
D
4
18
13 14 15 16
28 29
19 20
17
27
F 30 31 32 33
12
10 11
MI04G029
Key
1. MAIN LIGHT SWITCH 15. RIGHT HAND REAR CAB INNER WORK LIGHT 27. MAIN CAB CHASSIS GROUND SPLICE 11 A. TO TAIL LIGHTS
2. FUSE 7 (5 AMP) 16. RIGHT HAND REAR CAB OUTER WORK LIGHT 28. LEFT HAND FRONT CAB LOWER WORK LIGHT B. TO WORK LIGHTS
3. REAR WORK LIGHT SWITCH 17. MAIN CAB CHASSIS GROUND SPLICE 12 29. RIGHT HAND FRONT CAB LOWER WORK LIGHT C. TO RIGHT HAND CONSOLE LIGHTS AND RADIO
4. FUSE 4 (15 AMP) 18. INSTRUMENT CLUSTER 30. LEFT HAND FRONT CAB OUTER WORK LIGHT D. TO HEADLIGHTS
5. LEFT HAND REAR WORK LIGHT RELAY 19. LEFT HAND GRILLE WORK LIGHT 31. LEFT HAND FRONT CAB INNER WORK LIGHT D. TO HORN
6. RIGHT HAND REAR WORK LIGHT RELAY 20. RIGHT HAND GRILLE WORK LIGHT 32. RIGHT HAND FRONT CAB INNER WORK LIGHT E. FROM HEADLIGHTS
7. CIRCUIT BREAKER FUSE LOCATION 9 (25 AMP) 21. FRONT WORK LIGHT SWITCH 33. RIGHT HAND FRONT CAB OUTER WORK LIGHT F. FROM STARTER RELAY
8. CIRCUIT BREAKER FUSE LOCATION 3 (25 AMP) 22. CIRCUIT BREAKER FUSE LOCATION 12 (25 AMP) G. TO SPLICE E-SP5 - AIR CONDITIONING DIODE, AIR FILTER
9. FUSE 2 (25 AMP) 23. CIRCUIT BREAKER FUSE LOCATION 44 (25 AMP) RESTRICTION SWITCH, COOLANT LEVEL SENDER
10. LEFT HAND REAR FENDER WORK LIGHT 24. GRILLE AND FRONT LOWER CAB WORK LIGHT RELAY
11. RIGHT HAND REAR FENDER WORK LIGHT 25. LEFT HAND FRONT CAB WORK LIGHT RELAY
12. 7 PIN TRAILER CONNECTOR 26. RIGHT HAND FRONT CAB WORK LIGHT RELAY
13. LEFT HAND REAR CAB OUTER WORK LIGHT
14. LEFT HAND REAR CAB INNER WORK LIGHT
SM 8-12540 Issued 09-2004
60 SECTION 4001
MAIN CONNECTORS
Connector 1 Connector 2
Location: Instrument Panel Location: Cab Roof
INSTRUMENT PANEL TO CAB HARNESS CAB HARNESS TO CAB ROOF HARNESS

(CAB HARNESS SIDE) (CAB HARNESS SIDE)
Cavity Wire No Circuit Cavity Wire No Circuit

A 830 R FRONT WIPER MOTOR B+ A 750 BR RH REAR TURN SIGNAL (**)
B 835 O FRONT WIPER/WASHER B 750 BR RH REAR WORK LIGHT
C 871 R INTERIOR LIGHT, RADIO C 784 BR NUMBER PLATE LIGHT (*)
D 923 O A/C HIGH PRESSURE SWITCH D 877 BR AERIAL GROUND
E 924 O A/C HIGH PRESSURE SWITCH E 790 BR LH REAR WORK LIGHT
F 962 O A/C COMPRESSOR F 781 V RH FRONT WORK LIGHT
G 870 R RADIO SWITCHED B+ G 726 P NUMBER PLATE LIGHT (*)
H 756 P LH TURN SIGNAL H 791 V LH FRONT WORK LIGHT
J 757 P RH TURN SIGNAL J 794 P RH REAR WORK LIGHT
K 784 V LOWER CAB WORK LIGHTS K 756 P LH TURN SIGNAL (**)
L 776 P ROTARY BEACON LIGHT L 757 P RH TURN SIGNAL (**)
M 794 P LH REAR CAB WORK LIGHTS M 794 P LH REAR WORK LIGHT
N 794 P RH REAR CAB WORK LIGHTS N 750 BR LH FRONT WORK LIGHT
P 726 P RH POSITION LIGHT/NO PLATE P 790 BR RH FRONT WORK LIGHT
LIGHT
R 750 BR NOT USED
R 707 P LH POSITION LIGHT S 750 BR NOT USED
S 840 R REAR WINDSCREEN WIPER B+
T 750 BR LH FRONT WORK LIGHT
T 842 O REAR WINDSCREEN WASHER
U ----- OPEN
U 952 B BLOWER MOTOR PWM
V ----- OPEN
CONTROLLER CLEAN GROUND
W ----- OPEN
V 953 B BLOWER MOTOR PWM
CONTROLLER CLEAN GROUND X ----- OPEN
W 781 V RH FRONT CAB WORK LIGHTS Y ----- OPEN
X 791 V LH FRONT CAB WORK LIGHTS Z ----- OPEN
Y 747 P CAB HEADLIGHTS (HIGH)

Z 746 P CAB HEADLIGHTS (LOW)
(*) European Specification Tractors Only.
(**) American Specification Tractors Only.
SM 8-12540 Issued 09-2004

SECTION 4001 61
Connector 10
Location: Cab Firewall
DI99A036
ENGINE TO INSTRUMENT PANEL HARNESS

(ENGINE HARNESS SIDE)

1 802 O A/C HIGH PRESSURE SWITCH 22 737 P LH HEADLIGHT - LOW BEAM
2 625 W B+ FROM STARTER 23 740 P LH HEADLIGHT - HIGH BEAM
3 804 O A/C HIGH PRESSURE SWITCH 24 ----- OPEN
4 162 R UNSWITCHED B+ - CLOCK, RADIO 25 280 BR RADAR GROUND
AND INSTRUMENT CLUSTER
26 281 Y RADAR SIGNAL
5 200 BR/W INSTRUMENT CLUSTER CLEAN 27 280 R RADAR B+
GROUND (BATTERY - TERMINAL)
28 282 Y RADAR PRESENT
6 803 O A/C COMPRESSOR CLUTCH
29 603 R VP44 POWER (10A)
7 ----- OPEN
30 600 R BATTERY B+ (7.5A)
8 ----- OPEN
31 784 V WORK LIGHTS
9 231 Y COOLANT LEVEL
32 601 R BATTERY B+ (7.5A)
10 216 Y ALTERNATOR ‘W’ TERMINAL,
ENGINE RPM 33 132 R SWITCHED B+
11 ----- OPEN 34 602 R BATTERY B+ (7.5A)
12 ----- OPEN 35 603 R VP44 POWER (10A)
13 266 Y AIR FILTER RESTRICTION SWITCH 36 900 Y CAN HIGH
14 121 Y ALTERNATOR D+ TERMINAL, 37 900 LG CAN LOW

WARNING LIGHT AND EXCITE 38 ----- OPEN
15 829 BR/W ATC CLEAN GROUND 39 ----- OPEN
16 890 R HORN B+ 40 644 Y REMOTE THROTTLE SIGNAL
17 890 BR HORN GROUND 41 644 R REMOTE THROTTLE (5V)
19 738 P RH HEADLIGHT - LOW BEAM 43 ----- OPEN
20 741 P RH HEADLIGHT - HIGH BEAM 44 651 BR REMOTE THROTTLE (0V)
21 ----- OPEN 45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12540 Issued 09-2004

62 SECTION 4001
Location: Right Hand Console Location: Right Hand Console
477I96
MI04J044
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
(RIGHT HAND CONSOLE HARNESS SIDE) (RIGHT HAND CONSOLE HARNESS SIDE)

A 599 BR AUDIBLE ALARM 1 240 Y AIR TRAILER BRAKE PRESSURE
B 707 P LH TAIL/POSITION LIGHT SWITCH
2 515 R LOADER CONTROLS B+
C 708 P RH TAIL/POSITION LIGHT
D 500 R HITCH B+ 3 656Y INCHING PEDAL
POTENTIOMETER SIGNAL
E 590 R CAB CONTROLLER SWITCHED B+
4 657 Y TOP OF PEDAL SWITCH
F 501 R HITCH CONTROLLER
SWITCHED B+ 5 600 Y BOTTOM OF PEDAL SWITCH
6 233 Y FUEL LEVEL SENDER
G 784 V REAR FENDER WORK LIGHTS
H 810 R SEAT B+ 7 656 BR INCHING PEDAL
POTENTIOMETER GROUND
J 530 R MFD AND DIFF LOCK B+
8 656 R INCHING PEDAL
K 134 R AUXILIARY POWER CONNECTOR POTENTIOMETER B+
SWITCHED B+
9 536 LB LEFT HAND BRAKE SIGNAL
L 756 P RH TURN SIGNAL
10 ----- OPEN
M 757 P LH TURN SIGNAL
11 500 R CAB CONTROLLER BATTERY B+
N ----- OPEN
12 550 R TRANSMISSION CONTROLLER
P 133 R AUXILIARY POWER SWITCHED B+
FENDER HARNESS
CONNECTOR (*) OR
7 PIN CONNECTOR (**)
R 135 R RH CONSOLE AUXILIARY POWER

UNSWITCHED B+
S 817 R CIGAR LIGHTER
T 269 Y PARK BRAKE WARNING LIGHT
U 702 R BRAKE LIGHTS (*)
V ----- OPEN
W 785 V REAR FOG LIGHTS (*)
X 254 Y PARK LOCK SIGNAL

Y 276 LB 1000 RPM PTO SWITCH
Z (VP) R AUXILIARY/REMOTE CONTROLLER
VP IN

SM 8-12540 Issued 09-2004

SECTION 4001 63
MI04J045 478I96

1 510 T F/N/R B+ A 835 O FRONT WINDSCREEN WASHER
2 511 T F/N/R - FORWARD B 845 O REAR WINDSHIELD WASHER
3 ----- OPEN C 550 R FRONT PTO B+
4 606 W IMPLEMENT INTERFACE D 551 LB FRONT PTO SIGNAL
CONNECTOR KEY SENSING E 590 R PTO B+
5 (IIC) R IMPLEMENT INTERFACE
F 161 R AUXILIARY/REMOTE VALVE
CONNECTOR BATTERY B+ CONTROLLER SWITCHED B+
6 513 T F/N/R - REVERSE
G 134 R IMPLEMENT INTERFACE
7 531 LB RIGHT HAND BRAKE SIGNAL CONNECTOR SWITCHED B+
8 514 T F/N/R - NEUTRAL H 776 P ROTARY BEACON LIGHT B+
9 ----- OPEN J 531 R SUSPENDED FRONT AXLE
BATTERY B+
10 281 Y HITCH RADAR SIGNAL
K 530 R SUSPENDED FRONT AXLE
SWITCHED B+
12 563 LB IMPLEMENT DOWN
L 900 Y CAN HIGH
M 900 LG CAN LOW
N 121 Y ALTERNATOR D+ EXCITE
P ----- OPEN
R ----- OPEN
S 644 R REMOTE THROTTLE (5V)
T 644Y REMOTE THROTTLE SIGNAL
U 644 BR REMOTE THROTTLE (0V)
V 160 R AUXILIARY/REMOTE VALVE
CONTROLLER BATTERY B+
W ----- OPEN
X 850 R CAB SUSPENSION CONTROLLER
SWITCHED B+
Y (ARM) R ARMREST SWITCHED B+
Z ----- OPEN
SM 8-12540 Issued 09-2004

64 SECTION 4001
Connector 30 (34 Pin) Connector 31 (26 Pin)

Location: Instrument Cluster Location: Instrument Cluster
MI04A057 MI04A056
INSTRUMENT CLUSTER CONNECTOR C1 INSTRUMENT CLUSTER CONNECTOR C2

1 ----- OPEN 1 202 R BATTERY POWER - CLOCK
2 ----- OPEN 2 ----- OPEN
3 563 LB TRAILED IMPLEMENT SWITCH 3 ----- OPEN
4 ----- OPEN 4 (BOOT) BOOTLOAD
5 ----- OPEN DB
5 ----- OPEN
6 ----- OPEN
7 ----- OPEN 6 590 R AUDIBLE ALARM
8 233 Y FUEL LEVEL 7 200 R SWITCHED B+

8 ----- OPEN
9 (GND) DB BOOTLOAD GROUND
10 900 Y CAN HIGH 9 ----- OPEN
11 551 LB FRONT PTO 10 ----- OPEN

13 269 Y PARK BRAKE WARNING LIGHT 12 121 Y ALTERNATOR D+ WARNING LIGHT
14 ----- OPEN 13 280 R RADAR B+

14 200 BR/W CLEAN GROUND
15 ----- OPEN
16 ----- OPEN 15 281 Y RADAR SIGNAL
17 280 BR RADAR GROUND 16 (RST) DB BOOTLOAD RESET

17 (TX DB RS232 TX
18 900 LG CAN LOW
19 ----- OPEN 18 ----- OPEN
20 ----- OPEN 19 ----- OPEN

20 ----- OPEN
21 769 P 1ST TRAILER TURN SIGNAL
22 757 P RIGHT HAND TURN SIGNAL 21 266 Y AIR FILTER RESTRICTION
23 ----- OPEN 22 216 Y ALTERNATOR W TERMINAL

23 (RX DB RS232 RX
24 706 P POSITION LIGHT
25 ----- OPEN 24 784 V FRONT LOWER WORK LIGHTS
26 ----- OPEN 25 784 P REAR LOWER WORK LIGHTS

26 201 R ACCESSORY POWER B+
27 770 P 2ND TRAILER TURN SIGNAL
28 276 Y 1000 PTO SWITCH
29 756 P LEFT HAND TURN SIGNAL
30 240 Y AIR TRAILER BRAKE PRESSURE
31 723 P HIGH BEAM WARNING LIGHT
32 ----- OPEN
33 ----- OPEN
34 ----- OPEN
SM 8-12540 Issued 09-2004

SECTION 4001 65
Location: Instrument Panel Location: Below Rear of Cab (Right Hand Side)
MI04J044 MI04A090
INSTRUMENT PANEL TO F/N/R/P HARNESS REAR FENDER HARNESS TO TRANSMISSION HARNESS

(INSTRUMENT PANEL HARNESS SIDE) (TRANSMISSION HARNESS SIDE)

1 622 W KEY SWITCH (START) A (GND) CLEAN GROUND
BR/W
2 625 W STARTER RELAY
B 240 Y AIR TRAILER BRAKE PRESSURE
3 562 R SWITCHED POWER
SENDER
4 254 Y PARK
C 233 Y FUEL LEVEL SENDER
5 513 T REVERSE
D (GND) CLEAN GROUND
6 511 T FORWARD BR/W
7 514 T NEUTRAL E 507 R HITCH POSITION /LOAD PIN B+
8 510 T F/N/R POWER F 507 LB HITCH POSITION SIGNAL
9 890 BR HORN G 507 BR/W HITCH POSITION GROUND
10 ----- NOT USED H (VP) R VP OUT B+
11 ----- NOT USED J 900 Y CAN HIGH
12 ----- NOT USED K 900 LG CAN LOW
L 515 LB LEFT HAND LOAD PIN SIGNAL
Connector 33 M 514 LB RIGHT HAND LOAD PIN SIGNAL
Location: Instrument Panel N 215 Y WHEEL SPEED SIGNAL
O 215 BR/W WHEEL SPEED GROUND
P 513 LB HITCH RAISE SOLENOID
Q 512 LB HITCH LOWER SOLENOID
R 511 LB HITCH SOLENOID COMMON
S 662 R BOTTOM OF PEDAL SIGNAL
T 550 R TRANSMISSION CONTROLLER
SWITCHED B+
U ----- OPEN
MI04B088
V 514 BR LOAD PIN GROUND
INSTRUMENT PANEL TO STALK SWITCH HARNESS W 276 T 540/1000 PTO SIGNAL
(INSTRUMENT PANEL HARNESS SIDE)
X 276 T 540/1000 PTO SWITCHED B+
Cavity Wire No Circuit
1 763 P TURN SIGNAL COMMON
2 756 P LEFT TURN
3 757 P RIGHT TURN
4 (FNR) BR GROUND (HEADLIGHT RELAYS
5 727 BR LOW BEAM RELAY GROUND
6 726 BR LOW BEAM RELAY GROUND
7 (FNR) BR HEADLIGHT FLASH GROUND
8 736 BR HORN
SM 8-12540 Issued 09-2004

66 SECTION 4001
Connector 50
Location: Cab Floor (Right Hand Console)
DI99A036
FENDER HARNESS TO ARMREST HARNESS

(FENDER HARNESS SIDE)

1 540 R POTENTIOMETER REFERENCE 5V 27 515 DB AUXILIARY VALVE JOYSTICK 1A
SIGNAL
2 540 BR ARM REST POTENTIOMETER 0V
3 508 DB AUXILIARY VALVE TIMER 1 SIGNAL 28 516 DB AUXILIARY VALVE JOYSTICK 1B
SIGNAL
4 509 DB AUXILIARY VALVE TIMER 2 SIGNAL
29 514 DB AUXILIARY VALVE JOYSTICK 2A
5 510 DB AUXILIARY VALVE TIMER 3 SIGNAL SIGNAL
8 511DB AUXILIARY VALVE FLOW 1 SIGNAL 31 518 DB 5TH AUXILIARY VALVE RAISE
9 512 DB AUXILIARY VALVE FLOW 2 SIGNAL 32 517 DB 5TH AUXILIARY VALVE LOWER
10 513 DB AUXILIARY VALVE FLOW 3 SIGNAL 33 527 DB GEAR SKIP SWITCH B+
11 530 DB AUXILIARY VALVE FLOW 4 SIGNAL 34 BR/W GEAR SKIP CLEAN GROUND
12 531 DB AUXILIARY VALVE FLOW 5 SIGNAL 35 (ARM) R ARMREST CONTROL

SWITCHED B+
13 644 R REMOTE THROTTLE (5V)
36 BR/W ARMREST CONTROL CLEAN
14 644Y REMOTE THROTTLE SIGNAL
GROUND
15 644 BR REMOTE THROTTLE (0V) 37 ----- OPEN
16 502 DB STOP SWITCH 38 ----- OPEN
17 503 DB STOP SWITCH
39 ----- OPEN
18 (ARM) R GEAR UP SHIFT SWITCHED B+
40 ----- OPEN
19 525 DB GEAR UP SHIFT SIGNAL
41 ----- OPEN
20 (ARM) R GEAR DOWN SHIFT SWITCHED B+
42 ----- OPEN
21 524 DB GEAR UP SHIFT SIGNAL 43 ----- OPEN
22 501 DB HITCH ENABLE SIGNAL 44 ----- OPEN
23 522 DB HITCH ENABLE LIGHT GROUND
45 ----- OPEN
24 571 R HITCH CONTROL SWITCH 10V
46 ----- OPEN
25 571 BR HITCH CONTROL SWITCH 0V
47 ----- OPEN
26 510 LB HITCH CONTROL SWITCH SIGNAL
48 ----- OPEN
SM 8-12540 Issued 09-2004

SECTION 4001 67
Connector 51
DI99A036
RIGHT HAND CONSOLE TO FENDER HARNESS


1 532 LB DIFFERENTIAL ON SIGNAL 25 513 T REVERSE SIGNAL
2 233 Y FUEL LEVEL SENDER 26 (ARM) R ARMREST CONTROL
3 591 LB REAR PTO ON SIGNAL SWITCHED B+
27 (VP) R AUXILIARY/REMOTE VALVE
4 592 LB REAR PTO STOP SIGNAL
CONTROLLER VP B+
5 592 LB AUTO PTO SIGNAL
28 514 T NEUTRAL SIGNAL
6 501 R HITCH SWITCHED B+
29 303 T OPERATOR PRESENCE SWITCH
7 541 LB MFD ON SIGNAL
30 590 R 540/1000 PTO SWITCH B+
8 254 Y PARK LOCK SIGNAL
9 ----- OPEN
32 ----- OPEN
10 590 R PTO INDICATOR LIGHT
33 551 LB FRONT PTO SOLENOID
11 563 LB IMPLEMENT UP SWITCH
34 BR/W CLEAN GROUND
12 594 LB AUTO PTO SET SIGNAL
35 565 LB AUTO MFD SIGNAL
13 510 T F/N/R B+
36 546 LB AUTO DIFFERENTIAL LOCK
14 511 T FORWARD SIGNAL SIGNAL
15 121 Y ALTERNATOR D+ 37 563 LB LEFT HAND BRAKE SIGNAL
16 595 LB AUTO PTO INDICATOR LIGHT 38 531 LB RIGHT HAND BRAKE SIGNAL
17 566 LB AUTO MFD INDICATOR LIGHT 39 516 T LOADER SOLENOID - RAISE
18 215 Y WHEEL SPEED SIGNAL 40 515 T LOADER SOLENOID - LOWER
19 539 LB AUTO DIFFERENTIAL LOCK 41 662 R BOTTOM OF PEDAL SIGNAL
INDICATOR LIGHT
42 657 Y TOP OF PEDAL SIGNAL
SWITCHED B+ 43 900 Y CAN HIGH
44 900 LG CAN LOW
21 500 R HITCH CONTROLLER BATTERY B+
45 663 R BOTTOM OF PEDAL SIGNAL (CAB
22 590 R CAB CONTROLLER SWITCHED B+
CONTROLLER)
23 160 R AUXILIARY/REMOTE VALVE
24 276 LB 540/1000 PTO SWITCH
48 644 BR REMOTE THROTTLE (0V)
SM 8-12540 Issued 09-2004

68 SECTION 4001
Connector 52


A 756 P LEFT HAND TURN SIGNAL
B 757 P RIGHT HAND TURN SIGNAL
C ----- OPEN
D 707 P LH TAIL/POSITION LIGHT
E 708 P RH TAIL/POSITION LIGHT
F 785 V REAR FOG LIGHT (EUROPE)
G 702 P BRAKE LIGHTS
H 590 R PTO REMOTE SWITCH B+
J ----- OPEN
K ----- OPEN
L 835 O FRONT WINDSCREEN WASHER
M 845 O REAR WINDSCREEN WASHER
N 776 P ROTARY BEACON LIGHT
P ----- OPEN
R ----- OPEN
S ----- OPEN
T 534 DB SUSPENDED FRONT AXLE ON
U 537 DB SUSPENDED FRONT AXLE INDICATOR LIGHT L2
V 536 DB SUSPENDED FRONT AXLE INDICATOR LIGHT L1
W 530 R SUSPENDED FRONT AXLE CONTROLLER
SWITCHED B+
aa 531 R SUSPENDED FRONT AXLE CONTROLLER
UNSWITCHED B+
bb 532 DB SUSPENDED FRONT AXLE OFF
cc ----- OPEN
dd 850 R CAB SUSPENSION CONTROLLER B+
ee ----- OPEN
ff ----- OPEN
gg ----- OPEN
hh ----- OPEN
1 133 R AUXILIARY POWER SWITCHED B+
2 784 P REAR FENDER WORK LIGHTS
3 ----- OPEN
4 ----- OPEN
SM 8-12540 Issued 09-2004

SECTION 4001 69
Connector 53
DI99A036


1 560 R HITCH UPPER LIMIT HIGH 25 ----- OPEN
2 560 LB HITCH UPPER LIMIT SIGNAL 26 ----- OPEN
3 560 BR HITCH UPPER LIMIT LOW 27 281 Y RADAR SIGNAL
4 502 R HITCH DROP SPEED HIGH 28 ----- OPEN
5 502 LB HITCH DROP SPEED SIGNAL 29 ----- OPEN
6 502 BR HITCH DROP SPEED LOW 30 ----- OPEN
7 504 LB HITCH HEIGHT/DEPTH SETTING 31 ----- OPEN
32 ----- OPEN
8 504 R HITCH HEIGHT/DEPTH SETTING
POTENTIOMETER (5V)
CONTROLLER SWITCHED B+
9 504 BR HITCH HEIGHT/DEPTH SETTING
34 ----- OPEN
POTENTIOMETER (0V)
10 505 R HITCH MODE (INTERMIX) HIGH
36 572 BR RIDE CONTROL INDICATOR LIGHT
11 505 LB HITCH MODE (INTERMIX) SIGNAL
GROUND
12 505 BR HITCH MODE (INTERMIX) LOW
37 571 R RIDE CONTROL B+
13 ----- OPEN
38 572 LB RIDE CONTROL ON SIGNAL
14 (AN) LB HITCH DIAGNOSTIC LIGHT SUPPLY
39 ----- OPEN
15 (CAT) BR HITCH DIAGNOSTIC LIGHT
40 ----- OPEN
GROUND
41 269 Y PARK BRAKE SIGNAL
16 ----- OPEN
42 ----- OPEN
17 656 Y INCHING PEDAL POSITION
POTENTIOMETER SIGNAL 43 ----- OPEN
18 656 BR INCHING PEDAL POSITION 44 ----- OPEN

POTENTIOMETER GROUND 45 ----- OPEN
19 656 R INCHING PEDAL POSITION 46 ----- OPEN
POTENTIOMETER HIGH
47 ----- OPEN
20 ----- OPEN
48 ----- OPEN
21 570 LB SLIP INDICATOR LIGHT
22 567 LB SLIP ON SIGNAL
23 567BR SLIP GROUND SIGNAL
24 ----- OPEN
SM 8-12540 Issued 09-2004

70 SECTION 4001
Connector 60
Location: Engine
MI04G013
ENGINE CONTROLLER HARNESS TO ENGINE HARNESS


A 132 R SWITCHED POWER
B 600 R UNSWITCHED POWER (1) B+
C 601R UNSWITCHED POWER (2) B+
D 602 R UNSWITCHED POWER (3) B+
E 600 BR/W CLEAN GROUND
F 600 BR/W CLEAN GROUND
G ----- OPEN
H 600 BR/W CLEAN GROUND
J ----- OPEN
k ----- OPEN
L ----- OPEN
M 603 R UNSWITCHED POWER (VP44) B+
N ----- OPEN
O ----- OPEN
P 600 BR/W CLEAN GROUND
Q ----- OPEN
R ----- OPEN
S 603 R UNSWITCHED POWER
T ----- OPEN
U ----- OPEN
V ----- OPEN
W 600 BR/W CLEAN GROUND
X ----- OPEN
SM 8-12540 Issued 09-2004

SECTION 4001 71
Connector 61
Location: Engine
MI04J042
ENGINE CONTROLLER CONNECTOR

(ENGINE HARNESS TO ENGINE CONTROLLER)

1 ----- OPEN 26 645 Y ON IDLE SIGNAL
2 ----- OPEN 27 ----- OPEN
3 ----- OPEN 28 ----- OPEN
4 ----- OPEN 29 643 R FOOT THROTTLE 5V POWER
5 ----- OPEN 30 643 Y FOOT THROTTLE SIGNAL
6 ----- OPEN 31 641 W COLD START RELAY 2 SIGNAL
7 ----- OPEN 32 ----- OPEN
8 ----- OPEN 33 ----- OPEN
9 644 Y HAND THROTTLE SIGNAL 34 ----- OPEN
10 644 R HAND THROTTLE 5V POWER 35 ----- OPEN
11 ----- OPEN 36 ----- OPEN
12 ----- OPEN 37 ----- OPEN
13 ----- OPEN 38 ----- OPEN
14 ----- OPEN 39 ----- OPEN
15 ----- OPEN 40 658 W WATER IN FUEL SIGNAL
16 ----- OPEN 41 640 W COLD START RELAY 1 SIGNAL
17 ----- OPEN 42 ----- OPEN
18 ----- OPEN 43 ----- OPEN
19 643 BR FOOT THROTTLE RETURN 44 ----- OPEN
20 644 BR HAND THROTTLE 0V 45 644 BR HAND THROTTLE PRESENT
21 ----- OPEN 46 ----- OPEN
22 ----- OPEN 47 ----- OPEN
23 ----- OPEN 48 ----- OPEN
24 ----- OPEN 49 ----- OPEN
25 646 Y OFF IDLE SIGNAL 50 ----- OPEN
SM 8-12540 Issued 09-2004

72 SECTION 4001
Connector 67 Trailer Connectors

Location: Engine (Firewall)
European Specification
MI04J043
ENGINE HARNESS TO HOOD HARNESS

Cavity Wire No Circuit 476I96

1 737 P LH HEADLIGHT LOW BEAM
VIEWED FROM HARNESS SIDE
2 738 P RH HEADLIGHT LOW BEAM
3 740 P LH HEADLIGHT HIGH BEAM
4 741 P RH HEADLIGHT HIGH BEAM 1 757 P LEFT HAND TURN SIGNAL
5 737 BR LH HEADLIGHT GROUND 2 789 V REAR FOG LIGHT

3 133 BR CHASSIS GROUND
6 726 BR RH HEADLIGHT GROUND
7 890 BR HORN (GROUND) 4 756 P RIGHT HAND TURN SIGNAL
5 708 P RIGHT HAND POSITION LIGHT
8 890 R HORN (B+)
6 702 P BRAKE LIGHTS
9 784 V WORK LIGHTS
10 784 BR WORK LIGHT GROUND 7 707 P LEFT HAND POSITION LIGHTS
11 ----- OPEN A 776 P BEACON LIGHT
12 ----- OPEN
American Specification
VIEWED FROM HARNESS SIDE

1 133 BR CHASSIS GROUND
2 784 P WORK LIGHT
4 133 R SWITCHED AUXILIARY POWER B+
5 756 P RIGHT HAND TURN SIGNAL
6 708 P TAIL LIGHTS
7 133 R SWITCHED AUXILIARY POWER B+
SM 8-12540 Issued 09-2004

Section
4002
4002
INSTRUMENTCLUSTERPROGRAMMING
ZTXSeriesTractors
©2004McCormickTractorsInternationalLimited.
SM8-12440 March2004
2 SECTION4002
TABLEOFCONTENTS
GENERALINFORMATION.................................................................................................................................. 3
IGNITIONON/RUNMODE
Duringnormaloperation.............................................................................................................................. 5
EnteringTheProgrammingMode ............................................................................................................... 6
AreaFunction(Menu1)............................................................................................................................... 7
DistanceFunction(Menu2) ...................................................................................................................... 12
PercentageWheelSlip(Menu3) .............................................................................................................. 14
FuelRate(Menu4) ................................................................................................................................... 14
FuelRemainingTimer(Menu5)................................................................................................................ 14
ElectricalSystemVoltage(Menu6) .......................................................................................................... 14
ClusterHitchPositionDisplayCalibration(Menu7).................................................................................. 15
TransmissionCalibration(Menu8) ........................................................................................................... 15
DynamicCalibration(Menu9)................................................................................................................... 16
ACCESSORYMODE
EnteringTheProgrammingMode ............................................................................................................. 17
ProgrammingMPHorkm/h(Menu1) ....................................................................................................... 17
ProgrammingTyreRadius(Menu2) ......................................................................................................... 18
ProgrammingtheServiceIntervals(Menu3)............................................................................................ 21
ServiceReminders(Menu4)..................................................................................................................... 23
ProgrammingImplementWidth(Menu5) ................................................................................................. 23
ProgrammingtheìOLdîInstrumentClusterHours(Menu6) .................................................................... 24
ProgrammingthePTOConstants(ALLPTOoptions)(Menu7) ............................................................... 24
ProgrammingATrueGroundSpeedSensor(Radar)Constant(Menu8) ................................................ 25
ProgrammingtheAxleRatioConstant(Menu9)s..................................................................................... 26
SM8-12440 Issued03-2004
SECTION4002 3
GENERALINFORMATION
1 1A 2 3
4 4
5 5
6
MI03C064
1. FUELLEVELGAUGE 3. ENGINECOOLANTTEMPERATUREGAUGE-
Yellowarea:lowtemperature.
1A.LOWFUELWARNINGLAMP
Greenarea:normalworkingtemperature.
2. McCORMICKLOGO
Redarea:highoperatingtemperature.
or
AIRPRESSUREGAUGE(IfEquipped)-indicates 4. TURNSIGNALINDICATORLAMPS
systempressureforpneumatictrailerbrakes.
5. INDICATOR LAMPS - refer to Operators
Manualformoreinformation.
2B
6. MAIN DIGITAL DISPLAY - refer to Operators
Manualformoreinformation.
2A
MI03D106
NOTE: If the pressure drops below 4 bar (58

psi) the master warning lamp (2A) and low air
pressure lamp (2B) will illuminate and an
audiblealarmwillsound.
SM8-12440 Issued03-2004
4 SECTION4002
The Universal Data Display on the deluxe cluster provides various menus from service reminders, tractor
performanceandotherclusterprogrammingmenus.Thedisplaywillshowdifferentinformationdependingupon
Keyswitchposition.
1. IGNITION ON/RUN MODE (Keyswitch one position clockwise from OFF). - The display provides tractor
performanceinformation,servicereminders,calibrationprocedures,wheelslipetc.etc.
2. ACCESSORY (PROGRAMMING) MODE (Keyswitch one position counterclockwise from OFF). This
positionwillallowtheoperatortoprogramcertainpartsofthecluster.
Thedeluxeinstrumentclusterisprogrammedwhenleavingthefactory.Furtherprogrammingoftheinstrument
clusterwillbenecessaryifthereartyresizehasbeenchangedorifanewinstrumentclusteristobeinstalled.
ProgrammingtheinstrumentclusterrequiresanumberofpredeterminedìConstantsîbeingenteredintothe
instrumentclustermemory.TheseìConstantsîvarybetweenthedifferenttractormodels,itisimportantthatthe
correctprocedureisfollowedforeachmodelsoanaccurateread-outisdisplayedbytheinstrumentcluster.
Toenabletheareafunctiontoworkaccurately,theimplementwidthmustbeprogrammedintothecluster.Also
ifamoreaccurateloadedtireradiusforthegroundspeedisrequiredDynamicCalibrationoftheclustershould
becarriedout.Thesetwofunctionsmustbecarriedoutbytheoperatorduringfieldoperation.
IMPORTANT: Ifaccessoryorbatterypowerislostbeforesavingtheprogrammedconstantinthecluster
memory,theselectedconstantwillnotbestored.Whenthepowerisrestoredtheclusterwillreturnto
itsnormaloperatingmodeandnottotheprogrammingmode.
SM8-12440 Issued03-2004
SECTION4002 5
1. IGNITIONON/RUNMODE
Duringnormaloperation
While the tractor is in operation the cluster and various controllers are monitoring the tractors performance. On
occasionstheclusterwilldisplaycertainmessages/symbolsontheUniversalDataDisplaytoadvisetheoperator.
Wait-To-Start.
Donottryandstarttheenginewiththis symbolilluminated.Waituntilthesymbolgoesoff
beforetryingtostarttheengine.
Thissymbolmayalsoilluminateafterstartuptoindicatetheheaterisstillactivated.
LowTransmissionOilPressure.
Onenginestart-upthissymbolwillilluminateforafewsecondsuntilboosterpumppressureis
maintained.
Ifthesymbolilluminatesduringoperationstopthetractorimmediatelyandrefertosection8001.
WaterinFuelDetected.
Drainfuelfilter.
TractorMalfunction.
Anerrorhasbeendetectedwithinoneormoreofthetractoríscontrollersystemsandanerror
codehasbeengenerated(activeerrorsonly).
IdentifyControllerErrors:
Press the menu button to enter the
menu. Using the UP button scroll through to
establishifmorethanonecontrollerhas
detectederrors.
Each controller is shown on the Universal Data
Display,
Toviewerrorcodes:
Example:
Identify the controller with errors detected, as per
ENG =ENGINE previousprocedure.
IC =INSTRUMENTCLUSTER Press the menu button to enter the
MCC =CABCONTROLSorTRANSMISSION controllererrorcodemenu.
EHR =ELECTRONICHITCH
AVC =AUXILLIARYVALVES If more than one error code has been
generated use the UP button to scroll
followed by the number of indentified errors for throughandidentifyeacherrorcode.
eachcontroller.
NOTE:
Example: MCCcodes1to120=Transmission.
MCCcodes121to162=Cab.
EHR Nohitcherrors.
0
Pressthemenubuttontoexit.
EHR Fourhitcherrorsdetected.
4
SM8-12440 Issued03-2004
6 SECTION4002
QuickReferenceExample: EnteringTheProgrammingMode
STEP1
EHR Threehitcherrors
3 detected.
Press and hold the menu button for 2
seconds.
14 ErrorCode14
STEP2
Use the UP button scroll through each
34 ErrorCode34
menu until you reach the required
display.
The programming structure consists of a number
41 ErrorCode41
main menus. Certain main menus are then
subsequently split into sub menus and sub sub
menus. An example of the programming structure
Exitmenu. isshownbelow.
Main Sub SubSub

Menu Menu Menu
For further information and listings of error codes

refertorelevantservicemanualcontrollersections.
etc.(upto9)
etc.
Exittheprogrammingmodeatanytimebyturning
the keyswitchto the OFF position. When thekey
switch is turned to the on position the cluster will
returntoitsnormaloperatingmode.
SM8-12440 Issued03-2004
SECTION4002 7
AreaFunction(Menu1)
Tochangethecurrentareafunctionstatus
(Menu1-1):
STEP1
Momentarily press the menu button to

enterthesubmenu.
The area function can display the sub-total area

worked per field (up to a maximum of 9 fields), the The current area function status (1) will be
totalareaworked(thetotalofallfieldsworked)and displayedundertheareaicon.
theareaworkedperhour.
NOTE:Priortousingtheareafunctiontheimplement
width must be programmed into the cluster. See
ProgrammingImplementWidth(Menu5)onPage 23
forcorrectprocedure.
NOTE: For trailed implements, a connector is
provided on the harness behind the seven terminal 1
auxiliary electrical socket, to connect an implement
position switch. This will turn the area function off
whennotrequired.Refertomainmanualforfurther STEP2
information with regard to the external implement
switch. Momentarily press the menu button
again.
NOTE: You MUST first enter the main menu
beforebeingabletoviewthesubmenus,as
explainedonPage 6.
Use the UP and Down buttons to
changethestatusaccordingly.
OFF=AreaFunctionOff.
MAN(ON)=AreaFunctionOn.
AUTO=AutoModewillonlyaccumulate
theareaworkedwhentheimplementis
intheloweredposition(working).The
areacountwillturnonandoff
automaticallywhenusingeitherthehitch
raise/lowerswitch,oranexternal
implementswitch,whichhasbeen
connectedintothewiringharness.
STEP3

store the new setting and return to the
mainmenu.
SM8-12440 Issued03-2004
8 SECTION4002
Toselectaspecificfieldandviewareaworkedwiththatfield(Menu1-2):
STEP1 Onceyouhavefoundthecorrectmenu,
momentarily press the menu button
again to enter the sub sub menu. The
enterthesubmenu.
scroll up/down symbol (4) will appear
nexttothecurrentfieldselected.
STEP2
UsetheUPbuttontoscrollthroughthe
sub menus until the field selection
menuisdisplayed,asshownbelow.
NOTE: The STAR (1) next to the field number

identifieswhichfieldiscurrentlyselected,(upto
amaximumofnine).
4
STEP3
UsetheUPandDownbuttonstoscroll
through the sub sub menus until the
3 requiredfieldisfound.
STEP4

storethenewfield.
2
1
1. CURRENTFIELDSELECTED
2. UNITOFMEASUREMENT
3. AREACOVERED

shouldappeartoidentifythenewfieldhasbeen
successfullyselected.
SM8-12440 Issued03-2004
SECTION4002 9
Toresetaspecificfieldareacounter(tozero) Toviewthetotalareaworked(ofallfields,uptoa
(Menu1-3): maximumofnine)(Menu1-4):
STEP1 STEP1
Momentarily press the menu button to Momentarily press the menu button to
enterthesubmenu. enterthesubmenu.
STEP2 STEP2
UsetheUPbuttontoscrollthroughthe UsetheUPbuttontoscrollthroughthe
sub menus until the correct menu is sub menus until the correct menu is
displayed,asshownbelow. displayed,asshownbelow.

identifieswhichfieldiscurrentlyselected.
STEP3
1 UsetheUPandDownbuttonstoscroll
throughtothenextsubmenu.
Onceyouhavefoundthecorrectmenu,
momentarily press the menu button
again to enter the sub sub menu.The
scrollup/downsymbolwillappearnextto
thecurrentfieldselected.
STEP3
through the sub sub menus until the
requiredfieldisfound.
STEP4
Momentarilypressthemenubuttonand
the area counter will zero, will return to
the sub menu and display the current
fieldselected.
SM8-12440 Issued03-2004
10 SECTION4002
Toresetthetotalareacounter(tozero) Toviewthetotalareaperhour(ofallfields,upto
(Menu1-5): amaximumofnine)(Menu1-6):
STEP1 STEP1
STEP2 STEP2
Onceyouhavefoundthecorrectmenu, STEP3
momentarily press the menu button to
resetthetotalareacounter. UsetheUPandDownbuttonstoscroll
NOTE:Whenyouresetthetotalarea throughtothenextsubmenu.
counter each individual field counter
will also be reset and will return to
Menu1-4.
SM8-12440 Issued03-2004
SECTION4002 11
Programminghectaresoracres(Menu1-7):
STEP1

enterthesubmenu.
STEP2
sub menus until the correct menu is
displayed,asshownbelow.
STEP3
enterthesubmenu.

changetheunitofmeasurement.

submenu.
NOTE: If you hold the menu button
youwillexittheprogrammingmode.
SM8-12440 Issued03-2004
12 SECTION4002
DistanceFunction(Menu2)
Tostartthedistancefunction(Menu2-1):
STEP1

enterthesubmenu.
STEP2
The distance function records and displays the
distancetravelled.
sub menus until the correct menu is
Within the Distance menu there are three sub displayed,asshownbelow.
menus, one to turn the distance function On/Off,
one to read current distance travelled and one to
readaaccumulativedistancetravelled.
NOTE: The units for distance travelled is

automatically selected based upon the ground
speedunits.
eg. If your cluster is programmed for mph, then
miles will be displayed. If your cluster is
programmed for km/h, then kilometers will be
displayed.

beforebeingabletoviewthesubmenus,as Onceyouhavefoundthecorrectmenu,
explainedonPage 6. momentarily press the menu button
again to enter the sub menu. The scroll
up/down symbol (1) will appear next to
thecurrentstatus.
STEP3
Use the UP and Down buttons to turn

thedistancefunctionONorOFF.
STEP4
store the new status and return to the
submenu.
SM8-12440 Issued03-2004
SECTION4002 13
Toviewthecurrenttotaldistanceworked To view the accumulative total distance worked

(Menu2-2: (Menu2-3):
STEP1 STEP1
STEP2 STEP2
Toresetthecounter:, Toresetthecounter:,
simply press the menu button and the simply press the menu button and the
totalareawillzero. totalareawillzero.
NOTE: When you reset the

accumulative total counter the
currenttotalcounterwillalsoresetto
zero.
SM8-12440 Issued03-2004
14 SECTION4002
PercentageWheelSlip(Menu3) FuelRate(Menu4)
Thisscreenwillshowtheactualwheelslipandby This screen displays an instantaneous fuel

enteringtheprogrammemenuthesliplimitcanbe consumption(inlitresperhour).
changed.
STEP1 FuelRemainingTimer(Menu5)
enterthemenu.
Thecurrentwheelslipsettingwillbedisplayed.
This screen displays the approximate number of

engine hours remaining before the Low Fuel
WarningLampilluminates.
ElectricalSystemVoltage(Menu6)
Use the UP and Down buttons change
thesettingaccordingly.
Maximum setting is 25% and the

minimumis10%.
STEP2

mainmenu. This screen displays the approximate electrical
systemvoltage.
SM8-12440 Issued03-2004
SECTION4002 15
ClusterHitchPositionDisplayCalibration(Menu7)
STEP4
Theíhitchoverrideíiconwillappearonthedisplay.
Fortheclustertodisplayanaccuratehitchposition
thehitchneedstobecalibrated.
againandreturntothe
STEP1 mainmenu.
Simplypress
Calibrationisnow
completed.
enterthecalibrationmode.
STEP2
The ílower the hitchí icon will appear on the
display. TransmissionCalibration(Menu8)
Lowerthehitchtothebottomstop.
Press tostorethelowerhitchposition.
Refertosection10006forfurtherinformation.
STEP3
Theí raise the hitchí icon will now appear on the
display.
Raisethehitchtotheupperlimit.
NOTE: MakesuretheUpperLimitControlisset
tomaximum(11)position.
Press tostoretheupperhitchposition.
SM8-12440 Issued03-2004
16 SECTION4002
DynamicCalibration(Menu9)
STEP3
60METRES
197FEET
START FINISH
PriortoenteringtheDynamicCalibration
DI96J517
Mode:
Start the tractor and drive SLOWLY toward the
STEP1 startline.
60METRES When the tractor reaches the start line,

momentarilypressthemenubutton.
197FEET
START FINISH
The number of pulses displayed on the cluster will

Markoffastraightlinedistanceof60metres(197 start to increase and the following icon will be
ft). Use an acceptable method to mark the start displayed.
lineandfinishline.
ToentertheDynamicCalibrationMode:
STEP2

enterthecalibrationmode.
The cluster will prompt you to drive the tractor to

thestartlinebydisplayingthefollowingicon. STEP4
When the tractor reaches the finish line,

momentarilypressthemenubutton.
The number of pulses displayed will be stored

automatically into the cluster and will return to the
mainmenu.
Calibrationisnowcompleted.
SM8-12440 Issued03-2004
SECTION4002 17
ACCESSORYMODE-
2. (OnepositioncounterclockwisefromOFF)
EnteringTheProgrammingMode ProgrammingMPHorkm/h
(Menu1)
STEP1
Pressandholdthemenubuttonfor2
seconds.
STEP2
UsingtheUPandDownbuttonsscroll
through each menu until you reach
therequireddisplay. STEP1
Momentarilypressthemenubuttonto
enterthemenu.
The programming structure consists of a number
main menus. Certain main menus are then
subsequentlysplitintosubmenus. Anexampleof
theprogrammingstructureisshownbelow.
Main Sub
Menu Menu changethesettingaccordingly.
STEP2
storethenewsettingandreturntothe
mainmenu.
etc.
etc.
SM8-12440 Issued03-2004
18 SECTION4002
ProgrammingTyreRadius(Menu2)
STEP1

enterthemenu.
In order for the cluster to display the correct

ground speed, the correct tyre radius constant
must be programmed. This setting is normally
programmed into the cluster at the factory and
should not have to be changed. However if 1
differentwheel/tyreequipmentisinstalledthenthe
newtyreradiusconstantmustbeprogrammedinto
thecluster. 2
NOTE: UsethetablesonPage 19andPage 20
thedeterminethecorrecttireradiusconstantto
beprogrammedintothecluster. Thecurrenttyreradiusconstant(1)will beshown
under the icon and directly under that will be the
The radius can differ depending on tyre newconstanttobeprogrammed(2).
manufacturer, tyre wear, tyre pressures and
load.Thetyreradiusconstantsquotedinthetable STEP2
above will provide the correct tractor ground
speed, however the if a more accurate reading is
required then a dynamic calibration is Use the UP and Down buttons to
recommended. See page 16 for further changetheconstantaccordingly.
information.

beforebeingabletoviewthesubmenus,as
explainedonPage 17.
STEP3

store the new constantand return to the
mainmenu.
SM8-12440 Issued03-2004
SECTION4002 19
TireRadiusConstantTable
RearTireSize Constant RearTireSize Constant

8.3-24 470 16.9-24 620
8.3-32 570 16.9-24IND 610
8.3-36 620 16.9-26 645
8.3-38 645 16.9-28 670
8.3-44 720 16.9-28IND 660
9.5-20 445 16.9-30 695
9.5-24 495 16.9-34 745
9.5-28 545 16.9-34IND 730
9.5-36 645 16.9-38 795
9.5-38 670 16.9-42 845
9.5-44 745 17.5L-24IND 580
9.5-48 795 18.4-24IND 635
11.2-20 465 18.4-26 670
11.2-24 515 18.4-26IND 665
11.2-28 565 18.4-28IND 685
11.2-36 665 18.4-30 720
11.2-38 690 18.4-30IND 715
12.4-20 490 18.4-34 770
12.4-24 540 18.4-38 837
12.4-28 590 18.4R-42(R1TREAD) 883
12.4-32 640 18.4-42(R1TREAD) 889
12.4-36 690 18.4R-42(R2TREAD) 903
12.4-38 720 18.4R-46(R1TREAD) 936
12.4-42 796 18.4-46 930
12.4-46 820 19.5L-24IND 610
12.4-54 942 20.8-34 805
13.6-24 560 20.8-38(R2TREAD) 873
13.6-28 610 20.8R-38(R1TREAD) 872
13.6-36 715 20.8R-38(R1WTREAD) 869
13.6-38 740 20.8R-38(R2TREAD) 885
13.6-46 845 20.8-42(R1TREAD) 918
14.9-24 590 20.8-42(R1WTREAD) 919
14.9-24IND 580 20.8R-42(R1TREAD) 926
14.9-26 615 21L-24IND 635
14.9-28 640 21L-30 720
14.9-28IND 630 21.3-26 760
14.9-30 665 21.3-26IND 750
14.9-38 765 21.3-30 810
14.9R-46 882 21.3-34 860
15.5-38 745 24.5-32 848
24.5R-32 851
SM8-12440 Issued03-2004
20 SECTION4002
RearTireSize Constant RearTireSize Constant

28L-26 720 540/70R34 770
30.5LR32 863 540/65R24 620
210/80R16 345 540/65R26 645
260/70R16 360 540/65R28 670
260/70R18 390 540/65R30 695
260/70R20 415 540/65R34 745
300/70R16 375 540/65R38 795
300/70R18 405 580/70R26 670
300/70R20 445 580/70R38 875
300/95R46(R1TREAD) 831 580/70R42 905
320/70R20 465 600/65R28 695
320/70R24 515 600/65R34 770
320/70R28 565 600/65R38 820
340/75R20 480 600/70R30 745
360/70R20 490 620/65R42 860
360/70R24 540 620/70R26 720
360/70R28 590 620/70R38 855
380/70R20 510 620/70R42 905
380/70R24 560 620/75R26 760
380/70R28 610 620/75R30 810
380/75R26 500 620/75R34 860
400/70R24 560 650/65R42 915
420/70R24 590 650/70R26 745
420/70R28 640 650/70R30 795
420/70R30 665 650/65R38 855
420/80R46(R1TREAD) 886 650/65R42 905
440/65R24 560 650/75R32 835
440/65R28 610 650/75R34(R1WTREAD) 881
460/70R24 590 680/70R32 820
480/65R24 590 680/70R34 855
480/65R28 640 680/75R32 870
480/70R24 620 710/75R34 905
480/70R26 645 710/70R38(R1WTREAD) 920
480/70R28 670 750/65R26 770
480/70R30 695 800/60R32 820
480/70R34 745 800/65R32 870
480/70R38 795
500/70R34 745
NOTE: If the size of tire installed on the tractor
is not listed, refer to the tire manufactures
520/70R26 650
specification for the rolling circumference.
520/70R30 720 Divide the specified rolling circumference by
520/70R34 770 6.28 to give the correct Ground Speed tire
520/70R38 820 radiusconstant.
520/85R46(R1WTREAD) 979
SM8-12440 Issued03-2004
SECTION4002 21
ProgrammingtheServiceIntervals(Menu3)
STEP2

changetheserviceintervalaccordingly.
This menu allows the you to program numerous STEP3

service reminders. With each service item
programmed, once the relevant time has elapsed Momentarily press the menu button to
theserviceindicatorsymbolwillilluminate. store the new interval and return to the
mainmenu.
WithintheServiceTimersmenutherearenumerous
sub menus. Each menu allowing the operator to
programtherelevantserviceinterval.Theseservice STEP4
intervals will normally be factory set and will Ifyouwishtochangeafurtherserviceintervalyou
correspond with the Service Interval Quick willhavetoenterthemenuagain.
ReferenceChart found in theLubricationSection of
this manual, however they may be changed as
required. Momentarily press the menu button to
STEP1 enterthemenu.

enterthemenu.
through the menus until you reach the
requiredservice.
Thecurrentserviceinterval(1)willbeshownunder
the icon and directly under that will be the new
intervaltobeprogrammed(2).
SM8-12440 Issued03-2004
22 SECTION4002
STEP5 IconRecognition
Momentarilypressthemenubutton.
TractorMainService
Battery
EngineCoolant
1
EngineAirFilters
2
EngineOil
Once again the current service interval (1) will be
shown under the icon and directly under that will
bethenewintervaltobeprogrammed(2). EngineOilFilter
STEP6
EngineFuelFilter
changetheserviceintervalaccordingly.
Transmission/HydraulicOil
Transmission/HydraulicFilters
STEP7

storethenewinterval. CabAirFilter
Bypressingthebuttonagainyouwillexit Transmission/HydraulicStrainer
the sub menus and return to the main
menu.
EngineCoolantFilter
Repeatssteps4to7asrequired.
SM8-12440 Issued03-2004
SECTION4002 23
ServiceReminders(Menu4) ProgrammingImplementWidth
(Menu5)
This menu displays the total number of hours

remaining before a service is due for each of the To calculate an accurate Area Worked it is
pre programmed service intervals, (as per the necessary to programme the correct implement
previousmenu). widthintothecluster.
As each service interval has elapsed the service STEP1
indicatorsymbol(Spanner/Wrench)willilluminate.
STEP1 Momentarilypressthemenubutton.
STEP2
STEP2 Use the UP and Down buttons to

change the implement width
PresseithertheUPandDownbuttons accordingly.
todisplaytherelevantserviceiconand
the hours remaining before the next
serviceisrequired.
STEP3
STEP3 storethenewimplementwidthandreturn
tothemainmenu.
returntothemainmenu.
SM8-12440 Issued03-2004
24 SECTION4002
Programmingtheì OLdî ProgrammingthePTOConstants

InstrumentClusterHours(Menu6) (ALLPTOoptions)(Menu7)
STEP1
The cluster hourmeter display reading can not be
changed.Anewclusterwillalwaysstartrecording
enterthemenu.
at ë0î. If a new cluster is installed, the recorded
hoursfromtheoldclustercanbeprogrammedinto
a separate ëOLd hour display in the new cluster.
This function provides the option to store and STEP2
display the hours recorded by a replaced cluster,
soanaccuraterecordingofthetractorstotalhours UsetheUPandDownbuttonstoscroll
canbekeptelectronically. through the menus until you reach the
requiredPTOconstanttochange.
STEP1
STEP2
UsetheUPandDownbuttonstoinput
the old cluster engine hours
accordingly.
STEP3
STEP3 OncethecorrectPTOoptionhasbeen
found Momentarily press the menu
Momentarily press the menu button to button. This allows you to enter the
storetheoldhoursandreturntothemain menuandchangetheconstant.
menu.
The current constant will be shown
under the icon and directly under that
will be the new constant to be
programmed.
SM8-12440 Issued03-2004
SECTION4002 25
STEP4 ProgrammingATrueGround
SpeedSensor(Radar)Constant
thenewconstants. (Menu8)
Refertothefollowingtableforthecorrect
constantstoinputintothecluster.
540 750 1000

Model
PTO* PTO PTO
EuropeanSpecification 0 1 1
AmericanSpecification 0 0 1
*NOTE: Even though the ZTX series does not

have a 540 rpm PTO option a zero (0) must be If a true ground speed radar is installed via the
programmed into the cluster. This informs the factoryaconstantwillhavebeenprogrammedinto
cluster that this option is not available and the cluster. However if a McCormick radar is
therefore the cluster will not display any installed as adealeroption it willbe necessaryto
informationforthatoption. programmethecluster.
STEP5 STEP1
storethenewconstantandreturntothe enterthemenu.
mainmenu.
STEP2
theconstant,4150.
STEP3

storetheconstantandreturntothemain
menu.
SM8-12440 Issued03-2004
26 SECTION4002
ProgrammingtheAxleRatio
Constants(Menu9)
STEP1
Momentarily press the menu button

toenterthemenu.
STEP2
theconstant,360.
STEP3
store the new constant and return to
themainmenu.
SM8-12440 Issued03-2004
Section
4004
4004
BATTERY SERVICING AND TESTING

SM 8-10160 March 2001
2 SECTION 4004
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 3
SAFETY PROCEDURES ......................................................................................................................................... 4
MAINTENANCE
Electrolyte Level................................................................................................................................................... 4
Inspecting and Cleaning the Battery, Cables and Terminals ............................................................................... 4
BATTERY TESTING
Method One - Five Step Battery Test .................................................................................................................. 5
Method Two - Using Heavy Duty Battery Tester.................................................................................................. 6
CHARGING THE BATTERY .................................................................................................................................... 8
PREPARING A DRY CHARGED BATTERY FOR USE........................................................................................... 8
BOOSTER BATTERY CONNECTIONS................................................................................................................... 9
SM 8-10160 Issued 03-2001

SECTION 4004 3
SPECIFICATIONS
Type of System ....................................................................................................................12 Volt, Negative Ground
Batteries .........................................................................................One 12 Volt, Low Maintenance Hybrid Battery or
Two 12 Volt, Low Maintenance Hybrid Batteries Connected in Parallel
DIN Type 60527, Top Stud Terminals
BATTER SAE (COLD CRANKING AMPERE RESERVE

IEC DIN
Y TYPE CAPACITY) HOURS CAPACITY
SPECIAL TOOLS
DD98H086 DD98H115
MC10930 HEAVY DUTY BATTERY TESTER MC10932 OPTICAL ENGINE COOLANT AND
OR EQUIVALENT BATTERY ELECTROLYTE TESTER
OR EQUIVALANT
DD98H115
MC10931 RECHARGEABLE BATTERY PACK

OR EQUIVALANT
SM 8-10160 Issued 03-2001

4 SECTION 4004
SAFETY PROCEDURES
WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
! SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND
BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
WARNING: BATTERY ACID CAUSES WARNING: Do not charge a frozen battery,

SEVERE BURNS. Batteries contains ! it can explode, causing serious injury. M529
sulphuric acid. Avoid contact with skin, eyes
or clothing. Antidote: EXTERNAL - flush with
water. INTERNAL - drink large quantities of WARNING: Battery explosion and/or
water or milk. Follow with milk of magnesia, damage to electrical components can result
beaten egg or vegetable oil. Call a physician from improper connection of booster
immediately. EYES - flush with water for 15 ! batteries or charger. Connect positive to
! minutes and get prompt medical attention. positive and negative to negative. Externally,
BATTERIES PRODUCE EXPLOSIVE battery acid can cause burns and blindness,
GASES. Keep sparks, flame and cigarettes and taken internally is poison. M146A
away. Ventilate when charging or using in an
enclosed space. Always shield eyes when
WARNING: Always connect the ground
working near batteries. KEEP OUT OF
cable last and disconnect the ground cable
REACH OF CHILDREN. M144A
! first so you do not cause a spark at the
battery. A spark can cause a battery
WARNING: When working around storage explosion and cause injury. M530
batteries, remember that all of the exposed
! metal parts are ‘live’. Never lay a metal
object across the terminals because a spark
or short circuit will result. M145A
MAINTENANCE
Electrolyte Level
Check the electrolyte level in each cell every 300 hours of operation. The machine is equipped with either one
(1) or two (2) Low Maintenance batteries.
If electrolyte level is low add distilled water to just cover the top of the separators. DO NOT OVER FILL. Do
not use water which contains minerals. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well.
When distilled water is added at ambient temperatures below 0oC (32oF) the batteries must be charged imme-
diately to mix the water and electrolyte or the water will freeze, because the water will stay on top of the elec-
trolyte.
Inspecting and Cleaning the Battery, Cables and Terminals

Inspect the battery at regular intervals for dirt, corrosion and damage. Electrolyte and dirt on the top of the bat-
tery can cause the battery to discharge by providing a passage for the current to flow. Make sure the vents are
installed firmly in position and the battery top is clean and dry. The battery terminals must be kept clean and
tight. Remove all corrosion with a wire brush, then wash with a weak solution of baking soda or ammonia.
Apply petroleum jelly to the terminals to prevent more corrosion. DO NOT apply grease.
SM 8-10160 Issued 03-2001

SECTION 4004 5
BATTERY TESTING
Method One - Five Step Battery Test

Follow STEP 1 to STEP 5 to correctly determine the condition of the battery if Automatic Battery Tester
MC10930 is not available.
NOTE: Batteries may be overcharged or undercharged due to a fault in the tractors electrical system. Always make sure the
electrical system is working correctly.
NOTE: If the Voltmeter Reading in STEP 2 shows a reading of below 10 volts, it may not be possible to successfully recharge
the battery and its further service life is often greatly reduced.
NOTE: Where discoloured electrolyte is observed, this is always due to a service related condition.
STEP 1. VISUAL CHECK

• Make sure cable connections are clean and tight. Clean foreign material from the battery top.
• Inspect the battery case, battery posts and cables for damage.
• Check the electrolyte level, refer to “Electrolyte Level” on page 4
• If you added distilled water to the battery, the battery must be charged for 15 minutes at 15 to 20 amperes to mix
the water with the electrolyte.
STEP 3. HIGH
STEP 2. STEP 5.
RATE STEP 4. HYDROMETER
VOLTMETER BATTERY
DISCHARGE READING (see NOTE 1)
READING CONDITION
TEST
10 to 11.5 volts Below 9 volts REPLACE
(voltage often GREEN (ABOVE 1260 SG) BATTERY
rises) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)

(voltage often GREEN (ABOVE 1260 SG) BATTERY
rises) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)

(voltage normally GREEN (ABOVE 1260 SG) BATTERY
zero) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)

(voltage steadily GREEN (ABOVE 1260 SG) BATTERY
falls) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)
Below 10 volts Below 3 volts RECHARGE

(voltage can be GREEN (ABOVE 1260 SG) BATTERY
zero) WHITE (1225 to 1260 SG) (see NOTE 2)
RED (BELOW 1225 SG)
Above 11.5 volts 3 to 9 volts RECHARGE

(voltage remains GREEN (ABOVE 1260 SG) BATTERY
stable) WHITE (1225 to 1260 SG)
RED (BELOW 1225 SG)
NOTE 1: Record readings from each battery cell. The cell nearest the positive terminal is cell number 1. Using the hydrometer
as a pump check the two end cells for discoloured electrolyte.
NOTE 2: The battery is over discharged and may not recover after recharging.
SM 8-10160 Issued 03-2001

6 SECTION 4004
Method Two - Using Heavy Duty Battery Tester
4 1 5
6
7
8
3 2
DD98H087
1. CONTROL KNOB (SAE CRANK AMPS)
2. TEMPERATURE SWITCH
3. TEST BUTTON
4. CHARGE LEVEL INDICATOR
5. BATTERY CONDITION INDICATOR
6. TEST IN PROGRESS INDICATOR LAMP
7. TEST COMPLETE INDICATOR LAMP
8. RE-TEST AFTER CHARGING INDICATOR LAMP
STEP 1
Connect MC10930 heavy duty battery tester onto the battery. Set the AMPS SAE control knob (1) to the cor-
rect SAE (cold cranking capacity) for the battery installed, refer to “SPECIFICATIONS” on page 3
STEP 2
Make sure the TEMPERATURE switch (2) is in the >0°C (normal) position.
NOTE: In temperatures below 0°C (32°F) move the TEMPERATURE switch (2) to the <0°C (cold) position.
STEP 3
Connect the positive (+ RED) cable clamp of the automatic battery tester to the positive (+ RED) cable termi-
nal on the machine battery.
Connect the negative (- BLACK) cable clamp of the automatic battery tester to the positive (- BLACK) cable
terminal on the machine battery.
NOTE: It is not necessary to disconnect and remove the battery from the tractor. If the automatic battery tester is incorrectly
connected it will not work. If the bleeper sounds the battery must be recharged before the test can continue, refer to “CHARGING
THE BATTERY” on page 8.
STEP 4
Press the TEST button (3) and the test will begin automatically. The test will be completed in 40 seconds or
less, to determine the condition of the battery refer to “Test Results” on page 7.
STEP 5
If the battery charge level is below 20% it is not possible to complete the test without a booster battery, the re-
test after charging indicator lamp (8) will flash and a bleeper will sound. To re-test the battery, using the cables
supplied connect MC10930 heavy duty battery tester to a booster battery and repeat STEP 4.
Alternatively connect MC10931 Rechargeable Battery Pack to MC10930 heavy duty battery tester and repeat
STEP 4.
SM 8-10160 Issued 03-2001

SECTION 4004 7
Test Results
BATTERY CHARGE LEVEL
CHARGE LEVEL
DISPLAY READING RESULT
INDICATOR
Flashing Display Result being calculated

Solid Display Result confirmed
5 Bars Illuminated 100% (fully charged)
4 Bars Illuminated 80%
1 Bar Illuminated 20%
1 Bar Flashing BATTERY FLAT, refer to “CHARGING
THE BATTERY” on page 8
BATTERY CONDITION
CONDITION INDICATOR DISPLAY READING RESULT
Flashing Display Result being calculated

Solid Display Result confirmed and bleeper sounds
3 Green Bars Illuminated Good battery - return to service
2 Green Bars Illuminated Good battery - return to service
1 Green Bar Illuminated Battery performance adequate
(but may need replacing in near
future)
1 Red Bar Illuminated Replace battery - unserviceable
2 Red Bars Illuminated Replace battery - unserviceable
NOTE: Red bars continue to flash at end of test.
SM 8-10160 Issued 03-2001

8 SECTION 4004
CHARGING THE BATTERY

IMPORTANT: If the battery has been in storage check
WARNING: Do not charge a frozen battery, the voltmeter reading, if the reading is above 12.5 volts
! it can explode, causing serious injury. M529 the batter y does not need charging. If the voltmeter
reading is below 12.5 volts follow the charging procedure
IMPORTANT: Before charging the battery check the to recharge the battery.
electrolyte level, refer to “Electrolyte Level” on page 4
STEP 1
Install the battery onto a suitable variable battery charger. Select the correct battery type installed on your
tractor, refer to “SPECIFICATIONS” on page 3. Set the charging rate at 5 to 7 amps for batteries above 90
Ampere Hours (set charging rate of 3 to 4 amps for batteries below 90 Ampere Hours). Charge the battery for
12 hours.
NOTE: If an automatic battery charger is used, battery charging is complete when the GREEN indicator light is illuminated.
STEP 2
After charging allow the battery to stand for 24 hours before measuring battery voltage, the voltage reading
should be above 12.7 volts.
If the battery is immediately required measure the cells with a hydrometer, the hydrometer reading for each
cell should be a minimum of 1.270 Sg
NOTE: If the voltage reading or hydrometer readings are not correct repeat STEP 2 and recharge the battery. If after a second
charge the battery fails to achieve the correct readings, refer to “BATTERY TESTING” on page 5
PREPARING A DRY CHARGED BATTERY FOR USE

STEP 1
Remove the battery vents and fill each cell with electrolyte to just cover the top of the separators. DO NOT
OVER FILL. The level should be 3 to 6 mm (0.12 to 0.24 inch) below vent well. Install the battery vents.
STEP 2
Follow the procedure above for CHARGING THE BATTERY.
SM 8-10160 Issued 03-2001

SECTION 4004 9
BOOSTER BATTERY CONNECTIONS
WARNING: Battery explosion and/or WARNING: Always connect the ground

damage to electrical components can result cable last and disconnect the ground cable
from improper connection of booster ! first so you do not cause a spark at the
! batteries or charger. Connect positive to battery. A spark can cause a battery
positive and negative to negative. Externally, explosion and cause injury. M530
battery acid can cause burns and blindness,
and taken internally is poison. M146A
IMPORTANT: When connecting a booster battery to the machine battery make sure the booster batter y and the
discharged battery have the same voltage (i.e. 12 VOLTS). Make sure you connect positive to positive and negative to a
good ground on the machine chassis frame. DO NOT connect booster battery cables across the terminals of the starter.
Always follow the procedure in your Operators Manual for Starting the Engine.
STEP 1
Position the machine with the booster battery next to the machine with the discharged battery so the booster
cables can be easily connected. MAKE SURE the machines do not touch.
STEP 2
Check the electrolyte levels and inspect the batteries, “MAINTENANCE” on page 4.
STEP 3
On both machines turn OFF all electrical loads. Connect the positive (+) cable clamp of the booster battery to
the positive (+ RED) cable terminal on the discharged battery. Connect the negative (-) cable clamp of the
booster battery to a good ground on the chassis frame of the machine with the discharged battery.
STEP 4
Start the engine of the machine with the booster battery and run for approximately two minutes.
STEP 5
Follow the procedure in your Operators Manual and start the engine of the machine with the discharged bat-
tery. If the engine will not start after 30 seconds STOP THE PROCEDURE. Wait three minutes to allow the
starter motor to cool.
STEP 6
After starting allow the machine to idle, remove the negative (-) cable clamp from the chassis frame, then
remove the negative (-) cable clamp from the booster battery. Remove the positive (+) cable clamp from the
discharged battery, then remove the positive (+) cable clamp from the booster battery.
TO STARTER SWITCH
BOOSTER BATTERY DISCHARGED BATTERY
BOOSTER CABLES
TO GROUND TO GROUND
CHASSIS GROUND
DI98J017
SM 8-10160 Issued 03-2001

Section
5
STEERING
How it Works
5
ZTX Series Tractors

DT50-50280 March 2004
SECTION 5
This page is intentionally blank
Page 2 DT50-50280 McCormick Service Training

SECTION 5
Contents Page
Introduction ...........................................................................................................4
Illustration of steering circuit ..................................................................................4
Steering oil supply and priority ..............................................................................5
Steering valve .......................................................................................................6
Operation in neutral................................................................................................7
Steering operation .................................................................................................7
Safety shock valves................................................................................................7
McCormick Service Training DT50-50280 Page 3

SECTION 5
Introduction
The steering circuit receives hydraulic oil from the PFC(Pressure Flow
Compensating) axial piston pump via a steering priority spool fitted within the
distribution block on the right hand side of the transmission intermediate housing.
(steering always takes priority over all other hydraulic functions.)
This oil is then fed to the steering orbitrol control valve, which directs the oil to the
desired side of the steer ram according to operator inputs.
Should for any reason the engine fail whilst the tractor is moving the steering orbitrol
valve will act as a hand pump, and the operator would still be able to control the
machine. Return oil from the steering is fed back to tank.
Should the steering not be used then the pump oil flow would be directed onto the
next priority, (hydraulic trailer brake.) or if there was no demand for oil flow the signal
line from the steering valve would shut the PFC pump back down to low pressure
standby.
Illustration of steer circuit
Distrubution block containing

Steering priority valve and
Trailer brake valve(if fitted)

SECTION 5
Steering priority
Hydraulic oil is fed from the main PFC piston pump to the distribution block, this
block houses either the steering priority valve (if there is no hydraulic trailer brake
valve fitted), or both the combined steering and hydraulic trailer brake, priority valve,
and the steering priority valve.
The combined priority valve is sprung open allowing all oil flow from the PFC pump
to go straight to the steering priority valve. When the steering has enough oil to
operate correctly and satisfy its demand pressure builds in the steering signal line,
passes through an orifice and on to a second orifice, this oil the acts on the end of
the steering priority spool and moves it across to the allow oil to the next priority
which is hydraulic trailer brake.
If the brakes are not applied then the pressure also builds in the line between the
combined priority spool and the steering priority spool. It then passes through
another orifice and acts on the end of the combined priority spool and pushes it
against its spring to allow oil to the tractors remaining hydraulic circuits, as described
in the hydraulic section.
When the steering is operated, the steering signal line pressure rapidly increases,
and is felt on the spring side of both the combined priority spool, and steering
priority spool also, and spring pressure plus signal line pressure opens the priority
spools to allow oil to the steering
.
There is a check valve fitted in the steering spool to the un-sprung end, which allows
oil to leave the end of this spool when it is sprung across without having to pass
through both of the orifices. This allows the spool to move over faster to meet the
demand of the steering. (See hydraulic section for illustration of priority valves.)

SECTION 5
Steering valve description

The steering control valve fitted to ZTX is a hydrostatic type valve. The unit consists
of an integral rotary control section and a double metering pump section.
The control section controls the direction of oil from the pump, and either sends it to
the right or left side of the power track rod type steer ram.
It also controls the flow off return oil from the opposite side of the steer ram, back to
tank. The metering section controls a fixed amount of oil sent to and from the steer
ram, depending on resistance at the wheels and operator input.
If the oil flow from the main hydraulic pump should fail for any reason, the valve will
automatically act as a hand pump and one section of the double metering unit will
act as a gerotor pump, supplying oil to the steering ram to give the operator full
control of the steering.
The steering control valve fitted to ZTX is a load sensing unit to be compatible with
the main PFC piston pump used on the tractor. This is as the signal line is required
to bring the PFC pump on stroke when there is demand for oil, and to destroke the
pump when demand is met.

SECTION 5
Operation in neutral
When the steering valve is in its neutral position, inlet oil flow from the pump via the
priority valves is blocked at the control valve inlet by the rotary control spool, and so
the pump, will sense that there is no demand and destroke to just maintain enough
flow to meet the leakage within the valve, and to maintain low pressure stand by.
The sensing line within the steer valve is connected to tank via orifices in the valve
so there is always a very small amount of oil flow going through the valve.
Steering operation left or right

When the operator turns the steering in either direction the control valve spool is
rotated by the leaf springs that join the input shaft and the spool. This opens the
valve to allow oil flow through its passages, into the metering unit at its base, and out
to the steering ram, as the wheel is turned.
Pressure is also felt at the signal line and builds up to bring the PFC pump on stroke,
and so build enough pressure to turn the wheels easily. When the operator stops
steering the control spool is returned to neutral by the leaf springs and so the valve
returns to its neutral state.
Safety shock valves

There are shock valves fitted into the steering control valve that link both the ports of
the steer ram together.
These are fitted as a safety feature so that if the wheels should be subjected to an
impact, and a greater pressure should be felt than the steering system was designed
to take, the valve would open and allow oil to pass from one side of the steering ram
to the other and so stopping damage occurring to the steering system components
or to the operator. This valve is set to 225-250 bar opening pressure.

5001
Section
5001
STEERING COLUMN AND

STEERING HAND PUMP REMOVAL

SM 8-12410 March 2004
2 SECTION 5001
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUES ............................................................................................................................................... 3
SPECIAL TOOLS ..................................................................................................................................................... 3
STEERING COLUMN
Removal and Installation ...................................................................................................................................... 4
Disassembly and Assembly ................................................................................................................................. 5
STEERING HAND PUMP

Removal ............................................................................................................................................................. 10
Installation .......................................................................................................................................................... 11
SM 8-12410 Issued 03-2004

SECTION 5001 3
SPECIFICATIONS
Lower Splined Shaft Lubricant..................................................................................... Multi Purpose Lithium Grease
SPECIAL TORQUES
Steering Column Retaining Locknut ........................................................................................................ 29 to 32 Nm
Steering Wheel Retaining Nut ................................................................................................................. 45 to 54 Nm
Mounting Bracket to Steering Hand Pump
Retaining (Shoulder) Screw ................................................................................................................ 41 to 61 Nm
SPECIAL TOOLS
DD98H114
MC2612 BUSHING INSTALLER

(USE WITH HANDLE MC1924)
SM 8-12410 Issued 03-2004

4 SECTION 5001
STEERING COLUMN
Removal and Installation

NOTE: Items are numbered in the order of Removal, for Installation follow the Removal procedure in
reverse order.
Before removing the Steering Column it will be necessary to carry out the following:
• Park the tractor on hard level ground and apply the parking brake.
• Stop the engine and remove the key.
• Put blocks in front of and behind the rear wheels.
STEP 1 STEP 4
Disconnect the battery, negative (-) terminal first.
NOTE: For Installation, connect the battery,

positive (+) terminal first.
STEP 2
Remove the RH and LH instrument panel side
covers.
3 4
NOTE: Disconnect the harness from the
auxiliary power socket on the RH side cover.
MD03M071
STEP 3 Remove the steering wheel cap. Remove the
retaining nut (3) and washer (4), remove the steering
wheel.
NOTE: For Installation, tighten the steering wheel

retaining nut (3) to a torque of 45 to 54 Nm.
STEP 5
2
5
1 1
DP98B076
Remove the cab floor mat and remove the two

retaining screws (1) and remove the steering column 6
cover (2).
MD03M071
Remove the four retaining screws (5). Disconnect

the harness and remove the instrument cluster (6).
SM 8-12410 Issued 03-2004

SECTION 5001 5
STEP 6 Disassembly and Assembly

NOTE: Items are numbered in the order of
Disassembly, for Assembly follow the same
8 procedure in the reverse order.
STEP 8
1 3
7
DP98B073
Disconnect the FNR switch/turn signal harness

connector (7) and turn signal self cancelling
harness connector (8) (if equipped).
2
STEP 7
DD98A288
Remove the torx screw (1). Remove the rubber

11 bellows (2) from the upper cover (3).
STEP 9
9 10
DP98B072
Remove the harness from the clip. Support the

steering column and remove and discard the four
5
locknuts (9). Remove washers (10) and remove the
steering column assembly (11).
4
DD98A292
NOTE: For Installation, install new locknuts (9) Remove the harness (4) from the clip and remove
and tighten to a torque of 29 to 32 Nm. the lower cover (5).
NOTE: For Installation, apply Multi Purpose

Lithium grease, or equivalent, to the splines of the
lower shaft of the steering column assembly (11).
SM 8-12410 Issued 03-2004

6 SECTION 5001
NOTE: For tractors equipped with self cancelling STEP 12

turn signal switches it will be necessary to
remove the FNR assembly top cover retaining
screw and top cover. Loosen the locking allen 8
screw and remove the self cancelling ring.
STEP 10
2
A DD98A296
Remove the knob (8) from the tilt/telescope lever

and remove the rubber bellows (2).
STEP 13
DD98A293
Gain access to the Allen screw through cut out (A) in 9

the side of the FNR assembly, loosen the Allen
screw (6) and raise the FNR assembly.
NOTE: For installation, install and tighten allen

screw (6) to a torgue of 3Nm.
STEP 11
DD98G264
2 Put the splined end of the steering column in a soft

jawed vice. Use a lever between the steering column
and vice body, as shown, to remove the lower
splined shaft, seal ring and bushings from the
steering column. Remove the bushings (9).
7
STEP 14
For steering columns equipped with a seal ring (10),
remove seal ring (10) and o-ring (11) from the lower
DD98A295
splined shaft (12).
Remove the plate (7) from the rubber bellows (2),
thread the harness through the rubber bellows (2)
and remove the FNR assembly from the steering
column.
SM 8-12410 Issued 03-2004

SECTION 5001 7
13 19
19
14
15 20
16
17
18 22
29
21
24
30 25
25
23
25
9
26
28 27
31
10 9
12
11
DI98G231
NOTE: Refer to STEP 15 to STEP 21 for Installation of bushings (9), seal ring (10) and o-ring (11).
9. BUSHING (2) 17. BUSHING 25. SPRING

10. SEAL RING (IF EQUIPPED) 18. RETAINING RING 26. RETAINING SCREW
11. O-RING (IF EQUIPPED) 19. LEVER 27. TOOTH SEGMENT PLATE (3)
12. LOWER SPLINED SHAFT 20. BUSHING 28. PIVOT PIN
13. RETAINING RING 21. LOWER LINK ARM 29. ARM
14. FLANGE LOCKNUT 22. RIVET 30. SPRING
15. WASHER 23. WASHER 31. SPRING
16. UPPER LINK ARM 24. LINK
SM 8-12410 Issued 03-2004

8 SECTION 5001
STEP 15
9 A
10
B 12
DP98B358 DI98H078
Install one half of bushing (9) onto splined shaft (12),

11 make sure shoulder (B) of lower splined shaft (12)
A and lip (A) of seal ring (10) (if equipped) locate into
B 10 the groove in bushing (9).
12
STEP 18
DI98H121
For steering columns equipped with a seal ring (10).

Install a new seal ring (10) onto lower splined shaft
(12) make sure the lip (A) of seal ring (10) is against
shoulder (B) of lower splined shaft (12). Install a new 9
o-ring (11) into the groove (C) in seal ring (10).
DD98G265
STEP 16
Install the second half of bushing (9) onto splined
Lubricate the seal ring (10) and internal splines of shaft (12), make sure the tabs and slots in bushing
lower splined shaft (12) with Multi Purpose Lithium (9) are aligned.
grease.
STEP 17
B 9
DD98G266
SM 8-12410 Issued 03-2004

SECTION 5001 9
STEP 19 STEP 20
G
E
F
9
DD98H117 DD98H118
Install the steering column into a suitable press. Install seal installer (F) MC2612 over the lower
Install the lower splined shaft (12) onto the upper splined shaft onto bushing (9). Press bushing (9)
shaft splines. Align tab (E) of the bushing (9) with into position.
the mounting holes as shown.
NOTE: Use handle (G) MC1924 as a spacer if
necessary.
STEP 21
Lubricate the drive splines of lower splined shaft
(12) with Multi Purpose Lithium grease.
SM 8-12410 Issued 03-2004

10 SECTION 5001
STEERING HAND PUMP
Removal
Before removing the Hand Pump it will be necessary to carry out the following:
• Raise the hood and remove the side panels.
STEP 1 STEP 5
Disconnect the battery, negative (-) terminal first.
STEP 2
2 3
1
DP98B354
Remove the four retaining screws (1) and washers

(2), remove the bracket (3).
MD01C053
STEP 6
Put identification marks on and disconnect and cap
the hoses from the steering hand pump, remove
and discard the o-rings from the fittings.
STEP 3
4
Support the steering hand pump and remove the
Steering Column, refer to Page 4.
NOTE: It is not necessary to remove the

steering wheel.
STEP 4
DP98B355
Remove the Steering Hand Pump. Remove the seal (4), check for wear or damage and
replace if necessary.
SM 8-12410 Issued 03-2004

SECTION 5001 11
STEP 7 Installation
5
STEP 8
3 4
DP98B356
Check for wear or damage to the four rubber

grommets (5) in the bracket (3) and replace if DP98B355
necessary. Install seal (4) onto the steering hand pump.
NOTE: For the Disassembly and Assembly of

STEP 9
the steering hand pump, refer to Section 5002.
3
2
1
DP98B354
Install the bracket (3), washers (2) and retaining

screws (1). Tighten the retaining screws to a torque
of 41 to 61 Nm.
STEP 10
Install the Steering Hand Pump and support in
position.
STEP 11
Install the Steering Column, refer to Page 4.
SM 8-12410 Issued 03-2004

12 SECTION 5001
STEP 12 STEP 13
Connect the battery, positive (+) terminal first.
STEP 14
Start and run the engine and check the operation of
the steering hand pump. DO NOT hold the steering
wheel during engine start up.
WARNING: Never operate the engine in a

! closed building. Proper ventilation is required
under all circumstances. SM100A
MD01C053
Remove the caps from the tubes and fittings.

Lubricate and install new o-rings the fittings and
connect and tighten the hoses.
SM 8-12410 Issued 03-2004

5002
Section
5002
REXROTH STEERING HAND PUMP
ZTX Series Tractors

SM 8-12390 March 2004
2 SECTION 5002
TABLE OF CONTENTS
SPECIFICATIONS.....................................................................................................................................................3
SPECIAL TORQUES.................................................................................................................................................3
SPECIAL TOOLS ......................................................................................................................................................3
STEERING HAND PUMP

(ZTX Series Tractors)
Disassembly......................................................................................................................................................4
Inspection..........................................................................................................................................................6
Assembly ..........................................................................................................................................................6
SM 8-12390 Issued 03-2004

SECTION 5002 3
SPECIFICATIONS
STEERING HAND PUMP DISPLACEMENT
ZTX Tractors.................................................................................................Dual 60/220cc/rev
SPECIAL TORQUES
Steering Hand Pump End Cover Retaining Bolts .................................................................................... 25 to 35 Nm
SPECIAL TOOLS
DD97G084
MC2552 SEAL INSTALLER
SM 8-12390 Issued 03-2004

4 SECTION 5002
STEERING HAND PUMP

(ZTX Series Tractors)
Disassembly STEP 5
STEP 1
Secure the steering hand pump in a clean soft jaw
vice, DO NOT overtighten the vice. Remove the B
fittings, remove and discard the o-rings. Make a
note of the position of the sensing hose fitting.
STEP 2
2 24
DD00F065
Turn spool and sleeve assembly (B) until pin (24) is
parallel to the fitting mounting face. Remove spool
and sleeve assembly (B) and thrust bearing assembly
(23) from pump body (37).
A
STEP 6
Remove pin (24) from spool and sleeve assembly
(B). Remove the spool (25) from sleeve (26),
D00H095
Put alignment marks (A) on pump body (37), valve remove centering springs (27) and (28) from spool
plate (7) and (16), stators (5) and (13), valve body (25).
(10) and end cover (3). Remove retaining bolts (1),
make a note of the position and remove special bolt STEP 7
(2). Remove the end cover (3), spacer (4), stator
(5), rotor (6) and valve plate (7). Remove and Remove and discard seal (29) and dust seal (30).
discard o-rings (8) and (9).
STEP 8
STEP 3
Remove threaded bushing (31) and ball (32).
Remove valve body (10), drive shaft (11), spacer
(12), stator (13), rotor (14), drive shaft (15) and IMPORTANT: DO NOT use a magnet to remove
valve plate (16). Remove and discard o-rings (17), ball (32).
(18), (19) and (20).
STEP 9
STEP 4
Mark the position and remove valve pins (33) and
Remove spool (21) and spring (22) from valve body balls (34). Remove shock valve assemblies (35).
(10).
IMPORTANT: DO NOT use a magnet to remove
balls (34).
IMPORTANT: DO NOT remove check valve (36)

from pump body (37).
SM 8-12390 Issued 03-2004

SECTION 5002 5
NOTE: Items are numbered in order of Disassembly.
9 7
6
5
8 4
3
16
2 19
13
1
12 15
1
11
14 36
22 37
21 32 30
31
18
24 29
10
23
17
26
25
34
27 20
28 33
35
DI99J104
1.BOLT (6) 11.SHAFT 21.SPOOL 31.THREADED BUSHING

2.SPECIAL BOLT 12.SPACER 22.SPRING 32.BALL (8 MM DIAMETER)
3.END COVER 13.STATOR 23.THRUST BEARING 33.VALVE PIN (2)
4.SPACER 14.ROTOR 24.PIN 34.BALL (2) 5 MM DIAMETER)
5.STATOR 15.DRIVE SHAFT 25.SPOOL 35.SHOCK VALVE (2)
6.ROTOR 16.VALVE PLATE 26.SLEEVE 36.CHECK VALVE
7.VALVE PLATE 17.O-RING 27.OUTER CENTERING SPRING (2) 37.PUMP BODY
8.O-RING 18.O-RING 28.INNER CENTERING SPRING (2)
9.O-RING 19.O-RING 29.SEAL
10.BODY 20.O-RING 30.DUST SEAL
SM 8-12390 Issued 03-2004

6 SECTION 5002
Inspection Assembly
STEP 10 NOTE: Refer to Page 9 for component
identification.
Clean and inspect parts for wear or damage.
NOTE: During assembly lubricate all parts with
STEP 11 clean transmission oil.
14 13 STEP 13
6 5
E
SM1298
Measure the thickness of rotor (6) and stator (5). If the
rotor is 0.051 mm less than the stator, replace the 29
steering hand pump.
DD98G094
Measure the thickness of rotor (14) and stator (13). If

the rotor is 0.051 mm less than the stator, replace the
steering hand pump.
37
STEP 12
14
6
13 5
F E
DD00F072
Lubricate a new seal assembly (29) with clean
transmission oil. Using MC2552 seal installer,
install locator (D) onto arbor (E), install seal
C assembly (29) onto locator (D) as shown. Install
sleeve (F) into pump body (37). Fully install arbor
SM1297
Align rotor (6) and stator (5) as shown. Measure gap (E) against the shoulder in the pump body (37).
(C) between the rotor and stator, if the gap is 0.127 Remove arbor and sleeve, remove the locator
mm or more, replace the steering hand pump. forwards from pump body.
Align rotor (14) and stator (13) as shown. Measure

gap (C) between the rotor and stator, if the gap is
0.127 mm or more, replace the steering hand pump.
SM 8-12390 Issued 03-2004

SECTION 5002 7
STEP 14 STEP 16
25 23
25 A B C
27
28
SM1303
DD00F074
Install thrust washer assembly (23) onto spool (25)
in the following order, small thrust washer (A),
thrust bearing (B) and large thrust washer (C).
STEP 17
27
28
H 24
27
DDOOF069
Install and centralize the outer and inner centering B
springs (27) and (28) into the spool (25), in the
positions shown.
NOTE: Make sure the centering springs (27) DD00F065
and (28) are installed with the cut outs (H) Carefully install the spool and sleeve assembly into
towards the bottom of the spool (25). the pump body (37) with pin (24) parallel to the
fitting mounting face as shown. DO NOT turn the
STEP 15 spool and sleeve assembly (B).
NOTE: Heat from your hands may expand spool

25
and sleeve assembly (B), preventing the
assembly being installed, DO NOT use force to
install spool and sleeve assembly (B). Allow the
assembly to cool and repeat STEP 16.
STEP 18
24 Install shock valve assemblies (35). Install balls
(34) and install pins (33) in the positions noted in
STEP 9, Page 4.
26
DD00F073
STEP 19
Install the spool (25) into sleeve (26). Make sure the Install ball (32) and install and tighten threaded
springs (27) and (28) locate in slots of sleeve (26), bushing (31).
install pin (24).
NOTE: Heat from your hands may expand spool
(25) preventing it from being installed. Allow the
spool (25) to cool and repeat STEP 15.
SM 8-12390 Issued 03-2004

8 SECTION 5002
STEP 20 STEP 23
Install spring (22) and spool (21) into valve body
16 (10). Lubricate and install new o-rings (18) and (17)
and into valve body (10). Align the marks made in
STEP 2, Page 4, install valve body (10) and drive
shaft (11).
15
STEP 24
Align the marks made in STEP 2, Page 4 and install
G
valve plate (7). Install rotor (6) onto splines of drive
shaft (11).
DD98G278 STEP 25
Lubricate and install a new o-ring (20) into the
groove in the pump body (35). Install the valve plate Lubricate and install a new o-ring (9) into stator (5).
(16), align marks made in STEP 2, Page 4. With pin Align the marks made in STEP 2, Page 4 and install
(24) parallel to fitting mounting face (G), install drive stator (13).
shaft (15). Make sure the pin (24) is between the
slot in drive shaft (15). STEP 26
STEP 21 Install spacer (4) on top of drive shaft (11).
STEP 27
15
G Lubricate and install a new o-ring (8) into end cover
(3).
STEP 28
Install the end cover (3) and install the special bolt
24 (2) in the position noted in STEP 2, Page 4. Install
14 the remaining bolts (1), tighten the bolts (1) and
special bolt (2) to a torque of 25 to 35 Nm.
STEP 29
SM1296
Install rotor (14) onto drive shaft (15). When pin Install a new dust seal (30). Install new o-rings onto
(24) is in the correct position one of the rotor gear the fittings removed in STEP 1, Page 4.
teeth will be aligned with the connector mounting
face (G) as shown. STEP 30
NOTE: If rotor (14) is installed incorrectly the Install clean transmission oil into the return port and
steering hand pump will operate as a motor supply port. Cover all the ports with a clean cloth
when installed onto the tractor and the engine is and slowly turn the pump input shaft clockwise and
running. The steering wheel will rotate counterclockwise.
continually which may cause damage and
injury. STEP 31
STEP 22 Repeat STEP 30 until the steering hand pump is
primed with oil.
Lubricate and install a new o-ring (19) into stator
(13). Align the marks made in STEP 2, Page 4 and
install stator (13).
Install spacer (12) on top of drive shaft (15).
SM 8-12390 Issued 03-2004

SECTION 5002 9
NOTE: Items are numbered in order of Assembly.
9 7
6
5
8 4
3
16
2 19
13
1
12 15
1
11
14 36
22 37
21 32 30
31
18
24 29
10
23
17
26
25
34
27 20
28 33
35
DI99J104
1.BOLT (5) 11.SHAFT 21.SPOOL 31.THREADED BUSHING

2.SPECIAL BOLT (2) 12.SPACER 22.SPRING 32.BALL (8 MM DIAMETER)
3.END COVER 13.STATOR 23.THRUST BEARING 33.VALVE PIN (2)
4.SPACER 14.ROTOR 24.PIN 34.BALL (2) 5 MM DIAMETER)
5.STATOR 15.DRIVE SHAFT 25.SPOOL 35.SHOCK VALVE (2)
6.ROTOR 16.VALVE PLATE 26.SLEEVE 36.CHECK VALVE
7.VALVE PLATE 17.O-RING 27.OUTER CENTERING SPRING (2) 37.PUMP BODY
8.O-RING 18.O-RING 28.INNER CENTERING SPRING (2)
9.O-RING 19.O-RING 29.SEAL
10.BODY 20.O-RING 30.DUST SEAL
SM 8-12390 Issued 03-2004

Section
6
TRANSMISSION
How it Works
ZTX Series Tractors

DT50-50290 March 2004
SECTION 6

SECTION 6
Contents Page
Introduction ...........................................................................................................4
Drive Path Description............................................................................................5
Powershift gearbox description .............................................................................6
Cutaway illustration of powershift gearbox ............................................................7
Clutch pack reference chart ..................................................................................8
Clutch pack layouts (powershift section) ................................................................9
Oil supply for powershift gearbox ...........................................................................10
Suction screen ........ .............................................................................................10
Powershift box oil pump .........................................................................................10
Diagram of powershift hydraulic circuit...................................................................11
Main powershift filter .............................................................................................12
Powershift pressure maintaining valve ...................................................................12
Clutch control circuit . .............................................................................................13
Clutch pressure test points.....................................................................................14
Lubrication and cooling ..........................................................................................15
Creep speed ..........................................................................................................16
Rear axle description..............................................................................................17
Park lock ...............................................................................................................18
Crown wheel and pinion ........................................................................................19
Differential lock ......................................................................................................20
Double final drive reduction units ..........................................................................21
Illustration of double reduction unit .......................................................................21
Rear PTO arrangement..........................................................................................22
Rear PTO brake arrangement................................................................................23
Rear PTO brake operation .....................................................................................23
Rear PTO engagement ..........................................................................................23
Powershift transmission service procedure under warranty ...................................24

SECTION 6
Introduction
The McCormick AG250 transmission is made up of 4 main sections:
1. A powershift section, containing 18 forward, and 8 reverse gears and clutch

packs.
2. A mid section that houses creep speed, MFD clutch pack, hydraulic pump and
drive train, and the pinion shaft that carries the park brake and park lock assemblies.
3. The rear axle houses the rear differential, double planetary reductions, brakes
and sliding beam axle drive shafts.
4. The rear section houses the PTO clutch pack drive gears, and speed selector
mechanism, and output shaft depending on market to which type is fitted.
When creep speed is fitted there are 36 forward and 16 reverse gears available, as
creep is available in all gears.
Creep should not be used for draft applications.
For certain markets gears can be electrically blocked out for safety or speed
legislation reasons.(18th forward is blocked for 30kph only. In some markets only 6
reverse speeds may be fitted)
POWERSHIFT MID SECTION REAR PTO

SECTION (CREEP E.T.C.) AXLE BOX

SECTION 6
Drive path description

Drive is transmitted from the engine via a torsional damper to a short splined stub
shaft that joins the damper to the powershift box, this is fitted to allow a greater
flexibility on alignment and stop damage occurring to both the damper and
powershift input shaft which could cause oil leakage into the bellhouseing of the
engine.
Drive is then fed into the powershift box 38 tooth input gear on the input shaft and
then straight out of the back of the powershift box to the PTO drive shaft coupling.
The hydraulic pump drive is also taken at this point. A shaft then takes direct engine
power, to the PTO clutch pack. From here it is directed to whichever speed is
selected.
Drive from the input shaft drive gear in the powershift box is transferred onto the
other gears that are in constant mesh, and then depending on which powershift gear
is selected, fed through a combination of clutches(As shown in the shift pattern
chart) to select the chosen powershift gear.
Drive is then fed either direct onto the pinion shaft or into the creep speed gears,
depending on the option fitted.
The pinion shaft then drives the MFD drop gears and clutch pack, and the rear
differential that transmits drive into the double reduction final drive units via a short
stub shaft that also has the rear brake friction discs splined onto them. The double
reduction epicyclic gears then drive the sliding bar half shafts driving the rear wheels.

SECTION 6
Drive path description

This illustration shows the gear, clutch hub, and bearing types and locations, within
the powershift gear box casings.

SECTION 6
Powershift gearbox description

There are 9 clutch packs in 3 groups. For the tractor to move 1 clutch from each of
the 3 groups has to be engaged at any one time.(As shown in chart)
Each clutch pack is controlled by its own dedicated PWM (pulse width modulation)
solenoid valve. These are located around the front transmission housing which
allows the oil supply galleries to each clutch pack to be almost equal in length and
therefore give a smoother and more progressive gearchange.
The PWM solenoids are all controlled by the transmission control module directly,
and the transmission controller is in turn controlled by the McCormick cab controller
via the tractors CAN BUS link.
The cab controller takes its inputs from the multi-function control lever in the cab
arm rest.
All gears are helically cut for a high contact ratio to give strength and minimise noise.
All shafts are supported on both, ball and roller bearings that are pressure lubricated
apart from the rear output shaft bearing, which is lubricated by oil from the output
clutch baffle. With the use of ball and roller bearings in the design off this gearbox it
makes it simple and robust with no complicated set up or shimming procedures.
Powershift
control
lever

SECTION 6
Clutch pack reference chart
SHIFT PATTERN
GEAR RATIO SELECTED CLUTCHES ENGAGED
F1 1,A,L
F2 2,A,L
F3 1,B,L
F4 1,A,M
F5 2,B,L
F6 2,A,M
F7 1,C,L
F8 1,B,M
F9 2,C,L
F10 2,B,M
F11 1,A,H
F12 1,C,M
F13 2,A,H
) 2,C,M
F15 1,B,H
F16 2,B,H
F17 1,C,H
F18 2,C,H
R1 R,A,L
R2 R,B,L
R3 R,A,M
R4 R,C,L
R5 R,B,M
R6 R,A,H
R7 R,C,M
R8 R,B,H

SECTION 6
Clutch pack layouts (Powershift section)

SECTION 6
Oil supply for powershift gearbox
The oil for the transmission on ZTX is a common gallery with different levels in each
compartment depending on the lubrication requirements of that particular section.
The lowest point in the transmission is the centre section that houses the creep
speed, park brake and lock, and MFD clutch pack. Due to this the section of the
gearbox is used as the reservoir, and the oil supply for the powershift box is removed
from here, and allowed to flow back into it by a cascade type system in the rear
powershift gearbox casing.This is because on overfull powershift box would
overheat.
Suction screen
The oil is drawn out of the centre section of the transmission through a removable
suction screen that is mounted in the lower right hand side. This screen has a
filtration level of 250 microns, and should be removed and cleaned every 1000 hours
and replaced in the event of a component failure causing any major contamination.
Oil is then passed out of the strainer and up to the powershift box pump externally
via a large bore steel pipe on the right side of the transmission.
Powershift box oil pump

The powershift gearbox has its own dedicated oil pump that is mounted internally in
the rear casing of the unit. Access is gained to the pump by separating the
powershift from the centre section of the gearbox.
The pump is of the gerotor type and is driven by the PTO output shaft that passes
directly through the middle of it. Oil is fed into it from the suction strainer through an
internal gallery in the right of the rear powershift casing, and then back out of the left
side of the same casing.
The pump is capable of delivering 110 litres per min of flow at 2200RPM engine
speed
Gearbox pump Location

SECTION 6
Diagram of powershift hydraulic circuit
40 to 50 litres min
flow in this area
aprox
50 to 60 litres min flow for lubrication

SECTION 6
Main powershift filter
The oil supply to control, lubricate, and cool the powershift box is passed through a
pressure filter canister on the left hand side of the gearbox. This filter has a filtration
level of 15 microns, and should be replaced at 50 hours and then every 500 hours
there after. Mounted inside the filter head is a filter bypass/ flow divider valve that
splits the flow of oil according to demand between regulated pressure supply to the
PWM solenoids to engage the clutch packs, and cooling and lubrication.
This valve works on a pressure difference of 3.5 bar between the filtered oil gallery
and the unfiltered oil in the filter bowl (i.e. 17 bar regulated pressure + 3.5 bar bypass
valve spring pressure = 20.5 bar filter bypass pressure) This means that unless the
filter becomes blocked and will not pass oil, the 17 bar and cooling flow will always
be met first and then any excess flow will be used for powershift lubrication
If the filter becomes blocked there is a pressure warning switch that will trigger an
error code on the instrument cluster. The switch is closed when there is no 17 bar
pressure and opens at approximately 11 bar. If the filter becomes blocked there
would be no oil flow into the 17 bar gallery and therefore the switch contacts would
stay closed generating an error code.
Diagram of pressure filter

Showing oil flows in and out
Powershift pressure maintaining valve

The regulated pressure required to operate the powershift clutch packs is 17 bar.
This is controlled by the pressure maintaining valve. The valve is screwed directly
into the left side of the front powershift casing and is mounted in the oil gallery being
fed from the pressure filter housing.
It is a very simple valve consisting of a spool and housing and spring. When the oil
pressure in the gallery exceeds 17 bar the spool simply moves against its spring to
allow any excess flow on to the thermostatic valve for cooling and lubrication.
The pressure maintaining valve has a tightening torque of 41to 47 Nm.

SECTION 6
Clutch control circuit

The 9 clutch packs within the powershift gearbox require a 17 bar regulated oil
pressure supply to engage. As described earlier there must be 3 clutch packs
engaged at any time for the tractor to drive.
These clutch packs are controlled by there own individual PWM solenoids. The
solenoids are mounted equally spaced around the front powershift casing in the 17
bar gallery near the ends of the gearbox shafts which contain the oil ways to the
clutch packs.
This is so that the distance from the PWM solenoid to the clutch is kept to a
minimum to give a more even and repeatable gear change that will not vary
according to transmission temperature.
The solenoids are controlled by the transmission controller, which is in turn
controlled by the McCormick cab controller.
The hydraulic test points for the powershift gearbox are also mounted next to the
solenoids as shown in the illustration.
The test points for the gearbox are the following sizes:
x Regulated pressure 17 bar = 7/8 -14 UNF
x Clutch pack pressure 17 bar = 7/16 - 20 UNF
x Lubrication Pressure 1 to 6 bar = 9/16 - 18 UNF

SECTION 6
Clutch pressure test points
R
B
A,2
C,1
M
L

SECTION 6
Lubrication and cooling

The oil that is not required to work the clutch packs, that has passed over the 17 bar
pressure regulator then flows through into another internal gallery in the front
powershift casing. This Gallery contains the lubrication oil pressure relief valve that is
situated behind the union leaving the casing to the thermostatic valve, and is set at 6
bar.
If the oil cooler was to become blocked or its return hose trapped for any reason then
there is also a oil cooler bypas valve that would open at 2.4 bar and allow the oil flow
back to lubrication, and so stopping damage to the cooler or its hoses.
If the oil is cold the thermostatic valve simply returns the oil back to the gearbox
lubrication gallery.
If the oil is hot then the flow of oil is sent from the thermostatic valve to the oil cooler,
and then back to the gearbox for lubrication, and cooling.
The thermostatic valve is located on the right of the tractor between the side of the
engine and the chassis.
Care should be taken if the hoses are removed from the valve as if they are
incorrectly installed the transmission will rapidly overheat.
Thermostatic valve is
mounted on inside of
chassis
(approximately here)

SECTION 6
Creep speed
This option allows very low forward speeds (600 m/h at 2000 rpm).
It consists of an epicyclical type gear set fitted in the intermediate housing of the
gearbox.
It includes an input shaft acting as a sun gear, 3 planetaries and a ring gear.
The input shaft drives the planetaries that makes the planetary carrier rotate.
A sliding coupler connects the output shaft:

- Either to the planetary carrier (1:4 ratio)
- Or to the input shaft (1:1 ratio)
The coupler is mechanically actuated by means of a cable operated by a lever

situated in the cab.
A switch located on the lever, signals to the Transmission Controller (TC) that the
creeper is engaged.
CREEPER UNIT LOCATION

SECTION 6
Rear axle description

The ZTX series tractors rear axle assembly comprises of five main housings.
The rear axle assembly includes the following:
- Crown wheel and pinion.( Hypoid on all tractors.)

- Differential and differential lock.
- Final double reduction units.
- Brake disc assemblies.
- Transmission park lock.
- 4 wheel drive clutch.
- Power Take Off (PTO) drive system.
- Park brake.
- Creeper unit.

SECTION 6
Park lock
The park lock fitted on ZTX tractors is the mechanical means of locking the pinion
shaft and is situated in the intermediate housing.(A park brake is also fitted as
described in the brakes section)
It comprises of:
- A toothed sleeve, fitted to the pinion shaft
- An arm, with a “ratchet” on it to lock the toothed sleeve when required
- An operating linkage which is attached to a hydraulically activated rod
- An hydraulic oil supply (solenoid valve) to release the park lock via the rod
- A switch, on the left side of the intermediate housing, that is linked to the
transmission controller (TC).
The rod is spring loaded to the right side of the tractor to activate the park lock.
To release the lock, oil pressure is delivered by the solenoid valve to the piston
chamber on the right side of the rod to push it to the left. When it has moved and
released the lock, the rod acts on the switch closing its contacts to complete the
safety circuit for the TC.
The operation is “fail safe” by using a spring to engage the lock and hydraulic oil
pressure to disengage it.
Engaged position condition

The park lock is engaged when:
- The engine is switched off.
- The tractor is stationary with the engine running, the shifting lever is in “P“
position.
Disengaged position condition

The park lock is disengaged when the engine is running, and the shuttle lever is
moved from “P“ position to “N“ position.
“Limp home” facility

Should the rod not be moved hydraulically, the rod can be moved mechanically. By
unlocking and turning the bolt that is on the outside of the hydraulic head, it should
be screwed in to push the rod to the left side of the tractor thereby releasing the lock
and activating the switch for the TC.

SECTION 6
Crown wheel and pinion

The hypoid type crown wheel and pinion are mounted in adjacent housings, the
centre housing and the intermediate housing respectively.
The pinion is mounted into the rear of the intermediate housing and has the parking
brake and 4WD gear splined to it. Two taper roller bearings support the pinion, the
rear cone being a tight fit to the shaft and the front being slip fit. The bearing cups
are tight fit to their respective housings. The gearbox output shaft drives the pinion.
The crown wheel is mounted in the centre housing. It comprises of the differential
and the multi-disc differential lock unit. This assembly is supported on taper roller
bearings, that are, in turn on the support plates bolted to each side of the centre
housing. The right hand cone, being a tight fit, to the support plate and the left hand
being slip fit. The bearing cups are tight fit to their respective housings. The crown
wheel is bolted to the differential housing.
The differential unit comprises of one casing that houses the four planet gears, two
output sun gears, a cross joint including four half shafts and one location piece, and
thrust washers.
There are a number of settings that are applied to the crown wheel and pinion. They
need to be done as appropriate, dependant on the work being done on the tractor.
The settings are:
1-Pinion protrusion that is adjusted by means of shims placed
between the pinion bearing casing and the intermediate housing.
2-Pinion bearing preload which is adjusted by using shims placed
between the bearing cone and the thrust washer.
3-Crownwheel and pinion backlash pre-shimming by means of shims
placed between the differential casing and the bearing cup.
4-Differential bearing preload set by shims placed between the left-
hand support plate and the bearing cone.
5-Crownwheel and pinion backlash checking to be done only when
satisfied that the above settings are correct.
All the above setting procedures can be found in the service manual section 6018.

SECTION 6
Differential lock
A soft engage multi-disc type differential lock is used on the ZTX Tractors and is
located on the left side of the differential casing.
The multi-disc type comprises:

- A cover assembled with a piston and containing 8 discs and 7 inter-plates
- A hub that is a part of the differential left-hand output sun gear.
A piston chamber in the cover, connects with a channel in the left-hand support
plate, to allow 17 bar to act on the piston. The piston is sealed using two O-rings.
Engaged position – operation

When the differential lock solenoid valve is actuated, regulated oil pressure (17 Bar)
is directed to the chamber of the piston.
The piston compresses the discs and the intermediate plates, they are coupled with
the cover and the hub by lugs and splines respectively.
The action of the differential is cancelled when in this engaged position.
Disengaged position – operation

When the oil pressure is cut-off, the piston moves back and the clamping pressure is
released from the discs and inter-plates. This allows the differential to resume its
function.

SECTION 6
Double final drive reduction units

The double reduction unit is housed at the inboard end of the trumpet housing, it
comprises:
- An input epicyclic reduction with sun gear, three planet gears and
- A ring gear
- A second, stronger output epicyclic reduction with six planet gears
- Both ring gears are positioned between the trumpet housing and spacers,
they are located with dowels and the trumpet housing bolts.
The epicyclic reduction and the bearings are lubricated by the same oil as the main
transmission.
The spacer on centre housing side has a drilling allowing oil to lubricate and cool the
brake units.
An oil transfer pipe is fitted between the trumpet housing and the centre housing to
control the oil level due to the brake lubrication flow.
Illustration of double reduction unit

SECTION 6
PTO Arrangement
Due to different markets, the ZTX series is available with various PTO arrangements:
x Fixed PTO - 1000 rpm (20 spline)

x Shiftable PTO - 750 (540E)/1000 (20 spline) speed changed via lever in cab
Optional 6 or 21 spline shafts available.

540 rpm obtained through engine rpm.
The PTO arrangement basically utilises the housing to the rear of the centre
housing, this includes all the mechanical parts that make up the PTO function.
Drive comes from the Powershift gearbox, the drive is transmitted via four shafts.
The first, second and third shafts pass drive from the engine through to the hydraulic
pump drive gear. The forth shaft is splined to the pump drive gear and then, at the
rear is splined to the PTO clutch. The PTO clutch is controlled by the Transmission
Controller (TC) via a proportional solenoid valve.

SECTION 6
PTO Brake arrangement

A brake system is fitted in the PTO housing to stop the output shaft turning due to
the drag effect of the clutch discs when the PTO is off. It is controlled by a solenoid
valve that is also controlled by the TC. For safety reasons the PTO brake
automatically turns on 6 seconds after the PTO switch is disengaged, this is done to
stop very low torque PTO implements from running for periods of any longer than 6
seconds after the initial turning off of the PTO. However the PTO brake default value
can be reset using the McCormick tractors service tool to accommodate implements
using large flywheels (i.e. Big balers and Foragers.) that need longer run down
periods. This time can be set to between 6 and 66 seconds.
PTO Brake operation

The brake piston is moved by the oil pressure, also from the 17 bar circuit, and
presses against the outside of the clutch housing, in turn this holds the drive gears
that are splined to the clutch shaft.
A small drilling through the brake piston allows the lubrication of the outer face of the
piston when it moves.
The brake is fitted for safety purposes and is intended to hold the PTO output shaft
stationary when the tractor is being operated but the PTO is not in use.
When turning off the PTO system, particularly when driving high inertia implements,
it is normally most efficient to close the engine throttle (to idle) to slow the PTO drive
line. With the engine at idling speed then turn off the PTO.
It is not intended for the PTO brake to be used for slowing down and stopping the
tractor and implement PTO system.
PTO Engagement
When the PTO switch in the cab is turned to the on position a signal is sent to the
McCormick cab control module, which in turn sends a signal to the transmission
control module. If the transmission controller senses that the engine is running and
that regulated pressure is present it will then turn on the PTO clutch solenoid and
release the PTO brake at the same time. If however the PTO fails to reach its full
operating speed compared to engine speed within 8 seconds the transmission
controller will automatically disengage the PTO clutch solenoid and turn the PTO
brake back on and an error code will be sent to the McCormick cab controller.
Should the transmission controller also see more than 3% slip in the PTO clutch at
any time when it is engaged, it will also disengage automatically, and send out an
error code. This is sensed by a speed sensor on the input and output shafts of the
PTO.

SECTION 6
Powershift transmission service procedure under

warranty
When an internal failure within the powershift section of the transmission is
diagnosed, the complete powershift section will have to be replaced under the
McCormick exchange policy. This is due to the complex assembly procedure and
the extensive testing required.
This exchange policy and procedure is explained in Service Bulletin DBT1014.

6003
Section
6003
GUIDELINES FOR SPLITTING THE TRACTOR
ZTX Series Tractors

SM 8-12380 March 2004
2 SECTION 6003
TABLE OF CONTENTS
Splitting - Powershift/Intermediate housing

General ................................................................................................................................................................ 3
A. Preliminary operations ..................................................................................................................................... 3
B. Uncoupling ....................................................................................................................................................... 5
C. Coupling .......................................................................................................................................................... 6
D. Final operations ............................................................................................................................................... 7
Splitting - Intermediate housing/Centre housing

General ................................................................................................................................................................ 8
A. Preliminary operations ..................................................................................................................................... 8
B. Uncoupling ..................................................................................................................................................... 10
Separating the powershift from the intermediate housing ............................................................................. 10
Splitting the intermediate and centre housings .............................................................................................. 10
C. Coupling ........................................................................................................................................................ 12
D. Final operations ........................................................................................................................................ 13
Splitting - PTO housing/ Centre housing

A. Preliminary operations ................................................................................................................................... 15
B. Disassembling ........................................................................................................................................... 16
C. Reassembling ................................................................................................................................................ 16
D. Final operations ............................................................................................................................................. 17
SM 8-12380 Issued 03-2004

SECTION 6003 3
Splitting - Powershift/Intermediate housing
General STEP 12
Due to the diversity of the hydraulic and mechanical Remove the fuel tanks.
options available on the ZTX series tractors, mention
will only be made of the main pipes or connections to STEP 13
be disconnected.
Mark positions of following parts then
disassemble from the transmission:
For this reason, before and when splitting the tractor,
ensure no connections remain between the fixed
Harnesses, sensors (intermediate speeds, engine
assembly and the moving assembly.
speeds, road speed, powershift temperature and
pressure), connectors to receptacles A, B, C, D, E, F
ATTENTION: When splitting any part of the tractor, make
of the TC unit installed on the right-hand side of the
sure appropriate splitting equipment is used.
Powershift box.
A. Preliminary operations STEP 14

Drain the intermediate housing.
STEP 1
Disconnect the battery terminals. STEP 15
Remove suction pipe (1) (Fig. 1) at the Gerotor
STEP 2 pump, and the elbow unions fitted on the
Remove cab. intermediate housing and the Full Powershift
powershift.
STEP 3
Position the rear wheels in wide tread.
STEP 4
Remove the side panels and hood.
STEP 5
Remove the right footstep and battery compartment.
STEP 6
Disconnect and blank the front differential and front
axle pipes.
STEP 7
Figure 1
Remove the guard and the MFD transmission shaft.
STEP 16
STEP 8
Disconnect the creeper control on the right hand side
Mark then disconnect the steering hoses from the
of the intermediate housing.
Orbitrol steering unit.
STEP 9
Remove the left footstep.
STEP 10
Drain the fuel tanks. Remove balance pipe guard and
balance pipe.
STEP 11
Mark and disconnect the harness to the fuel tank
gauge and the fuel supply and return hoses.
SM 8-12380 Issued 03-2004

4 SECTION 6003
STEP 17 STEP 18
Block front axle (1), using suitable chocks - "C" (Fig. 2). Chock the rear wheels.
Figure 2
SM 8-12380 Issued 03-2004

SECTION 6003 5
B. Uncoupling
STEP 19
In order to free lower shaft (2) (Fig. 3 - 4), turn the
special screw on the Park lock control unit clockwise
until a hard point is felt (See Section 6018).
STEP 20
Fit the appropriate splitting equipment.
STEP 21
Remove the bolts attaching the powershift to the
housing.
STEP 22
Assisted by an operator, separate the assemblies,
taking care to identify the position of the coupling Figure 3
sleeves on connecting shafts (1) and (2) (Fig. 3).
Figure 4
Figure 5
SM 8-12380 Issued 03-2004

6 SECTION 6003
C. Coupling
Assembling the powershift and the intermediate
housing
STEP 23
Clean the mating surfaces of the powershift and the
housing.
STEP 24
Coat the mating face of the housing with sealing
product Loctite 510 or equivalent.
STEP 25
Check the presence of the locating pins on the
housing.
STEP 26
Check the presence of connecting shafts (1) and (2)
and sleeves (3) (4) (Fig. 3).
NOTE: Position the machined groove on the

outside diameter of each sleeve towards the
powershift.
ATTENTION: On ZTX series tractors without creeper unit

and fitted with the Full Powershift transmission, spring ( 1 )
located at the front of shaft ( 2 ) maintains the latter in
position (Fig. 4).
STEP 27
Screw two diametrically opposed guide studs into the
powershift.
Figure 6
STEP 28
Assemble powershift (8) onto housing (19).
STEP 29
Remove the guide studs. Install and torque bolts (1)
(Fig. 6) to 240 to 320 Nm. (177 to 236 lb ft).
SM 8-12380 Issued 03-2004

SECTION 6003 7
D. Final operations STEP 44

Top-up the oil system and check the level on the sight
STEP 30 glass located on the left of the centre housing.
Remove the chocks from the front axle.
NOTE: The intermediate housing drain plug is
special. It has a cylindrical part which the other
STEP 31
plugs do not. It is therefore essential to check its
Refit the creeper control unit, if fitted. For adjustment position during reassembly.
(See Section 9001).
STEP 45
STEP 32
Pour fuel into the tanks.
Refit the Gerotor pump sleeves and suction pipe.
STEP 46
STEP 33
Top-up the fluid level in the cooling system and the
Reconnect the return hose from the brake master- expansion tank.
cylinder tank.
STEP 47
STEP 34
Reset the special screw on the Park lock control unit
Reconnect the return hoses for the Orbitrol steering to its initial position (See Section 6018).
unit and power-assisted braking on the powershift.
STEP 48
STEP 35
Refit the wheels in initial position.
Reconnect the connectors for receptacles A, B, C, D,
E, F of the TC unit, the sensors and the solenoid STEP 49
valves.
Carry out a road test on all of the controls.
STEP 36
STEP 50
Reinstall the fuel tanks.
Check for hydraulic or coolant leaks and top up as
necessary
STEP 37
Reconnect the fuel supply and return hoses
STEP 38
Reconnect the fuel gauge harness.
STEP 39
Reinstall the left footstep.
STEP 40
Reassemble the transmission shaft, guard and
balance pipe gaurd. Reconnect the front differential
lock control (MFD) (If mounted).
STEP 41
Reinstall the battery compartment and right footstep.
STEP 42
Refit the cab (See Section 9006)
STEP 43
Reconnect the battery terminals.
SM 8-12380 Issued 03-2004

8 SECTION 6003
Splitting - Intermediate housing/Centre housing
General STEP 12
Due to the diversity of the hydraulic and mechanical Disconnect the cooler hoses and the 17 bar pipe on
options available on the ZTX series tractors, mention the right-hand hydraulic cover.
will only be made of the channels or main
connections to be disconnected. For this reason, STEP 13
before and when splitting the tractor, ensure no
connections remain between the fixed assembly and Disconnect the supply and pilot-flow hoses on the
the moving assembly. Orbitrol steering unit on the priority block(s).
STEP 14
A. Preliminary operations
Drain the intermediate housing and Centre housing.
Mark the plug contours.
STEP 1
Set the lifting arm to the fully DOWN position. STEP 15
Remove suction pipe (1) (Fig. 7) from the Gerotor
STEP 2
pump, and the elbow unions fitted in the intermediate
Disconnect the battery terminals. housing and Full Powershift gearbox.
STEP 3
Remove cab (See Section 9006).
STEP 4
Position the rear wheels in wide track.
STEP 5
Remove the side panels and hood.
STEP 6
Disconnect and blank the front differential and front
axle pipes.
STEP 7 Figure 7
Remove the left footstep, right footstep and battery
compartment. STEP 16
Remove the lubricating tubes located on the
STEP 8 intermediate housing.
Remove the MFD drive shaft guard, the MFD drive
shaft and the balance pipe guard STEP 17
Mark then disconnect the harness to the solenoid
STEP 9 valves on the right-hand hydraulic cover, and the
Drain the fuel tanks, disconnect the fuel gauge harness to the Park lock transmission lock located on
harness and pipes. Remove the fuel tanks. the right-hand side of the intermediate housing.
STEP 10 STEP 18
Disconnect and blank the hoses of the left and right Mark then disconnect the harness to the low-
brake pipes located above the intermediate housing pressure switch and the one to the clogging switch
on the main filter (15 microns), the harnesses to the
load sensors,
STEP 11
Disconnect the hose (17 bar) towards the power
assisted braking on the right-hand hydraulic cover,
SM 8-12380 Issued 03-2004

SECTION 6003 9
STEP 19
Mark then disconnect the connectors to the
(MoveUp-MoveDown) solenoid valves of the lift
control valve, and the harnesses to the position
sensors on the right-hand lift bearing and the drive
sensor on the centre housing,
STEP 20
Mark then disconnect the PTO sensors (dual driving
gear and output shaft) on the rear housing.
STEP 21
Immobilise the front axle (1), using suitable chocks
"C" (Fig. 8).
Figure 8
SM 8-12380 Issued 03-2004

10 SECTION 6003
B. Uncoupling STEP 27
Remove and release the cover (3) of the MFD
Separating the powershift from the mechanism (if assembled (Fig. 12). Locate the
intermediate housing screws (2) that attach the intermediate housing (19)
and the centre housing.
STEP 22
STEP 28
For tractors fitted with Park lock transmission, free
Disconnect any hoses or pipes that may have
lower shaft (2) (Fig. 3) by turning the special screw
remained connected to the various assemblies.
on the unit located on the right-hand side of the
intermediate housing clockwise until a hard point is
felt (See Section 6018). STEP 29
Chock the rear wheels. Install an axle stand beneath
STEP 23 the centre housing.
Fit the appropriate splitting equipment.
STEP 30
STEP 24 Sling the intermediate housing using suitable lifting
fixture.
Remove the bolts securing the powershift to the
intermediate housing.
STEP 31
STEP 25 Remove the screws (2) attaching the housings.
Install guide studs of suitable length and proceed
Assisted by an operator, separate the assemblies
with splitting (Fig. 12).
(Fig. 6).
NOTE: Note: On the tractors fitted with a creeper

unit, monitor the separation at the powershift
output shaft and drive pinion.
Splitting the intermediate and

centre housings
STEP 26
Remove the right and left hand covers in order to
access hidden screws (2) (Fig. 9) (See Section 8005).
Figure 9
SM 8-12380 Issued 03-2004

SECTION 6003 11
Figure 10
(1) Full Powershift gearbox .
NOTE: If the splitting operation is not easy, insert

two screws of suitable length into tapped "T"
holes located on the right and left attachment
flanges of the intermediate housing (Fig. 11).
Shaft (28) (Fig. 12) located between the drive
bearing of the pumps and the PTO clutch comes
out with the intermediate housing. Before
removing the shaft, if required visually mark land
"D" to allow passage of the crown wheel (Fig. 12)
Figure 11
SM 8-12380 Issued 03-2004

12 SECTION 6003
C. Coupling
Assembling the intermediate STEP 38.

housing and the centre housing Remove the guide studs. Install and torque bolts (2)
to 300 - 420 Nm.
STEP 32 STEP 39
Clean the mating surfaces of the housings. Clean the mating surfaces of intermediate housing
(19) and cover (3) (Fig. 12).
STEP 33
Coat the mating face of the centre housing with STEP 40
sealing product - Loctite 510 or equivalent. Coat the mating face of the housing with Loctite 510.
Refit the cover and tighten the retaining bolts (4)
STEP 34 (Fig. 12) to a torque of 50 to 70 Nm (44 to 51 lb ft).
Check for presence and position of locating pin (1)
force fitted into the centre housing (Fig. 12). STEP 41
Reinstall the right and left hand covers (See
NOTE: The stud has two flats positioned parallel Section 8005).
with the centre line of the housing (Fig. 12).
STEP 35
If removed, reposition PTO shaft (28), checking the
position of land "D" (Fig. 12).
STEP 36
Screw two guide studs at diametrically opposite
positions on the centre housing.
STEP 37
Assemble the intermediate housing on the centre
housing. Turn the pump driving gear in order to mesh
the shaft grooves (28) with those of the PTO clutch
SM 8-12380 Issued 03-2004

SECTION 6003 13
STEP 42
Assemble the powershift and the intermediate
housing. (See Page 6
Figure 12

Reconnect the supply and pilot-flow hoses to the
STEP 43 orbitrol steering unit on the priority block(s), the 17
Reconnect the PTO sensors, position and forward bar pipe on the right-hand hydraulic cover and the
sensors and the solenoid valves (Move up Move cooler hoses routed to the right-hand hydraulic
down) on lift control valve cover.
STEP 44 STEP 48
Reconnect the load sensors and the switch Reconnect the 17-bar hose to the power-assisted
harnesses (low pressure and clogging) braking on the right-hand hydraulic cover, the hoses
on the brake pipes and the return hose from the
brake tank on the intermediate housing (Full
STEP 45
Powershift gearbox).
Reconnect the solenoid-valve harness on the right
hand hydraulic cover and transmission park lock on STEP 49
the intermediate housing.
Refit cab (See Section 9006)
STEP 46
STEP 50
Reconnect the clutch lubricating pipe, the suction
Reinstall the fuel tanks, the balance pipe and the
pipe (1) at Gerotor pump and sleeves (Fig. 7).
tank gauge harness.
Reconnect and adjust creeper unit control (if fitted)
(See Section 9001).
STEP 51
Reconnect the fuel supply and return hoses,
SM 8-12380 Issued 03-2004

14 SECTION 6003
STEP 52 STEP 58
Refit the balance pipe guard, the MFD drive shaft, Start the engine.
and the MFD drive shaft guard.
STEP 59
STEP 53 Bleed the main brake system (See Section 9001).
Reconnect the front differential lock control pipe
(if mounted). STEP 60
Refit and close the bonnet.
STEP 54
Refit the footsteps, battery box and battery. STEP 61
Reconnect the battery terminals.
Re calibrate the transmission and carry out a road
test on all of the controls.
STEP 55
Refit the wheels in initial position. STEP 62
Check for any oil leaks and that all electrical and
Top up the oil system and check the level in the sight
hydraulic equipment is operating correctly.
glass located on the left of the centre housing.
NOTE: The intermediate housing drain plug is

special. It has a cylindrical part which the other
plugs do not have. It is therefore essential to
check its position during reassembly.
STEP 56
Pour fuel into the tanks.
STEP 57
If the tractor is equipped with a transmission park
lock, return the special screw on the control panel to
its initial position (See Section 6018).
SM 8-12380 Issued 03-2004

SECTION 6003 15
Splitting - PTO housing/ Centre housing
A. Preliminary operations
STEP 1
Drain the centre housing.
STEP 2
Mark the position of the hoses (1) and disconnect
hydraulic couplers (2) (Fig. 13).
STEP 3
Disconnect the clutch pipes (low pressure and
lubrication) located on the right-hand side of the PTO
housing.
STEP 4
Disconnect PTO sensors (1) and (3) (Fig. 14) on the
driving gear and the output shaft.
STEP 5
Remove the right and left hand guards over the
harnesses connected to the load sensors.
STEP 6
On housing (4), remove two diametrically opposite
bolts (2) (Fig. 14), and replace with two guide studs
of sufficient length (230 mm approximately) (local
manufacture).
STEP 7 Figure 14
Assisted by an operator, or using a suitable sling,

remove support hook (1) (Fig. 15).
Figure 13
SM 8-12380 Issued 03-2004

16 SECTION 6003
C. Reassembling
STEP 11
Clean the mating surfaces of the housings.
STEP 12
Coat the mating face of the centre housing with
sealing product - Loctite 510 or equivalent.
STEP 13
Check the presence of the locating pins on the centre
housing.
Note: The insertion dimension for the studs is

11.40mm in relation to the surface of the centre
housing. The studs are coated with Loctite 638 or
equivalent before fitting.
STEP 14
Check that piston (1) in the PTO brake slides freely.
Place the piston in abutment on cylinder (3) (Fig. 16)
to allow passing the PTO clutch during re assembly
of the housing.
STEP 15
Coat friction washer (20) with miscible grease and
apply against bearing (24) (reversible PTO only).
STEP 16
Ensure that driven pinions (7) and (18) are correctly
Figure 15 positioned on shaft (12) and that they rotate normally
(PTO all types).
B. Disassembling
STEP 17
STEP 8 Position complete housing (4) (Fig. 16) on the guide
Remove the remaining bolts. Unstick and disengage studs installed previously.
the PTO housing from the centre housing by levering,
then remove using suitable lifting equipment. STEP 18
Progressively slide the housing onto the studs in
NOTE: The PTO housing comes out complete order to engage the splines of shaft (28) in the clutch
with the clutch and driving/driven pinions. Shaft splines, and those on end of shaft (12) inside bearing
(28) remains in the intermediate housing and (24).
centre housing.
STEP 19
STEP 9
Offer up the PTO housing to the centre housing.
Clean the mating surfaces of the housings. Install the support hook (1) (Fig. 3). Remove the
guide studs. Install screws (2) (Fig. 15 and 16) and
STEP 10 torque to 480 to 640Nm (345 to 472lb ft) (apply
Coat the mating face of the centre housing with Loctite 542).
sealing product - Loctite 510 or equivalent.
SM 8-12380 Issued 03-2004

SECTION 6003 17
Figure 16

Check for oil leaks on the mating face of the PTO
STEP 20 housing and hydraulic unions.
Reinstall the side guards.
STEP 25
STEP 21 Check the operation of the PTO clutch, including
Connect pipes and sensors (1) and (3) (Fig. 14). PTO brake (all types).
STEP 22
Fix the hoses to the hydraulic couplers.
STEP 23
Service the oil system and check the level on the
transparent tube located on the left of the centre
housing.
SM 8-12380 Issued 03-2004

Section
6006
FULL POWERSHIFT
TRANSMISSION
6006
ZTX Series Tractors

SM 8-12310 March 2004
2 SECTION6006
TABLEOFCONTENTS
FULLPOWERSHIFTGEARBOX
General.................................................................................................................................................................3
Characteristics......................................................................................................................................................3
Servicerecommendations ....................................................................................................................................3
Transmission ........................................................................................................................................................ 4
Overallview......................................................................................................................................................5
FrontView ........................................................................................................................................................ 6
Topview...........................................................................................................................................................7
Right-handview ...............................................................................................................................................8
Left-handview.................................................................................................................................................. 9
BottomView ...................................................................................................................................................10
DiagramshowingthemeshingofAG250Pinions.........................................................................................11
Powertransmission-Description....................................................................................................................... 12
Powertransmissionroute...............................................................................................................................13
PowertransmissionrouteF1speed(1stforward) .........................................................................................14
PowertransmissionrouteR4speed(4threverse).........................................................................................15
PowertransmissionrouteF14speed(14thforward) .....................................................................................16
PowertransmissionrouteF18speed(18thforward) .....................................................................................17
SM8-12310 Issued03-2004
SECTION6006 3
FULLPOWERSHIFTGEARBOX
General Servicerecommendations
The AG250 Full Powershift gearboxes comprise When an internal failure within the powershift
forwardandrearhousingscontainingsevenshafts section of the transmission is diagnosed, the
and nine clutches. Six speed clutches and three complete powershift section will have to be
range clutches. Three clutches must be replaced under the McCormick exchange policy.
hydraulically engaged in order to transmit engine Thisisduetothecomplexassemblyprocedureand
power. These transmissions are fitted with their theextensivetestingrequired
own Gerotor hydraulic pump, filter, pressure
regulating valve, metering valve and nine Thisexchangepolicyandprocedureisexplainedin
proportional solenoid valves to engage the ServiceBulletinDBT1014.
clutches.Thesetransmissionsuseanoiltankthat
iscommontothegearboxandaxleassembly.The
gearbox is coupled to the engine via a splined
coupling shaft situated in the transmission and a
damperlocatedontheengineflywheel.
Characteristics
The AG250 Full Powershift gearboxes have the
followingcharacteristics:
18forwardspeeds.
6 or 8 reverse speeds depending on the
specificationsineachcountry.
Constantmeshing,helicalgears.
Ballandrollerbearingstoeliminateallvibration.
Commonaxle/gearboxoiltank.
Hydraulicallycontrolledmultiplateclutches.
Electro-hydraulicgearchanges.
100%modulatedgearchanges. Figure1
Adaptationtospeedandmovement.
Reverseshuttle.
Compactdesignina2-parthousing.
Housing also acts as the tractor chassis between
theengineandtherearaxleunit.
Pressurelubricationofallclutches.
Self-controlledhydraulicpump.
Vibrationdamperintheengineflywheel.
Electronicallyprotected.
SM8-12310 Issued03-2004
4 SECTION6006
Transmission
(Figs.2to7)
Par ts Lists
1. Forwardtransmissionhousing
2. Reartransmissionshousing
3. Locationofthefirststageshaft
4. Locationofthesecondstageshaft
5. Locationofthethirdstageshaft
6. Locationofthefourthstageshaft
7. Locationofthefifthstageshaft
8. Locationofthesixthstageshaft
9. Locationoftheseventhstageshaft
10. Inputshaftandseal
11. 260psi(18bar)pressureregulatingvalve
12. Clutch2proportionalsolenoidvalve
13. ClutchAproportionalsolenoidvalve
14. ClutchRproportionalsolenoidvalve
15. ClutchBproportionalsolenoidvalve
16. Clutch1proportionalsolenoidvalve
17. ClutchCproportionalsolenoidvalve
18. ClutchLproportionalsolenoidvalve
19. (AG250)clutchHproportionalsolenoidvalve
20. (AG250)clutchMproportionalsolenoidvalve
21. 130psi(9bar)pumppressureswitch
22. Enginespeedsensor
23. Forwardspeedsensor
24. Calibrationspeedsensor
25. Temperaturesensor
26. Clutchhydraulictestport-7/16"plugs
27. Lubricatingpressuretestport-9/16"plugs
28. Pumphydraulictestports-wideplugs
29. INport(inlet)ofthepumpfromthetank
30. INport(inlet)ofthepumpfromthetank
31. Freereturntohousingport
32. Pumppressureoutletport
33. Pumppressureinletporttoforwardhousing
34. Oiloutletporttowardsoilcoolerandlubricatingrelief-valve
35. Returnportforoilfromoilcooler
36. Gearboxserialandmodelnumberidentificationplate.
SM8-12310 Issued03-2004
SECTION 6006 5
Overall view
Figure 2
SM 8-12310 Issued 03-2004

6 SECTION6006
FrontView
Figure3
SM8-12310 Issued03-2004
SECTION6006 7
Topview
Figure4
SM8-12310 Issued03-2004
8 SECTION6006
Right-handview
SM8-12310 Issued03-2004
SECTION6006 9
Left-handview
Figure5
SM8-12310 Issued03-2004
10 SECTION6006
BottomView
Figure6
SM8-12310 Issued03-2004
SECTION6006 11
DiagramshowingthemeshingofAG250Pinions
80T
Figure7
SM8-12310 Issued03-2004
12 SECTION6006
Powertransmission-Description
The engine power is transmitted to the 1st stage Thanks to this configuration, the various clutches
shaftthatdrivestheshaftsofthe2nd,3rdand4th supply six forward and three reverse ratios to the
stages.The1ststageshaftalsodrivestheGerotor transmission,inaccordancewiththeinputclutches
hydraulic pump for the gearbox and acts as the (1,2orR)oroutputclutches(A,BorC)selected.
PTO input shaft. The shafts of the 2nd and 4th Theoutputfromspeedclutchesdirectsthepowerto
stagesactasforwardspeedswiththevariousratios the clutch to the selected range (L, M or H), thus
ofinputspeed,whiletheshaftofthe3rdstageacts providing18forwardspeedsand8reversespeeds.
as reverse with a single input speed ratio. This IntheNorthAmericanmarker,theelectroniccontrol
allowstoobtainforwardandreversespeeds.When does not permit the engaging of the two highest
clutch1,2Risengaged,itlockstheclutchhousing speeds.Otherinternationalmarketsmayauthorise
tothecorrespondingshaft.Eachclutchhousingis thesereversespeedsinrelationtothelegislationin
fittedwithapinionthatmesheswithothershafts(all forceintheircountries.(Figs.10to14).
having the same ratio), permitting the power to
enterviaaclutch(1,2orR)andtoexitviaanother
clutch(A,BorC)andanothershaft.
POWERTRANSMISSIONROUTE
Speed Clutches (Fig8.)
F1 1-A-L A-C-E-F-G-I-H-J-K-L-M-P
F2 2-A-L A-B-I-H-J-K-L-M-P
F3 1-B-L A-C-E-F-J-K-L-M-P
F4 1-A-M A-C-E-F-I-O-Q-P
F5 2-B-L A-B-G-F-J-K-L-M-P
F6 2-A-M A-B-I-O-Q-P
F7 1-C-L A-C-K-L-M-P
F8 1-B-M A-C-E-F-H-I-O-Q-P
F9 2-C-L A-B-G-F-E-K-L-M-P
F10 2-B-M A-B-G-F-H-I-O-Q-P
F11 1-A-H A-C-E-F-G-I-O-N
F12 1-C-M A-C-K-J-H-I-O-Q-P
F13 2-A-H A-B-I-O-N
F14 2-C-M A-B-G-F-E-K-J-H-I-O-Q-P
F15 1-B-H A-C-E-F-H-I-O-N
F16 2-B-H A-B-G-F-H-I-O-N
F17 1-C-H A-C-K-J-H-I-O-N
F18 2-C-H A-B-G-F-E-K-J-H-I-O-N
R1 R-A-L A-D-F-G-I-H-J-K-L-M-P
R2 R-B-L A-D-J-K-L-M-P
R3 R-B-M A-D-F-G-I-O-Q-P
R4 R-C-L A-D-F-E-K-L-M-P
R5 R-B-M A-D-H-I-O-Q-P
R6 R-A-H A-D-F-G-I-O-N
R7 R-C-M A-D-F-E-K-J-H-I-O-Q-P
R8 R-B-H A-D-H-I-O-N
SM8-12310 Issued03-2004
SECTION6006 13
Powertransmissionroute
Figure8
SM8-12310 Issued03-2004
14 SECTION6006
PowertransmissionrouteF1speed(1stforward)
Figure9
SM8-12310 Issued03-2004
SECTION6006 15
PowertransmissionrouteR4speed(4threverse)
Figure10
SM8-12310 Issued03-2004
16 SECTION6006
PowertransmissionrouteF14speed(14thforward)
Figure11
SM8-12310 Issued03-2004
SECTION6006 17
PowertransmissionrouteF18speed(18thforward)
Figure12
SM8-12310 Issued03-2004
Section
6017
MFDCLUTCH
ZTXSeriesTractors
6017
©2003McCormickTractorsInternationalLimited.
SM8-12510 March2004
2 SECTION6017
TABLEOFCONTENTS
MFDCLUTCH
General .................................................................................................................................................... 3
A.Preliminaryoperations .......................................................................................................................... 6
B.Removing,refittingtheclutchassemblyandshaft ................................................................................ 6
C.Disassembling,reassemblingandshimmingtheclutch ........................................................................ 8
D.Shimmingtheshaft ............................................................................................................................ 10
SM8-12510 Issued03-2004
SECTION6017 3
MFDCLUTCH
General Operation
Declutchedposition
OntheZTXseriestractorstheclutchassemblyfor
the front axle is fitted in the lower part of the TheMFDsolenoidvalve,fittedontheright-handside
intermediatehousing.Acoverbeneaththehousing hydrauliccoverandcontrolledbythetractor ís
givesaccesstotheclutch,whichcomprisesof: electronicsystem,suppliestheinterioroftheshaft
with17-barpressureviachannel(A).Thepressureis
Ashaft(2)rotatingintwotaperrollerbearings(8)(9) maintainedbysealrings(32).Piston(39)movesin
and(4)(16)fittedintheboreofthehousing. hub(30)and drawsclutchcover(23) thus
Ahydraulicclutchassemblyintegralwiththerotating compressingtheBellevillewashers(26)andfreeing
shaft. theplates(36).Thebellshapedgear(10)thenidles
ontheshaft.
Abell-shapedgear(10)drivingclutchplates(36)and
centredontheshaftbyafrictionbush(6). Clutchedposition
Thebellshapedhelicalgear(10)isconstantly Whenthepressureiscut-off,theBellevillewashers
meshedwiththedrivingpinion(17)thatisintegralvia (26)pushtheclutchcover(23),matingtheclutch
splineswiththedrivepinion. plateswiththebell-shapedgear(10)andthus
Theshaft isshimmed to providean operating allowingfortherotationofshaft(2).
clearanceof0mmto0.1mmusingshim(s)(18)
placedbetweenthesealholder(20)andbearingcup Lubrication
(4). Theoilfromthelubricatingcircuitarrivesviareducer
Theclutchassembly(15)isshimmedtoobtaina union(22)andlubricatestheclutchplates(36)via
clearanceof0.9mmto1.1mmbetweencirclip(34) thetransferpipe(21)andchannel(B)drilledinshaft
andshim(s)(35)inthedeclutchedposition(solenoid (2).
valveactivated).
Abush(7)heldbytransferpipe(28)suppliesthe
clutchwith17barpressureviaunion(27).
Theoiltightnessoftheshaftisensuredbyalipseal
(1)andadustseal(41),andtheoiltightnessofthe
housingbyanO-ring(19).
SM8-12510 Issued03-2004
4 SECTION6017
MH04C103
SM8-12510 Issued03-2004
SECTION6017 5
MH04C104
SM8-12510 Issued03-2004
6 SECTION6017
A.Preliminaryoperations STEP10
Removetheclutchassembly,thebellshapedgear
STEP1 andbearingcone(9).
Immobilisethetractor.Chocktherearwheels.Apply
thehandbrake. STEP11
Extractcup(8).Removecirclip(33).
STEP2
NOTE: Tocarryoutmaintenanceondrivingpinion
Disconnectthefrontdifferentialcontrolpiping(block (17), remove the entire unit assembly with drive
offthepiping).Removethetransmissionshaft. pinion(seesection6018accordingtotheversion).
STEP3 STEP12
Draintheintermediatehousing. RemovetheMFDclutch17barsupplypipe,union
(27)andtransferpipe(28)usingcirclippliers.Take
STEP4 offbush(7).RemoveO-ring(31).
Removebolts(12).Releaseandremovecover(11). Strippingtheshaft
B.Removing,refittingtheclutch STEP13
assemblyandshaft Takeoffoilsealrings(32).
ATTENTION: Bush ( 7 ) is held solely by transfer pipe STEP14

( 28 ). If removal of only the transfer pipe is necessary,
check that the bush has not accidentally been E xtract bearing c one (16) us ing a press and
moved.This bush has a drilled hole ( T ) that is turned appropriatefixture.
downwards and allows for pressure relief of the bearing.
Reassemblingtheshaft
Removal
STEP15
STEP5 Ensurethatchannels(A)and(B)arenotobstructed.
Takeoffcirclip(3). Checkforthepresenceoftherivetsateachendof
theshaft.
STEP6
STEP16
Wrapthesplinedsectionofshaft(2)withaflexible
protectivetape.Takeoutdustseal(41).Extractthe Insertbearingcone(16)thrustagainsttheshoulder
sealholder(20)fittedwithitsseal(1)usingtwo onshaft(2).
locallymanufacturedhooksplacedininternalgroove
(G)ofthesealholder.Extractseal(1). STEP17
Placetheoilsealrings(32)inthegroovesofthe
STEP7 shaft.Hooktheirends.Ensurethattheyturnfreely.
TakeoutO-ring(19).
STEP8
Removetheshim(s)(18)andbearingcup(4).
STEP9
Takeouttheshaftassembly(2)fittedwithbearing
cone(16)whileholdingtheclutch(15)andthebell
shapedgear(10)assembly.
SM8-12510 Issued03-2004
SECTION6017 7
Refittingtheclutchassemblyandshaft STEP23
Holdtheclutchassemblyandbellshapedpinion.
STEP18 Engageshaft(2)fittedwithbearingcone(16)and
Cleanandinspectthecomponents.Replaceany lubricatedsealrings(32),intheclutchassembly,
partsfoundtobedefective. bearingcone(9)andbush(7).
STEP19 STEP24
Positionbush(7)fittedwithanewO-ring(31),with Placecup(4).Lightlycoatshim(s)(18)withmiscible
port(O)ofthebushfacingthetransferpipe(28)and greaseandstickthemagainstthecup.
hole(T)positionedfacingdownwards.Insertthe
pipe.Screwonunion(27)fittedwithitsseal.Replace STEP25
theclutchpressuresupplypipe.
Usingapressandanappropriatefixture,insertlip
seal(1)inthesealholder(20).
STEP20
Refitcirclip(33).Insertcup(8). STEP26
FitO-ring(19).
STEP21
Smearbearingcone(9)withmisciblegreaseand STEP27
placeitincup(8).
Protectthesplinedsectionofshaft(2).Inserttheseal
NOTE: If the intermediate housing, shaft (2), holderfittedwithseal(1)previouslylubricated,using
bearings(8)(9)and(4)(16),sealholder(20)and a l o c a l l y m a n u fa c t u r e d s l e e v e . R e m o v e t h e
circlips (3) (33) have been replaced, carry out J2 protectionmaterial.
shimming,(seePage 10).
STEP28
STEP22
Fitcirclip(3).
Refittheclutch(15)andthebellshapedgear(10)
assembly.
SM8-12510 Issued03-2004
8 SECTION6017
C.Disassembling,reassemblingandshimmingtheclutch
Disassembly STEP38
RemovetheBellevillewashers(26).
STEP29
Removetheclutchassembly(seePage 6). Reassembly
STEP30 STEP39
Separatethebellshapedgear(10)fromtheclutch Inspectandcleanthecomponents.Replaceany
assembly(15). partsfoundtobedefective.Checkthatchannels(A)
and(B)arenotobstructed.
STEP31
STEP40
Takeoffcirclip(38).Removepiston(39).
STEP32
TakeofftheO-rings(24)(40).
STEP33
MH04C106
PositiontheBellevillewashers(26)intheclutch
cover(23).
STEP41
MH04C105 LubricateandfitO-ring(25)onhub(30).
Usingapressandanappropriatefixture,compress STEP42
theBellevillewashers(26).
Positionhub(30)inclutchcover(23)andthrusting
STEP34 againsttheBellevillewashers.
Takeoffcirclip(34),theshim(s)(35). STEP43
STEP35 Placetheclutchfrictionplates(36)aligningthetabs,
theintermediateplates(37)andfitthecoverplate
Removethefixture.Takeoffcoverplate(29),clutch (29).
plates(36)andintermediateplates(37).
STEP36
Separatehub(30)fromclutchcover(23).
STEP37
TakeoffO-ring(25).
SM8-12510 Issued03-2004
SECTION6017 9
Shimmingtheclutch STEP47
J1shimming Position the shim(s) selected in operation 45
betweenthecoverplateandthecirclip.
STEP44 IMPORTANT: Fitthesplinedshimonthecirclip
side.
STEP48
Refitthecirclip.
STEP49
LubricateandfittheO-rings(24)(40)onpiston(39)
andrefitit.
STEP50
Fitcirclip(38).
STEP51
Coupleclutchassembly(15)andbellshapedgear
(10).
MH04C107
NOTE: Bush (6) is force fitted in the bell-shaped
Usingapressandanappropriatefixture,applya gearandthenrebored.
loadof2000daN(45lbf)soastofullycompressthe
Bellevillewashers(26). STEP52
STEP45 Refittheclutchassembly(15)andbellshapedgear
(10).Carryoutsteps21to28.
MH04C108
Fitcirclip(34).Usingasetoffeelergauges,measure
thegap(X),betweencoverplate(29)andcirclip(34).
Selectathicknessofshim(s)(35)toprovidea
clearanceof:
J1=0.9mmto1.1mm.
STEP46
Removecirclip(34).
SM8-12510 Issued03-2004
10 SECTION6017
D.Shimmingtheshaft STEP56
Repeatstep54,thistimewhilepushing.
NOTE: The MFD clutch is mechanically engaged
when stationary by the Belleville washers and STEP57
throughthelinkwiththerearaxledrivepinion,itis
impossibletoturnthedrivingshaft(2). Inrelationtotheclearancemeasured,selectashim
(18)thicknesstoprovideaclearanceof:
I M P O R TA N T: To c a r r y o u t J 2 s h i m m i n g ,
provisionallyfitbearingcone(9),shaft(2)fitted J2=0mmto0.1mm
withtaperrollerbearing(16)withoutfittingthe
clutch(15),bell shapedgear (10)andshim(s) STEP58
(18)assembly.Fitbearingcup(4),sealholder
Removecirclip(3),sealholder(20),shaft(2)andthe
(20)andcirclip(3).
bearings.
J2shimming
STEP59
STEP53 Definitivelyfittheclutch(15),bellshapedgear(10)
andshaft(2)assembly.Carryoutsteps21to28.
MH04C109
Place the index of a dial gauge on the end of

shaft(2).
STEP54
Sinceaccessislimitedaroundtheshaft,pullhard
usingvicegrippliers,andalternativelyturningitleft
andrightinordertocorrectlyseattheconesand
cups.
STEP55
Setthedialgaugetozero.
SM8-12510 Issued03-2004
SECTION6017 11
E.Finaloperations
STEP60
Cleancover(11)anditsmatingfaceonthehousing.
STEP61
SmearthecovermatingfacewithLoctite510orits
equivalent.
STEP62
Refittheinspectioncover.Tightenthebolts(12)toa
torqueof70-90Nm.(52-66lbft).
STEP63
Refillthehousingsandchecktheoillevelonthe
transparenttubeontheleft-handsideofthecentre
housing.
STEP64
Refitthetransmissionshaft.
STEP65
Reconnectthedifferentiallockcontrolpiping.
STEP66
Removethechocksfromthewheels.Carryouta
roadtestoftheMFDclutch.
STEP67
Checkforanyoilleaks.
SM8-12510 Issued03-2004
Section
6018
REAR AXLE
ZTX Series Tractors
6018

SM 8-12300 March 2004
2 SECTION 6018
TABLE OF CONTENTS
REAR AXLE
Description ........................................................................................................................................................... 4
A. Removing and refitting the trumpet assembly ............................................................................................... 11
Removal ......................................................................................................................................................... 11
Refitting .......................................................................................................................................................... 13
B. Removing and refitting brake plate, crown wheels, spacer and epicyclic reducer gears .............................. 14
Removal ......................................................................................................................................................... 15
Refitting .......................................................................................................................................................... 16
C. Replacing the cassette seal .......................................................................................................................... 17
D. Disassembling and reassembling the planetary gears .................................................................................. 18
Disassembly .................................................................................................................................................. 18
Reassemble ................................................................................................................................................... 18
E. Replacing the axle shaft bearings ................................................................................................................. 19
Disassembly .................................................................................................................................................. 19
Reassemble ................................................................................................................................................... 20
F. Shimming the axle shaft bearings .................................................................................................................. 20
G. Service tools .................................................................................................................................................. 22
REAR AXLE - DIFFERENTIAL

Description ......................................................................................................................................................... 23
General .......................................................................................................................................................... 23
A. removing and refitting the carriers ................................................................................................................. 28
Left-hand carrier ............................................................................................................................................ 28
Right Hand Carrier ......................................................................................................................................... 29
B. Removing and refitting the differential unit assembly .................................................................................... 29
Removing the differential unit ........................................................................................................................ 29
Refitting .............................................................................................................................................................. 30
Final operations ............................................................................................................................................. 31
C. removing and refitting multi-disc lock ............................................................................................................ 32
Removal ......................................................................................................................................................... 32
Reassembly ................................................................................................................................................... 32
D. removing and refitting planetary gears, sun gears and disassembling and reassembling the crown wheel. 33
Disassembling the crown wheel .................................................................................................................... 34
Refitting the crown wheel ............................................................................................................................... 34
Refitting planetary gears and sun gears ........................................................................................................ 34
E. Adjusting and checking the multidisc ............................................................................................................. 36
Disassembly .................................................................................................................................................. 36
Pre-adjustment .............................................................................................................................................. 36
Checks ........................................................................................................................................................... 37
F. Shimming the differential unit ........................................................................................................................ 37
G. Removing and refitting the drive pinion ......................................................................................................... 40
Removing the drive pinion ............................................................................................................................. 40
Refitting the drive pinion ................................................................................................................................ 41
H. Adjusting the position and shimming and drive pinion .................................................................................. 42
Adjusting the drive pinion position ................................................................................................................. 43
I. Service tools ................................................................................................................................................... 45
REAR AXLE - BRAKE PISTONS AND SEALS

Description ......................................................................................................................................................... 47
Exploded view .................................................................................................................................................... 49
A.Dissassembly ................................................................................................................................................. 50
B. Reassembly ................................................................................................................................................... 51
Positioning of seals ........................................................................................................................................ 52
Tests .............................................................................................................................................................. 52
C. Service tools .................................................................................................................................................. 52
SM 8-12300 Issued 03-2004

SECTION 6018 3
REAR AXLE - PARK LOCK

Description ..................................................................................................................................................... 53
Exploded View ............................................................................................................................................... 55
A. Unlocking the system and positioning the special bolt. .................................................................................. 56
B. Removing and refitting the sleeve .................................................................................................................. 57
Removal ......................................................................................................................................................... 57
Refitting .......................................................................................................................................................... 57
C. Disassembling the control .............................................................................................................................. 57
Disassembly ................................................................................................................................................... 57
D. Reassembling the control .............................................................................................................................. 58
REAR AXLE - LIFT CYLINDER SUPPORTS

Description ......................................................................................................................................................... 60
Overall view, Right-hand support ................................................................................................................... 62
Exploded view ................................................................................................................................................ 63
A. Cylinder attaching points ................................................................................................................................ 64
B. Preliminary operation ..................................................................................................................................... 65
C. Removing and refitting the shaft .................................................................................................................... 65
D. Disassembling and reassembling the supports ............................................................................................. 66
Disassembly ................................................................................................................................................... 66
Reassembly ................................................................................................................................................... 66
E. Final operations ............................................................................................................................................. 67
F.Service tools .................................................................................................................................................... 67
REAR AXLE -CREEPER

Description ..................................................................................................................................................... 68
Overall View ................................................................................................................................................... 69
A. Removing and refitting the unit ...................................................................................................................... 72
Removal ......................................................................................................................................................... 72
Refitting .......................................................................................................................................................... 72
B. Disassembling, reassembling and adjusting the selection mechanism ......................................................... 74
Disassembly ................................................................................................................................................... 74
Refitting .......................................................................................................................................................... 74
Shimming ....................................................................................................................................................... 74
Adjustment ..................................................................................................................................................... 75
C. Disassembling and reassembling the epicyclic gear ..................................................................................... 78
Disassembly ................................................................................................................................................... 78
Reassembly ................................................................................................................................................... 78
REAR AXLE - REAR HITCH MECHANISM

A. Disassembling and reassembling a lift cylinder ............................................................................................. 79
Disassembly ................................................................................................................................................... 79
Reassembly ................................................................................................................................................... 79
SM 8-12300 Issued 03-2004

4 SECTION 6018
Rear Axle
Description B. Layout of the main components

(Fig. 1 and 2)
A. General 1. Intermediate housing
The rear axle is made up of five main housings: 2. Centre housing
3. PTO housing
The intermediate housing comprising: 4. Bevel gear (crown wheel and drive pinion)
5. Handbrake unit
Inside: 6. Creeper gearbox (if fitted)
7. PTO clutch drive pinion(s)
The drive pinion. 8. 540/1000 rpm pinions
The hand brake unit. (See Section 7001) 9. 4 WD clutch
The hydraulic pump pinion. (See Section 8005) 10. Park lock unit
The 4 WD clutch. (See Section 6019) 11. Hydraulic pump drive pinion
The Park Lock system. 12. Removable PTO rpm shaft.
The PTO clutch transmission shaft.
Outside:
The right hand and left-hand side covers.
The centre housing containing:
Inside:
The drive pinion crown wheel and differential.

The PTO brake. (See Section 6019)
Outside:
The two trumpet housings.
The PTO housing containing:
In the upper part:
The double clutch and double pinion driving the PTO

rpm pinions. (See Section 6019)
In the lower part:
The removable PTO rpm shaft depending on the

desired speed and the PTO rpm pinions. (See Section
6019)
The left and right trumpet housings act as the housings

for the rear wheel drive system.
SM 8-12300 Issued 03-2004

SECTION 6018 5
Centre housing assembly (longitudinal section)
Figure 1
Version with hypoid bevel gear.
NOTE: On a hypoid bevel gear, the axial line of the drive pinion is not common with the centre of the
crown wheel
SM 8-12300 Issued 03-2004

6 SECTION 6018
Rear Axle- Trumpets with double reduction
Figure 1
SM 8-12300 Issued 03-2004

SECTION 6018 7
General Operation
ZTX tractors are fitted with trumpets containing two Special Point
epicyclic gear trains, also known as double In order to maintain an operational clearance
reductions. between the planetary gears, the sun gears and
crown wheels, the secondary sun gear (51) floats on
These drive units allow for higher reduction ratio and ball bearings (19) (49).
lower transmission torque.
Kinematics (Fig. 1)
They are housed in a compartment and are
comprised of the trumpet, two primary crown wheels
(47) and two secondary crown wheels (15) and a
Primary epicyclic gear train
spacer (48). The brake plate (30) partially closes the
drive unit compartment. The primary planetary carrier (24) is integral via splines
with the secondary sun gear (51) and comprises three
planetary gears (20) that engage with crown wheel (47)
Construction and primary sun gear (44) splined onto input shaft (31).
The axle shaft is supported by two bearings
comprising cups (8) (12) and bearing cones (7) (13)
mounted in opposition to each other. The input shafts
Secondary epicyclic gear train
(31) are of different lengths; the long shaft is fitted in
the left hand side trumpet. The crown wheels, spacer The secondary planetary carrier (25) integral via
and brake plate are positioned by pins (14). The pre- splines with axle shaft (2) possesses six planetary
loading of the taper roller bearings is provided by gears (18) in constant engagement with crown wheel
shims (26) placed at the end of the axles shaft. Shaft (15) and secondary sun gear (51). It receives
(2) and planetary carrier (25) are held by washer (27) movement coming from the primary epicyclic gear train
and bolt (28). to then transmit it to the axle shaft (2).
The oil tightness between the trumpet, crown wheels

spacer and brake plate is provided by silicone seals
(Silicomet type).
The cassette seal (3) protects the outer bearing

comprising cup (8) and cone (7).
The oil splash lubrication for the mechanical

assemblies is provided by transmission oil coming
from the shared oil tank formed by the intermediate
housing and the centre housing. The centre housing
is linked to the lower part of the trumpet by an
external transfer pipe. The brake plate contains a
port (O) (FIg. 2) allowing lubrication and cooling of
the discs by a flow of oil coming from the booster
circuit. The transmission oil within the trumpet is kept
at the correct level via an oblique pipe (56). This pipe
is located in the drive unit compartment and
communicates with the external transfer pipe.
The inner chamber of the trumpet is maintained at

atmospheric pressure by a breather pipe screwed
onto the left lift ram support. This breather pipe also
ensures the venting of the shared oil tank.
The input shaft (31) drive discs (35) via a splined hub
(32) held by snap ring (33).
SM 8-12300 Issued 03-2004

8 SECTION 6018
Par ts List
1. Bush
2. Straight shaft
3. Cassette seal
4. Thrust washer
5. Locating pin
6. Circlip
7. Bearing cone
8. Bearing cup
9. Washer
10. Trumpet
11. Nut
12. Bearing cup
13. Bearing cone
14. Pins
15. Secondary crown wheel
16. Tab washer
17. Stop ring
18. Secondary planetary gears
19. Ball bearing
20. Primary planetary gears
21. Circlip
22. Roller bearing
23. Roller bearing
24. Primary planetary carrier
25. Secondary planetary carrier
26. Shim(s)
27. Lock washer
28. Bolt
29. Circlip
30. Brake plate
31. Input shaft
32. Splined hub
33. Snap ring
34. Studs
35. Brake discs
36. Stud
37. Studs
38. Itermediary plate
39. Drilled stop pin
40. Bolt
41. Stop pin
42. Circlip
43. Magnetic drain plug
44. Primary sun gear
45. Circlip
46. Washer
47. Primary crown wheel
48. Spacer
49. Ball bearing
50. Washer
51. Secondary sun gear
52. O-ring
53. O-rings
54. Transfer tube
55. Cup plug
56. Oblique pipe
57. Locating pin
SM 8-12300 Issued 03-2004

SECTION 6018 9
Rear Axle - Trumpets with double reduction)
Figure 2
SM 8-12300 Issued 03-2004

10 SECTION 6018
Rear Axle - Trumpets with double reduction)
Figure 3
SM 8-12300 Issued 03-2004

SECTION 6018 11
A. Removing and refitting the trumpet assembly
Removal STEP 4
If necessary, slightly raise the side of the cab and
STEP 1 check that there is no interference with nearby
elements. Chock the cab using a suitably adapted
axle stand.
STEP 5
Figure 4
Drain the centre housing and the oil trapped in the
trumpet that is being removed.
NOTE: The drain plug (43) of the trumpet is Figure 6

located behind the transfer tube (54) (Fig. 4).
Remove bolts (1) and the stabiliser support (2)
STEP 2 (Fig.6).
Immobilise the tractor. Take off the wheel. Place an STEP 6

axle stand beneath the centre housing.
STEP 3
Figure 7
Take off circlip (1) and remove the lower pin (2) of the
lift ram. (Fig. 7). Using a strap, pull the ram away from
Figure 5 the trumpet.
Remove the bolt (1) holding the cab and if necessary

also take out bolt (2) from the rear support above the
trumpet (Fig. 5).
SM 8-12300 Issued 03-2004

12 SECTION 6018
STEP 7 STEP 9
Position a suitable support beneath the trumpet. Unstick and separate the trumpet assembly
complete with the input shaft (31), brake plate (30),
STEP 8 crown wheel (15) (47) and spacer (48) from the
Remove nuts (11) and washers (9) without taking out centre housing. Recover the brake discs (35) the
bolts (40). intermediate plate (38) and the stop pins (39) (41)
(Fig. 7).
NOTE: These bolts serve to hold the crown
wheel, spacer and brake plate assembly on the STEP 10
trumpet. Remove the transfer tube (54) and discard the O-
rings (53).
Figure 8
NOTE: Brake piston (P) remains in the housing (1) (Fig.8).
WARNING: Take care not to press the brake

! pedal concerned, or fit a piston retainer tool
on the centre housing.
SM 8-12300 Issued 03-2004

SECTION 6018 13
Refitting STEP 15
Check that port (O) on the brake plate (30) is not
ATTENTION: The studs ( 34 ) ( 36 ) ( 37 ), screwed into the obstructed (Fig. 2).
centre housing are of different lengths. Before fitting, their
threads must be lightly smeared with Loctite 270 or STEP 16
equivalent (Fig.9).
Check for the presence of the radial drilled holes on
the intermediate plate (38).
Figure 9 Figure 10
NOTE: Place the studs in the housing respecting their

length and location, according to Fig. 3:
(34): Dia 16mm - Length 363 mm
STEP 11
Clean the site of the silicone seal on brake plate (30)
and the centre housing.
Check that all previous traces of sealing compound

have been removed and the components are dry.
STEP 12
Coat angle (D) of the centre housing (1) Figs 10-11)
with a sealing compound (Silicomet type).
The diameter of the bead (seal) must be uniform, Figure 11

small section and without joins.
STEP 13
Check that discs (35) slide normally on the hub (32).
Check that the stop pins (39) (41) are free in:
-the drilled holes of piston (P) and the

intermediate plate (38) (Fig. 7).
-The recesses of the brake plate (30) and the
centre housing (1) (Fig. 7).
STEP 14
Check for the presence of locating pin (5) on the
centre housing.
SM 8-12300 Issued 03-2004
14 SECTION 6018
STEP 17 B. Removing and refitting brake

On the trumpet, fit plate (38) by placing either side of plate, crown wheels, spacer and
it a brake disc (35) on the hub (32) and position the epicyclic reducer gears
stop pins (39) (41) (Fig. 7).
NOTE: The drilled pin is fitted in the upper

recess of the brake plate.
STEP 18
Fit new O-rings (53) smeared with miscible grease
into the transfer pipe (54). Introduce the pipe into the
trumpet port.
STEP 19
With the help of a second operator and the support
equipment used for removal, engage the trumpet on
the studs. Turn the axle shaft and push the trumpet
until it mates with the centre housing. Check that the
end of the transfer tube (54) as well as the stop pins
(39) (41) are correctly positioned in their respective
grooves in the housing.
STEP 20
Place washers (9). Fit and tighten nuts (11) to a
torque of 247-253 Nm. Remove the support from
beneath the trumpet. Refit the lift ram. Replace the
stabiliser support and tighten bolts to 480-640 Nm.
STEP 21
Refit various elements that surround the trumpet.
Refit the wheel and tighten the nuts or studs to the
correct torque depending on the version. (See
Section 6003)
Tightening Torque
Cab fixing bolt (silent bloc): 200-260 Nm, Loctite 270 or

equivalent.
STEP 22
Top up the oil level in the housings and check on the
transparent tube located on the left-hand side of the
centre housing.
STEP 23
Check the operation of the lift system. Carry out a
road test of the brake circuit.
STEP 24
Check the tightness of the trumpet and the O-rings
(53) located on the transfer tube (54).
Figure 12
SM 8-12300 Issued 03-2004

SECTION 6018 15
Removal STEP 32
Take out the secondary planetary carrier (25).
STEP 25 Remove the planetary gears (18) (see Page 18).
Remove the trumpet assembly (see Page 11).
STEP 33
If possible, place the trumpet in a vertical position, If necessary, extract bearing (19) from the input shaft
the input shaft (31) at the top (Fig. 13). (31).
Unstick and remove the secondary crown wheel (15)

(see special points below).
Special Points
The reason for the secondary crown wheel (15) are
the large forces exerted, and it’s heat treatment is
different compared to that if the primary crown wheel
(47).
To identify the crown wheels the perimeter of the

secondary crown wheel has two machined flats "M"
(Fig. 14).This crown wheel also possesses an
additional locating pin (57) (Fig. 2).
Figure 13
STEP 26
Remove the bolts (40). Unstick and remove the brake
plate (30). IF necessary, take off snap ring (33) and
hub (32).
STEP 27
Disengage circlip (42) from it’s groove and remove
the primary sun gear (44).
STEP 28
Disengage circlip (21) and take off washer (46) and
remove the input shaft (31) fitted with ball bearing
race (19).
STEP 29
Take off circlip (45). Take out the primary planetary
carrier (24). remove the planetary gears (20) (see
Page 18).
STEP 30
Unstick and remove the primary crown wheel (47).
Immobilise the planetary carrier (25). Take off bolts
(28). Remove holding washer (27) and shims (26).
STEP 31
Disengage the secondary sun gear (51). remove the
thrust washer (4) Figure 14
SM 8-12300 Issued 03-2004

16 SECTION 6018
Refitting STEP 39
Coat the inner angle (B) of the trumpet (10)(with a
STEP 34 silicone sealing compound (silicoment type) (Fig.
Clean the components. replace any parts found to be 16).
defective. Remove all traces of previous sealing
compound in the internal angles of the trumpet, on
the crown wheels (15) (47), the spacer (48) and the
brake plate (30).
Special Points
If the replacement of the oblique pipe (56) is
necessary, lightly smear the end concerned with
Loctite 648 or it’s equivalent and introduce it into the
trumpet, the oblique profile turned towards bearing
(12) (13) Fig. 15).
The bearing cup plug (55) fitted at the end of the

channel (see exploded view) must likewise be
smeared with Loctite 542 or equivalent before
insertion.
Figure 16
NOTE: The diameter of the bead (seal) must be

uniform, small section and without joins.
NOTE: This fitting information also holds true for

all later sealing operations.
STEP 40
Position the secondary crown wheel (15), with the
flats (M) (Fig 14) along the horizontal axis of the
tractor.
STEP 41
If necessary, reassemble the secondary planetary
Figure 15 gears (18) with bearings (23) and stop rings (17).
STEP 35 STEP 42
Check for the presence of the tab washer (16). Refit the secondary planetary gears correctly
positioned on the planetary carrier (25). Fit circlips
STEP 36 (29) (see Page 18).
Refit the secondary planetary carrier (25).
STEP 43
STEP 37 Place the shim(s) (26) removed during disassembly
and refit the holding washer (27). Immobilise the
Refit the thrust washer (4) as in the overall view. Refit
planetary carrier. Smear bolts (28) with Loctite 242
the secondary sun gear (51) comprising ball bearing
and tighten them to a torque of 100 - 130 Nm.
(49), washer (50) and circlip (6).
STEP 44
STEP 38
Coat the internal angles (A) and (C) of spacer (48)
Place pin (14) and the locating pin (57) in their
with silicone sealing compound (Silicomet type) (Fig.
respective grooves located on the trumpet.
16).
SM 8-12300 Issued 03-2004

SECTION 6018 17
STEP 45 STEP 57
Position the spacer on the secondary crown wheel Refit the trumpet assembly (see Page 11).
(15).
C. Replacing the cassette seal
STEP 46
Place the second pin (14) in its groove in the spacer. Preliminary operations
IF necessary, refit the primary planetary gears (20)
correctly positioned with bearings (22) on the
STEP 58
corresponding planetary carrier. Fit the circlips (29)
(see Page 18). Partially drain the trumpet concerned.
STEP 47 STEP 59
Position the primary crown wheel (47) on the spacer Chock the front wheels. Remove the rear wheel.
(48). Place and axle stand beneath the trumpet (See
Section 6003).
STEP 48
Slide the primary planetary carrier (47) on the
Removal
secondary sun gear. Turn the planetary gears to Special points
facilitate their engagement. Some models are fitted with axle shafts with a
diameter of 110mm. The shape of this shaft is
different from that of the same diameter fitted to
STEP 49
other models (depending on option) and models
Fit circlip (45). fitted with composite drive unit.
STEP 50 Bush (1) Fig. 17 has a larger bore and is referenced

If disassembled, insert the ball bearing race (19) on in the spare parts catalogue.
the input shaft (31).
The cassette seal (3) (Fig. 17) retains the same
characteristics as that fitted to trumpets with
STEP 51
composite drive unit.
Engage shaft (31) fitted with its bearing in the
secondary sun gear (51). Place washer (46) and
circlip (21).
STEP 52
Slide the primary sun gear (44) correctly orientated
(Fig. 2) onto shaft (31). Fit circlip (42).
STEP 53
Coat the internal angle (E) of the brake plate (30)
with a silicone sealing compound (silicomet type)
(Fig. 16.).
STEP 54
Position the brake plate on the primary crown wheel
(47).
STEP 55
Fit bolts (40) and tighten them to a torque of 90 - 120 Figure 17
Nm.
STEP 56 The bore of the bush is smeared with Loctite 648 or

Slide hub (32) onto shaft (31). using suitable pliers fit equivalent. The bush is placed on the shaft flush with
the snap ring (33). the thrust face of the bearing cone (7) (Fig. 18).
SM 8-12300 Issued 03-2004

18 SECTION 6018
D. Disassembling and reassembling

the planetary gears
Disassembly
STEP 67
Remove the trumpet assembly (see Page 11) and
the epicyclic reducer gears (see Page 14).
Primary planetary carrier (24) (Fig. 20).
STEP 68
Note visually the shape of the planetary gears (20)
Figure 18 and roller bearings (22) (Fig. 9). Take off the circlips
(29). Remove the three planetary gears.
STEP 60
Secondary planetary carrier (25) (Fig. 20)
Using a locally manufactured tool, extract the
cassette seal (3) without leaving any marks on the
trumpet or external diameter of the bush (1) (Fig. 17).
STEP 69
Note visually the shape of the planetary gears (28)
Refitting and roller bearings (23) (Fig. 9). Take off the circlips
(29). Remove the six planetary gears.
STEP 61
Reassemble
Clean the groove of the seal on the trumpet and bush
(1).
STEP 70
STEP 62 Check the components. Replace any parts found to
be defective.
Lightly smear the external diameter of the seal with
Loctite 648 or equivalent and moderately lubricate its
internal diameter with transmission oil.
STEP 71
Fit the planetary gears with their roller bearings and
STEP 63 respective snap rings. Refit the planetary gears on
the corresponding carrier by turning the clearance
Using service tool ref. 3378151M1 (See Page 22),
(D) on the bearings (Fig. 19) towards the throat (C)
insert the seal. Wipe away any remaining traces of
of the reducer gears (Fig. 20).
Loctite.
NOTE: The design of the service tool determines

STEP 72
the position of the cassette seal in its groove in Fit the circlips (29) (Fig. 20)
the trumpet.
STEP 64
Refit the wheel and tighten the wheel nuts or studs to
the correct torque depending on the version.
STEP 65
Top up the oil level in the housing and check it on the
transparent tube locate on the left-hand side of the
centre housing.
STEP 66
Road test. Check the oil tightness of the cassette seal.
SM 8-12300 Issued 03-2004

SECTION 6018 19
Figure 19
Figure 20
STEP 73 Disassembly
Manually check the rotation of each planetary gear.
STEP 77
STEP 74 Take off washer (16) and shaft assembly (2).
Refit the epicyclic reducer gears (see Page 14) and
the trumpet assembly (see Page 11). NOTE: The bearing cone (13) is free on the
shaft.
E. Replacing the axle shaft bearings STEP 78
Preliminary operations Remove cone (13). extract bearing cone (7).
STEP 75 STEP 79
Remove the trumpet assembly (see Page 11). Drive out the cassette seal (3).
STEP 76 STEP 80
Remove the brake plate, crown wheels, spacer and Using an extractor or a locally manufactured tool,
epicyclic reducer gear (see Page 14). remove the bearing cups (8) (12).
SM 8-12300 Issued 03-2004
20 SECTION 6018
Reassemble STEP 94
Top up the level of the housings and check the oil
STEP 81 level on the transparent tube located on the left hand
Clean and check the components. Replace any parts side of the centre housing.
found to be defective.
F. Shimming the axle shaft bearings
STEP 82 Components concerned by shimming
Lubricate the bores of the cups (8) (12) with
transmission oil. Axle shaft (2), taper roller bearings (7)(8) and (12)
(13), trumpet, tab washer (16), secondary planetary
STEP 83 carrier (25), washer (4), ball bearing race (49).
Insert the cups into their respective bores thrusting
NOTE: The pre-loaded shimming of the taper
against the shoulder.
roller bearings of the axle shaft is carried out
using shim(s) (26) placed between the end of the
STEP 84 shaft (2) and washer (27) (Fig. 21).
Lubricate the bore of the bearing cone (7) and insert
it so as to mate with the shoulder on shaft (2).
STEP 85
Lubricate the bearing cup (8)
STEP 86
Introduce the prepared shaft into the trumpet fitted
with its cups.
STEP 87
Lubricate and fit the bearing cone (Fit the circlips
(29) (Fig. 20)) an the tab washer (16).
Final operations
STEP 88
Refit the secondary planetary carrier (25), thrust
washer (4), secondary sun gear (51) comprising
bearing (49), washer (50) and the circlip (6).
STEP 89
Carry out shimming of the bearings (see Page 20).
STEP 90
Complete the refitting of the epicyclic reducer gear,
spacer, crown wheels and brake pate (see Page 14).
STEP 91
Refit the trumpet assembly (see Page 11).
STEP 92 Figure 21
Insert a new cassette seal (see Page 17).
NOTE: To carry out the correct shimming of the
bearings, place the trumpet in a vertical position
STEP 93
(Fig. 22).
Refit the wheel and tighten the wheel nuts or studs to
the correct torque depending on the version (See
Section 6003).
SM 8-12300 Issued 03-2004
SECTION 6018 21
STEP 95
Check for the presence of bearing cone (13), the tab
washer (16), the planetary carrier (25) and the
secondary sun gear (51) (Fig. 23).
Figure 22
Figure 23
STEP 96 STEP 97
Press hard on the secondary sun gear while Using an appropriate depth gauge (Fig. 24),
simultaneously turning the trumpet several times in measure distance (E) between side (A) of the ball
order to seat the bearing cones and cups. bearing race (49) and side (B) at the end of shaft (2).
SM 8-12300 Issued 03-2004

22 SECTION 6018
G. Service tools
-3378151M1- Fitting tools for rear shafts cassette
(Dia 110 mm) (Fig. 25).
Figure 24
STEP 98 Figure 25
Determine the thickness of shim(s) (26) to be fitted
to obtain a pre-loading of P1 = 0.02 to 0.12 mm
(Fig. 2), according to:
E - (0.02 to 0.12)
STEP 99
Place the previously selected shims on the end of the
shaft. Fit washer (27) on ball bearing race (49).
Smear bolts (28) with Loctite 242 or equivalent and
tighten them to a torque of 100-130 Nm.
SM 8-12300 Issued 03-2004

SECTION 6018 23
Rear Axle - Differential
Description
General (28) and the differential half-housing (21).

The ZTX tractors are equipped with a centre housing
They are fitted with an AG250 Full Powershift Differential lock
gearbox and have a wide intermediate housing which The multi-disc lock system comprises:
the axial position of the drive pinion has been
redesigned for the fitting of a hypoide bevel gear. A unit (21) housing the disc (56) and the
intermediate plates (55).
Construction A hub (33) integral via splines with the left-hand
The bevel gear, moved in rotation by the gearbox trumpet input sun gear.
output shaft, drives the rear axle. A cover (50) made up by piston assembly (52)
and supported by taper roller bearings (46) (47).
The helical drive pinion is supported by two taper
roller bearings mounted in opposition. The piston chamber lodged in the cover
communicates with a channel in the left-hand carrier
The bearing cone (7) is force fitted on the drive (40), allowing (17 bar) low pressure to act upon the
pinion, and cups (2) (10) are likewise force fitted into piston. two seal rings (49) ensure oil tightness of the
the intermediate housing (19) and bearing support circuit.
(13). The bearing cone (1), mounted free on the drive
pinion, allows to fit the shims (3) required for Operation
shimming.
Clutched position
The crown wheel is fastened to the differential When the differential lock solenoid valve is activated,
housing by bolts. the differential assembly rotates on the pressure flows through the channels in left-hand
two taper roller bearings supported by two lateral carrier (40) and cover (50) on unit (21) and enters
carriers centered by bushes (23) and fixed by bolts to piston chamber (52). the piston compresses the
the housing. intermediate plates (55) and discs (56) integral
respectively via stops and splines in lock unit (21)
The differential assembly is formed by two halves and hub (33).
holding four planetary gears (31) and two sun gears
(32) (33). The left-hand side sun gear also serves as In this clutched position, the input sun gears of the
the hub for the differential lock discs (56). The right-hand and left-hand trumpets turn at the same
planetary gears turn on four half shafts (35) housed speeds.
in the unit and the differential yoke (34). They are
held in place by pins and bolts.
Declutched position
The lubrication of the planetary gears is carried out When the pressure is cut, the piston returns, the
by axial and radial channels drilled in the half shafts. discs and intermediate plates are no longer
The sun gears, left-hand carrier (40), cover (50) and compressed and allow the sun gears and planetary
the differential yoke contain drilled lubrication gears to carry out their differential function.
channels allowing transmission oil to reach bushes
(36) (37), discs (56) and the differential lock system.
The drive pinion, which bears the 4WD pinion (17), is
located on the intermediate housing. The adjustment
of it’s position is carried out by shims (12) fitted
between bearing carrier (13) and the housing. The
pre-loading of the bearings is obtained by shim(s) (3)
fitted between the bearing cone (1) and the thrust
washer (4). the pre-loading via shimming of the
differential assembly is carried out via shims (48)
placed between bearing cone (46) and the left-hand
carrier (40).
Backlash of the drive pinion and the crown wheel is

obtained by using shims (29) inserted between cup
SM 8-12300 Issued 03-2004
24 SECTION 6018
Figure 1
SM 8-12300 Issued 03-2004

SECTION 6018 25
Overall view
Figure 2
SM 8-12300 Issued 03-2004

26 SECTION 6018
Exploded View
Figure 3
SM 8-12300 Issued 03-2004

SECTION 6018 27
Figs 1, 2 and 3 Par ts list 30. Spherical washer

1. Bearing cone 31. Planetary gear
2. Bearing cup 32. Right sun gear
3. Shim(s) 33. Left sun gear
4. Thrust washer 34. Differential yoke
5. Circlip 35. Planetary gear half shafts
6. ntermediate plates (handbrake) 36. Shouldered bush
7. Bearing cone 37. Shouldered bush
8. Bolt 38. Needle bearings
9. Drive pinion 39. Bolt
10. Bearing cup 40. Left-hand carrier
11. Bolt 41. Transfer tube
12. Shim(s) 42. O-ring
13. Bearing carrier 43. O-ring
14. Discs 44. Union
15. Handbrake unit 45. Centre housing
16. Mechanism 46. Bearing cone
17. 4 WD drive pinion 47. Bearing cup
18. Nut 48. Shim(s)
19. ntermediate housing 49. Seal rings
20. Crown wheel 50. Cover
21. Unit 51. Bolt
22. Bolts 52. Piston
23. Centring bushes 53. O-ring
24. Bolts 54. O-ring
25. Right-hand carrier 55. Intermediate plates (differential lock)
26. O-rings 56. Discs
27. Bearing cone 57. Lubricating pipe
28. Bearing cup 58. Rivet
29. Shim(s) 59. Rivet
SM 8-12300 Issued 03-2004

28 SECTION 6018
A. removing and refitting the STEP 4

carriers Remove the brake piston.
Left-hand carrier STEP 5

Remove bolts (24) on from the left-hand carrier.
NOTE: It is possible to carry out maintenance on Place two diametrically opposed guide studs "G" on
carrier (40) and seal rings (49) of the differential the housing as shown in Figure 6, their ends pushing
lock by removing only the left-hand trumpet against cover (50) of the lock unit.
housing.
STEP 1
Remove the left-hand trumpet housing
(See Page 11).
STEP 2
Take off union (44). (Fig. 4).
Figure 6
STEP 6
Extract the carrier by inserting two bolts "V" through
the tapped holes (Fig. 6); take it off and recover cone
(46) and shim(s) (48).
NOTE: The guide studs "G" hold and centre the

Figure 4 differential assembly in the housing (Fig. 7). Do
not unscrew the guide studs. This may throw off
STEP 3 centre the assembly and damage the seal rings
Raise the transfer tube (41) (Fig. 5) (49) during refitting of the carrier.
.
Figure 5 Figure 7
SM 8-12300 Issued 03-2004

SECTION 6018 29
STEP 7 STEP 19
Check for the presence of centring bush (23) on the Tighten uniformly and alternately the four bolts (24)
housing, the shim(s) (48) and bearing cone (46). to a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque.
STEP 8
Check that the seal rings (49) are not damaged and STEP 20
that they turn normally in their grooves. After this Check the oil tightness of seal (26) on carrier (25).
check, remove the seal rings and coat them with
miscible grease, so that they remain at the bottom of B. Removing and refitting the
the groove during refitting of the carrier.
differential unit assembly
STEP 9
Fit new O-rings (26) (42).
Preparation for fitting
STEP 10 STEP 21
Slide the carrier onto the guide studs "G" (Fig. 6) and Uncouple the tractor between the intermediate
alternately and uniformly tighten the four bolts (24) to housing and the centre housing (See Section 6003).
a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque. STEP 22
If necessary, separate the PTO housing from the
STEP 11 centre housing (See Section 6003).
Position the transfer tube (41) in carrier (40).
STEP 23
STEP 12 Remove the trumpet housings.
Screw in and position union (44).
STEP 24
STEP 13 Take off union (44) and raise the transfer tube (42)
Refit the brake piston (See Section 7001). (Fig. 5). Unscrew the ground speed sensor to avoid
interference with the crown wheel.
STEP 14
STEP 25
Check the oil tightness of seal (26) on carrier (40).
Remove the brake pistons.
STEP 15
STEP 26
Refit the left-hand trumpet housing.
Place and tighten sling ref. 3378116M1, (see
Page 45) in position 2 (this position corresponds to a
Right Hand Carrier differential assembly with a multidisc differential lock
on the rear axle with an AG250 Full Powershift
NOTE: The access to the right-hand carrier (25) gearbox). Using the sling, hold the differential
is similar to that of the left-hand carrier (40). assembly in the axis of the left and right-hand
carriers (25) (40).
STEP 16
Take out bolts (24) and place diametrically opposed Removing the differential unit
guide studs "G" in the housing, their ends thrust
against the half-housing (21). STEP 27
Remove bolts (24) from the carriers and fit the guide
STEP 17
bolts "G" in accordance with Figure 6.
Extract the carrier by inserting two bolts "V" through
the tapped holes and remove it. STEP 28
Extract and remove the carriers by inserting two bolts
STEP 18
"V" through the tapped holes as shown in Figure 6.
Check for the presence of the centring pin (23) on the Recover the cone (46) and shims (48) from carrier
housing and O-ring (26). (40).
SM 8-12300 Issued 03-2004

30 SECTION 6018
STEP 29
Remove the O-rings (26).
STEP 30
Take out the differential assembly from the centre
housing (Fig. 8).
Figure 9
Assembling the left-hand carrier (40)
STEP 33
Slide bearing cone (46) on to tool, ref. 3378117M1
(see § Page 45), adapted for the differential with
hypoid bevel gear and multidisc lock. Using the tool,
Figure 8 centre the differential assembly in the housing by
manually turning the central bolt clockwise until it
Refitting encounters resistance.
NOTE: Since space is limited around the STEP 34

differential unit, it is essential to fit the auxiliary Screw two diametrically opposed guide studs into
spool valve and lift control valve return pipe in two holes in the centre housing, their ends thrusting
the housing (45) before refitting the unit. against cover (50) of the differential lock. This
In order not to damage the seal rings (49), it is method allows the centring of the differential
necessary to correctly align the differential assembly assembly to be retained after removal of tool ref.
along the axis of the centre housing before inserting 3378117M1, in order to later provide a correct fitting
carriers (25) (40). of the left-hand carrier (40) without damaging the
seal rings (49). Remove the tool and recover the
STEP 31 bearing cone (46).
Using the sling, introduce the differential assembly
into the centre housing and hold it in the axis of the STEP 35
trumpet housings. Check for the presence of centring bush (23) in the
housing and fit a new O-ring (26) on to carrier (40)
Assembling the right-hand carrier (25) (Fig. 10).
STEP 32
centre housing. Check for the presence of centring
bush (23). Lubricate and fit a new O-ring (26) (Fig. 9).
Insert the carrier (25) using the four bolts (24)
uniformly and alternately tightened to a torque of 100
– 130 Nm. Tighten the other bolts to the same torque.
SM 8-12300 Issued 03-2004

SECTION 6018 31
Figure 11
Figure 10
Tighten the bolts (3) previously lightly smeared with
STEP 36 Loctite 542 to a torque of 25 - 35 Nm.
Check that the seal rings (49) have not been
damaged and that they turn normally in their NOTE: The end of the sensor must always be
grooves. After this check, remove the seal rings (Fig. placed above the teeth of the crown wheel of the
10) and coat them with miscible grease so that they differential. Fit and adjust the ground speed
remain at the bottom of the groove during refitting of sensor lightly smeared with Loctite 577 (See
the carrier. Section 9001).
STEP 37 STEP 41
Place shim(s) (48) and slide the bearing cone (46) on Refit transfer tube (41) and union (44).
carrier (40).
Final operations
STEP 38
Insert the carrier into the housing using the four STEP 42
bolts (24) uniformly and alternately tightened to a Refit the trumpet housings.
torque of 100 - 130 Nm. Tighten the other bolts to the
same torque. STEP 43
If the PTO housing has been removed, assemble it
STEP 39 with the centre housing.
After fitting the carriers, manually check the rotation
of the differential assembly. STEP 44
Couple the tractor between the intermediate housing
STEP 40 and the centre housing.
Refit the brake pistons.
STEP 45
Special points
Check the correct operation of all controls
If the carrier (1) of the ground speed sensor (2) has
(mechanical, hydraulic and electronic).
been removed, position the carrier previously lightly
smeared with Loctite 510, with the offset of the
sensor turned towards the longitudinal axis of the STEP 46
centre housing as shown in Fig. 11. Carry out a road test. Check the oil tightness of the
mating faces and hydraulic unions.
SM 8-12300 Issued 03-2004

32 SECTION 6018
C. Removing and refitting multi-disc STEP 51

lock Gently tap the cover (50) on a wooden block to
remove the piston (52). Remove O-rings (53) (54).If
Preliminary operations necessary, drive out cup (47).
On the left-hand carrier (40)

STEP 47
Remove the differential unit (see steps 21 to 30). STEP 52
Remove the seal rings (49) and O-ring (42).
Removal
Reassembly
NOTE: If unit (21), cover (50) and carrier (40)
have been replaced, it is mandatory to carry out
shimming of the differential unit (see Page 37)
and to check the backlash between the drive
pinion and the crown wheel (see Page 36).
STEP 53
Clean and check the components. Replace any parts
STEP 54
Check that the hydraulic channel in cover (50) is not
obstructed.
STEP 55
Lubricate and fit new O-rings (53) (54) on piston (52).
STEP 56
Insert the piston by tapping around its rim with a
plastic hammer.
STEP 57
Check that there are no seal fragments after
insertion.
STEP 58
Figure 12 Assemble the intermediate plates (55) and discs (56)
as shown in the overall view.
STEP 48
Place the differential unit with the lock turned STEP 59
upwards. Position cover (50) fitted with piston (52). Fit bolts
(51) lightly smeared with Loctite 270 and tighten to a
STEP 49 torque of 100 - 130 Nm.
Loosen and take out bolts (51).Take off the cover
(50). STEP 60
Manually check that the discs and intermediate
STEP 50 plates are not constrained in any way.
Separate the discs (56) and intermediate plates (55)
from the left-hand sun gear (33). STEP 61
Refit the differential unit assembly
(see steps 31 to 38).
SM 8-12300 Issued 03-2004

SECTION 6018 33
STEP 62 Preliminary operations

Adjust the forward speed sensor (see special points
and remarks, B). Refit the transfer tube (41) and STEP 64
union (44). Remove the differential unit assembly
(see steps 21 to 30).
Final operation
STEP 65
STEP 63 Remove the locking system (see Page 32).
Complete the refitting of the various assemblies,
carry out operations 42 to 46. Removal
D. Removing and refitting planetary STEP 66
gears, sun gears and disassembling Remove the left-hand sun gear (33).
and reassembling the crown wheel.
STEP 67
To remove the half shafts (35), it is necessary to
disassemble the crown wheel (see over).
STEP 68
Remove bolts (39).
STEP 69
Take out pins (38) from unit (21).
STEP 70
Push on a half shaft in the direction of the arrow to
drive out the opposite half shaft. Repeat the
operation for the remaining half shafts. Recover the
spherical washers (30). Remove the planetary gears
(31).
STEP 71
Remove the differential yoke and the right-hand sun
gear (32).
STEP 72
If necessary, drive cup (28) off the unit (21) and
recover the shim(s) (29).
Figure 13
SM 8-12300 Issued 03-2004

34 SECTION 6018
Disassembling the crown wheel Refitting planetary gears and sun

The replacement of the crown wheel automatically gears
requires replacement of the drive pinion.
NOTE: If necessary, place shim(s) (29) and
Both parts bear the same number and they must insert cup (28) in unit (21).
always be fitted as pairs.
Special points
STEP 73
If replacement of the friction bushes (36) (37) is
Remove bolts (22) (Fig. 14).
necessary, insert the new bushes lightly smeared
with Loctite 638 using a suitable fixture.
Check after insertion that the lubricating ports have

not been blocked by Loctite.
STEP 78
Refit the right-hand sun gear (32) in the friction bush
(36). Refit the differential yoke (34) as shown in the
overall view.
STEP 79
Check that the central channels and radial drilled
passages in the half shafts (35) are not obstructed.
STEP 80
Assemble planetary gears (31), friction washers (30)
Figure 14 and the half shafts, with the holes turned towards bolt
(39) as shown in the overall view.
Refitting the crown wheel
STEP 81
IMPORTANT: D u r i n g r e p a i r s , u s e t h e b o l t s Position the shafts. Fit and tighten bolts (39) lightly
referenced in the spare parts catalogue. smeared with Loctite 270 and tighten them to a
torque of 25 - 35 Nm.
STEP 74
Clean the mating faces of the new crown wheel (20) STEP 82
and unit (21) as well as bolts (22). Manually check the rotation of the planetary gears
and the right-hand sun gear (32).
STEP 75
Screw two diametrically opposed guide studs into the STEP 83
tapped holes of the crown wheel. Assemble the Refit the crown wheel (see Page 33).
crown wheel on the unit.
STEP 84
STEP 76 Refit the intermediate plates, discs and cover (see
Smear the first few threads of the bolts with Loctite Page 33).
270 and screw them into the crown wheel. Remove
the guide studs. STEP 85
Refit the differential unit assembly (see operations
STEP 77 31 to 38) and the brake pistons).
Tighten the bolts to a torque of 240 - 320 Nm.
STEP 86
Fit and adjust the forward speed sensor (see special
points and remarks, B). Refit the transfer tube (41)
and union (44).
SM 8-12300 Issued 03-2004

SECTION 6018 35
Final operation
STEP 87
Finish the refitting of the different assemblies. Carry
out operations 42 to 46.
SM 8-12300 Issued 03-2004

36 SECTION 6018
E. Adjusting and checking the Pre-adjustment

multidisc The thickness of the shim(s) "E" required to obtain
the correct backlash is calculated as follows:
NOTE: The backlash between the crown wheel
and drive pinion ensures reliability of the bevel E = Dc + 0.10 mm
gear and the correct operation of the where:
assembly.This backlash must be checked after:
E Thickness of shim(s) (29) to be fitted
- adjusting the bevel gear distance
- shimming the differential unit. Dc crown wheel offset
NOTE: The Dc (example shown: -0.10) engraved

Disassembly on the external diameter of the crown wheel (Fig.
15) after the pairing number and letter (31 A)
may range between 0 and -0.60 mm.
STEP 88
Using an appropriate extractor, remove cup (28).
ATTENTION: When calculating (E) do not t a ke the
n e g a t i ve s i g n p r e c e d i n g t h e D c i n t o c o n s i d e r a t i o n ( F i g .
15).
Figure 15
SM 8-12300 Issued 03-2004

SECTION 6018 37
STEP 89 F. Shimming the differential unit

Place the previously selected shim(s) in the bore of
the unit (21). Insert bearing cup (28) and check that NOTE: If the centre housing (45), crown wheel
it is in contact with the shims. (see Page 33), taper roller bearings and carriers
(25) (40) have been replaced, carry out
STEP 90 shimming of the differential unit.
Refit and shim the differential unit . NOTE: Check beforehand that the shim(s) (29)
used for providing the multidisc (see Page 36) are
Checks fitted between unit (21) and cup (28).
Couple and temporarily fix the intermediate housing
to the centre housing using several diametrically
opposed bolts tightened to a torque of 540 – 680 Nm.
Shimming preparation
With the PTO housing taken off, through the rear
opening of the centre housing (45), place the index STEP 92
of a dial gauge half way across the length of a tooth Place the differential assembly in the housing using
of the crown wheel (Fig. 16). sling ref. 3378116M1 (see Page 45). Screw two
diametrically opposed guide studs into the centre
housing. Insert carrier (25) fitted with a new O-ring
(26) using four bolts (24). Remove the guide studs.
Complete the refitting of the other bolts and tighten
to a torque of 100 - 130 Nm.
STEP 93
Remove bearing cone (46) and shim(s) (48) from
carrier (40).
STEP 94
Slide bearing cone (46) on tool, ref. 3378117M1 (see
Page 45), adapted for the hypoid differential unit with
multidisc lock. Using two bolts, fix the tool onto the
housing (Fig. 17).
Figure 16
Check that the multidisc is between 0.15 mm and
0.45 mm. Carry out this check at three points around
the crown wheel.
If the backlash is incorrect, the adjustment principle

is to reduce or increase the thickness of shim(s) (29).
In this case, select and fit a different thickness of

shim(s). Carry out the shimming of the differential
unit again in order to obtain the pre-loading of
bearings (27) (28) and (46) (47).
Check a second time the backlash between the drive

pinion and the crown wheel.
Figure 17
STEP 91
When the final adjustment has been obtained, go on
with the refitting operations.
SM 8-12300 Issued 03-2004

38 SECTION 6018
STEP 95
Tighten the centre bolt to 10 Nm (Fig. 17).
NOTE: Turn the crown wheel several times to

seat the cones correctly in the cups. Check the
tightening torque of the centre bolt again.
Dimensions to be measured on the

housing (45) (Fig. 18-19)
STEP 96
Using an appropriate depth gauge, measure
dimension "B" at two opposed points (work out
average of the two measurements) and determine
dimension "C" between bearing cup (46) and the
thrust face of the carrier (40) on the housing (Fig.
18):
C = B - 10 mm
10 mm is the thickness of tool, ref. 3378117M1).
Figure 18
Figure 19
SM 8-12300 Issued 03-2004

SECTION 6018 39
Dimension to be measured on carrier (40) (Fig. 20)
Figure 20
STEP 97
Measure dimension "Y" using an appropriate depth
gauge and rule.
STEP 98
Calculate distance "E" between the thrust faces of
bearing cup (46) and carrier (40):
E=C–Y
Fill in space "E" with a thickness of shims (48).
STEP 99
In space "E", add additional shims between 0.05 mm
and 0.15 mm, in order to obtain P2 (Fig. 21):
Figure 21
P2 = 0.05 mm to 0.15 mm
Final operations
STEP 100
Remove the tool and bearing cup (46).
STEP 101
On carrier (40), place the shims determined in step
99. Centre the differential assembly, carry out steps
33 and 34. Insert the carrier, carry out steps 35 to 38.
SM 8-12300 Issued 03-2004

40 SECTION 6018
G. Removing and refitting the drive STEP 109

pinion Release and immobilise nut (18) using wrench, ref.
3378118M1 (see Page 45). Place special socket, ref.
Preliminary operations 3378119M1 (see Page 45), on the end of the drive
pinion (Fig. 23) and turn clockwise.
STEP 102
Uncouple the tractor between the intermediate
housing and the centre housing.
STEP 103
Remove the creeper unit (if fitted).
STEP 104
Free the ratchet of the Park Lock transmission lock (if
fitted).
STEP 105
Locate the position of and take out the sleeve linking
the drive pinion and the lower shaft.
STEP 106 Figure 23

Remove the hydraulic pump bearing / drive pinion
assembly. STEP 110
Remove bearing cone (1), shims (3) and thrust
Removing the drive pinion washer (4).
STEP 107 STEP 111

Disconnect control pin of the handbrake mechanism Take out two diametrically opposed bolts (11) on
(See Section 7001). bearing carrier (13). In their place, screw two guide
studs "G" (Fig. 24) into the tapped holes. Finishing
STEP 108 removing the other bolts.
Remove bolt (1). Take off pipe (57) located at the
taper end of the drive pinion (Fig. 22). STEP 112
Extract carrier (13) using two bolts "V" of sufficient
length (Fig. 24) placed in the tapped holes.
Figure 22
Figure 24
SM 8-12300 Issued 03-2004
SECTION 6018 41
STEP 113 STEP 123

Take off the carrier (13) assembly / unit (15), shims Check that the 4 WD drive pinion (17) (if fitted) is
(12) and 4 WD pinion (17). Visually note the position oriented as shown in the overall view. Correctly
of the components. position the carrier assembly (13) and unit (15) on
the guide studs. Turn the drive pinion in order to
STEP 114 engage the splines in pinion (17). Continue to push
Remove circlip (5). Unscrew and remove bolts (8). the unit assembly until it reaches its inserted
Separate the carrier (13) and the unit (15) (See position.
Section 7001).
STEP 124
STEP 115 Use the remaining bolts (11) and insert uniformly
Remove the discs (14), the intermediate plates (6) and alternately the carrier assembly (13) and unit
and handbrake mechanism (16) (See Section 7001). (15). Remove the guide studs. Lightly smear bolts
(11) with Loctite 270 and tighten them to a torque of
100 - 130 Nm.
STEP 116
If necessary, extract the bearing cups (2) (10) and STEP 125
cone (7) on the drive pinion.
Check that carrier (13) is in contact with shims (12).
Refitting the drive pinion STEP 126
NOTE: If the drive pinion (see Page 33 It is essential to place thrust washer (4) against
Disassembly of the crown wheel), taper roller shoulder "E" of the drive pinion (Fig. 29). Slide on
bearings (7) (10) (1) (2), bearing carrier (13), shims (3). Lubricate the bearing cone (1) with
thrust washer (4) and intermediate housing (19) transmission oil and fit it on to the drive pinion in
have been replaced, it is essential to adjust the contact with the shims.
position of the drive pinion (bevel distance) and
then shim the taper roller bearings (see STEP 127
Page 42). Degrease the threads of nut (18) as well as those on
the drive pinion.
STEP 117
Clean and check the components. Replace any parts STEP 128
found to be defective. Lightly smear the threads of the nut with Loctite 270
(or its equivalent) and immobilise it using wrench, ref.
STEP 118 3378118M1 (Fig. 25). Using socket, ref. 3378119M1
If bearing cone (7) has been disassembled, insert it (Fig. 25), turn the drive pinion anti clockwise and
to thrust against the drive pinion and cup (10) in tighten it to a torque of 200 - 250 Nm.
contact with bearing carrier (13), using a press and
an appropriate fixture. IMPORTANT: Take care to correctly position the
torque wrench. Remove the tool. Manually check
STEP 119 the rotation of the drive pinion. Lock the nut by
bending the lock washer into the grooves of the
Lubricate the taper roller bearings (7) (10) with pinion without breaking it, using an appropriate
transmission oil. tool.
STEP 120 STEP 129

Refit mechanism (16), the intermediate plates (6) Fit pin (25) into the handbrake mechanism, correctly
and discs (14). Assemble unit (15) and carrier (13) positioned to provide clearance. Place the washer
(See Section 7001). and retaining pin. Adjust the control (See Section
7001).
STEP 121
tapped bolt holes (11).
STEP 122
Position and slide shims (12) on to the guide studs.
SM 8-12300 Issued 03-2004

42 SECTION 6018
H. Adjusting the position and

shimming and drive pinion
NOTE: It is essential to adjust the position of the
drive pinion before carrying out shimming of the
taper roller bearings (7) (10) and (1) (2). Under
no circumstances should this adjustment be
modified without readjusting the shimming of the
drive pinion bearings.
Preliminary operations
STEP 139.
Using a press, insert cup (10) thrust against bearing
carrier (13).
STEP 140
Figure 25 Using a suitable fixture, insert cup (2) to thrust
against housing (19). Screw in two diametrically
Final operations opposed guide studs into the tapped holes (11). Fit
the carrier alone without shims (12). Alternatively
STEP 130 and progressively, tighten the four bolts (11) to a
torque of 100 -130 Nm. Check that carrier (13) is in
Refit the hydraulic pump bearing / drive pinion
contact with the intermediate housing (19).
assembly.
STEP 131 STEP 141

Using a press and an appropriate fixture, insert cone
Refit the ratchet and locking sleeve of the Park Lock
(7) to thrust against the drive pinion.
transmission.
STEP 132 STEP 142

Lubricate the taper roller bearings (7) (10) with
Refit the creeper unit (if fitted). Adjust the fork.
transmission oil.
STEP 133
STEP 143
Couple the tractor between the intermediate housing
Temporarily fit the drive pinion without shims (3) but
and the centre housing (See Section 6003).
with thrust washer (4) placed between the bearing cone
(1) and nut (18).
STEP 134
NOTE: If replacement of the crown wheel and STEP 144
drive pinion has been carried out, check the Pre-tighten the nut to a torque of 30 - 50 Nm using
backlash (see Page 36). wrench, ref. 3378118M1 and socket, ref. 3378119M1
(Figs. 33 - 34, I) taking care to correctly position the
STEP 135 torque wrench.
Check the operation of all the controls.
STEP 145
STEP 136 Turn the drive pinion several times to correctly seat the
Carry out a road test. bearing cones in the cups. Check the correct pre-
tightening of nut (18) again.
STEP 137
Check the oil tightness of the mating surfaces.
STEP 138
Check the oil tightness of the hydraulic unions.
SM 8-12300 Issued 03-2004

SECTION 6018 43
Adjusting the drive pinion position X Is the dimension measured between the end of the
The thickness of shims (12) required to position the drive pinion and the rear face of the intermediate
drive pinion is calculated as follows: housing (Fig. 28).
E Is the thickness of shims (12) to be fitted. E = 241 – (X + 139) - 0.05:
Z Is the nominal dimension between the rear face of NOTE: Note: The drive pinion and the crown
the intermediate housing (19) and the axis of the wheel are matched pairs and have a number and
differential crown wheel (20) = 241 (Fig. 26). letter engraved on each component.
Y Is the nominal dimension of the positioning of the

drive pinion = 139.00
Figure 26
SM 8-12300 Issued 03-2004

44 SECTION 6018
Procedure (Steps 146 and 147) Shimming taper roller bearings (7)
STEP 146 (10) and (1) (2) of the drive pinion
Using a depth gauge, measure dimension "X" (Fig. 28).
STEP 150
On the drive pinion, slide the thickness of shims (3)
required to obtain a provisional clearance of 0.10 mm
to 0.15 mm maximum, in order to prepare P1
shimming.
NOTE: The thrust washer (4) must be placed

against shoulder (E) of the drive pinion (Fig. 29).
STEP 151
Lubricate bearing cup (2). Fit bearing cone (1).
Figure 28
STEP 147
After having taken the measurement, use the formula
to determine "E", the thickness of the shim(s) (12) to
be fitted in order to correctly position the drive pinion.
Checks
Temporarily reassemble the assembly fitted with the
previously determined shims and measure
dimension "X" again.
Check that X + Y does in fact equal Z.
STEP 148
Remove the drive pinion and bearing carrier (13).
STEP 149
On bearing carrier (13), refit the mechanism, the
intermediate plates, the discs and unit (15). Refit the
assembly on the intermediate housing (19). Carry
out steps 119 to 125.
ATTENTION: Carr y out shimming of the drive pinion

taper roller bearings.
Figure 29
SM 8-12300 Issued 03-2004

SECTION 6018 45
STEP 152 STEP 160

Using wrench, ref. 3378118M1 and socket, ref. Degrease the threads of nut (18) as well as those of
3378119M1, temporarily tighten nut (18) to a torque the drive pinion. Fit and definitively tighten the nut, its
of 30 - 50 Nm. threads previously lightly smeared with Loctite 270,
to a torque of 200 - 250 Nm.
STEP 153
Place the index of the dial gauge on the tapered end STEP 161
of the pinion (Figs. 29 - 30). Manually check the rotation of the drive pinion.
STEP 162
Lock the nut by bending its lock washer into the
grooves of the pinion without breaking it, using an
appropriate tool.
I. Service tools
Tools available in the McComick network
3378116M1 - Differential unit sling (Fig. 31).
Figure 30
STEP 154
Pull strongly on the pinion via the front of the
intermediate housing while alternately turning the
pinion left and right to correctly seat the bearing
cones in their cups.
STEP 155
With the assistance of another operator, set the dial
gauge to zero.
STEP 156 Figure 31

Repeat operation 153 but this time pushing.
3378117M1 - Shimming tool (Fig. 32)
STEP 157
In relation to the clearance measured, select a new
thickness of shims (3) in order to obtain pre-loading
(Fig. 29):
P1 = 0.04 mm to 0.10 mm
STEP 158
Loosen and take off nut (18).
STEP 159
Slide the shims (3) selected during step 147 between
thrust washer (4) (see note, step 150) and bearing Figure 32
cone (1).
SM 8-12300 Issued 03-2004

46 SECTION 6018
3378118M1 - Locking wrench for drive pinion nut 3378119M1 - Drive pinion tightening socket (Fig. 34).
(Fig. 33)
Figure 34
Figure 33
SM 8-12300 Issued 03-2004

SECTION 6018 47
Rear Axle - Brake pistons and seals
Description Parts list
General 1. Centre housing

The brake pistons (2) are housed in two cavities 2. Piston
formed by the centre housing and the differential 3. O-ring
carrier, concentric with the thrust face of each 4. O-ring
trumpet housing. The brake pistons are guided by 5. O-ring
three locating pins (6) force fitted into the centre 6. Stop pin
housing and have an annular face that is submitted 7. Pin
to pressure from the master cylinder. The other face 32. Hub
has a larger surface area and acts upon a disc that is 35. Disc(s)
integral via splines with the input sun gear of the 38. Intermediate plate
trumpet housing and on the wall of a compartment 39. Stop pin (drilled)
that also serves as the brake plate. This 41. Stop pin
compartment is centred by locating pins that are
force fitted into the trumpet housing which may or not Identification of ports
be oil tight depending on the type of assembly. O Disc lubricating port
The oil tightness of the pistons is provided by O-rings P Pressure from master cylinders
fitted into the grooves of the centre housing and the
differential carriers. Two other seals placed in the
angle of each carrier stop the pressure in the piston
chamber from communicating with the interior of the
centre housing.
The shape of the pistons differs according to the

options and the type of trumpet housing.
Each piston is controlled by a master cylinder the oil

level of which is maintained by a residual oil flow from
the lubricating circuit.
When the brake is released, a minimum clearance is

provided between the piston and the disc. The
brakes are self-adjusting and maintain a constant
brake pedal position.
When they are not in use, the discs are lubricated by

an oil flow from the lubricating circuit on the right-
hand cover. This oil also serves to cool the discs
when they are used.
ATTENTION: On tractors fitted with trumpet housings

with double drive unit, the brake pistons ( 2 ) are fitted in
the same cylinders as previously mentioned. They are
guided by three stop pins ( 39 ) ( 41 ) mounted free in the
housing. Pin ( 39 ) fitted in the upper part of the housing
has a drilled central port to allow pressure venting from
the trumpet housing into the rear axle and breather pipe.
The pistons act upon a two-disc system ( 35 ) running in an
oil bath and integral via splines with hub ( 3 2 ) and the
trumpet housing input shaft. The discs are separated by an
intermediate plate ( 38 ) that is guided by the previously
mentioned pins.
During braking, the double-disc system is thrust
against the centre brake plate by pin (7) on the centre
housing.
SM 8-12300 Issued 03-2004

48 SECTION 6018
Overall view Assembly with trumpet housing fitted with double drive unit
Figure 4
SM 8-12300 Issued 03-2004

SECTION 6018 49
Exploded view
Figure 5
SM 8-12300 Issued 03-2004

50 SECTION 6018
A.Dissassembly
STEP 1
Remove the trumpet housing(s) concerned.
STEP 2
Remove the master cylinder brake supply pipe from the
union above the centre housing. Progressively drive
out piston (2) from housing (1) using a compressed air
jet connected to the union (3) (Fig. 6).
Figure 7
ATTENTION:
The seals (3) (4) not being mounted on the brake
piston, their movement and wear is limited.
The O-rings (5) fitted between the differential carriers

and the centre housing (Fig. 1 - 4) ensure the oil
tightness of the piston chambers.
STEP 4
If necessary, remove the differential carrier(s) to
Figure 6 replace the previously mentioned O-rings.
STEP 3
Remove the O-rings (3) (4) fitted on the housing and
differential carriers respectively (Fig. 7).
SM 8-12300 Issued 03-2004

SECTION 6018 51
B. Reassembly
STEP 5
STEP 6
If removed, refit the differential carrier(s) with a new
seal.
Checks before reassembly

STEP 7
Remove the -rings (3) (4) (Fig. 9) and place the
piston in the housing.
Figure 9
STEP 8
Check that the piston slides freely in its bore and that
there are no stiff spots on stop pins (6) (39) or (41)
(depending on the version) (Fig. 8 and 9).
STEP 9
When the check is completed, definitively fit the new
seals previously lubricated with transmission oil (Fig.
7) and position the piston on the stop pins (Fig. 8),
turning the more numerous lubricating ports
upwards.
ATTENTION: To avoid damaging the seals, place the

piston in its bore using a locally manufactured tool (see §
Page 52 ) and with the aid of two bolts " V " of a suitable
Figure 8 length that are alternatively and progressively tightened
(Fig. 8).
SM 8-12300 Issued 03-2004

52 SECTION 6018
STEP 10 Tests
Remove the tool. If necessary, complete the fitting by Pressurize the circuit again to a pressure of
alternatively tapping on the face of the piston using a approximately 0.3 bar.
plastic hammer. Check that there are no fragments of
O-rings after fitting. Close the pressure relief-valve.
Hydraulic test (Fig. 10) Over a period of one minute, no drop in pressure
should be seen on the pressure gauge.
After the test, remove the pressure gauge and take

off the retainer tool.
Final operations
STEP 11
Refit the trumpet housing(s) depending on the
version).
STEP 12
Purge the main brake system.
STEP 13
Carry out a road test of the brake circuit.
STEP 14
Check the oil tightness of:
trumpet housing seals (silicone)
brake lubricating pipes
C. Service tools
Locally manufactured tools

Brake piston fitting tool (Fig. 11)
a: rubber or plastic
Figure 10
Positioning of seals
ATTENTION: Use a pressure gauge that has previously
been checked for pressure tightness and fit the piston
retainer tool onto the housing (see Page 52 and Fig. 10).
U s i n g c o m p r e s s e d a i r, p r e s s u r i z e t h e c i r c u i t t o
approximately 5 bar. Disconnect the pressure gauge and
push the piston back using a plastic hammer.-Repeat the
above operation several times.
Figure 11
SM 8-12300 Issued 03-2004

SECTION 6018 53
Rear axle - Park Lock
Description Par ts list
1.Piston
General 2.O-ring
3.Control unit
The Park lock system, fitted inside the centre
4.Bolt
housing, comprises a ratchet (17) and a toothed
5.O-ring
sleeve (15), integral via splines with the drive pinion
6.Special bolt
and the lower shaft connected to the gearbox.
7.Solenoid valve
8.O-ring
This system is activated by a control unit (3) attached
9.Nut
to the right-hand side of the housing and through a
10.Spring
spring-loaded control rod.
11.Control rod
12.Split pin bolt
The Park lock is only fitted to transmissions equipped
13.Links
with a Full Powershift gearbox.
15.Toothed sleeve
16.Pin and washer
Operation 17.Ratchet
Engaged position (speed control in position P) 18.Seal(s)
19.Switch
When the tractor is halted with the engine running, 20.O-ring
the Park lock provides a mechanical locking of the 23.Non-return valve
transmission. In the engaged position, the solenoid
valve (7) is not activated and the system functions in
a purely mechanical manner. Version without Park lock
24.Plug
Spring (10) pushes piston (1) towards unit (3). The 25.Plug
control rod (11) screwed into the piston drives the 26.Threaded plug
links (13) that engage ratchet (17) in the toothed
sleeve (15), thus locking the lower transmission Key to letters
shaftline. D.:Disengaged position
E.:Engaged position
With the engine halted, the Park lock is engaged

automatically.
Disengaged position (hydraulic activation)
When the speed control is placed in the P or N

position, the electronic unit (TC) controls solenoid
valve (7) that supplies control unit (3) which
disengages the Park lock. The pressure in the piston
chamber (1), acting upon the front face of the piston,
compresses spring (10) and frees ratchet (17) from
the toothed sleeve (15).
The electronic unit (TC) is informed through the

position of switch (19).
SM 8-12300 Issued 03-2004

54 SECTION 6018
Overall view
Figure 1
SM 8-12300 Issued 03-2004

SECTION 6018 55
Exploded View
Figure 2
SM 8-12300 Issued 03-2004

56 SECTION 6018
A. Unlocking the system and STEP 2

positioning the special bolt. Using wrenches, hold the bolt in the previously
stated position and tighten nut (9) against the unit
ATTENTION: The Park lock system must be unlocked housing to a torque of 85 - 115 Nm.
before carrying out certain maintenance operations on the
tractor or when the hydraulic or electronic circuits of the
Park lock system fail.
Unlocking
STEP 1 .
Take off nut (9) and turn the special bolt (6) (Fig. 3)
clockwise until piston (1) comes into contact with the
shoulder of the housing.
Action obtained
During this operation, the control rod (11) is moved

to the right and compresses the spring (10) freeing
ratchet (17) from the toothed sleeve (15) (Figs. 3 - 4)
Restoring the initial position of the

special bolt
After any intervention on the special bolt (6), it is
important to restore it in its initial position, i.e.
completely unscrewed and locked at a torque of 40 -
50 Nm in order to ensure both the correct operation
of the Park lock system and oil tightness of its control Figure 4
unit (3).
Test
Check the correct operation of the transmission lock.
Figure 3
SM 8-12300 Issued 03-2004

SECTION 6018 57
B. Removing and refitting the sleeve STEP 12

Chock between the frame and the front axle.
Preliminary operation
STEP 13
STEP 3 Remove the rear wheels or place them in the wide
Uncouple the tractor between the gearbox and the track position. If the wheels are removed, position
intermediate housing (See Section 6003). axle stands.
Removal STEP 14
Remove the left and right-hand hydraulic covers (See
STEP 4 Section 8005).
Disengage the Park lock system (see Page 56) and
remove the creeper drive unit. STEP 15
Disconnect solenoid valve (7) fitted on the Park lock
STEP 5 unit (3).
Visually locate the position of the sleeve and remove
it.If necessary, take out the snap ring located inside Disassembly
it.
STEP 16
Refitting Remove two diametrically opposed bolts (4) and
screw instead two sufficiently long M6 x 100
STEP 6 threaded rods, fitted with nuts and washers, to make
contact with unit (3) (Fig. 5).
Clean and check the components. Replace any
defective parts.
STEP 7
If previously removed, replace the snap ring.
STEP 8
Check that the sleeve slides easily on the drive
pinion and on the lower shaft coming from the
gearbox. Place the sleeve in its final position on the
drive pinion, the long part turned towards the pinion.
Refit the creeper unit.
Final operations
STEP 9
Couple the tractor between the gearbox and the
inter-mediate housing (See Section 6003). Figure 5
STEP 10 STEP 17
Place the special bolt (6) in its initial position (see Remove the two other bolts.
Page 56).
STEP 18
C. Disassembling the control Loosen nut (9) and turn the special bolt (6) (Fig. 5)
several turns clockwise to slightly free the lower pin
Preliminary operations bolt (12) (Fig. 1).
STEP 11 STEP 19
Through the opening of the right-hand side cover,
Immobilise the tractor. Chock the front wheels.
take out the pin and remove the bolt.
SM 8-12300 Issued 03-2004

58 SECTION 6018
STEP 20 STEP 28
Progressively and alternately unscrew the wing nuts If fitted, screw piston (1) on to rod (11) with its
"E" on the two threaded rods in order to release the threads lightly smeared with Loctite 270 and tighten
spring (10) (Fig. 6). to a torque of 50 - 70 Nm. Using a punch, mark the
external face of piston (1) and rod (11) with two
diametrically opposed marks (Fig. 7).
Figure 6
STEP 21 Figure 7
Remove unit (3), piston (1) fitted with O-ring (8), rod STEP 29
(11) and spring (10).
Replace and lubricate the O-rings (2) (8) (20). In the
STEP 22 opening of the intermediate housing, position piston
(1) with rod (11) (Fig. 7) and spring (10) by aligning
Recover the O-rings (2) (20). the hole of the shaft with the two links (13).
STEP 23 STEP 30
Through the opening of the left-hand side cover, Use unit (3) to push on piston (1) and compress
remove the pin from bolt (16) and thus remove spring (10) by using the threaded rods, washers and
ratchet (17). wing nuts used for disassembly.
STEP 24 STEP 31
If necessary, remove the switch (19) fitted with its Fit pin (12) with its retaining pin turned towards the
seal (18). front.
D. Reassembling the control STEP 32

Fit and tighten the two bolts (4) to a torque of 10 -
STEP 25 14 Nm.
found to be defective. STEP 33
Remove the nuts, washers and threaded rods.
STEP 26
Refit the ratchet. Carry out step 19 in reverse order. STEP 34
Special point Fit the other two bolts and tighten to the previously
indicated torque.
STEP 27
Limit the axial clearance of pin bolt (16) to the
maximum (tolerance 0 mm to 2 mm), by if possible
placing a washer on the pin bolt between the housing
and the pin.
SM 8-12300 Issued 03-2004
SECTION 6018 59
Final operations
STEP 35
Refit the right and left hand side covers (See Section
8005).
STEP 36
Reconnect solenoid valve (7).
STEP 37
Remove the axle stands (if used) refit the wheels or
place them in their initial position. Carry out the
tightening of nuts and bolts to their indicated torque
(See Section 6003). Check the correct operation of
the dashboard indicator lamp and the display of the
letters P and N in relation to the speed control.
STEP 38
Check the oil tightness of the control unit (3).
Torques
Switch (19): 20 Nm
Bolts (4): 10 - 14 Nm
Solenoid spool valve (7): 18 - 20 Nm
Knurled nut (solenoid valve): 3 - 4 Nm or manual

tightening
ATTENTION: The letter " R" (Fig. 7) indicates the unit ( 3)

oil retur n por t.
SM 8-12300 Issued 03-2004

60 SECTION 6018
Rear Axle - Lift cylinder supports
Description Assembly 2
On support (16), air venting in the centre and trumpet
General housings is solely ensured by channel "C" and
The lift shaft (7) fits into supports (2) (16) fitted to the breather (18).
centre housing. The lift shaft is splined at its ends
and operates the arms (5) (15). A plug (30) blocks the unused port.
The arm (5) is positioned by locating pin (4) inserted ATTENTION: In both assembly configurations, an O-ring
into cam (8), itself integral with the shaft via splines. ( 19 ) between the housing and the suppor t provides oil
The shaft drives the cam that informs the ELC tightness for channel " C ".
calculator of the arm position via sensor (11). Tractors also exist without hydraulic lift. In this case, a
plate covers the location of the supports ( 2 ) ( 16 ).
Each support is positioned by two locating pins (13)
force fitted into the centre housing.
The lower and lateral supports (1) of drawbars (7)
Oil tightness of the bearings including friction bushes are positioned by locating pins (3) and retained by
(10) is provided by seals (1) (3) inserted in both sides bolts (4) on to the centre housing (Fig. 1).
of the support.
Each support is fitted with a draft sensor (8) held by
Special point locking plate (2), spacers (6) and bolts (5) (Fig. 1).
Two types of assemblies are possible on the left- A guard (9) fixed to supports (1) protects the sensor
hand support (Fig. 2). harness (Fig. 1).
Tightening torques
Assembly 1
On support (16), a channel "C" and a port "O", linked Bolts (4) on supports (1) (Fig. 1): 480 - 640 Nm,
to the trumpet housings by external pipes, provide for Loctite 270
air venting in the centre housing and trumpet
housings via breather pipe (18). Bolts (5): 50 Nm, Loctite 270.
Figure 1
SM 8-12300 Issued 03-2004

SECTION 6018 61
Par ts list
Assembly types (Fig. 2)
1.Seal Assembly 1
2.Right-hand support
3.Seal Tractors fitted with Heavy Duty trumpet housings with
4.Locating pin sealed compartment or composite drive units.
5.Right-hand side lift arm
6.Bolts and washers Assembly 2
7.Shaft
8.Cam
9.Bolts and washers
10.Friction bushes Tractors fitted with standard or double drive unit
11.Position sensor trumpet housings.
12.Nut
13.Locating pins
14.Grease nipples
15.Left-hand side lift arm
16.Left-hand side support
17.Grooved spacer
18.Breather pipe
19.O-ring
30.Plug
31.O-ring
32.O-ring
SM 8-12300 Issued 03-2004

62 SECTION 6018
Overall view, Right-hand support
Left hand support
Assembly 1
Assembly 2
Figure 2
SM 8-12300 Issued 03-2004

SECTION 6018 63
Exploded view
Figure 3
SM 8-12300 Issued 03-2004

64 SECTION 6018
A. Cylinder attaching points

Layout of components 27. Lower pins
28. Circlips
20. Upper pins 29. Friction bushes
21. Retaining pins
22. Cylinders
23. Washers Lift cylinder upper and lower
24. Grease nipples attaching points
25. Snap rings
26. Washers
Figure 4
SM 8-12300 Issued 03-2004

SECTION 6018 65
B. Preliminary operation STEP 7

Take out bolts (9) on each support. Using straps,
STEP 1 sling together the pin, supports and lifting arm and
Immobilise the tractor. Chock the front wheels. remove them.
STEP 2 STEP 8
If necessary, chock between the cylinder and the Recover the O-ring (19).
front axle. Remove the rear wheels or place them in
the wide track position. Position axle stands as STEP 9
required. Remove the rear silent block bolts and Take out bolts (6). Remove the lift arms, noting their
slightly tilt the cab forwards, checking that nothing direction for reassembly. If necessary, extract bushes
hinders this or touches the forward face of the cab. (29) (Fig. 3).
ATTENTION: Access to the right-hand side support is STEP 10

difficult since one of the four retaining bolts is masked by
the high-pressure pipe ( 1 ) of the lift control and auxiliary Remove the cam (8) and grooved spacer (17).
spool valves (Fig. 5).To remove the support, disconnect
this pipe that runs from the manifold on one hand, and the STEP 11
priority blocks on the other (depending on options). Note the position of the supports (2) (16) and
separate them from the shaft.
STEP 3
Refitting
STEP 12
STEP 13
Use protector, ref. 3378123M1 (see F). Slide sup-
port (16) onto shaft (7) (Fig. 6) in the position
previously noted in operation 11. Proceed in the
same way with support (2).
Figure 5
Disassemble union (2) (Fig. 5).
STEP 4
Remove the position sensor (11).
STEP 5
Take out the upper pins (20) from cylinders (22) and
the lift rod pins (Fig. 4).
C. Removing and refitting the shaft

Removal
Figure 6
STEP 6
Take off breather pipe (18). Disconnect and remove STEP 14
the union screwed into port "O" on support (16)
Check for the presence of locating pin (4) on cam (8).
(depending on the assembly type, see Fig. 2).
SM 8-12300 Issued 03-2004

66 SECTION 6018
STEP 15 D. Disassembling and reassembling

On shaft (7), insert grooved spacer (17) and cam (8) the supports
in contact with their respective supports (2) (16). (2) (16)
STEP 16
If necessary, replace friction bushes (29) using pin Disassembly
(20) as an insertion tool.
STEP 26
STEP 17 On each support, remove seals (1) (3) and grease
Mark the position of locating pin (4) with a line of nipples (14).
paint on cam (8) and arm (5).
NOTE: The reference for bush (10) is not found in
STEP 18 the spare parts catalogue. If it is worn or
damaged, replace the suppor t.
Lightly coat the splined ends of the shaft with Anti-
seize grease or its equivalent.
Reassembly
STEP 19
STEP 27
Refit the lift arms with the paint mark made
previously on the arm (5) aligned with that on cam (8) Lightly smear the external diameter of seals (1) (3)
and side "A" of the arm flush with side "B" of the pin with Loctite 542 and insert them using service tool,
(see Fig. 2). ref. 3378124M1, with the lip turned towards the
outside of the support (see Page 67).
STEP 20
STEP 28
Assemble the washers and bolts (6) the threads
lightly smeared with Loctite 270. Tighten to a torque Fit the grease nipples (14).
of 240 - 320 Nm.
STEP 21
Check for the presence of locating pins (13) inserted
into the centre housing at the location of each support
and O-ring (19) on the left-hand side support.
STEP 22
Using straps, correctly sling the assembly of pin,
supports and lift arm and position them on locating
pins (13).
STEP 23
Fit the washers on bolts (9) the threads lightly
smeared with Loctite 270. Tighten to a torque of 240
-320 Nm.
STEP 24
Check that none of the channels in support (16) are
obstructed. In the case of an Assembly 2 type (Fig. 2),
refit the plug (30) fitted with seal (31). On an Assembly
1 type, fit the hydraulic union and reconnect the pipe
(see step 6). On each type of assembly, check the
cleanliness of breather pipe (18) and screw it fitted with
O-ring (32) onto the left-hand side support.
STEP 25
Manually check the axial clearance and the rotation
of the shaft.
SM 8-12300 Issued 03-2004

SECTION 6018 67
E. Final operations
3378124M1 - Seal insertion tools (Fig. 8).
STEP 29
Refit the upper cylinder pins fitted with grease
nipples (24) respecting the location of washer (23).
STEP 30
Fit and adjust the position sensor.
STEP 31
Refit union (2) on the manifold and reconnect the
high pressure pipe (1) from the auxiliary and lift
control spool valves that was disassembled in step 3.
STEP 32
If needed, place the cab on its rear supports. Tighten
the bolts previously lightly smeared with Loctite 270
to a torque of 200 - 260 Nm. Refit the wheels or place
them in their initial position. Remove the axle stands
(if used). Tighten all nuts and bolts to their correct
torque.
STEP 33
Using a grease gun, grease the supports (2) (16),
and pins (20) (27).
Figure 8
STEP 34
Check the lift control operation. Check the oil tightness
of pipe (1) and union (2) (Fig. 5).
F.Service tools
Tools available in the McCormick network
378123M1 - Protector (Fig. 7)
Figure 7
SM 8-12300 Issued 03-2004

68 SECTION 6018
Rear Axle -Creeper
Description Operation (Fig. 1)

The coupler (29) is integral via splines with the
General layshaft (30). The moving of the control lever to the
All tractors fitted with an AG250 Full Powershift "Snail" position moves the coupler rearwards and
gearbox may be fitted, according to options, with a locks it to the planetary carrier (20) via coupler ring
creeper. (22). The speed of the output shaft is 1/4 of that of
the input shaft.
This reducer unit (24) comprises a simple epicyclic
gear train having a planetary carrier and crown wheel Lubrication
mounted at the front of the intermediate housing (19) The lubrication of the mechanical components of the
(Fig.1). epicyclic reducer gear is ensured by an oil splash.
The drive pinion and the layshaft (30) have an axial
It is controlled by a lever on the right-hand side drilled channel, this allows flow "D" from the right-
console in the cab that is linked via a cable to a link hand side hydraulic cover to lubricate needle bearing
fitted on the front right-hand side of the intermediate (34) (Fig. 1).
housing. This link moves the coupler control fork.
The bearing supports the layshaft and permits a
The coupler, fitted with straight teeth, must only be difference in rotation of the shafts when in the
engaged when the tractor is stationary. "Creeper" position.
Figure 1
SM 8-12300 Issued 03-2004

SECTION 6018 69
Overall View
Figures 2 & 3
SM 8-12300 Issued 03-2004

70 SECTION 6018
Par ts list Figs 2 & 3
1. Snap ring
2. Connecting shaft
3. Bolts
4. Sleeve
5. Support
6. Snap ring
7. Bearing carrier
8. Circlip
9. Circlip
10. Ball bearing
11. Snap ring
12. Friction washer
13. Pin
14. Friction plates
15. Sun gears
16. Crown wheel
17. Spacers
18. Roller bearings
19. Intermediate housing
20. Planetary carrier
21. Snap ring
22. Coupler ring
23. Bolts
24. Planetary carrier assembly (reducer gear)
25. Locating pin
26. Nut
27. Fork
28. Guide rod
29. Coupler
30. Layshaft
31. Snap ring
32. Sleeve
33. Snap ring
34. Needle bearing
35. Locking stud
36. Spring
37. Plug
38. Pin
39. Finger
40. O-ring
41. Pin
42. Link
43. Bolt
44. Housing
45. Shim(s)
SM 8-12300 Issued 03-2004

SECTION 6018 71
Exploded view
Figure 4
SM 8-12300 Issued 03-2004

72 SECTION 6018
A. Removing and refitting the unit
STEP 1
Uncouple the tractor between the gearbox and the
intermediate housing (See Section 6003).
STEP 2
Remove the sleeve (4).
Removal
STEP 3
Remove bolts (3). Remove the shaft (2) and unit (24)
assembly.
NOTE: The locating pins (25) are force fitted into

the intermediate housing (19).
Refitting
STEP 4
Check for the presence of the locating pins on the
intermediate housing.
STEP 5
Screw two guide studs of suitable length in the place
of two bolts (3).
STEP 6
Place coupler (29) in contact with snap ring (31).
STEP 7
Refit shaft (2) and unit (24) assembly turning the
machined recess "E" on support (5) towards the
adjusting nut (26) on guide rod (28) (Fig. 3). Turn
shaft (2) several turns to engage the exterior splines
of coupler ring (22) in those of coupler (29).
STEP 8
Alternately and uniformly tighten bolts (3) lightly
smeared with Loctite 241 to a torque of 90 - 120 Nm.
STEP 9
SM 8-12300 Issued 03-2004

SECTION 6018 73
Figure 5
SM 8-12300 Issued 03-2004

74 SECTION 6018
B. Disassembling, reassembling and adjusting the selection mechanism
Preliminary operations STEP 21

Lubricate a new seal (40) and fit it on pin (41). Enter
STEP 10 the pin through the chamfered port of the
Remove unit (24) (see Page 72). intermediate housing (19).
ATTENTION: To limit axial clearance of the pin, it is

STEP 11
recommended to carry out shimming with a tolerance of
Disconnect the control cable fitted to link (42). 0.1 mm to 0.6 mm.
Disassembly Shimming
(Fig. 5) On the pin, place an approximate thickness of
shim(s) (45). Fit finger (39) and partially fit pin (39).
STEP 12 Reassemble the link (42) and bolt (43).
Remove plug (37). Recover spring (36) and locking Manually evaluate the existing clearance.
stud (35).
ATTENTION: The ad jus tme nt pr inc ip le c ons is ts i n
STEP 13 obtaining a minimum clearance between the various parts.
Remove the Allen screw (43). Remove the link (42)
and pin (41) fitted with seal (40) and finger (39). Action
Recover the shim(s) (45). Drive out pin (38) linking If the clearance is outside the maximum stated
the pin and the finger. tolerance, determine a new thickness of shim(s).
After shimming, check for the correct orientation of
STEP 14 the finger and the link. Definitively insert pin (38), fit
Disengage the guide rod (28) from the fork (27) and and tighten Allen screw (43).
the intermediate housing (19).
STEP 22
STEP 15 Fit the shaft, coupler and fork in the intermediate
If necessary, loosen, unscrew and discard nut (26). housing.
STEP 16 STEP 23
Remove the fork, coupler and shaft (30) fitted with Refit the guide rod and nut assembly.
needle bearing (34).
STEP 24
STEP 17 Refit the unit (24) (See Page 72). Adjust the fork (see
Remove snap ring (31). subsequent operations).
STEP 18 Final operations

If necessary, extract the bearing.
STEP 25
Refitting Couple the tractor between the gearbox and the
STEP 19
STEP 26
found to be defective. Connect the control cable and adjust it if necessary
(see Section 9001).
STEP 20
If fitted, using an appropriate fixture, insert bearing
(34) thrust against the shoulder on layshaft (30) and
check that the needle bearing turns normally. Place
snap ring (31).
SM 8-12300 Issued 03-2004

SECTION 6018 75
Figure 6
Adjustment STEP 29
(Fig. 6) Maintain the fork thrust against the coupler in
accordance with F2. Turn the guide rod (28) in nut
(25) according to F3 so as to place in contact the
STEP 27) oblique face of groove G1 with locking stud (35) while
Fit the locking stud (35), spring (36) and plug (38). simultaneously holding nut (26) against spot-faced
Partially tighten the plug. face B of the intermediate housing (19).
STEP 28 STEP 30
Position coupler (29) in accordance with F1, its Using a depth gauge, measure X1 between the
forward face thrust against shaft (2). forward face of the guide rod and face A of the
intermediate housing (19).
SM 8-12300 Issued 03-2004

76 SECTION 6018
STEP 31
Hold the fork thrust against the coupler in
accordance with F2.
STEP 32
Turn the guide rod in the nut in accordance with F4
so as to place the other oblique face of groove G1 in
contact with the locking stud while holding nut (26) as
previously.
Measure X2 in the same manner as X1.
Determine the position of adjustment X using the

following formula:
X = (X1 + X2) : 2
Provisionally position guide rod (28) to dimension X.
Place coupler (29) in the "Creeper unit" position.

Manually check for locking of the control and the
clearance between the fork and the coupler.
If this check is satisfactory, remove unit (24), plug

(37), the spring and the locking stud.
STEP 33
Grease the threads of the guide rod and the threads
of nut (26).
STEP 34
Tighten the nut, previously lightly smeared with
Loctite low resistance thread lock, and definitively
position the guide rod according to the previously
calculated dimension X.
STEP 35
Lock the nut by bending its collar into the machined
groove of the guide rod.
STEP 36
Reassemble the locking mechanism. Tighten plug
(37) to a torque of 50 - 70 Nm. Refit unit (24) (see
Page 72).
SM 8-12300 Issued 03-2004

SECTION 6018 77
Figure 7
SM 8-12300 Issued 03-2004

78 SECTION 6018
C. Disassembling and reassembling the epicyclic gear

(Fig. 7)

Refit the sun gears and position the friction plates
STEP 37 (14). Refit pins (13) correctly turning the spot-face for
the fitting of snap ring (11).
Remove unit (24) (see Page 72).
STEP 49
STEP 38
Fit the snap ring.
Take out bolts (23). Remove housing (44).
STEP 50
STEP 39
Manually check the axial clearance and rotation of
Disengage reducer gear (20) from shaft (2). Remove each sun gear.
crown wheel (16).
STEP 51
STEP 40
Lightly smear the faces of the reducer gear with
Separate supports (5) (7). miscible grease and fit the friction washers (12), with
the tabs lodged in the appropriate grooves.
STEP 41
If necessary, take off snap ring (6) and circlips (8) (9). Final operations
Extract bearing (10).
STEP 52
Disassembly If disassembled, insert bearing (10) on shaft (2)
using an appropriate fixture.
STEP 42
Remove the friction washers (12). STEP 53
Fit circlips (8) (9) and snap ring (6).
STEP 43
Take off circlip (11). STEP 54
Assemble supports (5) (7).
STEP 44
Drive out pins (13). STEP 55
Engage reducer gear (20) on shaft (2).
STEP 45
Remove sun gears (15) taking care not to lose the STEP 56
needle bearings (18), spacers (17) and the friction Refit the crown wheel (16).
plates (14).
STEP 57
ATTENTION: The coupler ring ( 22) is fitted in the
Position housing (44), with the cut out turned
planetar y carr ier using a press. Snap r ing ( 21 ) pr ov i de s
downward.
a d d i t i o n a l l o ck i n g o f t h e va r i o u s p a r t s.
STEP 58
Reassembly
Assemble and tighten bolts (23) previously lightly
smeared with Loctite 241 and tighten to a torque of
STEP 46 10 - 14 Nm.
Check and clean the components. Replace any parts
found to be defective. STEP 59
Refit unit (24) (seePage 72).
STEP 47
Fit each sun gear (15) with both needle bearings (18)
and spacer (17) smeared with miscible grease.
SM 8-12300 Issued 03-2004

SECTION 6018 79
Rear Axle - Rear hitch mechanism
A. Disassembling and reassembling a lift cylinder
Preliminary operations IMPORTANT: New s e al s an d s n ap r in g s mu s t

always be fitted.Use an appropr iate fixture to
force fit the parts without damaging the seals. Fit
STEP 1
the ram into the cylinder with care.
Run the engine and lower the lower bars to their
maximum using the ELC.
STEP 2
Disconnect the feed hose, remove the cylinder and
empty it of oil.
Disassembly
(Fig. 7)
STEP 3
Remove the 90° union ( 1) fitted with its O-ring.
STEP 4
Push the cylinder ram (5) until snap ring (4) is visible
in port O of the union.
STEP 5
Introduce a screwdriver in this port and while turning
the cylinder ram push the snap ring into the V-
shaped recess.
STEP 6
Remove the ram and seal (4). Drive off scraper seal
(2) and oil seal (3) (systematically discard these
three parts).
Reassembly
IMPORTANT: C ar ef ul ly c le an a ll c om pon en ts.
Replace any par ts that are scratched or bowed.
I n c a s es o f s e i zi n g up or s e r i ou s s c ra tc hi n g, Figure 7
replace the cylinder and ram.
Final operations
STEP 7
Dry all components using compressed air.
STEP 10
Lubricate the upper and lower pins with anti-seize
STEP 8 grease and refit them. Reconnect the feed hose.
Lubricate the assembly with clean transmission oil.
STEP 11
STEP 9 Run the engine. Using the ELC, raise the lower hitch
bars into the high position and vice versa.
Proceed with assembly of the cylinder. Carry out
operations 3 to 6 in reverse order.
STEP 12
Check that the hitch is operating correctly and that
there are no oil leaks around either cylinder or ram.
SM 8-12300 Issued 03-2004

Section
6019
POWER TAKE-OFF
ZTX Series Tractors
6019

SM 8-12340 March 2004
2 SECTION 6019
TABLE OF CONTENTS
POWER TAKE-OFF- DESCRIPTION
General ................................................................................................................................................................ 4
DRIVING PINIONS - BEARINGS - LAYSHAFT

General ................................................................................................................................................................ 7
A. Removing and refitting the driving pinion, bearings and layshaft .................................................................. 10
Removal ........................................................................................................................................................ 10
Refitting ......................................................................................................................................................... 11
B. Shimming ....................................................................................................................................................... 12
POWER TAKE-OFF- SHIFTABLE PTO SHAFT

General .............................................................................................................................................................. 13
Lubricating the pinions ................................................................................................................................... 13
A. Disassembling and reasembling 750 - 1000 rpm pinions, fork and bearing .................................................. 16
Disassembling pinions and fork ..................................................................................................................... 16
Disassembling bearing .................................................................................................................................. 16
Reassembling the bearing ............................................................................................................................. 16
Reassembling pinions and fork ..................................................................................................................... 16
B. Removing, refitting and disasembling, reassembling the rear bearing block, oil seal and shaft bearings ..... 18
Removing the bearing block .......................................................................................................................... 18
Disassembling the rear bearing block, oil seal and shaft bearings ................................................................ 18
Reassembly ................................................................................................................................................... 18
Refitting the bearing block ............................................................................................................................. 18
C . Shimming ..................................................................................................................................................... 19
D. Long shaft version ......................................................................................................................................... 20
E. Adjusting the control ...................................................................................................................................... 20
F. Service tools .................................................................................................................................................. 21
POWER TAKE-OFF - 1000 RPM SHAFT

General .............................................................................................................................................................. 22
Lubrication ......................................................................................................................................................... 22
Overall view ....................................................................................................................................................... 23
Exploded view .................................................................................................................................................... 24
A . Disassembling and reassemblying 1000 rpm pinion and bearing ................................................................ 25
Disassembling ............................................................................................................................................... 25
Reassembling ................................................................................................................................................ 25
Final operation ............................................................................................................................................... 25
B . Removing, refitting and disassembling, reassembling the rear bearing block, oil seal and shaft bearings .. 26
Removing the bearing block .......................................................................................................................... 26
Disassembling the rear bearing, oil seal and shaft bearings ......................................................................... 26
Reassembly ................................................................................................................................................... 26
Refitting the bearing block ............................................................................................................................. 26
C. Shimming ...................................................................................................................................................... 27
D. Long shaft version ......................................................................................................................................... 28
E. Service tools .................................................................................................................................................. 28
POWER TAKE-OFF- CLUTCH AND BRAKE

A. General .......................................................................................................................................................... 29
Operation ........................................................................................................................................................... 29
Clutched position ........................................................................................................................................... 29
Power take-off brake ..................................................................................................................................... 29
B. Removing and refitting the clutch .................................................................................................................. 35
Preliminary operation ..................................................................................................................................... 35
Removal ........................................................................................................................................................ 35
Refitting ......................................................................................................................................................... 36
SM 8-12340 Issued 03-2004

SECTION 6019 3
C. Disassembling and reassembling the clutch ..................................................................................................37

Preliminary operation .....................................................................................................................................37
Disassembly ...................................................................................................................................................37
Reassembly ...................................................................................................................................................37
D. Service tools ..................................................................................................................................................39
SM 8-12340 Issued 03-2004

4 SECTION 6019
POWER TAKE-OFF- DESCRIPTION
General
The PTO housing, fitted to the rear of the centre
housing, houses all mechanical components of the
rear PTO on the ZTX series tractors.
On tractors fitted with an AG250 Full Powershift

gearboxes, the engine speed is transmitted to the
PTO clutch by a shaftline comprising four shafts.
The first shaft is likewise driven via the vibration

damper fitted to the engine flywheel. The second
shaft, passing through the gearbox, is linked to the
third shaft by a sleeve and drives the hydraulic pump
drive pinion. As in the version mentioned above, the
last shaft is splined at the front on the hydraulic pump
drive pinion and at the rear on the PTO clutch.
Types of PTO available Figure 1
b. with a jaw coupler and short or long shaft with disc.

750 / 1000 rpm
c. with fixed coupler and shaft with disc. 1000 rpm
Type b. (Fig. 4)
The clutch unit is integral via splines with two pinions

that are constantly engaged with the 750 / 1000 rpm
pinions that rotate the PTO output shaft when the
coupler is either moved forwards, to the 750 rpm
position, or rearwards to the 1000 rpm position,
depending on the speed required.
Type c. (Fig. 5)
The clutch unit is integral via splines with a single

pinion that is constantly engaged with the 1000 rpm
pinion that rotates the PTO output shaft.
ATTENTION: In the type "c" a spacer replaces the 540

or 750 rpm drive pinion. The coupler is integral via splines
with the 1000 rpm drive pinion. It is held in place by a snap
ring located on the hub. This hub is itself immobilised by
another snap ring fitted on the output shaft.
When the clutch is disengaged and the control button

in the cab is placed in the "PTO brake" position, the
17 bar pressure acts upon piston (1) and it enters in
contact with the outside edge of unit (6) and thus
brakes its rotation (Fig. 1).
SM 8-12340 Issued 03-2004

SECTION 6019 5
Construction
The clutch, located on the upper shaftline, is

supported by two taper roller bearings. The bearing
cups are fitted in two carriers fixed to the PTO
housing and the bearing cones are positioned on two
spans inside the clutch housing.
The front bearing cone is force fitted on:
The 750 rpm pinion drive pinion (type "b" PTO)
The spacer (type "c" PTO)
The rear bearing cone is mounted free on all types.

The bearing clearance is adjusted by means of shims
placed between the two carriers.
The lower shaftline comprises: Figure 2

A unit fixed by bolts on the rear of the centre housing,
in which a roller bearing (type "a" PTO) is fitted.
On the other types, this bearing is force fitted,

preceded by an oil deflector, in the centre housing.
A rear bearing comprising two taper roller bearings;

their clearance is adjusted by shims placed between
the PTO housing and the bearing.
A cassette seal provides oil tightness for the bearing.
Depending on the type of PTO, the type of tool that is

to be driven and the recommended rotational speed,
the output shafts (Fig. 2) (removable or with
interchangeable end-piece) may be of different
lengths and have 6, 20 or 21 splines.
SM 8-12340 Issued 03-2004

6 SECTION 6019
Overall views
Type "b"
Figure 4
Type "c"
Figure 5
SM 8-12340 Issued 03-2004

SECTION 6019 7
DRIVING PINIONS - BEARINGS - LAYSHAFT
General Parts list

On tractors in the ZTX series, the layshaft, clutch,
bearings and driving pinion form the upper shaft line 1. Circlip
of the rear PTO. 2. Bearing cone
3. Bearing cup
The upper shaftline passes through the intermediate 4. Cover
and centre housings to then transmit the engine 5. Shims
speed to the driving pinions located in the rear 6. Unit housing
housing. 7. Bearing cone
8. Bearing cup
The layshaft is supported at the front by a bearing 9. Driving pinion
block mounted on two ball bearings housed in the 10. Spacer
bore of the intermediate housing and at the rear by 11. Driving pinion(s)
the clutch assembly (15) in which the driving pinions 12. Circlip
are integral via splines. 27. Bolt
28. Layshaft
On unit (23), the cups (3) (8) are free mounted in
their respective bores. The bearing cone (7) is
mounted free on the splined part of the clutch.
Depending on the type of PTO, the bearing cone (2)
is force fitted on:
the clutch unit (15)
the pinion (9)
the spacer (10)
Identification of the assemblies corresponding to the

types of PTO available
"b" : jaw coupler
"c" : 1000 rpm
SM 8-12340 Issued 03-2004

8 SECTION 6019
Overall view- front bearing with fullpowershift gearbox
Figure 1
SM 8-12340 Issued 03-2004

SECTION 6019 9
Exploded view
Figure 2
SM 8-12340 Issued 03-2004

10 SECTION 6019
A. Removing and refitting the driving pinion, bearings and layshaft

ATTENTION: Uncouple the PTO from the centre housing
(see section 6003) to carr y out maintenance on the
following components.
Driving pinion(s)
Unit housing ( 6 )
Cover ( 4 )
Bearings ( 2 ) ( 3 ) and ( 7 ) ( 8 ).
NOTE: If the layshaft (28) (Fig 1) mounted on

tractors fitted with Full Powershift transmission
has to be replaced, it is absolutely necessary to
remove the left-hand side hydraulic cover (see
section 8005) to gain access to circlip (1), since
this will not pass through the hole provided in the
wall of the intermediate housing. Before
removing the shaft, visually note its profile in
order to later pass the crownwheel of the bevel Figure 3
gear through.On tractors fitted with Heavy Duty
transmission, the layshaft does not have a circlip
(1).
Removal
STEP 1
Remove and separate the clutch (15) and unit (23)
assembly (See Page 35 ).
Assembly "b" (Fig. 2 - 4).
STEP 2
Remove pinion (9) and bearing cone (2). Take out
cup (3) from the cover (4).
STEP 3 Figure 4
Remove the cover and shim(s) (5).
STEP 4
Take out cup (8) from unit (6). Extract cone (2) (as
required).
Assembly "c" (Fig. 2)
On this type of assembly, the method is similar to that

used for assembly (b) type.
SM 8-12340 Issued 03-2004

SECTION 6019 11
Refitting
ATTENTION: If maintenance has been carried out on one
of the components stated at the beginning of this section,
it is important to carry out shimming of the bearings ( 2 ) ( 3 )
and ( 7 ) ( 8 ) (See Page 12 ).
Assembly "b"
STEP 5
If disassembled, place cups (3) and (8) in cover (4)
and unit (6) respectively.
STEP 6
Position pinion (11) in unit (6), the long offset
"D"turned to face cover (4) (Fig. 1 - 4).
STEP 7
Refit the shim(s) (5) (if adjustment is not necessary),
the cover (4) and bolts (27) on unit (6).
STEP 8
Using a press and an appropriate fixture, insert
bearing cone (2) in pinion (9).
Assembly "c"
In this type of assembly, assemble the components

using the assembly principle used in the (b) type
assembly.
STEP 9
Reassemble and refit clutch (15) and unit (23)
assembly (See Page 35).
SM 8-12340 Issued 03-2004

12 SECTION 6019
B. Shimming
Preparation for shimming
STEP 10
Assemble clutch (15) with unit (23) (See Page 35).
STEP 11
Fasten the cover (4) and the unit housing (6) with four
bolts (27) and nuts (14) that should be supplied
locally (Figs. 5 - 6). Hold the assembly (23) in a vice
fitted with soft jaws (Fig. 5).
Shimming (Fig. 5 – 6)
STEP 12
Place the index of a dial gauge on the end of the
sleeve (10).
STEP 13
Pull hard on the clutch unit while turning it
alternatively left and right in order to correctly seat
the cones in the cups.
STEP 14
Reset the dial gauge to zero.
STEP 15
Repeat operation 19, but this time by pushing.
STEP 16
According to the provisional clearance measured on
the dial gauge, determine a new thickness of shim(s)
(5) to obtain a definitive clearance (Fig. 6):
J1 = 0 to 0.10 mm.
Figure 6
Figure 5
SM 8-12340 Issued 03-2004

SECTION 6019 13
POWER TAKE-OFF- SHIFTABLE PTO SHAFT
General Par ts list
On tractors in the ZTX series, the driven pinions (7) 1. Locking ring
(18) are fitted on the PTO shaft located at the lower 2. Circlip
part of the rear housing. 3. Bearing cone
4. Castellated washer
These pinions are constantly engaged with the 5. Interchangeable end piece (shaft with disc)
driving pinions driven by the upper shaftline where 6. Bolt
the engine speed is transmitted via the PTO clutch. 7. 540 or 750 rpm driven pinion
8. Bearing cone
The PTO shaft is supported at the front by a roller 9. Protector
bearing (24) that is force fitted into the centre 10. Coupler
housing. It is free fitted in bearing cones (3) and (8) 11. Hub
of the rear bearing block (22). 12. Shaft
13. Bolt
Hub (11) of the coupler is integral with shaft (12) via 14. Cassette seal
splines. The pinions (7) (18) drive the shaft when 15. O-ring
coupler (10) is moved either forwards (750 rpm), or 16. Circlip
rearward (1000 rpm). When one of the pinions (7) 17. Circlip
(18) transmits movement to the lower layshaft, the 18. 1000 rpm driven pinion
other pinion is passive and idles on its shaft. 19. Bearing cup
20. Splined washer
A fork (31) fitted on pin (28) allows selection of the 21. Bearing cup
required speed (750 or 1000 rpm). This fork may be 22. Bearing block
controlled by an external lever located on the right- 23. Shim(s)
hand side of the housing or via a cable operated by 24. Roller bearing
a lever placed inside the cab. 25. Oil deflector
26. Locking ring
The oil tightness of the rear bearing block is ensured 27. O’ring
by cassette seal (14) and O-ring (15). 28. Pin
29. Pads
Bearing clearance is adjusted by shim(s) (23) 30. Set screw
inserted between the rear housing and bearing block 31. Fork
(22). 32. O-ring
33. Control link
The castellated washer (4), via its rotation, transmits 34. Bolt
information to the sensor (output speed of shaft (12) 35. Locating pin
and equally serves as a spacer for bearing cones (3) 36. Plug
(8).
Lubricating the pinions Identifying the controls (Fig. 1 - 2)

Lubrication is ensured by the transmission oil. The oil A. External control
splashed and held in deflector (25) lubricates roller B. nternal control via cable and lever
bearing (24) and taper roller bearings (3) (19) (8)
(21) via the shaft (12) which is fitted with an axial
channel and drilled radial ports.
SM 8-12340 Issued 03-2004

14 SECTION 6019
Overall View
750
Figure 1
SM 8-12340 Issued 03-2004

SECTION 6019 15
Exploded View
750
Figure 2
SM 8-12340 Issued 03-2004

16 SECTION 6019
A. Disassembling and reasembling 750 - 1000 rpm pinions, fork and bearing
NOTE: The removal of the PTO housing is necessary STEP 10

for all maintenance concerning the lower layshaft line,
Using an appropriate insertion drift, fit bearing (24)
except for the disassembly of the interchangeable
with the rounded cage facing the front end of shaft
shaft (5).The centre housing must be drained during
(12) and thrust against the deflector.
maintenance and refilled afterwards
Preliminary operation Reassembling pinions and fork

NOTE: If the locking ring (1) (not referenced in
STEP 1 the spare parts catalogue) is worn, replace the
Uncouple the PTO housing from the centre housing pinions (7) (18) (Fig. 3). The rings are bored and
(see section 6003). brought to the correct dimension after insertion.
Disassembling pinions and fork

STEP 2
Take off circlip (2) and splined washer (20).
STEP 3
Remove the clutch (15), unit (23) and pinion (7)
assembly (See Page 35).
STEP 4
Take out set screw (30). Remove pin (28), link (33)
and the fork fitted with its pads (29).
STEP 5
Figure 3
Take off the locking ring (26), hub (11) and coupler
(10); locking ring (1) and driven pinion (18).
STEP 11
STEP 6 Lubricate the ring (1) of pinion (18) (Fig. 3). Slide the
pinion on to shaft (12).
Take off and discard the O-rings (27) (32) on pin (28).
STEP 12
Disassembling bearing
Assemble the locking ring (1).
(24)
STEP 13
STEP 7
Assemble the hub assembly (11), coupler (10) and
Where necessary, note the direction of bearing (24) fork (31) assembly with the pads (29) smeared with
and then extract it from the centre housing using an miscible grease. Fit new O-rings (27) (32) on pin (28)
inertia tool. Remove deflector (25). and slide it through the bores of the PTO housing.
Reassembling the bearing STEP 14

Position the fork. Fit and tighten the set screw (30)
STEP 8 previously lightly smeared with Loctite 241. Fit ring
Clean the components. Replace any parts found to (26).
be defective. Check that the oil channels in shaft (12)
are not obstructed. STEP 15
Lubricate ring (1) of pinion (7) (Fig. 3).
STEP 9
Position deflector (25) in the bore of the centre
housing in accordance with Fig. 1.
SM 8-12340 Issued 03-2004

SECTION 6019 17
STEP 16
Slide pinion (7) on to shaft (12). Refit the clutch (15)
and unit (23) assembly (See Page 35). Place washer
(20) and fit circlip (2).
STEP 17
Manually check the rotation of the mechanical
assemblies.
STEP 18
Assemble link (33). Tighten bolt (34).
STEP 19
Using either the external control or the control
located inside the cab, check that coupler (10)
engages correctly on the 1000 rpm or 750 - 1000 rpm
pinions.
Final operation
STEP 20
Couple the PTO housing to the centre housing (see
section 6003).
SM 8-12340 Issued 03-2004

18 SECTION 6019
B. Removing, refitting and disasembling, reassembling the rear bearing

block, oil seal and shaft bearings
Removing the bearing block STEP 29

STEP 21 found to be defective. Check that the oil channels in
Disassemble the 1000 rpm or 750 - 1000 rpm pinions shaft (12) are not obstructed.
(see Page 16).
STEP 30
STEP 22 Before assembly of seal (14), see note on Page 19.
Take out the sensor (shaft output speed (12)) located Lightly smear the external diameter of the seal with
on the right-hand side of the housing. Loctite 542. Using a press and tool, ref. 3378115M1
(see Page 21), insert the cassette seal into bearing
block (22) with the lip turned to face bearing cone (8).
STEP 23
Remove bolts (13), pull on the interchangeable end STEP 31
piece (5) and take out the bearing block assembly
(22) comprising of: Lubricate the internal diameter of seal (14) with
transmission oil. Insert shaft (12) in the seal of
Oil seal (14). bearing block (22).
O-ring (15).
STEP 32
Shim(s) (23).
Place circlip (16), refit cup (21), bearing cone (8),
Bearing cups (3) (8). castellated washer (4) and bearing cone (3). Fit
Castellated washer (4). circlip (17).
STEP 24 Refitting the bearing block

Take cup (19) out of the housing.
STEP 33
Disassembling the rear bearing Refit cup (19) and shaft (12) previously assembled
with bearing block (22), the bearings and O-ring (15)
block, oil seal and shaft bearings and place in the bore of the PTO housing.
STEP 25 STEP 34
Take off circlip (17), remove the bearing cone (3), Place and tighten bolts (13) to a torque of 72 - 96 Nm.
castellated washer (4), cone (8), cup (21) and circlip
(16).
STEP 35
STEP 26 Refit the 540 - 1000 rpm or 750 - 1000 rpm pinions
and fork (see Page 16).
Separate bearing block (22) from shaft (12).
STEP 36
STEP 27
Couple the PTO housing and the centre housing (see
Extract cassette seal (14) and take off O’ring (15). section 6003).
STEP 28 STEP 37
If needed, take out bolts (6) and remove the Refit the sensor fitted with its O-ring.
interchangeable end-piece (5) (Fig. 1).
STEP 38
Reassembly
If the interchangeable end-piece (5) has been
disassembled, check for the presence of locating pin
ATTENTION: If the PTO housing, bearing block ( 22 ),
(35). Refit the end-piece. Lightly smear the threads
bearings ( 3 ) ( 19 ) ( 8 ) ( 21 ) or castellated washer ( 4 ) has
of bolt (6) with Loctite 241 and tighten it to a torque
been replaced, carry out shimming of the bearings (see
of 120 - 140 Nm.
Page 19).
SM 8-12340 Issued 03-2004

SECTION 6019 19
C . Shimming
(Fig. 4 – 5)
NOTE: The shimming of bearings (3) (19) (8)

(21) must be carried out before fitting seal (14).
STEP 39
Using a depth gauge, measure dimension A on the
PTO housing.
STEP 40
On shaft (12) fit: bearing block (22), circlip (16), cup
(21), cone (8), castellated washer (4), cone (3) and
circlip (17).
STEP 41
Place the shaft and bearing block (22) assembly in
thrust on a suitable fixture. Using another operator,
press hard on the rim of cup (19) in a continuous
manner. At the same time, turn the shaft left and right
to seat the cones in their cups. Measure dimension
B at two diametrically opposed points. Use the
average of the two measurements.
STEP 42
Apply the formula: B - A
Place a thickness of shim(s) (23) to obtain a

clearance (Fig. 5) of:
J1 = 0.05 mm to 0.15 mm
Figure 4
Figure 5
SM 8-12340 Issued 03-2004

20 SECTION 6019
D. Long shaft version E. Adjusting the control

The removal of the long shaft is identical to the On link B (Fig. 8)
interchangeable end-piece version.
STEP 43
The long shaft is centred by a locating pin (35) and
fixed by bolts (6) to shaft (12) (Fig. 6). Turn link B towards the front of the tractor in the 1000
rpm position.
STEP 44
Screw yoke (9) flush with the threaded part of cable
(6).
STEP 45
Fit yoke (9) on link B using clip (10). Tighten nut (11).
STEP 46
Adjust the threaded sheath end (12) on bracket (8)
using nut (13), taking care that link B does not move.
STEP 47
Tighten nut (14) while checking that the cable is not
constrained.
Figure 6
STEP 48
Check the operation of the control lever in the
position 750 rpm.
Figure 8
SM 8-12340 Issued 03-2004

SECTION 6019 21
F. Service tools
Tool available in the McCormick network
-3378115M1 - Tool for fitting cassette seal (14) on

the PTO bearing block (Fig. 9).
Figure 9
SM 8-12340 Issued 03-2004

22 SECTION 6019
POWER TAKE-OFF - 1000 RPM SHAFT
General Par ts list
Certain types of tractors in the ZTX series may be 1. Locking ring

fitted with a 1000 rpm PTO. 2. Circlip
3. Bearing cone
The driven pinion (18) is fitted on the PTO shaft 4. Castellated washer
located at the lower part of the rear housing. 5. Interchangeable end-piece (shaft with disc)
6. Bolt
This pinion is constantly engaged with the driving 8. Bearing cone
pinion driven by the upper shaft line where the 9. Protector
engine speed is transmitted via the PTO clutch. 10. Coupler
11. Hub
The PTO shaft is supported at the front by a roller 12. Shaft
bearing (24) that is force fitted into the centre 13. Bolt
housing. It is mounted free in the bearing cones (3) 14. Cassette seal
(8) of the rear bearing block (22). 15. O-ring
16. Circlip
The hub (11) is integral with shaft (12) via splines. 17. Circlip
Rotation is transmitted to the driven pinion (18) via 18. 1000 rpm driven pinion
the coupler (10). This coupler is held in position 19. Bearing cup
permanently by circlip (2). 21. Bearing cup
22. Bearing block
The oil tightness of the rear block is provided by 23. Shim(s)
cassette seal (14) and O-ring (15). 24. Roller bearing
25. Oil deflector
The clearance of the bearings is adjusted by shim(s) 26. Locking ring
(23) inserted between the rear housing and bearing 35. Locating pin
block (22). 36. Plugs
During rotation, the serrated washer (4) transmits

information to the output shaft speed sensor (12) and
equally serves as a spacer between bearing cones
(3) and (8).
Lubrication
Lubrication is provided by the transmission oil. The
projected oil is held in deflector (25) and lubricates
roller bearing (24) and bearing cones (3) (19) (8) (21)
via the intermediary of shaft (12) that contains an
axial channel and radial drilled ports.
SM 8-12340 Issued 03-2004

SECTION 6019 23
Overall view
Figure 1
SM 8-12340 Issued 03-2004

24 SECTION 6019
Exploded view
Figure 2
NOTE: The removal of the PTO housing is

necessary for all maintenance operations on the
lower shaftline, apar t from the disassembly of the
interchangeable shaft (5). The centre housing
must be drained and then brought back up to
level after the maintenance operation.
SM 8-12340 Issued 03-2004

SECTION 6019 25
A . Disassembling and reassemblying 1000 rpm pinion and bearing

STEP 1 STEP 11
Uncouple the PTO housing from the centre housing Check for the presence of circlip (2) and fit locking
(see section 6003). ring (26).
Disassembling STEP 12
Check the presence of plugs (36) Figs. 1 - 2).
STEP 2
Take off locking ring (26). Slide hub (11) and coupler Final operation
(10) along shaft (12). Take off pinion (18).
STEP 13
STEP 3 Couple the PTO housing to the centre housing (see
Where necessary, visually locate the direction that section 6003).
bearing (24) is fitted and then extract it from the
centre housing using an inertia tool.
STEP 4
Remove the deflector (25).
Reassembling
STEP 5
Clean the components. Replace any parts found to
be defective. Check that the channels in shaft (12)
are not obstructed.
STEP 6
Position deflector (25) in the bore of the centre
housing in accordance with Fig. 1.
Figure 3
STEP 7
Using an appropriate insertion tool, fit bearing (24)
thrust against the deflector, with the rounded part of
the cage turned towards the front end of the shaft
(12).
NOTE: If the locking ring (1) (not referenced in

the spare part catalogue) is worn, replace pinion
(18) (Fig. 3). The ring is bored to the correct
dimension after insertion.
STEP 8
Lubricate locking ring (1) of pinion (18) (Fig. 3). Slide
the pinion on the shaft (12).
STEP 9
Fit locking ring (1)
STEP 10
Fit the hub assembly (11) and coupler (10).
SM 8-12340 Issued 03-2004

26 SECTION 6019
B . Removing, refitting and disassembling, reassembling the rear bearing

block, oil seal and shaft bearings
Removing the bearing block STEP 21

STEP 14 found to be defective. Check that the oil channels in
Disassemble the 1000 rpm pinion. (See Page 25). shaft (12) are not obstructed.
STEP 15 STEP 22
Take out the speed sensor (output shaft (12) speed Before fitting seal (14), (see note on Page 27) lightly
sensor) located on the right-hand side of the smear the external diameter of the seal with Loctite
housing. 542. Using a press and tool, ref. 3378115M1 (see
Page 21), insert the cassette seal in bearing block
(22) with its lip turned to face bearing cone (8).
STEP 16
Remove bolts (13), pull on the interchangeable end STEP 23
piece (5) and take out the bearing block assembly
(22) comprising: Lubricate the inside diameter of seal (14) with
transmission oil. Insert shaft (12) in the seal of
Oil seal (14) bearing block (22).
O-ring (15) STEP 24

Shim(s) (23) Fit circlip (16), refit cup (21), bearing cone (8),
Cups (19) (21) castellatedwasher (4), bearing cone (3). Fit circlip
(17).
Bearing cones (3) (8)
Castellated washer (4) Refitting the bearing block
STEP 17 STEP 25
Take cup (19) out of the housing. In the bore of the PTO housing, refit cup (19) and
shaft (12) previously assembled on bearing block
Disassembling the rear bearing, oil (22), along with the bearings and o’ring (15).
seal and shaft bearings STEP 26
STEP 18 Place and tighten bolts (13) to a torque of 72 - 96
Nm.
Take off circlip (17), remove bearing cone (3),
castellated (4), bearing cone (8), bearing cup (21)
STEP 27
and circlip (16).
Refit the 1000 rpm pinion (See Page 25).
STEP 19
STEP 28
Separate bearing block (22) from shaft (12).
STEP 20 section 6003).
Where necessary, take out bolts (6) and remove the

STEP 29
interchangeable end piece (5) (Fig. 1).
Refit the sensor with its o’ring.
Reassembly
STEP 30
ATTENTION: If replacement is necessary of the PTO If removing of the interchangeable end-piece (5) is
housing, bearing block ( 22 ), bearings ( 3 ) ( 19 ) ( 8 ) ( 21 ) or necessary, check for the presence of locating pin
castellated washer ( 4 ), carry out shimming of the bearings (35). Refit the end-piece. Lightly smear the threads
(See Page 27). of bolts (6) with Loctite 241 and tighten them to a
torque of 120 - 140 Nm.
SM 8-12340 Issued 03-2004

SECTION 6019 27
C. Shimming
NOTE: The shimming of bearings (3) (19) (8)
(21) must be carried out before fitting seal (14).
STEP 31
Using a depth gauge, measure dimension A on the
PTO housing.
STEP 32
On shaft (12), fit: bearing block (22), circlip (16), cup
(21), cone (8), castellated washer (4), cone (3) and
circlip (17).
STEP 33
Place the shaft and bearing block assembly (22) to
thrust against a locally manufactured fixture. Using
another operator, apply strong pressure around the
rim of cup (19) in a sustained manner. At the same
time turn the shaft alternately left and right in order
to correctly seat the bearings in their cups. Measure
dimension B at two diametrically opposed points.
Calculate the average of the two measurements.
STEP 34
Use the formula: B - A.
Place a thickness of shims (23) to obtain a clearance

of: J1 = 0.05 mm to 0.15 mm
Figure 4
Figure 5
SM 8-12340 Issued 03-2004

28 SECTION 6019
D. Long shaft version

The removal of the long shaft is identical to that of the
interchangeable end-piece.
The long shaft is centred by locating pin (35) and

fixed by bolts (6) on shaft (12) (Fig. 6).
Figure 6
E. Service tools
Tool available in the McCormick network.
- 3378115M1 - Tool for inserting cassette seal (14)

on the PTO shaft (Fig. 7)
Figure 7
SM 8-12340 Issued 03-2004

SECTION 6019 29
POWER TAKE-OFF- CLUTCH AND BRAKE
A. General Power take-off brake

On the ZTX series tractors, the PTO clutch is fitted in (Fig. 1)
the rear housing and driven by the upper shaftline .
When the supply to the PTO clutch is halted, spring
Depending upon the type of tractor, the clutch (8) pushes piston (19) against unit (6).
contains a different number of clutch plates and
intermediate plates. The pressure is then directed towards the PTO brake
and moves piston (1) which presses against the
ZTX tractors external periphery of unit (6) thus braking the driving
pinion (11) or (9) (if fitted) (Figs. 4 - 5) that is integral
7 clutch plates, 7 intermediate plates with the clutch housing via splines.
The clutch assembly comprises: A channel communicating with piston chamber (1)
provides lubrication to the rim of unit (6) and the
A clutch unit (6) supported by two taper roller forward face of the piston during its travel.
bearings
The cylinder of piston (1) (Fig. 1) is positioned on the
A sleeve (10) centred by a ring in the rear housing centre housing by Mecanindus pins.
and by a ball bearing (13) inserted in hub (1). It has
two lubricating channels:
A central channel for the bearings

An axial channel for piston (19)
A hub (1) supporting the clutch plates (4)
A cover (2) that receives the intermediate plates.
Operation
Clutched position
The clutch is supplied via the PTO proportional
solenoid valve by the 17 bar hydraulic circuit located
on the right-hand side cover and by an external pipe
connected to the rear housing of the PTO.
Oil enters unit (6) via channels a, c and chamber b Figure 1

(Fig. 2). It pushes piston (19) that then compresses
clutch plates (4) against the intermediary plates (3).
The latter are integral with cover (2) via tabs and
bolts (16). Clutch plates (4) are integral with hub (1)
via splines. The movement is transmitted to driving
pinions (11) (9) (Fig. 4 - 5), depending on the type of
PTO, via shaft (28) housed in hub (1).
In the clutched position, the brake piston (1) of the

PTO located in the centre housing is at rest and this
frees clutch unit (6) (Fig. 1) allowing the 540 rpm -
1000 rpm pinions to turn freely. When the clutch is
engaged, oil from the lubricating circuit coming from
channel d cools and lubricates the clutch plates
(Fig. 2).
SM 8-12340 Issued 03-2004

30 SECTION 6019
Parts list (Fig. 2 - 3)

1. Drive hub
2. Cover
3. Intermediate plates
4. Clutch plates
5. Progressivity washer
6. Clutch housing
7. Valve
8. Spring
9. O-ring
10. Sleeve
11. Bolt
12. Chamfered washer
13. Ball bearing
14. Circlip
15. Clutch assembly
16. Bolt
17. Spring seat
18. O-ring
19. Piston
20. Support
21. O-ring
22. Seal rings
28. Intermediate shaft
29. Reducer
30. Threaded plug
31. Deflector
SM 8-12340 Issued 03-2004

SECTION 6019 31
Overall view
Figure 2
SM 8-12340 Issued 03-2004

32 SECTION 6019
Exploded view
Figure 3
SM 8-12340 Issued 03-2004

SECTION 6019 33
Figure 5
Figure 6
SM 8-12340 Issued 03-2004

34 SECTION 6019
Figure 7
SM 8-12340 Issued 03-2004

SECTION 6019 35
B. Removing and refitting the clutch
STEP 1
Remove the PTO housing
(see section 6003). Remove the sensor located on
the upper right-hand side of the PTO housing.
Removal
PTO with jaw coupler (Fig. 5)
STEP 2
Take off circlip (2) and splined washer (20).
STEP 3
Figure 8
Remove bolts (27).
STEP 4
Disengage the clutch (15), unit (23) and pinion (7)
assembly.
1000 rpm PTO
ATTENTION: To remove the clutch on this type of PTO,

no operations need be carried out on the lower shaftline.
STEP 5
Remove the seal rings (22) (Fig. 8).
STEP 6
Using a press, an "S" support and service tool, ref.
3378135M1 (See Page 39), moderately compress
the Belleville washer (24) until the recess of snap
ring (26) groove can be reached. Remove the snap
ring and washer (25) while noting their positioning for
later reassembly, then the Belleville washer.
Separation of the assembly (15) (23)

STEP 7
Separate the clutch (15) and unit (23) assembly (Fig.
6 - 7, depending on the type of PTO). Remove the
bolts (27).
Check
STEP 8
Figure 9
Check that the hydraulic channels in the PTO
housing are not obstructed.
SM 8-12340 Issued 03-2004

36 SECTION 6019
NOTE: If disassembled, using an appropriate STEP 17

insertion drift, position ring (5) (Fig. 10) according to
Place washer (20) and assemble circlip (2). On each
the dimension 16 mm ± 0.1 mm measured between
type of PTO, manually check the rotation of the
the thrust face of the PTO housing and the end of
mechanical assembly.
ring (5) (Fig. 4 or 5) and in such a manner that the
machined groove on the outside of the ring matches
the 17 bar channel of the PTO housing. Final operations
Reassembling assembly STEP 18

(15) (23) Lightly smear the threads of the upper sensor with
Loctite 577 (Sensor Sealing or equivalent).
Assemble and adjust the sensor:
STEP 9
Place bolts (27) on unit (23). Assemble clutch (15) Screw the sensor fully home without forcing it until it
and unit (23) (Fig. 6 or 7). touches the driving pinion,
Unscrew the sensor by 3/4 turn
STEP 10
Moderately tighten the lock nut.
Fit a new Belleville washer (24) respecting its
assembly direction, then fit washer (25) turning the STEP 19
countersinking towards snap ring (26).
section 6003). Test the clutch and its brake.
STEP 11
Slide the new snap ring (a new snap ring must be
fitted) on sleeve (10) opening its diameter to the
minimum.
STEP 12
Compress the washer as in operation 10. Fit and
correctly position the snap ring in the countersunk
washer (25).
STEP 13
Place the seal rings (22) in their grooves and hook
their ends (Fig. 8). After assembly, check that they
rotate freely.
Refitting
IMPORTANT: In order to facilitate the refitting of Figure 10
the clutch assembly, tilt the PTO housing, with
the inside face turned upwards.
STEP 14
Lubricate the seal rings with transmission oil
PTO with jaw coupler (Fig. 5)
STEP 15
With the help of another operator, refit the assembly
(clutch (15) and unit (23) accompanied by pinion (7)).
STEP 16
Tighten bolts (27) to a torque of 50 - 70 Nm.
SM 8-12340 Issued 03-2004

SECTION 6019 37
C. Disassembling and reassembling the clutch
Preliminary operation STEP 28

Replace and lubricate the O-rings (9) (18) (21).
STEP 20
Remove and separate the clutch (15) and unit (23) STEP 29
(See Page 35). Lubricate sleeve (10) and piston (19) and insert it in
unit (6) by tapping it moderately around the rim with
Disassembly a plastic hammer.
STEP 21 STEP 30
Tighten unit (6) in a vice fitted with soft jaw If disassembled, insert bearing (13) in hub (1). Fit
protectors. circlip (14).
STEP 22 STEP 31
Take out bolts (16). Separate the unit from the cover Refit progressivity washer (5) in accordance with the
(2). Remove clutch plates (4) and intermediate plates overall view, support (20), spring (8), spring seat (17)
(3). and drive hub (1).
STEP 23
Using a locally manufactured tool (See Page 39),
hold the hub (1). Take out bolts (11) and washer (12).
Release spring (8) (Fig. 11). Remove the tool.
STEP 24
Remove the drive hub (1), spring seat (17), spring
(8), support (20) and progressivity washer (5).
STEP 25
Where necessary, take off circlip (14) and extract
bearing (13).
STEP 26
Using a compressed air jet, drive out piston (19) and
take off the O-rings (9) (18) (21).
Figure 11
Reassembly
STEP 32
NOTE: Valve (7) is crimped in unit (6). The
restrictor (29) is placed in sleeve (10). The Compress the spring using the previously used tool,
bearing cone E is force fitted (Fig. 2). The sleeve foit washer (12) and bolt (11) (Fig. 11) lightly
(10), previously lightly smeared with Loctite 648, smeared with Loctite 241. Tighten to a torque of 24-
is fitted by press. If disassembly was necessary, 28 Nm.
on reassembly check that the 17 bar and
lubrication channels are not obstructed by
Loctite. Threaded plug (30) is lightly smeared
with Loctite 542 or equivalent.
STEP 27
SM 8-12340 Issued 03-2004

38 SECTION 6019
STEP 33
Assemble the intermediate plate on hub (1), placing
the tabs T between the drilled holes V and
alterbnating them wuith previously lubricated clutch
plates (Fig. 12).
Figure 12
Remark. Depending on the type of tractor, the
numver of clutch plates and intermediate plates
differs.
STEP 34
Positon cover (2). Fit bolts (16) the threads lightly
smeared with Loctite 242 and tighten to a torque of
25.5 - 34.5 Nm.
STEP 35
Manally check that the hub turns freely.
Final Operations
STEP 36
reconstitute and refit the clutch assembly (15)(23)
(See Page 35)
STEP 37
section 6003)
SM 8-12340 Issued 03-2004

SECTION 6019 39
D. Service tools
Tool availiable in McCormick network
-3378135M1 - Belleville washer (24) compression

sleeve (Fig. 13).
Figure 13
Locally manufactured tool
clutch spring holding tool (Fig. 14).
Figure 14
SM 8-12340 Issued 03-2004

6021
Section
6021
FRONT AXLE
ZTX Series Tractors
20.49 Axle

SM 8-12431 March 2004 (Revised September 2004)
2 SECTION 6021
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUES ............................................................................................................................................... 4
SPECIAL TOOLS ..................................................................................................................................................... 5
GENERAL INFORMATION ...................................................................................................................................... 8
PLANETARY GEAR
Removal and Installation...................................................................................................................................... 8
Disassembly and Assembly ................................................................................................................................. 9
WHEEL HUB
Disassembly....................................................................................................................................................... 10
Assembly ........................................................................................................................................................... 13
AXLE BEAM
Disassembly....................................................................................................................................................... 16
Assembly ........................................................................................................................................................... 18
DIFFERENTIAL SUPPORT
Disassembly....................................................................................................................................................... 19
Assembly ........................................................................................................................................................... 22
DIFFERENTIAL
Disassembly....................................................................................................................................................... 26
Assembly ........................................................................................................................................................... 28
PINION
Disassembly....................................................................................................................................................... 30
Assembly ........................................................................................................................................................... 32
TOE-IN AND STEERING ANGLE

Toe-in adjustment .............................................................................................................................................. 35

Steering angle adjustment ................................................................................................................................. 37
SM 8-12431 Issued 09-2004

SECTION 6021 3
SPECIFICATIONS
DIFFERENTIAL
Pinion Bearing Pre-load..........................................................80 to 120 N 18 to 27 lb f
Pinion Bearing and Differential
Bearing Total Pre-load.......................................... 80 (+95) to 120 (+115) N 18 (+21.3) to 27 (+25.8) lb f
Bevel Gear Backlash ...................................................... 0.18 to 0.23 mm 0.007 to 0.009 inch
Shim Thickness for Pinion Height Setting...... 2.5 (min.) to 3.4 mm (max.) 0.098 (min.) to 0.134 inch (max.)
LUBRICANTS
Grease ..................................................................................................................... Multi-purpose Lithium Grease
MFD Axle Pivot Pin ................................................................................................... Loctite Anti Seize Compound
MFD Axle Capacities
Type ......................................................................................................................... SAE 85W-140 EP Gear Oil
Planetary ..............................................................................................................................................1.9 Litres
Differential .............................................................................................................................................10 Litres
Front Wheel Toe-In (Axle Fully Lowered) ........................................................................................................... 2 mm
SM 8-12431 Issued 09-2004

4 SECTION 6021
SPECIAL TORQUES
Pinion Shaft Nut ........................................................................................... Refer to SPECIFICATIONS for Pre-load
Differential Housing to Axle Bolt..................................................................169 Nm 125 lb ft
Locking Plate Bolt..........................................................................................13 Nm 10 lb ft
Ring Gear to Differential Housing Bolt with Loctite 542 ..............................190 Nm 140 lb ft
Breather Plug ................................................................................................10 Nm 7 lb ft
Oil Fill/Level Plugs .........................................................................................80 Nm 59 lb ft
Differential Bearing Cap Bolt .......................................................................413 Nm 304 lb ft
King Pin Retaining Bolt................................................................................300 Nm 221 lb ft
Steering Stop Locknut .................................................................................150 Nm 111 lb ft
Steering Cylinder to Differential Support Bolt..............................................120 Nm 89 lb ft
Ball Joint on Steering Cylinder ....................................................................300 Nm 221 lb ft
Track Rod Locknut.......................................................................................250 Nm 185 lb ft
Ball Joint to Swivel Housing Locknut...........................................................250 Nm 185 lb ft
Planetary Gear to Swivel Housing Bolt .......................................................220 Nm 162 lb ft
Wheel Stud with Loctite 542..........................................................................70 Nm 52 lb ft
Planetary Gear Carrier to Wheel Hub Screw ................................................25 Nm 18 lb ft
Front Weight Frame Bolts............................................................................425 Nm 314 lb ft
Front Wheel Nuts .............................................................................530 to 570 Nm 391 to 420 lb ft
MFD Axle Retaining Bolts ................................................................570 to 645 Nm 420 to 475 lb ft
Planetary Gear Retaining Bolt.......................................................................75 Nm 55 lb ft
Pinion Flange Bolt .......................................................................................139 Nm 102 lb ft
SM 8-12431 Issued 09-2004

SECTION 6021 5
SPECIAL TOOLS
The special tools used to fit seals, bearings and bushes should always be used with the interchangeable handle
CA119033 and a suitable safety handle to protect the hands.
CA119033 CA119196
CA715039
CA119053
CA715042
CA119060
SM 8-12431 Issued 09-2004

6 SECTION 6021
CA715118 CA715270
CA715266 CA715271
CA715268
CA715272
CA715269 CA715278
SM 8-12431 Issued 09-2004

SECTION 6021 7
CA715422 CA715512
CA715423 CA715528
CA715428
CA715739
CA715433
SM 8-12431 Issued 09-2004

8 SECTION 6021
GENERAL INFORMATION
NOTE: It is not necessary to remove the MFD Axle to service the following components:
• Planetary Gear Assembly, refer to Page 8.
• Wheel Hub, refer to Page 10.
• Steering cylinder, refer to section 5002.
• Some of the photographs and illustrations may not show your axle, but the procedure is the same.
PLANETARY GEAR

NOTE: Steps are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Planetary Gear assembly it will be necessary to carry out the following:
• Park the tractor on hard level ground, apply the parking brake.
• Loosen the front wheel nuts. Use a hydraulic jack under the centre of the front axle, raise the tractor and support
the tractor on suitable axle stands. Remove the front wheels.
NOTE: Before draining the oil, loosen the axle breather to release any internal pressure.
STEP 1 STEP 2
2
3
1
DP99C254 DP99C254
Turn the wheel hub until the drain/level plug (1) is at Remove the two countersunk screws (2) and remove
the bottom. Put a container with a capacity of at the planetary carrier assembly (3). Remove and
least 2.0 Litres under the wheel hub, remove the discard the o-ring from the planetary carrier
drain/level plug (1) and drain the oil. assembly.
NOTE: For Installation, turn the wheel hub until NOTE: For Installation, install a new o-ring onto
the drain/level plug is in the horizontal position. the planetary carrier.
Fill the hub to the correct level with the correct
NOTE: For Installation, tighten the screws (2) to
grade of oil, refer to Specifications, Page 3.
a torque of 25 Nm.
Install the drain/level plug (1) and o-ring, tighten
to a torque of 80 Nm. NOTE: For Installation, follow the same
procedure in reverse order.
SM 8-12431 Issued 09-2004

SECTION 6021 9
Disassembly and Assembly

NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
5 4
6
7
75 NM
8 1 (55 LB FT)
2
3
DS99D050
1. RETAINING BOLT 5. PLANETARY GEAR

2. WASHER 6. NEEDLE ROLLER BEARINGS
3. THRUST WASHER 7. THRUST WASHER
4. RETAINING PIN 8. HUB
STEP 3 STEP 6
Put identification marks on planetary gears (5) and
shafts. 8
STEP 4
Remove retaining bolt (1), washer (2), thrust
washer (3) and retaining pin (4). Remove planetary B
gear (5), needle roller bearings (6) and thrust C
washer (7). Repeat the procedure for the remaining
planetary gears.
NOTE: For Assembly, tighten the retaining bolt
(1) to a torque of 75 Nm (55lb ft).
STEP 5 Only remove bushes (B) and washers (C) if they

Clean all parts in cleaning solvent, and dry with require replacing. Removing them is a destructive
compressed air. Face protection MUST be worn. operation.
Check all components for wear or damage and NOTE: When fitting new bushes (B) apply heat to
replace as necessary. them of 120 o C for 5 minutes
NOTE: For Assembly, follow the Disassembly
SM 8-12431 Issued 09-2004

10 SECTION 6021
WHEEL HUB
Disassembly
Before Disassembly of the Wheel Hub it will be necessary to carry out the following:
• Remove the Planetary Gear Assembly, refer to Page 8.
• Some of the following pictures may not show your axle but the procedure is the same
21
26
19 25
20
14
24
23
11 22
18
9
8 13 17
12
5 16
10
2 7 15
1
6 220 NM (162 LB FT)
STEP 1 STEP 2
8
Using suitable circlip pliers remove circlip (1) and Remove the retaining bolts (6) from the wheel
washer (2). carrier (8).
NOTE: for installation tighten the retaining bolts
(6) to 220 Nm (162 lb ft).
SM 8-12431 Issued 09-2004

SECTION 6021 11
STEP 3 STEP 6
6 13
8 A
11
DP96M054
To remove the wheel carrier (8) and ring gear (5) Position the wheel hub (11) on a flat surface and
screw two of the retaining bolts (6) into the threaded take out the seal (13) with a lever
holes (A) and tighten evenly.
NOTE: This is a destructive operation for the seal.
STEP 4 STEP 7
9
10
7
12
5 8
DI99D052
Remove the steel lock ring (9) and separate the
Remove bearing cups (10) and (12) on both sides of
wheel carrier (8) from the ring gear (5). If
the hub using a hammer and suitable drift. Remove
necessary, remove the centering bushes (7) with a
bearing cone (12) from swivel housing (14).
hammer and special tool CA715278.
STEP 8
STEP 5
14 21
11
9
10
14
15 16
Install suitable lifting equipment to swivel housing

Remove bearing cone (10) and wheel hub (11). (14). Remove retaining bolts (21) from the upper
king pin (20) and retaining bolts (15) from lower
king pin (16).
SM 8-12431 Issued 09-2004

12 SECTION 6021
STEP 9 STEP 11
Remove the kin pins (20),(16) and the belleville
washers (19) and (18).
STEP 10
14
26
14
Position the swivel housing (14) on a flat surface

and with a suitable drift remove bush (25), take out
seal (26) with a lever.
Remove the swivel housing (14) from the axle
beam.
SM 8-12431 Issued 09-2004

SECTION 6021 13
Assembly
STEP 1 STEP 3
19
17
14 16
23
24
22 18
If steering stop has been removed, reassemble bolt

If cone (17) has been removed, reassemble it to the
(24) with nut (23) and spacers (22). Make sure
lower king pin (16) using special tool CA715042
spacers are between nut (23) and swivel housing (14).
under a press. Grease the king pin housings (16)
and (20) with specific grease. position the belleville
STEP 2 washers (18) and (19) on the king pin (16) and (20)
housings.
14 STEP 4
21
20
14
Using special tool CA715423 fit bush (25) into swivel 16

housing (14). Fit new seal (26) with special tool
CA715428.
Secure the swivel housing (14) with a belt or a rope
to a hoist or any other supporting device. Protect
the splined end of the axle shaft with adhesive tape
and to avoid damage to the seal (26). Assemble
swivel housing on axle beam (14) and remove
adhesive tape. Assemble king pins (16), (20) and
tighten bolts (15) and (21) to a torque of 300Nm
(221lb ft).
NOTE: Make sure that the belleville washers
(18) and (19) remain in their position
SM 8-12431 Issued 09-2004

14 SECTION 6021
STEP 5 STEP 8
11 8
Fit bearing cups (10) and (12) to the wheel hubs Assemble the wheel carrier (8) and the epicyclic
(11) using special tool CA715528 under a press or ring gear (5) with locking ring (9).
a hammer. Insert seal 13 using special tool
CA715528 and a hammer. STEP 9
STEP 6
14
12 10
11
Assemble the wheel carrier on to the wheel hub

(11) using the two projecting bushes (7) as dowel
Assemble the bearing cone (12) and the wheel hub pins and screw in relative bolts 6 to secure the
(11) on to the swivel housing (14). Place bearing wheel carrier to the hub.
cone (10) into position.
STEP 10
STEP 7
7 6
7
8
Using a hammer and special tool CA715278,
Position wheel carrier (8) on a workbench and if the correctly fit all bushes (7) to the carrier. Assemble
bushes (7) have been removed, assemble them into all the bolts (6) and tighten to a toque of 220 Nm
the carrier with special tool CA715278. (162 lb ft).
NOTE: Two of the bushes (7) (diametrically
opposed) must be set slightly higher than the
carrier surface level to be used as dowel pins.
SM 8-12431 Issued 09-2004
SECTION 6021 15
STEP 11 STEP 12
1 2
Insert a lever into the universal joint between the Slide thrust washer (2) on to shaft and fit retaining
axle beam and swivel housing. Lever the universal ring (1) making sure it is correctly seated.
joint in the direction of the final drive to make it
easier to fit the retaining ring.
SM 8-12431 Issued 09-2004

16 SECTION 6021
AXLE BEAM
Disassembly
2 3
5
11
1
6
8
9
10
STEP 1 STEP 2
1 11
1
6
8
9
10
7
9
Remove the double universal joint (10) from the Remove seal (9) with a suitable lever.
axle beam (1) NOTE: This is a destructive operation for the
seal.
Using a suitable extractor remove bush (8), from the
axle beam (1).
Remove shim (11) and take out the upper king pin
bush (6) and the bearing cup (7).
NOTE: It is only necessary to remove the
bushes if wear conditions require it.
SM 8-12431 Issued 09-2004
SECTION 6021 17
STEP 3
2 3
4
5
Remove the retaining nut (5) and related washer

(4). Pull out the pivot lock pin (2) from the axle beam
(1) using a punch and a hammer. Remove the pivot
pin (3) from the axle beam (1) using a hammer and
suitable drift, if necessary.
SM 8-12431 Issued 09-2004

18 SECTION 6021
Assembly
STEP 1 STEP 3
11
1
6
10
Assemble the upper king pin bush (6) on the axle Insert the double universal joint (10) into the axle
beam housing with special tool CA715039 and a beam (1).
hammer. Place shim (11) on the axle beam hous-
ing. Assemble the ball bearing cup (7) on the axle ATTENTION: Be careful not to damage the oil seal (9).
beam housing with special tool CA715039 and a
hammer. STEP 4
NOTE: To make the assembly easier, it is
advisable to cool the upper king pin bush (6) 2 3
and the ball bearing cup (7) at a temperature
lower than -100 °C.
4
ATTENTION: Wear safety gloves. 5
STEP 2 1
Assemble the pivot pin (3) into the axle beam (1)
using a hammer and suitable drift, if necessary.
Assemble the pivot lock pin (2) into the axle beam (1)
using a punch and a hammer. Assemble washer (4)
and retaining nut (5) to a torque of 45 Nm (33lb ft).
1
Assemble the bush (8) on the axle beam (1) with

special tool CA119053 and a hammer. Assemble
oil seal (9) on the axle beam (1) with special tool
CA715272 and a hammer.
NOTE: grease carefully the oil seal (9).
SM 8-12431 Issued 09-2004

SECTION 6021 19
Disassembly
• Before disassembly, see axle beam
9 1
2 5
4
10 3
1
21
22
6 24 16
20 18 12
28
23 15 13
25
17 14
26 7 19
29 27
STEP 1 STEP 2
25 22
24
27
29
23
28 26
Drain the oil from the differential. Remove bolt (29), Remove seal ring (24) with a lever. remove O-ring
washer (28) and shim (27). Remove the flange (26) (23) and the washer (22) from the pinion end.
with the protection cover (25).
NOTE: This is a destructive operation for the
NOTE: Only if necessary, remove the protection seal ring.
cover (25) from the flange (26).
SM 8-12431 Issued 09-2004

20 SECTION 6021
STEP 3 STEP 6
1
6
10
14
Remove bolts (6) and the differential support (2). Unscrew and remove the adjuster ring nut (10), (14)
using special tools CA715270 and CA715271.
ATTENTION: Use suitable lifting equipment to remove
NOTE: The ring nuts (10), (14) are different, so
the deferential support.
take note of their position with regard to the
NOTE: Only if necessary, remove the dowel crown gear.
pins (7).
STEP 7
STEP 4
5
8 12
4
9 13
Remove the 4 bearing cap retaining bolts (5) and

Remove bolts (8) and (12). Remove ring nut the retaining caps (4).
retainers (9) and (13).
NOTE: Check that the bushes (3) remain in their
housings.
STEP 5
5
4
10
Before removing the bearing cap bolts (5), mark the

bearing caps (4) and the differential support (2) to
avoid incorrect replacement.
SM 8-12431 Issued 09-2004

SECTION 6021 21
STEP 8 STEP 9
15
21 20
11 17 19
16 18
Remove the differential assembly. Remove the Remove the washer (21) and the O-ring (20) from
spacer (18), seal rings (17), (19) and the washer the bearing seat on the crown gear side.
(16). Remove differential bearing cups (11), (15).
ATTENTION: Do not mismatch the bearing cups (11) ,

(15) if they are not to be replaced.
SM 8-12431 Issued 09-2004

22 SECTION 6021
Assembly
STEP 1 STEP 3
17 19
5
4
11
18
16 2
15
Assemble the bearing cups (11) and (15) on the Position the differential assembly on the differential
taper roller bearings. On the crown gear side, support (2). Position the bearing caps (4) onto the
assemble the washer (16), spacer (18) and new differential support using the reference marks and
lightly greased seal rings (17) (19). retaining bolt (5).
ATTENTION: Do not mismatch the bearing cups (11) , STEP 4

STEP 2
21 20 14
10
3
2
Assemble and tighten the adjuster rings (10), (14)

in the differential support (2) with special tools
CA715270 and CA715271 until the backlash is
Before positioning the differential assembly on the eliminated and the bearings are slightly preloaded.
differential support (2), insert a new O-ring (20) and
NOTE: Check that the bearings are correctly
washer (21) in the bearing housing on the crown
seated, if necessary slightly knock them with a
gear side. Check that all the bushes (3) are in their
soft hammer.
housings.
SM 8-12431 Issued 09-2004

SECTION 6021 23
STEP 5 STEP 7
Position a dial gauge on the differential support (2) Adjust the ring nuts 10, 14 remembering that if the
so that the feeler touches the surface a crown gear backlash is less than the given tolerance range,
tooth with a 90o angle. unscrew the ring nut 14 and screw in the ring nut 10
by the same amount A. If the backlash is greater
STEP 6 than the given tolerance range, unscrew the ring nut
10 and screw in the ring nut 14 by the same amount
B.
STEP 8
Lock the pinion and move the crown gear

alternatively and note the backlash. Repeat the
operation on two or more teeth to obtain an average
value. Check if the measured backlash is within the
requested range. Once the adjustment of the crown gear backlash
has been carried out, check that there is a minimum
0.18 to 0.23 mm
preload on the differential bearings. repeat step 7
Adjustment is made by turning the ring nuts (10), until the indicated conditions are reached.
(14) using special tools CA715270 and CA715271.
SM 8-12431 Issued 09-2004

24 SECTION 6021
STEP 9 STEP 11
8 12
9 13
10 14
Once the crown gear backlash has been Once all the adjustment operations have been
established, measure the total preloading (T) of the completed, assemble the ring nut retainers (9), (13)
Bearings, crown gear and pinion using a and the retaining bolts (8), (12) tightening them to
dynamometer and cord wound round the splined a torque of 13 Nm (10 lb ft).
end of the pinion shaft. The measured value should
be within the following range. STEP 12
T=(P+9.5) to (P+11.5) da N
P is the measured pinion preload. (see pinion). 5
ATTENTION: All preloades must be measured without

seal ring (24)
4
STEP 10
Tighten the bolts (5) of the bearing caps (4) to a

torque of 413 Nm (304 lb ft).
STEP 13
1
6
If the preload is not within the requested range

adjust the ring nuts (10), (14) as follows.
If the total preload is less than the given range,
screw in both ring nuts (10), (14) by the same
amount keeping the crown gear backlash
unchanged A.
7
If the total preload is greater than the given range,
unscrew both ring nuts (10), (14) by the same 2
unchanged B. Before assembling the differential (2) to the axle
beam, (1) make sure the contact surfaces are
perfectly clean and degreased. Apply a film of
loctite 510, position the differential on the dowel
pins (7) and tighten the retaining bolts (6) to a
SM 8-12431 Issued 09-2004

SECTION 6021 25
STEP 14
SHIM RANGE
Thickness - mm 0.05 0.10 0.20
Quantity --- --- ---
24
STEP 17
2
Assemble a new well lubricated seal (24) into the 25

differential support (2) using special tool CA715266
27
STEP 15
29
23
28 26
22 Remove the flange (26) leaving the washer (22) in its
25 housing. Place a new O-ring (23) on the pinion shaft
and assemble the flange (26) with the protective
cover (25). assemble bolt (29) with washer (28) and
shims (27) on the pinion end. Tighten the bolt (29) to
a torque of 139 Nm (102 lb ft). Top up oil in the
differential.
26
Assemble the washer (22) and the flange (26) with

the protection cover (25) on the pinion end. Do not
assemble the O-ring (23).
STEP 16
25
22
27
26
Check that the flange (26) is inserted completely

and measure the indicated dimension Q. This is
measured from the pinion end to the rebate surface
of the flange (26) for washer (28). Choose the
shims (27) to be placed on the pinion shaft end to
give a backlash of:
0.00 to 0.05 mm
SM 8-12431 Issued 09-2004

26 SECTION 6021
DIFFERENTIAL
Disassembly
13
9
20
10 15
8 14
11 12 4
3
1 6
18
7 16 17
2
5
19
STEP 1 STEP 2
5 18
6
1
19
Secure the differential in a vice. Remove the Remove the cover (6) and the piston (19) from the
retaining bolts (5) and the crown gear (1). differential (3). Remove and discard the O-rings
(18).
SM 8-12431 Issued 09-2004

SECTION 6021 27
STEP 3 STEP 5
9 15
20 7 10
17
3
3
14
13 8
12
11
Remove the separator plates (14) the friction plates Remove the spider (15) planetary gears (10) sun
(13) the washer (12) and the sun gear (20). gear (8) and the drive plate (7).
NOTE: Check all the internal components for
STEP 4 wear or damage.
17 11 STEP 6
3 3
4
16
2
Using a thin punch, remove the three locking pins 6
(16) in order to remove the short (17) and the long
pins (11).
Using a suitable extractor remove the bearings (2)
and (4) from the differential housing (3) and the
differential cover (6).
SM 8-12431 Issued 09-2004

28 SECTION 6021
Assembly
STEP 1 STEP 3
4
17 11
3
3
6
16
2
Assemble the bearing cones on the deferential Rotate the short pins (17) and the long pin (16) to
housing (3) and differential cover (6) using special align the locking pin holes with the ones in the
tool CA715739 and a hammer. differential housing (3). insert the locking pins (16).
STEP 2 STEP 4
9 15
7 10 20
17
3
3
14
8 13
12
11
Position the differential housing (3) on a bench and Position the inner components in the differential
assemble all its inner components: spider (15), housing (3) as show: the sun gear (20), washer
planetary gear (10), thrust washer (9), sun gear (8), (12), separator plates (14), and friction plates (13).
and drive plate (7). Insert the short pins (17) and
the long pin (11) into their housings constraining the
planetary gears (10) and the spider (15).
SM 8-12431 Issued 09-2004

SECTION 6021 29
STEP 5 STEP 6
18
1
5
3
19
Assemble new, well lubricated O-rings (18) on the Position the grown gear (1) on the differential
differential piston (19) and the differential cover (6). housing 3, Apply loctite 542 to the threads of the
retaining bolts (5) and tighten to a torque of 190 Nm
(140 lb ft).
SM 8-12431 Issued 09-2004

30 SECTION 6021
PINION
Disassembly
NOTE: Before disassembling the pinion, see differential suppor t
2
3
4
5
6
9
10
STEP 1 STEP 2
10
Secure differential support in a vice. Unscrew the Remove ring nut (10) and washer (9).
lock nut (10) using special tools CA119060 and
CA715269.
NOTE: This operation will damage the lock nut.
SM 8-12431 Issued 09-2004

SECTION 6021 31
STEP 3 STEP 5
8
3
5
2
1
1
6
4
Tap the shaft with a soft hammer to remove the Remove the inner bearing cone (3) from the pinion
pinion (1). Remove the washers (4) and (6), the using a standard puller. remove the underlying shim
collapsible spacer (5) and the outer cone of the (2).
taper roller bearing (8).
STEP 6
STEP 4
3 5
7 10
Check all the pinion components for wear.

Place the differential support (7) on a fat surface
and remove the bearing cups (3) and (8) using a ATTENTION: The ring nut (10) and the collapsible
drift and a hammer. spacer (5) must be replaced when reassembling.
SM 8-12431 Issued 09-2004

32 SECTION 6021
Assembly
STEP 1 STEP 3
3 7
7
8
3
8 10
Place the differential support (7) on a work bench. Insert the bearing cones (3) and (8) into their
Fit the bearing cups (3) and (8) using special tools housings. Assemble the false pinion and its ring nut
CA715421 and CA715422. (10). Tighten the ring nut until the backlash is
eliminated.
STEP 2
STEP 4
10
Prepare the kit consisting of special tools called

false pinion CA119196, false differential box Install false differential box special tools into the
CA715512, CA715512 and a depth gauge. differential support (7) and lock it with the bearing
caps.
SM 8-12431 Issued 09-2004

SECTION 6021 33
STEP 5
SHIM RANGE
Thickness - mm 2.5 2.6 2.7 2.8 2.9
Quantity --- --- --- --- ---
Thickness - mm 3.0 3.1 3.2 3.3 3.4
Quantity --- --- --- --- ---
STEP 8
Assembly diagram of the false differential box tools. 7

Use a depth gauge to measure distance (X)
(between the axis of the differential bearings and
the point at which the pinion head is supported, or
base of the bearing).
8
STEP 6 3
10
Remove the false differential box from the

differential support (7). Remove the ring nut (10),
false pinion and the bearing cones (3), (8).
STEP 9
3 6
5
In order to determine the necessary thickness 4
2
value (S) between the pinion and the bearing,
subtract the value (V) stamped on the pinion head
(V= requested conical distance) from the
measured value (X). 1
1
S=X-V mm
STEP 7
Place the chosen shim (2) with the chamfer against

the gear onto the pinion shaft (1). Force the bearing
cone (3) onto the pinion shaft (1) with special tool
CA715433 under a press making sure that it is well
seated. Place shims (4), (6) and a new collapsible
spacer (5) onto the pinion.
NOTE: Always use a new collapsible spacer.
Select a shim (2) of the thickness value (S) from the

range of available shims.
SM 8-12431 Issued 09-2004
34 SECTION 6021
STEP 10 ATTENTION: The torque setting is given by the preload

measurement on the bearings (3) and (8) : tighten the
ring nut gradually. Tap both ends of the pinion with
8 a soft hammer to help seat the bearings
NOTE: If the ring nut is over tightened, the
collapsible spacer must be replaced and the
procedure repeated.
1
STEP 13
Insert the pinion (1) into the differential support (7).

Force the bearing cone (8) onto the pinion shaft
using special tool CA715433 and a hammer.
STEP 11
7
Carry out the preloading measurement (P) of the
pinion bearings (3), (8) using a dynamometer and
cord wound round the splined end of the pinion
shaft (1). The adjustment is carried out by gradually
10 increasing the torque of the ring nut (10) taking care
not to exceed.
9
P=8 to 12 da N
ATTENTION: All preloadings must be measured without

the seal.
Assemble washer (9) and a new ring nut (10) on the
pinion. STEP 14
STEP 12
Once the preload value is achieved, lock the ring

nut (10) into the groove on the pinion shaft using a
Tighten the ring nut (10) using the ring nut wrench, hammer and chisel.
CA119060 and the pinion retainer CA715269.
SM 8-12431 Issued 09-2004

SECTION 6021 35
Toe-in adjustment
5 6
1 3 4
2
9 10
7 8
STEP 1 STEP 2
Put two equal one meter long bars on the wheel Measure the distance in mm (M) between the ends
sides and lock them with two nuts on the wheel of the bars with a tape measure.
studs.
NOTE: Rotate the wheel hub in two 20° stages
NOTE: The two bars should be fixed so the and repeat Steps 1 and 2 at each stage. Take
centre of each bar is perpendicular to the and note the minimum value (M).
centre line of the hub and parallel to the pinion
shaft axis.
SM 8-12431 Issued 09-2004

36 SECTION 6021
STEP 3 STEP 4
To adjust toe-in, loosen the lock nuts (3) and (4).

Screw in or out the tie rods (5) and (6) in equal
turns until the toe-in is within the requested range.
STEP 5
Check that the difference of the measurements

between the wheel hubs diameter ends are within
the requested tolerance range. The nominal toe-in
value (A) refers to the external diameter of the
wheel hubs. The measured value (M) refers to the
ratio between the length of the bar and hub
diameter.
Nominal toe-in = A -2
Measured toe-in = M - 5
After adjusting, tighten the lock nuts (3) and (4) to

a torque of 250 Nm (185 lb ft).
SM 8-12431 Issued 09-2004

SECTION 6021 37
Steering angle adjustment

STEP 1 STEP 3
Use the same bars assembled for the toe-in Adjust the steering stop by screwing in or out the
adjustment and a long bar perfectly placed over special screws (7) and (8) locking them with the lock
the machined part of the central body (pinion nuts (9) and (10) to a torque of 150 Nm (111 lb ft).
side), so that the two bars form an acute angle at Turn steering to other side and repeat operations
the maximum turning point.
STEP 2
Adjust a bevel protractor to an angle of 35 o and

position it on the long bar. Move the wheel side
until it forms with the two bars, the angle fixed by
the bevel protractor.
SM 8-12431 Issued 09-2004

Section
6022
6022
FRONT SUSPENDED AXLE
ZTX Series Tractors
20.49 Axles

2 SECTION 6022
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TORQUES ............................................................................................................................................... 4
SPECIAL TOOLS ..................................................................................................................................................... 5
GENERAL INFORMATION .................................................................................................................................... 10
PLANETARY GEAR
Removal and Installation.................................................................................................................................... 10
Disassembly and Assembly ............................................................................................................................... 11
WHEEL HUB
Disassembly....................................................................................................................................................... 12
Assembly ........................................................................................................................................................... 15
AXLE BEAM
Disassembly....................................................................................................................................................... 18
Assembly ........................................................................................................................................................... 19
AXLE SENSOR
Disassembly....................................................................................................................................................... 20
Assembly ........................................................................................................................................................... 22
SUSPENSION ARMS
Disassembly....................................................................................................................................................... 23
Assembly ........................................................................................................................................................... 26
Disassembly....................................................................................................................................................... 34
Assembly ........................................................................................................................................................... 37
DIFFERENTIAL
Disassembly....................................................................................................................................................... 41
Assembly ........................................................................................................................................................... 43
PINION
Disassembly....................................................................................................................................................... 45
Assembly ........................................................................................................................................................... 47

Toe-in adjustment .............................................................................................................................................. 50

Steering angle adjustment ................................................................................................................................. 52
SM 8-12421 Issued 09-2004

SECTION 6022 3
SPECIFICATIONS
DIFFERENTIAL
Pinion Bearing Pre-load..........................................................80 to 120 N 18 to 27 lb f
Pinion Bearing and Differential
Bearing Total Pre-load.......................................... 80 (+95) to 120 (+115) N 18 (+21.3) to 27 (+25.8) lb f
Bevel Gear Backlash ...................................................... 0.18 to 0.23 mm 0.007 to 0.009 inch
Shim Thickness for Pinion Height Setting...... 2.5 (min.) to 3.4 mm (max.) 0.098 (min.) to 0.134 inch (max.)
LUBRICANTS
Grease ..................................................................................................................... Multi-purpose Lithium Grease
MFD Axle Pivot Pin ................................................................................................... Loctite Anti Seize Compound
MFD Axle Capacities
Type ......................................................................................................................... SAE 85W-140 EP Gear Oil
Planetary ..............................................................................................................................................1.9 Litres
Differential .............................................................................................................................................10 Litres
Front Wheel Toe-In (Axle Fully Lowered) ........................................................................................................... 2 mm
SM 8-12421 Issued 09-2004

4 SECTION 6022
SPECIAL TORQUES
Pinion Shaft Nut ........................................................................................... Refer to SPECIFICATIONS for Pre-load
Differential Housing to Axle Bolt..................................................................169 Nm 125 lb ft
Locking Plate Bolt..........................................................................................13 Nm 10 lb ft
Ring Gear to Differential Housing Bolt with Loctite 542 ..............................190 Nm 140 lb ft
Breather Plug ................................................................................................10 Nm 7 lb ft
Oil Fill/Level Plugs .........................................................................................80 Nm 59 lb ft
Differential Bearing Cap Bolt .......................................................................413 Nm 304 lb ft
King Pin Retaining Bolt................................................................................300 Nm 221 lb ft
Steering Stop Locknut .................................................................................150 Nm 111 lb ft
Steering Cylinder to Differential Support Bolt..............................................120 Nm 89 lb ft
Ball Joint on Steering Cylinder ....................................................................300 Nm 221 lb ft
Track Rod Locknut.......................................................................................250 Nm 185 lb ft
Ball Joint to Swivel Housing Locknut...........................................................220 Nm 162 lb ft
Planetary Gear to Swivel Housing Bolt .......................................................220 Nm 162 lb ft
Wheel Stud with Loctite 542..........................................................................70 Nm 52 lb ft
Planetary Gear Carrier to Wheel Hub Screw ................................................25 Nm 18 lb ft
Front Weight Frame Bolts............................................................................425 Nm 314 lb ft
Front Wheel Nuts .............................................................................530 to 570 Nm 391 to 420 lb ft
MFD Axle Retaining Bolts ................................................................570 to 645 Nm 420 to 475 lb ft
Planetary Gear Retaining Bolt.......................................................................75 Nm 55 lb ft
Potentiometer Cover Retaining Bolt ..............................................................10 Nm 7 lb ft
Potentiometer Retaining Bolts .........................................................................3 Nm 2 lb ft
Axle Suspension Pin Cover Bolts ..................................................................60 Nm 44 lb ft
Suspension cylinder, lower Cover Bolts ........................................................60 Nm 44 lb ft
Pinion Flange Bolt .......................................................................................139 Nm 102 lb ft
SM 8-12421 Issued 09-2004

SECTION 6022 5
SPECIAL TOOLS
The special tools used to fit seals, bearings and bushes should always be used with the interchangeable handle
CA119033 and a suitable safety handle to protect the hands.
CA119033 CA119196
CA715039
CA119053
CA715042
CA119060
SM 8-12421 Issued 09-2004

6 SECTION 6022
CA715118 CA715271
CA715266 CA715272
CA715268 CA715278
CA715269 CA715345
SM 8-12421 Issued 09-2004

SECTION 6022 7
CA715349 CA715353
CA715350 CA715362
CA715351 CA715381
CA715352 CA715382
SM 8-12421 Issued 09-2004

8 SECTION 6022
CA715383 CA715422
CA715384 CA715423
CA715385 CA715428
CA715421 CA715433
SM 8-12421 Issued 09-2004

SECTION 6022 9
CA715512 CA715528
CA715517 CA715739
CA715527
SM 8-12421 Issued 09-2004

10 SECTION 6022
GENERAL INFORMATION
NOTE: It is not necessary to remove the MFD Axle to service the following components:
• Planetary Gear Assembly, refer to Page 10.
• Wheel Hub, refer to Page 12.
• Steering cylinder, refer to section 5002.
• Some of the photographs and illustrations may not show your axle, but the procedure is the same.
PLANETARY GEAR

NOTE: Steps are numbered in order of Removal, Installation is in the reverse order of Removal.
Before removing the Planetary Gear assembly it will be necessary to carry out the following:
• Park the tractor on hard level ground, apply the parking brake.
• Loosen the front wheel nuts. Use a hydraulic jack under the centre of the front axle, raise the tractor and support
the tractor on suitable axle stands. Remove the front wheels.
NOTE: Before draining the oil, loosen the axle breather to release any internal pressure.
STEP 1 STEP 2
2
3
1
DP99C254 DP99C254
Turn the wheel hub until the drain/level plug (1) is at Remove the two countersunk screws (2) and remove
the bottom. Put a container with a capacity of at the planetary carrier assembly (3). Remove and
least 2.0 Litres under the wheel hub, remove the discard the o-ring from the planetary carrier
drain/level plug (1) and drain the oil. assembly.
NOTE: For Installation, turn the wheel hub until NOTE: For Installation, install a new o-ring onto
the drain/level plug is in the horizontal position. the planetary carrier.
Fill the hub to the correct level with the correct
NOTE: For Installation, tighten the screws (2) to
grade of oil, refer to Specifications, Page 3.
a torque of 25 Nm.
Install the drain/level plug (1) and o-ring, tighten
to a torque of 80 Nm. NOTE: For Installation, follow the same
SM 8-12421 Issued 09-2004

SECTION 6022 11
Disassembly and Assembly

NOTE: Items are numbered in order of Disassembly. Assembly is in the reverse order of Disassembly.
5 4
6
7
75 NM
8 1 (55 LB FT)
2
3
DS99D050
1. RETAINING BOLT 5. PLANETARY GEAR

2. WASHER 6. NEEDLE ROLLER BEARINGS
3. THRUST WASHER 7. THRUST WASHER
4. RETAINING PIN 8. HUB
STEP 3 STEP 6
Put identification marks on planetary gears (5) and
shafts. 8
STEP 4
Remove retaining bolt (1), washer (2), thrust
washer (3) and retaining pin (4). Remove planetary B
gear (5), needle roller bearings (6) and thrust C
washer (7). Repeat the procedure for the remaining
planetary gears.
NOTE: For Assembly, tighten the retaining bolt
(1) to a torque of 75 Nm (55lb ft).
STEP 5 Only remove bushes (B) and washers (C) if they

Clean all parts in cleaning solvent, and dry with require replacing. Removing them is a destructive
compressed air. Face protection MUST be worn. operation.
Check all components for wear or damage and NOTE: When fitting new bushes (B) apply heat to
replace as necessary. them of 120 o C for 5 minutes
NOTE: For Assembly, follow the Disassembly
SM 8-12421 Issued 09-2004

12 SECTION 6022
WHEEL HUB
Disassembly
Before Disassembly of the Wheel Hub it will be necessary to carry out the following:
• Remove the Planetary Gear Assembly, refer to Page 10.
21
26
19 25
20
14
24
23
11 22
18
9
8 13 17
12
5 16
10
2 7 15
1
6 220 NM (162 LB FT)
STEP 1 STEP 2
8
Using suitable circlip pliers remove circlip (1) and Remove the retaining bolts (6) from the wheel
washer (2). carrier (8).
NOTE: for installation tighten the retaining bolts
(6) to 220 Nm (162 lb ft).
SM 8-12421 Issued 09-2004

SECTION 6022 13
STEP 3 STEP 6
6 13
8 A
11
DP96M054
To remove the wheel carrier (8) and ring gear (5) Position the wheel hub (11) on a flat surface and
screw two of the retaining bolts (6) into the threaded take out the seal (13) with a lever
holes (A) and tighten evenly.
STEP 4 STEP 7
9
10
7
12
5 8
DI99D052
Remove the steel lock ring (9) and separate the
Remove bearing cups (10) and (12) on both sides of
wheel carrier (8) from the ring gear (5). If
the hub using a hammer and suitable drift. Remove
necessary, remove the centering bushes (7) with a
bearing cone (12) from swivel housing (14).
hammer and special tool CA715278.
STEP 8
STEP 5
14 21
11
9
10
14
15 16
Install suitable lifting equipment to swivel housing

Remove bearing cone (10) and wheel hub (11). (14). Remove retaining bolts (21) from the upper
king pin (20) and retaining bolts (15) from lower
king pin (16).
SM 8-12421 Issued 09-2004

14 SECTION 6022
STEP 9 STEP 11
Remove the kin pins (20),(16) and the belleville
washers (19) and (18).
STEP 10
14
26
14
Position the swivel housing (14) on a flat surface

and with a suitable drift remove bush (25), take out
seal (26) with a lever.
Remove the swivel housing (14) from the axle
beam.
SM 8-12421 Issued 09-2004

SECTION 6022 15
Assembly
STEP 1 STEP 3
19
17
14 16
23
24
22 18
If steering stop has been removed, reassemble bolt

If cone (17) has been removed, reassemble it to the
(24) with nut (23) and spacers (22). Make sure
lower king pin (16) using special tool CA715042
spacers are between nut (23) and swivel housing (14).
under a press. Grease the king pin housings (16)
and (20) with specific grease. position the belleville
STEP 2 washers (18) and (19) on the king pin (16) and (20)
housings.
14 STEP 4
21
20
14
Using special tool CA715423 fit bush (25) into swivel 16

housing (14). Fit new seal (26) with special tool
CA715428.
Secure the swivel housing (14) with a belt or a rope
to a hoist or any other supporting device. Protect
the splined end of the axle shaft with adhesive tape
and to avoid damage to the seal (26). Assemble
swivel housing on axle beam (14) and remove
adhesive tape. Assemble king pins (16), (20) and
tighten bolts (15) and (21) to a torque of 300Nm
(221lb ft).
NOTE: Make sure that the belleville washers
(18) and (19) remain in their position
SM 8-12421 Issued 09-2004

16 SECTION 6022
STEP 5 STEP 8
11 8
Fit bearing cups (10) and (12) to the wheel hubs Assemble the wheel carrier (8) and the epicyclic
(11) using special tool CA715528 under a press or ring gear (5) with locking ring (9).
a hammer. Insert seal 13 using special tool
CA715528 and a hammer. STEP 9
STEP 6
14
12 10
11
Assemble the wheel carrier on to the wheel hub

(11) using the two projecting bushes (7) as dowel
Assemble the bearing cone (12) and the wheel hub pins and screw in relative bolts 6 to secure the
(11) on to the swivel housing (14). Place bearing wheel carrier to the hub.
cone (10) into position.
STEP 10
STEP 7
7 6
7
8
Using a hammer and special tool CA715278,
Position wheel carrier (8) on a workbench and if the correctly fit all bushes (7) to the carrier. Assemble
bushes (7) have been removed, assemble them into all the bolts (6) and tighten to a toque of 220 Nm
the carrier with special tool CA715278. (162 lb ft).
NOTE: Two of the bushes (7) (diametrically
opposed) must be set slightly higher than the
carrier surface level to be used as dowel pins.
SM 8-12421 Issued 09-2004
SECTION 6022 17
STEP 11 STEP 12
1 2
Insert a lever into the universal joint between the Slide thrust washer (2) on to shaft and fit retaining
axle beam and swivel housing. Lever the universal ring (1) making sure it is correctly seated.
joint in the direction of the final drive to make it
easier to fit the retaining ring.
SM 8-12421 Issued 09-2004

18 SECTION 6022
AXLE BEAM
Disassembly
2
1
4
5
STEP 1 STEP 2
1 1
2
4
5
3
5
Remove the double universal joint (6) from the axle Remove seal (5) with a suitable lever.
beam (1) NOTE: This is a destructive operation for the
seal.
Using suitable extractors remove bushes (2), (3)
and (4)
NOTE: It is only necessary to remove bushes
(2), (3) and (4) if wear conditions require it.
SM 8-12421 Issued 09-2004

SECTION 6022 19
Assembly
STEP 1 STEP 3
1
2
Assemble the upper king pin bush (2) on the axle Insert the double universal joint (6) into the axle
beam housing with special tool CA715039 and a beam (1).
hammer. Assemble the ball bearing cup (3) on the
axle beam housing with special tool CA715039 and ATTENTION: Be careful not to damage the oil
a hammer. seal (5).
advisable to cool the upper king pin bush (2)
and the ball bearing cup (3) at a temperature
lower than -100 °C.
ATTENTION: Wear safety gloves.
STEP 2
Assemble the bush (4) on the axle beam (1) with

special tool CA119053 and a hammer. Assemble
oil seal (5) on the axle beam (1) with special tool
CA715272 and a hammer.
NOTE: grease carefully the oil seal (5).
SM 8-12421 Issued 09-2004

20 SECTION 6022
AXLE SENSOR
Disassembly
1
2
1
6
5 7
6
8
10
STEP 1 STEP 2
2
5
7
8
Remove the retaining screws (1) of the sensor Remove both retaining screw (6) of the sensor (7).
cover wiring-in kit (2). Disconnect the connecting If necessary, remove the connector cable and
plug (5) from the sensor. washer (8).
ATTENTION: Ta k e c a r e n o t t o d a m a g e t h e
electrical wires.
SM 8-12421 Issued 09-2004

SECTION 6022 21
STEP 3
9 10
Remove the rubber guide (9) of the sensor control

pin assembled on the position ring (10). Remove
the rubber position ring (10) taking note of its
position in the hosing plate.
position ring.
SM 8-12421 Issued 09-2004

22 SECTION 6022
Assembly
STEP 1 STEP 3
10 6
10
7
8
Insert the position ring (10) into the sensor plate Place washer (8) on the sensor control pin.
(respecting its position on removal) using special Assemble sensor (7) making sure the flat surface of
tool CA715362. the pin is in line with the rubber guide. Assemble,
without tightening, the two retaining screws (6).
STEP 2 Reconnect the harness.
NOTE: Before assembling the sensor cover,
adjust the sensor position. (See section 10003)
STEP 4
10 1
9
Assemble the rubber guide (9) in the position ring

(10) the text “OUT SIDE” on the out side.
NOTE: the rubber outer boss must be inserted
in the hole on the position ring.
Assemble sensor cover (2) and tighten retaining
screws (1) to a torque of 60 Nm (44lb ft).
SM 8-12421 Issued 09-2004

SECTION 6022 23
SUSPENSION ARMS
Disassembly
8 2
3
10 9
12 11 7
6
14 13 5
15 17 16
19 18
21 20
23 22 26
24 28
25
30
4
32 27
29
34
31
33
60 40 45 43
1 41
47 44
61 42 51 50
49
52
62 53
46
48
63 55 3
57 54
5
56
60
64
65
SM 8-12421 Issued 09-2004

24 SECTION 6022
STEP 1 STEP 3
40 41
42
8
9
57
Secure the arms to prevent any unwanted Remove the retaining screws (9) and extract the
movement. Remove nut (40), washer (41) and conic upper pins (8) with a suitable extractor, using the
pin (42). Remove the pivot pin (57). special threaded hole in the pin.
ATTENTION: Suspension arms are very heavy, they ATTENTION: This operation sets the arms free. If the
could move and harm the operator. upper and lower arms are not correctly supported, they
could move harming the operator.
STEP 2
STEP 4
10
12
14
3
11
13 1
7
15 22 6
24
25
23
Remove retaining screws (15) (34) and 25.Remove

the pin covers (14), (33) and the sensor plate 24. Remove the upper arms (1), (3), using suitable
Remove and discard O-rings (13), (23) and (32) lifting equipment.
Remove shims (12) bearings (11) and seals (10)
from the upper pin (8). ATTENTION: The lower arms (2) and (4) could rotate
harming the operator.
NOTE: This is a destructive operation for the seals.
Remove seal rings and shims where they are
present. If necessary, replace the shock absorber
pad (7) removing the relative screws (6).
SM 8-12421 Issued 09-2004

SECTION 6022 25
STEP 5 STEP 7
62
63
18
20 60
64
17 61
19
21 65
Remove retaining bolts (65) lower cover (64). and

Remove retaining bolts (21), (31) and thrust
cylinder (60). Remove and discard O-ring (61) and
washers (20), (30). If present, remove shims (19),
seal (62). Only if replacement is required remove
(29). Using a suitable extractor remove bearings
bush (63) with a suitable extractor.
(18), (28). Remove and discard O-rings (17), (27).
NOTE: Thrust washers (20) and (30) are
different, care must be taken during assembly
to make sure thrust washer (20) is installed on
the left hand pin and thrust washer (30) is
installed on the right hand side as shown.
STEP 6
16
Remove pins (16), (26) using a suitable extractor

and the threaded holes in the pin. Remove lower
arms (2), (4).
SM 8-12421 Issued 09-2004

26 SECTION 6022
Assembly
STEP 1 STEP 2
63
5
64
65
Insert bush (63) into the suspension cylinder Assemble lower cover (64) on to the bottom of the
housing, applying Loctite 510 on the retaining lip. axle beam and tighten the retaining bolts (65) to a
torque of 60 Nm (44lb ft).
NOTE: position the bush (63) with opening on
the on the pinion side as shown. NOTE: Before assembling the cove, check that
the position of the O-ring (61) in the bottom of
STEP 1 the cylinder is correct.
STEP 3
62 S1
60
61
16
Assemble seal ring (62) on to axle beam (5).

Grease new O-ring (61) and insert into the housing
on the bottom of the suspension cylinder (60). Place the lower arms on the axle beam and aline
Lubricate bush (63) and seal ring (62). Insert the the pins housing with special tool CA715350 (S1)
cylinder in to the axle beam. inserted from the opposite side of the beam. Insert
the lower pins (16), (26) into their housings with
special tool CA715353.
advisable to cool the pins to a temperature
lower than -100 o c.
ATTENTION: Always wear safety gloves when handling

frozen parts.
SM 8-12421 Issued 09-2004

SECTION 6022 27
STEP 4 STEP 6
18
20
17
r1
r1
21
Assemble the seal ring (17) (27) on ever pin in the Assemble a reference spacer (r1) of appropriate
lower arms using special tool CA715352 and a dimension (1mm) on the pinion side and the thrust
hammer. Insert bearings (18), (28) using special washer (20), (30) with the retaining bolts (21), (31)
tool CA715349. on all lower pins to a torque of 190 Nm (140 lb ft).
STEP 5 ATTENTION: The spacer must have an outer diameter

lower than the inner diameter of the bearing.
NOTE: Thrust washer (20) is different and must
be fitted to the correct pin(16).
STEP 7
NOTE: On the lower pins (16), (26) the bearings

(18), (28) must be inser ted with the cup on the
inner side (in the arm housing) and the cone on
2
the outer side (on the pin).
Position a dial gauge on the axle beam (5) so that

the feeler touches the lower arm (2) and zero the
gauge. Position a lever between the arm and the
axle beam and measure the backlash with the dial
gauge. Repeat this operation several times to find
an average value (X).
SM 8-12421 Issued 09-2004

28 SECTION 6022
STEP 8 STEP 10
23
22
24 33
25
34
32
Insert the seal ring (22) on the sensor plate with

special tool CA715345. Place new O-rings (23),
(32) in the relative housings on the three covers
SHIM RANGE (33) and the sensor plate (24) fill housings with
grease and tighten the retaining bolts to a torque of
Thickness - mm 0.1 0.3
60 Nm (44 lb ft).
Quantity --- ---
STEP 11
In order to determine the necessary thickness (S) to
give a preload to the bearing, subtract from the
known value (R) of the reference shim the
measured value (X) and the prescribed one (V). 3
S=(R-X)-V
1
V=0.2 to 0.3mm 7
6
Choose from the available shims (19), (29) a
quantity to reach the determined value
STEP 9
Using suitable lifting equipment Place arms (1), (3)

on a work bench
NOTE: The arms are very heavy and must be
18 handled with care to avoid injury.
20 If necessary replace shock absorber pad (7) and
tighten retaining bolt (6) to a torque of 10 Nm (7 lb ft).
19
21
Remove retaining bolts (21),(31) from the pinion

side and the reference shim r1. Place the shims
(19), (29) between thrust washer (20), (30) and the
bearings (18), (28).
NOTE: shims must be fitted to the pinion side only.
Reassemble the retaining bolts, apply Loctite 542 to
the threads and tighten them to a torque of 190 Nm
(140 lb ft).
SM 8-12421 Issued 09-2004

SECTION 6022 29
STEP 12 STEP 14
50 1
r3
48
49
3
51
56
r4
55 3
Assemble the pivot bushes (51), (55) into the Place spacer (r3) (Special tool CA715517) in the
suspension arm (3) using special tool CA715385 arm (1) pivot pin housing. See Step 24. In the
and a hammer. opposite side insert false thrust washer (r4)
(Special tool CA71538 in the spacer housing.
advisable to cool the bushes to a temperature
lower than -100 o c. STEP 15
1
ATTENTION: Always wear safety gloves when handling
frozen parts.
Insert the seal rings (50), (56) using CA715383. 5
Insert the spacer (49) on the inner side fork using
special tool CA715384 and a new well lubricated 8
O-ring (48) in the spacer.
9
STEP 13
2
r2
With suitable lifting equipment, place the (1), (3)
3 on the axle beam (5) couple them to the lower
arms (2), (4) and the suspension cylinder (60).
Insert the arms pins (8) in their housings using
special tool CA715353.
advisable to cool the pins to a temperature
lower than -100 o c.
Insert spacer (r2) (special tool CA715517) in the ATTENTION: Always wear safety gloves when handling
inner side fork. See Step 24 frozen parts.
Assemble the retaining bolts (9) applying loctite
542 on the threads and tighten them to a torque
of 190 Nm (140 lb ft).
SM 8-12421 Issued 09-2004

30 SECTION 6022
STEP 16 STEP 18
11
15
10 2
14
Assemble seal rings (10) on all the arms pins with Position a dial gauge on the upper arm (1) so that
special tool CA715351. Insert bearings (11) using the feeler touches the lower arm (2) and zero the
special tool CA715349. See step 17 to verify the gauge. By means of a lever move the arm from both
correct position of the bearings. Assemble the sides and measure the backlash with the dial
cover (14) with the retaining bolts (15). Move gauge. Repeat this operation several times to find
arms to insure bearings are seated correctly and an average value (X).
tighten to a torque of 60 Nm (44 lb ft).
STEP 19
NOTE: Do not insert any spacers under the
cover
STEP 17
SHIM RANGE
On the upper pins (8) the bearings must be inserted
with the cone in the inner side (on the pin) and the Thickness - mm 0.1 0.2 0.5
cup on the outer side (in the arm).
On the lower pins (16), (26) the bearings have the Quantity --- --- ---
cup on the inner side (in the arm) and the cone on
the outer side (on the pin). In order to determine the necessary thickness (S) to
preload the bearing, add the measured value (X) to
the prescribed value (V)
S=X+V
V=0.2 to 0.3
Choose a quantity of shims (12) to reach the
determined value (S).
SM 8-12421 Issued 09-2004

SECTION 6022 31
STEP 20 STEP 23
11
13
10
15
12
14
Repeat the described procedures on the other

lower arm (4). Remove the arms pin covers from the
pinion side, insert shims (12), a new O-ring (13)
and fill the housing with grease. SHIM RANGE
NOTE: The shims are only added to the pinion Thickness - mm 0.1 0.3
side. Remove the covers from the opposite side,
fill the housing with grease and reassemble Quantity --- ---
them with a new O-ring (13).
In order to determine the necessary shim pack (T)
STEP 21 to give backlash (G) to the arms, calculate:
T=X-G
G=0.4 to 0.7
Choose a quantity of shims (46) to reach the
determined value (T).
STEP 24
s2
Align the pivot pin housings using guide pin 60

CA715382 (s2).
STEP 22
r3 r2
Using feeler gauges, measure dimension (Y) and

(Z) between the spacer (r2) (r3) and the cylinder
(60).
49 r4
Using feeler gauges, measure dimension (X)

between the spacer (49) and the false thrust
washer (r4).
SM 8-12421 Issued 09-2004
32 SECTION 6022
STEP 25 STEP 27
1
47
46
Remove the guide pin CA715382 (s2) and release

the spacers on the arms (1), (3). Remove the false
washer (r4). Insert the shims (46) chosen in step 24
SHIM RANGE and the spacer (47) in the thrust washer housing
with special tool CA715527.
Thickness - mm 0.1 0.3
NOTE: position the spacer 47 with the notches
Quantity --- --- on the outer side.
In order to determine the necessary shim pack (U) STEP 28

to give backlash (G), calculate:
U=(Y+Z-2G)/2 1
44
G=0.15 to 0.25
Choose a quantity of shims (44), (53) to reach the 43
determined value (U).
53
45
STEP 26
52
3 54
15
Remove the spacers (r2) (r3) Insert the shims (45),
(52) chosen in step 25 and the spacers (44), (53)
using special tool CA715384.
14
Loosen the upper pin covers (14) retaining bolts

(15).
NOTE: This operation is necessary to release
the upper arms (1), (3) from the suspension
cylinder head (60).
SM 8-12421 Issued 09-2004

SECTION 6022 33
STEP 29 STEP 31
40 41
42
60
47 44 53
57 49
Aline arms (1), (3) and suspension cylinder (60) Using feeler gauges measure dimension (A)
using special tool CA751382, then drive the pin (57) between spacers (47), (49) and dimensions (B), (C)
in the housing. between the spacers (44), (53) and the cylinder
head (60). If the dimensions are out of the
ATTENTION: Hold the special tool CA751382 when prescribed range, repeat operations from Step 21.
exiting the housing.
A=0.4 to 0.7 mm
Secure pivot pin with conical pin (42). Assemble the
washer (41) and tighten nut (40) to a torque of (45) B, C=0.1 to 0.3 mm
Nm (33 lb ft).
STEP 30
14
15
15
15
Tighten the upper pin covers (14) retaining bolts

(15). to a torque of 60 Nm (44 lb ft).
SM 8-12421 Issued 09-2004

34 SECTION 6022
Disassembly
• Before disassembly, see axle beam
9 1
2 5
4
10 3
1
21
22
6 24 16
20 18 12
28
23 15 13
25
17 14
26 7 19
29 27
STEP 1 STEP 2
25 22
24
27
29
23
28 26
Drain the oil from the differential. Remove bolt (29), Remove seal ring (24) with a lever. remove O-ring
washer (28) and shim (27). Remove the flange (26) (23) and the washer (22) from the pinion end.
with the protection cover (25).
NOTE: Only if necessary, remove the protection seal ring.
cover (25) from the flange (26).
SM 8-12421 Issued 09-2004

SECTION 6022 35
STEP 3 STEP 6
1
6
10
14
Remove bolts (6) and the differential support (2). Unscrew and remove the adjuster ring nut (10), (14)
using special tools CA715270 and CA715271.
ATTENTION: Use suitable lifting equipment to remove
NOTE: The ring nuts (10), (14) are different, so
the deferential support.
take note of their position with regard to the
NOTE: Only if necessary, remove the dowel crown gear.
pins (7).
STEP 7
STEP 4
5
8 12
4
9 13
Remove the 4 bearing cap retaining bolts (5) and

Remove bolts (8) and (12). Remove ring nut the retaining caps (4).
retainers (9) and (13).
NOTE: Check that the bushes (3) remain in their
housings.
STEP 5
5
4
10
Before removing the bearing cap bolts (5), mark the

bearing caps (4) and the differential support (2) to
avoid incorrect replacement.
SM 8-12421 Issued 09-2004

36 SECTION 6022
STEP 8 STEP 9
15
21 20
11 17 19
16 18
Remove the differential assembly. Remove the Remove the washer (21) and the O-ring (20) from
spacer (18), seal rings (17), (19) and the washer the bearing seat on the crown gear side.
(16). Remove differential bearing cups (11), (15).
ATTENTION: Do not mismatch the bearing cups (11) ,

SM 8-12421 Issued 09-2004

SECTION 6022 37
Assembly
STEP 1 STEP 3
17 19
5
4
11
18
16 2
15
Assemble the bearing cups (11) and (15) on the Position the differential assembly on the differential
taper roller bearings. On the crown gear side, support (2). Position the bearing caps (4) onto the
assemble the washer (16), spacer (18) and new differential support using the reference marks and
lightly greased seal rings (17) (19). retaining bolt (5).
ATTENTION: Do not mismatch the bearing cups (11) , STEP 4

STEP 2
21 20 14
10
3
2
Assemble and tighten the adjuster rings (10), (14)

in the differential support (2) with special tools
CA715270 and CA715271 until the backlash is
Before positioning the differential assembly on the eliminated and the bearings are slightly preloaded.
differential support (2), insert a new O-ring (20) and
NOTE: Check that the bearings are correctly
washer (21) in the bearing housing on the crown
seated, if necessary slightly knock them with a
gear side. Check that all the bushes (3) are in their
soft hammer.
housings.
SM 8-12421 Issued 09-2004

38 SECTION 6022
STEP 5 STEP 7
Position a dial gauge on the differential support (2) Adjust the ring nuts 10, 14 remembering that if the
so that the feeler touches the surface a crown gear backlash is less than the given tolerance range,
tooth with a 90o angle. unscrew the ring nut 14 and screw in the ring nut 10
by the same amount A. If the backlash is greater
STEP 6 than the given tolerance range, unscrew the ring nut
10 and screw in the ring nut 14 by the same amount
B.
STEP 8
Lock the pinion and move the crown gear

alternatively and note the backlash. Repeat the
operation on two or more teeth to obtain an average
value. Check if the measured backlash is within the
requested range. Once the adjustment of the crown gear backlash
has been carried out, check that there is a minimum
0.18 to 0.23 mm
preload on the differential bearings. repeat step 7
Adjustment is made by turning the ring nuts (10), until the indicated conditions are reached.
(14) using special tools CA715270 and CA715271.
SM 8-12421 Issued 09-2004

SECTION 6022 39
STEP 9 STEP 11
8 12
9 13
10 14
Once the crown gear backlash has been Once all the adjustment operations have been
established, measure the total preloading (T) of the completed, assemble the ring nut retainers (9), (13)
Bearings, crown gear and pinion using a and the retaining bolts (8), (12) tightening them to
dynamometer and cord wound round the splined a torque of 13 Nm (10 lb ft).
end of the pinion shaft. The measured value should
be within the following range. STEP 12
T=(P+9.5) to (P+11.5) da N
P is the measured pinion preload. (see pinion). 5
ATTENTION: All preloades must be measured without

seal ring (24)
4
STEP 10
Tighten the bolts (5) of the bearing caps (4) to a

STEP 13
1
6
If the preload is not within the requested range

adjust the ring nuts (10), (14) as follows.
If the total preload is less than the given range,
screw in both ring nuts (10), (14) by the same
unchanged A.
7
If the total preload is greater than the given range,
unscrew both ring nuts (10), (14) by the same 2
unchanged B. Before assembling the differential (2) to the axle
beam, (1) make sure the contact surfaces are
perfectly clean and degreased. Apply a film of
loctite 510, position the differential on the dowel
pins (7) and tighten the retaining bolts (6) to a
SM 8-12421 Issued 09-2004

40 SECTION 6022
STEP 14
SHIM RANGE
Thickness - mm 0.05 0.10 0.20
Quantity --- --- ---
24
STEP 17
2
Assemble a new well lubricated seal (24) into the 25

differential support (2) using special tool CA715266
27
STEP 15
29
23
28 26
22 Remove the flange (26) leaving the washer (22) in its
25 housing. Place a new O-ring (23) on the pinion shaft
and assemble the flange (26) with the protective
cover (25). assemble bolt (29) with washer (28) and
shims (27) on the pinion end. Tighten the bolt (29) to
a torque of 139 Nm (102 lb ft). Top up oil in the
differential.
26
Assemble the washer (22) and the flange (26) with

the protection cover (25) on the pinion end. Do not
assemble the O-ring (23).
STEP 16
25
22
27
26
Check that the flange (26) is inserted completely

and measure the indicated dimension Q. This is
measured from the pinion end to the rebate surface
of the flange (26) for washer (28). Choose the
shims (27) to be placed on the pinion shaft end to
give a backlash of:
0.00 to 0.05 mm
SM 8-12421 Issued 09-2004

SECTION 6022 41
DIFFERENTIAL
Disassembly
13
9
20
10 15
8 14
11 12 4
3
1 6
18
7 16 17
2
5
19
STEP 1 STEP 2
5 18
6
1
19
Secure the differential in a vice. Remove the Remove the cover (6) and the piston (19) from the
retaining bolts (5) and the crown gear (1). differential (3). Remove and discard the O-rings
(18).
SM 8-12421 Issued 09-2004

42 SECTION 6022
STEP 3 STEP 5
9 15
20 7 10
17
3
3
14
13 8
12
11
Remove the separator plates (14) the friction plates Remove the spider (15) planetary gears (10) sun
(13) the washer (12) and the sun gear (20). gear (8) and the drive plate (7).
NOTE: Check all the internal components for
STEP 4 wear or damage.
17 11 STEP 6
3 3
4
16
2
Using a thin punch, remove the three locking pins 6
(16) in order to remove the short (17) and the long
pins (11).
Using a suitable extractor remove the bearings (2)
and (4) from the differential housing (3) and the
differential cover (6).
SM 8-12421 Issued 09-2004

SECTION 6022 43
Assembly
STEP 1 STEP 3
4
17 11
3
3
6
16
2
Assemble the bearing cones on the deferential Rotate the short pins (17) and the long pin (16) to
housing (3) and differential cover (6) using special align the locking pin holes with the ones in the
tool CA715739 and a hammer. differential housing (3). insert the locking pins (16).
STEP 2 STEP 4
9 15
7 10 20
17
3
3
14
8 13
12
11
Position the differential housing (3) on a bench and Position the inner components in the differential
assemble all its inner components: spider (15), housing (3) as show: the sun gear (20), washer
planetary gear (10), thrust washer (9), sun gear (8), (12), separator plates (14), and friction plates (13).
and drive plate (7). Insert the short pins (17) and
the long pin (11) into their housings constraining the
planetary gears (10) and the spider (15).
SM 8-12421 Issued 09-2004

44 SECTION 6022
STEP 5 STEP 6
18
1
5
3
19
Assemble new, well lubricated O-rings (18) on the Position the grown gear (1) on the differential
differential piston (19) and the differential cover (6). housing 3, Apply loctite 542 to the threads of the
retaining bolts (5) and tighten to a torque of 190 Nm
(140 lb ft).
SM 8-12421 Issued 09-2004

SECTION 6022 45
PINION
Disassembly
NOTE: Before disassembling the pinion, see differential support
2
3
4
5
6
9
10
STEP 1 STEP 2
10
Secure differential support in a vice. Unscrew the Remove ring nut (10) and washer (9).
lock nut (10) using special tools CA119060 and
CA715269.
NOTE: This operation will damage the lock nut.
SM 8-12421 Issued 09-2004

46 SECTION 6022
STEP 3 STEP 5
8
3
5
2
1
1
6
4
Tap the shaft with a soft hammer to remove the Remove the inner bearing cone (3) from the pinion
pinion (1). Remove the washers (4) and (6), the using a standard puller. remove the underlying shim
collapsible spacer (5) and the outer cone of the (2).
taper roller bearing (8).
STEP 6
STEP 4
3 5
7 10
Check all the pinion components for wear.

Place the differential support (7) on a fat surface
and remove the bearing cups (3) and (8) using a ATTENTION: The ring nut (10) and the collapsible
drift and a hammer. spacer (5) must be replaced when reassembling.
SM 8-12421 Issued 09-2004

SECTION 6022 47
Assembly
STEP 1 STEP 3
3 7
7
8
3
8 10
Place the differential support (7) on a work bench. Insert the bearing cones (3) and (8) into their
Fit the bearing cups (3) and (8) using special tools housings. Assemble the false pinion and its ring nut
CA715421 and CA715422. (10). Tighten the ring nut until the backlash is
eliminated.
STEP 2
STEP 4
10
Prepare the kit consisting of special tools called

false pinion CA119196, false differential box Install false differential box special tools into the
CA715512, CA715512 and a depth gauge. differential support (7) and lock it with the bearing
caps.
SM 8-12421 Issued 09-2004

48 SECTION 6022
STEP 5
SHIM RANGE
Thickness - mm 2.5 2.6 2.7 2.8 2.9
Quantity --- --- --- --- ---
Thickness - mm 3.0 3.1 3.2 3.3 3.4
Quantity --- --- --- --- ---
STEP 8
Assembly diagram of the false differential box tools. 7

Use a depth gauge to measure distance (X)
(between the axis of the differential bearings and
the point at which the pinion head is supported, or
base of the bearing).
8
STEP 6 3
10
Remove the false differential box from the

differential support (7). Remove the ring nut (10),
false pinion and the bearing cones (3), (8).
STEP 9
3 6
5
In order to determine the necessary thickness 4
2
value (S) between the pinion and the bearing,
subtract the value (V) stamped on the pinion head
(V= requested conical distance) from the
measured value (X). 1
1
S=X-V mm
STEP 7
Place the chosen shim (2) with the chamfer against

the gear onto the pinion shaft (1). Force the bearing
cone (3) onto the pinion shaft (1) with special tool
CA715433 under a press making sure that it is well
seated. Place shims (4), (6) and a new collapsible
spacer (5) onto the pinion.
NOTE: Always use a new collapsible spacer.
Select a shim (2) of the thickness value (S) from the

range of available shims.
SM 8-12421 Issued 09-2004
SECTION 6022 49
STEP 10 ATTENTION: The torque setting is given by the preload

measurement on the bearings (3) and (8) : tighten the
ring nut gradually. Tap both ends of the pinion with
8 a soft hammer to help seat the bearings
NOTE: If the ring nut is over tightened, the
collapsible spacer must be replaced and the
procedure repeated.
1
STEP 13
Insert the pinion (1) into the differential support (7).

Force the bearing cone (8) onto the pinion shaft
using special tool CA715433 and a hammer.
STEP 11
7
Carry out the preloading measurement (P) of the
pinion bearings (3), (8) using a dynamometer and
cord wound round the splined end of the pinion
shaft (1). The adjustment is carried out by gradually
10 increasing the torque of the ring nut (10) taking care
not to exceed.
9
P=8 to 12 da N
ATTENTION: All preloadings must be measured without

the seal.
Assemble washer (9) and a new ring nut (10) on the
pinion. STEP 14
STEP 12
Once the preload value is achieved, lock the ring

nut (10) into the groove on the pinion shaft using a
Tighten the ring nut (10) using the ring nut wrench, hammer and chisel.
CA119060 and the pinion retainer CA715269.
SM 8-12421 Issued 09-2004

50 SECTION 6022
Toe-in adjustment
1 5 6 2
3 4
7 8
9 10
STEP 1 STEP 2
Put two equal one meter long bars on the wheel Measure the distance in mm (M) between the ends
sides and lock them with two nuts on the wheel of the bars with a tape measure.
studs.
NOTE: Rotate the wheel hub in two 20° stages
NOTE: TThe two bars should be fixed so the and repeat Steps 1 and 2 at each stage. Take
centre of each bar is perpendicular to the and note the minimum value (M).
centre line of the hub and parallel to the pinion
shaft axis.
SM 8-12421 Issued 09-2004

SECTION 6022 51
STEP 3 STEP 4
To adjust toe-in, loosen the lock nuts (3) and (4).

Screw in or out the tie rods (5) and (6) in equal
turns until the toe-in is within the requested range.
STEP 5
Check that the difference of the measurements

between the wheel hubs diameter ends are within
the requested tolerance range. The nominal toe-in
value (A) refers to the external diameter of the
wheel hubs. The measured value (M) refers to the
ratio between the length of the bar and hub
diameter.
Nominal toe-in = A -2
Measured toe-in = M - 5
After adjusting, tighten the lock nuts (3) and (4) to

a torque of 250 Nm (185 lb ft).
SM 8-12421 Issued 09-2004

52 SECTION 6022
Steering angle adjustment

STEP 1 STEP 3
Use the same bars assembled for the toe-in Adjust the steering stop by screwing in or out the
adjustment and a long bar perfectly placed over special screws (7) and (8) locking them with the lock
the machined part of the central body (pinion nuts (9) and (10) to a torque of 150 Nm (111 lb ft).
side), so that the two bars form an acute angle at Turn steering to other side and repeat operations
the maximum turning point.
STEP 2
Adjust a bevel protractor to an angle of 35 o and

position it on the long bar. Move the wheel side
until it forms with the two bars, the angle fixed by
the bevel protractor.
SM 8-12421 Issued 09-2004

Section
7
BRAKES
How it Works
ZTX Series Tractors

DT50-50300 March 2004
SECTION 7

SECTION 7
Content Page
Brake Description ..................................................................................................4

Park brake Description ..........................................................................................5
Sectional illustration of master cylinder and booster valve .....................................6
Brake booster schematic .......................................................................................7

SECTION 7
Brake system description

TThe ZTX tractors are fitted with oil immersed double brake discs.
The double brake disc system comprises a pair of 313 mm diameter brake discs in
each, trumpet housing. The discs are mounted on the high speed differential output
shafts and are oil immersed plus receive a constant flow of lubrication/cooling oil.
Each brake is hydraulically actuated by a power boosted master cylinder, when the
operator puts his foot on the pedal. The piston takes the form of an annular ring that
is operated from a recess in the centre housing. The piston acts on the friction discs
and forces them into contact with the reaction surfaces of the disc inter-plate and of
the spacer of the final reduction epicyclic unit.
The piston is sealed using O-rings that are fitted into grooves in the centre housing.
When the brake is released, the sealing arrangement allows a minimal running
clearance between the piston and the brake discs. The brakes are self-adjusting and
maintain the correct brake pedal free travel.
The brake surfaces are lubricated with a flow of oil that is circulated via the hydraulic
system from the tractor rear axle. This maintains a constant oil flow past the braking
surfaces, whilst the tractor is running, to cool the braking components.
The brakes are applied via twin pedals connected to twin power boosted master
cylinders. The fluid used is transmission oil, and the master cylinder reservoir is
automatically “topped up“ by the tractor gearbox hydraulic system. No regular
maintenance is required. Each brake is independent of the other. When both brakes
are applied together, the circuits are inter-connected and automatically balanced.
An accumulator is also fitted in the oil supply line to the booster valve to provide
system pressure for several applications of the brake pedal after the engine has
been stopped.
A hydraulic trailer brake valve is also fitted. This is controlled by the brake master
cylinder also. The brake pedals should be latched together when using the trailer
brakes.

SECTION 7
Park brake description

The parking brake unit is installed on the pinion shaft in the intermediate housing.
It consists of an expander mechanism placed between the six discs, coupled with the
pinion shaft, and the five intermediate plates.
The expander is housed in a casing that is mounted on the bearing casing of the
drive pinion and consists of two cast iron plates held by springs and separated by
balls housed in rails.
It is actuated by a tie rod mounted on a relay rod fitted with a cam that is in contact
with a sliding rod which, itself, bears on a second cam that is splined onto a pin
controlled by a link.
The discs are distributed as follows in the front and rear sections.
Front half Parking brake Rear half

Discs Plates Expander Discs Plates
3 2 in the middle 3 2
On ZTX series tractors the parking brake assembly is lubricated with an oil flow from
the tractor hydraulic system that is circulating via a lubrication pipe through a gallery
in the drive pinion.

SECTION 7
Sectional illustration of brake master cylinder

and booster valve

SECTION 7
Brake booster schematic

7001
Section
7001
PARKING BRAKE
ZTX Series Tractors

SM 8-12400 March 2004
2 SECTION 7001
TABLE OF CONTENTS
HANDBRAKE AND CONTROL LINK

General ................................................................................................................................................................ 3
A . Disassembling and reassembling the handbrake unit .................................................................................... 6
Disassembly .................................................................................................................................................... 6
Reassembly ..................................................................................................................................................... 6
B . Disassembling, reassembling and adjusting the controls ............................................................................... 8
Disassembly .................................................................................................................................................... 8
Reassembly ..................................................................................................................................................... 8
SM 8-12400 Issued 03-2004

SECTION 7001 3
Handbrake and control link
General Parts list (Fig. 1)

The mechanical control assembly of the handbrake
is fitted on drive pinion (9) located on the (1) O-ring
intermediate hou-sing. (2) Bolt
(3) Link
It consists of a mechanism (16) placed between six (4) Holding plate
discs (14) that are integral with the drive pinion and (5) Bolt
four intermediary plates (6). (6) Intermediate plates
(7) Housing
The mechanism housed in a unit (15) fixed to the rear (8) Bolt
bearing carrier is composed of two cast-iron plates (9) Drive pinion
held by springs and separated by ball bearings (10) Friction ring
lodged in raceways. (11) Pin
(12) Oil seal
It is operated via a rod (23) fitted on relay pin (26) by (13) Bearing carrier
means of relay cam (22) which is in contact with rod (14) Disks
(19), itself thrusting against a second cam (31) (15) Housing
integral via splines with pin (11) controlled by link (3). (16) Spreader mechanism
(17) Bolt
(18) Washer
Remarks (19) Rod
Depending on the type of tractor, the lubrication of (20) Pin
the handbrake discs is ensured by an oil mist coming (21) Adjuster nut
from a central channel and radial drilled holes (22) Cam
machined into the drive pinion (see section 6018 (23) Link
depending on the version). (24) Clevis
(25) Pin
Operation (26) Pin
When the handbrake lever is pulled upwards, the (27) Friction rings
cable acts upon link (3) integral with pin (11) via (28) Special bolt
splines. (29) Mecanindus pin
(30) Set screw
Pin (11) pivots and turns cam (31) that pushes rod (31) Cam
(19) to thrust against a relay cam (22) that turns (32) Spring
freely on pin (26), thus causing the spreading of (33) O-ring
mechanism (16) by way of threaded link pin (23). (34) Lever
(35) Nuts
When the handbrake lever is in the off position, the (36) Grower washer
link (3) returns to its initial position by means of (37) Cable
spring (32). The adjuster nut of the mechanism is (38) Ratchet
accessible via a plug screwed on to the top of the (39) Quadrant
intermediary housing. The oil tightness of housing (40) Clevis
(7) is provided by seal (12) and that of pin (11) by (41) Rod
O-ring (1). (42) Shouldered washer
(43) Washer
(44) Push-button
(45) Spring
SM 8-12400 Issued 03-2004

4 SECTION 7001
Overall view
Figure 1
SM 8-12400 Issued 03-2004

SECTION 7001 5
Overall view
4
35
37
5
36
34
Figure 2
SM 8-12400 Issued 03-2004

6 SECTION 7001
A . Disassembling and reassembling the handbrake unit
Remark Reassembly
To carry out operations on the handbrake
mechanism comprising discs (14), intermediate STEP 9
plates (6) and mechanism (16), it is necessary to
uncouple the tractor and remove the intermediate
found to be defective or buckled.
housing as well as the drive pinion.
Check that the central channel and radial drilled
Preliminary operations holes of the drive pinion (depending on versions) are
not obstructed.
STEP 1
Uncouple the tractor between the gearbox and the Check also, the oil discharge ports located at the
intermediate housing (see section 6003). base of the handbrake unit housing.
STEP 2
Separate the intermediate housing from the centre
housing (see section 6003).
STEP 3
Remove the creeper unit (if fitted) (see section
6018).
If necessary, remove the sleeve and ratchet of the

Park Lock (depending on equipment) and the
bearing assembly / hydraulic pump drive pinion.
STEP 4
Remove the drive pinion and handbrake unit (see
section 6018 depending on the version).
Disassembly
STEP 5 Figure 3
Remove circlip (5)
STEP 6
Loosen and remove bolts (8)
Separate the housings (13) (15).
STEP 7
Place the drive pinion on the workbench, the bevel
gear at the bottom.
STEP 8
Remove the discs, intermediate plates and the brake
mechanism.
SM 8-12400 Issued 03-2004

SECTION 7001 7
STEP 10 STEP 21
Place carrier (13) on the bearing cone of the drive Check all the functions (mechanical and electrical) of
pinion, with the cup previously lubricated. the handbrake lever.
STEP 11 STEP 22
Correctly orient control"C". Refit mechanism (16) by Road test.
placing it between discs (14) and the intermediate
plates (6) as shown in the overall view. Correctly STEP 23
position stops "T".
Check the oil tightness of the mating faces and the
hydraulic unions.
STEP 12
Assemble the handbrake unit (15) on bearing carrier
(13).
STEP 13
Fit bolts (8) previously lightly smeared with Loctite
270 or its equivalent and tighten to a torque of 120 -
160 Nm.
STEP 14
Fit circlip (5).
Final operations
STEP 15
Refit the drive pinion unit and handbrake (see
section 6018 depending on the version).
STEP 16
Turn and fit axle (25) to mechanism (16) so as to
clear it easily. Fit the washer and a new split pin.
Adjust the control (see Page 8).
STEP 17
Refit the bearing / hydraulic pump drive pinion
assembly, the ratchet and the Park Lock sleeve
(depending on equipment). Fit the creeper unit
(if fitted).
STEP 18
Reassemble the intermediate housing and centre
housing (see section 6003).
STEP 19
intermediate housing (see section 6003).
STEP 20
Check the correct operation of all the controls.
SM 8-12400 Issued 03-2004

8 SECTION 7001
B . Disassembling, reassembling and adjusting the controls
Disassembly
STEP 24
Remove the entire unit (7) and rod (19). If necessary,
take out each component in the unit.
NOTE: To take out pin (26) and cam (22), it is

necessary to uncouple the tractor between the
gearbox and the intermediate housing (see section
6003).
Reassembly
STEP 25
Reverse the order of the previous operations and Figure 4
respect the following special points.
Special points
On unit (7)
Insert friction bush (10) using a locally manufactured
drift. Insert oil seal (12) in contact with unit (7) using
a suitable fixture. After inserting, lubricate the seal.
lightly smear with Loctite 241 the Philips head bolt
(30) of cam (31). lightly smear with Loctite 510 the
mating face of unit (7) and the intermediate housing.
Tighten bolts (2) to a torque of 25 - 35 Nm and bolt
(17) to a torque of 14 - 20 Nm.
NOTE: During assembly, do not forget O-ring (1)

that provides oil tightness between pin (11) and
the link (3).
On cam (22)
Insert the friction bush (27) flush with face ’F’ (Fig. 4).
Lightly smear bolt (28) with Loctite 542 (solely on an

assembly without an O-ring) and tighten to a torque
of 25 - 35 Nm.
On cam (31)
Moderately tighten set screw (30) smeared with
Loctite 241.
On the brake mechanism (16)

Fit pin (25) in such a manner as to provide
clearance. Lightly smear the thread of link rod (23)
with Loctite 270 and tighten it in clevis (24).
SM 8-12400 Issued 03-2004

SECTION 7001 9
Adjustment
With cam (31) in contact with unit (7) (Fig. 5) via the
port located above the intermediate housing, act on
nut (21) in order to obtain a clearance "J" of 1.2 mm
to 1.3 mm between the discs, intermediate plates
and mechanism (Fig. 7).
STEP 26
Position link (3) on pin (11) to obtain a dimension of
210 mm to 235 mm between the centre of the cable
and cable holder (4) (position A - Fig. 6) by checking
that cam (31) is in contact with the housing (7).
STEP 27
Check that the travel of the link (3) falls between 30
mm and 45 mm with a force of 10 - 25 daN exerted
at the point where the cable is fixed (position B -
Fig. 6).
Figure 6
ATTENTION: To adjust the tractor handbrake, take off the
wheel concerned and slightly tilt the cab to the left , taking
care not to damage any of the components attached to it.
Position an axle stand. Remove the plug located above the
intermediate housing. Using a locally manufactured short
spanner, adjust nut ( 21 ) in order to obtain the travel stated
in operation 27. After adjustment, check the free
movement of the tractor with the handbrake in the off
position.
NOTE: Tightening torque for wheel nuts or studs

(see section 6003).
Figure 7
Figure 5
SM 8-12400 Issued 03-2004

10 SECTION 7001
C . Disassembling, reassembling the lever and replacing the cable
Disassembling the handbrake lever Refitting

(Fig. 9)
NOTE: If necessary, before refitting the new
cable, hold it ver tically and inject a few drops of
STEP 28
Vaseline oil between the cable and sheath. Wait
Disconnect the electrical connector (1) to the switch for several moments for the oil to descend the
and the handbrake cable (37) (Fig. 8). length of the cable.
STEP 29 STEP 34
Unscrew the push-button (44). Carry out the fitting of the cable on its respective
fixing points.
STEP 30
Recover spring (45). STEP 35
Check the following points to ensure correct
Reassembly operation of the handbrake lever:
STEP 31 Put the handbrake on, its initial travel should be

approximately 10 to 13 clicks of the ratchet with a
Refit the lever. Reverse the disassembly operations. force of around 10 - 25 daN exerted at the point of
cable connection.
STEP 32 The signal lamp on the dashboard should light.
Check the correct operation of the lever (see STEP 35). Release the handbrake.
If necessary, adjust the handbrake (see Page 8). The assembly should return to the handbrake off
position.
Replacing the cable The assembly should operate freely without any
"hard" points or sticking.
In the handbrake off position, the dashboard light
STEP 33 must go out.
Disconnect the ends of the cable and sheath (Fig. 8).
Remove the cable.
Figure 8
SM 8-12400 Issued 03-2004

Section
8
HYDRAULICS
How it Works
ZTX Series Tractors

DT50-50310 March 2004
SECTION!8

SECTION!8
Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !Page
Introduction ............................................................................................................4
Suction!strainer!! ....................................................................................................5
Charge!pump! ........................................................................................................5
Main!hydraulic!filter! ...............................................................................................5
5!bar!pressure!warning!switch................................................................................5
Main!hydraulic!pump ..............................................................................................6
Cutaway!illustration!of!PFC!axial!piston!pump .......................................................7
Main!distribution!valve!block ..................................................................................8
Steering!and!hydraulic!trailer!brake!priority!valve!..................................................8
Illustration!of!inner!slice!of!distribution!valve!block! ................................................9
17!Bar!priority!valve!...............................................................................................10
Hydraulic!trailer!brake!valve! ..................................................................................10
Illustration!of!outer!slice!of!distribution!valve!block!................................................11
Schematic!drawing!of!hydraulic!distribution!valve!block!........................................12
Rear!hitch!operation . .............................................................................................13
Rear!hitch!controls .................................................................................................13
Illustration!showing!position!of!auxiliary!valves!and!hitch!valve .............................14
Rear!hitch!neutral!position!.....................................................................................15
Rear!hitch!raise!position.........................................................................................16
Rear!hitch!lower!position ........................................................................................17
Shock!valve!operation ............................................................................................17
Auxiliary!valves!description! ...................................................................................18
Distribution!Block! ..................................................................................................19
Diagram!of!auxiliary!valves,!hitch!valve!and!distribution!block! ..............................19
Pressure!reducing!valve.........................................................................................20
Electro!hydraulic!spool!valve!description................................................................20
Drawing!of!auxiliary!valve!slice!(neutral!position)...................................................21
Valve!operation!(raise) ...........................................................................................22
Valve!operation!(lower)! .........................................................................................23
Valve!operation!(float) ............................................................................................24
Motor!spool!operation.............................................................................................24

SECTION!8
Introduction
ZTX!is!fitted!with!closed!centre!Pressure!flow!compensating!hydraulics!(PFC).
Oil!is!drawn!out!of!the!intermediate!section!of!the!gearbox!through!a!replaceable
suction!strainer!element!located!on!the!left!hand!side!cover!by!the!charge!pump.
This!is!a!gear!pump!that!is!mounted!on!the!inside!of!the!left!hand!side!plate!and!is
driven!directly!by!the!gear!fitted!to!the!PTO!drive!shaft.!Oil!from!the!charge!pump!is
passed!through!internal!steel!pipes!from!the!pump!to!the!pressure!filter!housing!on
the!right!hand!side!of!the!gearbox.!Any!excess!oil!from!the!5!bar!valve!is!also
dumped!back!into!the!charge!pump!suction!pipe!internally!in!the!gearbox.
Flow!from!the!charge!pump!then!passes!through!the!pressure!filter!and!is!split!three
ways!according!to!demand.
1.! ñ!According!to!tractor!demand!the!majority!of!the!flow!is!sent!to!the!inlet!port!of
the!PFC!pump.!(Either!110!L/min!or!150L/min!depending!on!pump!option)
2.! !ñ!Approximately!34!Litres/min!are!directed!for!lubrication!to!the!MFD!clutch,!PTO
arrangements,!pump!drive!gears!and!bearings,!park!brake!and!creeper!and!left
and!right!rear!axle!housings!for!brake!cooling!and!lubrication.
3.! ñ!The!PFC!pump!inlet!pressure!is!limited!to!5!bar!max!by!a!relief!valve.!Any
excess!oil!flow!as!described!earlier!is!then!fed!back!into!the!charge!pump!suction
pipe.
If!for!any!reason!charge!pump!pressure!is!low!a!light!will!be!illuminated!on!the!dash
and!a!pressure!test!point!is!also!fitted,!with!which!charge!pressure!can!be!measured.
The!PFC!axial!piston!pump!is!either!mounted!internally!within!the!right!hand!side!of
the!intermediate!gearbox!housing!(110!L/min!option).!Or!it!is!mounted!externally!on
the!right!hand!side!(150!L/min!option)!and!is!also!driven!by!a!gear!on!the!PTO!input
shaft.!Both!pump!options!are!controlled!by!an!externally!mounted!pressure!flow
regulator,!connected!to!a!signal!line.!The!pump!outlet!has!a!230!bar!shock!valve
fitted!to!protect!it!from!pressure!spikes.
Main!pump!pressure!is!then!directed!to!the!distribution!blocks!on!the!right!hand!side
of!the!transmission!where!the!priority!valves!are!fitted.
There!are!pressure!test!points!fitted!to!the!distribution!block!to!measure!both!main
pump!pressure!and!signal!line!pressure.

SECTION!8
Suction!strainer
This!is!a!cartridge!type!strainer!fitted!within!polycarbonate!housing,!giving!a!filtration
level!of!150!microns.!The!suction!strainer!element!should!be!replaced!every!1000
hours.!It!should!also!be!noted!that!this!strainer!has!no!bypass!valve!or!vacuum
switch!to!warn!of!a!blockage.
Charge!pump
The!charge!pump!fitted!to!ZTX!is!a!Rexroth!gear!type!pump!with!a!capacity!of!60cc
per!revolution.!This!gives!a!total!flow!at!2200!engine!rpm!of!165!Litres!per!min.
However!if!the!optional!large!main!hydraulic!pump!is!fitted!then!a!larger!charge
pump!is!also!fitted.!This!has!a!capacity!of!80!cc!per!revolution!giving!a!flow!of!195
L/min!at!2200!engine!rpm.
Main!hydraulic!filter
This!is!also!a!cartridge!type!filter!with!a!filtration!level!of!15!microns.!It!is!mounted!in
housing!on!the!right!of!the!tractor.!The!filter!should!be!replaced!at!first!50!hour
service!and!then!every!500!hrs.
Oil;!passes!from!outside!to!inside!of!the!filter,!and!it!is!fitted!with!a!bypass!valve!and
a!pressure!differential!switch!and!a!temperature!switch.
Note:!When!this!filter!is!replaced!care!must!be!taken!not!to!starve!the!PFC!pump!of
oil.
5!Bar!pressure!warning!switch
This!is!fitted!into!the!pressure!filter!head!to!measure!charge!pressure.!It!can!be
identified!by!its!green!tip!colour.!It!is!closed!in!neutral!and!opens!at!3!bar!and!closes
at!2!bar.

SECTION!8
Main!hydraulic!pump
This!is!a!pressure!flow!compensating!axial!piston!pump!sometimes!also!called
Closed!Centre!Load!Sensing!CCLS!!with!9!pistons!!and!as!stated!previously!is
available!with!2!size!options.!The!specs!of!each!are!as!follows
110!L/min
Manufacturer-!Brueninghaus!Hydraulik!(Rexroth!ñ!Bosch)
Variable!capacity!from!0!to!45!ccs!per!rev.!Giving!0!to!110!L/min!flow!at!180bar!at
2200!engine!rpm.
Charge!pressure!5!bar.
Pressure!and!flow!compensated!to!control!pump!delivery.
Standby!pressure!adjustment=22!bar.!Maximum!pump!pressure!=200!bar.!Shock
valve!setting
230!bar.
150!L/min
Manufacturer-Brueninghuas!Hydraulik!(Rexroth!ñ!Bosch)
Variable!capacity!from!0!to!60!cc!per!rev.!Giving!0!to!150!L/min!flow!at!180!bar!at
2200!engine!rpm
Charge!pressure!5!bar
Pressure!and!flow!compensated!to!control!pump!delivery.
Standby!pressure!adjustment=22!bar.!Maximum!pump!pressure=200!bar.!Shock
valve!setting!230!bar.

SECTION!8
Cutaway!illustration!of!PFC!axial!piston!pump
Pressure!Flow
Compensator
Swash!plate Spool
Spring
Drive
Shaft
Swash
Plate
Pumping
Case Element
Drain (Piston)
Port

SECTION!8
Main!distribution!valve
Pump!pressure!is!fed!directly!from!the!PFC!pump!into!the!distribution!valve!block
which!houses!the!steering!and!trailer!brake!combined!priority!valve(Only!if!hydraulic
trailer!brake!is!fitted.!If!no!hydraulic!trailer!brake!is!fitted!the!priority!is!to!steering
only.),!the!steering!priority!valve,!hydraulic!trailer!brake!valve!itself!and!17!bar!circuit
priority!valve.!After!these!priority!circuits!have!been!supplied!all!remaining!oil!flow!is
directed!to!operate!the!hitch!and!auxiliaries.
Steering!and!brake!priority!valve
Pump!flow!enters!the!block!and!is!directed!across!the!combined!steering!and!trailer
brake!priority!valve!to!the!steering!priority!valve,!which!is!sprung!open!to!the
steering.!When!the!steering!is!in!neutral!and!no!oil!flow!is!required,!pressure!builds
in!the!steering!line,!passes!through!an!orifice!and!then!to!a!second!orifice,!and!acts
on!the!steering!priority!spool!and!pushes!it!against!its!spring!to!allow!oil!to!pass!to
the!trailer!!brake!valve.
!When!there!is!no!demand!for!oil!to!either!the!steering!or!the!trailer!brakes!pressure
also!builds!back!to!the!combined!steering!and!trailer!brake!priority!valve!and!through
an!orifice!and!acts!on!the!end!of!the!spool!to!push!it!against!its!spring,!and!allow!oil
flow!through!to!the!17!bar!priority!valve.!When!either!the!steering!is!operated!or!the
trailer!brakes,!are!applied!pressure!drops!in!the!line!and!allows!the!spring!pressure
plus!signal!line!pressure!to!act!on!the!end!of!the!combined!steering!/!brake!priority
spool!and!move!it!across!directing!all!oil!flow!back!to!the!steering!priority!valve.
Should!the!steering!then!be!operated!a!combination!of!spring!pressure!and!signal
line!pressure!move!the!steering!priority!valve!spool!back!over!to!allow!oil!to!the
steering!valve!only,!until!its!demand!has!been!met.
!In!order!to!let!the!steering!priority!spool!move!back!over!quickly!there!is!a!check
valve!fitted!in!the!end!of!the!spool!that!will!allow!oil!to!flow!away!from!its!end!quickly
without!having!to!flow!through!an!orifice.

SECTION 8
Inner slice of Priority and distribution valve block
SIGNAL LINE
FROM REGULATED
MAIN AUXILIARY PRESSURE
HYDRAULIC VALVES PORT
SUPPLY ( 17 BAR)
17 BAR
SPOOL
STEERING
&
HYDRAULIC
TRAILER
BRAKE
SPOOL
STEERING OUTLET
STEERING SIGNAL TO WHEN NO TRAILER
SIGNAL PUMP BRAKE VALVE
LINE IN COMPENSATOR FITTED
VALVE (PLUGGED IF
EQUIPPED WITH
TRAILER BRAKE
VALVE.)

SECTION!8
17!Bar!priority!valve
When!all!oil!demand!for!both!steering!and!brakes!has!been!met!the!combined
steering!and!brake!priority!valve!is!held!against!its!spring!allowing!oil!to!be!sent!to
the!17!bar!priority!valve.!!The!spool!in!the!valve!is!sprung!open!and!so!oil!pressure
quickly!builds!in!its!gallery!and!a!line!internally!joins!this!to!the!end!of!the!17!bar
priority!spool!where!the!oil!pressure!pushes!it!over!diverting!all!remaining!oil!flow!to
the!hitch!and!auxiliaries
Hydraulic!trailer!brake!valve
A!signal!is!felt!at!the!trailer!brake!spool!from!the!service!brake!circuit!and!this!acts
directly!on!the!end!of!the!spool!and!moves!it!over!to!allow!pump!pressure!to!the
trailer!brakes.!An!oil!way!also!allows!oil!in!the!line!to!the!trailer!brakes!to!act!on!the
end!off!the!spool!to!push!it!back!to!its!neutral!position.!A!maximum!of!150!bar!signal
pressure!can!be!felt!at!the!spool!as!a!relief!valve!is!fitted!in!the!circuit.!When!the
spool!returns!to!neutral!it!also!opens!the!trailer!line!to!tank,!letting!off!the!trailer
brake.

SECTION 8
Outer slice of priority and distribution valve block

TO HYDRAULIC
HYDRAULIC TRAILER TRAILER BRAKE
BRAKE VALVE COUPLING
ACCTUATION LINE
(FROM FOOT
BRAKES)
HYDRAULIC
TRAILER
BRAKE
VALVE SPOOL
STEERING
PRIORITY
SPOOL
SIGNAL LINE STEERING OIL FLOW

FROM VALVE FROM INNER
HYDRAULIC SUPPLY DISTRIBUTION
TRAILER PORT BLOCK
BRAKE VALVE STEERING
AND STEERING AND BRAKE
PRIORITY
GALLERY

SECTION!8
Schematic!of!distribution!valve!block

SECTION!8
Rear!hitch!operation
ZTX!is!fitted!with!a!Bosch!electronic!draft!control!system!to!operate!the!rear!hitch.
It!uses!lower!link!draft!load!sensing!pins,!a!hitch!position!sensor,!and!hitch!valve
containing!raise!and!lower!solenoids,!a!Bosch!electronic!control!module,!and!various
other!switches!to!control!all!its!functions!as!shown!below.
!Oil!is!supplied!to!the!hitch!from!the!distribution!valve!after!all!other!priority!circuits
have!had!there!demand!met.!The!rear!hitch!valve!is!bolted!in!between!the!spool
valve!slices!and!the!auxiliary!valve!distribution!block!mounted!on!the!rear!of!the
transmission!case,!above!the!PTO!housing.
Rear!hitch!controls
Hitch/Depth
Control!lever Draft/Position!Control
(Intermix)!potentiometer
Full!position!=!1
Full!draft!=11
Hitch!drop!rate
Potentiometer Max!lift!height
potentiometer
Rear!hitch!fender!raise!and Multi!function!control!lever
Lower!Control!buttons hitch!raise,!lower!and!quick
entry!switch

SECTION!8
Position!of!rear!hitch!valve!and!auxiliary!valves
Hitch!and!auxiliary!valve!position!on!tractor

SECTION!8
Rear!hitch!neutral!position
TWhen!the!rear!hitch!is!in!the!neutral!position!neither!the!raise!or!lower!proportional
control!solenoid!is!energised!and!the!raise!and!lower!control!spools!are!in!there!rest
positions.
The!service!port!check!valve!is!on!its!seat!and!so!the!linkage!arms!are!held!in
position.
Oil!flow!enters!the!valve,!and!fills!the!gallery!around!the!flow!control!spool.
It!also!passes!down!a!passage,!to!the!end!of!the!spool,!and!as!there!is!no!signal!line
pressure!to!act!on!the!other!end!of!the!spool,!it!moves!over!against!its!spring!to
close!of!the!oil!flow!and!allow!the!main!hydraulic!pump!to!go!into!stand!by.
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!8!!!!!!2!!!!!!!!!!!!!!!!!!!!!!1

SECTION!8
Rear!hitch!raise!position
Power!is!sent!to!the!proportional!raise!solenoid!from!the!Bosch!electronic!control
module,!this!then!moves!the!raise!spool!to!its!raise!position,!allowing!oil!from!the
inlet!gallery!to!pass!into!the!service!port!gallery,!this!is!connected!to!the!load!sensing
signal!line!and!therefore!to!the!bottom!of!the!flow!control!spool.!This!signal!line
pressure!combined!with!spring!pressure!pushes!over!the!flow!control!spool!to!open!it
to!allow!a!faster!oil!flow.
As!the!pump!comes!on!stroke!the!pressure!increases!in!the!signal!line!until!the
pump!has!developed!enough!pressure!to!push!the!service!port!check!valve!of!its
seat!and!therefore!raise!the!link!arms.!When!the!correct!lift!height!is!achieved!the
hitch!control!module!senses!from!the!position!sensor!or!draft!sensing!pin,!and!turns
off!the!raise!solenoid,!allowing!the!valve!to!return!to!the!neutral!position,!and!the
PFC!pump!to!de-stroke!back!to!stand!by.
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!4!!!!!3!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!5

SECTION!8
Rear!hitch!lower
When!the!operator!gives!the!command!to!lower!the!implement!the!Bosch!electronic
control!module!looks!at!the!desired!rate!of!drop!set!on!the!drop!rate!potentiometer
and!powers!the!proportional!solenoid!accordingly,!this!then!moves!the!lower!spool!to
give!the!desired!lower!speed!and!height!on!the!linkage!arms.!The!lower!spool
connects!the!service!port!of!the!valve
directly,!to!the!tank!port!when!operated.
Shock!valve!operation
A!shock!valve,!or!cushion!valve!as!it!is!sometimes!called,!is!fitted!in!the!service!port
gallery!linking!it!directly!to!tank.!This!valve!is!held!closed!by!its!spring.!If!however!a
heavy!implement!should!bounce!whilst!being!carried!in!the!air!and!inflict!the
hydraulic!system!to!a!pressure!spike!that!is!likely!to!damage!the!hydraulics!or
anything!else!on!the!tractor,!the!shock!valve!will!open,!and!release!a!small!amount
of!oil!to!cushion!the!shock.!The!Bosch!hitch!module!will!then!sense!that!the
implement!has!dropped!from!its!set!position!and!lift!it!back!up!accordingly.

SECTION!8
Auxiliary!valves!description
ZTX!is!fitted!with!CAN!BUS!controlled!electro!hydraulic!auxiliary!valves.!There!can
be!a!maximum!of!5!valves!fitted,!4!of!which!are!joy!stick!controlled!and!have!a!float
position!and!a!further!valve!slice!that!is!operated!by!means!of!2!buttons!on!the!!multi
function!control!lever.!This!valve!however!has!no!float!facility
.
All!5!valves!have!a!flow!and!timer!facility!built!into!them,!and!can!be!set!by!the
means!of!a!separate!potentiometer!for!each!function!built!into!the!armrest!of!the
seat.!The!timer!for!each!valve!can!be!set!for!between!1!and!30!seconds!and!if!the
potentiometer!is!turned!fully!clockwise,!when!the!valve!is!turned!on!it!will!run!until
manually!turned!off!by!moving!the!joystick!back!to!either!neutral!or!float
.
The!flow!control!allows!between!0%!and!100%!of!available!pump!flow!to!be!set!on
each!valve,!i.e.!if!there!is!110!litres!available!and!number!1!valve!is!set!at!50%!it
would!take!55!litres!and!there!would!be!55!litres!available!for!all!other!valves,!so!if
number!2!valve!was!also!set!at!50%!it!would!supply!25.5!litres!of!oil.!This!means!that
if!equal!flow!is!required!from!two!or!more!valves!the!potentiometers!will!need!to!be
set!differently.
A!master!power!switch!is!fitted!within!the!arm!rest!also!to!turn!the!auxiliary!valves!on
and!a!separate!red!switch!on!the!side!will!turn!them!of.!If!the!ignition!is!turned!off!the
valves!have!to!be!re-enabled!before!they!can!be!used.
Auxiliary!valve!joystick!controls Auxiliary!valve!flow!and!timer!controls
Master!off!switch Master!on!Switch 5th!Auxiliary!valve

for!auxiliary!Valves for!auxiliary!Valves Control!buttons

SECTION!8
Distribution!block
The!auxiliary!valves!are!mounted!as!shown!previously!on!the!rear!of!the
transmission!behind!the!cab!and!are!bolted!onto!the!distribution!block.!This
distribution!block!has!an!inlet!from!the!pump,!an!outlet!to!tank!and!a!load!sensing
signal!line,!with!which!to!control!the!PFC!pump.
The!distribution!block!also!has!ports!for!a!Power!Beyond!facility,!to!run!any!hydraulic
attachment!that!should!require!its!own!dedicated!supply,!it!should!be!remembered
though!that!there!must!be!a!one!way!check!valve!fitted!in!the!implements!load
sensing!line.!Failure!to!fit!one!will!cause!the!tractors!PFC!pump!to!operate
incorrectly.
.
Diagram!of!auxiliary!valves,!hitch!valve!and!distribution!block
Auxiliary
Auxiliary
Valve!No.
valve!No.
Hitch
Auxiliary
Valve
Valve!No. Auxiliary Auxiliary
Valve!No. Valve!No.
Distribution!block!and
Power!beyond
Pressure!reducing
Valve!section
Rear!view!of!tractor!looking!at!valve!bank

SECTION!8
Pressure!reducing!valve
This!valve!is!fitted!onto!the!left!hand!side!of!the!auxiliary!and!hitch!valve!stack!at!the
rear!of!the!tractor!and!acts!as!a!safety!valve.!When!turned!off!regulated!pressure
required!to!work!the!electro!hydraulic!auxiliary!valve!slices!is!stopped!from!getting!to
them!making!them!inoperative.
When!the!solenoid!on!the!reducing!valve!receives!12!volts!from!the!auxiliary!valve
control!module!it!opens!up!the!valve!and!regulated!pressure!is!again!fed!to!the
auxiliary!valves,!to!allow!them!to!function,!when!they!get!a!signal!from!the!CAN!BUS
from!the!Auxiliary!valve!control!module.
The!pressure!reducing!valve!will!turn!off!whenever!the!tractor!ignition!is!turned!off!or
whenever!the!red!button!on!the!armrest!is!pressed.!To!turn!it!back!on!the!black
button!on!the!armrest!must!be!pushed.!(This!also!must!be!done!to!operate!the
auxiliary!valves!after!start!up!every!time.)
Electro!hydraulic!spool!valve!description
There!can!be!up!to!five!valves!fitted!to!ZTX!and!each!valve!is!made!up!of!2!main
sections,!these!are:-
An!electro!hydraulic!pilot!control!valve;!this!contains!a!CAN!BUS!operated
proportional!electro!hydraulic!pilot!valve,!that!controls!pilot!pressure!acting!on!the
main!spool,!an!inductive!position!transducer/sensor!that!tells!the!auxiliary!valve
control!module!the!position!of!the!valve!over!the!CAN!BUS,!and!a!diagnostic!LED.
A!main!spool!valve!block;!this!consists!of!the!valve!main!body!containing!main!spool,
compensator!spool!and!spring,!load!hold!check!valve,!signal!line!check!valve.
Load!hold!check!valves!can!be!fitted!to!both!service!ports!of!the!valves.

SECTION!8
Drawing!of!auxiliary!valve!slice!(neutral!position)
6
13
1.! Electrical!connection A!!!Service!port

2.! Control!unit!circuit!board B!!!Service!port
3.! Pilot!control!pin LS!Signal!pressure
4.! Pilot!pin!spring P!!!!Pressure!gallery
5.! Pilot!pin!spring T!!!!Return!oil!gallery
6.! Pilot!pressure!gallery P1!Regulated!pressure
7.! Pilot!pressure!gallery XR!Pilot!pressure!return
8.! Main!spool
9.! Main!spool!centring!spring
10.!Compensator!spool
11.!Compensator!spring
12.!Service!port!load!hold!check!valve
13.!Spool!position!transducer

SECTION!8
Valve!operation!(raise)
When!switched!by!the!operator!the!valve!receives!a!signal!from!the!Auxiliary!valve
control!module!on!the!CAN!BUS,!it!then!responds!accordingly!powering!the!pilot
valve!block!to!direct!pilot!pressure!(P1)!into!the!main!spool!control!piston!gallery(6).
This!causes!the!main!spool!to!move!across!allowing!oil!to!flow!from!gallery!P,!across
compensator!spool!(10),!and!onto!the!main!spool!which!has!opened!up!to!port!B!and
the!signal!line!also.!Pressure!is!sent!back!to!the!PFC!pump!regulator!and!the!pump
comes!on!stroke.!When!the!main!spool!was!moved!across!pin!acting!on!the!load
hold!check!valve!was!pushed!up!by!a!ramp!on!the!spool!opening!it!to!allow!oil!past.
The!compensator!spools!task!is!to!deliver!a!constant!pressure!and!flow!regardless!of
engine!speed!or!variation.
1
2
7 6 8
Signal!line!check
!!!!!!!!!Valve
!10

SECTION!8
Valve!operation!(lower)
When!switched!by!the!operator!the!valve!receives!a!signal!from!the!auxiliary!control
valve!module!on!the!CAN!BUS,!it!then!switches!the!valve!to!lower!by!energising!the
pilot!valve!to!direct!oil!into!the!main!spool!control!piston!gallery!(7),!to!push!the!spool
over,!opening!up!the!oil!flow!from!gallery!P!across!the!compensator!spool!and!along
to!service!port!B!and!to!the!signal!line!also.!The!pilot!valve!will!let!oil!flow!from!the
spool!control!piston!gallery!6!return!to!tank!through!line!XR.!Return!oil!from!service
port!A!of!the!valve!is!also!opened!up!to!tank!by!the!main!spool!and!should!it!have!a
check!valve!fitted!(not!shown)!this!will!have!been!opened!by!its!pin!being!pushed!up
by!a!ramp!on!the!spool.
3
1
8
7 6
10

SECTION!8
Spool!valve!operation!(float)
When!the!spool!valves!on!the!tractor!are!required!to!go!into!the!float!position!the
operation!is!the!same!as!the!lower!mode!except!the!spool!travel!is!110%!of!normal
operation.
It!should!be!noted!that!float!is!only!available!on!the!valves!that!are!joystick!operated.
Motor!Spool!Operation
ZTX!has!the!ability!to!operate!a!hydraulic!motor!from!any!of!its!5!spool!valves,
however!as!the!5th!valve!has!no!float!facility!this!makes!it!not!really!suitable,!as!the
motor!would!be!stopped!dead!when!turned!of!causing!possible!damage.
To!set!a!spool!for!motor!operation!the!following!procedure!should!be!followed:-
Set!the!timer!potentiometer!to!maximum!(fully!clockwise)!on!the!chosen!spool.
Ensure!that!the!motor!pipework!is!correctly!fitted!in!the!chosen!spool.
Push!the!chosen!spool!control!joystick!to!the!desired!direction!and!allow!back!to!its
neutral!position!within!1!second,!and!the!spool!will!now!give!a!constant!flow!until!the
joystick!is!moved!again.(!if!the!joystick!is!not!pushed!and!released!within!1!second
then!the!spool!will!just!act!as!if!it!were!to!be!used!manually!)
To!turn!the!valve!off,!simply!push!the!joystick!through!to!the!float!position,!and!when
the!motor!is!stationary!return!the!joystick,!to!neutral.
The!flow!of!oil!to!the!motor!can!also!be!varied!using!the!flow!control!potentiometer

8001
Section
8001
HYDRAULICS TROUBLESHOOTING
AND SCHEMATICS
ZTX Series Tractors

SM 8-12370 March 2004
2 SECTION 8001
TABLE OF CONTENTS
Hydraulics - Description
A. General ............................................................................................................................................................ 3
B. Principle ........................................................................................................................................................... 4
C. Centre housing lubricating circuit .................................................................................................................... 4
D.Layout of components in AG250 powershift transmission ............................................................................... 6
Hydraulics - Hydraulic tests

A. General .......................................................................................................................................................... 11
B. Testing the high pressure 110 l/min circuit .................................................................................................... 12
C. Testing the low pressure 110 l/min circuit ..................................................................................................... 18
D. Testing the high pressure 150 l/min circuit .................................................................................................... 20
E. Testing the low pressure 150 l/min circuit ..................................................................................................... 25
F. Testing the low pressure hydraulic functions of the Powershift transmission ................................................ 26
HYDRAULIC SCHEMATIC
Hydraulic Schematic for Tractors Without Trailer Brake
and With Integeral Steering Pressure Relief Valve ............................................................................................ 31
Hydraulic Schematic for Tractors With Trailer Brake and
Integeral Steering Pressure Relief Valve ........................................................................................................... 32
Hydraulic Schematic for Tractors Without Trailer Brake and
With External Steering Pressure Relief Valve .................................................................................................... 33
Hydraulic Schematic for Tractors With Trailer Brake and
External Steering Pressure Relief Valve ............................................................................................................ 34
SM 8-12370 Issued 03-2004

SECTION 8001 3
Hydraulics - Description
A. General Component characteristics

The hydraulic circuit is of the closed centre type and
is equipped with controlled pressure and flowrate. It
consists of two separate high and low pressure Suction strainer (37)
circuits, supplied by a variable displacement pump. Type ........................................................ cartridge
The variable displacement pump is fed by a charge Filtration threshold ........................................ 150 µ
pump.
Charge pump (38)
Both pumps are driven by a pinion fitted on the upper Trademark ...................................... Rexroth Sigma
shaftline of the PTO located in the intermediate Capacity (110 l/min) ............ 60 cm3 per revolution
housing. Capacity (150 l/min) ............ 80 cm3 per revolution
Output (110 l/min)................ 165 l/min at 2200 rpm
The charge pump fitted on the left-hand cover sucks Output (150 l/min)................ 215 l/min at 2200 rpm
oil through a suction strainer to feed the common
tank formed by the centre housing, the intermediate Main filter (13)
housing and the powershift transmission. The charge Filtration threshold .......................................... 15 µ
pump oil flow is then directed to the right-hand With differential pressure bypass ................ 3,5 bar
hydraulic cover where it passes through the main With differential pressure switch ................. 2,4 bar
filter before flowing to the variable displacement
pump and then to the oil manifold of the centre Safety valve (26)
housing to supply the following components: Calibration ................................................... 22 bar
Fitted on the low pressure circuit
The trumpet housings
The PTO clutch Safety valve (25)
Calibration ..................................................... 5 bar
The hydraulic pump drive bearing
No slave device used ...........supplies charge pump
The 4WD unit Switch ........... 5 bar (clogging indicator on main filter)
Opens ........................................................... 3 bar
The handbrake mechanism
Closes ........................................................... 2 bar
The creeper unit (if fitted) Fitted in parallel to filter
Linked to signal lamp on dashboard
The variable displacement pump supplies two
priority blocks, these are fitted on the right-hand side Variable displacement pump (48)
hydraulic cover. The inner block has the first and last Trademark ....................................... Brueninghaus
levels of priority. The first priority is to supply the Type .................................................. Axial pistons
steering and trailer brake valves. These are in the Variable capacity (110 l/min).......... 0 to 45 cm 3 per
outer block. Provided that their need is satisfied oil revolution
can then pass to the second part of the inner (first) Variable capacity (150 l/min).......... 0 to 60 cm 3 per
block and then supply the 17 bar system. The last revolution
priority is the auxiliary spool valves. Output (110 l/min)......... 0 to 105 l/min at 2200 rpm
Output (150 l/min)......... 0 to 150 l/min at 2200 rpm
In the second block there is a priority valve to ensure Min. pressure .............................................. 22 bar
oil is available firstly to the steering and then Max. pressure............................................ 200 bar
subsequently to the trailer brakes. Internal lubrication with return to housing
All the pilot signals from the various high pressure

valves are directed to the priority block(s) to then be
re transmitted to the variable displacement pump
controller.
The controller takes into account the pilot signal

corresponding to the function requiring the highest
pressure.
SM 8-12370 Issued 03-2004

4 SECTION 8001
B. Principle
The purpose of the closed centre hydraulic system is
to limit the power absorbed by the engine. If no
hydraulic slave device is actuated, no flow is
discharged by the variable displacement pump.
When a function is activated, the pump only supplies

the output required for that function.
NOTE: If the housing is drained, or if the main

filter is replaced, make sure the (red) charge
pressure signal lamp on the cluster goes out a
few seconds after star t up.
C. Centre housing lubricating circuit

Par ts list (Fig. 1)
A Trumpet housing lubrication

B Centre housing lubricating manifold
C Pump bearing lubrication
D General supply from charge circuit
E PTO clutch lubrication
F Lubrication for handbrake mechanism and
creeper unit(if fitted)
G Transfer pipe for trumpet housings with
double drive unit
SM 8-12370 Issued 03-2004

SECTION 8001 5
Figure 1
SM 8-12370 Issued 03-2004

6 SECTION 8001
D.Layout of components in AG250 powershift transmission

Par ts list (Fig 2, 3)
1. Tank
2. Brake master cylinders
3. Servo brake
4 to 12. Transmission proportional to solenoid Valves
13. Main filter (15 u)
14. Suction strainer (250 u)
15. Pump
16. Variable displacement pump regulator
17. Load Sensing diagnostic connector
18 to 21. Solenoid valves: PTO, PTO brake,
differential to lock (front, rear) and 4WD
22. Steering priority spool valve
23. 17 bar pressure spool valve
24. High pressure diagnostic connector
25. 5 bar safety valve
27. Priority block without trailer braking
28. Right-hand cover
29. Charge pump pressure diagnostic connector
30. Low pressure diagnostics connector
31. Discharge pressure limiter
32. Lift rams
33. Couplers
34. PTO brake
35. PTO clutch
36. Auxiliary spool valves
37. Suction strainer (150 µ)
38. Charge pump
39. Centre housing lubricating manifold
40. 4WD clutch
41. Lift control valve
42. Rear differential lock
43. Left-hand cover
44. 3-way filter
45. Temperature probe
46. Transmission pressure regulating valve (17 bar)
47. Hydrostatic steering spool valve (Orbitrol)
48. Variable displacement pump
49. Thermostatic valve
50. Front differential lock
51. Steering rams
52. Oil cooler
53. Pump drive pinion bearing
54. Park Lock control
55. Park Lock solenoid valve
62. Priority blocks with trailer braking
63. Trailer brake valve
64. Trailer brake coupler
65. High pressure spool valve
SM 8-12370 Issued 03-2004

SECTION 8001 7
Powershift transmission- Rigid front axle- without trailer brake
Figure 2
SM 8-12370 Issued 03-2004

8 SECTION 8001
Powershift transmission - Rigid front axle with trailer braking
Figure 3
SM 8-12370 Issued 03-2004

SECTION 8001 9
Right-hand side
Figure 4
(A) Ports and suction pipe of the Gerotor pump
(B) Return port (Orbitrol and braking assistance)
(C) Intermediate housing
(D) Powershift Transmission
SM 8-12370 Issued 03-2004

10 SECTION 8001
Left-hand side
Figure 5
(E). Engine speed sensor
SM 8-12370 Issued 03-2004

SECTION 8001 11
Hydraulics - Hydraulic tests
A. General NOTE: Always check the oil flow direction to

The ZTX series tractors are fitted with a closed avoid damaging the flowmeter. In addition, select
centre hydraulic system that provides a flowrate of pressure gauges, hose piping and unions of
110 l/min, or 150 l/min depending on option and sufficient capacity and strength.
characteristics of the charge pump and the variable
displacement pump. Values measured during the tests:
The hydraulic system comprises two separate circuits: Maxi flowrate .............105 to 115 l/min or 150 l/min
low and high pressure. (depending on option)
Mini flowrate ............................................... 5 l/min
The Powershift transmission has a specific pump Maxi pressure ............................................ 200 bar
fitted to the rear of its housing. This discharges oil Mini pressure.............................................. 0,4 bar
towards the low pressure functions of the
transmission and lubricates various mechanical
assemblies under pressure.
The other 17 bar functions of the rear axle are
identical for tractors with a Powershift or Heavy Duty
transmission. These are supplied via the priority
blocks by the oil flow under pressure coming from the
variable displacement pump that is located either in
the intermediate housing or on the outside of the
right-hand side hydraulic cover (depending on
options).
Before beginning the tests, run the engine in order to
bring the oil temperature up to 80oC minimum (176oF).
To facilitate the increase in oil temperature:
Run the engine at 2000 rpm

Connect a flowmeter to an auxiliary spool valve
maintain the spool valve activated
Limit the flow through the flowmeter
As soon as the oil temperature is above 80oC,
release the spool valve and open the flowmeter valve
to the maximum.
To carry out the tests indicated in this section, it is

recommended that the following equipment available
through the McCormick network be used:
MF 3001: Pressure gauge kit
MF 3016: turbine flowmeter - 4 - 160 l/min
MF 3017: Hose piping assembly for MF 3016
flowmeter
3378174M1: Hose piping kit with diagnostic
connectors.
3582045M1: Diagnostic coupler
If the above is not available, use equivalent suitable
equipment.
SM 8-12370 Issued 03-2004

12 SECTION 8001
B. Testing the high pressure 110 l/min circuit

The high pressure, 110 l/min circuit supplies the
following functions:
T1
Steering
Auxiliary Spool Valves
Lift Control
Trailer Braking
1. Charge pressure of the variable

displacement pump
Connect a pressure gauge on to the diagnostic
connector located on the right-hand side hydraulic
cover (Figs. 1 - 3) and check T1:
Engine speed T1
(rpm) (bar)
1000 5.2 ± 1
Figure 1
2200 6.3 ± 1
T2
2. Standby pressure and XLS

pressure
Connect a pressure gauge to the diagnostic
connector (Fig. 2 - 3) located:
on the pump controller: XLS pressure = T2
on the right-hand side hydraulic cover: pump
pressure = T3
T3
CAUTION: Do not activate any high pres-
sure function such as the steering. This
Figure 2
! may cause a momentary pressure greater
than that the T2 and T3 pressure gauges
can withstand. T3 T2
Engine speed T2 T3
(rpm) (bar) (bar)
1000 4 26 ± 1 T1
2200 4 26 ± 1
NOTE: Pump pressure = XLS pressure + 22 bar

± 1 bar. T3 = T2 + 22 ± 1 bar.
Figure 3
SM 8-12370 Issued 03-2004

SECTION 8001 13
3. Maximum flowrate and pressure

Connect a flowmeter to an auxiliary spool valve
(Fig. 4). Activate and hold the spool valve lever to
obtain Q1.
Connect a pressure gauge on each diagnostics

on the pump controller:

XLS pressure = T2
on the right-hand side hydraulic cover:

pump pressure = T3
Set the control of the flowrate controller of the

auxiliary spool valve concerned to the maximum
flowrate.
IMPORTANT: Activate the auxiliar y spool valve

and progressively close the valve of the
flowmeter in order to read the flowrate and
increase the pressure.
Engine Q1 T2 T3
speed (l/min) (bar) (bar)
(rpm)
2200 100 ± 10 110
2200 100 ± 10 130

T2 = T3 -
2200 100 ± 10 22 ± 1 150
Figure 4
2200 100 ± 10 170
2200 100 ± 10 180
2200 0 190 190 T2
NOTE: If the flowmeter is fitted with a pressure

gauge, the pressure indicated must be taken into
account.
T3
Figure 5
SM 8-12370 Issued 03-2004

14 SECTION 8001
4. Checking the auxiliary spool

valve flow-rate controller T2
Connect a flowmeter to a spool valve (Fig. 4) in order
to obtain Q2.
Connect a pressure gauge on each diagnostics

on the pump controller: XLS pressure: T2

pressure = T3
Controller Engine T2 T3 Q2
position speed (bar) (bar) mini
(rpm) (l/min)
Maxi 2200 T2 = T3 -22 ± 1 130 100 ± 10 Figure 8
Mini 2200 T2 = T3 -22 ± 1 35 5±1 5. Lift control

Maximum pressure
Set the control of the controller concerned slowly to Connect a pressure gauge to each diagnostics
its minimum stop. Q2 must drop progressively to a connector (Fig. 9) located:
flowrate of 5 ± 1 l/min.
on the pump controller:
XLS pressure = T2
T2
on the right-hand side hydraulic cover:
pump pressure = T3
Run the engine at 1000 rpm.
Use the external lift control buttons to reach the

T3 maximum lift position
T2 and T3 = 190 bar.
Shock valve
With the engine stopped, disconnect hose supply

piping to the ram (Fig. 10).
Inject a pressure in the circuit using a calibration

Figure 7 pump (note the opening pressure):
T4 = 220 - 240 bar.
SM 8-12370 Issued 03-2004

SECTION 8001 15
6. Steering
T2
Maximum steering
Connect a pressure gauge to each diagnostics

connector (Fig. 9) and run the engine at 1000 rpm.
Slowly turn the steering and make sure that T2 and

T3 gradually increase:
T2 = 185 + 2 bar
T3 = 170 + 2 bar
Steering circuit leak

T3
Place the front wheels on full lock and apply a torque

Figure 9
of 4 Nm, measured along the axis of the steering
column, to the steering wheel. The steering wheel
must not turn more than 2 rpm. If it rotates at more
than 2 rpm, disconnect the piping supplying the rams
and block off both ports.
Apply the same torque to the steering wheel, if it

turns less than 2 rpm, this indicates a leak from the
hydraulic ram.
SM 8-12370 Issued 03-2004

16 SECTION 8001
High pressure 110 l/min circuit
T5
T3 T2
T4 T4
Figure 10
SM 8-12370 Issued 03-2004

SECTION 8001 17
High pressure 110 l/min circuit
Figure 11
SM 8-12370 Issued 03-2004

18 SECTION 8001
7. Trailer braking (if fitted)

Maximum pressure T6
Connect a pressure gauge to the trailer braking

quick-disconnect coupling (Fig. 12) in order to read
T6.
With the brake pedals latched, apply a progressive

pedal pressure.
The observed pressure must increase gradually and

reach:
T6 = 130 to 150 bar maximum
If the pressure does not increase gradually, bleed the Figure 12

brake circuit
Flowrate C. Testing the low pressure 110 l/

min circuit
Connect a flowmeter, with its load valve fully open, to On ZTX tractors fitted with a 110 l/min circuit, the
the trailer braking quick-disconnect coupling (Fig. 12). rear axle 17 bar low pressure supplies the following
functions:
Connect the return to the manifold union that
supports the auxiliary spool valves. Rear Power Take Off Clutch
MFD Clutch
Carry out the reading of Q3. Front And Rear Differential Lock
Power Braking Assistance
Front Power Take Off (if fitted)
Engine T6 Q3
speed (bar) (l/min)
(rpm)
1. 17 bar circuit
1000 0 47 ± 1 Connect a pressure gauge to the diagnostic
connector (Figs. 14) located at the front of the right-
2200 53 ± 1 hand side hydraulic cover in order to check T7.
0
Still connected as indicated, progressively close the
load valve to increase the pressure and read the Q3 De-clutch (zero pressure in engine clutch) and de-
flowrate again. activate all the low pressure components.
The MFD must be engaged, the pressure is only

Engine T6 Q3 used when de-clutching.
speed (bar) (l/min)
(rpm) Engage each function, the pressure must not drop
below 14 bar and must return to its initial level after
1000 90 25 ± 1
each disengagement.
2200 26 ± 1
90 T7 = 17 ± 1 bar
SM 8-12370 Issued 03-2004

SECTION 8001 19
2. Charge circuit and oil cooler 3. Oil cooler (optional)

safety Connect a pressure gauge to the oil cooler inlet to
Connect a pressure gauge to the diagnostic check T8 and to the oil cooler outlet to check T9.
connector (Fig. 15) located on the right-hand side
hydraulic cover in order to check T1
Engine T8 T9
speed (bar) (bar)
Engine speed T1 (rpm)
(rpm) (bar)
1000 2 ± 0.5 1.9 ± 0.5
1000 5.2 ± 1
2200 2.3 ± 0.5 2 ± 0.5
2200 6.3 ± 1
Figure 14
T1
Figure 15
SM 8-12370 Issued 03-2004

20 SECTION 8001
D. Testing the high pressure 150 l/min circuit
The high pressure circuit supplies the following

functions:
T1
Steering
Auxiliary Spool Valves
Lift Control
Trailer Braking
1. Charge pressure of the variable

displacement pump
Connect a pressure gauge on the diagnostic
connector located on the cover (Fig. 27 - 29) and
check T1:
Engine speed T1
(rpm) (bar)
1000 5.2 ± 1 Figure 27
2200 6.3 ± 1 T2
2. Standby pressure and XLS

pressure
Connect a pressure gauge to each diagnostics
on the right-hand cover: pump pressure = T3
ATTENTION: Do not activate any high pressure elements

(e.g. steering) in order to avoid a rise in pressure greater
than that the T2 and T3 pressure gauges can withstand. T3
Engine T2 T3
speed (bar) (bar) Figure 28
(rpm)
1000 26 ± 1
4
2200 26 ± 1
4
NOTE: Pump pressure = XLS pressure + 22 bar

± 1 bar
T3 = T2 + 22 ± 1 bar.
SM 8-12370 Issued 03-2004

SECTION 8001 21
T1
T2 T3
Figure 29
3. Maximum pressure and flowrate

The Q1 flowrate is obtained by using a flowmeter
connected to two auxiliary spool valves.
Connect a flowmeter according to the previous

remark and Fig. 30. Activate and hold the levers of
the spool valves to obtain Q1.
Connect a flowmeter to each diagnostics connector

located (Fig. 31 - 33):
on the right-hand cover: pump pressure = T3 Figure 30
T3
T2
Figure 31
SM 8-12370 Issued 03-2004

22 SECTION 8001
Place the control of the flowrate controller of the

auxiliary spool valves concerned to maximum
flowrate.
Simultaneously activate the spool valve levers and

progressively close the flowmeter valve to read the
flowrate and increase the pressure.
Engine Q1 T2 T3
speed (l/min) (bar) (bar)
(rpm)
2200 145 ± 10 110

T2 T3
2200 145 ± 10 130
T2 = T3 -
2200 145 ± 10 22 ± 1 150 Figure 33
2200 145 ± 10 170
2200 145 ± 10 180
2200 0 190 190
NOTE: If the flowmeter is fitted with a pressure

gauge, the pressure indicated must not be taken
into account.
4. Checking the auxiliary spool

valves flow controller
Connect a flowmeter to a spool valve.
T3
Connect a pressure gauge to the right-hand cover
(Fig. 31 - 33) to read T3 pump pressure.
Increase the engine speed to 2200 rpm and

progressively close the flowmeter valve to obtain a Figure 34
T3 pressure of 130 bar.
Place the control of the flow controller concerned on

the minimum position and note that the flowrate is 5
± 1 l/min at a T3 pressure of approximately 35 bar.
NOTE: The auxiliary valve controls must be

turned fully clockwise to obtain continuous
maximum flow
SM 8-12370 Issued 03-2004

SECTION 8001 23
5.Lift control 6. Steering

Maximum pressure Maximum pressure
Connect a pressure gauge on each diagnostics Connect a pressure gauge to each diagnostics
connector (Fig. 35) located: connector (Fig. 35) and run the engine at 1000 rpm.
on the pump controller: XLS pressure = T2 Slowly turn the steering and ensure that T2 and T3
gradually increase:
pressure = T3 T2 = 185 ± 2 bar
Run the engine at 1000 rpm. T3 = 170 ± 2 bar
Utilise the external lift control buttons to reach the Shock valve
maximum high position:
With the engine stopped, connect a hand calibration
T2 and T3 = 190 bar pump to one of the two supply pipes of the steering
ram (Fig. 36).
Shock valve
Inject a pressure using the calibration pump (note the
With the engine stopped, disconnect the hose piping opening pressure):
supplying the rams (Fig. 36).
T5 = 225 - 250 bar
Inject a pressure in the circuit using a calibration
pump (note the opening pressure): Carry out the same procedure with the second ram
supply.
T4 = 220 - 240 bar
Steering circuit leakage

T3
Place the front wheels on full lock and apply a torque
of 4 Nm to the steering wheel axis. The steering
wheel must not turn more than 2 rpm. If the steering
wheel rotates faster than 2 rpm, disconnect the
piping supplying the rams and block off both pipe
ports.
Apply the same torque to the steering wheel, if it

rotates less than 2 rpm, there is a leak from the
steering ram.
T2
Figure 35
SM 8-12370 Issued 03-2004

24 SECTION 8001
Rigid front axle- High pressure 150 l/min circuit
T5
T2
T3
T4 T4
Figure 36
SM 8-12370 Issued 03-2004

SECTION 8001 25
7. Trailer braking (if fitted) T6

Maximum pressure
Connect a pressure gauge to the trailer brake quick-

disconnect coupling (Fig. 38) in order to read T6.
With the brake pedals latched, apply a progressive

pressure.
The pressure that is read must increase gradually

and reach:
T6 = 130 to 150 bar maximum
If the pressure does not increase gradually, bleed the

Figure 38
brake circuit
Flowrate E. Testing the low pressure 150 l/

min circuit
Connect a flowmeter, with its load valve open to the On ZTX series tractors fitted with a 150 l/min circuit,
maximum, on to the trailer brake quick-disconnect the 17 bar low pressure of the rear axle supplies the
coupling (Fig. 36). following functions:
Connect the return to the manifold union that rear power take clutch
supports the auxiliary spool valves.
power take off brake
Carry out a reading of Q3.
4WD clutch (depending on version)
Engine T6 Q3
front diff lock (if fitted) and rear diff lock
speed (bar) (l/min mini)
(rpm)
power braking assistance
1000 47 ± 1
0 front power take off clutch (if fitted)
2200
0
53 ± 1 1. 17 bar circuit
connector (Fig. 39) located above the right-hand side
Still connected as previously described, hydraulic cover to check T7.
progressively close the flowmeter load valve in order
to increase the pressure and read the new Q3 Run the engine at 1000 rpm.
flowrate.
De-activate all low pressure components.
Engine T6 Q3
The front axle must be engaged since pressure is
speed (bar) (l/min mini)
used only when de-clutching.
(rpm)
1000 25 ± 1 Activate each function, the pressure must not drop

90 below 14 bar and must restore to its initial level when
each component is de-activated.
2200 26 ± 1
90 P7 = 17 ± 1 bar
SM 8-12370 Issued 03-2004

26 SECTION 8001
2. Charge circuit of the variable

displacement pump and rear axle T1
lubricating circuit
The oil used for boosting the variable displacement
pump is also used to lubricate the following
functions:
power take off clutch
the trumpets (depending on model)
the handbrake system and mainly the creeper

transmission (if fitted)
the 4WD unit
the hydraulic pump drive bearing block
Connect a pressure gauge to the diagnostics Figure 40

connector located on the charge pump manifold
above the right-hand side hydraulic cover (Fig. 40) in F. Testing the low pressure
order to check T1.
hydraulic functions of the
Powershift transmission
Engine T1 The Powershift transmission possesses its own
speed (bar hydraulic supply and clutch lubricating system.
(rpm)
An inspection plate located beneath the pedals and
1000 5,2 ± 1 bolted to the cab floor allows access to the different
plugs corresponding to the various channels: pump
outlet (17 bar), clutch pressure and lubrication (1) (2)
2200 6,3 ± 1 (A) (B) (C) and (R).
In order not to eliminate the operation of the pressure
switch (17 bar) during the pressure tests,
provisionally screw the pressure switch (13) (red dot)
and its relief-valve at the location of the large plug
(12) (Fig. 41). Reconnect the wiring loom to the
pressure switch.
Fit in the port previously used by the pressure switch,

the diagnostics connector and reducer found in kit,
ref. 3378174M1, in order to test T1 (Fig. 41).
Remove the 7/16 plugs. Screw the diagnostic hose

piping provided with kit, ref. 3378174M1, into the
T7 corresponding ports (1) (2) (A) (B) (C) and (R) (Fig.
41) and the diagnostics connectors into the ports (L)
(H) and (M) (Fig. 42).
Figure 39
SM 8-12370 Issued 03-2004

SECTION 8001 27
Before checking the clutch pressure (see paragraph

3), check the pump pressure, the operation of the 17
bar valve and the lubrication pressure in the
clutches.
1. Pump pressure and valve

operation
connector and check T1 (Fig. 41).
Engine speed T1
(rpm) (bar)
1000 18 ± 1
T1 2200 18 ± 1
2. Clutch lubricating pressure

Connect a pressure gauge to the diagnostics
connector and check T2 (Fig. 43).
Engine speed T2
(rpm) (bar)
1000 0,6 ± 0,2
2200 1,8 ± 0,2
Figure 41
T2
Figure 42 Figure 43
Take out the 9/16 plug (14) located on the upper left-
side of the transmission (Fig. 43). Fit a diagnostic
connector in its location.
Run the engine to bring the oil up to a temperature of

80° C minimum (176° F).
SM 8-12370 Issued 03-2004

28 SECTION 8001
3. Clutch pressures Clutch Pressure

1 T3 = 17 ± 1
NOTE: For each ratio, selected with the gear shift
lever, three clutches are engaged. The clutch 2 T4 = 17 ± 1
pressure test is carried out using three pressure R T5 = 17 ± 1
gauges of approximately 30 bar capacity that are
A T6 = 17 ± 1
moved in relation to the clutches to be tested (F
= Forward and R = Reverse) B T7 = 17 ± 1
Ratios selected R-B-L C T8 = 17 ± 1
F1 1-A-L L T9 = 17 ± 1
F2 2-A-L M T10 = 17 ± 1
F3 1-B-L H T11 = 17 ± 1
F4 1-A-M NOTE: The value read on each pressure gauge

F5 2-B-L must be constant when the clutch is fully
F6 2-A-M engaged.
F7 1-C-L
Final operations
F8 1-B-M
After carrying out the tests, restore the tractor to the
F9 2-C-L state prior to the tests (17 bar pressure switch is refitted
F10 2-B-M in its initial location - all connectors and hose piping
removed
F11 1-A-H
F12 1-C-M
F13 2-A-H
F14 2-C-M
F15 1-B-H
F16 2-B-H
F17 1-C-H
F18 2-C-H
R1 R-A-L
R2 R-B-L
R3 R-A-M
R4 R-C-L
R5 R-B-M
R6 R-A-H
R7 R-C-M
R8 R-B-H
NOTE: The reading of the pressures is carried

out inside the cab, with the tractor moving.
Connect the pressure gauges to the connectors and

diagnostics hose piping of the clutches engaged
(Fig. 44) according to the ratio selected.
Drive the tractor in this ratio, note and then check the
T3 to T11 pressures according to the following table:
SM 8-12370 Issued 03-2004

SECTION 8001 29
HYDRAULIC SCHEMATIC
Hydraulic Circuit Components
1 MAIN SUCTION SCREEN (150 MICRONS) 23 HITCH/AUXILIARY REMOTE VALVE BLOCK

2 CHARGE PUMP 23a PRESSURE REDUCING VALVE
3 FILTER 23b AUXILIARY REMOTE VALVE
3a FILTER BY-PASS VALVE - 2.4 BAR (34.8 PSI) 23c AUXILIARY REMOTE VALVE
4 MAIN PUMP MOUNTING MANIFOLD 23d AUXILIARY REMOTE VALVE
4a MAIN PUMP (PFC) 23e AUXILIARY REMOTE VALVE
4b MAIN PUMP COMPENSATOR SPOOL 23f AUXILIARY REMOTE VALVE
4c SPOOL VALVE - 200 BAR (2900 PSI) 23g HITCH VALVE
4d SPOOL VALVE - 22 BAR (319 PSI) 24 HITCH CYLINDERS
4e SAFETY RELIEF VALVE - 230 BAR (3335 PSI) 25 POWER BEYOND PRESSURE SUPPLY
4f PRESSURE RELIEF VALVE - 22 BAR (319 PSI) 25a POWER BEYOND RETURN
4g DIFFERENTIAL LOCK SOLENOID VALVE 25b POWER BEYOND LOAD SENSING
4h MFD SOLENOID VALVE 26 LUBRICATION MANIFOLD
4j PTO SOLENOID VALVE 26a MFD CLUTCH LUBRICATION
4k PTO BRAKE SOLENOID VALVE 26b PTO CLUTCH LUBRICATION
5 PRESSURE RELIEF VALVE - 5 BAR (72.5 PSI) 26c PUMP DRIVE GEAR LUBRICATION
6 PRESSURE SWITCH - 5 BAR (72.5 PSI) 26e REAR AXLE LUBRICATION CHECK VALVE
7 OUTER DISTRIBUTION BLOCK 26f LEFT HAND REAR AXLE LUBRICATION
7a TRAILER BRAKE SPOOL VALVE 150 BAR (2175 PSI) 26g RIGHT HAND REAR AXLE LUBRICATION
7b STEERING PRIORITY VALVE 27 OIL COOLER
7c TRAILER BRAKE COUPLER 28 THERMAL BY-PASS VALVE
8 INNER DISTRIBUTION BLOCK 29 POWERSHIFT LUBRICATION RELIEF VALVE
- 6 BAR (87 PSI)
8a PRESSURE REGULATOR VALVE - 17 BAR (246 PSI)
30 POWERSHIFT PRESSURE REGULATOR VALVE
8b STEERING/TRAILER BRAKE PRIORITY VALVE
-17 BAR (246 PSI)
9 PRESSURE SWITCH - 17 BAR (246 PSI)
31 POWERSHIFT PRESSURE SWITCH
10 PTO BRAKE PISTON -17 BAR (246 PSI)
11 PTO CLUTCH 32 SUCTION SCREEN (250 MICRON)
12 MFD CLUTCH 33 POWERSHIFT PUMP 110 L/MIN
13 DIFFERENTIAL LOCK CLUTCH 34 POWERSHIFT PRESSURE FILTER HOUSING
14 PARK LOCK SOLENOID VALVE 35 POWERSHIFT SOLENOID VALVE ’M’
15 PARK LOCK PISTON 35a POWERSHIFT CLUTCH ’M’
16 CAB SUSPENSION VALVE BLOCK (IF EQUIPPED) 35b POWERSHIFT CLUTCH ’M’ LUBRICATION
17 CAB SUSPENSION ACCUMULATOR (IF EQUIPPED) 36 POWERSHIFT SOLENOID VALVE ’H’
18 CAB SUSPENSION CYLINDER (IF EQUIPPED) 36a POWERSHIFT CLUTCH ’H’
19 BRAKE ACCUMULATOR 36b POWERSHIFT CLUTCH ’H’ LUBRICATION
19a BRAKE CHECK VALVE 37 POWERSHIFT SOLENOID VALVE ’C’
20 BOOSTER BRAKE VALVE 37a POWERSHIFT CLUTCH ’C’
20a TRAILER BRAKE PRESSURE SENSING VALVE 37b POWERSHIFT CLUTCH ’C’ LUBRICATION
21 LEFT HAND BRAKE CYLINDER 38 POWERSHIFT SOLENOID VALVE ’1’
22 RIGHT HAND BRAKE CYLINDER 38a POWERSHIFT CLUTCH ’1’
38b POWERSHIFT CLUTCH ’1’ LUBRICATION
SM 8-12370 Issued 03-2004

30 SECTION 8001
39 POWERSHIFT SOLENOID VALVE ’B’ 44 STEERRING CONTROL UNIT

39a POWERSHIFT CLUTCH ’B’ 44a EXTERNAL STEERING PRESSURE RELIEF VALVE
39b POWERSHIFT CLUTCH ’B’ LUBRICATION 45 STEERING CYLINDER
40 POWERSHIFT SOLENOID VALVE ’R’ 46 FRONT SUSPENSION AXLE CONTROL VALVE
BLOCK
40a POWERSHIFT CLUTCH ’R’
47 FRONT SUSPENSION AXLE ACCUMULATOR
40b POWERSHIFT CLUTCH ’R’ LUBRICATION
41 POWERSHIFT SOLENOID VALVE ’A’
41a POWERSHIFT CLUTCH ’A’
50 FRONT SUSPENSION AXLE CYLINDER
41b POWERSHIFT CLUTCH ’A’ LUBRICATION
50 MFD AXLE DIFFERENTIAL LOCK
42 POWERSHIFT SOLENOID VALVE ’2’
42a POWERSHIFT CLUTCH ’2’
42b POWERSHIFT CLUTCH ’2’ LUBRICATION
43 POWERSHIFT SOLENOID VALVE ’L’
43a POWERSHIFT CLUTCH ’L’
43b POWERSHIFT CLUTCH ’L’ LUBRICATION
SM 8-12370 Issued 03-2004

SECTION8001 31
HydraulicSchematicforTractorsWithoutTrailerBrakeandWithIntegralSteeringPressureReliefValve-refertokeyonpage29.
45
20
21
8 19
47
20a
8a
48
19a
22
18
50 8b 23a
17
46
16
44
49
23b
4f
51
34 23c
4g
35b
33 9
35a 35
36b 4e
32 4h
36a 4d
36
23d 25a
4c
37a
37 31
4j
37b
4b
38b 24
38a 30 6 23
38 4a
25
29 4k
28
39a 39
39b
40b 5 4 23g
40a
40
3a
10
27
41a 26a 26 3 11
41 23e
43b 41b 26c 12
42b
26b 13
42a 26d
42 2
26e
43b
14
1
43a 23f
43 26f 26g 15
25b
MI03M077
SM8-12370 Issued03-2004
32 SECTION8001
HydraulicSchematicforTractorsWithTrailerBrakeandIntegralSteeringPressureReliefValve-refertokeyonpage29.
45
19 20
21
8
47
7
7a
20a
8a
48
19a
8b
22
18
7b
50 23a
17
46 16
44
7c
49
23b
51 4f
34
4g 23c
35b 33 9
35a 35
36b
4e
32 4h
36a 4d
36
23d 25a
4c
37a 31
37
4j
37b
4b
38b 24
38a 30 6 23
38 4a
25
29 4k
28
39a 39
39b
40b 5 4 23g
40a
40
3a
10
27
41a 26a 26 3 11
41 23e
41b 26c 12
43b
42b
26b 13
42a 26d
42 2
26e
43b
14
1
43a 23f
43 26f 26g 15
25b
MI03K084
SM8-12370 Issued03-2004
SECTION8001 33
HydraulicSchematicforTractorsWithoutTrailerBrakeandWithExternalSteeringPressureReliefValve-refertokeyonpage29.
45
20
21
8 19
47
20a
8a
48
19a
22
18
50 8b 23a
17
46
16
44a
44
49
23b
4f
51
34 23c
4g
35b
33 9
35a 35
36b
32 4h
36a 4d
36
23d 25a
4c
37a
37 31
4j
37b
4b
38b 24
38a 30 6 23
38 4a
25
29 4k
28
39a 39
39b
40b 5 4 23g
40a
40
3a
10
27
41a 26a 26 3 11
41 23e
43b 41b 26c 12
42b
26b 13
42a 26d
42 2
26e
43b
14
1
43a 23f
43 26f 26g 15
25b
MI04075
SM8-12370 Issued03-2004
SECTION8001 34
HydraulicSchematicforTractorsWithTrailerBrakeandExternalSteeringPressureReliefValve-refertokeyonpage29.
45
19 20
21
8
47
7
7a
20a
8a
48
19a
8b
22
18
7b
50 23a
17
46 16
44
7c
49
23b
44a
51 4f
34
4g 23c
35b 33 9
35a 35
36b
4e
32 4h
36a 4d
36
23d 25a
4c
37a 31
37
4j
37b
4b
38b 24
38a 30 6 23
38 4a
25
29 4k
28
39a 39
39b
40b 5 4 23g
40a
40
3a
10
27
41a 26a 26 3 11
41 23e
41b 26c 12
43b
42b
26b 13
42a 26d
42 2
26e
43b
14
1
43a 23f
43 26f 26g 15
25b
MI03K084
SM8-12370 Issued03-2004
Section
8005
RIGHT HAND AND LEFT HAND

HYDRAULIC COVERS
8005
ZTX Series Tractors

SM 8-12330 March 2004
2 SECTION 8005
TABLE OF CONTENTS
HYDRAULICS - RIGHT-HAND COVER

General ................................................................................................................................................................ 4
Description ........................................................................................................................................................... 4
A. Removing and refitting the cover ................................................................................................................... 14
Removal (Fig. 10) .......................................................................................................................................... 14
Refitting ......................................................................................................................................................... 15
B. Description and operation of the variable displacement pump ...................................................................... 18
Description ..................................................................................................................................................... 18
Maximum pressure - zero flowrate ................................................................................................................ 20
C. Removing and refitting the pump .................................................................................................................. 21
Removal ........................................................................................................................................................ 21
Refitting ......................................................................................................................................................... 21
Final operation ............................................................................................................................................... 21
E. Removing and refitting - Disassembling and
reassembling the pump bearing .................................................................................................................... 22
Preliminary operations ................................................................................................................................... 22
Removal ........................................................................................................................................................ 22
Refitting ......................................................................................................................................................... 22
Disassembling the bearing block ................................................................................................................... 22
Reassembly ................................................................................................................................................... 22
HYDRAULICS- 150 L/MIN RIGHT-HAND COVER

General .............................................................................................................................................................. 25
Description ......................................................................................................................................................... 25
Hydraulic routing ............................................................................................................................................ 25
A. Removing and refitting the cover ................................................................................................................... 35
Preliminary operations ................................................................................................................................... 35
Removing the priority block(s) ....................................................................................................................... 35
Removing the cover ....................................................................................................................................... 35
Refitting the cover .......................................................................................................................................... 36
Refitting the priority block(s) .......................................................................................................................... 37
B. Description and operation of the variable displacement pump ...................................................................... 38
Description ..................................................................................................................................................... 38
Identification of ports and components (Fig. 17) ........................................................................................... 38
Working position - full capacity ...................................................................................................................... 39
Working position - partial capacity ................................................................................................................. 39
Maximum pressure - zero flowrate ................................................................................................................ 39
Pressure relief-valve ...................................................................................................................................... 40
C. Removing and refitting the pump .................................................................................................................. 40
Removal ........................................................................................................................................................ 40
Refitting ......................................................................................................................................................... 41
Final operation ............................................................................................................................................... 42
D. Disassembling, reassembling and shimming of the idler pinion .................................................................... 42
Disassembly .................................................................................................................................................. 42
Reassembly ................................................................................................................................................... 42
Preparation for shimming the idler pinion ...................................................................................................... 43
Shimming ....................................................................................................................................................... 44
E. Removing and refitting -
SM 8-12330 Issued 03-2004

SECTION 8005 3
Disassembling and reassembling the pump bearing block ............................................................................44

Preliminary operations ....................................................................................................................................44
Removal .........................................................................................................................................................44
Refitting ..........................................................................................................................................................44
Disassembly ...................................................................................................................................................45
Reassembly ....................................................................................................................................................45
Final operations ..............................................................................................................................................45
HYDRAULICS - LEFT-HAND COVER

General ...............................................................................................................................................................47
Description ..........................................................................................................................................................47
Identification of channels and ports ................................................................................................................52
A. Removing and refitting the cover ....................................................................................................................53
Removal .........................................................................................................................................................53
Refitting ..........................................................................................................................................................53
B. Removing and refitting the booster pump ......................................................................................................54
Removal .........................................................................................................................................................54
Refitting ..........................................................................................................................................................54
Final operation ................................................................................................................................................55
C. Replacing the pump seals ..............................................................................................................................56
Disassembly ...................................................................................................................................................57
Refitting ..........................................................................................................................................................57
Final operation ................................................................................................................................................57
SM 8-12330 Issued 03-2004

4 SECTION 8005
Hydraulics - Right-hand cover
General
The right hand cover is mounted on the intermediate
housing. It acts as a support for numerous
components and contains the different booster,
lubricating and low flowrate channels and circuits.
On its internal face, the cover contains:
The variable displacement pump (41) and its drive

pinion (39).
The safety valve (45) of the low pressure circuit

calibrated at 22 bar
The safety valve (44) of the booster circuit and 5 bar

lubricating circuit.
On its external face, the cover is fitted with:

Figure 1
The main 15 micron filter (27)
One or two priority blocks serving different functions

of the low and high flowrate circuits
The pressure relief-valve (2)
The regulator (12) of the variable displacement pump
The 4 solenoid valves (15) to (18) of the low pressure

control functions (depending on options)
The high and low pressure diagnostic connectors

(11) (48), lubricating booster (29), LS (9)
The engine speed sensor (25) (depending on

options)
The low pressure (14) and booster (42) switches as

well as the main filter clogging indicator (34).
Description
The movement transmitted to pinion (1) by the
engine, via shaft (2), drives pinion (39) of the variable
displacement pump (41) (Fig. 1). The oil coming from
the booster pump, located on the left-hand cover is
directed towards the priority blocks through pipe (54)
(Fig. 2) via the variable displacement pump (41), in
order to supply the function requested. The pipe (55)
(Fig. 2) directs oil coming from the 5 bar safety valve
(44) to the suction manifold fitted on the booster
pump.
SM 8-12330 Issued 03-2004

SECTION 8005 5
Figure 2
(22) Mecanindus pin A: Suction

(52) O-ring PCV: To variable displacement pump
(53) O-ring VS: 5 bar safety valve (44)
(54) Booster pipe C: Intermediate housing compartment
(55) Safety valve pipe (44)
SM 8-12330 Issued 03-2004

6 SECTION 8005
Par ts list
1. Bolt
2. Pressure relief-valve
3. Supply to Orbitrol
4. Bolt
5. LS pilot flow from the Orbitrol
6. LS pilot flow to the pump regulator
7. Priority block(s)
8. Cover
9. LS diagnostics connector
10. Plugs (depending on version)
11. HP diagnostic connector
12. Pump regulator
13. Union (LS)
14. LP switch (17 bar)
15. To 18. Solenoid valves (PTO, PTO brake, to differential lock (front and rear if fitted) and 4WD
19. Plugs
20. Park Lock union or plug (depending on assembly)
21. PTO clutch union
23. PTO brake union
24. 2WD or 4WD differential lock union
25. Plug or speed sensor (Heavy Duty gearbox)
26. 4WD union
27. 15 micron main filter
28. LP union
29. Diagnostic connector for booster and lubricating pressure
30. Supply to lift control valve manifold and auxiliary spool valves
31. LS pilot flow from auxiliary spool valves and lift control valve
32. Bolt
33. Trailer brake valve pilot line
34. Clogging indicator
36. Centring pins
37. Nut
38. Washer
39. Pinion
40. Key
42. Booster and lubricating pressure switch
43. Union and pipe to manifold and lubrication (depending on assembly)
45. Safety - valve 22 bar
46. Plug
47. Pump attachment screw
48. LP diagnostics connector
49. Rivets
50. Trailer brake to quick-disconnect coupler
SM 8-12330 Issued 03-2004

SECTION 8005 7
External overall view without trailer braking
Figure 3
SM 8-12330 Issued 03-2004

8 SECTION 8005
External overall view with trailer braking
Figures 3 A
SM 8-12330 Issued 03-2004

SECTION 8005 9
Internal overall view
Figure 4
SM 8-12330 Issued 03-2004

10 SECTION 8005
Exploded view - Right-hand cover with trailer braking
Figures 5 A
25. Plug
46. Plug
SM 8-12330 Issued 03-2004

SECTION 8005 11
Identification of ports and channels (Figs 6-7)
Figures 6 & 7
C. 22 bar adjusting screw (9). LS diagnostics connector

D. 200 bar adjusting screw (12). Pump regulator
P. HP from variable displacement pump
R. To control piston of variable displacement pump ATTENTION: Adjusting screws C and D are factory set.
S. Regulator return Do not modify these settings.
SM 8-12330 Issued 03-2004

12 SECTION 8005
Identification of ports and channels (Figs 8-9)
Figures 8 & 9
F. 15 micron main filter S. Regulator return

G. Booster S1. Return from priority block(s)
L. Lubrication (2). Pressure relief-valve
P. HP outlet from variable displacement pump (44). 5 bar safety valve
R. To control piston of variable displacement pump (45). 22 bar safety valve
SM 8-12330 Issued 03-2004

SECTION 8005 13
Figure 10
SM 8-12330 Issued 03-2004

14 SECTION 8005
A. Removing and refitting the cover
Removal (Fig. 10)

STEP 1
Immobilise the tractor. Chock the left rear wheel.
STEP 2
STEP 3
Partially drain the intermediate housing.
STEP 4
Remove or place the right rear wheel in the wide
track position. Position axle stand(s) as necessary.
STEP 5
Disconnect pipes and hose pipes (3) (5) (6) (20) (21)
(23) (24) (26) (28) (30) (31) (43), solenoid valve
electrical harnesses (15) to (18) (depending on
version), switches (14) (42) (34), engine speed
sensor (25) and switch (46) (according to version).
STEP 6
Take out bolts (32). Remove the main filter assembly
(27).
STEP 7
Take out bolts (4). Remove the priority block(s). Figure 11
STEP 8
Take out bolts (1). Unstick and remove the cover.
Remove the booster pipe (54) and pipe (55) of the 5
bar safety valve (Fig. 2) (optional).
NOTE: One upper bolt holding the cover may be

masked by the union screwed into regulator (12).
Take off the regulator in order to facilitate the
removal of the cover. To disassemble the safety
valve (45) of the LP circuit, compress spring (3)
using a screwdriver and remove circlip (1).
Remove parts (2) to (4) (Fig. 12). Check that
valve (4) slides freely in its housing.
Figure 12
SM 8-12330 Issued 03-2004

SECTION 8005 15
Refitting STEP 17
Reconnect the engine speed sensor (see following
NOTE: Check for the presence of the rivets on special points). Reconnect the switches, the
the channels provided on the external face of the harnesses of the solenoid valves and the hydraulic
cover, as well for those (45) on the internal face pipes.
(Fig. 4).
Also check for the fitting of plugs (10). STEP 18
Raise the tractor, refit the wheel or place it in its initial
STEP 9
position. Remove the axle stands where necessary
Clean the mating faces of the housing and the cover. and tighten the wheel nuts or studs to the torque
shown in section 6003.
STEP 10
Check for the presence of the two pins (36) (Fig. 13). STEP 19
Top up the oil level in the housings.
STEP 11
If it has been removed, insert pipe (55) of the 5 bar STEP 20
safety valve. Position its end fitted with seal (53) in Check the operation of the electrical circuits, LP
the Mecanindus pin (22) located on compartment "C" switches (14), booster (lubrication) switches (42),
of the intermediate housing (Fig. 2). clogging switch (34) and the solenoid valves.
STEP 12 STEP 21
Place booster pipe (54) fitted with O-ring (52) (Fig. Check the oil tightness of the cover, the mating faces
2), its slot held by pin (1) (Fig. 11). Lightly smear seal and the hydraulic unions.
(4) with miscible grease and position it on the collar
of pipe (54) (Fig. 11).
12.Smear the mating face of the housing with a

sealing product (Loctite 510 or equivalent). Place the
guide studs "G" (Fig. 11).
STEP 13
Fill pump (41) with transmission oil via port "O"
(Fig. 10).
STEP 14
Slide the cover on the guide studs "G" (Fig. 11).
Using a bronze hammer, tap the rim of the cover to
engage pins (36) in the housing. Between the mating
faces of the cover and housing, check that pipe (55)
(Fig. 2) is correctly positioned on the 5 bar valve (44).
STEP 15 Figure 13
Tighten bolts (1) to a torque of 120 - 160 Nm.
NOTE: If resistance is felt during tightening, do

not continue. Move the cover away from the
housing and check the position of pipe (55) on
the 5 bar valve (44) (Fig. 2). Also check for the
rotation of pinion (39).
STEP 16
Replace seals (3) to (5) (Fig. 14) and refit the priority
block(s). Tighten bolts (4) smeared with Loctite 542
(Fig. 10) to a torque of 25 - 35 Nm.
SM 8-12330 Issued 03-2004

16 SECTION 8005
Tightening torques
Solenoid valve spools (15) to (18): 18 - 20 Nm.
Hexagonal nut (PTO differential solenoid valve)

moderate tightening.
5 bar valve (44): smear threads with Loctite 241 and

tighten to a torque of 10 - 20 Nm using a locally
manufactured tool.
Sensor nut (25) (depending on options, Heavy Duty

gearbox only): 10 - 15 Nm.
Pressure relief-valve (2): 150 Nm.
Knurled nuts: 4 - 5 Nm.
Figure 14
NOTE: Lightly smear the threads of the booster

(lubrication) switch (42) and low pressure switch
(14) with Loctite 542 or its equivalent before
fitting them.
ATTENTION: If replacement of the pump is necessary

(see Page 21), carr y out hydraulic tests (see section
6003).
SM 8-12330 Issued 03-2004

SECTION 8005 17
Figure 15
Rotates to the left, shaft facing the operator

G. From variable displacement pump
P. HP outlet to priority block(s)
R. To control piston (10)
SM 8-12330 Issued 03-2004

18 SECTION 8005
B. Description and operation of the Depending on the inclination of the plate, the length
of travel of the axial pistons (4) is modified, thus
variable displacement pump permitting the flowrate to adjust to the operating
conditions.
Description
(Fig. 15) The distribution plate (11), behind the cylinder,
places in communication the piston chambers with
The variable displacement pump, fitted inside the the suction and discharge ports of the pump.
right-hand cover, is driven by a pinion fixed by bolts
to a bearing block and located in the intermediate The ball joints (5) are drilled to provide lubrication
housing (see Page 22). between the pads (7) and plate (6). The oil is then
sent to the housing via port "O" (Fig. 10).
It comprises a body (1) and a cylinder (3) driven by
shaft (13). The cylinder has nine axial pistons (4) The pressure relief-valve (2) is screwed into the
thrust on ball joints (5) that are in contact with plate upper left of the cover (Fig. 3 or 3A).
(6) via the intermediary of pads (7).
The inclination of the plate is obtained by the balance

between spring (8), pushrod (9) and piston (10) that
is controlled by a regulator receiving the LS pilot
pressure from the HP components via the priority
block(s).
SM 8-12330 Issued 03-2004

SECTION 8005 19
Figure 16
(1). Priority blocks (17). Lift control spool valve

(10). Piston (20). Auxiliary spool valves
(12). Variable displacement pump regulator (21). Spool valves (17) (20) manifold
SM 8-12330 Issued 03-2004

20 SECTION 8005
Working position - full capacity Identification of ports and channels (Fig. 17)
When a high flowrate function is activated, for C. 22 bar adjusting screw

example an auxiliary spool valve, the pump exits the D. 200 bar adjusting screw
standby position and enters the maximum flowrate O. Decompression port
position. The flowrate in the spool valve is not slowed P. Pump pressure
enough to allow the pump pressure to compress the R. To piston ( 10 )
22 bar spring of spool a. The pump remains in the S. Return
maximum flowrate position. The LS pilot pressure is LS. Signal
slightly higher than the pump pressure, minus 22 bar.

IMPORTANT: The adjusting screws C and D are
Working position - partial capacity factory set. Do not modify these settings.
The partial opening of the spool valve causes an

increase in pressure that results in a LS pilot
pressure being sent to the pump. This pressure
pushes spool a, allowing the pump to be set at full
capacity. The pressure of the pump increases and
pushes spool a into its equilibrium position where the
pump pressure is greater than 22 bar in accordance
with the LS pilot signal.
If the receiver load increases, the LS pilot pressure

increases on the spring side of the spool a and
communication is set up between ports R and S. The
pressure on piston (10) drops, the spring (8) pushes
plate (6) and increases the pump flowrate in order to
finally stabilise itself in a position where spool a is in
an position of equilibrium. Figure 17
If a higher flowrate is requested, requiring a further

opening of the spool valve. The pressure drops and
the flowrate of the pump increases until it reaches a
new equilibrium.
Maximum pressure - zero flowrate

When the pressure at port P reaches 200 bar, spool
b is pushed forwards compressing its spring. The
ports P and R are placed in communication and
piston (10) is brought to the zero flowrate position.
The regulator (12) (Fig. 17), fitted on cover (8)

regulates the flow of pump pressure according to
information transmitted by the LS signal.
Figure 18
Pressure relief-valve (2) (Fig. 18)

The high pressure flow discharged by the variable
displacement pump passes through channel P in the
cover (8) (Fig. 8) and is directed towards the priority
block(s). The pressure relief-valve calibrated at 230
bar and screwed onto the cover, ensures the safety
of the high pressure circuit. In the case of abnormally
high pressure, valve (1) opens and oil is directed to
the housing via the intermediary of ports R of the
relief-valve.
SM 8-12330 Issued 03-2004
SECTION 8005 21
C. Removing and refitting the pump

STEP 22
Remove the right-hand cover. (See Page 14).
STEP 23
Removal
STEP 24
Remove pump (41) with idler pinion (39).
STEP 25
Unscrew nut (37). Remove washer (38). Using an
appropriate extractor, remove the pinion. Recover
key (40). Figure 19
Refitting
STEP 26
Clean all components. Replace any parts found to be
defective. Check that none of the channels in the
cover are obstructed.
STEP 27
Check for the presence of the locating pins (4)
(Fig. 19).
STEP 28
Replace O’ring (1) to (3) (Fig. 19).
STEP 29
Carry out the removal operations in reverse order.
Tighten bolts and nuts to the indicated torque.
NOTE: Inside the cover, apply a small continuous

bead of Loctite 574 or its equivalent around the
bolt holes (47). Use the same method as used
with the left-hand cover.
Final operation
STEP 30
Refit the right-hand cover (see Page 14).
Tightening torques
Nut (37) 50 - 60 Nm, Loctite 241.
Bolt (47) 120 - 160 Nm, Loctite 241.
Bolt (4) 25 - 35 Nm, Loctite 542.
Sensor nut (depending on assembly) 10 - 15 Nm.
SM 8-12330 Issued 03-2004

22 SECTION 8005
E. Removing and refitting - Disassembling and

reassembling the pump bearing

Place the rear wheels in the wide track position. Check that the bearing block assembly is correctly
positioned and that it turns normally.
Uncouple the tractor between the gearbox and the
intermediate housing (see section 6003). STEP 38
Remove the components of the creeper unit (if fitted) Refit the pinion (1). Tighten bolts (4) lightly smeared
that might hinder the removal of the pump drive with Loctite 241 to a torque of 72 - 96 Nm.
pinion (see section 6018).
Disassembling the bearing block
Free the ratchet of the Park Lock (depending on (11) (Fig. 20)
assembly). See section 6018 and take out the
toothed sleeve linking the drive pinion and the shaft,
STEP 39
after carefully noting its position.
Remove the bearing block.
Remove pump drive pinion (1) fixed on bearing block
(11) (Fig. 20). STEP 40
Take off circlip (10). Extract bearings (6) from the
Removal bearing block. Remove spacer (5).
(Fig. 20)
Reassembly
STEP 31
Take out plug (8). Using a threaded rod screwed into STEP 41
the tapped hole, pull on locating pin (7) so as to free Clean and check the parts. Replace any components
spacer (5). found to be defective.
STEP 32 STEP 42
Through the front of the intermediate housing, pull on Using a press and an appropriate fixture, insert
bearing block (11) and take it out through the bore. bearings (6) separated by spacer (5).
Refitting STEP 43
(Fig. 20) Place circlip (10).
STEP 33 STEP 44
Check that neither the channel nor drilled holes in Refit the bearing block.
the spacer are blocked.
STEP 45
STEP 34 Fix the pinion on the bearing block using bolts (4)
Check for the presence of circlip (12) on the upper lightly smeared with Loctite 241 and tighten to a
shaft of the power take off (only on tractors fitted with torque of 72 - 96 Nm.
Heavy Duty gearbox). Refit the bearing block
assembly, carry out operation 32 in reverse order. NOTE: The union (9) has a calibrated port “R” to
provide a metered lubrication of the bearings (6).
STEP 35
Position the groove of spacer (5) along the axis of the
port provided for plug (8).
STEP 36
Fit the locating pin, inserting the flats in the groove of
the spacer. Tighten the plug.
SM 8-12330 Issued 03-2004

SECTION 8005 23
Figure 20
SM 8-12330 Issued 03-2004

24 SECTION 8005
Final operations
If fitted, refit the ratchet and sleeve of the Park Lock.
The long part of the sleeve must be turned towards
the drive pinion.
Refit and adjust the elements of the creeper gearbox

if fitted (see section 6018).

Replace the rear wheels in their original position.

Tighten wheel nuts or studs to the torque shown in
section 6003.
Check the correct operation of all controls.
Road test.
Check the oil tightness of the mating faces and

hydraulic unions. Figure 21
SM 8-12330 Issued 03-2004

SECTION 8005 25
Hydraulics- 150 l/min right-hand cover
General
Certain ZTX tractors may be fitted with a 150 l/min
flowrate Load Sensing circuit.
The right-hand side hydraulic cover of this circuit is

fitted on the intermediate housing as is the 110 l/min
flowrate Load Sensing circuit. The cover serves as a
support for numerous components and contains
various channels for the booster, lubricating and low
flowrate circuits.
On its internal face, the cover contains:
An idler pinion (82) also known as the "relay" pinion.
The safety valve (44) of the booster and lubricating

circuit calibrated at 5 bar.
The safety valve (45) of the low pressure circuit (17 Figure 1
bar).
Hydraulic routing
On its external face, the cover is fitted with: The oil coming from the booster pump located on the
left-hand cover flows into the priority block(s) (7)
The variable displacement pump (41) and its (depending on version) via the main filter (27) and
regulator (12) the variable displacement pump (41) (Fig. 2).
The main 15 micron filter (27) The tube (55) (Fig. 3) sends the oil coming from the
5 bar safety-valve into the suction manifold of the
One or two priority block(s) (7) (depending on booster pump when no hydraulic slave device is
assembly) serving the various functions of the low used.
and high flowrate circuits
The high pressure relief-valve (2) calibrated at 230

bar
The four solenoid valves (15) to (18) controlling the

low pressure functions (depending on options) one of
which (power take off clutch) is of the proportional
type.
The high and low pressure diagnostics connectors

(11) (48), booster (lubrication) (29) and Load
Sensing (9).
The low pressure (14) and booster (42) switches as

well as the clogging indicator (34) of the main filter
(27).
Description
The engine movement transmitted to pinion (1) by
shaft (2) drives the variable displacement pump
pinion via the "relay" pinion (82) (Fig. 1).
SM 8-12330 Issued 03-2004

26 SECTION 8005
Parts list
1. Bolt 58. Sleeve

2. High pressure relief-valve 59. O-ring and dust cover
3. Orbitrol spool valve supply port 60. O-ring and dust cover
4. Bolt 61. Composite seal (O-ring and anti-extrusion bush)
5. Load Sensing control port from Orbitrol spool 62. Dust cover
valve 63. Suction manifold and bolt
6. Load Sensing control port to pump regulator 64. Discharge manifold and bolt
7. Priority block(s) 65. Lubricating port for relay pinion
8. Cover 66. Port to brake power assistance
9. Load Sensing diagnostics connector 67. Studs
10. Return pipe 68. Nuts
11. High pressure diagnostic connector 69. Plug
12. Pump regulator 70. Closing plate and seal
13. Load Sensing union 71. Plug
14. Low pressure (17 bar) switch 72. Spacer
15. To 18. Solenoid valves. 73. Bolt
power take off, power take off brake, differential 74. Obturator and seal
lock front and rear if fitted and 4WD 75. Bolt
19. Hydraulic cover assembly 76. Washer
20. Park Lock union 77. Bearing cone
21. Power take off clutch port 78. Bearing cup
22. Mecanindus pin 79. Shim(s)
23. Power take off brake 80. Circlips
24. 2WD or 4WD differential lock port 81. Spacer
25. O-ring 82. Idler pinion
26. Port for 4WD union 83. Pin
27. 5 micron main filter 84. O-ring
28. Low pressure port
29. Booster pressure and lubricating diagnostic
connector
30. Supply port for lift control valve and auxiliary
spool valves via the manifold
31. Load Sensing control port from auxiliary spool
valves and lift control valve
32. Bolt
33. Control port of trailer brake valve
34. Clogging indicator
35. O-ring
36. Centring pins
37. Nut
38. Washer
39. Pump pinion
40. Key
42. Pressure switch (booster and lubrication)
43. Port to lubricating manifold located above centre
housing
46. Plug
47. Bolt
48. Low pressure diagnostic connector
49. Rivets
50. Port to trailer braking quick disconnect coupling
51. Transfer pipe
56. Composite seal (O-ring and anti-extrusion bush)
57. Dust cover
SM 8-12330 Issued 03-2004

SECTION 8005 27
Figure 2
SM 8-12330 Issued 03-2004

28 SECTION 8005
Figure 3
(22). Mecanindus pin A. Suction

(52). O-ring PCV. To variable displacement pump (41)
(53). O-ring VS. Bar safety valve (44)
(54). Booster pipe C. Intermediate housing compartment
(55). Safety valve (44) pipe
SM 8-12330 Issued 03-2004

SECTION 8005 29
External overall view without trailer braking
Figure 4
SM 8-12330 Issued 03-2004

30 SECTION 8005
External overall view with trailer bearing
Figure 5
SM 8-12330 Issued 03-2004

SECTION 8005 31
External overall view
Figure 6
Figure 7
SM 8-12330 Issued 03-2004

32 SECTION 8005
Internal overall view
Figure 8
SM 8-12330 Issued 03-2004

SECTION 8005 33
Figure 9
SM 8-12330 Issued 03-2004

34 SECTION 8005
Exploded view
Figure 10
SM 8-12330 Issued 03-2004

SECTION 8005 35
A. Removing and refitting the cover STEP 9

Release and remove the cover (see following safety
Preliminary operations precaution).
STEP 1 NOTE: Certain nuts and bolts on the cover are

Immobilise the tractor. Chock the left rear wheel. difficult to access. Where necessary, use a
locally manufactured wrench.
STEP 2
STEP 3
STEP 4
Disassemble the right rear wheel. Position an axle
stand.
Removing the priority block(s)

STEP 5
Proceed with the removal of the priority block(s) by
removing bolts (4) after previously disconnecting hose
pipes (3) (5) (6) (28) (30) (31) (50) (Figs. 4 or 5).
Figure 11
NOTE: On tractors fitted with trailer braking,
remove the priority block(s) (7) without
disconnecting hose (33) (Fig. 5). This precaution WARNING: The cover and pump together
will avoid bleeding of the valve pilot circuit when are extremely heavy. Their removal must
refitting the cover. ! be carried out with care using a locally
manufactured support that replaces the
head of a trolley jack.
Removing the cover
(8) (Fig. 11)
)Rivets
STEP 6 STEP 10
Disconnect pipes (10) (21) (23) (24) (26) (43), the After removing the cover, take out pipes (54) (55)
solenoid valve harnesses (15) to (18) (depending (optional).
on the version) and switches (14) (34) (42) (Figs.
4, 5 and 7). IMPORTANT: The 22 bar safety valve (45) (Fig. 13)
comprises of:
STEP 7
(1) a circlip
Take out bolts (32) and remove the main filter
assembly (27). (2) a stop
STEP 8 (3) a spring

Remove bolts (1) and nuts (68).
(4) a valve
IMPORTANT: Check that there is no hydraulic or
electr ical link that remains connected between
the cover and the intermediate housing.
SM 8-12330 Issued 03-2004

36 SECTION 8005
Refitting the cover

IMPORTANT: Check for the presenc e of r ivets
(49) at the end of the channels located on the
external and internal faces of the cover.
STEP 11
Clean the mating faces of the housing and the cover.
STEP 12
Check for the presence of the two centring pins (36)
(Figs. 8 - 14).
STEP 13
If removed place seal (53) on pipe (55) (Figs. 3 - 9).
Position the end of the pipe in the Mecanindus pin
(22) located on compartment "C" of the intermediate
housing (Fig. 3). Place seal (52) on pipe (54) (Figs.
3 - 9). Position the machined slot of the flange in pin
(1) (Fig. 12).
Figure 13
Figure 14
STEP 14
Lightly smear the seal (4) with miscible grease and
stick it to the flange (Fig.12).
Figure 12
SM 8-12330 Issued 03-2004

SECTION 8005 37
STEP 15 STEP 24
Check the location of the pins (67) in the Top up the oil levels in the housings and check the
intermediate housing. transparent tube on the left-hand side of the centre
housing.
ATTENTION: The pins are first lightly smeared with
Loctite 241 before fixing them on the housing. STEP 25
Remove the chocks. Start the engine and check:
STEP 16
Smear the mating face of the housing with Loctite The operation of the hydraulic and electrical
510 or its equivalent. components
The oil tightness of the mating faces, pipes and
STEP 17 hoses.
With the assistance of another operator and the tool
recommended in the preceding remark "WARNING", ATTENTION: If the variable displacement pump has been
refit the cover by aligning its holes with the studs on replaced, carry out hydraulic tests (see section 8001).
the housing.
STEP 26
STEP 18 Carry out a road test.
Push the cover progressively while simultaneously
checking between housing and cover mating faces
that the 5 bar safety valve is correctly housed in pipe
(55) (Fig. 3).
STEP 19
Tighten bolts (1) and nuts (68) to a torque of 120 -
160 Nm.
IMPORTANT: I f t h e r e i s a ny r e s i s t a n c e, s t o p
tightening and open the gap between housing
and cover to check on the correct alignment of
pipe (55) and the 5 bar valve.
STEP 20
Refit the main filter assembly (27) and tighten
bolts (32).
STEP 21
Reconnect the harnesses to the solenoid valves and
switches. Carry out operation 6 in reverse order.
Refitting the priority block(s)

STEP 22
Refit the priority block(s) and check for the presence
of seals (3) (4) (5) (Fig. 15). Tighten bolts (4)
previously smeared with Loctite 542 to a torque of 25
35 Nm. Reconnect the pipes or hoses. Carry out step
5 in reverse order.
Final operations
Figure 15
STEP 23
Refit the rear wheel. Remove the axle stand. Tighten
the wheel nuts or studs (depending on version) to the
torque shown in section 6003.
SM 8-12330 Issued 03-2004
38 SECTION 8005
B. Description and operation of the Depending on the angle of the plate, the travel of the
axial pistons (4) varies and permits the flowrate to be
variable displacement pump adapted to operating requirements.
Description The distributor plate (11) at the rear of the cylinder,

(Fig. 16) places the piston chambers in communication with
the suction ports and the pump discharge.
The variable displacement pump (41) is fitted on the
external face of the right-hand side cover. It is driven The ball joints (2) (5), fitted respectively to the axial
by an idler pinion known as the relay pinion that is pistons and the inclined plate, are drilled to ensure
itself driven by a driving pinion driven by the engine. the lubrication of all moving parts. The oil is then
directed to a port and an external pipe to lubricate
The variable displacement pump comprises a body the relay pinion bearings.
(1) and a cylinder (3) driven by shaft (13). The
cylinder contains nine axial pistons thrust against The pressure relief-valve is screwed into the lower
ball joints (5) in contact with plate (6) via the pads (7). right front of the cover.
The angle of the plate results from a balance Rotation to the right, shaft facing the operator
between spring (9) and piston (10) controlled by a G. Booster from left pump
regulator (12) that receives the LS pilot pressure P. HP outlet to the priority block(s)
from the high pressure components via the priority P1. HP pressure
block(s). R1. To control piston (10)
S. Return from the regulator
Figure 16
Identification of ports and (1). Priority block(s)

(10). Piston
components (Fig. 17) (12). Variable displacement pump regulator
C. 22 bar adjusting screw (17). Lift control spool valve
D. 200 bar adjusting screw (20). Auxiliary spool valves
P. HP pressure from variable displacement pump (21). Manifold for spool valves (17) (20)
P1. HP pressure to regulator
R. Return
R1. To control piston (variable displacement pump)
S. Return from regulator
SM 8-12330 Issued 03-2004

SECTION 8005 39
IMPORTANT: Screws C and D are factor set.Do not modify these settings.
Figure 17
Working position - full capacity up between ports R1 and S. The pressure on piston
When a high flowrate function is activated, for (10) drops, the spring (8) pushes plate (6) and
example an auxiliary spool valve, the pump exits the increases the pump flowrate in order to finally
stand-by position and enters the maximum flowrate stabilise itself in a position where spool a is in an
position. The flowrate in the spool valve is not slowed position of equilibrium. If a higher flowrate is
enough to allow the pump pressure to compress the requested, requiring a further opening of the spool
22 bar spring of spool a. The pump remains in the valve. The pressure drops and the flowrate of the
maximum flowrate position. The LS pilot pressure is pump increases until it reaches a new equilibrium.
slightly higher than the pump pressure, minus 22 bar.
Maximum pressure - zero flowrate
Working position - partial capacity When the pressure at port P1 reaches 200 bar, spool
The partial opening of the spool valve causes an b is pushed downwards compressing its spring. The
increase in pressure that results in a LS pilot ports P1 and R1 are placed in communication and
pressure being sent to the pump. This pressure piston (10) is brought to the zero flowrate position.
pushes spool a, allowing the pump to be set at full The regulator (12) (Fig. 17), fitted on pump (41)
capacity. The pressure of the pump increases and regulates the flow of pump pressure according to
pushes spool a into its equilibrium position where the information transmitted by the LS signal.
pump pressure is greater than 22 bar in accordance
with the LS pilot signal. If the receiver load
increases, the LS pilot pressure increases on the
spring side of the spool a and communication is set
SM 8-12330 Issued 03-2004

40 SECTION 8005
Figure 18
Identification of ports and channels (Fig. 18) Figure 19
C. 22 bar adjusting screw

D. 200 bar adjusting screw C. Removing and refitting the pump
O. Decompression port
P. Pump pressure Preliminary operation
R. To piston (10)
S. Return STEP 27
XLS. Signal
Remove the right-hand side cover (see Page 14).
IMPORTANT: The adjusting screws C and D are
factory set. Do not modify these settings. Removal
(Fig. 20 - 21)
Pressure relief-valve
STEP 28
(2) (Fig. 19)
Disconnect any pipes linked to the pump (41).
The high pressure flowrate discharged by the
variable displacement pump is directed towards the STEP 29
priority block(s). Take out the obturator (74) along with its seal.
The pressure relief-valve calibrated at 230 bar and
screwed into the cover, ensures the safety of the high STEP 30
pressure circuit. In case of any abnormal variation in Immobilise the pump shaft by blocking pinions (39)
pressure, valve (1) raises and the oil is directed to (82) using a bronze drift.
the housing via ports R in the relief-valve.
STEP 31
Unscrew nut (37) and recover washer (38).
STEP 32
Via the port obturator, introduce an extractor so that
its threaded rods screw into and lock in the threaded
holes of the pinion. Operate the extractor and
remove the pinion from the conical pump shaft.
SM 8-12330 Issued 03-2004

SECTION 8005 41
STEP 33
Remove the hydraulic suction A and discharge R
manifolds from the pump. Discard the seals and
recover the transfer pipe (51).
STEP 34
Take out bolts (47) and remove the pump from the
cover (8).
STEP 35
Discard seal (84).
Figure 20
Figure 21
Refitting STEP 39
Position the pump on the cover by checking the
STEP 36 alignment of the key in the slot on the pinion. Tighten
Clean and inspect all the parts. Replace any bolts (47), lightly smeared with Loctite 542 or its
components found to be defective. equivalent, to a torque of 200 - 260 Nm.
STEP 37 STEP 40
Degrease the threads of the pump shaft. Slide washer (38) onto the shaft.
STEP 38 STEP 41
Place an new O-ring (84) in the bore of the pump Degrease the threads of nut (37) and lightly smear
housing and position key (40) in its slot at the end of them with Loctite 241 or its equivalent, then tighten
the shaft. to a torque of 80 - 100 Nm.
SM 8-12330 Issued 03-2004

42 SECTION 8005
STEP 42 D. Disassembling, reassembling

Manually check the rotation of the pump and check and shimming of the idler pinion
the pinion backlash.
Disassembly
STEP 43
(Fig. 23)
Fit the obturator with a new seal and refit the
assembly in the port in the cover.
STEP 46
STEP 44 Remove the variable displacement pump (see
Page 40).
Replace the hydraulic manifolds and the transfer
pipe fitted with new seals. Fit spacer (72). Tighten
STEP 47
the bolts (Fig. 20) using the torques shown below:
Unlock and remove bolts (75).
Manifold A: 90 - 120 Nm
STEP 48
Manifold R: 50 - 70 Nm
Take out pin (83) and pinion (82) and pair together
Spacer (51): 50 - 70 Nm the bearing cones and cups (77) (78) if they are to be
re-used. Recover the shim(s) (79) and spacer (81).
Final operation
STEP 49
STEP 45 On the pinion, remove the bearing cups (78) and
Refit the right-hand side cover (see Page 14). circlips (80).
IMPORTANT: Fill the variable displacement pump Reassembly

(41) with transmission oil via the por t of pipe (1)
(Fig. 22) before star ting the engine.
STEP 50
Place the bearing cups (78) thrust against the
previously fitted circlips.
STEP 51
Reassemble the turning hub of the idler pinion (82)
by assembling the bearing cones (77), spacer (81),
the shim(s) and pin (83).
ATTENTION: If required, carry out the shimming of the

idler pinion (see steps 56 to 64). Otherwise continue the
reassembly operations.
STEP 52
Assemble the pinion and pin on the cover.
STEP 53
Degrease the threads of bolt (75) and lightly smear it
Figure 22 with Loctite 241 or its equivalent.
STEP 54
Fit washer (76) and tighten the bolt to a torque of
100 - 130 Nm.
STEP 55
Manually check the rotation of the pinion.
SM 8-12330 Issued 03-2004

SECTION 8005 43
Preparation for shimming the idler

pinion
Parts concerned by shimming (Figs. 24 - 25)
The pinion (82), the circlips (80), the bearing cones

and cups (77) (78) and spacer (81).
ATTENTION: The clearance of the taper roller bearings

is adjusted by shim(s) ( 79 ) placed between the front cone
( 77 ) and spacer ( 81 ). (Fig. 24).
ATTENTION: To carry out the correct shimming of the

bearings, place the cover in a vice with the pump pinion
( 39 ) protruding as shown in Figure 25.
Figure 23 Figure 24
Figure 25
SM 8-12330 Issued 03-2004

44 SECTION 8005
Shimming E. Removing and refitting -

Disassembling and reassembling
STEP 56 the pump bearing block
Place the index of the dial gauge on the pinion (82)
(Fig. 25). Preliminary operations
Place the rear wheels in the wide track position.
STEP 57
Push the pinion strongly downwards, alternatively Uncouple the tractor between the gearbox and the
turning the pinion left and right in order to correctly intermediate housing (see section 6003).
seat the cone in the bearing cup.
Remove the creeper unit components (if fitted, see
STEP 58 section 6018).
Reset the dial gauge to zero.
Free the ratchet of the Park Lock (if fitted, see section
6018). Take out the toothed sleeve after carefully
STEP 59 noting its position.
Repeat the operation, this time pulling on the pinion
instead of pushing. Removal
STEP 60 STEP 65
Depending on clearance measured, select a Immobilise pinions (1) (82) using a bronze drift. Take
thickness of shim(s) in order to provide a clearance out bolts (4) and extract pinion (1) (Fig. 26).
of: J1 = 0.03 to 0.13 mm (Fig. 25)
STEP 66
ATTENTION: Wherever possible, shim the bearings to
the minimum clearance. Take out plug (8). Using a threaded rod screwed into
the threaded hole in locating pin (7), pull on it so as
STEP 61 to free spacer (5) (Fig. 27).
Fit the definitive shim(s) selected in operation 60.

STEP 67
STEP 62 67.Through the front opening of the intermediate
housing, pull on the bearing block to disengage it
Degrease the threads of bolt (75) and lightly smear from the bore of the housing.
the threads with Loctite 241 or its equivalent.
STEP 63
Refitting
Fit washer (76) and tighten the bolt to a torque of STEP 68
100 - 130 Nm.
Check that the hydraulic channels and ports of the
spacer are not obstructed.
STEP 64
Manually check the rotation of the pinion. STEP 69
Refit the bearing block. Carry out operation 67 in
reverse order.
STEP 70
Place the groove of the spacer in the axis of the port
provided for the plug (8) (Fig. 27).
STEP 71
Fit the locating pin, with the flats lodged in the groove
in the spacer. Tighten the plug.
SM 8-12330 Issued 03-2004

SECTION 8005 45
STEP 72 STEP 80
Check that the bearing block assembly is correctly Refit the bearing block and fit the pinion. Tighten the
positioned and that it turns normally. bolts to the torque shown in operation 73.
STEP 73 NOTE: The union (9) has a calibrated port for the
lubrication of bearings (6).
Fit pinion (1). Tighten bolts (4) previously smeared
with Loctite 241 or its equivalent to a torque of 72 -96
Nm (Fig. 26). Final operations
If fitted, unclamp the ratchet and position the sleeve
of the Park Lock.
ATTENTION: The long part of the ratchet must face the

drive pinion.
STEP 81
Refit and adjust the creeper unit components (if
fitted, see section 6018).
STEP 82
STEP 83
Replace the wheels in their initial positions. Tighten
the wheel nuts or studs to the torque shown in
Figure 26 section 6003.
STEP 84
Disassembly
Check the operation of all the controls.
STEP 74
STEP 85
Remove the bearing block.
Carry out a road test.
STEP 75
STEP 86
Take off circlip (10). Extract bearings (6) and recover
spacer (5) (Fig. 27). Check the oil tightness of the mating faces and
hydraulic unions.
Reassembly
STEP 76
STEP 77
Using a press and an appropriate fixture insert
bearings (6), placing spacer (5) between them.
STEP 78
Fit circlip (10).
STEP 79
Check for the presence of circlip (12) on the upper
shaft of the power take off (Fig. 27).
SM 8-12330 Issued 03-2004

46 SECTION 8005
Figure 27
SM 8-12330 Issued 03-2004

SECTION 8005 47
Hydraulics - Left-hand cover
General Description
The left hand side cover, fitted on the intermediate Pinion (1) taking its rotation from shaft (2), drives
housing, forms the support for the following pinion (12) of the booster pump (Fig. 1). The oil is
components: sucked into the intermediate housing via the
manifold (4). It is then directed towards the strainer
On its inside face (Figs. 3 - 4) (6) and the booster pump (2) (Fig. 2) through an
The booster pump (2), the capacity of which differs internal channel in the cover.
depending on the hydraulic characteristics as shown
in the table below. The oil is then discharged towards the variable
displacement pump by the booster pipes (3) (54)
The suction manifold (4) held by compartment (C) of the intermediate housing
(Fig. 2).
The pipe (55) directs the oil coming from the 5 bar
safety-valve towards the suction manifold (4).
Load Sensing hydraulic circuit
Booster pump Variable displacement

pump (*)
60 cm3/rpm 0 à 45 cm3/rpm
80 cm3/rpm 0 à 60 cm3/rpm
On the outside face

The 150 micron suction strainer (6) differs through
the size of its filtering surface and depends on the
capacity of the variable displacement pump (96 mm
long with the 60 cm pump and 139 mm long with the
3
80 cm version).
3
ATTENTION: The figures given in this section are for the

60 cm pump and its surrounding elements. The
3
construction of the 80 cm pump is identical in principle to

3
Figure 1
the former.
It should be noted however, that the internal pinions as
wel l as the body of the pump have slightly different
profiles.
SM 8-12330 Issued 03-2004

48 SECTION 8005
Figure 2
(25). O-ring PCV. To the variable displacement pump

(26). Mecanindus pin VS. 5 bar safety-valve
(54). Booster pipe C. Compartment of the intermediate housing
(55). Safety-valve pipe.
A. Suction
SM 8-12330 Issued 03-2004

SECTION 8005 49
Parts list
1. Nut
2. Booster pump
3. Booster pipe
4. Suction manifold
5. O-ring
6. Strainer
7. Studs
8. Plug
9. Seal
10. Bolt
11. Washer
12. Pinion
13. Key
14. Cover
15. Nut
16. Centring pins
17. O-ring
18. Gasket
19. Bolt
20. Bowl
21. O-ring
22. Bolt
23. O-ring
24. Locating pins
SM 8-12330 Issued 03-2004

50 SECTION 8005
Overall view
Figure 3
SM 8-12330 Issued 03-2004

SECTION 8005 51
Exploded view
Figure 4
SM 8-12330 Issued 03-2004

52 SECTION 8005
Identification of channels and ports
Figure 5
Figure 6
A: Suction from manifold (4) G: Booster supply to the variable displacement pump
B: Strainer (150 microns)
SM 8-12330 Issued 03-2004

SECTION 8005 53
A. Removing and refitting the cover STEP 11

Place a new O-ring (25) on the booster pipe (3).
Removal Insert the pipe, its end positioned in the Mecanindus
pin (26) (Fig. 2).
STEP 1
Take off the wheel on the side concerned. Position an
axle stand.
STEP 2
STEP 3
Unscrew the bowl (20). Remove the strainer (6)
(Fig. 7)
STEP 4
Take off nuts (1) and bolts (10) (19) (Fig. 7).
STEP 5
Remove the cover (14) and then the suction
manifold (4). If necessary, remove the studs (7)
(Figs. 4 and 7).
Refitting
STEP 6
Clean the mating faces of the housing and the cover.
Smear the mating face of the housing with Loctite
510 or its equivalent.
STEP 7
Replace the O-ring (17) and position the seal (5) on
the suction manifold (4) (Fig. 3).
STEP 8
Refit manifold (4), the end fitted with seal (5) inserted
into compartment (C) of the intermediate housing
(Fig. 2).
STEP 9
Lightly smear the face of the gasket (18) on the
suction manifold (4) with Silicomet type silicone.
Spool the gasket over the studs (7), the adhesive
facing the cover. Screw two diametrically opposed
guide studs G on to the intermediate housing (Fig.
8).
STEP 10
Check for the presence of the two centring pins (16)
(Fig. 6).
Figure 7
SM 8-12330 Issued 03-2004

54 SECTION 8005
STEP 12
Spool the cover on to the guide studs G and studs (7)
(Fig. 8). Using a bronze hammer, tap the cover to
engage the pins (16) in the housing.
STEP 13
Take out the guide studs G. Fit and alternately and
uniformly tighten the bolts (10) (19) to a torque of 90
- 120 Nm.
NOTE: In case of any resistance felt while

tightening, move the cover away from the
housing and check the position of pipe (3) in the
pump port. Also turn pinion (12).
STEP 14
Fit nuts (1) (Fig. 7) smeared with Loctite 241 and
tighten to a torque of 15 - 20 Nm. B. Removing and refitting the
booster pump
STEP 15
If necessary, replace O-ring (21) on bowl (20). Put ATTENTION: The removal and refitting procedures are
the strainer (6) in place and tighten the bowl. the same for a 60 cm or 80 cm pump.
3 3
STEP 16 Preliminary operation

Carry out operations 1 and 2 in reverse order.
STEP 18
STEP 17 Take off the cover (see Page 35).
Check the oil tightness of the mating face of the
cover as well as that of the bowl. Removal
Tightening torques STEP 19
Remove bolts (22) and pump (2) (Fig. 3). If
Nuts (1): 15 - 20 Nm (Loctite 241)
necessary, remove pinion (12) from the pump.
Recover key (13).
Bolts (10) (19): 90 - 120 Nm
Wheel nuts or studs: see section 6003 Refitting

Bowl (20): moderate tightening. STEP 20
Clean the mating faces of the pump and cover.
STEP 21
Check for the presence of the locating pins (24)
(Fig. 9).
STEP 22
Inside the cover, apply a bead (C) of Loctite 574 or
its equivalent around the bolt holes (Fig. 9). The dia-
meter of the bead should be small in section so as to
not touch the groove of seal (23). Fit a new seal.
SM 8-12330 Issued 03-2004

SECTION 8005 55
STEP 23
If disassembled, replace key (23) and refit pinion
(12). Tighten nut (15) to the torque indicated below.
Position the pump on the centring pins.
STEP 24
Fit bolts (22) smeared with Loctite 241 or its
equivalent and tighten to a torque of 40 - 50 Nm.
STEP 25
Manually check the rotation of the pump.
Final operation
STEP 26
Refit the cover (see Page 35).
Tightening torques
Nut (15): 50 - 60 Nm (Loctite 241)
Bolt (22): 40 - 50 Nm (Loctite 241)
Figure 8
SM 8-12330 Issued 03-2004

56 SECTION 8005
C. Replacing the pump seals Preliminary operation

(Fig. 10)
STEP 27
Remark Remove the left-hand side cover (see Page 35) and
the booster pump (see Page 54)
Whatever the hydraulic characteristics of the pump,
the operational procedure for the replacement of the
seals remains identical.
Figure 9
SM 8-12330 Issued 03-2004

SECTION 8005 57
Disassembly
STEP 28
Tighten the pump in a vice fitted with plastic jaw
protectors.
STEP 29
Remove bolt (1) and cover (7) (Fig. 11).
STEP 30
Take off circlip (3), seal (4) (Fig. 12) and O-rings (5)
(6) (Fig. 13).
Refitting
STEP 31
Lubricate seal (4) and insert it using an appropriate Figure 11
fixture. Place circlip (3).
STEP 32
Lightly smear the O-rings (5) (6) with miscible grease
and position them on the cover (7) (Fig. 13).
STEP 33
Position the cover (Fig. 14). Fit and tighten bolts (1)
to a torque of 30 - 40 Nm (Fig. 11)
STEP 34
Manually check for the free rotation of the pump.
Final operation
STEP 35 Figure 12
Refit the booster pump (see Page 54) and the left-
hand cover (see Page 53).
Figure 13
Figure 10
SM 8-12330 Issued 03-2004
Section
8006
HYDRAULIC PRIORITY
VALVE BLOCKS
8006
ZTX Series Tractors

SM 8-12350 March 2004
2 SECTION 8006
TABLE OF CONTENTS
HYDRAULICS - PRIORITY BLOCKS

A. General ............................................................................................................................................................ 3
Tightening torques ........................................................................................................................................... 3
A. Identification of ports ....................................................................................................................................... 6
B. Operation of spool valves ................................................................................................................................ 7
Steering priority spool valve ............................................................................................................................ 7
Trailer brake spool valve ................................................................................................................................. 7
HYDRAULICS - PRIORITY BLOCKS WITHOUT TRAILER BRAKING

General ................................................................................................................................................................ 9
Tightening torques ........................................................................................................................................... 9
A. Identification of ports ..................................................................................................................................... 10
B. Operation ....................................................................................................................................................... 13
1 st priority: Steering ...................................................................................................................................... 13
Steering in neutral position: ........................................................................................................................... 13
Steering wheel turned: ................................................................................................................................... 13
2nd priority: 17 bar pressure holding valve .................................................................................................... 13
HYDRAULICS - LIFT CONTROL SPOOL VALVE

General .............................................................................................................................................................. 15
Description ..................................................................................................................................................... 15
Lift control spool valve with Bosch auxiliary spool valves .............................................................................. 15
A. Diagrams ....................................................................................................................................................... 17
B. Removing and refitting the spool valve .......................................................................................................... 18
C. Neutral position ............................................................................................................................................. 19
D. Raise position ................................................................................................................................................ 20
E. Lower position ............................................................................................................................................... 21
SM 8-12350 Issued 03-2004

SECTION 8006 3
Hydraulics - Priority blocks
A. General
Depending on options, the ZTX Load Sensing series
tractors fitted with the 110 l/min or 150 l/min variable
displacement pump, may be fitted with a trailer brake
mechanism.
The hydraulic unit attached on the right-hand side

cover has two priority blocks mounted in series.
The internal block (1) (Fig. 1) ensures priority for the

17 bar circuit and manifold that supplies the auxiliary
spool valves and lift control valve.
The external block (4) (Fig. 1) shares priority

between the steering function and trailer braking.
To facilitate access to the trailer-braking device,

either remove the rear wheel or place it in its wide
track position (see section 6003). Figure 1
Tightening torques
Bolts V: 25 - 35 Nm. Loctite 542 (Fig. 2 - 3)
Wheel studs or nuts: (see section 6003)
NOTE: Check the oil tightness of the unions and

O-rings on priority blocks fitted against the
hydraulic cover. If the priority blocks have been
replaced, carry out hydraulic tests and check the
operation of the controls. Carry out a road test.
SM 8-12350 Issued 03-2004

4 SECTION 8006
Load sensing 110 l/min
Figure 2
SM 8-12350 Issued 03-2004

SECTION 8006 5
Figure 3
SM 8-12350 Issued 03-2004

6 SECTION 8006
A. Identification of ports
(Figs. 2 to 4)
NOTE: Drilled port B on cover (2) (see Page 10 Fig. 2) allows the priority blocks to be supplied in series
A Supply to steering spool valve (Orbitrol)

C Load Sensing (LS) pilot flow to pump controller
D Load Sensing (LS) pilot flow from the Orbitrol
E To trailer brake connection
F Pressure to lift control valve and auxiliary spool valves
G LS pilot flow from lift control valve and auxiliary spool valves
I 17 bar output
J Plugs
K Pilot flow from brake master cylinders
P.dir (St.pr) Steering priority

BP (LP) Low pressure spool valve
HP high pressure spool valve
Bottom view Bottom view
Front view Front view
Top view Top view
Figure 4
SM 8-12350 Issued 03-2004

SECTION 8006 7
B. Operation of spool valves
Steering priority spool valve Trailer brake spool valve

The control slide moves to the left under the action of (6) (Fig. 5)
spring (5). The flow coming from channel B is by
priority directed to the Orbitrol spool valve via When the trailer brake is not actuated, the pressure
channel A. When the steering in a central position, in channel K is zero and the spool valve allows
there is no flow through this channel. The increasing communication between the L and R channels.
pressure forces the spool to move to the right and
compress spring (5) thus allowing the flow to pass As soon as the tractor brake is activated, the
into channel J. pressure existing in channel K moves piston (7), this
pushes the spool valve to the left allowing oil to flow
During operation, a pilot pressure from the Orbitrol between the J and L channels.
arrives through channel D and pushes the spool
valve to the left thus allowing the flowrate required by The increasing pressure in channel L acts on the end
the steering to enter into channel A. of spool valve (6) and compresses spring (8) to re-
establish the balance, allowing pressure in channel L
The remaining flow is directed into channel J. to be maintained in relation to the pressure existing
in channel K. The maintenance of this pressure is
obtained by placing in communication channel L with
either channel J or R port.
NOTE: As with the (no trailer braking) priority

block, a flowrate of 0.5 l/min flows through
channel A towards channel D (dynamic steering)
via a drilled hole and a pressure relief valve
mounted in the spool valve (2).
SM 8-12350 Issued 03-2004

8 SECTION 8006
Figure 5
Parts list (Fig. 5) P High pressure

R Return below oil level
(4) Priority block LS Signal to pump controller via the priority blocks
(17) Lift control valve
(20) Auxiliary spool valves
(21) Manifold
(31) LS signal
SM 8-12350 Issued 03-2004

SECTION 8006 9
Hydraulics - Priority blocks without trailer braking
General
The priority block (1) (Fig. 1) comprises two spool
valves (Fig. 5) and is fitted on the right-hand side
hydraulic cover (2) (Fig. 2). It receives the oil flow
coming from the variable displacement pump. It
ensures priority for the steering circuit and the low
pressure circuit (17 bar). The oil is then directed to
the manifold for use by the auxiliary spool valves and
lift control valve.
To facilitate access to the priority block, remove the

rear wheel or place it in its wide track position (see
section 6003).
Tightening torques
Bolts V 25 - 35 Nm. Loctite 542 (Figs. 2 to 4).
Wheel nuts or studs: (see section 6003).

Figure 1
NOTE: Check the oil tightness of all unions and
O-rings fitted between the priority block and the
hydraulic cover. If the priority block has been
replaced, carry out hydraulic tests and check the
operation of the controls. Carry out a road test.
SM 8-12350 Issued 03-2004

10 SECTION 8006
A. Identification of ports
(Fig. 2 to 4)
A Supply to steering (Orbitrol)

B HP supply from variable displacement pump
(drilled port on mating face of priority block and hydraulic cover) (Fig. 2)
C Load Sensing (LS) pilot to pump controller
D Load Sensing (LS) pilot from the Orbitrol
F Pressure to lift control valve and auxiliary spool valves
G LS pilot flow from lift control valve and auxiliary spool valves
H Internal channel (Fig. 5)
I 17 bar output
J Plug
HP high pressure spool valve

LP low pressure spool valve
Load sensing 150 l/min Load sensing 150 l/min
Bottom View Bottom View
Front View Front View
Top View Top View
Figure 2
SM 8-12350 Issued 03-2004

SECTION 8006 11
Figure 3
SM 8-12350 Issued 03-2004

12 SECTION 8006
Figure 4
SM 8-12350 Issued 03-2004

SECTION 8006 13
B. Operation
(Fig. 5)
1 st priority: Steering 2nd priority: 17 bar pressure

The spool valve (2) moves to the left under the action holding valve
of spring (3). The spool valve (4) moves to the left under the action
of spring (5), allowing the oil flow from channel H to
The oil flow coming from the variable displacement be directed into port I (17 bar low pressure). As soon
pump via channel B (Fig. 2) is by priority directed as the pressure in this port reaches 17 bar, the spool
towards the Orbitrol spool valve via channel A. valve reaches equilibrium thus allowing the low
pressure to be maintained and the oil flow to be
Steering in neutral position: directed towards port F (lift control and auxiliary
The steering spool valve (Orbitrol) is closed. The spool valves).
pump pressure moves spool valve (2) to the right and
the oil flow is directed into channel H. When the lift control and auxiliary spool valves are
used, a pilot pressure LS is sent to the block via port
Steering wheel turned: G to join the LS line at port C.
A pilot pressure from the Orbitrol arrives at port D
Parts list
and pushes the spool valve (2) to the left, allowing
the oil flow to enter into port A and supply the (1) Priority block
Orbitrol. (17) Lift control valve
NOTE: An oil flow of approximately 0.5 l/min (21) Manifold
flows through port A towards port D via a drilled (31) LS signal
hole and restrictor in spool valve (2). This
flowrate causes a pressure of approximately 6 P High pressure
bars at port D. The line LS directs this pressure R Return below oil level
to the pump controller which is adjusted to 22 bar LS Signal to pump controller via the priority block
in order to obtain a standby pressure of 28 bar.
SM 8-12350 Issued 03-2004

14 SECTION 8006
Figure 5
SM 8-12350 Issued 03-2004
SECTION 8006 15
Hydraulics - Lift control spool valve
General
The lift control spool valve is fixed to a manifold Lift control spool valve with Bosch
provided with three drilled channels. It is mounted on
the centre housing, in front of the lift control shaft.
auxiliary spool valves
The lift control spool valve is located between the
The role of the spool valve is to regulate the oil flow, manifold (21) provided with four ports (Fig. 4) and the
the feed to and return from the lift rams, in relation to right-hand end plate, or the fourth auxiliary spool
signals transmitted by the electronic linkage control valve (if fitted).
(ELC) calculator. It has a LS port for the Load
Sensing system. It is integral with the auxiliary spool valve unit at the
rear of the tractor.
This control port allows the spool valve to transmit
pressure information to the variable displacement Designation of the ports
pump, via the priority block(s). On the manifold (21)
Description Fig. 4: with Bosch auxiliary spool valves

(15) Return to housing
(Fig. 12 to 14)
(30) HP feed from variable displacement pump via the
priority block(s)
The Bosch spool valve comprises two parts: (31) LS signal
Hydraulic part (spool valve)

(2) Spool assembly used during the Lower phase On the lift control spool valve (17).
(4) Control spool
(5) Flowrate adjustment spool
Fig. 5 - 6: with Bosch auxiliary spool
(6) Shock valve valves
(9) Flowrate adjustment spool spring (15) Return to housing
(10) Control spool spring (16) HP feed to rams
(11) Spool assembly spring (30) HP feed from variable displacement pump via the
(12) Non-return valve holding oil in the rams priority block(s)
(31) LS signal
Electrical part (solenoid valve) (Fig. NOTE: To distinguish a hydraulic problem from
an electrical problem, operate the push buttons
2 - 5) on the end of the solenoid valves (13) (14), thus
(13) Move Up solenoid valve eliminating the effect of the electrical circuit on
(14) Move Down solenoid valve (brown connector) lift control.
ATTENTION: The number of hydraulic ports on the Bosch ATTENTION: The return oil from the lift control spool
lift control spool valve varies depending on whether it is valve is directed to the centre housing at the manifold ( 21 )
assembled with: outlet by a large section pipe the end of which is beneath
.a manifold ( 21 ) and Bosch auxiliary spool valves (Fig. 4) the oil level. This pipe is also used for the return from the
-In all cases, the operating principle remains identical auxiliary spool valves.
-Note the different location on the tractor.
SM 8-12350 Issued 03-2004

16 SECTION 8006
Figure 6
Figure 4
Figure 5
SM 8-12350 Issued 03-2004

SECTION 8006 17
A. Diagrams
(1) Priority block(s)

(17) Lift control spool valve
(21) Manifold
(31) LS signal to pump regulator via the priority
block(s)
P High pressure
P2 Secondary high pressure port
R Return beneath the oil level
V Lift rams
SM 8-12350 Issued 03-2004

18 SECTION 8006
B. Removing and refitting the spool valve
On the manifold with Bosch

auxiliary spool valves
ATTENTION: The lift control spool valve ( 17 ) is integral
with the auxiliary spool valve assembly.
It is situated between the manifold (21) and the right-

hand end plate (14) (Fig. 11) or the fourth auxiliary
spool valve (if fitted).
Consequently, it is necessary to remove (and then to

refit) the auxiliary spool valve assembly in order to
access to the lift control spool valve for servicing.
Figure 11
SM 8-12350 Issued 03-2004

SECTION 8006 19
C. Neutral position
When the engine is not running and the spool valve
is in the neutral position, the control spool (4) and the
other spools (2) are maintained in position by springs
(10) and (11). The flowrate adjustment spool (5) is
pushed downwards by spring (9).When the engine is
running and the spool valve is at rest, no pressure
information is transmitted to the variable
displacement pump. The LS line communicates with
the return.
Figure 12
SM 8-12350 Issued 03-2004

20 SECTION 8006
D. Raise position
When the Move Up solenoid valve (13) is activated, the As soon as the pressure on valve (12) is greater than
control spool (4) is moved upwards. The LS pressure that in the rams, the lift control arms raise. The LS line
information acting on the upper face of the flowrate communicates with outlet (16) informs the regulator of the
regulating spool (5) (spring (9) side) moves the spool variable displacement pump. If the pressure in the rams is too
downwards the right thus directing the flow to the high (shocks received on the lift arms) the valve (6) opens
control spool and the non-return valve (12). The and excess pressure is vented to the housing.
movement of the flowrate regulating spool is dampened
by the volume of oil present in chamber "d".
Figure 13
SM 8-12350 Issued 03-2004

SECTION 8006 21
E. Lower position
When the Move Down solenoid valve (14) is
activated to lower the lift control arms, the spool
assembly (2) allows the flow coming from the rams to
enter the return. The LS pressure information is
transmitted to the side of the flowrate regulating
spool (5) (spring (9) side) and to the variable
displacement pump.
Figure 14
SM 8-12350 Issued 03-2004

Section
8008
AUXILLIARY SPOOL VALVES
ZTX Series Tractors
8008

SM 8-12360 March 2004
2 SECTION 8008
TABLE OF CONTENTS
HYDRAULICS - CLOSED CENTRE

AUXILIARY SPOOL VALVES
General ................................................................................................................................................................ 3
Description of the components ........................................................................................................................ 3
Operation of the pressure relief valve .............................................................................................................. 5
A. Layout of components and identification of channel and ports ........................................................................ 6
On the auxiliary spool valves (Fig. 8 to 10) ..................................................................................................... 8
B. Diagram ........................................................................................................................................................... 9
C. Spool valve assembly .................................................................................................................................... 10
Removal ........................................................................................................................................................ 10
Splitting the spool valve assembly on the workbench ................................................................................... 10
Assembling the spool valve ........................................................................................................................... 10
Refitting the spool valve assembly ................................................................................................................ 11
D. Assembly procedure ...................................................................................................................................... 12
SM 8-12360 Issued 03-2004

SECTION 8008 3
Hydraulics - Closed Centre

Auxiliary spool valves
General Parts list (Fig. 1)
(1) Electro-hydraulic auxiliary spool valves

Description of the components (6) Left-hand end plate with pressure relief valve
The SB23LS - EHS BOSCH type spool valves that (14) Right-hand end plate, LS outlet
control the supply to the hydraulic couplers comprise (17) Lift control spool valve
two parts: (21) Oil manifold
A hydraulic part:
See operation below.
An electro-hydraulic part comprising:

An ON / OFF solenoid valve and a 3-way pressure
relief valve located on the left-hand end plate of the
distribution block,
A pilot valve fitted in the electro-hydraulic unit.
This section only deals with the hydraulic part. For

the electronic part, (see section 10001).
The SB23LS - EHS electro-hydraulically operated

spool valves are fitted as standard equipment to ZTX
series tractors with a closed centre hydraulic circuit.
They are supplied with high pressure, high flow rate
oil from the priority blocks.
When no functions are being activated, the entire

flowrate is directed towards the spool valves. When
certain functions are being supplied, the remaining
flow then remains available to the auxiliary spool
valves.
The main spool of the spool valve directs oil towards

the outlet ports A or B.
Each outlet port is linked to the LS pilot line of the

variable displacement pump regulating valve via the
priority block(s).
The spool valves consist of both electronic and

hydraulic components, the latter containing spools
and valves.
Some elements cannot be repaired by replacing with

spare parts.
The tractors are fitted with a basic block, comprising

three to four spool valves (according to options).
SM 8-12360 Issued 03-2004

4 SECTION 8008
Exploded view
Figure 1
SM 8-12360 Issued 03-2004

SECTION 8008 5
Operation of the pressure relief valve

When the ON - OFF solenoid valve (18) located on
end plate (6) is open, the flow from the pump is
directed to the 3-way relief valve (3) (Fig. 2). The
latter supplies the pilot valve (5) (Fig. 3) with a
pressure of 21 bar to 24 bar via a pressure balancing
valve (Fig. 2).
The pilot valve receives a signal from the digital

device (6) and moves the main spool (1) (Fig. 3) in
accordance with information received from the
Joystick.
The digital device is informed of the position of the

main spool by a displacement sensor (7) (Fig. 3).
The pilot valve and the digital device are housed in

unit (2) fixed on the base of the spool valve.
Electro-hydraulic spool valve (2)

(Fig. 3)
Parts list
1. Main valve spool

2. Electro-hydraulic unit
3. Return spring
4. Piston Figure 2
5. Pilot valve FP Filter
6. Digital electronic system
7. Displacement sensor X3 plug 12 x 1.50: Location of diagnostics connector.
P Pressure
R Return
IMPORTANT: Channels P and R are linked to the

auxiliary spool valve.
Operation of the auxiliary spool

valve (Fig. 7- 9)
When spool (1) is moved electro-hydraulically
upwards, via the pilot valve (5) (Fig. 3), high-
pressure oil penetrates via channel P, passes
through restrictor C and grooves D. It is then directed
to channel E, where it pushes ball (2) and gains
access to chamber F. Simultaneously, the ramp on
the spool raises valve (3) and oil flows via port B.
Port A is supplied by moving spool (1) downwards.
Figure 3
SM 8-12360 Issued 03-2004

6 SECTION 8008
A. Layout of components and identification of channel and ports
Layout of components (Fig. 7)

(1) Main spool
(2) Valve
(3) Non-return valve
(5) Pressure balancing valve
(6) Cover
Identification of channels and ports

On oil manifold (21) and the support (1) (Fig. 4 to 6)
P High pressure supply from the variable displacement

pump via the priority block(s) (depending on version)
R Return from the auxiliary spool valves (beneath the

oil level)
LS Signal to the pump regulating valve via the lift

control spool valve and the priority block(s)
(depending on version)
Figure 6
Figure 4
Figure 5
SM 8-12360 Issued 03-2004

SECTION 8008 7
Figure 7
SM 8-12360 Issued 03-2004

8 SECTION 8008
On the auxiliary spool valves (Fig. 8 to 10)

A Outlet to coupler
B Outlet to coupler
C Restrictor
D Grooves
E Channel
F Chamber
P - R and LS (See Page 6 ).
Figure 10
Figure 8
Figure 9
SM 8-12360 Issued 03-2004

SECTION 8008 9
B. Diagram
Figure 11
(1) Priority block(s) P High pressure
(17) Lift control valve P High pressure port (not yet available)
(20) Auxiliary spool valves R Return beneath the oil level
(21) Manifold LS Signal to the pump regulator via the
priority block(s)
SM 8-12360 Issued 03-2004

10 SECTION 8008
C. Spool valve assembly

NOTE: The lift control valve (17) is integral with Splitting the spool valve assembly
the spool valve assembly.
on the workbench
STEP 1
NOTE: The spool valve components are
On the lift control valve (Fig. 12), locate and maintained on either side of the oil manifold (21)
disconnect the solenoid valve harnesses: by six studs, of which 3 are of a different length.
MoveUp E1
STEP 5
MoveDown E2 (brown connector)
Unscrew the nuts on each end plate of the spool
valve assembly.
STEP 2
Disconnect the high pressure pipe, lift rams feed STEP 6
pipe, LS hose, solenoid valve (18) located on the left
hand end plate (6), connector(s) "C" linked to the Remove the spool valves separately taking care not
electro hydraulic unit(s) of the spool valve(s), to lose the seals inserted between the components.
carefully marking their position(s).
Assembling the spool valve
Removal
IMPORTANT: If it is feasible to replace the studs
NOTE: The spool valve assembly must be m e n t i o n e d a b o ve, l i g h t l y s m e a r o n e o f t h e i r
removed in full. Any operations carried out on the threaded ends with Loctite 241 or equivalent and
spool valves require scrupulous cleanliness. First lock them on the manifold (21) (Fig. 1). Wipe off
correctly clean the spool valves (lift control and any excess Loctite if necessary.
auxiliary), and the areas around them on the
tractor, before removing them. STEP 7
Clean the mating faces of the manifold (21) without
STEP 3 removing the adhesive shims (1) (inserts) (Fig. 14)
Locate the hose pipe(s) between spool valves and and the spool valves (auxiliary - lift control)
couplers and disconnect them.
STEP 8
STEP 4 Check the presence of new seals (3) to (5) in each
Remove the spool valve assembly. spot-faced port of the spool valves (1) (Fig. 13) and
(3) to (6) in each spot-faced port of the manifold (21)
(Fig. 14)
STEP 9
Assemble the spool valve on the workbench, using
the procedure described on Page 12.
Figure 12
SM 8-12360 Issued 03-2004

SECTION 8008 11
STEP 11
Refit the spool valve assembly on its support.
Tighten the oil manifold (21) on the support (1) as
follows,
Screws 50 - 70 Nm
Nuts 90 - 120 Nm
Final operations
STEP 12
Assemble the hose pipes between the spool valves
Figure 13 and couplers, according to the marks.
STEP 13
Reconnect the pipes (high pressure pipe, lift rams
feed pipe and LS hose.
STEP 14
Reconnect the MoveUp and MoveDown solenoid
valve connectors in accordance with marks made
during removal.
STEP 15
Reconnect the connector(s) connected to the
electro-hydraulic housing(s) in accordance with
marks made during removal. Reconnect the ON -
OFF solenoid valve located on the left-hand end
plate.
STEP 16
Start the engine.
STEP 17
For each spool valve position, check the operation of
hydraulic devices and electronic devices.
STEP 18
Figure 14
Check the oil tightness of the spool valves and
hydraulic unions.
Refitting the spool valve assembly
STEP 10
Check tightening of the studs (2) on the support (1)
and replace the O’ring (3) (Fig. 15).
IMPORTANT: I f i t i s a b s o l u t e l y n e c e s s a r y t o
replace the studs, lightly smear the shor t threads
with Loctite 270 or equivalent, and lock the studs
on the suppor t. Wipe off any excess Loctite if
necessary.
Figure 15
SM 8-12360 Issued 03-2004

12 SECTION 8008
D. Assembly procedure
IMPORTANT: To obtain the correct assembly of
seals (3) (4) (5) (6) (Fig. 13 - 14), the reassembly of
each spool valve (1) on the oil manifold (21) must be
carried out ver tically on a clean workbench (Fig.
16).
NOTE: Adhesive shims also known as “inserts”

allow the tightening load to be distributed among the
three studs and not on the entire contact surface of
the spool valves. To avoid jamming the spools, it is
important to respect the fitting of the shims and to
tighten nuts to a torque of 30 - 33 Nm.
Assembly
(Fig. 17)
STEP 19
After refitting the spool valve assembly, tighten the
nuts (3) in contact with each end plate, without
locking them.
STEP 20
Place the spool valve assembly in a vertical position.
Tighten a first series of nuts to a torque of 30 - 33
Nm. Turn the assembly over and complete the
assembly process by tightening the second series of Figure 16
nuts to the same torque.
STEP 21
Use a suitable lever to check the mobility of each
spool valve.
Figure 17
SM 8-12360 Issued 03-2004

Section
9
CLIMATE CONTROL
How it Works
ZTX Series Tractors

DT50-50330 March 2004
SECTION 9

SECTION 9
Contents Page
Introduction to climate control ................................................................................4

Illustration of climate control panel .........................................................................5
Operation of climate control ...................................................................................7
Table of inputs and outputs ....................................................................................7
Smart pressure switch operation ...........................................................................7
ATC Display ...........................................................................................................8
Automatic temperature control operation ...............................................................9
De-fog operation ....................................................................................................9
Climate control fault codes ....................................................................................10

SECTION 9
Introduction to climate control

ZTX is fitted with an air conditioning system that is fully automatic in its functions,
and can, (if the operator desires), adjust the following parameters on its own.
These functions are:-
x Cab blower motor speed

x Cab temperature control (Heating)
x Cab temperature control (Cooling)
x Cab demist control (Humidity)

SECTION 9
Illustration of climate control panel
Temperature
Control dial
Cab recirculation
control dial
Climate control
Display panel
Mode control
switch
(Auto)
Blower control (Manual)
dial (Demist)

SECTION 9
Operation of climate control

The ATC (Automatic temperature control) is a closed loop control device, which
takes the data from a number of inputs and executes output instructions to the
devices it controls. The desired controlling parameter is cab inside temperature. The
operator selects a desired cab temperature set point. The controller then utilizes the
A/C compressor, electronic water valve, and system blower to drive the cab
temperature to and hold the desired set point. This is done through a number of
controlling algorithms and look up tables, which define the controller's response
based upon the current actual cab temperature and the desired cab temperature set
point.
Manual adjustment of the blower speed overrides the ATC Control Module's control
of this function. Control remains manual until the system is shutoff and turned back
on. Temperature control is always automatic.
In AUTO mode, the A/C compressor only runs when needed to maintain cab
temperature. In DE-FOG mode, the compressor runs continuously until the
evaporator core sensor reaches its maximum setting and cuts out. In OFF mode, the
compressor is disabled but the blower motor continues to circulate air at the rate
selected by the operator.

SECTION 9
Table of inputs and outputs
INPUTS OUTPUTS
Cab temperature sensor AIC compressor engagement via relay
Coil temperature sensor Heater control valve position
Set point temperature Blower speed control via PWM signal
Low pressure switch status Data for liquid crystal display
High pressure switch status Conditioned power for servo actuators
(+12V)
Mode inputs OFF/AUTO/DEFOG LCD conditioned power (+5V)
Manual blower speed control
O O
F/ C Display selection
B+
Common ground
Ground
Smart pressure switch cycling system

The ATC control system is equipped with pressure switch cycle counters. The
compressor will not be locked out until four cycles of the low-pressure switch occur
within a 60 second interval. The compressor will not be locked out until two cycles of
the high-pressure switch occur within a 60 second rolling interval, which starts with
the first cycle of the switch.
NOTE: - On cool days below 4.5oC (40oF), the system may not operate due to the
low-pressure switch lock out even though the cab temperature is warm. The system
is not malfunctioning if this occurs. To provide the necessary compressor protection,
systems are not designed to operate on days below 4.5oC (40oF).

SECTION 9
ATC Display
A. Temperature Setting
B. Defog Mode Indicator
C. Automatic Mode Indicator
D. Service Indicator

SECTION 9
Automatic Temperature Control (ATC) Operation

x To activate the automatic temperature control mode, depress the top of the
climate control switch. An "A" will appear in the display to indicate that the
automatic mode has been selected.
x Select desired cab temperature using the temperature control dial.

¾ Full counterclockwise will provide maximum cooling;
¾ Fully clockwise will provide rnaximum heat.
x The fan speed will automatically regulate to achieve and maintain the
requested cabin temperature.
In maximum set mode, the cab fan speed will also be at maximum unless manually
adjusted. To return to automatic control rotate knob away from maximum.
NOTE: - When in cold climates and auto mode selected the cab fan will not go to
high speed until the evaporator core has reached a temperature above 2oC (34oF).
¾ To override the automatic fan speed, rotate blower control to the desired fan
speed setting. The "A" will disappear from the temperature display to indicate
auto fan speed is no longer active.
¾ To return to automatic mode, turn the climate control switch to the, OFF,
position and then return to the automatic switch position.
NOTE: - Degrees Celsius or degrees Fahrenheit can be used for the units of
measurement.
De-fog Control Operation

¾ To activate the defog mode depress the bottom of the climate control switch.
The defog icon will appear in the Display to indicate defog mode selected.
¾ Select desired cab temperature using the temperature control dial.
¾ Use blower control dial to select desired fan speed.

SECTION 9
Climate control fault codes
Fault codes that relate to a malfunction in the automatic temperature control system
can only be viewed through the ATC display. In the event of a fault occurring the
display will cycle through any active fault codes & the currently selected
temperature.
The ATC controller has no memory facility; therefore only active faults will be
displayed.
Code Description
High pressure Switch lockout. Switch cycled twice within 30
seconds
01 Compressor clutch will no longer engage due to high-pressure
switch setting being exceeded. Switch has opened shutting down
the system.
Low pressure Switch lockout. Switch cycled 4 times within 60

seconds
02 Compressor clutch will no longer engage due to low-pressure
switch setting being exceeded. Switch has opened shutting down
the system.
03 Blower motor over current condition
Blower control potentiometer circuit failure. Exceeds 11000 ohms

04
Blower will only operate at maximum speed and cannot be varied
with he blower control knob.
Temperature control potentiometer circuit failure. Exceeds 11000
ohms
05
Cab temperature will default to 20oC and cannot be varied.
Fresh air/recirculation air door control potentiometer circuit

06
failure. Exceeds 11000 ohms
07 Mode control potentiometer circuit failure. Exceeds 11000 ohms
Cab air temperature sensor circuit open or shorted high.

08 Displayed if temperature sensed is below –17oC (0oF).
(Cab temperature will default to 20oC and cannot be varied.)

SECTION 9
Code Description
Cab air temperature sensor short circuit.
09
Displayed if temperature sensed is above 82.2oC (180oF).
Cab temperature will default to 20oC and cannot be varied.
Freeze sensor open or shorted high.

10
Displayed if temperature sensed is below –17oC (0oF).
Freeze sensor short circuit.

11
Displayed if temperature sensed is above 82.2oC (180oF).
Cab temperature will default to 20oC and cannot be varied

9001
Section
9001
PEDAL, LEVER AND SWITCH ADJUSTMENTS
ZTX Series Tractors

SM 8-12480 June 2004
2 SECTION 9001
TABLE OF CONTENTS
SPECIAL TORQUES.................................................................................................................................................3
SPECIAL TOOLS ......................................................................................................................................................3
BRAKE PEDAL
Brake Pedal Stop Adjustment ...............................................................................................................................4
Master Cylinder Rod Adjustment...........................................................................................................................4
Brake Pedal Maximum Travel Adjustment ............................................................................................................4
Brake Light Switch Adjustment..............................................................................................................................4
CREEP CONTROL CABLE ADJUSTMENT..............................................................................................................6
SHIFTABLE PTO ADJUSTMENT..............................................................................................................................7
DROMONE AUTO HITCH ADJUSTMENT (if Equipped)

Cable Adjustment ..................................................................................................................................................8
Lift Rod Adjustment ...............................................................................................................................................9
REMOVING AIR FROM THE BRAKE SYSTEM .....................................................................................................10
GROUND SPEED SENSOR ...................................................................................................................................12
SM 8-12480 Issued 06-2004

SECTION 9001 3
SPECIAL TORQUES
Rear Wheel Nuts
Wheel Hub to Tapered Bushing
Evenly in 50 Nm (36 lb. ft) intervals to ........................................ 500 to 600 Nm (369 to 443 lb. ft)
Wheel to Wheel Hub........................................................................ 640 to 680 Nm (472 to 502 lb. ft)
SPECIAL TOOLS
HYDRAULIC TEST KIT
1002T1
MULTIMETER, MC2616
SM 8-12480 Issued 06-2004

4 SECTION 9001
BRAKE PEDAL
Before any adjustments are made carry out the following:
• Remove the RH and LH instrument panel side covers.
NOTE: Disconnect the harness from the auxiliary power socket on the RH side cover.
NOTE: All adjustments must be carried out before connection of brake tubes and hoses.
Brake Pedal Stop Adjustment Brake Pedal Maximum Travel

Adjustment
STEP 1
STEP 4
Engage the brake pedal latch to lock both brake
pedals together. Fully depress the RH brake pedal, adjust bolt (6)
until it is in contact with the brake pedal. Release
STEP 2 the brake pedal and turn bolt (6) one full turn
clockwise, tighten locknut (7).
Make sure one of the brake pedals is in contact with
surface (1). Adjust bolts (2) until they are in contact NOTE: The master brake cylinder will be
with both brake pedals and the latch can be damaged if excessive force is used to depress
removed without moving the other brake pedal, the brake cylinder.
tighten lock nuts (3).
STEP 5
Master Cylinder Rod Adjustment
Repeat Step 4 for the LH brake pedal.
STEP 3
Brake Light Switch Adjustment
Adjust clevis (4) so that the cylinder is fully
extended and there is 1.0 mm clearance between
STEP 6
the cylinder rod and piston when the brake pedals
are fully against bolts (2), tighten locknut (5). Loosen locknut (8) and adjust switch (9) until the
plunger is fully depressed by the brake pedal when
the brake pedal is against stop bolt (2). Turn switch
(9) half to one turn counter clockwise so the
locating tabs on the switches are facing away from
each other.
SM 8-12480 Issued 06-2004

SECTION 9001 5
8 7
5
1
4
DI97J179
SM 8-12480 Issued 06-2004

6 SECTION 9001
CREEP CONTROL CABLE ADJUSTMENT

STEP 1 STEP 3
7
1 8 9
6
DD98C316 418 mm
Put lever (1) in the disengaged position, fully
downward.
STEP 2
3 2
MI04E047
5 Make sure creeper rod (6) is set at 418 mm. Assemble

pivot bolt (7) and nut (8) with lithium grease and
4 tighten to a torque of 24 to 31 Nm (18 to 23 lb ft).
Adjust switch (9) so that the creeper light on the
MD04D010 instrument cluster is illuminated when the creeper is
Put lever (2) in the disengaged position, fully engaged.
forward. Install cable (3) into bracket (4) and adjust
nuts (5) until the end of cable (3) can be easily
installed into lever (2), tighten nuts (5) and install
the clip onto cable (3).
SM 8-12480 Issued 06-2004

SECTION 9001 7
SHIFTABLE PTO ADJUSTMENT

STEP 1 STEP 2
5
4
1
5
3
MD04D004 MD04D003
Put the PTO lever (1) in the 750 rpm position, fully Put lever (2) in the 750 rpm position, fully rearward.
downward. Install cable (3) into bracket (4) and adjust nuts (5)
until the end of cable (3) can be easily installed into
lever (2), tighten nuts (5) and install the clip onto
cable (3).
SM 8-12480 Issued 06-2004

8 SECTION 9001
DROMONE AUTO HITCH ADJUSTMENT (if Equipped)

• Put blocks in front of and behind the front wheels.
Cable Adjustment STEP 2

4
STEP 1 5 6
5
6
2 3
1
MD04C160
Make sure the auto hitch latch handle is pushed

MD04C156 fully down. Install pin (2) and clip (3) through the
Make sure the auto hitch is in the raised position clevis. Install cable (4) into the bracket with an
with latches (1) in the locked position. adjusting nut (5) and washer (6) on either side.
Tighten the adjusting nuts (5).
SM 8-12480 Issued 06-2004

SECTION 9001 9
Lift Rod Adjustment
A
1
DI04C161
3 MM
STEP 3 STEP 4
Pull the auto hitch release control to unlock the Start the engine and lower then raise the hitch to
locking latches (1). Check the clearance between the upper limit to check the operation of the locking
the latch (1) and the lock bar (A), this should be latches.
3mm (0.1 inch) if necessary adjust the LH and RH
lift rod adjusting nuts to obtain the correct
clearance.
SM 8-12480 Issued 06-2004

10 SECTION 9001
REMOVING AIR FROM THE BRAKE SYSTEM

NOTE: The air removal procedure will be faster if the hydraulic oil is heated to a temperature of approximately
49°C (120°F).
STEP 1 STEP 2
MD04D007 MD04D009
Put the other end of the clear plastic tube in the

transmission oil fill tube. Start and run the engine at
1200 to 1500 rpm.
2
! closed building. Proper ventilation is required
under all circumstances.
STEP 3
Lock the brake pedals together. Fully depress the
pedals a minimum of 10 strokes, and make sure
there are no air bubbles present in either plastic
MD04D008
bleed tube.
Attach a length of 5mm (0.2 inch) ID clear plastic
tube to each valve. Open LH brake valve (1) and RH IMPORTANT: Depress the pedals smoothly and
brake bleed valve (2) 1 turn counter clockwise. quickly and release SLOWLY.
SM 8-12480 Issued 06-2004

SECTION 9001 11
STEP 4 STEP 5 TRAILER BRAKE ONLY

Connect a length of clear plastic tube to the bleed
valve on the trailer brake valve. Open the bleed
2 valve on the trailer brake 1/2 to 3/4 of a turn.
STEP 6
With the brake pedals latched together, fully
depress the brake pedals, a minimum of three
strokes, until there are no air bubbles present in the
plastic bleed tubes.
STEP 7
MD04D008
To remove air from the brake balance line, close the Tighten the bleed valves and remove the plastic
RH bleed valve (2) and continue to depress the tubes. Depress the brake pedal several times. Stop
brake pedals, a minimum of 5 strokes, until there the engine.
are no air bubbles present in the LH plastic bleed
tube. Close the LH bleed valve.
NOTE: Tractors not equipped with a trailer

brake valve refer to STEP 7.
SM 8-12480 Issued 06-2004

12 SECTION 9001
WHEEL SPEED SENSOR

NOTE: The Wheel Speed sensor is located on STEP 3

the top of the centre housing above the crown
wheel. 4
STEP 1
Disconnect and remove the sensor.
3
STEP 2
2
DI04C026
Install the sensor (3) until it just touches the tooth

of the crown wheel. Turn the sensor anticlockwise
1-3/4 turns. Tighten the lock nut (4).
1
STEP 4
Connect the sensor to the transmission harness
DI04C025
Check to make sure that a tooth of the crown wheel

(1) is in the position shown, directly under the
sensor opening (2).
IMPORTANT: if the sensor is installed with the

crown wheel in the incorrect position the sensor
will be damaged
SM 8-12480 Issued 06-2004

10
Section
10
ELECTRICAL
CONTROLLERS
How it Works
ZTX Series Tractors

DT50-50340 March 2004
SECTION!10

SECTION!10
Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !Page
Introduction ............................................................................................................4
What!!is!CAN!BUS .................................................................................................4
Diagram!of!CAN!BUS!layout ..................................................................................5
Description!of!control!modules ...............................................................................5
Control!module!location..........................................................................................6
Electronic!Draft!Control ..........................................................................................9
Functions!of!electronic!draft!control .......................................................................9
Electronic!draft!control!components!positions! .......................................................10
Electronic!draft!control!tractor!requirements...........................................................11
Electronic!draft!control!operation............................................................................11
Position!control!operation.......................................................................................12
Draft!control!operation............................................................................................12
Ride!control!operation! ...........................................................................................14
Slip!control!operation!.............................................................................................15
Auto!MFD!diff!lock!&!PTO!operation ......................................................................17

SECTION!10
Introduction
The!electrical!system!used!on!ZTX!is!a!CAN!BUS!system.!Using!this!system!has
allowed!McCormick!tractors!to!fully!integrate!all!the!different!areas!of!the!tractor!and
bring!them!together!to!work!as!one.
It! has! also! allowed! the! total! number! of! wires! running! around! the! tractor! to! be! cut
down!for!maximum!reliability!and!the!time!it!takes!for!messages!to!be!passed!from
component!to!component!has!been!vastly!reduced!and!therefore!smoother!operation
and!greater!productivity!can!be!achieved.
What!is!CAN!BUS
CAN!BUS!is!the!name!that!is!given!to!the!method!of!data!transfer,!on!many!types!of
machinery!now.!Its!name!comes!from!the!computer!industry,!and!stands!for;
Computer!Area!Network
This!term!simply!means!the!networking!of!components!and!controllers!and!within
this!network!the!exchange!of!data!between!components!via!a!data!bus!system.
CAN!BUS!in!very!basic!terms!is!a!pair!of!insulated!wires!twisted!together!that!run
around!the!tractor!between!each!control!module!and!some!components,!and!are
joined!at!each!end!by!a!terminal!resistor.!These!wires!therefore!are!the
communication!link!for!the!whole!of!the!tractor.!The!engineering!name!for!these
wires!is!CAN!High!and!CAN!Low.!These!wires!are!very!often!green!and!yellow
colours.
This!means!that!ultimately!each!component!that!is!controlled!by!a CAN!BUS!link
only!needs!4!wires!to!it.!These!are!CAN!High,!CAN!Low,!B+!(power)!and!Ground
(earth).
Electrical!messages!are!then!sent!out!around!the!can!bus!system!as!digital!pulses,
and!are!seen!by!all!the!components!linked!to!the!CAN!BUS.
Depending!on!the!type!of!messages!sent!on!the!CAN!BUS!the!number!of!messages
seen!at!any!one!time!can!be!between!781!messages!per!second!and!1851
messages!per!second.
Although!all!components!see!all!the!messages!they!will!only!act!on!the!messages
that!are!relevant!at!the!time!to!themselves.!This!is!because!each!message!has!an
identifier!(address)!attached!to!it
This!means!that!all!the!control!modules!are!constantly!linked!and!as!soon!as!one
sends!out!a!signal!that!all!other!modules!need!to!act!on,!they!can!do!so!immediately.
There!is!however!a!priority!system!in!place!that!will!allow!more!important!messages
to!be!transferred!before!non!important!ones.
Because!of!this!most!of!the!wires!found!on!the!tractor!will!actually!be!connecting
sensors,!switches,!solenoids,!potentiometers!and!lights!to!the!control!modules.

SECTION!10
Line!drawing!of!ZTX!CAN!BUS
Climate
Diagnostic Instrument
Control Hitch
Socket Cluster
Module Control
Module
Terminal Terminal
Resister Resister
Engine Transmission
McCormick Auxiliary!Valve
Control Controller
Tractors Control!Module
Module
Cab!Controller
Control!Modules!(Controllers)
There! are! 7! separate! control! modules! located! around! the! tractor! to! control! its
functions!these!are!as!follows.
•! McCormick!Cab!Controller!Module
•! McCormick!Instrument!Cluster
•! Hitch!Controller
•! Auxiliary!Valve!Control!Module
•! Engine!Control!Module.
•! Transmission!Control!Module
•! Climate!Control!Module,!(Not!linked!on!the!CAN.)
These! modules! above! fit! into! two! different! categories,! they! are! either! intelligent
modules!that!can!analyse!data!and!act!on!it!or!they!are!dumb!modules!that!control
what!they!are!told!to!do.

SECTION!10
Controller!locations
Engine
Controller
Transmission
Controller

SECTION!10
The!following!controllers!are!mounted!underneath!the!rear!cab
trim!panel.
McCormick!Cab
Auxiliary/Remote Controller
Hitch!(Bosch)
Valve!Controller
Controller

SECTION!10
The!climate!control!module!is!located!within!the!climate!control
unit
The!instrument!cluster!is!also!a!controller

SECTION!10
Bosch!electronic!draft!control!system
The!hitch!control!system!used!on!ZTX!is!a!version!of!the!tried!and!tested!Bosch
electronic!draft!control.
This!version!is!fully!CAN!BUS!compatible,!and!therefore!is!linked!to!the!rest!of!the
tractor!to!monitor!all!its!functions!to!enable!it!to!carry!out!its!own!functions!at!the
correct!times,!as!requested!by!the!operator.
Functions!of!Electronic!draft!control
Depending!on!the!options!fitted!specific!to!the!market!it!is!supplied!into!the!electronic
draft!control!system!has!the!following!functions:
•! Implement!position!control
•! Implement!draft!control!(or!a!mixture!of!position!and!draft)
•! Implement!quick!entry!(float,!momentary!position!only)
•! Auxiliary!lift!control!(fender!buttons)
•! Area!meter!cut!out
•! Auto!MFD
•! Auto!diff!lock
•! Auto!PTO!cut!out
•! Auxiliary!PTO!cut!out!(fender!buttons)
•! Wheel!slip!control
•! Ride!control
There!are!also!controls!for!maximum!implement!lift!height!and!implement!drop
speed,!and!a!lamp!on!the!right!rear!dash!to!show!the!hitch!status,!and!to!display
error!codes!also.

SECTION!10
Electronic!draft!control!components!positions
Hitch!raise/work!& Hitch!control!panel!&!PTO
quick!entry!switch (Including!auto!switces!&
Electronic
ride!control)
draft
control
module
Fender
buttons
Radar
unit
Hitch!control!valve
mounted!in
Auxiliary!valve!bank
Lower!link!draft
sensing!pins
Hitch!position
Sensor

SECTION!10
Electronic!draft!control!tractor!requirements
The!EDC!requires!a!permanent!12!volt!fused!supply!and!a!key!switched!12!volt
fused!supply!also.!It!requires!a!connection!to!ground!(earth),!a!signal!that!the!engine
alternator!is!charging!so!that!it!can!recognise!that!the!engine!is!running,!a!tractor
speed!signal,!and!a!radar!speed!signal,!although!the!EDC!will!function!without!both
these!speed!signals,!as!it!only!requires!these!for!the!wheel!slip!and!ride!control
functions!to!operate.
Electronic!draft!control!operation
The!operator!must!start!the!tractor!and!ensure!that!the!engine!alternator!warning
lamp!has!gone!off!and!then!the!hitch!can!then!be!captured!(Unlocked).
When!the!ignition!switch!is!cycled!on!the!EDC!controller!will!perform!a!self!test!and
will!momentarily!illuminate!the!hitch!diagnostic!light,!on!the!right!console!and!the!slip
light!on!the!instrument!cluster!!also.!After!a!short!time!the!diagnostic!light!will
illuminate!and!then!stay!on!until!the!EDC!has!been!captured.
The!procedure!to!capture!the!hitch!is!as!follows:
The!raise/work/quick!entry!switch!must!be!in!the!work!position
The!implement!depth/height!lever!must!then!be!cycled!to!its!end!stops.!Whilst!this!is
being!done!the!hitch!diagnostic!light!will!flash!with!very!high!frequency!to!warn!the
operator!that!hitch!capture!may!occur.!Should!the!hitch!not!capture!then!the!light!will
stay!permanently!on!unless!there!is!an!error!code!that!it!needs!to!flash!up.!If!the
hitch!has!captured!then!the!light!will!go!out!and!the!hitch!become!operational.
After!the!hitch!has!been!captured,!the!first!time!the!hitch!is!raised!and!lowered!the
EDC!control!module!will!only!allow!slow!operation!regardless!of!the!setting!of!the
drop!rate!potentiometer!for!safety!reasons,!but!when!the!hitch!is!cycled!again!the
EDC!module!will!revert!back!to!normal!operation.
If!the!rear!fender!buttons!are!used!!at!any!time!then!the!EDC!will!go!back!into!a
locked!state!for!safety!reasons!and!the!diagnostic!light!would!be!illuminated!and!the
hitch!would!have!to!be!captured!again.
When!the!fender!buttons!are!operated!the!EDC!will!also!only!move!the!hitch!slowly
for!safety!reasons!also.!This!is!done!by!the!EDC!module!limiting!the!voltage!sent!to
the!raise!and!lower!PWM!solenoid!valves.

SECTION!10
Position!control!operation
When!the!tractor!is!operated!in!full!position!control!(0!on!the!potentiometer)!the!EDC
module!is!only!looking!for!information!from!the!hitch!position!sensor,!the!implement
depth!lever,!the!maximum!lift!height!potentiometer,!the!drop!speed!potentiometer,
and!the!hitch!raise/work/quick!entry!switch.
The!operator!sets!the!desired!implement!height!on!the!depth!set!lever,!which!works
on!a!linear!scale!that!at!the!bottom!of!the!quadrant!is!fully!lowered(maximum!depth)
and!at!the!top!is!fully!raised!(transport),!and!anything!in!between!is!proportionally
between!the!two.
Raising!and!lowering!of!the!implement!is!then!controlled!by!the!Raise/work/quick
entry!switch,!with!the!height!that!the!implement!lifts!to!being!controlled!by!a
combination!of!the!signals!the
EDC!control!module!receives!from!them!both,!and!the!position!sensor!also.
When!the!implement!is!lowered!the!EDC!module!looks!at!the!signal!it!is!receiving
from!the!drop!rate!potentiometer!and!then!adjusts!the!voltage!it!sends!to!the!lower
PWM!solenoid!valve!on!the!hitch!valve!slice,!and!lowers!to!the!point!that!the!depth
lever!is!set!to.!The!EDC!module!knows!the!position!of!the!hitch!from!the!signal!it
receives!from!the!position!sensor!on!the!hitch!rock!shaft.
Draft!control!operation
When!the!tractor!is!set!in!full!draft!control!(11!on!the!potentiometer)!the!EDC!module
is!looking!for!all!the!same!signals!that!it!was!in!position!control,!but!it!is!now!also
looking!for!a!load!reading!from!the!lower!link!draft!sensing!pins
These!pins!contain!electrical!windings!and!circuitry!that!convert!voltage!sent!to!them
into!a!signal!that!the!EDC!module!can!recognise!and!act!upon.
!When!the!draft!pin!is!in!its!neutral!state!(i.e.!no!loading)!the!EDC!module!recognises
this!and!will!hold!the!implement!at!the!exact!depth!set!on!the!depth!setting!lever,!as
it!would!in!full!position!control.
If!the!draft!sensing!pin!seeís!a!positive!draft!load!placed!upon!it!a!signal!is!sent!back
to!the!EDC!control!module,!which!will!raise!the!hitch!until!the!load!on!the!pin!is
reduced!sufficiently!for!the!EDC!module!to!see!a!neutral!load!and!stop!lifting.
When!a!negative!draft!load!is!placed!on!the!pin!it!has!the!opposite effect, and the
EDC module will lower the hitch until a neutral load is found again.

SECTION!10
Full!draft!control Mixture!of!position!and!draft
Widely!variable!depth!but!maximum Constant!depth!but!some!wheel!slip.
traction.
This!all!means!that!in!changing!soil!conditions!a!constant!depth!cannot!be!achieved
and!this!may!not!be!acceptable!to!the!operator,!therefore!we!can!have!a!mixture!of
draft!and!position!control!to!overcome!this!situation.
This!is!achieved!by!the!EDC!control!module!looking!at!the!setting!on!the
position/draft!potentiometer!and!it!damping!the!draft!signals!accordingly.!The!further
that!we!move!the!potentiometer!away!from!full!draft!control!the!wider!the!neutral
band!on!the!draft!sensing!pin!becomes!that!the!EDC!module!sees.!This!therefore
means!that!a!greater!positive!or!negative!draft!load!is!needed!before!the!implement
is!raised!or!lowered!and!therefore!a!constant!depth!is!maintained,!although!the!load
upon!the!tractor!may!now!be!great!enough!to!cause!wheel!slip,!and!therefore!the
potentiometer!would!need!to!be!set!back!closer!to!full!draft!to!maintain!forward
travel.!The!industry!standard!for!acceptable!wheel!slip!is!between!10!&16%
!Draft!pin!neutral!band!full!draft Draft!pin!neutral!band!50%!mix
Hitch Hitch
Hitch!lower Hitch!neutral Hitch!raise Hitch!Neutral
!lower raise

SECTION!10
Ride!control!operation
When!the!operator!requires!he!can!switch!on!the!ride!control!that!will,!if!all!its
requirements!are!met!allow!the!hitch!to!damp!the!shock!loadings!that!it!is!subjected
to!whilst!carrying!an!implement!at!relatively!high!speeds,!this!then!takes!the!worst
amounts!of!strain!off!the!tractors!linkage!and!the!implement!also.
There!are!also!other!benefits!such!as!improved!steering!safety,!due!to!the!front
wheels!staying!in!contact!with!the!ground,!improved!operator!comfort,!and!therefore
forward!speed!and!productivity,!and!the!stabilisation!of!the!implements!above!ground
height!whilst!moving.
The!following!criteria!must!be!met!for!ride!control!to!be!active:
The!EDC!must!be!captured!(unlocked)
The!implement!depth!lever!must!be!in!the!transport!position!(at!the!top!of!its
quadrant)
Ride!control!switch!must!be!in!the!on!position
The!tractor!must!be!travelling!at!above!approximately!8!kph!(288Hz!speed!sensor
frequency)
When!all!of!the!above!criteria!are!met!the!ride!control!will!become!active!and!the
hitch!will!lower!approximately!4%!from!its!upper!limit!position,!and!will!try!to!maintain
this!set!point.!When!the!tractor!goes!over!a!bump!though!and!the!hitch!seeís!a!shock
load!on!the!down!stroke!the!EDC!module!will!allow!the!hitch!to!drop!a!further!4%!to
damp!the!movement,!and!the!when!the!implement!bounces!back!up!again!the!EDC
will!allow!it!to!move!back!to!the!max!lift!point!thus!giving!an!8%!band!of!movement
for!damping!on!the!next!down!stroke.(4%!above!and!below!the!ride!control!height)
8kph
8% forward
total speed
movement
4%!up
4%!down
Should!the!tractors!forward!speed!drop!below!75%!of!the!switch!on!speed!(8!kph)
the!ride!control!will!automatically!turn!off.!This!is!for!safety!purposes!to!ensure!the
implement!is!held!at!full!height!when!stationary.
The!control!of!the!implement!bounce!is!all!done!electronically!within!the!EDC!module
that!is!taking!readings!from!the!hitch!position!sensor!and!the!shock!loadings!on!the
draft!pins,!and!controlling!the!hitch!raise!and!lower!solenoids!accordingly!to!damp
and!control!hitch!movement.

SECTION!10
Slip!control!operation
When!fitted!with!radar!ZTX!can!be!fitted!also!with!wheel!slip!control!that!will!allow!the
EDC!module!to!optimise!the!hitch!depth!according!to!not!only!the!draft!control!setting
but!also!the!actual!wheel!slip!that!the!tractor!has!at!that!time.
This!wheel!slip!is!measured!on!the!tractor!by!the!EDC!module.!This!is!done!by!it
taking!a!signal!from!the!tractors!radar!unit!(true!ground!speed!signal),!and!the
transmission!speed!transducer,!and!comparing!the!two!signals!and!working!out!the
actual!wheel!slip,!and!then!combining!these!readings!with!the!draft!control!readings
to!adjust!the!hitch!accordingly,!depending!on!the!figure!that!the!operator!has!set!on
the!instrument!cluster.
Should!the!operator!wish!to!view!his!actual!wheel!slip!then!this!can!be!done!on!the
instrument!cluster,!but!this!may!not!be!the!exact!figure!that!the!EDC!control!module
is!actually!setting!the!hitch!to!because!it!is!capable!of!working!faster!than!the!display
can!respond.(there!is!damping!in!the!cluster!software!to!erratic!readings!occurring)
When!the!tractor!is!new!and!leaves!the!factory!it!has!default!figures!in!the!EDC
control!module!that!will!allow!the!wheel!slip!to!work!approximately,!but!not!as
efficiently!as!it!is!capable!of!doing.!This!is!because!there!are!so!many!variants!on
each!individual!tractor!depending!on!tyre!equipment,!and!pressure,!tractor!weighting
and!ballasting,!and!also!things!like!implement!size!weight!and!hitch!fitting!type!(3
point!hitch!such!as!plough!or!subsoiler,!or!lower!link!semi!mounted!such!as!a!large
cultivater!or!drill)

SECTION!10
Slip!control!operation!(Cont'd)
Because!of!this!there!is!a!procedure!to!be!followed!that!will!allow!the!hitch!to!learn!its
proper!calibrations.!This!procedure!is!called!normalisation!of!the!transmission!signal,
and!it!can!be!carried!out!by!the!operator,!if!he!feels!that!the!wheel!slip!control!will
benefit!from!his!doing!so.
The!procedure!is!as!follows:
With!the!engine!running!the!EDC!must!be!captured!(unlocked)
There!must!be!some!loading!of!the!draft!pins!(this!is!to!tell!the!EDC!module!that!the
tractor!tyres!are!loaded!i.e.!maximum!side!wall!deflection,!and!therefore!reduced
rolling!radius)
The!hitch!must!be!in!the!transport!position!(raise/lower/quick!entry!switch!in!the!raise
position!and!the!implement!depth!lever!at!maximum!depth)
The!tractor!must!then!be!driven!at!a!speed!greater!than!15kph!for!a!minimum!period
of!12!minutes!on!firm!level!ground!(the!road!for!example)
When!all!this!has!been!done!the!EDC!module!will!self!learn!from!the!information!it
has!received!from!the!radar!and!the!transmission!speed!transducer!and!the!module
will!be!dynamically!calibrated!for!maximum!accuracy.

SECTION!10
Auto!MFD,!Diff!lock!&!PTO!operation
The!auto!functions!on!the!tractor!controlled!by!the!EDC!control!module!are!all!done
in!very!much!the!same!way,!but!!the!hitch!inputs!that!trigger!these!functions!are
different.
The!EDC!module!takes!a!switch!input!from!the!auto,!MFD,!diff!lock,&!PTO!switches
on!the!right!hand!console.
When!the!hitch!is!raised!and!auto!MFD!or!auto!diff!lock!is!switched!on!the!EDC
module!will!put!a!message!on!the!CAN!BUS!to!say!it!is!raising!This!is!seen!by!the
McCormick!cab!controller!which!in!turn!sends!a!message!on!the!CAN!to!the
transmission!controller!to!tell!it!to!turn!of!both!the!MFD!or!MFD!and!diff!lock.
When!the!hitch!is!lowered!again!a!message!is!also!sent!out!and!the!whole!process
repeated!in!reverse.
When!the!EDC!module!receives!the!auto!PTO!switch!input!it!will!look!at!the!position
of!the!rear!hitch!and!if!it!is!in!the!lower!3rd!of!its!operating!band!it!will!leave!the!PTO
function!turned!on.!If!the!hitch!is!raised!it!will!turn!the!PTO!off!when!the!hitch!reaches
1/3rd!lift!height.!This!is!not!however!done!directly!by!the!EDC!module.
The!actual!way!that!this!all!happens!is!that!the!EDC!module!sends!a!CAN!BUS
message!out!to!say!that!the!hitch!has!reached!1/3rd!lift!height,!this!is!then!seen!by
the!McCormick!cab!controller!(MCC)!which!in!turn!tells!the!transmission!controller
(TC)!to!turn!off!the!PTO.
When!the!hitch!is!lowered!1/3rd!from!the!top!of!its!maximum!height!the!EDC!module
will!also!send!out!a!message!on!the!CAN!and!this!will!also!be!seen!by!the!MCC
which!will!then!tell!the!TC!to!turn!the!PTO!back!on!again

10001
Section
10001
AUXILIARY/REMOTE CONTROLLER
Error Codes, Troubleshooting

and Schematics
ZTX Series Tractors

SM 8-12490 June 2004
2 SECTION 10001
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 4
GENERAL INFORMATION FOR ELECTRONIC

AUXILIARY/REMOTE VALVE CONTROL ............................................................................................................... 5
Auxiliary/Remote Valve Operation ....................................................................................................................... 5
CAN Bus Communication .................................................................................................................................... 5
ERROR CODES GENERAL INFORMATION .......................................................................................................... 6

Retrieving Instrument Cluster Displayed Active Error Codes. ............................................................................. 6
AUXILIARY/REMOTE VALVE MANUAL OPERATION ........................................................................................... 7
CIRCUIT TESTING
General Information ............................................................................................................................................. 8
ERROR CODE TROUBLESHOOTING GUIDE
Auxiliary/Remote Valve Controller Error Codes

No Auxiliary/Remote Valve Controller Error
(No Power to Auxiliary/Remote Valve Controller) ....................................................................................... 9
Controller Error Code 10 ............................................................................................................................... 11
SM 8-12490 Issued 06-2004

SECTION 10001 3
Controller Error Code 51................................................................................................................................ 34

Multiple Controller Potentiometer Low Signal Error Codes............................................................................ 49
Multiple Controller Potentiometer High Signal Error Codes ........................................................................... 50
Auxiliary/Remote Valve Error Codes

Valve Error Code 11 and 12 .......................................................................................................................... 51
Valve Error Code 13 and 14 .......................................................................................................................... 52
Valve Error Code 15 ...................................................................................................................................... 52
Valve Error Code 16 ...................................................................................................................................... 52
Valve Error Code 17 ...................................................................................................................................... 53
Valve Error Code 21 ...................................................................................................................................... 53
Valve Error Code 22 ...................................................................................................................................... 54
Valve Error Code 23 ...................................................................................................................................... 54
Valve Error Code 24 ...................................................................................................................................... 55
Valve Error Code 25 ...................................................................................................................................... 55
Valve Error Code 26 ...................................................................................................................................... 56
Valve Error Code 41 ...................................................................................................................................... 56
Valve Error Code 42 ...................................................................................................................................... 56
Valve Error Code 43 ...................................................................................................................................... 57
Valve Error Code 81 ...................................................................................................................................... 57
Valve Error Code 82 ...................................................................................................................................... 58
Valve Error Code 83 ...................................................................................................................................... 58
Arm Rest Components ....................................................................................................................................... 59
Right Hand Console Components...................................................................................................................... 60
Rear Fender Components.................................................................................................................................. 61
SCHEMATIC CIRCUIT ..........................................................................................................................................62
MAIN CONNECTORS ............................................................................................................................................65
SM 8-12490 Issued 06-2004

4 SECTION 10001
SPECIAL TOOLS
DD98H120 MD04C017
MC2616 MULTIMETER KIT includes: 1025T1 MCCORMICK DIAGNOSTIC CENTRE
MC2616-1 MULTIMETER ONLY 1014T1 COMMUNICATIONS ADAPTER
MC2616-2 TEST LEADS 1004T2 DOWNLOAD HARNESS
MC2616-3 TEMPERATURE PROBE 1029T1 ADAPTER HARNESS
DD97E383
DD99A051
MC2656 TEST PROBE KIT MC31000B HARNESS REPAIR KIT
SM 8-12490 Issued 06-2004

SECTION 10001 5
GENERAL INFORMATION FOR ELECTRONIC

AUXILIARY/REMOTE VALVE CONTROL
The electronic Auxiliary/Remote valve system comprises of an Auxiliary/Remote valve controller and up to five
individual Auxiliary/Remote valves. Each Auxiliary/Remote valve is directly controlled by a control unit incorporated
within the valve.
Auxiliary/Remote Valve Operation

When the key is turned on the auxiliary/remote valve controller will carry out a self test, during the self test procedure
the enable light (LED) in the enable switch will be illuminated momentarily.
The Auxiliary/Remote valves system will only operate when the self test has been completed (enable light off) and
the system has been enabled. The system is enabled by momentarily pressing the enable switch; the system enable
light in the switch will illuminate when the system is enabled.
In the case of an emergency or to prevent accidental operation of the Auxiliary/Remote valves the system can be
disabled by pressing the stop switch.
The Auxiliary/Remote valve controller controls the correct operation of each Auxiliary/Remote valve by processing
and monitoring signals directly from the following switches and potentiometers.
• Auxiliary/Remote valve enable switch.
• Auxiliary/Remote valve emergency stop switch.
• Auxiliary/Remote valve control levers (joysticks).
• Auxiliary/Remote valve flow potentiometers.
• Auxiliary/Remote valve timer potentiometers.
• Auxiliary/Remote valve multi function lever auxiliary/remote buttons.
The Auxiliary/Remote valve controller processes and transmits information to the control unit of each Auxiliary/
Remote valve. If the operation of a valve is required, information received by the valve control unit is processed and
the control unit controls the activation of the spool solenoid within the valve. The valve control unit also monitors oil
temperature and spool movement and transmits the information to the Auxiliary/Remote valve controller over the
CAN bus.
If an error occurs within Auxiliary/Remote valve controller or any of the Auxiliary/Remote valves during normal
operation the valve spools will return to their neutral positions and an error code will be generated. When an error
occurs the error warning will be displayed on the instrument cluster.
NOTE: Always check for the same error code in each of the auxiliary/remote valves. The same error in
all valves may be an indication of a auxiliary/remote valve controller error. Before troubleshooting the
auxiliary/remote valve error codes, first check and correct any auxiliary/remote valve controller error
codes that may be present.
Faults in the Auxiliary/Remote valve units are classified into four categories and the reaction of the Auxiliary/
Remote valve varies according to the severity of the fault.
Category 1 - Control Section Faults.
Category 2 - Minor Faults.
Category 3 - Serious faults with internal safety shut-down.
Category 4 - Serious faults requiring external safety shut-down.
WARNING: If category 4 error codes 81, 82 or 83 are displayed STOP

! the engine immediately.
CAN Bus Communication

The CAN Bus circuit comprises of a twisted pair of wires, CAN High (Yellow) and CAN Low (Green), with a
termination 120 Ohm resistor at each end. It is important that these wires remain twisted together and the
termination resistors are connected to reduce any electrical interference that may disrupt the CAN messages.
SM 8-12490 Issued 06-2004

6 SECTION 10001
ERROR CODES GENERAL INFORMATION

Each controller on the tractor continually monitors the control systems for errors. If an error is detected a error
message will be transmitted over the CAN circuit to the instrument cluster, which will display an error warning to alert
the operator to a problem. Depending on the nature of the fault the instrument cluster may display the Red engine
STOP and or the Amber main warning light, also the audible alarm may sound.
NOTE: The instrument cluster will only display current (active) error codes apart from the auxiliary/
remote valve controller error codes; 11, 12, 13 and 15. These codes will only be displayed using the
‘McCormick Diagnostic Centre’.
Each controller will store all error codes that have been detected in the controller memory. These stored error codes
can be viewed and cleared using the ‘McCormick Diagnostic Centre’.
IMPORTANT: When faults occur in the Auxiliar y/Remote Valve system always check for both AVC
(Auxiliary Valve Controller) and AV1 to AV5 (Auxiliary Valves) error codes.
Retrieving Instrument Cluster Displayed Active Error Codes.

If an error occurs during normal operation in one of the tractor controller systems the symbol will appear on
the instrument cluster.
If the error warning symbol appears park the tractor on hard level ground, put the F/N/R/P lever in PARK and apply
the park brake. Turn the key to the OFF position.
WARNING: Some errors will only be active when the tractor is

operated, the codes for these errors will be stored in the relevant
! controller and MUST only be retrieved using the ‘McCormick
Diagnostic Centre’. DO NOT retrieve error codes when driving the
tractor.
To read the error codes carry out the following procedure:

Turn the key to the on position and press the menu button.
Each controller will be identified on the Universal Data Display as follows:
ENG - ENGINE
IC - INSTRUMENT CLUSTER
MCC - CAB CONTROLLER OR TRANSMISSION CONTROLLER
EHR - ELECTRONIC HITCH
AVC - AUXILIARY VALVE CONTROLS
AV1 to AV5 - AUXILIARY VALVES
The displayed controller will also display the number of active error codes.
Example:
ENG = ENGINE
0 = No Active Errors
Press the button to scroll through each controller until MCC is display Universal Data Display.
AV1 = Auxiliary Valve 1
1 = 1 Active Error
To view the error code, press the menu button.

25 = Error Code 25
If more than one AV1 error has been detected, press the button to identify the remaining errors.
For AV1 to AV5 and AVC Error Codes refer to the Error Code Troubleshooting Guide in this section.
SM 8-12490 Issued 06-2004

SECTION 10001 7
AUXILIARY/REMOTE VALVE MANUAL OPERATION

IMPORTANT: Manual operation of the auxiliary/ STEP 2
remote vales MUST ONLY be used if the valve
develops a fault, where the valve can not be
operated using the normal cab controls. 1
WARNING: Keep everybody clear of the

! tractor and implement when manually
operating the auxiliary/remote valves.
WARNING: MAKE SURE the area around

the implement is clear of obstructions and
there is enough space for the implement to
! be lowered into its working/transport
position if necessary. Disconnect the
MD04E088
implement from the tractor according to the
Manually push the mechanical linkage (1) of the faulty
implement manufactures instructions.
valve fully down into the FLOAT position to lower the
implement where it can be safely disconnected from
WARNING: To prevent injury ONLY the tractor. It may be necessary to use a suitable bar
! operate the auxiliary/remote valve
mechanical linkage from inside the cab.
to operate the linkage.
IMPORTANT: A c c e s s t o t h e auxiliary/remote
STEP 1 valve mechanical linkage is through the cab rear
window. CARE must be taken when operating the
If possible, park the tractor on hard level ground, apply linkage.
the parking brake, turn the key to the OFF position
and remove the key. Put blocks in front and behind the STEP 3
rear wheels.
When the implement is fully lowered, disconnect the
implement from the tractor according to the
implement manufactures instructions.
SM 8-12490 Issued 06-2004

8 SECTION 10001
CIRCUIT TESTING
General Information

WARNING: Before carrying out any checks on the auxiliary/remote

valves, disconnect any attached implements from auxiliary/remote valve
hydraulic couplers and the rear hitch. If the implement can not be operated
! using the normal cab controls to relieve the pressure in the system the
implement can be operated using the valve manual linkage, refer to
“AUXILIARY/REMOTE VALVE MANUAL OPERATION” on page 7.
IMPORTANT: All electrical checks must be made with the tractor parked on hard level ground with the
parking brake engaged and the engine OFF unless otherwise stated.
switches may occur.
made.
connected when the checks are completed.
SM 8-12490 Issued 06-2004

SECTION 10001 9
Auxiliary/Remote Valve Controller Error Codes

No Auxiliary/Remote Valve Controller Error
(No Power to Auxiliary/Remote Valve Controller)
IMPORTANT: If the auxiliary/remote valve controller power circuit fails an instrument cluster error code
304 will be displayed.
Fault Description.
Auxiliary/remote valve controller will not power up.
System Response.
The auxiliary/remote valve system will not enable.
Possible Cause.
1. Blown fuse 20 or fuse 35.
2. Auxiliary/remote valve controller valve power (VP in) short to ground.
3. Auxiliary/remote valve controller switched power (VF in) open circuit or short to ground.
IMPORTANT: Before carrying out the following tests, refer to “CIRCUIT TESTING” on page 8.
Circuit Checks/Corrective Action.
1. Check fuses 20 and 35.
- If fuses 20 and 35 are OK go to check 2.
- If fuse 20 has blown go to check 8
- If fuse 35 has blown go to check 11.
Fuse 20 and 35 OK.
2. Turn the key to the ON position and check for a voltage reading at terminal 1 of the auxiliary/remote valve
diagnostic connector 1 for wire (VP) Red.
- If 12 volts is detected go to check 3.
- If 12 volts is not detected check the following:
- Wire 146 Red between the switch power stud and fuse 35.
- The switched power stud connection.
- Wire 161 Red between fuse 35 and splice IP-SP12.
3. Turn the key to the OFF position and disconnect the auxiliary/remote valve controller at connector 44. Check
for continuity between ground and connector 44 pin 6 for the Brown/White clean ground wire.
- If continuity is not detected check the Brown/White clean ground wire between connector 44 and the
battery negative terminal. Also check connector 44 and the battery negative terminal connection.
4. Disconnect connector 53 (fender harness to right hand console harness). Check for continuity between
connector 44 pin 3 and connector 53 pin 33 for wire 161 Red.
- If continuity is not detected check wire 161 Red between connector 44 and connector 53.
connector 44 pin 4 and connector 51 pin 23 for wire 160 Red.
6. Turn the key to the ON position and check the voltage at the right hand console harness side of connector
29 pin F (instrument panel harness to right hand console harness) for wire 161 Red.
- If 12 volts is not detected check wire 161 between connector 29 and splice IP-SP12. Also check connector
29.
- If 12 volts is detected check the right hand console harness wire 161 Red between connector 29 and
connector 53. Also check connector 53.
continued.....
SM 8-12490 Issued 06-2004

10 SECTION 10001
7. Check the voltage at the right hand console harness side of connector 29 pin V (instrument panel harness
to right hand console harness) for wire 160 Red.
- If 12 volts is not detected check the following:
- Wire 160 Red between connector 29 and fuse 20.
- Connector 29.
- Wire 160 Red between the battery power stud and fuse 20.
- The battery power stud connection.
- If 12 volts is detected check the right hand console harness wire 160 Red between connector 29 and
Fuse 20 Blown.
8. Disconnect the auxiliary/remote valve controller at connector 44 and disconnect connector 51 (fender
harness to right hand console harness). Check for continuity between ground and connector 44 pin 4 for
wire 160 Red.
- If continuity is detected check wire 160 Red between connector 44 and connector 51.
9. Disconnect connector 29 (instrument panel harness to right hand console harness). Check for continuity
between ground and connector 29 pin V (right hand console harness side) for wire 160 Red.
- If continuity is detected check the right hand console harness wire 160 Red between connector 29 and
10. Remove fuse 20 and check for continuity between ground and connector 29 pin V (instrument panel
harness side) for wire 160 Red.
- If continuity is detected check wire 160 Red between fuse 20 and connector 29.
Fuse 35 Blown.
11. If the tractor is not equipped with five auxiliary/remote valves, check the spare auxiliary/remote valve
connector(s) for corrosion or damage. Make sure the protective plug is installed.
12. Disconnect the auxiliary/remote valve controller at connector 44 and disconnect connector 53 (fender
harness to right hand console harness). Check for continuity between ground and connector 44 pin 3 for
wire 161 Red.
- If continuity is detected check wire 161 Red between connector 44 and connector 53.
ground and connector 44 pin 17 for wire (VP) Red.
- If continuity is detected check the following:
- Wire (VP) Red between connector 44 and splice F-SP16
- Wire (VP) Red between connector 51 and splice F-SP16.
- Wire (VP) Red between the auxiliary/remote valve controller diagnostic connector 1 and splice F-SP16.
14. Disconnect connector 40 (fender harness to transmission harness) and check for continuity between ground
and connector 44 pin 9 for wire (VP) Red.
- If continuity is detected check wire (VP) Red between connector 40 and connector 44. Also check
connector 40.
15. Put identification marks on all the auxiliary/remote valve connectors and disconnect the auxiliary/remote
valves and pressure reducing valve from the harness. Check for continuity between ground and connector
40 pin H (transmission harness side) for wire (VP) Red.
- If continuity is detected check the following wires for damage.
- Wire VP Red between valve AV1 and splice T-SP10.
- Wire VP Red between the pressure reducing solenoid and splice T-SP10.
- Wire VP Red between connector 40 pin H and splice T-SP10.
Also check connector 40.
16. Disconnect connector 50 (fender harness to armrest harness). Check for continuity between ground and
connector 50 pin 35 for wire (ARM) Red.
- Wire (ARM) Red between connector 50 pin 35 and splice F-SP24.
continued.....
SM 8-12490 Issued 06-2004

SECTION 10001 11
17. Disconnect connectors 26 and 29 (instrument panel harness to right hand console harness). Check for
continuity between ground and connector 26 pin Z (right hand console harness side) for wire (VP) Red.
- If continuity is detected check the right hand console harness wire (ARM) Red between connector 26 and
18. Check for continuity between ground and connector 29 pin Y (right hand console harness side) for wire
(ARM) Red.
- If continuity is detected check the right hand console harness wire (ARM) Red between connector 29 and
19. Check for continuity between ground and connector 29 pin F (right hand console harness side) for wire 161
Red.
- If continuity is detected check the right hand console harness wire 161 Red between connector 29 and
20. Remove fuse 35 and check for continuity between ground and connector 29 pin F (instrument panel harness
side) for wire 161 Red.
- Wire 161 Red between splice IP-SP12 and connector 29.
- Wire (ARM) Red between splice IP-SP12 and connector 29.
- Wire (VP) Red between splice IP-SP12 and connector 26.
- Wire 161 Red between splice IP-SP12 and fuse 35.
Controller Error Code 10

Fault Description.
Auxiliary/remote valve controller input (VP IN) voltage is too low or (VP IN) voltage not detected.
System Response.
Possible Cause.
1. Alternator output too low or poor battery condition.
2. Auxiliary/remote valve controller valve power (VP IN) open circuit.
1. Check for controller error codes 11 and 12 using the ‘McCormick Diagnostic Centre’.
- if error code 11 is present go to Controller Error Code 11.
- if error code 12 is present go to check 2.
2. Check the battery condition.
3. Check the alternator.
4. Check the following connectors:
- Connector 51 right hand console harness to fender harness.
- Connector 10 engine harness to instrument panel harness.
- Connector 26 instrument panel harness to right hand console harness.
SM 8-12490 Issued 06-2004

12 SECTION 10001

NOTE: Controller error code 11 can only be read using the ‘McCormick Diagnostic Centre’.
Fault Description.
Auxiliary/remote valve controller does not detect valve power (VP IN).
System Response.
Possible Cause.
1. Auxiliary/remote valve controller valve power (VP IN) open circuit.
1. Turn the key to the ON position and check for a voltage reading at terminal 1 of the auxiliary/remote valve
diagnostic connector 1 for wire (VP) Red.
- If 12 volts is detected check wire (VP) red between the auxiliary/remote valve connector 44 and splice F-
SP16. Also check connector 44.
- If 12 volts is not detected check go to check 2.
2. Turn the key to the OFF position and disconnect the connector 51 (fender harness to right hand console
harness). Check for continuity between connector 51 pin 27 and terminal 1 of the auxiliary/remote valve
controller diagnostic connector for wire (VP) Red.
- If continuity is not detected check wire (VP) Red between connector 51 and splice F-SP16.
3. Connect connector 51, turn the key to the ON position and check for 12 volts at connector 26 pin Z (right
hand console side) for wire (VP) Red.
- If 12 volts is not detected check the instrument panel harness wire (VP) Red between connector 26 and
splice IP-12. Also check connector 26.
- If 12 volts is detected check the right hand console harness wire (VP) Red between connector 26 and
connector 51. Also check connectors 26 and 51.

Fault Description.
Auxiliary/remote valve controller valve power (VP out) voltage is too low.
System Response.
Possible Cause.
1. Low valve power in (VP in) voltage.
2. Bad auxiliary/remote valve controller.
1. Check for controller error code 10 and repair as necessary.
2. Replace the auxiliary/remote valve controller.
SM 8-12490 Issued 06-2004

SECTION 10001 13

Fault Description.
Auxiliary/remote valve controller does not detect valve power (VP out) voltage.
System Response.
Possible Cause.
1. Bad valve power in (VP in) circuit.

Fault Description.
Auxiliary/remote valve controller switched power (VF) is too low.
System Response.
Possible Cause.
3. Check the following connectors:
- Connector 10 engine harness to instrument panel harness.
SM 8-12490 Issued 06-2004

14 SECTION 10001

NOTE: Controller error code 15 can only be read using the ‘McCormick diagnostic Centre’.
Fault Description.
Auxiliary/remote valve controller does not detect switched power (VF).
System Response.
Possible Cause.
1. Bad auxiliary/remote valve controller valve power (VF in) circuit.
2. Disconnect connector 53 (fender harness to right hand console harness) and disconnect the auxiliary/
remote valve controller at connector 44. Check for continuity between connector 44 pin 3 and connector 53
pin 33 for wire 161 Red.
- If continuity is not detected check wire 161 Red between connector 44 and connector 53. Also check
connector 53.
3. Connect connector 53 and disconnect the connector 29 (instrument panel harness to right hand console
harness). Check for continuity between connector 44 pin 3 and connector 29 pin F (right hand console side)
for wire 161 Red.
- If continuity is not detected check wire 161 Red between connector 29 and connector 53. Also check
connector 53.
4. Turn the key to the ON position and check for 12 volts at connector 29 pin F (instrument panel harness side).
- If 12 volts is not detected check wire 161 Red between connector 29 and splice IP-SP12. Also check
connector 29.

Fault Description.
Supply voltage to the flow, timer and joystick controls is too low.
System Response.
Possible Cause.
1. 5 volt supply circuit to the armrest control potentiometers short circuit to ground.
1. Disconnect connector 50 (fender harness to armrest harness) and disconnect the auxiliary/remote valve
controller from the harness at connector 44. Check for continuity between ground and connector 44 pin 10
for wire 540 Red.
- If continuity is detected check wire 540 Red between connector 44 and connector 50. Also check
connector 50.
- If continuity is not detected check the armrest controls and harness.
2. Remove the armrest lower cover and check the following:
- The armrest harness between connector 50 and printed circuit board connector X2.
- Armrest printed circuit board and connector X2.
SM 8-12490 Issued 06-2004

SECTION 10001 15

Fault Description.
Supply voltage to the flow, timer and joystick controls is too high.
System Response.
Possible Cause.
1. Supply to the armrest controller short circuit to a voltage above 5 volts.
1. Disconnect the auxiliary/remote valve controller from the harness at connector 44. Turn the key to the ON
position and check for a voltage reading at connector 44 pin 10 for wire 540 Red.
- If a voltage reading is not detected go to check 2.
- If a voltage reading is detected go to check 3.
2. Press and hold the following switches in turn while checking for a voltage reading at connector 44 pin 10 for
wire 540 Red.
- Auxiliary/remote valve enable switch.
- The multi function lever auxiliary/remote valve raise switch.
- The multi function auxiliary/remote valve lower switch.
- If a voltage reading is detected check the following:
- Wire 501 Dark Blue between connector 50 and connector 44.
3. Turn the key to the OFF position and disconnect connector 50 (fender harness to armrest harness). Turn the
key to the ON position and check for a voltage reading at connector 44 pin 10 for wire 540 Red.
- If a voltage reading is detected check wire 540 Red between the connector 44 and connector 50.
- The armrest harness between connector 50 and printed circuit board connectors X2 and X3.
- Armrest printed circuit board and connectors X1 and X2.

Fault Description.
Auxiliary/Remote valve controller has detected a stop signal on power up.
System Response.
Possible Cause.
1. Stop button held in when the key is turned to the ON position.
2. Stop switch open circuit.
1. Make sure the stop button is release before turning the key to the ON position.
2. Disconnect the auxiliary/remote valve controller from the harness at connector 44 and disconnect connector
50 (fender harness to armrest harness). Check for continuity between connector 44 pin 25 and connector 50
pin 16 for wire 502 Dark Blue.
- If continuity is not detected check wire 502 Dark Blue between connector 44 and connector 50 for damage.
3. Check for continuity between connector 44 pin 27 and connector 50 pin 17 for wire 503 Dark Blue.
- If continuity is not detected check wire 503 Dark Blue between connector 44 and connector 50 for damage.
5. Disconnect the stop switch from the printed circuit board at connector X12 and check for continuity between
the terminals of connector X12 (Black wires).
- If continuity is not detected check the switch wires and replace the stop switch as necessary.
continued.....
SM 8-12490 Issued 06-2004
16 SECTION 10001
6. Press and hold the stop switch button IN and check for continuity between the terminals of connector X12
(Black wires).
- If continuity is detected replace the stop switch.

Fault Description.
Auxiliary/Remote valve controller has detected a system enable signal on power up.
System Response.
Possible Cause.
1. Enable switch button held in when the key is turned to the ON position.
2. Enable switch button held in before the auxiliary/remote valve system self test has been completed.
3. Enable switch circuit shorted to 12 volts.
1. Make sure the enable switch is released before turning the key to the ON position.
2. Wait for the system self test to be completed before enabling the system.
50 (fender harness to armrest harness). Turn the key to the ON position and check for a voltage reading at
connector 44 pin 11 for wire 501 Dark Blue.
- If a voltage reading is detected check wire 501 Dark Blue between connector 44 and connector 50.
4. Turn the key to the OFF position and remove the armrest lower cover and check the following:
5. Disconnect the enable switch from the printed circuit board at connector X14 and check for continuity
between terminals 1 and 2 (Black wires) of connector X14.
- If continuity is detected check the switch wires and replace the enable switch as necessary.
6. Press and hold the enable switch button IN and check for continuity between the terminals 1 and 2 (Black
wires) of connector X14.
- If continuity is not detected replace the enable switch.

Fault Description.
Auxiliary/Remote valve controller internal relay coil high short (energised) at power up.
System Response.
Possible Cause.
1. Stop circuit shorted to 12 volts.
2. Check for a voltage reading at connector 44 pin 27 for wire 502 Dark Blue.
- Armrest printed circuit board and connector X1.
SM 8-12490 Issued 06-2004

SECTION 10001 17

Fault Description.
Auxiliary/Remote valve controller has detected VP out voltage at power up.
System Response.
The auxiliary/remote valve controller does not transmit CAN bus messages to the auxiliary/remote valves. All
the auxiliary/remote valves will display valve error codes 11 and 12.
Possible Cause.
1. VP out circuit shorted to 12 volts.
40 (fender harness to transmission harness). Turn the key to the ON position and check for a voltage
reading at connector 44 pin 9 for wire (VP) Red.
- If a voltage reading is detected check wire (VP) Red between connector 40 and connector 44.
2. Turn the key to the OFF position and connect connector 40 (fender harness to transmission harness). Turn
the key to the ON position and check for voltage reading at connector 44 pin 9 for wire (VP) Red.
- If a voltage reading is detected check the transmission harness.

Fault Description.
Auxiliary/Remote valve controller has detected a stop signal fault.
System Response.
Possible Cause.
1. Stop switch circuit shorted to ground.
50 (fender harness to armrest harness). Check for continuity between ground and connector 44 pin 25 for
wire 502 Dark Blue.
- If continuity is detected check wire 502 Dark Blue between connector 44 and connector 50.
2. Check for continuity between ground and connector 44 pin 27 for wire 503 Dark Blue.
- If continuity is detected check wire 503 Dark Blue between connector 44 and connector 50. Also check
connector 50.
4. Disconnect the stop switch from the printed circuit board at connector X12 and check for continuity between
the terminals of connector X12 (Black wires).
- If continuity is not detected check the switch wires and replace the stop switch as necessary.
5. Press and hold the stop switch button IN and check for continuity between the terminals of connector X12
(Black wires).
- If continuity is detected replace the stop switch.
SM 8-12490 Issued 06-2004

18 SECTION 10001

Fault Description.
Auxiliary/Remote valve controller internal relay coil high short.
System Response.
Possible Cause.
1. Stop circuit short to 12 volts.
2. Check for a voltage reading at connector 44 pin 27 for wire 502 Dark Blue.
4. - Armrest printed circuit board and connector X1.

Fault Description.
Auxiliary/Remote valve controller has detected a signal on power up from the multi function lever auxiliary/
remote valve raise switch.
System Response.
The multi function lever auxiliary/remote raise switch will not operate. If the tractor is equipped with five auxiliary/
remote valves, valve AV5 will display valve error codes 11 and 12.
Possible Cause.
1. The multi function lever auxiliary/remote raise switch held on when the key is turned to the ON position.
2. The multi function lever auxiliary/remote raise switch operated before the auxiliary/remote valve system self
test has been completed.
3. The multi function lever auxiliary/remote raise switch circuit shorted to 12 volts.
1. Make sure the multi function lever auxiliary/remote raise switch is release before turning the key to the ON
position.
2. Wait for the system self test to be completed before operating the multi function lever auxiliary/remote raise
switch.
5. Disconnect the auxiliary/remote raise switch from the printed circuit board at connector X19 and check for
continuity between the terminals of connector X19 (Black wires).
- If continuity is detected check the switch wires and replace the multi function lever as necessary.
6. Press and hold in the auxiliary/remote raise switch button and check for continuity between the terminals of
connector X19 (Black wires).
- If continuity is not detected check the switch wires and replace the multi function lever as necessary.
SM 8-12490 Issued 06-2004

SECTION 10001 19

Fault Description.
Auxiliary/Remote valve controller has detected a signal on power up from the multi function lever auxiliary/
remote valve lower switch.
System Response.
The multi function lever auxiliary/remote lower switch will not operate. If the tractor is equipped with five
auxiliary/remote valves, valve AV5 will display valve error codes 11 and 12.
Possible Cause.
1. The multi function lever auxiliary/remote lower switch held on when the key is turned to the ON position.
2. The multi function lever auxiliary/remote lower switch operated before the auxiliary/remote valve system self
test has been completed.
1. Make sure the multi function lever auxiliary/remote lower switch is release before turning the key to the ON
position.
2. Wait for the system self test to be completed before operating the multi function lever auxiliary/remote lower
switch.
5. Disconnect the auxiliary/remote lower switch from the printed circuit board at connector X18 and check for
continuity between the terminals of connector X18 (White wires).
- If continuity is detected check the switch wires and replace the multi function lever as necessary.
6. Press and hold in the auxiliary/remote lower switch button and check for continuity between the terminals of
connector X18 (White wires).
- If continuity is not detected check the switch wires and replace the multi function lever as necessary.

Fault Description.
The signal from the 1st/2nd auxiliary/remote valve joystick AV1 control potentiometer is too low.
System Response.
The auxiliary/remote valve controller does not transmit CAN bus messages to valve AV1. Valve AV1 will display
valve error codes 11 and 12.
Possible Cause.
1. Valve AV1 control potentiometer signal circuit, open or short circuit to ground.
2. Valve AV1 control potentiometer 5 volt reference open circuit.
3. Damaged armrest harness or printed circuit board.
4. Bad control potentiometer.
1. If a low potentiometer signal error code is present for all control, flow and timer potentiometers, refer to
“Multiple Controller Potentiometer Low Signal Error Codes” on page 49.
- If continuity is not detected check wire 515 Dark Blue between connector 44 and connector 50.
continued.....
SM 8-12490 Issued 06-2004

20 SECTION 10001
5. Disconnect the 1st/2nd and 3rd/4th auxiliary/remote valve joystick units from the printed circuit board at
connectors X16 and X17. Connect the 1st/2nd auxiliary/remote valve joystick unit to connector X17 and the
3rd/4th auxiliary/remote valve joystick unit to connector X16 and check the operation of the auxiliary/remote
valve system.
- If error code 30 is still present, replace the auxiliary/remote valve controller.
- If error code 34 appears, replace the 1st/2nd auxiliary/remote valve joystick unit.
IMPORTANT: When all checks are complete or a new auxiliary/remote joystick has been installed,
make sure the 1st/2nd auxiliar y/remote joystick unit is connected to the printed circuit board
connector X16 and the 3rd/4th auxiliary/remote joystick unit is connected to connector X17.

Fault Description.
The signal from the 1st/2nd auxiliary/remote valve joystick AV1 control potentiometer is too high.
System Response.
Possible Cause.
1. Valve AV1 control potentiometer signal circuit shorted to another circuit.
2. Valve AV1 control potentiometer ground open circuit.
1. If a high potentiometer signal error code is present for all control, flow and timer potentiometers, refer to
“Multiple Controller Potentiometer High Signal Error Codes” on page 50.
2. Disconnect the connector 50 (fender harness to armrest harness). Turn the key to the ON position, enable
the auxiliary valve system and check for a voltage reading at connector 50 pin 27 for wire 515 Dark Blue.
- If a voltage reading is not detected check the armrest harness and the valve AV1 control potentiometer.
valve system.
make sure the 1st/2nd auxiliary/remote valve joystick unit is connected to the printed circuit board
connector X16 and the 3rd/4th auxiliary/remote valve joystick unit is connected to connector X17.
SM 8-12490 Issued 06-2004

SECTION 10001 21

Fault Description.
The signal from the 1st/2nd auxiliary/remote valve joystick AV2 control potentiometer is too low.
System Response.
Possible Cause.
valve system.

Fault Description.
The signal from the 1st/2nd auxiliary/remote valve joystick AV2 control potentiometer is too high.
System Response.
Possible Cause.
continued.....
SM 8-12490 Issued 06-2004
22 SECTION 10001

valve system.

Fault Description.
The signal from the 3rd/4th auxiliary/remote valve joystick AV3 control potentiometer is too low.
System Response.
Possible Cause.
valve system.
- If error code 30 appears, replace the 3rd/4th auxiliary/remote valve joystick unit.
SM 8-12490 Issued 06-2004

SECTION 10001 23

Fault Description.
The signal from the 3rd/4th auxiliary/remote valve joystick AV3 control potentiometer is too high.
System Response.
Possible Cause.
4. Bad control potentiometer
valve system.

Fault Description.
The signal from the 3rd/4th auxiliary/remote valve joystick AV4 control potentiometer is too low.
System Response.
Possible Cause.
continued.....
SM 8-12490 Issued 06-2004
24 SECTION 10001
4. - If continuity is detected check wire 532 Dark Blue between connector 44 and connector 50.
valve system.

Fault Description.
The signal from the 3rd/4th auxiliary/remote valve joystick AV4 control potentiometer is too high.
System Response.
Possible Cause.
valve system.
SM 8-12490 Issued 06-2004

SECTION 10001 25

Fault Description.
The signal from the AV1 flow control potentiometer is too low.
System Response.
Possible Cause.
1. Valve AV1 flow control potentiometer signal circuit, open or short circuit to ground.
2. Valve AV1 flow control potentiometer 5 volt reference open circuit.
4. Bad AV1 flow control potentiometer.
1. If a low potentiometer signal error code is present for all, control, flow and timer potentiometer, refer to
- If continuity is detected check wire 511 Dark Blue between connector 44 and connector 50 for damage.
5. Disconnect the auxiliary/remote valve AV1 flow control and timer control potentiometers from the printed
circuit board at connector X5. Check the resistance reading between terminals 1 and 3 (Red and Brown
- If a reading of approximately 5000 Ohms is not detected replace the AV1 flow control and timer control
potentiometer assembly.
6. Turn the flow potentiometer knob to the 0% position and check the resistance reading between terminals 1
and 2 (Red and White wires) of connector X5.
7. Slowly turn the flow potentiometer knob from the 0% position to the 100% position and check the resistance
reading between terminals 1 and 2 (Red and White wires) of connector X5.
- A steadily reducing Ohms reading from approximately 5000 Ohms to approximately 1.5 Ohms should be
observed. If the readings are incorrect or an intermittent reading is detected replace the AV1 flow control
and timer control potentiometer assembly.
SM 8-12490 Issued 06-2004

26 SECTION 10001

Fault Description.
The signal from the auxiliary/remote valve AV1 flow control potentiometer is too high.
System Response.
Possible Cause.
1. Valve AV1 flow control potentiometer signal circuit shorted to another circuit.
2. Valve AV1 flow control potentiometer ground open circuit open circuit.
5. Turn the AV1 flow potentiometer knob to the 0% position and check the resistance reading between
terminals 1 and 2 (Red and White wires) of connector X5.
6. Slowly turn the AV1 flow potentiometer knob from the 0% position to the 100% position and check the
resistance reading between terminals 1 and 2 (Red and White wires) of connector X5.
SM 8-12490 Issued 06-2004

SECTION 10001 27

Fault Description.
The signal from the auxiliary/remote valve AV2 flow control potentiometer is too low.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

28 SECTION 10001

Fault Description.
System Response.
The auxiliary/remote valve controller does not transmit CAN bus messages to valve AV2. Valve AV2 will
display valve error codes 11 and 12
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 29

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

30 SECTION 10001

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 31

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

32 SECTION 10001

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 33

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

34 SECTION 10001

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 35

Fault Description.
The signal from the auxiliary/remote valve AV1 timer control potentiometer is too low.
System Response.
Valve AV1 will not operate in timer mode.
Possible Cause.
1. Valve AV1 timer control potentiometer signal circuit, open or short circuit to ground.
2. Valve AV1 timer control potentiometer 5 volt reference open circuit.
4. Bad AV1 timer control potentiometer.
6. Turn the AV1 timer potentiometer knob to the 0 second position and check the resistance reading between
7. Slowly turn the AV1 timer potentiometer knob from the 0 second position to the 30 second position and
check the resistance reading between terminals 4 and 5 (Red and White wires) of connector X5.
SM 8-12490 Issued 06-2004

36 SECTION 10001

Fault Description.
The signal from the auxiliary/remote valve AV1 timer control potentiometer is too high.
System Response.
Possible Cause.
2. Valve AV2 timer control potentiometer ground open circuit.
5. Turn the AV1 flow potentiometer knob to the 0 second position and check the resistance reading between
6. Slowly turn the AV1 flow potentiometer knob from the 0 second position to the 30 second position and check
the resistance reading between terminals 1 and 2 (Red and White wires) of connector X9.
SM 8-12490 Issued 06-2004

SECTION 10001 37

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

38 SECTION 10001

Fault Description.
System Response.
Possible Cause.
5. - If a reading of approximately 5000 Ohms is not detected replace the AV2 flow control and timer control
SM 8-12490 Issued 06-2004

SECTION 10001 39

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

40 SECTION 10001

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 41

Fault Description.
The signal from the auxiliary/remote valve AV4 timer control potentiometer too low.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

42 SECTION 10001

Fault Description.
System Response.
Possible Cause.
continued.....
SM 8-12490 Issued 06-2004

SECTION 10001 43

Fault Description.
System Response.
Valve AV5 will not operate in timer mode
Possible Cause.
- Armrest printed circuit board and connectors X2 and X8
SM 8-12490 Issued 06-2004

44 SECTION 10001

Fault Description.
System Response.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 45

Fault Description.
Auxiliary/Remote valve controller has not detected a signal from the auxiliary/remote valve system enable light
(LED).
System Response.
Possible Cause.
1. Auxiliary/remote valve system enable light open circuit.
2. Damaged armrest harness or printed circuit board
3. Bad auxiliary/remote valve enable switch.
3. Disconnect connector X14 from the printed circuit board. Using the multimeter Diode Test Function check
for continuity between the terminals 3 and 4 (Grey and Brown wires) of connector X14. Make sure the
positive lead of the multimeter is connected to terminal 3 (Grey wire).
- If continuity is not detected replace the auxiliary/remote valve enable switch.

Fault Description.
Auxiliary/remote valve controller has detected a configuration error.
System Response.
Possible Cause.
1. Auxiliary/remote valve controller configuration data is corrupt.
1. Reconfigure the auxiliary/remote valve controller, refer to Section 10010.
2. Reprogramme the auxiliary/remote valve controller, refer to Section 10010.
SM 8-12490 Issued 06-2004

46 SECTION 10001

Fault Description.
Auxiliary/Remote valve controller has not received a CAN message from the auxiliary/remote valve AV1.
System Response.
Valve AV1 fails to operate.
Possible Cause.
1. Valve AV1 CAN bus open circuit.
2. Valve AV1 feed or ground wires open circuit.
1. If a CAN message error code is present for all auxiliary/remote valves, check the following:
- Wire 900 Yellow between the transmission harness splice T-SP6 and splice T-SP11.
- Wire 900 Light Green between the transmission harness splice T-SP7 and splice T-SP12.
2. Disconnect the auxiliary/remote valve controller from the harness at connector 44 and disconnect valve AV1
from the harness. Check for continuity between connector 44 pin 9 and terminal 1 of the valve AV1
connector for wire (VP) Red.
- If continuity is not detected check wire (VP) Red between the valve AV1 connector and transmission
harness splice T-SP10.
3. Check for continuity between connector 44 pin 13 and terminal 3 of the valve AV1 connector for wire 900
Yellow.
- If continuity is not detected check wire 900 Yellow between the valve AV1 connector and transmission
Light Green.
- If continuity is not detected check wire 900 Light Green between the valve AV1 connector and transmission
5. Check for continuity between ground and the valve AV1 connector terminal 4 for wire (GND) Brown/White.
- If continuity is not detected check wire (GND) Brown/White between the valve AV1 connector and the
battery negative terminal.

Fault Description.
System Response.
Possible Cause.
Yellow.
continued.....
SM 8-12490 Issued 06-2004

SECTION 10001 47
Light Green.

Fault Description.
System Response.
Possible Cause.
Yellow.
Light Green.
SM 8-12490 Issued 06-2004

48 SECTION 10001

Fault Description.
System Response.
Possible Cause.
Yellow.
Light Green.

Fault Description.
System Response.
Possible Cause.
Yellow.
continued.....
SM 8-12490 Issued 06-2004

SECTION 10001 49
Light Green.
Multiple Controller Potentiometer Low Signal Error Codes

NOTE: Multiple controller potentiometer low signal error codes are as follows:
- Joystick control potentiometers 30, 32, 34, and 36.
- Flow control potentiometers 40, 42, 46, 48, 50.
- Timer control potentiometers 52, 54, 56, 60, and 62.
Fault Description.
Auxiliary/Remote valve controller has detected a multiple low potentiometer signal error code on all the armrest
control, flow and timer potentiometers.
System Response.
All the auxiliary/remote vales fail to operate.
Possible Cause.
1. Armrest control, 5 volt supply open circuit.
2. Damaged armrest harness.
3. Bad armrest control unit.
1. Turn the key to the OFF position and disconnect the auxiliary/remote valve controller from the harness at
connector 44. Check for continuity between connector 44 pin 10 and connector 50 pin 1 for wire 540 Red
2. Remove the armrest lower cover and check the armrest harness between connector 50 and printed circuit
board connector X2. Also check the printed circuit board and connector X2.
SM 8-12490 Issued 06-2004

50 SECTION 10001
Multiple Controller Potentiometer High Signal Error Codes

NOTE: Multiple controller potentiometer low signal error codes are as follows:
- Joystick control potentiometers 31, 33, 35, and 37.
- Flow control potentiometers 41, 43, 45, 47, 51.
- Timer control potentiometers 53, 55, 57, 61, and 63.
Fault Description.
Auxiliary/Remote valve controller has detected a multiple high potentiometer signal error code on all the armrest
control, flow and timer potentiometers.
System Response.
All the auxiliary/remote vales fail to operate.
Possible Cause.
1. Armrest control ground open circuit.
2. Damaged armrest harness.
3. Bad armrest control unit.
1. Turn the key to the OFF position and disconnect the auxiliary/remote valve controller from the harness at
connector 44. Check for continuity between connector 44 pin 1 and connector 50 pin 2 for wire 540 Brown
- If continuity is not detected check wire 540 Brown between connector 44 and connector 50.
2. Remove the armrest lower cover and check the armrest harness between connector 50 and printed circuit
board connector X2. Also check the printed circuit board and connector X2.
SM 8-12490 Issued 06-2004

SECTION 10001 51
Auxiliary/Remote Valve Error Codes
Valve Error Code 11 and 12

Fault Description.
The auxiliary/remote valve has not received a CAN message from the auxiliary valve controller.
Fault Category.
Category 1 - Control Section Fault.
System Response.
Valve returns to neutral.
Possible Cause.
1. Auxiliary/remote valve control circuit short to 12 volts.
2. CAN bus open circuit or disconnected.
3. Auxiliary/remote valves receiving power prior to auxiliary valves being enabled.
4. Bad auxiliary/remote valve.
1. If the error is detected on all the auxiliary/remote valves, go to check 4.
2. Check for auxiliary/remote valve controller error codes and repair as necessary.
3. Put identification marks on the auxiliary/remote valve connectors and swop the connector of a good valve
with the connector of the valve with the detected error. Check the operation of the auxiliary/remote valve.
- If the previously good valve now fails to operate go to check 4.
- If the same valve fails to operate, replace the valve.
4. Disconnect one of the auxiliary/remote valves from the harness, turn the key to the ON position (DO NOT
enable auxiliary/remote valve system). Check for 12 volts at terminal 1 of the auxiliary/remote valve
connector for wire VP Red.
- If 12 volts is detected check the following wires for damage:
- Wire VP Red between the pressure reducing solenoid and splice T-SP10.
- Wire VP Red between connector 40 pin H and splice T-SP10.
- Wire VP Red between connector 40 pin H and the auxiliary/remote valve controller connector pin 9.
- If 12 volts is not detected check the following wires for damage:
- Wire 900 Yellow between the connector 44 and the fender harness splice F-SP17.
- Wire 900 Light Green between the connector 44 and the fender harness splice F-SP18.
SM 8-12490 Issued 06-2004

52 SECTION 10001
Valve Error Code 13 and 14

Fault Description.
The auxiliary/remote valve has received an incorrect CAN bus message.
Fault Category.
System Response.
Possible Cause.
1. Auxiliary/remote valve control circuit failed.
2. CAN bus open circuit or disconnected.
1. If the error is detected on all the auxiliary/remote valves, go to check 4.
2. Check for auxiliary valve controller error codes and repair as necessary.
3. Put identification marks on the auxiliary/remote valve connectors and swop the connector of a good valve
with the connector of the valve with the detected error. Check the operation of the auxiliary/remote valve.
- If the previously good valve now fails to operate, check the following wires:
- Wire 900 Yellow between the connector 44 and the fender harness splice F-SP17.
- Wire 900 Light Green between the connector 44 and the fender harness splice F-SP18.
- If the same valve fails to operate, replace the valve.
Valve Error Code 15

Fault Description.
The auxiliary/remote valve has not detected a spool position potentiometer signal.
Fault Category.
System Response.
Possible Cause.
1. Incorrect auxiliary/remote valve installed.
1. Check the correct auxiliary/remote valve installation and replace as necessary.
Valve Error Code 16

Fault Description.
The auxiliary/remote valve EEPROM is inconsistent during self test.
Fault Category.
System Response.
Possible Cause.
1. Auxiliary/remote valve incorrectly programmed.
1. Replace the auxiliary/remote valve.
SM 8-12490 Issued 06-2004

SECTION 10001 53
Valve Error Code 17

Fault Description.
No fault, the auxiliary/remote valve control unit is waiting for a neutral signal form the auxiliary/remote valve
controller.
NOTE: If faults have occurred in the auxiliary/remote valve system which are no longer active a
valve error code 17 may be displayed. This error code will continued to be displayed until the
auxiliary/remote valve controls are placed in the neutral position. When the valve receives a CAN
bus, neutral message from the auxiliary/remote valve controller the error code will no longer be
displayed and the valves will operate normally.
Fault Category.
System Response.
Possible Cause.
1. Joystick not in the neutral position.
1. Make sure the joystick control is in neutral.
2. Check for auxiliary/remote valve controller error codes and correct as necessary.
Valve Error Code 21

Fault Description.
The battery signal is below specified limits.
Fault Category.
Category 2 - Minor Fault.
System Response.
Valve will not operate in the timer mode.
Possible Cause.
1. Supply Voltage to the auxiliary/remote valve is below specified limits.
2. Bad auxiliary/remote valve feed or ground circuit
NOTE: If the error is detected on one valve only follow Steps 1 and 2. If the error is detected on all
the valves follow Steps 3 to 5.
1. Disconnect the auxiliary/remote valve with the detected error from the harness. Turn the key to the ON
position and enable the auxiliary/remote valve system. Check the voltage reading at terminal 1 of the valve
connector for wire VP Red.
- If the reading is less than 12 volts check wire VP Red between the valve connector and splice T-SP10.
2. Turn the key to the OFF position and check the resistance reading between ground and terminal 2 of the
valve connector for wire GND Brown/White.
- If the resistance reading is high check wire GND Brown/White between the valve connector and the
5. Disconnect one of the auxiliary/remote valves from the harness. Turn the key to the ON position and enable
the auxiliary/remote valve system. Check the voltage reading at terminal 1 of the valve connector for wire
VP Red.
- If the reading is less than 12 volts check wire VP Red between the auxiliary/remote valve controller
connector 44 pin 9 and splice T-SP10. Also check connector 40.
SM 8-12490 Issued 06-2004

54 SECTION 10001
Valve Error Code 22

Fault Description.
The battery signal is above specified limits.
Fault Category.
System Response.
Possible Cause.
1. Alternator output is too high.
Valve Error Code 23

Fault Description.
The auxiliary/remote valve spool has not reached the set point position within the specified time limit.
Fault Category.
System Response.
Possible Cause.
1. Oil temperature too low.
2. Low pilot pressure.
3. Blocked hydraulic filter.
4. Blocked pressure reducing valve filter.
5. Auxiliary/remote valve spool is stuck.
6. Auxiliary/remote valve external linkage seized
7. Bad pressure reducing valve.
8. Bad auxiliary/remote valve control unit.
NOTE: If the error is detected on one valve only follow Steps 1 to 4. If the error is detected on all valves
follow Steps 5 to 9.
1. Check for auxiliary valve controller errors and correct as necessary.
2. Check the auxiliary/remote valve spool external linkage.
3. Check the auxiliary/remote valve spool and replace the valve as necessary.
4. Check the auxiliary/remote valve control unit connections.
5. Check the operation of the auxiliary/remote valves with the oil at normal operating temperature.
6. Check the operation of other hydraulic functions, if other function fail to operate check the hydraulic filter and
replace as necessary.
7. Disconnect pressure reducing valve solenoid from the harness. Turn the key to the ON position and enable
the auxiliary/remote valve system. Check the voltage reading at terminals 1 of the pressure reducing valve
solenoid for wire VP Red.
- If a reading of 12 volts is not detected check wire VP Red between splice T-SP10 and the pressure
reducing valve solenoid.
8. Turn the key to the OFF position and check for continuity between terminals 2 of the pressure reducing valve
solenoid and ground for wire GND Brown/White.
- If continuity is not detected check GND Brown/White between pressure reducing valve solenoid and
9. Check the pressure reducing valve and replace as necessary.
SM 8-12490 Issued 06-2004

SECTION 10001 55
Valve Error Code 24

Fault Description.
The auxiliary/remote valve spool has travelled beyond the set point position.
Fault Category.
System Response.
Possible Cause.
NOTE: If the error is detected on one valve only follow Steps 1 and 2. If the error is detected on all the
valves follow Step 3.
Valve Error Code 25

Fault Description.
The auxiliary/remote valve spool has not reached the open centre position (float) within the specified time limit.
Fault Category.
System Response.
Valve returns to neutral. When the fault has been corrected the joystick must be returned to neutral and then
back to float before the valve will operate, error code 17 will be displayed.
Possible Cause.
1. Oil temperature too low.
2. Low pilot pressure.
NOTE: If the error is detected on one valve only follow Steps 1 and 2. If the error is detected on all the
valves follow Steps 3 to 5.
3. Check the operation of the auxiliary/remote valves with the oil at normal operating temperature.
4. Check the operation of other hydraulic functions, if other function fail to operate check the hydraulic filter and
replace as necessary.
SM 8-12490 Issued 06-2004

56 SECTION 10001
Valve Error Code 26

Fault Description.
The auxiliary/remote valve spool has been operated manually when both the valve spool and control joystick are
in neutral.
Fault Category.
System Response.
1. Manual operation of the auxiliary/remote valve when the valve spool and control joystick are in neutral will
display error 26. When the valve spool returns to neutral the error code will no longer be displayed.
WARNING: Manually operating the auxiliary/remote valve spool at the

! same time as the joystick or multifuntion lever switches may result in
injury.
Possible Cause.
1. Manual deflection of the auxiliary/remote valve spool.
2. Auxiliary/remote valve external linkage seized.
1. Make sure the auxiliary/remote valve spool external linkage is not being held out of neutral accidentally.
Valve Error Code 41

Fault Description.
The battery signal excessively high.
Fault Category.
Category 3 - Serious Fault With Internal Safety Shut-down.
System Response.
Valve immediately returns to neutral and the internal safety transistor switches off.
Possible Cause.
1. Alternator output too high.
Valve Error Code 42

Fault Description.
The auxiliary/remote valve control unit solenoid circuit has failed.
Fault Category.
System Response.
Valve returns to neutral, the internal safety transistor switches off.
Possible Cause.
SM 8-12490 Issued 06-2004

SECTION 10001 57
Valve Error Code 43

Fault Description.
The auxiliary/remote valve control unit spool position sensor circuit has failed.
Fault Category.
System Response.
Valve returns to neutral, the internal safety transistor switches off.
Possible Cause.
Valve Error Code 81

Fault Description.
The auxiliary/remote valve spool can not return to neutral.
Fault Category.
Category 4 - Serious Fault requiring external Safety Shut-down.

System Response.
The internal safety transistor switches off and the auxiliary valve controller safety relay activates.
Possible Cause.
WARNING: Before carrying out any checks or repairs on the auxiliary/

remote valve system, manually relieve the pressure in the auxiliary/
remote valve system and disconnect any attached implements from
! auxiliary/remote valve hydraulic couplers (refer to “AUXILIARY/REMOTE
VALVE MANUAL OPERATION” on page 7). Disconnect any attached
implements from the rear hitch according to the implement manufactures
instructions.

SM 8-12490 Issued 06-2004

58 SECTION 10001
Valve Error Code 82

Fault Description.
The auxiliary/remote valve spool is not in neutral when the auxiliary/remote valve system is enabled.
Fault Category.

System Response.
Possible Cause.

instructions.

Valve Error Code 83

Fault Description.
The auxiliary/remote valve has detected a software error during self test and is unable to control the operation of
the valve.
Fault Category.

System Response.
Possible Cause.

instructions.

SM 8-12490 Issued 06-2004

SECTION 10001 59
Arm Rest Components
5 6
4
3
8 9
10
14
13 15 16
12
11
17 18 19 20

JOYSTICK 1 (VALVES 1 AND 2) 20. AUXILIARY/REMOTE VALVE5 TIMER CONTROL
SM 8-12490 Issued 06-2004

60 SECTION 10001
Right Hand Console Components
5
6
G2
1
2
3
4
1. CONNECTOR 26
2. CONNECTOR 27
3. CONNECTOR 28
4. CONNECTOR 29
5. CONNECTOR 52
6. CONNECTOR 53
7. CONNECTOR 51
SM 8-12490 Issued 06-2004

SECTION 10001 61
1
2 5
6
4 7 8
1. AUXILIARY/REMOTE VALVE CONTROLLER

DIAGNOSTIC CONNECTOR 2 (3 PIN)
DIAGNOSTIC CONNECTOR 1 (2 PIN)
4. PRESSURE REDUCING VALVE SOLENOID
5. AUXILIARY/REMOTE VALVES
6. CONNECTOR 51
7. CONNECTOR 53
8. CONNECTOR 52
SM 8-12490 Issued 06-2004

62 SECTION 10001
SCHEMATIC CIRCUIT
Auxiliary/Remote Valve Controller Connector

Pin Identification
1 ARMREST CONTROL GROUND SIGNAL (0 VOLTS)
2 AUXILIARY/REMOTE VALVE 5 TIMER POTENTIOMETER SIGNAL
3 SWITCHED POWER (VF IN)
4 UNSWITCHED BATTERY POWER
5 AUXILIARY/REMOTE VALVE AV2 JOYSTICK POTENTIOMETER SIGNAL
6 CLEAN GROUND (BATTERY NEGATIVE TERMINAL)
8 AUXILIARY/REMOTE VALVE AV3 FLOW POTENTIOMETER SIGNAL
9 AUXILIARY/REMOTE VALVE POWER (VP OUT)
10 ARMREST CONTROL 5 VOLT SUPPLY (REFERENCE)
11 AUXILIARY/REMOTE VALVE ENABLE SIGNAL
12 CAN HIGH
13 CAN LOW
14 AUXILIARY/REMOTE VALVE CONTROLLER PROGRAMMING
17 SWITCHED POWER (VP IN)
18 MULTI FUNCTION LEVER AUXILIARY/REMOTE SWITCH LOWER SIGNAL
19 RS232 IN (PROGRAMMING)
20 RS232 OUT (PROGRAMMING)
21 MULTI FUNCTION LEVER AUXILIARY/REMOTE SWITCH RAISE SIGNAL
25 AUXILIARY/REMOTE VALVE STOP SWITCH
27 AUXILIARY/REMOTE VALVE STOP SIGNAL
28 AUXILIARY/REMOTE VALVE AV4 TIMER POTENTIOMETER SIGNAL
29 AUXILIARY/REMOTE VALVE ENABLE LIGHT
30 NOT USED
31 NOT USED
SM 8-12490 Issued 06-2004

SECTION 10001 63
AUXILIARY/REMOTE VALVE CONTROLLER AND ARMREST CONTROLS AUXILIARY/REMOTE VALVES AND PRESSURE REDUCING VALVE SOLENOID
2
3
20
A 21
4
D E 22
5
19a
23
18a
6
18 18b 19 19b
7
8 9 10 11 12 13 14 15 16 17
mi03k087
Key
1. FUSE #35 (7.5 AMP) 14. AUXILIARY/REMOTE VALVE AV2 TIMER CONTROL POTENTIOMETER A. TO HITCH UP/DOWN SWITCH (MULTIFUNCTION LEVER)
2. FUSE #20 (7.5 AMP) 15. AUXILIARY/REMOTE VALVE AV3 TIMER CONTROL POTENTIOMETER B. TO CAN BUS CIRCUIT
3. AUXILIARY/REMOTE VALVE CONTROLLER DIAGNOSTIC CONNECTOR 1 16. AUXILIARY/REMOTE VALVE AV4 TIMER CONTROL POTENTIOMETER C. TO CAN BUS CIRCUIT (TRANSMISSION CONTROLLER)
4. MULTIFUNCTION LEVER AUXILIARY/REMOTE VALVE RAISE SWITCH 17. AUXILIARY/REMOTE VALVE AV5 TIMER CONTROL POTENTIOMETER D. FROM SPLICE RC-SP5 (REFER TO CAB CONTROLLER CIRCUIT SECTION 10006)
5. MULTIFUNCTION LEVER AUXILIARY/REMOTE VALVE LOWER SWITCH 18. 1ST/2ND AUXILIARY/REMOTE VALVE CONTROL JOYSTICK E. FROM HITCH CONTROLLER
6. AUXILIARY/REMOTE VALVE ENABLE SWITCH 18a. AUXILIARY/REMOTE VALVE AV1 CONTROL POTENTIOMETER
7. AUXILIARY/REMOTE VALVE STOP SWITCH 18b. AUXILIARY/REMOTE VALVE AV2 CONTROL POTENTIOMETER
8. AUXILIARY/REMOTE VALVE AV1 FLOW CONTROL POTENTIOMETER 19. 3RD/4TH AUXILIARY/REMOTE VALVE CONTROL JOYSTICK
9. AUXILIARY/REMOTE VALVE AV2 FLOW CONTROL POTENTIOMETER 19a. AUXILIARY/REMOTE VALVEAV3 CONTROL POTENTIOMETER
10. AUXILIARY/REMOTE VALVE AV3 FLOW CONTROL POTENTIOMETER 19b. AUXILIARY/REMOTE VALVE AV4 CONTROL POTENTIOMETER
11. AUXILIARY/REMOTE VALVE AV4 FLOW CONTROL POTENTIOMETER 20. CAN TERMINATION RESISTOR 2 (TRANSMISSION HARNESS)
12. AUXILIARY/REMOTE VALVE AV5 FLOW CONTROL POTENTIOMETER 21. AUXILIARY/REMOTE VALVE CONTROLLER DIAGNOSTIC CONNECTOR 2
13. AUXILIARY/REMOTE VALVE AV1 TIMER CONTROL POTENTIOMETER 22. SUSPENDED FRONT AXLE CONTROLLER CONNECTOR
23. PRESSURE REDUCING VALVE SOLENOID
SM 8-12490 Issued 06-2004
64 SECTION 10001
CAN Bus Schematic Circuit
MI03k001
Key
1. CAN TERMINATION RESISTOR 1 (ENGINE HARNESS)
2. CAN TERMINATION RESISTOR 2 (TRANSMISSION HARNESS)
3. J1939 DIAGNOSTIC CONNECTOR
SM 8-12490 Issued 06-2004

SECTION 10001 65
MAIN CONNECTORS
477I96
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS 478I96

(RIGHT HAND CONSOLE HARNESS SIDE)
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS
Cavity Wire No Circuit (RIGHT HAND CONSOLE HARNESS SIDE)
A 599 BR AUDIBLE ALARM
B 707 P LH TAIL/POSITION LIGHT
A 835 O FRONT WINDSCREEN WASHER
B 845 O REAR WINDSHIELD WASHER
D 500 R HITCH B+
C 550 R FRONT PTO B+
D 551 LB FRONT PTO SIGNAL
E 590 R PTO B+
SWITCHED B+
H 810 R SEAT B+
J 530 R MFD AND DIFF LOCK B+ CONNECTOR SWITCHED B+
K 134 R AUXILIARY POWER CONNECTOR H 776 P ROTARY BEACON LIGHT B+
SWITCHED B+
J 531 R SUSPENDED FRONT AXLE
L 756 P RH TURN SIGNAL BATTERY B+
M 757 P LH TURN SIGNAL K 530 R SUSPENDED FRONT AXLE
N ----- OPEN SWITCHED B+
P 133 R AUXILIARY POWER L 900 Y CAN HIGH

FENDER HARNESS M 900 LG CAN LOW
CONNECTOR (*) OR
P ----- OPEN
R ----- OPEN
UNSWITCHED B+
V ----- OPEN CONTROLLER BATTERY B+
W 785 V REAR FOG LIGHTS (*) W ----- OPEN
X 254 Y PARK LOCK SIGNAL X 850 R CAB SUSPENSION CONTROLLER
SWITCHED B+
VP IN Z ----- OPEN

SM 8-12490 Issued 06-2004

66 SECTION 10001
Connector 40 Connector 44 (34 Pin)

Location: Below Rear of Cab (Right Hand Side) Location: Cab Rear Panel
MI04A090 MI04A057
REAR FENDER HARNESS TO TRANSMISSION HARNESS AUXILIARY/REMOTE VALVE CONNECTOR

(TRANSMISSION HARNESS SIDE)
Cavity Wire No Circuit 1 540 BR ARMREST CONTROL GROUND
A (GND) CLEAN GROUND
2 529 DB VALVE 5 TIMER SIGNAL
BR/W
3 161 R SWITCHED POWER
SENDER 4 160 R UNSWITCHED POWER
C 233 Y FUEL LEVEL SENDER 5 516 DB VALVE 2 CONTROL SIGNAL
D (GND) CLEAN GROUND 6 BR/W CLEAN GROUND

BR/W 7 514 DB VALVE 3 CONTROL SIGNAL
E 507 R HITCH POSITION /LOAD PIN B+ 8 513 DB VALVE 3 FLOW SIGNAL
F 507 LB HITCH POSITION SIGNAL 9 (VP) R VALVE POWER (VP OUT)
G 507 BR/W HITCH POSITION GROUND 10 540 BR ARMREST CONTROL 5 VOLT
H (VP) R VP OUT B+ 11 551 LB ENABLE SIGNAL
J 900 Y CAN HIGH 12 900 Y CAN HIGH
K 900 LG CAN LOW 13 900 LG CAN LOW
L 515 LB LEFT HAND LOAD PIN SIGNAL 14 (AVC) W CONTROLLER PROGRAMMING
M 514 LB RIGHT HAND LOAD PIN SIGNAL 15 532 DB VALVE 4 CONTROL SIGNAL
N 215 Y WHEEL SPEED SIGNAL 16 530 DB VALVE 4 FLOW SIGNAL
O 215 BR/W WHEEL SPEED GROUND 17 ----- NOT USED
P 513 LB HITCH RAISE SOLENOID 18 517 DB VALVE 5 LOWER SIGNAL
Q 512 LB HITCH LOWER SOLENOID 19 (TX) W RS232 IN (PROGRAMMING)
R 511 LB HITCH SOLENOID COMMON 20 (RX) W RS232 OUT (PROGRAMMING)
S 662 R BOTTOM OF PEDAL SIGNAL 21 518 DB VALVE 5 RAISE SIGNAL
T 550 R TRANSMISSION CONTROLLER 22 515 DB VALVE 1 CONTROL SIGNAL
SWITCHED B+
23 511 DB VALVE 1 FLOW SIGNAL
U ----- OPEN
24 531 Db VALVE 5 FLOW SIGNAL
25 502 Db STOP SWITCH
W 276 T 540/1000 PTO SIGNAL
26 512 DB VALVE 2 FLOW SIGNAL
27 503 DB STOP SIGNAL
29 ----- NOT USED
30 ----- NOT USED
31 ----- NOT USED
SM 8-12490 Issued 06-2004

SECTION 10001 67
Connector 50
DI99A036


SIGNAL
2 540 BR ARM REST POTENTIOMETER 0V
SIGNAL

SWITCHED B+
GROUND
37 ----- OPEN
38 ----- OPEN
39 ----- OPEN
40 ----- OPEN
41 ----- OPEN
42 ----- OPEN
43 ----- OPEN
22 501 DB HITCH ENABLE SIGNAL
44 ----- OPEN
45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12490 Issued 06-2004

68 SECTION 10001
Connector 51
DI99A036


3 591 LB REAR PTO ON SIGNAL SWITCHED B+
CONTROLLER VP B+
30 590 R 540/1000 PTO SWITCH B+
9 ----- OPEN
32 ----- OPEN
13 510 T F/N/R B+
INDICATOR LIGHT
44 900 LG CAN LOW
CONTROLLER)
24 276 LB 540/1000 PTO SWITCH 47 644Y REMOTE THROTTLE SIGNAL
SM 8-12490 Issued 06-2004

SECTION 10001 69
Connector 53
DI99A036


32 ----- OPEN
8 504 R HITCH HEIGHT/DEPTH SETTING 33 161 R AUXILIARY/REMOTE VALVE
POTENTIOMETER (5V) CONTROLLER SWITCHED B+
9 504 BR HITCH HEIGHT/DEPTH SETTING 34 ----- OPEN
POTENTIOMETER (0V)
GROUND
12 505 BR HITCH MODE (INTERMIX) LOW 37 571 R RIDE CONTROL B+
13 ----- OPEN 38 572 LB RIDE CONTROL ON SIGNAL
39 ----- OPEN
15 (CAT) BR HITCH DIAGNOSTIC LIGHT 40 ----- OPEN
GROUND
16 ----- OPEN
42 ----- OPEN

POTENTIOMETER HIGH
47 ----- OPEN
20 ----- OPEN
48 ----- OPEN
24 ----- OPEN
SM 8-12490 Issued 06-2004

10002
Section
10002
HITCH CONTROLLER

and Schematics
ZTX Series Tractors

2 SECTION 10002
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 3
ELECTRONIC HITCH CONTROL GENERAL INFORMATION

CAN Bus Communication .................................................................................................................................... 4
Hitch Operation .................................................................................................................................................... 4
ERROR CODES GENERAL INFORMATION .......................................................................................................... 5

Retrieving Instrument Cluster Displayed Active Error Codes. ............................................................................. 5
Identifying Hitch Diagnostic Light Displayed Error Codes.................................................................................... 6
HITCH POTENTIOMETER REPLACEMENT AND ADJUSTMENT ......................................................................... 7
CIRCUIT TESTING
General Information ........................................................................................................................................... 11
HITCH CONTROLLER ERROR CODE TROUBLESHOOTING GUIDE

Error Code 11 ................................................................................................................................................ 12
Error Code 12 ................................................................................................................................................ 12
Error Code 13 ................................................................................................................................................ 13
Error Code 14 ................................................................................................................................................ 13
Error Code 15 ................................................................................................................................................ 14
Error Code 16 ................................................................................................................................................ 14
Error Code 17 ................................................................................................................................................ 15
Error Code 18 ................................................................................................................................................ 15
Error Code 22 ................................................................................................................................................ 16
Error Code 23 ................................................................................................................................................ 16
Error Code 24 ................................................................................................................................................ 17
Error Code 31 ................................................................................................................................................ 17
Error Code 32 ................................................................................................................................................ 18
Error Code 33 ................................................................................................................................................ 19
Error Code 34 ................................................................................................................................................ 19
Error Code 36 ................................................................................................................................................ 20
Error Code 41 ................................................................................................................................................ 20
Error Code 42 ................................................................................................................................................ 21
Arm Rest Components....................................................................................................................................... 22
Right Hand Console Components ..................................................................................................................... 23
Rear Fender Components ................................................................................................................................. 24
Transmission Hitch Components ....................................................................................................................... 25
SCHEMATIC CIRCUIT
Hitch Controller Schematic Circuit ..................................................................................................................... 26
CAN Bus Schematic Circuit ............................................................................................................................... 28
MAIN CONNECTORS ............................................................................................................................................ 29
SM 8-12451 Issued 09-2004

SECTION 10002 3
SPECIAL TOOLS
DD98H120 MD04C017
MC2616 MULTIMETER KIT includes: 1025T1 McCORMICK DIAGNOSTIC CENTRE

MC2616-2 TEST LEADS
DD97E383
DD99A051
MC31000B HARNESS REPAIR KIT (EUROPE)
SM 8-12451 Issued 09-2004

4 SECTION 10002
ELECTRONIC HITCH CONTROL GENERAL INFORMATION

The hitch controller controls the correct operation of the rear hitch by processing and monitoring signals directly
from the following switches and sensors.
• Hitch up/down switch.
• Height/depth setting potentiometer.
• Hitch mode (intermix) potentiometer.
• Hitch upper limit potentiometer.
• Hitch drop speed potentiometer.
• Slip and ride control switches.
• Hitch remote switches.
• Hitch position potentiometer.
• Load pin sensors.
• Wheel speed sensor.
• Ground speed radar.
• Alternator (engine running).
The hitch controller also transmits information from the wheel speed sensor and hitch position potentiometer over
the CAN Bus circuit to the instrument cluster:

Hitch Operation
The hitch will only operate when the system has been enabled. When the engine is started the hitch diagnostic light
will illuminate to indicate the hitch is ‘LOCKED’ and needs to be enabled.
To enable the hitch the main setting control (depth/height potentiometer) has to be moved to the position that
corresponds with the position of the hitch. When the main setting controls nears the unlocked position, the hitch
diagnostic light will begin to flash as a warning the hitch is about to move.
After enabling the hitch the speed at which the hitch will move is restricted by the hitch controller. This is done by
limiting the current to the hitch solenoids. After the initial movement the hitch will operate normally.
If an error occurs during normal operation the hitch diagnostic light will begin to flash to indicate a fault. Faults in the
hitch system are classified into three categories and the reaction of the hitch varies according to the severity of the
fault.
Category 1 - Serious Fault: The hitch will stop and lock, the hitch can only be unlocked once the fault has been
rectified.
Category 2 - Medium Fault: The hitch will stop and lock, the hitch can be unlocked by moving the main setting
control.
Category 3 - Minor Fault: The hitch will continue to operate.
SM 8-12451 Issued 09-2004

SECTION 10002 5

NOTE: The instrument cluster can only display current (active) error codes.


! controller and MUST only be retrieved using the ’McCormick
tractor.

ENG - ENGINE
Example:
ENG = ENGINE
EHR = ELECTRONIC HITCH CONTROLLER
1 = 1 Active Error

16 = Error Code 16
If more than one EHR error has been detected, press the button to identify the remaining errors.
For EHR Error Codes refer to the Error Code Troubleshooting Guide in this section.
SM 8-12451 Issued 09-2004

6 SECTION 10002
Identifying Hitch Diagnostic Light Displayed Error Codes.

If an error occurs during normal operation in hitch system the hitch diagnostic light will flash a series of
flashers to indicate a fault in the system.
An error code is a two digit number. Each digit of the error code is indicated by a series of flashers. The first series
of flashers represents the first digit of the error code and the second series of flashers represents the second digit.
EXAMPLE:
Long Pause - FLASH - FLASH- FLASH - Short Pause - FLASH - FLASH - FLASH - FLASH - FLASH - FLASH.
This series of flashers represents an error code of 36.
SM 8-12451 Issued 09-2004

SECTION 10002 7
HITCH POTENTIOMETER REPLACEMENT AND ADJUSTMENT

IMPORTANT: Before carr ying out the following STEP 4
procedure, remove any attached implement from the
rear hitch.
3
IMPORTANT: To prevent damage being caused
to the hitch potentiometer, the potentiometer
mu s t b e i n s t a l l e d w i t h t h e r e a r h i t c h i n t h e
raised position.
STEP 1
Park the tractor on hard level ground, apply the park
brake and put the F/N/R/P lever in park. Fully lower
the rear hitch and stop the engine. Put blocks in front
and behind the rear wheels.
MD04C001
Start the engine and press the hitch remote raise

STEP 2
switch (3) to raise the hitch. When the hitch relief valve
opens release the switch and stop the engine.

1
! closed building, proper ventilation is
required under all circumstances.
STEP 5
A B
MD04B058
Support the right hand rear hitch linkage and remove

the top hitch pin (1). Lower the right hand rear hitch
linkage to the ground.
C
WARNING: Watch for the trip hazard when
! working around the hitch with the hitch
linkage disconnected.
MD04C005
Put alignment marks (A) and (B) on the rockshaft

STEP 3
housing and the lift arm as shown. Put an alignment
mark (C) on the rockshaft housing 3 to 5 mm below
the alignment mark (A).
MD04B044
Disconnect the potentiometer (2) from the harness.
SM 8-12451 Issued 09-2004

8 SECTION 10002
STEP 6 STEP 7
4
MI04B051 MD04B044
Loosen the lock nut (5). If the potentiometer (2) is to

be replaced remove the potentiometer (2) from the
hitch rockshaft housing. Note the number of turns
required to remove the potentiometer.
B Install the new potentiometer into the hitch rockshaft
housing the same number of turns noted during
removal.
STEP 8
C Connect the potentiometer to the harness.
STEP 9
MD04C004
Press the hitch lower solenoid button (4) and lower the
hitch until marks (B) and (C) are aligned as shown.
WARNING: Watch for pinch points between

hitch linkage and the tractor when raising or
! lowering the hitch using the hitch remote
switches.
MI04b094
Connect the McCormick Diagnostic tool to the tractor.

Select CAN Analysis, EHR and position sensor as
shown.
SM 8-12451 Issued 09-2004

SECTION 10002 9
STEP 10 STEP 11
MI04C003 MD04C001
Start the engine and press the hitch remote lower

switch (7) to lower the hitch.
5 STEP 12
2
8
9
7
MD04B044
Turn the key to the ON position and the select Start

Measurement box (D) as shown. Screw the hitch
potentiometer (2) in or out until a reading of 7.01 to 6 MI03F014
7.05 volts is obtained in the Data column. Tighten the To check the operation of the hitch cycle the hitch
locknut (5) and check the reading. Turn the key to the control switch (6) and enable the hitch. With the
OFF position and disconnect the potentiometer from hitch control switch (6) in the centre (work) position,
the harness. set the hitch upper limit potentiometer (7) to the
Remove any twist introduced into the harness during maximum height. Set the hitch mode potentiometer
the adjustment of the potentiometer then reconnect (8) to ’0’ and move the main setting potentiometer
the potentiometer to the harness. (9) to the transport position to raise the hitch.
NOTE: Screwing the potentiometer out will If the hitch relief valve opens when the hitch is fully
lower the voltage reading and screwing the raised, repeat the hitch potentiometer adjustment
potentiometer in will raise the voltage reading. procedure.
SM 8-12451 Issued 09-2004

10 SECTION 10002
STEP 13
MD04B058
Stop the engine and remove the McCormick

diagnostic tool. Support the right hand rear hitch
linkage in position and install the top hitch pin (1).
SM 8-12451 Issued 09-2004

SECTION 10002 11
CIRCUIT TESTING
General Information

switches may occur.
made.
SM 8-12451 Issued 09-2004

12 SECTION 10002
HITCH CONTROLLER ERROR CODE TROUBLESHOOTING GUIDE
Error Code 11
Fault Description.
Raise solenoid circuit failed.
Fault Category.
Category 1 - Hitch system locked.
NOTE: The hitch controller unswitched power fuse position will vary between early and later production
tractors and between European and American specification tractors. For the correct fuse identification,
refer to the schematic key on Page 26 and the tractor fuse decal.
Possible Cause.
1. Bad fuse 33, 37 or 43 (see note above).
2. Open circuit or circuit shorted to ground between fuse 33, 37 or 43 (see note above) and the hitch controller.
3. Open circuit or circuit shorted to ground between the hitch controller terminal 35 and the hitch solenoids.
4. Open circuit between the hitch controller terminal 37 and the raise solenoid.
5. Bad hitch controller.
1. Check fuse 33, 37 or 43 (see note above) - if the fuse is OK go to check 4.
2. With fuse 33, 37 or 43 (see note above) removed and the hitch controller disconnected, check wires 500
Red between the fuse and the hitch controller terminal 29 for short circuit to ground.
3. Check the hitch solenoid feed wires 511 Light Blue between the hitch controller terminal 35 and the hitch
solenoids for short circuit to ground.
4. If error code 12 is also present check wire 511 Light Blue between the hitch controller terminal 35 and splice
T-SP13 for open circuit. Also check connector 40.
5. Check the raise solenoid feed wire 511 Light Blue between the splice T-SP13 and the raise solenoid for
open circuit.
6. Check the raise solenoid return wires 513 Light Blue between the hitch controller terminal 37 and the raise
solenoid for open circuit.
7. Reprogram the hitch controller.
Error Code 12
Fault Description.
Lower solenoid circuit failed.
Fault Category.
Possible Cause.
3. Open circuit or circuit shorted to ground between the hitch controller terminal 35 and the hitch solenoids.
4. Open circuit between the hitch controller terminal 19 and the lower solenoid.
1. Check fuse 33, 37 or 43 (see note above), if the fuse is OK go to check 3
continued.......
SM 8-12451 Issued 09-2004
SECTION 10002 13
4. If error code 11 is also present check wire 511 Light Blue between the hitch controller terminal 35 and splice
T-SP13 for open circuit. Also check connector 40.
5. Check the lower solenoid feed wire 511 Light Blue between the splice T-SP13 and the lower solenoid for
open circuit.
6. Check the lower solenoid return wires 512 Light Blue between the hitch controller terminal 19 and the lower
solenoid for open circuit.
7. Reprogram the hitch controller.
Error Code 13
Fault Description.
Current to the raise and lower solenoids too high.
Fault Category.
Possible Cause.
1. Bad raise or lower solenoid.
2. Short circuit between the raise solenoid feed and return wires.
3. Short circuit between the lower solenoid feed and return wires.
4. Raise or lower solenoid wires shorted to another circuit.
1. Check the raise and lower solenoids.
2. With hitch controller and the hitch solenoids disconnected check the following for short circuit.
- Between connector 49 terminal 19 for wire 512 Light Blue and the remaining terminals of connector 49.
3. Check the hitch controller and connector 49 for damaged pins.
4. With connector 40 (transmission to fender harness connector) disconnected the following for short circuit at
both the transmission harness and fender harness sides of the connector.
- Between connector 40 terminal Q for wire 512 Light Blue and the remaining terminals of connector 40.
- Between connector 40 terminal R for wire 511 Light Blue and the remaining terminals of connector 40.
- Between connector 40 terminal P for wire 513 Light Blue and the remaining terminals of connector 40.
Error Code 14
Fault Description.
The hitch controller has not detected a current at terminal 35 when the solenoid switching circuit is activated.
Fault Category.
Possible Cause.
3. Short to ground between the hitch controller terminal 35 and the hitch solenoids.
4. Open circuit in the raise solenoid feed or return wires.
5. Open circuit in the lower solenoid feed or return wires.
1. Check fuse 33, 37 or 43 (see note above), if the fuse is OK go to check 4.
continued.....
SM 8-12451 Issued 09-2004

14 SECTION 10002
4. With the hitch controller and hitch solenoids disconnected check for an open circuit between the following:
- Terminal 19 of the hitch controller connector for wire 512 Light Blue and the lower solenoid connector.
- Terminal 37 of the hitch controller connector for wire 513 Light Blue and the raise solenoid connector.
- Terminal 35 of the hitch controller connector for wire 511 Light Blue and splice T-SP13.
- Splice T-SP13 and the raise solenoid connector.
- Splice T-SP13 and the lower solenoid connector.
Error Code 15
Fault Description.
Hitch remote circuit failed.
Fault Category.
Possible Cause.
1. Hitch remote signal wire short circuit to ground.
1. With the hitch controller (connector 49) disconnected check between the following terminals or connector 49
for short circuit to ground.
- Between connector 49 terminal 9 for wire 571 Red.
- Between connector 49 terminal 17 for wire 528 Light Blue.
- Between connector 49 terminal 36 for wire 529 Light Blue.
Error Code 16
Fault Description.
Hitch control 10 volt circuit failed.
Fault Category.
Possible Cause.
1. Hitch control potentiometer 10 volt supply open circuit.
2. Hitch control potentiometer ground open circuit.
1. With the hitch controller connector 49, connector 50 (arm rest to fender harness) and connector 53 (right
hand console harness to fender harness) disconnected. Check for open circuit between connector 49
terminal 2 and the following terminals of connector 53 in turn:
- Terminal 1.
- Terminal 4.
- Terminal 8.
- Terminal 10.
- Terminal 37.
2. Check for open circuit between connector 49 terminal 2 and connector 50 terminal 24.
3. Check connector 49 terminal 2 for short circuit to ground.
4. Check for open circuit between connector 49 terminal 20 and the following terminals of connector 53 in turn:
- Terminal 3.
- Terminal 6.
- Terminal 8.
- Terminal 9.
5. Check for open circuit between connector 49 terminal 20 and connector 50 terminal 25.
continued....
SM 8-12451 Issued 09-2004

SECTION 10002 15

7. Connect connector 53 (right hand console harness to fender harness) and disconnect the following
components:
- Main setting (depth/height) potentiometer.
- Hitch mode (intermix) potentiometer.
- Hitch drop speed potentiometer.
- Hitch upper limit potentiometer.
- Ride control switch.
Check for open circuit between connector 49 terminal 2 and the following:
- Ride control switch connector, terminals 3 and 8 for wire 571 Red.
- Main setting (depth/height) potentiometer connector, terminal 2 for wire 504 Red.
- Hitch mode (intermix) potentiometer connector, terminal A for wire 505 Red.
- Hitch drop speed potentiometer connector, terminal 1 for wire 502 Red.
- Hitch upper limit potentiometer connector, terminal 4 for wire 560 Red.
9. Check for open circuit between connector 49 terminal 20 and the following:
- Main setting (depth/height) potentiometer connector, terminal 1 for wire 504 Brown.
- Hitch mode (intermix) potentiometer connector, terminal C for wire 505 Brown.
- Hitch drop speed potentiometer connector, terminal 3 for wire 502 Brown.
- Hitch upper limit potentiometer connector, terminal 6 for wire 560 Brown.
11. If the readings at checks 1 to 10 are correct, check the arm rest control harness.
Error Code 17
Fault Description.
The battery signal is above specified limits.
Fault Category.
Possible Cause.
1. Alternator output above 18 Volts.
Error Code 18
Fault Description.
The hitch controller has not detected a signal from the hitch control switch (hitch up and down).
Fault Category.
Possible Cause.
1. Hitch control switch signal wire open circuit.
2. Hitch control switch feed wire open circuit.
3. Hitch control switch ground wire open circuit.
1. With the hitch controller connector 49 and connector 50 disconnected check for open circuit between the
following:
- Between connector 49 terminal 2 and connector 50 terminal 24 for wire 571 Red.
- Between connector 49 terminal 20 and connector 50 terminal 25 for wire 571 Brown.
- Between connector 49 terminal 21 and connector 50 terminal 26 for wire 510 Light Blue.
2. Check the arm rest harness wires ‘B24’, ‘B25’ and ‘B26, for damage.
SM 8-12451 Issued 09-2004

16 SECTION 10002
Error Code 22
Fault Description.
The hitch controller has not detected a signal from the hitch position potentiometer.
Fault Category.
Possible Cause.
1. Hitch position potentiometer disconnected.
2. Hitch position potentiometer signal wire open or short circuit.
3. Hitch position potentiometer feed and ground wires open or short circuit.
1. Check the hitch position potentiometer is connected correctly to the harness.
2. Check the hitch position potentiometer adjustment.
3. Check hitch position potentiometer signal wire 507 Light Blue between the hitch controller terminal 6 and the
hitch position potentiometer for open circuit. Also check wire 507 Light Blue for short circuit to ground or
shorting to other circuits.
4. Check hitch position potentiometer feed wire 507 Red between splice T-SP8 and the hitch position
potentiometer for open circuit.
5. Check hitch position potentiometer ground wire 507 Brown/White between the hitch controller terminal 38
and the hitch position potentiometer for open circuit. Also check wire 507 Light Blue for short circuit to
ground or shorting to other circuits.
6. If error codes 31 and 32 are present check the following:
- The hitch position potentiometer/load sensing pin feed wire 507 Red between the hitch controller terminal
39 and splice T-SP8 for open circuit.
Error Code 23
Fault Description.
The hitch controller has not detected a signal from the hitch main setting potentiometer (depth/height).
Fault Category.
Possible Cause.
1. Hitch main setting potentiometer disconnected.
2. Hitch main setting potentiometer signal wire open or short circuit.
3. Hitch main setting potentiometer feed and ground wires open or short circuit.
1. Check the hitch main setting potentiometer is connected correctly to the harness.
2. Check the hitch main setting potentiometer signal wire 504 Light Blue between the hitch controller terminal
22 and the hitch main setting potentiometer for open circuit. Also check wire 504 Light Blue for short circuit
to ground or shorting to other circuits.
3. Check the hitch main setting potentiometer feed 504 Red wire between the splice F-SP9 and the hitch main
setting potentiometer for open circuit.
4. Check the hitch main setting potentiometer ground wire 504 Brown between the splice F-SP10 and the hitch
main setting potentiometer for open circuit.
5. If error codes 24, 34 and 36 are present check the following:
- The hitch control feed wire 571 Red between the hitch controller terminal 2 and splice F-SP9 for open
circuit.
- The hitch control ground wire 571 Brown between the hitch controller terminal 20 and splice F-SP10 for
open circuit.
SM 8-12451 Issued 09-2004

SECTION 10002 17
Error Code 24
Fault Description.
The hitch controller has not detected a signal from the hitch upper limit potentiometer.
Fault Category.
Possible Cause.
1. Hitch upper limit potentiometer disconnected.
2. Hitch upper limit potentiometer signal wire open or short circuit.
3. Hitch upper limit potentiometer feed and ground wires open or short circuit.
1. Check hitch upper limit potentiometer is connected correctly to the harness.
2. Check the hitch upper limit potentiometer signal wire 560 Light Blue between the hitch controller terminal 3
and the hitch upper limit potentiometer for open circuit. Also check wire 560 Light Blue for short circuit to
3. Check the hitch control feed wire 560 Red between the splice F-SP9 and the hitch upper limit potentiometer
for open circuit.
4. Check the hitch control ground wire 560 Brown between the splice F-SP10 and the hitch upper limit
- The hitch control potentiometer feed wire 571 Red between the hitch controller terminal 2 and splice F-
SP9 for open circuit.
- The hitch control potentiometer ground wire 571 Brown between the hitch controller terminal 20 and splice
F-SP10 for open circuit.
Error Code 31
Fault Description.
The hitch controller has not detected a signal from the right hand load pin or the detected load is too high.
Fault Category.
Category 1 - Hitch system locked (no signal detected).
NOTE: When a no signal fault is initially detected the fault category is 1 (system locked), turning the
key from ON to OFF then back to ON will allow the hitch to be operated in position control only.
Category 3 - Hitch system control enabled (load too high).
NOTE: If an overload fault is detected the hitch status light will flash error code 31 as a warning of an
overload condition only.
Possible Cause.
1. The right hand load sensing pin is overloaded.
2. Right hand load sensing pin disconnected.
3. Right hand load sensing pin installed incorrectly.
4. Right hand load sensing pin signal wire open or short circuit.
5. Right hand load sensing pin feed and ground wires open or short circuit.
1. Reduce the load on the right hand load sensing pin.
2. Check the right hand load sensing pin is connected correctly to the harness.
3. Check the right hand load sensing pin is installed correctly.
4. Check the right hand load sensing pin signal wire 514 Light Blue between the hitch controller terminal 26
and the right hand load sensing pin for open circuit. Also check wire 514 Light Blue for short circuit to ground
or shorting to other circuits.
5. Check the right hand load sensing pin feed wire 507 Red between splice T-SP8 and the right hand load
sensing pin for open circuit.
continued.......
SM 8-12451 Issued 09-2004

18 SECTION 10002
6. Check right hand load sensing pin ground wire 514 Brown between splice T-SP9 and the right hand load
sensing pin or open circuit.
39 and splice F-SP8 for open circuit.
8. If error code 32 is present check the load sensing pin ground wire 514 Brown between the hitch controller
terminal 1 and splice T-SP9 for open circuit.
Error Code 32
Fault Description.
The hitch controller has not detected a signal from the left hand load pin or the detected load is too high.
Fault Category.
Category 1 - Hitch system locked (no signal detected).
NOTE: When a no signal fault is initially detected the fault category is 1 (system locked), turning the
key from ON to OFF then back to ON will allow the hitch to be operated in position control only.
Category 3 - Hitch system control enabled (load too high).
NOTE: If an overload fault is detected the hitch status light will flash error code 31 as a warning of an
overload condition only.
Possible Cause.
1. The left hand load sensing pin is overloaded.
2. Left hand load sensing pin disconnected.
3. Left hand load sensing pin installed incorrectly.
4. Left hand load sensing pin signal wire open or short circuit.
5. Left hand load sensing pin feed and ground wires open or short circuit.
1. Reduce the load on the left hand load sensing pin.
2. Check the left hand load sensing pin is connected correctly to the harness.
3. Check the left hand load sensing pin is installed correctly.
4. Check the left hand load sensing pin signal wire 515 Light Blue between the hitch controller terminal 7 and
the left hand load sensing pin for open circuit. Also check wire 515 Light Blue for short circuit to ground or
5. Check the left hand load sensing pin feed wire 507 Red between splice T-SP8 and the left hand load
sensing pin for open circuit.
6. Check left hand load sensing pin ground wire 515 Brown between splice T-SP9 and the left hand load
sensing pin or open circuit.
39 and splice T-SP8 for open circuit.
8. If error code 31 is present check the load sensing pin ground wire 514 Brown between the hitch controller
terminal 1 and splice T-SP9 for open circuit.
SM 8-12451 Issued 09-2004

SECTION 10002 19
Error Code 33
Fault Description.
The battery signal is below specified limits.
Fault Category.
Category 3 - Hitch system control enabled.
Possible Cause.
1. Supply Voltage to the hitch controller is below 11.5 volts.
2. Battery in poor condition.
Error Code 34
Fault Description.
The hitch controller has not detected a signal from the drop speed potentiometer.
Fault Category.
Possible Cause.
1. Hitch drop speed potentiometer disconnected.
2. Hitch drop speed potentiometer signal wire open or short circuit.
3. Hitch drop speed potentiometer feed and ground wires open or short circuit.
1. Check the hitch drop speed potentiometer is connected correctly to the harness.
2. Check the hitch drop speed potentiometer signal wire 502 Light Blue between the hitch controller terminal
23 and the hitch drop speed potentiometer for open circuit. Also check wire 502 Light Blue for short circuit to
3. Check hitch control feed wire 502 Red between the splice F-SP9 and the hitch drop speed potentiometer for
open circuit.
4. Check hitch control ground wire 502 Brown between the splice F- SP10 and the hitch drop speed
SM 8-12451 Issued 09-2004

20 SECTION 10002
Error Code 36
Fault Description.
The hitch controller has not detected a signal from the mode potentiometer (intermix).
Fault Category.
Possible Cause.
1. Hitch mode potentiometer disconnected.
2. Hitch mode potentiometer signal wire open or short circuit.
3. Hitch mode potentiometer feed and ground wires open or short circuit.
1. Check the hitch mode potentiometer is connected correctly to the harness.
2. Check the hitch mode potentiometer signal wire 505 Light Blue between the hitch controller terminal 4 and
the hitch drop speed potentiometer for open circuit. Also check wire 505 Light Blue for short circuit to ground
or shorting to other circuits.
3. Check hitch control feed wire 571 Red between the splice F-SP9 and the hitch mode potentiometer for open
circuit.
4. Check hitch control ground wire 571 Brown between the splice F-SP10 and the hitch mode potentiometer.
for open circuit.
Error Code 41
Fault Description.
The hitch controller has not detected a signal from the ground speed radar.
Fault Category.
Category 3 - Hitch system control enabled, the fault will only occur when slip is selected.
Possible Cause.
1. Ground speed radar disconnected.
2. Ground speed radar signal wire open circuit.
1. Check the ground speed radar is connected correctly to the harness.
2. Check the ground speed radar signal wire 281 Yellow between the splice IP-SP4 and the hitch controller
terminal 10.
SM 8-12451 Issued 09-2004

SECTION 10002 21
Error Code 42
Fault Description.
The hitch controller has not detected a signal from the wheel speed sensor.
Fault Category.
Category 3 - Hitch system control enabled, the fault will only occur when slip is selected.
Possible Cause.
1. Wheel speed sensor disconnected.
2. Wheel speed sensor signal wire open or short circuit.
3. Wheel speed sensor return wire open or short circuit.
4. Bad wheel speed sensor.
1. Check the wheel speed sensor is connected correctly to the harness.
2. Check the wheel speed sensor.
3. Check the wheel speed sensor signal wire 215 Yellow between the hitch controller terminal 11 and the
wheel speed sensor for open circuit. Also check wire 215 Yellow for short circuit to ground or shorting to
other circuits.
4. Check the wheel speed sensor return wire 215 Brown/White between the hitch controller terminal 45 and
the wheel speed sensor for open circuit. Also check wire 215 Brown/White for short circuit to ground or
SM 8-12451 Issued 09-2004

22 SECTION 10002
Arm Rest Components
5 6
4
3
8 9
10
14
13 15 16
12
11
MI02F149A
17 18 19 20
MI02F151A

SM 8-12451 Issued 09-2004

SECTION 10002 23
7 9
8 10
5 6
4
3
2 11
17
14
15
1
12
16
13
18
19
20
22 21 G2
24
25
23
MI04J041
1. HITCH MAIN SETTING LEVER (HEIGHT/DEPTH) 14. HITCH MODE CONTROL (INTERMIX)
4. REAR PTO INDICATOR LIGHT 17. HITCH DIAGNOSTIC LIGHT
5. REAR PTO SWITCH 18. AUDIBLE ALARM
6. RIDE CONTROL SWITCH 19. CONNECTOR 52
7. SLIP CONTROL SWITCH 20. CONNECTOR 53
8. DIFFERENTIAL LOCK SWITCH 21. CONNECTOR 51
9. MFD SWITCH 22. CONNECTOR 26
10. FRONT SUSPENDED AXLE ON/OFF SWITCH 23. CONNECTOR 27
11. CIGAR LIGHTER 24. CONNECTOR 28
12. AUXILIARY POWER SOCKET 25. CONNECTOR 29
SM 8-12451 Issued 09-2004

24 SECTION 10002
4
5
6
2
1
3
11 12
10
9
G5
7
8
MI04J048
1. HITCH FENDER REMOTE SWITCH 6. CAB (MCC) CONTROLLER

2. PTO REMOTE SWITCH 9. CONNECTOR 52 (RIGHT HAND CONSOLE HARNESS)
3. CONNECTOR 50 (ARMREST) 10. CONNECTOR 53 (RIGHT HAND CONSOLE HARNESS)
5. HITCH CONTROLLER 12. CONNECTOR 40 (TRANSMISSION HARNESS)
G5. CHASSIS GROUND CONNECTOR G5.
SM 8-12451 Issued 09-2004

SECTION 10002 25
Transmission Hitch Components

3
6
4 7
MD04B062 MD04C019 MD04B071
MD04B044
MD04C018
MI04B067
1. RIGHT HAND LOAD PIN CONNECTOR 4. HITCH RAISE SOLENOID 6. RIGHT HAND LOAD PIN CONNECTOR
2. HITCH POSITION POTENTIOMETER 5. WHEEL SPEED SENSOR 7. CONNECTOR 40 (TRANSMISSION HARNESS TO FENDER HARNESS)
3. HITCH LOWER SOLENOID
SM 8-12451 Issued 09-2004

26 SECTION 10002
Hitch Controller Schematic Circuit
HITCH SOLENOIDS AND HITCH SWITCH HITCH POTENTIOMETERS, LOAD PINS AND WHEEL SPEED SENSOR HITCH REMOTE SWITCHES
2 3 4 5
6 7
9 10 13
A
12
11
8
14
MI03K085
Key
1. HITCH UP/DOWN SWITCH 10. RIGHT HAND LOAD PIN 19. FUSE 33 (7.5 AMP) - EARLY PRODUCTION TRACTORS A. TO IMPLEMENT INTERFACE CONNECTOR
2. HITCH MAIN SETTING POTENTIOMETER (DEPTH/HEIGHT) 11. WHEEL SPEED SENSOR FUSE 43 (7.5 AMP) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS B. TO INSTRUMENT CLUSTER
3. HITCH UPPER LIMIT POTENTIOMETER 12. HITCH REMOTE SWITCH CONNECTOR FUSE 37 (7.5 AMP) - LATER PRODUCTION AMERICAN SPECIFICATION TRACTORS C. FROM CAB CONTROLLER
4. HITCH DROP SPEED POTENTIOMETER 13. LEFT HAND FENDER REMOTE SWITCH 20. IMPLEMENT UP/DOWN SWITCH CONNECTOR D. TO CAN BUS CIRCUIT
5. HITCH MODE POTENTIOMETER (INTERMIX) 14. RIGHT HAND FENDER REMOTE SWITCH 21. SUSPENDED FRONT AXLE CONNECTOR E. FROM AUXILIARY/REMOTE CONTROLLER
6. HITCH LOWER SOLENOID 15. RIDE CONTROL SWITCH 22. GROUND SPEED RADAR F. FROM SPLICE RC-5 (REFER TO CAB CONTROLLER CIRCUIT
7. HITCH RAISE SOLENOID 16. SLIP CONTROL SWITCH 23. ALTERNATOR SECTION 10006)
8. HITCH POSITION POTENTIOMETER 17. HITCH DIAGNOSTIC LIGHT G. FROM AUXILIARY REMOTE VALVE PROGRAMMING CONNECTOR
9. LEFT HAND LOAD PIN 18. FUSE 27 (7.5 AMP) H. FROM ARM REST CONTROL
J. FROM STARTER MOTOR
SM 8-12451 Issued 09-2004
SECTION 10002 27
RIDE CONTROL SLIP CONTROL HITCH DIAGNOSTIC LIGHT
15 16 17
18
19
B C
20 A
J
21
22
23
MI03K086
HITCH CONTROLLER PIN IDENTIFICATION
1 LOAD PIN GROUND 12 SLIP INDICATOR LIGHT 23 HITCH DROP SPEED SIGNAL 34 NOT USED 45 WHEEL SPEED GROUND
(*) - EUROPEAN SPECIFICATION TRACTORS ONLY
2 CONTROL POTENTIOMETER (10V) 13 ALTERNATOR D+ 24 SWITCHED B+ 35 HITCH SOLENOID B+ 46 NOT USED
3 HITCH UPPER LIMIT SIGNAL 14 NOT USED 25 NOT USED 36 REMOTE HITCH LOWER 47 NOT USED
(**) - AMERICAN SPECIFICATION TRACTORS ONLY
4 HITCH MODE SIGNAL (INTERMIX) 15 RIDE CONTROL INDICATOR LIGHT 26 RIGHT HAND LOAD PIN SIGNAL 37 HITCH RAISE SOLENOID 48 NOT USED
5 SLIP ON SIGNAL 16 NOT USED 27 NOT USED 38 HITCH POSITION GROUND 49 NOT USED
6 HITCH POSITION SIGNAL 17 REMOTE HITCH RAISE 28 CLEAN GROUND 39 HITCH POSITION/LOAD PIN B+ 50 CAN HIGH
7 LEFT HAND LOAD PIN SIGNAL 18 NOT USED 29 UNSWITCHED B+ 40 NOT USED 51 NOT USED
8 NOT USED 19 HITCH LOWER SOLENOID 30 NOT USED 41 HITCH DIAGNOSTIC LIGHT GROUND 52 CAN LOW
9 REMOTE HITCH (10V) 20 CONTROL POTENTIOMETER (0V) 31 HITCH DIAGNOSTIC LIGHT 42 NOT USED 53 NOT USED
10 RADAR SIGNAL 21 HITCH SWITCH SIGNAL 32 RIDE CONTROL ON SIGNAL 43 NOT USED 54 NOT USED
11 WHEEL SPEED SIGNAL 22 HITCH SETTING POTENTIOMETER SIGNAL 33 NOT USED 44 SLIP GROUND SIGNAL 55 NOT USED
SM 8-12451 Issued 09-2004

28 SECTION 10002
MI03k001
Key
SM 8-12451 Issued 09-2004

SECTION 10002 29
MAIN CONNECTORS
Connector 10
DI99A036


AND INSTRUMENT CLUSTER
26 281 Y RADAR SIGNAL
5 200 BR/W INSTRUMENT CLUSTER CLEAN 27 280 R RADAR B+
29 603 R VP44 POWER (10A)
7 ----- OPEN
30 600 R BATTERY B+ (7.5A)
8 ----- OPEN
32 601 R BATTERY B+ (7.5A)
11 ----- OPEN 34 602 R BATTERY B+ (7.5A)
12 ----- OPEN 35 603 R VP44 POWER (10A)

21 ----- OPEN 45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12451 Issued 09-2004

30 SECTION 10002
477I96 MI04J044

SWITCH
5 600 Y BOTTOM OF PEDAL SWITCH
SWITCHED B+
G 784 V REAR FENDER WORK LIGHTS 6 233 Y FUEL LEVEL SENDER
7 656 BR INCHING PEDAL
H 810 R SEAT B+
SWITCHED B+
10 ----- OPEN
N ----- OPEN
FENDER HARNESS
CONNECTOR (*) OR

UNSWITCHED B+
V ----- OPEN

VP IN

SM 8-12451 Issued 09-2004

SECTION 10002 31
MI04J045 478I96

CONNECTOR KEY SENSING
E 590 R PTO B+
5 (IIC) R IMPLEMENT INTERFACE F 161 R AUXILIARY/REMOTE VALVE
CONNECTOR BATTERY B+
6 513 T F/N/R - REVERSE G 134 R IMPLEMENT INTERFACE
BATTERY B+
SWITCHED B+
L 900 Y CAN HIGH
M 900 LG CAN LOW
P ----- OPEN
R ----- OPEN
W ----- OPEN
SWITCHED B+
Z ----- OPEN
SM 8-12451 Issued 09-2004

32 SECTION 10002

MI04A057 MI04A056

2 ----- OPEN 2 ----- OPEN
5 ----- OPEN DB
5 ----- OPEN
6 ----- OPEN

8 ----- OPEN

14 ----- OPEN 13 280 R RADAR B+

15 ----- OPEN

17 (TX DB RS232 TX
18 900 LG CAN LOW
19 ----- OPEN 18 ----- OPEN
20 ----- OPEN 19 ----- OPEN

20 ----- OPEN

23 (RX DB RS232 RX

32 ----- OPEN
33 ----- OPEN
34 ----- OPEN
SM 8-12451 Issued 09-2004

SECTION 10002 33
Connector 40
Location: Below Rear of Cab (Right Hand Side)
MI04A090
REAR FENDER HARNESS TO TRANSMISSION HARNESS


BR/W
SENDER
BR/W
E 507 R HITCH POSITION /LOAD PIN B+
F 507 LB HITCH POSITION SIGNAL
G 507 BR/W HITCH POSITION GROUND
H (VP) R VP OUT B+
J 900 Y CAN HIGH
K 900 LG CAN LOW
M 514 LB RIGHT HAND LOAD PIN SIGNAL
N 215 Y WHEEL SPEED SIGNAL
SWITCHED B+
U ----- OPEN
SM 8-12451 Issued 09-2004

34 SECTION 10002
Connector 49
Location: Cab Rear Panel
MI04A055
HITCH CONTROLLER CONNECTOR

1 514 BR LOAD PIN GROUND 28 BR/W CLEAN GROUND
2 571 R CONTROL POTENTIOMETER 10V 29 500 R UNSWITCHED B+ B+
4 505 LB HITCH MODE (INTERMIX) SIGNAL 31 (AN) LB HITCH DIAGNOSTIC LIGHT
5 567 LB SLIP ON SIGNAL 32 572 LB RIDE CONTROL ON SIGNAL
6 507 LB HITCH POSITION SIGNAL 33 ----- OPEN
7 515 LB LEFT HAND LOAD PIN SIGNAL 34 ----- OPEN
8 ----- OPEN 35 511 LB HITCH SOLENOID COMMON B+
9 571 R REMOTE HITCH (10V) 36 529 LB REMOTE HITCH LOWER
10 281 Y RADAR SIGNAL 37 513 LB HITCH RAISE SOLENOID
11 215 Y WHEEL SPEED SIGNAL 38 507 BR/W HITCH POSITION GROUND
12 570 LB SLIP INDICATOR LIGHT 39 507 R HITCH POSITION /LOAD PIN B+
13 121 Y ALTERNATOR D+ 40 ----- OPEN
14 ----- OPEN 41 (CAT) BR HITCH DIAGNOSTIC LIGHT

GROUND
GROUND 42 ----- OPEN
16 ----- OPEN 43 ----- OPEN
17 528 LB REMOTE HITCH RAISE 44 567BR SLIP GROUND SIGNAL
18 ----- OPEN 45 215 BR/W WHEEL SPEED GROUND
19 512 R HITCH LOWER SOLENOID 46 ----- OPEN
20 571 BR CONTROL POTENTIOMETER 0V 47 ----- OPEN
21 510 LB HITCH CONTROL SWITCH SIGNAL 48 ----- OPEN

POTENTIOMETER SIGNAL 50 900 Y CAN HIGH
24 501 R HITCH SWITCHED B+ 52 900 LG CAN LOW
25 ----- OPEN 53 ----- OPEN
26 514 LB RIGHT HAND LOAD PIN SIGNAL 54 ----- OPEN
27 ----- OPEN 55 ----- OPEN
SM 8-12451 Issued 09-2004

SECTION 10002 35
Connector 50
DI99A036


2 540 BR ARM REST POTENTIOMETER 0V SIGNAL
28 516 DB AUXILIARY VALVE JOYSTICK 1B
SIGNAL

SWITCHED B+
GROUND
37 ----- OPEN
38 ----- OPEN
39 ----- OPEN
40 ----- OPEN
41 ----- OPEN
42 ----- OPEN
43 ----- OPEN
44 ----- OPEN
45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12451 Issued 09-2004

36 SECTION 10002
Connector 51
DI99A036


SWITCHED B+
3 591 LB REAR PTO ON SIGNAL
CONTROLLER VP B+
30 590 R 540/1000 PTO SWITCH B+
9 ----- OPEN
32 ----- OPEN
13 510 T F/N/R B+
INDICATOR LIGHT
43 900 Y CAN HIGH
SWITCHED B+
44 900 LG CAN LOW
22 590 R CAB CONTROLLER SWITCHED B+ 45 663 R BOTTOM OF PEDAL SIGNAL (CAB
CONTROLLER)
CONTROLLER BATTERY B+ 46 644 R REMOTE THROTTLE (5V)
24 276 LB 540/1000 PTO SWITCH
SM 8-12451 Issued 09-2004

SECTION 10002 37
Connector 52


C ----- OPEN
J ----- OPEN
K ----- OPEN
P ----- OPEN
R ----- OPEN
S ----- OPEN
SWITCHED B+
UNSWITCHED B+
cc ----- OPEN
ee ----- OPEN
ff ----- OPEN
gg ----- OPEN
hh ----- OPEN
3 ----- OPEN
4 ----- OPEN
SM 8-12451 Issued 09-2004

38 SECTION 10002
Connector 53
DI99A036


POTENTIOMETER (0V)
GROUND
39 ----- OPEN
GROUND
16 ----- OPEN
42 ----- OPEN

POTENTIOMETER HIGH
47 ----- OPEN
20 ----- OPEN
48 ----- OPEN
24 ----- OPEN
SM 8-12451 Issued 09-2004

Section
10003
10003
FRONT SUSPENDED AXLE
CONTROLLER
Calibration, Error Codes,
Troubleshooting and Schematics
ZTX Series Tractors

2 SECTION 10003
TABLE OF CONTENTS
SPECIAL TOOLS ...................................................................................................................................................... 3
GENERAL INFORMATION AXLE CONTROL .......................................................................................................... 4
CALIBRATION
General Information .............................................................................................................................................. 5
Calibration Procedure ........................................................................................................................................... 5
AXLE POTENTIOMETER
Potentiometer Check ............................................................................................................................................ 6
Potentiometer Adjustment..................................................................................................................................... 8
MANUAL LOWERING OF THE FRONT AXLE ....................................................................................................... 10
ERROR CODES
Identifying Error Codes ....................................................................................................................................... 11
CIRCUIT TESTING
General Information ............................................................................................................................................ 12

No Error Code - Axle Will Not Operated ............................................................................................................ 13
No Error Code - Axle Will Not Raise .................................................................................................................. 14
No Error Code - Axle Will Not Lower ................................................................................................................. 14
Error Code 21 .................................................................................................................................................... 15
Error Code 31 .................................................................................................................................................... 15
Error Code 32 .................................................................................................................................................... 16
Error Code 33 .................................................................................................................................................... 16
Error Code 41 .................................................................................................................................................... 17
Right Hand Console Components ...................................................................................................................... 19
Front Suspended Axle Control Unit Components ............................................................................................... 20
FRONT SUSPENDED AXLE CONTROLLER SCHEMATIC CIRCUIT ................................................................... 21
MAIN CONNECTORS............................................................................................................................................. 23
SM 8-12461 Issued 09-2004

SECTION 10003 3
SPECIAL TOOLS
DD98H120 MD01G010
MC2616 MULTIMETER KIT includes: MC3000 POTENTIOMETER TEST HARNESS
MC2616-2 TEST LEADS
DD97E383
MC31000B HARNESS REPAIR KIT)
DD99A051
SM 8-12461 Issued 09-2004

4 SECTION 10003
GENERAL INFORMATION AXLE CONTROL
1
2 1
3
SUSPENSION OFF
SUSPENSION ON
MI03M073
1. SUSPENDED FRONT AXLE SWITCH

2. SUSPENDED FRONT AXLE ON INDICATOR LIGHT
3. SUSPENDED FRONT AXLE OFF INDICATOR LIGHT
The suspended front axle has two modes, Off and Axle Suspension, controlled by a single rocker switch on the
right hand console.
Suspension ON
To select axle suspension fully press then release the top of the switch, the switch will automatically return to the
mid position and the upper switch green indicator lamp will illuminate.
After approximately 20 seconds both the WV1 and WV2 solenoids will energise raising the front axle to the mid-
position of the axle suspension travel.
Suspension OFF
To select no axle suspension fully press then release the bottom of the switch, the switch will automatically return to
the mid position and the lower switch red indicator lamp will illuminate.
Solenoid WV2 will energise and the axle will fully lower to the bottom limit of the suspension cylinder and the axle
will operate as a rigid axle.
SM 8-12461 Issued 09-2004

SECTION 10003 5
CALIBRATION
General Information
If any repairs are carried out to the axle suspension system that require the replacement or adjustment of any
components, then it will be necessary to calibrate the axle control module.
IMPORTANT: I f t h e a x l e p o t e n t i o m e t e r h a s b e e n r e m ov e d o r r e p l a c e d t h e a d j u s t m e n t o f t h e
potentiometer must be set before the axle is calibrated, refer to “AXLE POTENTIOMETER” on page 6.
The control module will indicate when the calibration mode has been selected by flashing the axle suspension ON
indicator light (located in the top of axle suspension switch) at a rate of 1 Hz (1 flash per second).
Calibration Procedure
1. Start and run the engine at low idle.
2. Hold the axle suspension switch in the axle suspension ON momentary position for 10 seconds.
3. Release the switch when the axle suspension ON indicator light begins to flash at a rate of 1 Hz (1 per
second).
4. Calibration Mode has now been entered.
5. Hold the Suspended Front Axle Switch in the Suspension OFF position. After a short delay the axle will
fully lower.
6. Release the switch when the axle is at the LOWER mechanical stops.
7. Hold the Suspended Front Axle Switch in the Suspension ON position. The axle will begin to raise.
8. Release the switch when the axle is at the UPPER mechanical stops.
9. The axle suspension indicator light will stop flashing if the calibration has been accepted and the axle will
lower to the mid position.
NOTE: If the indicator light continues to flash, the calibration has not been accepted stop the engine
and repeat the calibration procedure. If the calibration still will not be accepted, check the axle
potentiometer adjustment, refer to refer to “AXLE POTENTIOMETER” on page 6.

SM 8-12461 Issued 09-2004

6 SECTION 10003
AXLE POTENTIOMETER
Potentiometer Check STEP 4
IMPORTANT: The potentiometer check is to be

c ar r ie d ou t in the c al ib rati on m ode fr om t he B
operators seat.
STEP 1
Park the tractor on hard level ground, apply the
p a r k i n g b ra ke, l owe r t h e a x l e t o t h e b o t t o m
mechanical stops and STOP the engine. Put blocks
in front of and behind the rear wheels.
C
STEP 2
MD01G015
Connect the multimeter MC2616 (B) to test points 2

of MC3000. Put switch (C) in the CENTRE position
1 and set the multimeter to read Milliamperes (mA).
IMPORTANT: Before star ting the engine make
sure switch (C) is the in the center position, the
m u l t i m e t e r i s sw i t c h e d o n a n d s e t t o r e a d
milliampere (mA). Failure to do so will cause an
error code to be displayed.
STEP 5
MD04B081
Disconnect the potentiometer harness connector (1).
STEP 3
3
A
2
MD04B086
Start and run the engine at low idle. Press and hold
the suspended front axle switch (2) in the suspension
ON position for 10 seconds. When the suspension
ON indicator light (3) begins to flash release the
switch.
MD04B082
Connect Green wedge connectors of the test WARNING: Never operate the engine in a
harness MC3000 (A) to the axle potentiometer closed building. Proper ventilation is required
harness. Route the test harness through the left hand ! under all circumstances.
cab door into the cab.
SM 8-12461 Issued 09-2004

SECTION 10003 7
STEP 6 STEP 8
Fully lower the suspension axle. STOP the engine
and remove the key.
STEP 9
The readings should be as follows:-
Bottom Stop 5.00 mA (minimum)
Upper Stop 19.00 mA (maximum)
The difference between the upper and bottom stop
readings must NOT BE LESS than 9.35 mA.
Example:
Bottom stop reading 7.15 mA
2
Upper reading must not be less than 17.76 mA
MD04B086
Press and hold the suspended front axle switch (2) in IMPORTANT: Bottom stop reading of less than 4 mA
the suspension OFF position. When the axle reaches and a upper stop reading of more than 20.00 mA will
the lower mechanical stops release the switch and cause an error code to be displayed.
make a note of the multimeter reading.
STEP 10
STEP 7
If the readings are not correct adjust the
potentiometers, refer to “Potentiometer Adjustment”
on page 8.
NOTE: If no reading is obtained check the

potentiometer circuit.
2
MD04B085
Press and hold the suspended front axle switch (2) in

the suspension ON position. When the axle reaches
the upper mechanical stops release the switch and
make a note of the multimeter reading.
SM 8-12461 Issued 09-2004

8 SECTION 10003
Potentiometer Adjustment STEP 3
STEP 1
p a r k i n g b ra ke, l owe r t h e a x l e t o t h e b o t t o m
mechanical stops and STOP the engine. Put blocks
A
in front of and behind the rear wheels.
WARNING: Before any adjustments are

made to the front suspension axle
potentiometer, make sure the axle is fully
! lowered to the bottom mechanical stop, the
engine is not running and the key is
REMOVED. Failure to do this may result in MD04B082
serious injury. Connect Green wedge connectors of the test

harness MC3000 (A) to the axle potentiometer
IMPORTANT: I f a fa u l t o c c u r s w i t h t h e fr o n t harness.
suspension axle the axle suspension will
become inoperative and the axle may remain in STEP 4
it’s last position. The axle MUST BE lowered
manually. Refer to “MANUAL LOWERING OF
THE FRONT AXLE” on page 10.
STEP 2
2
1
MI04B087
Remove the cover (2) from the axle potentiometer

housing.
MD04B081
Disconnect the potentiometer harness connector (1).
SM 8-12461 Issued 09-2004

SECTION 10003 9
STEP 5 STEP 7
Check the multimeter reading and repeat STEP 6 as
necessary.
STEP 8
Install the potentiometer housing cover and tighten
the retaining screws to a torque of 13 Nm.
B
STEP 9
Check the operation of the potentiometers, refer to
“Potentiometer Check” on page 6. Also check the
C operation of the suspended front axle.
MD04B084
STEP 10
Connect the multimeter MC2616 (B) to test points 2
of MC3000. Put switch (C) in the CENTRE position. Remove the test harness and connect the axle
Set the multimeter to read Milliamperes (mA). potentiometer harness connector.
IMPORTANT: Before tur ning the key to the ON

p o s i t i o n m a ke s u r e sw i t c h ( C ) i s t h e i n t h e
center position, the multimeter is switched on
and set to read milliampere (mA). Failure to do
so will cause an error code to be displayed.
STEP 6
MD04B083
Turn the key to the ON position and loosen the

potentiom eter (3) r etainin g bolts, adjus t the
potentiometer until a reading of 6mA (+/- 0.5 mA) is
displayed on the multimeter. Tighten the retaining
bolts to a torque of 3 Nm.
SM 8-12461 Issued 09-2004

10 SECTION 10003
MANUAL LOWERING OF THE FRONT AXLE

STEP 1 STEP 3
parking brake and STOP the engine and remove the
key. Put blocks in front of and behind the rear wheels. 2
STEP 2
MI04B078
Loosen the lock nut and slowly loosen the AV bleed

d r a i n va l ve ( 2 ) o n e f u l l t u r n t o r e l e a s e t h e
accumulator pressure and to lower the front axle to
the bottom mechanical stop.
MI04B080 NOTE: Make sure the area around the front axle
Clean all dirt and debris from around the control is clear during the lowering operation.
valve block. Remove the plastic cap (1) from the .
manual shut off valve. WARNING: Watch for pinch points between
! front axle and the tractor when lowering the
front axle using the AV bleed drain valve.
STEP 4
When the axle is fully lowered tighten screw (2) and
tighten the locknut. Install the plastic cap (1).
SM 8-12461 Issued 09-2004

SECTION 10003 11
ERROR CODES
NOTE: Error codes will only be displayed when the fault occurs, the front suspension axle controller
does not store the codes in a memory.
Identifying Error Codes

An error code is a 2 digit number. Each digit of an error code number is represented by a series of flashes from
the axle suspension ON indicator light in the suspended front axle switch.
To identify an error code count the number of rapid flashes (0.5 seconds apart) from the axle suspension
indicator light separated by a 1 second pause.
The first series of flashes represent the first digit of the error code, the second series of flashes the second digit
of the error code.
Example: FLASH - FLASH - FLASH ---- 1 Second Pause ---- FLASH- FLASH ----2 Second Pause.
This series of flashes represents error code 32.
SM 8-12461 Issued 09-2004

12 SECTION 10003
CIRCUIT TESTING
General Information

switches may occur.
made.
SM 8-12461 Issued 09-2004

SECTION 10003 13
No Error Code - Axle Will Not Operated

Fault Description
Suspension axle will not raise or lower.
NOTE: For European specification tractors the instrument cluster/suspended front axle controller
unswitched power fuse position will vary between early and later production tractors (fuse 30 or 37). For
the correct fuse position refer to the schematic key on Page 21 and the tractor fuse decal.
NOTE: For American specification tractors the instrument cluster/suspended front axle controller
unswitched power fuse position is fuse 30 for both early and later production tractors.
Possible Cause
1. Bad fuse 28.
2. Bad fuse 30 or 37 (see notes above).
3. Circuit between fuse 28 and the suspended front axle switch or axle controller open circuit or short circuit to
ground.
4. Circuit between fuse 30 or 37 (see notes above) and the axle controller open circuit or short circuit to ground.
5. Circuit between the suspended front axle switch and the axle controller open circuit or short circuit to ground.
6. Axle controller clean ground wires open circuit.
Circuit Checks/Corrective Action
1. Check fuse 28, if the fuse is OK go to check 2, if the fuse has blown check the following:
- Wire 530 Red between fuse 28 and splice RC-SP6 for short circuit to ground.
- Wire 530 Red between splice RC-SP6 and terminal 4 of the axle controller for short circuit to ground.
Also check connectors 52, 80 and 81.
- Wire 530 Red between splice RC-SP6 and terminal 2 of the suspended front axle switch for short circuit
to ground.
- Wire 590 Red between splice RC-SP6 and the audible alarm for short circuit to ground.
- Wire 532 Dark Blue between the suspended front axle switch terminal 3 and the axle controller for short
circuit to ground.
- Wire 534 Dark Blue between the suspended front axle switch terminal 1 and the axle controller for short
circuit to ground.
- Wire 536 Dark Blue between the suspended front axle switch and the axle controller for short circuit to
ground.
2. Check fuse 30 or 37 (see note above), if the fuse is OK go to check 3, if the fuse has blown check the circuit
between the fuse and connector 81 for short circuit to ground. Also check connectors 52, 80 and 81.
3. Turn the key to the OFF position and check for continuity between terminal 1 of connector 81 for wire (SUSP)
Brown/White and ground.
- If continuity is not detected check the clean ground wire (SUSP) Brown/White between the axle
controller and splice F-SP19 for damage. Also check connectors 80 and 81.
4. Turn the key to the ON position, and check for 12 volts at terminal 4 of connector 81 for wire 530 Red.
- If 12 volts is detected go to check 6.
5. Release the suspended front axle switch from the right hand console and turn the key to the ON position.
Check for 12 volts at terminal 2 of the suspended front axle switch for wire 530 Red.
- If 12 volts is not detected at both checks 4 and 5 check wire 530 red between fuse 28 and splice RC-
SP6 for damage.
- If 12 volts is not detected at check 3 only check wire 530 Red between RC-SP6 and the axle controller for
damage. Also check connectors 52, 80 and 81.
- If 12 volts is not detected at check 4 only check wire 530 Red between RC-SP6 and the suspended front
axle switch for damage.
6. Check for 12 volts at terminal 3 of connector 81 for wire 531 Red.
- If 12 volts is not detected check wires 531 between fuse 30 or 37 (see notes above) and the axle
controller. Also check connectors 52, 80 and 81.
7. If the readings are correct check the axle controller harness between connector 81 and the controller for
damage.
SM 8-12461 Issued 09-2004

14 SECTION 10003
No Error Code - Axle Will Not Raise

Fault Description
The axle will not raise to the mid position when axle suspension ON mode is selected.
Possible Cause
1. Circuit between the suspended front axle switch and the axle controller open circuit.
2. Bad suspended front axle switch.
1. Release the suspended front axle switch from the right hand console and hold the suspended front axle
switch in the suspension ON position. Check for 12 volts at terminal 3 of the suspended front axle switch for
wire 534 Dark Blue.
- If 12 volts is not detected replace the suspended front axle switch.
2. Disconnect the axle controller at connector 81 and hold the suspended front axle switch in the suspension
ON position. Check for 12 volts at terminal 7 of connector 81 for wire 534 Dark Blue.
- If 12 volts is not detected check wire 534 Dark Blue between the suspended front axle switch and axle
connector 81. Also check connectors 52, 80 and 81.
damage.
No Error Code - Axle Will Not Lower

Fault Description
The axle will not lower to the suspension OFF position when axle suspension OFF mode is selected.
Possible Cause
1. Circuit between the suspended front axle switch and the axle controller open circuit.
1. Release the suspended front axle switch from the right hand console and hold the suspended front axle
switch in the suspension OFF position. Check for 12 volts at terminal 1 of the suspended front axle switch
for wire 532 Dark Blue.
- If 12 volts is not detected replace the suspended front axle switch.
2. Disconnect the axle controller at connector 81 and hold the suspended front axle switch in the suspension
OFF position. Check for 12 volts at terminal 6 of connector 81 for wire 532 Dark Blue.
- If 12 volts is not detected check wire 532 Dark Blue between the suspended front axle switch and axle
connector 81. Also check connectors 52, 80 and 81.
damage.
SM 8-12461 Issued 09-2004

SECTION 10003 15
Error Code 21
Fault Description
The axle controller does not detect a signal from the axle position potentiometer.
Possible Cause
1. Axle position potentiometer out of adjustment.
2. Bad circuit between the axle position potentiometer and the axle controller.
1. Check the potentiometer, refer to “Potentiometer Check” on page 6.
2. Remove the axle potentiometer cover and disconnect the potentiometer. Check the resistance between the
following terminals of the potentiometer.
- Terminals 1 to 3.
- Terminals 2 to 3.
- If a resistance reading of 0 ohms is detected replace and adjust the potentiometer, refer to
“Potentiometer Check” on page 6.
3. Disconnect the potentiometer from the controller at connector 82 and check the potentiometer harness for
continuity between the following terminals:
- Terminal 1 of the potentiometer connector and terminal C of connector 82.
- Terminal 2 of the potentiometer connector and terminal A of connector 82.
- Terminal 3 of the potentiometer connector and terminal B of connector 82.
- If continuity is not detected check potentiometer harness for damage.
4. If the readings at check 3 are correct check the axle controller potentiometer harness for damage.
5. Replace the axle controller.
Error Code 31
Fault Description
The axle controller has detected a fault in the WV1 solenoid when an axle raise command is selected
(Solenoids WV1 and WV2 are both on).
Possible Cause
1. WV1 solenoids resistance too low.
2. WV1 solenoid circuit shorted to the WV2 solenoid circuit.
1. Turn the key to the OFF position and disconnect the WV1 solenoid.
Check the resistance of the solenoid coil between terminals 1 and 2.
- The resistance reading should be approximately 8.0 Ohms.
If the reading is not correct replace the WV1 solenoid valve.
If the reading is correct check the axle controller solenoid harness for damage.
2. If the error remains, replace the axle controller.
SM 8-12461 Issued 09-2004

16 SECTION 10003
Error Code 32
Fault Description
The axle controller has detected a fault in the WV2 solenoid when an axle lower command is selected (Solenoid
WV1 is on and solenoid WV2 is off).
Possible Cause
1. WV2 solenoids resistance too low.
2. WV2 solenoid circuit shorted to the WV1 solenoid circuit.
1. Turn the key to the OFF position and disconnect the WV2 solenoid.
Check the resistance of the solenoid coil between terminals 1 and 2.
If the reading is not correct replace the WV1 solenoid valve.
If the reading is correct check the axle controller solenoid harness for damage.
Error Code 33
Fault Description
The axle controller has detected a fault in the WV1 or WV2 solenoid during normal operation (Solenoid WV1
and WV2 are both off).
Possible Cause
1. WV1 solenoid wire open circuit.
2. WV1 solenoid wire open circuit.
3. Bad WV1 solenoid.
4. Bad WV2 solenoid.
5. Bad axle controller clean ground circuit.
1. Turn the key to the OFF position and disconnect the WV1 and WV2 solenoids.
Check the resistance of both the WV1 and WV2 solenoid coil between terminals 1 and 2.
If the reading is not correct replace the solenoid valve.
If the readings are correct, check the axle controller solenoid harness for damage.
2. Turn the key to the OFF position and check for continuity between terminal 2 of connector 81 (axle controller)
for wire (SUSP) Brown/White and ground.
- If continuity is not detected check the clean ground wire (SUSP) Brown/White between the axle
controller and splice F-SP19 for damage. Also check connectors 80 and 81.
SM 8-12461 Issued 09-2004

SECTION 10003 17
Error Code 41
Fault Description
The axle controller has detected a axle raise and axle lower signal at the same time.
Possible Cause
1. The suspended front axle switch raise and lower circuits shorted together.
2. The circuit between the suspended front axle switch and the axle controller shorted to another circuit.
1. Turn the key to the OFF position and disconnect the axle controller at connector 82 and suspended front
axle switch.
Check for continuity between terminals 1 and 3 of the suspended front axle switch connector.
- If continuity is detected check wires 532 and 534 Dark Blue between the suspended front axle switch
and connector 82 for damage. Also check connectors 52, 80 and 81.
2. Turn the key to the ON position and check for a voltage reading at terminal 6 of connector 82.
- If a voltage reading is detected check wire 532 Dark Blue between the suspended front axle switch and
connector 82 for damage. Also check connectors 52, 80 and 81.
3. Turn the key to the ON position and check for a voltage reading at terminal 6 of connector 82.
- If a voltage reading is detected check wire 534 Dark Blue between the suspended front axle switch and
connector 82 for damage. Also check connectors 52, 80 and 81.
4. Turn the key to the OFF position and check for continuity between terminals 1 and 3 of the suspended front
axle switch with the switch in the OFF, suspension ON and Suspension OFF positions in turn.
- If continuity is detected replace the switch.
damage.
SM 8-12461 Issued 09-2004

18 SECTION 10003
This Page Has Been Left Blank.
SM 8-12461 Issued 09-2004

SECTION 10003 19

7 9
8 10
5 6
4
3
2 11
17
14
15
1
12
16
13
18
19
20
22 21 G2
24
25
23
MI04J041
1. HITCH MAIN SETTING LEVER (HEIGHT/DEPTH) 14. HITCH MODE CONTROL (INTERMIX)
4. REAR PTO INDICATOR LIGHT 17. HITCH DIAGNOSTIC LIGHT
5. REAR PTO SWITCH 18. AUDIBLE ALARM
6. RIDE CONTROL SWITCH 19. CONNECTOR 52
7. SLIP CONTROL SWITCH 20. CONNECTOR 53
8. DIFFERENTIAL LOCK SWITCH 21. CONNECTOR 51
9. MFD SWITCH 22. CONNECTOR 26
10. FRONT SUSPENDED AXLE ON/OFF SWITCH 23. CONNECTOR 27
11. CIGAR LIGHTER 24. CONNECTOR 28
12. AUXILIARY POWER SOCKET 25. CONNECTOR 29
SM 8-12461 Issued 09-2004

20 SECTION 10003
Front Suspended Axle Control Unit Components
1. V2 SOLENOID
2. V1 SOLENOID
3. FRONT SUSPENDED AXLE CONTROLLER
4. AV BLEED DRAIN OFF VALVE
SM 8-12461 Issued 09-2004

SECTION 10003 21
Front Suspended Axle Controller Schematic Circuit
SUSPENDED AXLE SWITCH SUSPENDED AXLE POTENTIOMETER SUSPENDED AXLE SOLENOIDS
1
2
5 6
3
L
F H
G J
MI03M072
Key
1. FUSE 37 (7.5 AMP) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS A. TO INSTRUMENT CLUSTER AND INTERIOR LIGHT/ RADIO CIRCUIT
FUSE 30 (7.5 AMP) - EARLY PRODUCTION EUROPEAN SPECIFICATION TRACTORS B. TO AUDIBLE ALARM B+
FUSE 30 - AMERICAN SPECIFICATION TRACTORS C. TO CAB SUSPENSION CONTROLLER
2. FUSE 28 (10 AMP) D. FROM AUTO PTO SWITCH
3. SUSPENDED AXLE SWITCH E. FROM IMPLEMENT INTERFACE CONNECTOR
4. SUSPENDED AXLE POSITION POTENTIOMETER F. FROM DIFFERENTIAL LOCK SWITCH
5. WV1 SUSPENDED AXLE SOLENOID (GREEN) G. FROM MFD SWITCH
6. WV2 SUSPENDED AXLE SOLENOID (BLACK) H. FROM ARM REST CONTROL
J. FROM AUXILIARY REMOTE VALVE DIAGNOSTIC CONNECTOR
K. FROM AUXILIARY/REMOTE CONTROLLER
SM 8-12461 Issued 09-2004

22 SECTION 10003
This Page Has Been Left Blank
SM 8-12461 Issued 09-2004

SECTION 10003 23
MAIN CONNECTORS
Connector 10
DI99A036


AND INSTRUMENT CLUSTER 26 281 Y RADAR SIGNAL
5 200 BR/W INSTRUMENT CLUSTER CLEAN
27 280 R RADAR B+
29 603 R VP44 POWER (10A)
7 ----- OPEN
30 600 R BATTERY B+ (7.5A)
8 ----- OPEN
32 601 R BATTERY B+ (7.5A)
11 ----- OPEN 34 602 R BATTERY B+ (7.5A)
12 ----- OPEN 35 603 R VP44 POWER (10A)

21 ----- OPEN 45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12461 Issued 09-2004

24 SECTION 10003
Location: Right Hand Console Location: Below Rear of Cab (Right Hand Side)
MI04A090
478I96
INSTRUMENT PANEL TO RIGHT HAND CONSOLE HARNESS REAR FENDER HARNESS TO TRANSMISSION HARNESS
(RIGHT HAND CONSOLE HARNESS SIDE) (TRANSMISSION HARNESS SIDE)

A 835 O FRONT WINDSCREEN WASHER A (GND) CLEAN GROUND
B 845 O REAR WINDSHIELD WASHER BR/W
C 550 R FRONT PTO B+
SENDER
D 551 LB FRONT PTO SIGNAL
E 590 R PTO B+
F 161 R AUXILIARY/REMOTE VALVE BR/W
CONNECTOR SWITCHED B+
H 776 P ROTARY BEACON LIGHT B+
H (VP) R VP OUT B+
J 531 R SUSPENDED FRONT AXLE
BATTERY B+ J 900 Y CAN HIGH
K 530 R SUSPENDED FRONT AXLE K 900 LG CAN LOW
SWITCHED B+
L 900 Y CAN HIGH
M 900 LG CAN LOW
P ----- OPEN P 513 LB HITCH RAISE SOLENOID
R ----- OPEN
V 160 R AUXILIARY/REMOTE VALVE SWITCHED B+
U ----- OPEN
W ----- OPEN V 514 BR LOAD PIN GROUND
X 850 R CAB SUSPENSION CONTROLLER W 276 T 540/1000 PTO SIGNAL
SWITCHED B+
Z ----- OPEN
SM 8-12461 Issued 09-2004

SECTION 10003 25
Connector 51
DI99A036


SWITCHED B+
4 592 LB REAR PTO STOP SIGNAL 27 (VP) R AUXILIARY/REMOTE VALVE
CONTROLLER VP B+
30 590 R 540/1000 PTO SWITCH B+
9 ----- OPEN
32 ----- OPEN
13 510 T F/N/R B+
INDICATOR LIGHT
21 500 R HITCH CONTROLLER BATTERY B+ 44 900 LG CAN LOW

CONTROLLER)
24 276 LB 540/1000 PTO SWITCH 47 644Y REMOTE THROTTLE SIGNAL
SM 8-12461 Issued 09-2004

26 SECTION 10003
Location: Below Rear of Cab (Right Hand Side) Location: Suspended Front Axle Control Unit
MI04B088 MI04B092
REAR FENDER HARNESS TO SUSPENDED FRONT AXLE SUSPENDED FRONT AXLE EXTENSION HARNESS TO
EXTENSION HARNESS SUSPENDED FRONT AXLE CONTROLLER
(FENDER HARNESS SIDE) (CONTROLLER SIDE)

1 BR/W CLEAN GROUND 1 LB CLEAN GROUND
2 BR/W CLEAN GROUND 2 R CLEAN GROUND
3 531 R UNSWITCHED BATTERY POWER 3 Y/DG UNSWITCHED BATTERY POWER
4 530 R SWITCHED BATTERY POWER 4 BR SWITCHED BATTERY POWER
5 536 DB SUSPENSION ON LIGHT L1 5 V SUSPENSION ON LIGHT L1
6 532 DB SUSPENSION OFF (BLOCKED) 6 B SUSPENSION OFF (BLOCKED)
7 534 DB SUSPENSION ON 7 R SUSPENSION ON
8 537 DB SUSPENSION OFF LIGHT L2 8 LB SUSPENSION OFF LIGHT L2
SM 8-12461 Issued 09-2004

Section
10009
INSTRUMENT CLUSTER CONTROLLER

and Schematics
ZTX Series Tractors
10009

SM 8-12521 June 2004 (Revised September 2004)
2 SECTION 10009
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 3
INSTRUMENT CLUSTER GENERAL INFORMATION

CAN Bus Communication..................................................................................................................................... 4
ERROR CODES GENERAL INFORMATION........................................................................................................... 5

Retrieving Instrument Cluster Displayed Active Error Codes. ..............................................................................5
INSTRUMENT CLUSTER CONFIGURATION ......................................................................................................... 6
CIRCUIT TESTING
General Information.............................................................................................................................................. 8

Error Code 100 .....................................................................................................................................................9
Error Code 101 .....................................................................................................................................................9
Error Code 102 ...................................................................................................................................................10
Error Code 103 ...................................................................................................................................................11
Error Code 200 ...................................................................................................................................................12
Error Code 201 ...................................................................................................................................................12
Error Code 202 ...................................................................................................................................................12
Error Code 300 ...................................................................................................................................................12
Error Code 301 ...................................................................................................................................................13
Error Code 302 ...................................................................................................................................................13
Error Code 303 ...................................................................................................................................................14
Error Code 304 ...................................................................................................................................................14
Engine Components ........................................................................................................................................... 15
Instrument Panel Components ........................................................................................................................... 16
Right Hand Console Components ...................................................................................................................... 17
SCHEMATIC CIRCUIT ........................................................................................................................................... 18
MAIN CONNECTORS ............................................................................................................................................ 21
SM 8-12521 Issued 9-2004

SECTION 10009 3
SPECIAL TOOLS
DD98H120 MD04C017
MC2616 MULTIMETER KIT includes: 1025T1 MCCORMICK DIAGNOSTIC CENTRE

MC2616-1 MULTIMETER ONLY 1014T1 AVG COMMUNICATIONS ADAPTER
MC2616-2 TEST LEADS 1026T1 USB COMMUNICATIONS LEAD
DD97E383
DD99A051
MC31000B HARNESS REPAIR KIT (EUROPE)
SM 8-12521 Issued 9-2004

4 SECTION 10009
INSTRUMENT CLUSTER GENERAL INFORMATION
4
3 5
2 2
MI03C095
1
1. MAIN DIGITAL DISPLAY 4. MCCORMICK LOGO OR AIR TRAILER
2. INDICATOR WARNING LAMPS BRAKE PRESSURE GAUGE (IF EQUIPPED)
3. FUEL GAUGE 5. ENGINE COOLANT TEMPERATURE GAUGE
The main function of the instrument cluster is to display information to the operator. To enable correct information to
be displayed, the cluster processes and monitors signals directly from the following components.
• Alternator (engine running, charging and engine speed).
• Air filter restriction switch.
• Coolant level sender.
• Ground speed radar.
• Trailed Implement switch.
• PTO speed selection switch.
• Park brake switch.
• Air trailer brake pressure sender.
• Fuel level sender.
• Turn signal switch.
• Light switch (position lights and high beam warning).
The instrument cluster controls the operation of the audible alarm and transmits the park brake switch status over
the CAN bus circuit to other controllers connected to the system.
The instrument cluster also receives information over the CAN bus circuit which includes the following:
• Selected gear and direction of travel.
• PTO speed.
• Hitch position.
• Wheel speed.
• MFD and differential lock engagement.
• Error codes.
In addition to displaying error codes from other controllers in the system the instrument cluster will display error
codes for faults that may occur in the instrument cluster circuit.

SM 8-12521 Issued 9-2004

SECTION 10009 5

Each controller on the tractor continually monitors the control systems for errors. If an error is detected an error
NOTE: The instrument cluster will only display current (active) error codes.


! controller and MUST only be retrieved using the ‘McCormick
tractor.

ENG - ENGINE
Example:
ENG = ENGINE
IC = INSTRUMENT CLUSTER
1 = 1 Active Error

104 = Error Code 104
If more than one instrument cluster error has been detected, press the button to identify the remaining errors.
For instrument cluster Error Codes refer to the Error Code Troubleshooting Guide in this section.
SM 8-12521 Issued 9-2004

6 SECTION 10009
INSTRUMENT CLUSTER CONFIGURATION

IMPORTANT: R e c o n f i g u r i n g t h e i n s t r u m e n t STEP 3
cluster will remove all the operators pre
selected settings. After reconfiguring the
instrument cluster the operators settings must
be reprogrammed into the instrument cluster,
refer to the Operators Manual.
STEP 1
brake, put the F/N/R/P lever in park and stop the
engine.
MI04D052
STEP 2 When the computer disc symbol and ‘10’ appear in
the instrument cluster main digital display, release
buttons (B) and (C).
STEP 4
MI04D054
Turn the key to the accessory position. When the

M.P.H./KPH symbol appears in the center of
instrument cluster main digital display (A) as shown,
simultaneously press buttons (B) and (C). MI04D052
When the computer disc symbol and ‘11’ appear in

the instrument cluster main digital display, press and
hold the menu button (B) for 2 seconds to store the
settings.
B C
A
MI04D053
SM 8-12521 Issued 9-2004

SECTION 10009 7
STEP 5
MI04D054
When the M.P.H./KPH symbol appears in the center of

instrument cluster main digital display (A) as shown,
turn the key to the OFF position.
SM 8-12521 Issued 9-2004

8 SECTION 10009
CIRCUIT TESTING
General Information

switches may occur.
of shor ting between the connector pins or terminals.
made.
SM 8-12521 Issued 9-2004

SECTION 10009 9
Instrument Cluster Error Codes
Error Code 100

Fault Description
Air trailer brake pressure sender signal short circuit.
Possible Cause
1. Air trailer brake pressure sender signal wire short circuit to ground.
2. Bad air trailer brake pressure sender.
1. Disconnect the air trailer brake pressure sender from the harness and disconnect connector 51 (fender
harness to right hand console harness). Make sure the sender signal wire does not short to ground. Check
wire 240 Yellow for continuity between ground and the air trailer brake pressure sender terminal.
- If continuity is detected check wire 240 Yellow between the air trailer brake pressure sender and connector
51 for damage. Also check connector 40.
2. Disconnect connector 27 (instrument panel harness to right hand console harness). Check wire 240 Yellow
for continuity between ground and connector 27 pin 1 (right hand console harness side).
- If continuity is detected check wire 240 Yellow between connector 27 and connector 51 for damage. Also
check connectors 27 and 51.
3. Disconnect the instrument cluster from the harness and check wire 240 Yellow for continuity between ground
and the instrument cluster connector C1 pin 30.
- If continuity is detected check wire 240 Yellow between the instrument cluster connector C1 and connector
4. Replace the air trailer brake sender.
WARNING: Before removing the air trailer brake pressure sender

! ALWAYS release the air pressure from the air reservoir using the drain
valve.
Error Code 101

Fault Description
Air trailer brake pressure sender signal open or short circuit.
Possible Cause
1. Air trailer brake pressure sender signal wire open circuit.
2. Air trailer brake pressure sender signal wire short circuit to voltage above 5 volts.
3. Bad air trailer brake pressure sender.
1. Disconnect the air trailer brake pressure sender from the harness. Make sure the sender signal wire does
not short to ground. Check wire 240 Brown/White for continuity between ground and the air trailer brake
pressure sender connector.
- If continuity is not detected check wire 240 Brown/White between the air trailer brake pressure sender and
the battery negative terminal.
2. Turn the key to the ON position and check the voltage reading at the sender connector for wire 240 Yellow.
- If a 0 voltage reading is obtained go to check 3.
- If a voltage reading above 5 volts is obtained go to check 6.
Continued...
SM 8-12521 Issued 9-2004

10 SECTION 10009
3. Disconnect connector 51 (fender harness to right hand console harness). Check wire 240 Yellow for
continuity between the air trailer brake pressure sender and connector 51 pin 31 (fender harness side).
- If continuity is not detected check wire 240 Yellow between the air trailer brake pressure sender and
connector 51 for damage. Also check connector 40.
4. Disconnect connector 27 (instrument panel harness to right hand console harness). Turn the key to the ON
position and check the voltage reading at connector 27 pin 1 (instrument harness side) for wire 240 Yellow.
- If a 0 voltage reading is obtained check wire 240 Yellow between the instrument cluster connector C1 and
connector 27.
- If a 5 volt reading is obtained check wire 240 Yellow between the connector 27 and connector 51.
5. Replace the air trailer brake sender.
WARNING: Before removing the air trailer brake pressure sender

! ALWAYS release the air pressure from the air reservoir using the drain
valve.
6. Disconnect connector 40 (fender harness to transmission harness). Turn the key to the ON position and
check the voltage reading at connector 40 pin B (fender harness side) for wire 240 Yellow.
- If a voltage reading of 5 volts is obtained check the transmission harness for damage.
position and check the voltage reading at connector 27 pin 1 (instrument panel harness side) for wire 240
Yellow.
- If a voltage reading of 5 volts is obtained check wire 240 Yellow between connector 27 and connector 51 for
damage. Also check connector 51.
- If a voltage reading above 5 volts is obtained check wire 240 Yellow between connector C1 and connector
Error Code 102

Fault Description
Fuel level sender signal short circuit.
Possible Cause
1. Fuel level sender signal wire short circuit to ground.
2. Bad fuel level sender.
1. Disconnect the fuel level sender from the harness and disconnect connector 51 (fender harness to right
hand console harness). Check wire 233 Yellow for continuity between ground and the fuel level sender
connector.
- If continuity is detected check wire 233 Yellow between the fuel level sender and connector 51 for damage.
2. Disconnect connector 27 (instrument panel harness to right hand console harness). Check wire 233 Yellow
for continuity between ground and connector 27 pin 6 (right hand console harness side).
- If continuity is detected check wire 233 Yellow between connector 27 and connector 51 for damage. Also
check connectors 27 and 51.
3. Disconnect the instrument cluster from the harness and check wire 233 Yellow for continuity between ground
and the instrument cluster connector C1 pin 8.
- If continuity is detected check wire 233 Yellow between the instrument cluster connector C1 and connector
4. Check the resistance reading between terminals A and B of the fuel level sender, refer to table below and
replace the fuel level sender as necessary.
EMPTY 251 OHMS
FULL 29 OHMS
SM 8-12521 Issued 9-2004

SECTION 10009 11
Error Code 103

Fault Description
Fuel level sender signal open or short circuit.
Possible Cause
1. Fuel level sender signal wire open circuit.
2. Fuel level sender signal wire short circuit to voltage above 5 volts.
3. Bad fuel level sender.
1. Disconnect the fuel level sender from the harness and check wire 233 Brown/White for continuity between
ground and the fuel level sender connector.
- If continuity is not detected check wire 233 Brown/White between the fuel level sender and the battery
negative terminal.
2. Turn the key to the ON position and check the voltage reading at the fuel level sender connector for wire 233
Yellow.
- If a 0 voltage reading is obtained go to check 3.
3. Disconnect connector 51 (fender harness to right hand console harness). Check wire 233 Yellow for
continuity between the fuel level sender connector and connector 51 pin 2 (fender harness side).
- If continuity is not detected check wire 233 Yellow between the fuel level sender and connector 51 for
Yellow.
- If a 0 voltage reading is obtained check wire 233 Yellow between the instrument cluster connector C1 and
- If a 5 volt reading is obtained check wire 233 Yellow between the connector 27 and connector 51 for
5. Check the resistance reading between terminals A and B of the fuel level sender, refer to table below and
replace the fuel level sender as necessary.
EMPTY 251 OHMS
FULL 29 OHMS
6. Disconnect connector 40 (fender harness to transmission harness). Turn the key to the ON position and
check the voltage reading at connector 40 pin C (fender harness side) for wire 233 Yellow.
- If a voltage reading of 5 volts is obtained check the transmission harness for damage.
Yellow.
- If a voltage reading of 5 volts is obtained check wire 233 Yellow between the connector 27 and connector
- If a voltage reading above 5 volts is obtained check wire 233 Yellow between the instrument cluster
connector C1 and connector 27. Also check connector 51.
SM 8-12521 Issued 9-2004

12 SECTION 10009
Error Code 200

Fault Description
Flash memory checksum error.
Possible Cause
1. Instrument cluster software problem.
2. Bad instrument cluster.
1. Reprogram the instrument cluster.
2. If the error remains, replace the instrument cluster.
Error Code 201

Fault Description
EEPROM signature error.
Possible Cause
1. Reconfigure the instrument cluster, refer to “INSTRUMENT CLUSTER CONFIGURATION” on page 6.
Error Code 202

Fault Description
Power up RAM check error.
Possible Cause
Error Code 300

Fault Description
The instrument cluster is not transmitting information over the CAN bus.
Possible Cause
1. Bad CAN bus circuit.
1. Disconnect the instrument cluster from the harness and disconnect connector 10 (engine harness to
instrument panel harness). Disconnect connector 51 (fender harness to right hand console harness) and
check wire 900 Yellow for continuity between the instrument cluster connector CN-1 pin 10 and terminal C of
the J1939 diagnostic connector.
- If continuity is not detected check wire 900 Yellow between connector CN-1 and splice IC-SP2.
2. Check wire 900 Light Green for continuity between the instrument cluster connector CN-1 pin 18 and
terminal D of the J1939 diagnostic connector.
- If continuity is not detected check wire 900 Light Green between connector CN-1 and splice IC-SP5.
3. If the readings are correct replace the instrument cluster.
SM 8-12521 Issued 9-2004

SECTION 10009 13
Error Code 301

Fault Description
The instrument cluster is not receiving information over the CAN bus from the engine controller.
Possible Cause
1. Engine Controller not powered up.
1. Check the engine controller power supply and clean ground circuits.
2. Disconnect the engine controller CAN connector from the engine controller and disconnect connector 10
(engine harness to instrument panel harness). Check wire 900 Yellow for continuity between connector 10
pin 36 and terminal A of the engine controller CAN connector (engine harness side).
- If continuity is not detected check wire 900 Yellow between connector 10 and engine controller CAN
connector. Also check splice E-SP1.
- If continuity is detected check the instrument panel harness wire 900 Yellow between connector 10 and
splice IC-SP2.
3. Check wire 900 Light Green for continuity between connector 10 pin 37 and terminal B of the engine
controller CAN connector (engine harness side).
- If continuity is not detected check wire 900 Light Green between connector 10 and engine controller CAN
connector. Also check splice E-SP3.
- If continuity is detected check the instrument panel harness wire 900 Light Green between connector 10
and splice IC-SP5.
Error Code 302

Fault Description
The instrument cluster is not receiving information over the CAN bus from the cab controller (MCC).
Possible Cause
1. Cab controller (MCC) not powered up.
1. Check the cab controller (MCC) power supply and clean ground circuits, refer to Section 10006.
2. Check for the presence of instrument cluster error codes 303 and 304.
- If error codes 303 and 304 are present check the following:
- Check connectors 51 and 29.
- Wire 900 Yellow between the instrument panel harness splice IC-SP2 and the fender harness splice F-
SP17.
- Wire 900 Light Green between the instrument panel harness splice IC-SP5 and the fender harness
splice F-SP18.
- If error codes 303 and 304 are not present check the following:
- Wire 900 Yellow between the fender harness splice F-SP17 and the cab controller connector J2.
- Wire 900 Light Green between the fender harness splice F-SP18 and the cab controller connector J2.
SM 8-12521 Issued 9-2004

14 SECTION 10009
Error Code 303

Fault Description
The instrument cluster is not receiving information over the CAN bus from the hitch controller.
Possible Cause
1. Hitch controller not powered up.
1. Check the hitch controller power supply and clean ground circuits, refer to Section 10002.
SP17.
splice F-SP18.
- Wire 900 Yellow between the fender harness splice F-SP17 and the hitch controller connector.
- Wire 900 Light Green between the fender harness splice F-SP18 and the hitch controller connector.
Error Code 304

Fault Description
The instrument cluster is not receiving information over the CAN bus from the auxiliary/remote valve controller.
Possible Cause
1. Auxiliary/remote valve controller not powered up.
1. Check the auxiliary/remote valve controller power supply and clean ground circuits, refer to Section 10001.
SP17.
splice F-SP18.
- Wire 900 Yellow between the fender harness splice F-SP17 and the auxiliary/remote valve controller
connector.
- Wire 900 Light Green between the fender harness splice F-SP18 and the auxiliary/remote valve
controller connector.
SM 8-12521 Issued 9-2004

SECTION 10009 15
Engine Components
1
MI04D006
1. STARTER MOTOR 4. COOLANT LEVEL SENDER

2. ALTERNATOR 5. AIR FILTER RESTRICTION SWITCH
3. ENGINE CONTROLLER CAN CONNECTOR
SM 8-12521 Issued 9-2004

16 SECTION 10009
Instrument Panel Components
3 4
2
G1
MI04D011
1. FUSE BOX 5. CAN DIAGNOSTIC CONNECTOR

2. INSTRUMENT CLUSTER CONNECTOR C2 6. PROGRAMMING CONNECTOR
3. SWITCHED POWER STUD 7. BATTERY POWER STUD (UNSWITCHED)
4. INSTRUMENT CLUSTER CONNECTOR C1
SM 8-12521 Issued 9-2004

SECTION 10009 17
7
8 G2
1
2
3
4
MI04c167
1. CONNECTOR 26 6. CONNECTOR 52
4. CONNECTOR 29 9. OPERATOR PRESENCE SWITCH CONNECTOR
5. AUDIBLE ALARM
SM 8-12521 Issued 9-2004

18 SECTION 10009
SCHEMATIC CIRCUIT
INSTRUMENT CLUSTER PIN IDENTIFICATION
CONNECTOR C1 CONNECTOR C2
1 NOT USED 1 BATTERY POWER (CLOCK)
2 NOT USED 2 NOT USED
3 TRAILED IMPLEMENT SWITCH 3 NOT USED
4 NOT USED 4 BOOTLOAD (PROGRAMMING)
6 NOT USED 6 AUDIBLE ALARM
7 NOT USED 7 SWITCHED B+
8 FUEL LEVEL 8 NOT USED
9 BOOTLOAD GROUND (PROGRAMMING) 9 NOT USED
10 CAN HIGH 10 NOT USED
11 FRONT PTO 11 COOLANT LEVEL
12 RADAR PRESENT 12 ALTERNATOR D+ WARNING
13 PARK BRAKE WARNING 13 RADAR B+
14 NOT USED 14 CLEAN GROUND
15 NOT USED 15 RADAR SIGNAL
16 NOT USED 16 BOOTLOAD RESET (PROGRAMMING)
17 NOT USED 17 RS232 TX
18 CAN LOW 18 NOT USED
21 1ST TRAILER TURN SIGNAL 21 AIR FILTER RESTRICTION SWITCH
22 RIGHT HAND TURN SIGNAL 22 ENGINE RPM (ALTERNATOR W TERMINAL)
23 NOT USED 23 RS232 RX
24 POSITION LIGHT INDICATOR 24 FRONT LOWER WORK LIGHT WARNING
25 NOT USED 25 REAR LOWER WORK LIGHT WARNING
26 NOT USED 26 ACCESSORY POWER B+
27 2ND TRAILER TURN SIGNAL
28 1000 PTO SWITCH
29 LEFT HAND TURN SIGNAL
30 AIR TRAILER BRAKE PRESSURE
31 HIGH BEAM WARNING
32 NOT USED
33 NOT USED
34 NOT USED
SM 8-12521 Issued 9-2004

SECTION 10009 19
ALTERNATOR, AIR FILTER RESTRICTION, COOLANT LEVEL AND AUDIBLE ALARM RADAR, TRAILED IMPLEMENT SWITCH, 540/1000 PTO SPEED, PARK BRAKE, FUEL LEVEL AND AIR BRAKE PRESSURE
D F T U
10 11
1 2 3 4 12 13 14
G
A C E
B P
H X
V Y
W
A Q
9
15
J
R
5 J
20
7 M
18 19
K
6 G
17
G 16
L J
MI04C10
Key
1. FUSE 37 (7.5 AMP) - LATER PRODUCTION EUROPEAN SPECIFICATION TRACTORS 12. FUSE 39 (7.5 AMP) A. TO SUSPENDED FRONT AXLE CONTROLLER M. FROM ENGINE COLD START RELAYS
FUSE 30 (7.5 AMP) - EARLY PRODUCTION EUROPEAN SPECIFICATION TRACTORS 13. FUSE 27 (7.5 AMP) (REFER TO SECTION 10003) N. FROM AIR CONDITIONING
FUSE 30 - AMERICAN SPECIFICATION TRACTORS 14. FUSE 33 (7.5 AMP) - LATER PRODUCTION TRACTORS B. TO INTERIOR LIGHT/RADIO CLOCK CONTROLLER
2. FUSE 28 (10 AMP) FUSE 37 (7.5 AMP) - EARLY PRODUCTION TRACTORS C. TO CAB SUSPENSION CONTROLLER P. FROM TURN SIGNAL CIRCUIT
3. FUSE 40 (7.5 AMP) 15. TRAILED IMPLEMENT CONNECTOR D. FROM KEY SWITCH TERMINAL 6 Q. FROM LIGHT CIRCUIT
4. FUSE 25 (7.5 AMP) 16. RADAR E. TO RADIO R. FROM FRONT PTO CIRCUIT
5. DIODE 17. PARK BRAKE SWITCH F. FROM KEY SWITCH TERMINAL 5 S. TO CAN BUS CIRCUIT
6. ALTERNATOR 18. AIR TRAILER BRAKE PRESSURE SENDER G. TO ENGINE CONTROLLER T. TO CIGAR LIGHTER
7. AIR FILTER RESTRICTION SWITCH 19. FUEL LEVEL SENDER H. FROM WORK LIGHT CIRCUIT U. TO CAB CONTROLLER (MCC)
8. COOLANT LEVEL SENDER 20. EUROPEAN SPECIFICATION 540/1000 PTO SPEED SWITCH J. TO HITCH CONTROLLER V. TO PTO SWITCH
9. AUDIBLE ALARM K. FROM STARTER MOTOR B+ W. TO AUTO PTO SWITCH
10. PROGRAMMING CONNECTOR L. TO AIR CONDITIONING COMPRESSOR DIODE X. TO OPERATOR PRESENCE SWITCH
11. DIAGNOSTIC CONNECTOR (9 PIN) Y. TO FENDER REMOTE PTO SWITCHES
SM 8-12521 Issued 09-2004

20 SECTION 10009
MI03k001
Key
SM 8-12521 Issued 09-2004

SECTION 10009 21
MAIN CONNECTORS
Connector 10
DI99A036


AND INSTRUMENT CLUSTER 26 281 Y RADAR SIGNAL
27 280 R RADAR B+
29 603 R VP44 POWER (10A)
7 ----- OPEN
30 600 R BATTERY B+ (7.5A)
8 ----- OPEN
32 601 R BATTERY B+ (7.5A)
11 ----- OPEN 34 602 R BATTERY B+ (7.5A)
12 ----- OPEN 35 603 R VP44 POWER (10A)

21 ----- OPEN 45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12521 Issued 9-2004

22 SECTION 10009
477I96 MI04J044

B 707 P LH TAIL/POSITION LIGHT SWITCH
C 708 P RH TAIL/POSITION LIGHT 2 515 R LOADER CONTROLS B+

SWITCHED B+ 5 600 Y BOTTOM OF PEDAL SWITCH
G 784 V REAR FENDER WORK LIGHTS 6 233 Y FUEL LEVEL SENDER
H 810 R SEAT B+ 7 656 BR INCHING PEDAL

SWITCHED B+
10 ----- OPEN
N ----- OPEN
FENDER HARNESS
CONNECTOR (*) OR

UNSWITCHED B+
V ----- OPEN

VP IN

SM 8-12521 Issued 9-2004

SECTION 10009 23
MI04J045 478I96

CONNECTOR KEY SENSING
E 590 R PTO B+
5 (IIC) R IMPLEMENT INTERFACE
CONNECTOR BATTERY B+
6 513 T F/N/R - REVERSE
10 281 Y HITCH RADAR SIGNAL BATTERY B+
11 281 Y RADAR PRESENT K 530 R SUSPENDED FRONT AXLE

SWITCHED B+
L 900 Y CAN HIGH
M 900 LG CAN LOW
P ----- OPEN
R ----- OPEN
W ----- OPEN
SWITCHED B+
Z ----- OPEN
SM 8-12521 Issued 9-2004

24 SECTION 10009

MI04A057 MI04A056

2 ----- OPEN 2 ----- OPEN
5 ----- OPEN DB
5 ----- OPEN
6 ----- OPEN

8 ----- OPEN

14 ----- OPEN 13 280 R RADAR B+

15 ----- OPEN

17 (TX DB RS232 TX
18 900 LG CAN LOW
19 ----- OPEN 18 ----- OPEN
20 ----- OPEN 19 ----- OPEN

20 ----- OPEN

23 (RX DB RS232 RX

27 770 P 2ND TRAILER TURN SIGNAL
32 ----- OPEN
33 ----- OPEN
34 ----- OPEN
SM 8-12521 Issued 9-2004

SECTION 10009 25
Connector 40
MI04A090


BR/W
SENDER
BR/W
H (VP) R VP OUT B+
J 900 Y CAN HIGH
K 900 LG CAN LOW
SWITCHED B+
U ----- OPEN
SM 8-12521 Issued 9-2004

26 SECTION 10009
Connector 51
DI99A036


SWITCHED B+
CONTROLLER VP B+
30 590 R 540/1000 PTO SWITCH B+
9 ----- OPEN
32 ----- OPEN
13 510 T F/N/R B+
INDICATOR LIGHT
43 900 Y CAN HIGH
SWITCHED B+
44 900 LG CAN LOW
CONTROLLER)
24 276 LB 540/1000 PTO SWITCH
SM 8-12521 Issued 9-2004

SECTION 10009 27
Connector 53
DI99A036


32 ----- OPEN
POTENTIOMETER (5V)
9 504 BR HITCH HEIGHT/DEPTH SETTING
34 ----- OPEN
POTENTIOMETER (0V)
GROUND
13 ----- OPEN
38 572 LB RIDE CONTROL ON SIGNAL
39 ----- OPEN
15 (CAT) BR HITCH DIAGNOSTIC LIGHT
40 ----- OPEN
GROUND
16 ----- OPEN
42 ----- OPEN

POTENTIOMETER HIGH
47 ----- OPEN
20 ----- OPEN
48 ----- OPEN
24 ----- OPEN
SM 8-12521 Issued 9-2004

Section
10006
TRANSMISSION AND CAB CONTROLLER
Calibration, Error Codes,
10006
Troubleshooting and Schematics
ZTX Series Tractors

2 SECTION 10006
TABLE OF CONTENTS
SPECIAL TOOLS .....................................................................................................................................................5
GENERAL INFORMATION FOR ELECTRONIC TRANSMISSION CONTROL .......................................................6
TRANSMISSION CALIBRATION .............................................................................................................................8
ERROR CODES GENERAL INFORMATION .........................................................................................................10
CIRCUIT TESTING .................................................................................................................................................12

Transmission Controller Error Codes ................................................................................................................. 13
Error Code 2 ...................................................................................................................................................13
Error Code 3 ...................................................................................................................................................13
Error Code 4 ...................................................................................................................................................13
Error Code 5 ...................................................................................................................................................14
Error Code 6 ...................................................................................................................................................14
Error Code 7 ...................................................................................................................................................14
Error Code 8 ...................................................................................................................................................15
Error Code 9 ...................................................................................................................................................15
Error Code 10 .................................................................................................................................................15
Error Code 11 .................................................................................................................................................16
Error Code 12 .................................................................................................................................................16
Error Code 13 .................................................................................................................................................16
Error Code 14 .................................................................................................................................................17
Error Code 15 .................................................................................................................................................17
Error Code 16 .................................................................................................................................................17
Error Code 17 .................................................................................................................................................18
Error Code 18 .................................................................................................................................................18
Error Code 19 .................................................................................................................................................18
Error Code 20 .................................................................................................................................................19
Error Code 21 .................................................................................................................................................19
Error Code 22 .................................................................................................................................................19
Error Code 23 .................................................................................................................................................20
Error Code 24 .................................................................................................................................................20
Error Code 25 .................................................................................................................................................20
Error Code 26 .................................................................................................................................................21
Error Code 27 .................................................................................................................................................21
Error Code 28 .................................................................................................................................................22
Error Code 29 .................................................................................................................................................22
Error Code 30 .................................................................................................................................................23
Error Code 31 .................................................................................................................................................23
Error Code 32 .................................................................................................................................................24
Error Code 33 .................................................................................................................................................24
Error Code 34 .................................................................................................................................................24
Error Code 35 .................................................................................................................................................25
Error Code 36 .................................................................................................................................................25
Error Code 37 .................................................................................................................................................25
Error Code 38 .................................................................................................................................................26
Error Code 39 .................................................................................................................................................26
Error Code 40 .................................................................................................................................................26
Error Code 41 .................................................................................................................................................27
Error Code 45 .................................................................................................................................................27
Error Code 46 .................................................................................................................................................27
SM 8-12471 Issued 09-2004

SECTION 10006 3
Error Code 49 ................................................................................................................................................28

Error Code 50 ................................................................................................................................................28
Error Code 53 ................................................................................................................................................28
Error Code 54 ................................................................................................................................................28
Error Code 55 ................................................................................................................................................29
Error Code 56 ................................................................................................................................................29
Error Code 57 ................................................................................................................................................29
Error Code 58 ................................................................................................................................................29
Error Code 59 ................................................................................................................................................30
Error Code 60 ................................................................................................................................................30
Error Code 61 ................................................................................................................................................30
Error Code 62 ................................................................................................................................................30
Error Code 63 ................................................................................................................................................31
Error Code 64 ................................................................................................................................................31
Error Code 65 ................................................................................................................................................31
Error Code 66 ................................................................................................................................................31
Error Code 67 ................................................................................................................................................32
Error Code 68 ................................................................................................................................................32
Error Code 69 ................................................................................................................................................32
Error Code 70 ................................................................................................................................................32
Error Code 71 ................................................................................................................................................33
Error Code 72 ................................................................................................................................................33
Error Code 73 ................................................................................................................................................33
Error Code 74 ................................................................................................................................................33
Error Code 75 ................................................................................................................................................34
Error Code 76 ................................................................................................................................................34
Error Code 77 ................................................................................................................................................34
Error Code 78 ................................................................................................................................................35
Error Code 79 ................................................................................................................................................35
Error Code 80 ................................................................................................................................................35
Error Code 81 ................................................................................................................................................35
Error Code 82 ................................................................................................................................................36
Error Code 83 ................................................................................................................................................36
Error Code 84 ................................................................................................................................................36
Error Code 85 ................................................................................................................................................36
Error Code 86 ................................................................................................................................................37
Error Code 87 ................................................................................................................................................37
Error Code 88 ................................................................................................................................................37
Error Code 89 ................................................................................................................................................37
Error Code 90 ................................................................................................................................................38
Error Code 91 ................................................................................................................................................38
Error Code 92 ................................................................................................................................................39
Error Code 93 ................................................................................................................................................40
Error Code 94 ................................................................................................................................................41
Error Code 95 ................................................................................................................................................41
Error Code 96 ................................................................................................................................................41
Error Code 97 ................................................................................................................................................42
Error Code 98 ................................................................................................................................................42
Error Code 99 ................................................................................................................................................42
Error Code 100 ..............................................................................................................................................43
Error Code 101 ..............................................................................................................................................43
Error Code 102 ..............................................................................................................................................43
Error Code 103 ..............................................................................................................................................44
Error Code 104 ..............................................................................................................................................44
Error Code 105 ..............................................................................................................................................44
Error Code 106 ..............................................................................................................................................45
Error Code 107 ..............................................................................................................................................45
Error Code 108 ..............................................................................................................................................45
SM 8-12471 Issued 09-2004

4 SECTION 10006
Error Code 109 ...............................................................................................................................................46

Error Code 110 ...............................................................................................................................................46
Error Code 111 ...............................................................................................................................................46
Error Code 112 ...............................................................................................................................................47
Error Code 113 ...............................................................................................................................................47
Error Code 114 ...............................................................................................................................................48
Error Code 115 ...............................................................................................................................................48
Error Code 116 ...............................................................................................................................................49
Error Code 117 ...............................................................................................................................................49
Error Code 118 ...............................................................................................................................................50
Error Code 119 ...............................................................................................................................................50
Cab Controller (MCC) Error Codes .................................................................................................................... 51
Error Code 121 ...............................................................................................................................................51
Error Code 122 ...............................................................................................................................................51
Error Code 123 ...............................................................................................................................................51
Error Code 124 ...............................................................................................................................................51
Error Code 125 ...............................................................................................................................................52
Error Code 126 ...............................................................................................................................................52
Error Code 128 ...............................................................................................................................................52
Error Code 129 ...............................................................................................................................................52
Error Code 130 ...............................................................................................................................................53
Error Code 131 ...............................................................................................................................................53
Error Code 132 ...............................................................................................................................................53
Error Code 133 ...............................................................................................................................................54
Error Code 134 ...............................................................................................................................................54
Error Code 135 ...............................................................................................................................................54
Error Code 136 ...............................................................................................................................................55
Error Code 137 ...............................................................................................................................................55
Error Code 138 ...............................................................................................................................................55
Error Code 139 ...............................................................................................................................................56
Error Code 140 ...............................................................................................................................................56
Error Code 141 ...............................................................................................................................................56
Error Code 142 ...............................................................................................................................................57
Error Code 143 ...............................................................................................................................................57
Error Code 144 ...............................................................................................................................................57
Error Code 145 ...............................................................................................................................................58
Error Code 146 ...............................................................................................................................................58
Error Code 147 ...............................................................................................................................................58
Error Code 148 ...............................................................................................................................................59
Error Code 149 ...............................................................................................................................................59
Error Code 162 ...............................................................................................................................................59
Transmission Harness Components .................................................................................................................. 65
SCHEMATIC CIRCUITS
Transmission Controller Schematic Circuit ........................................................................................................ 66
Cab Controller (MCC) Schematic Circuit............................................................................................................ 68
CAN Bus Schematic Circuit................................................................................................................................ 70
MAIN CONNECTORS ............................................................................................................................................71
SM 8-12471 Issued 09-2004

SECTION 10006 5
SPECIAL TOOLS
DD98H120 MD04C017
MC2616 MULTIMETER KIT includes: 1025T1 McCORMICK DIAGNOSTIC CENTRE

MC2616-2 TEST LEADS
DD97E383
DD99A051 MC31000B HARNESS REPAIR KIT (EUROPE)

SM 8-12471 Issued 09-2004

6 SECTION 10006
GENERAL INFORMATION FOR ELECTRONIC TRANSMISSION CONTROL

The McCormick cab and transmission controllers together control the correct operation of the transmission. The two
controllers are part of the CAN Bus circuit and information is continually passed between the two controllers.
Cab Controller
The cab controller processes the requests from the operator by monitoring signals directly from the following:
• Forward/Neutral/Reverse /Park switch.
• Gear shift selection switches.
• Inching pedal switches and position potentiometer.
• Rear PTO switch.
• MFD switch.
• Differential Lock switch.
• Auto PTO switch.
The cab controller also receives the following information transmitted over the CAN Bus circuit:
• Engine speed and load.
• Transmission speed.
• True ground speed.
• PTO clutch and output shaft speed.
• Transmission oil temperature.
The cab controller will process the information from the F/N/R/P switch and the gear shift selection switches to
determine the correct gear selection command. Also the cab controller will monitor the engine load to determine the
modulation of the gear change. The gear selection commands will then be transmitted to the Transmission controller
over the CAN Bus circuit.
There are 4 operating modes for the powershift transmission which will be determined by the information received
from the F/N/R/P switch and the gear shift selection switches as follows:
1. Pulse Shifting
When the operator presses and releases the Up shift or Down shift switch buttons the transmission will shift up or
down a single gear. The cab controller will limit the maximum speed at which the requested Up or Down shift will
take place to ensure a smooth gear change.
2. Sequential Shifting
If the operator holds the up or Down shift switch button in continually the transmission will shift up or down one gear
change at a time until the switch is released. As for pulse shifting the cab controller will limit the maximum speed at
which the each gear change will takes place to ensure a smooth gear change.
3. Shuttle Shifting
The operator can change direction (forward to reverse or reverse to forward) without waiting for the tractor to come
to a standstill. If the current speed is above that for the correct engagement speed of the preselected gear the Cab
controller will request a down shift until the correct speed is achieved.
i.e. If the tractor is travelling forward in F13 and a reverse gear selection is made the cab controller will request a
down shift gear change until the correct gear change speed for R5 (preselected and programmed into the controller)
is achieved.
Ground Speed Matching

If the operator presses the inching pedal or selects neutral while the tractor is moving the tractor will begin to slow
down. When the operator selects forward or reverse or release the inching pedal the cab controller will select a gear
which matches the speed of the tractor to ensure a smooth gear take up.
continued....
SM 8-12471 Issued 09-2004

SECTION 10006 7
The cab controller continually monitors the position of the inching pedal and transmits this information to the
transmission controller over the CAN Bus circuit to control the clutch engagement when inching control is required.
The cab controller will calibrate the inching pedal potentiometer as the pedal travels from fully released, to fully
depressed, activating the top of pedal and bottom of pedal switches.
The cab controller monitors the MFD, Differential Lock and PTO switch states. When the operator requests the
engagement or disengagement of these functions the controller transmits this information to the transmission
controller. The cab controller also monitors the engine load and the operator presence switch state.
If the PTO is engaged and the cab controller detects that the operator is not seated for 2 seconds continuously the
CAN Bus message will be transmitted by the cab controller to the instrument cluster. The instrument cluster will then
activate the audible alarm which will sound for 7 seconds or until the operator is seated.
If the seat switch does not change position for 25 hours the PTO controller will assume the seat switch is faulty. The
NEUTRAL lamp will flash and an error code will be stored. The PTO controller will continue to accumulate hours until
the seat switch changes position.
The cab controller also receives CAN Bus engine load information from the engine controller, this information is then
processed then transmitted to the transmission controller, enabling the transmission controller to control the correct
gear selection and clutch engagement modulation depending on engine load.
Transmission Controller
The transmission controller receives requests for gear change, MFD engagement, Differential Lock engagement and
PTO engagement from the Cab controller. Depending on the speed selected, transmission oil temperature and the
load on the engine the transmission controller will then control the engagement of the correct powershift clutch pack
solenoids, refer to “Powershift Clutch/Speed Chart” on page 11, to ensure a smooth gear take up.
The transmission controller also controls the solenoid engagement and disengagement of the Park Lock, MFD, PTO,
PTO Brake and Differential Lock.
The transmission controller also transmits information from the following switches and sensors over the CAN Bus
circuit to the cab controller:
• Park Lock switch.
• Creep engagement switch.
• Transmission oil temperature and pressure switches.
• Transmission oil filter restriction switch.
• Engine speed sensor (transmission input shaft).
• Powershift output shaft speed sensor.
• Powershift intermediate shaft speed sensor (transmission calibration only).
• PTO clutch and output shaft speed sensors.

termination 120 Ohm resistor at each end of the circuit. It is important that these wires remain twisted together and
the termination resistors are connected to reduce any electrical interference that may disrupt the CAN messages.
SM 8-12471 Issued 09-2004

8 SECTION 10006
TRANSMISSION CALIBRATION
IMPORTANT: T h e t r a n s m i s s i o n c a l i b r a t i o n To enter the Transmission Calibration
procedure MUST be carried out with the PARK Mode:
B RA K E E N G AG E D a n d t h e t ra n s m i s s i o n o i l
temperature at 49°C (120°F).
STEP 3
STEP 1
brake and put the F/N/R/P lever in park. Stop the
engine and remove the key.
STEP 2
1
2
3 MI04B011
Start and run the engine at 1300 rpm and press the
menu button . Using the buttons scroll
through the menu to enter the calibration mode. When
the calibration mode has been selected the above
icon will momentarily be displayed on the
instrument cluster.
MI03G056
NOTE: If the instrument cluster continues to
Disconnect the Yellow ‘CAL’ wire connector (1) from display the above icon, stop the engine, check
the Yellow ‘PTO’ wire connector (2) located behind the the calibration connectors and repeat Steps 2
right hand cab steps. Connect the Yellow ‘CAL’ wire and 3.
connector (1) to the Red ‘INT’ wire connector (3).
NOTE: On early production tractors the CAL wire is
Yellow and the connectors can be identified by CAL,
! closed building, proper ventilation is required
PTO and INT marked on the wires. Disconnect the
under all circumstances.
wires CAL to PTO and connect CAL to INT.
SM 8-12471 Issued 09-2004

SECTION 10006 9
STEP 4 STEP 5
MI04B012 MI0A063
When the above icon appears on the instrument Once the calibration is complete the above icon will
cluster fully depress the inching pedal and move the be displayed on the instrument cluster. Press and
Forward/Neutral/Reverse lever to the forward hold the menu button to store the calibration and
position. Release the inching pedal to begin the to return to the main menu. Put the F/N/R/P lever in
transmission calibration. the PARK position, STOP the engine and remove the
key.
WARNING: During calibration the engine
rpm will fluctuate and the tractor may try to STEP 6
move as each clutch is being calibrated.
Some rpm fluctuations and tractor MAKE SURE you return the calibration wire
movements are more severe than others connections, prior to calibration, to there original
! but should be considered normal. Only state.
competent person(s) should carry out this
procedure in a safe area clear of
obstructions and other person(s).
NOTE: To exit the calibration at anytime prior to

completion move Forward/Neutral/Reverse lever
to the neutral position and stop the engine.
SM 8-12471 Issued 09-2004

10 SECTION 10006

NOTE: The instrument cluster can only display current (active) error codes.


! controller and MUST only be retrieved using the ’McCormick
tractor.

ENG - ENGINE
Example:
ENG = ENGINE
MCC = CAB OR TRANSMISSION CONTROLLER
1 = 1 Active Error

138 = Error Code 138 (Cab Controller Error MCC)
If more than one MCC error has been detected, press the button to identify the remaining errors.
For MCC Error Codes refer to the Error Code Troubleshooting Guide in this section.
SM 8-12471 Issued 09-2004

SECTION 10006 11
Powershift Clutch/Speed Chart
SELECTED SPEED CLUTCHES ENGAGED
F1 1, A and L
F2 2, A and L
F3 1, B and L
F4 1, A and M
F5 2, B and L
F6 2, A and M
F7 1, C and L
F8 1, B and M
F9 2, C and L
F10 2, B and M
F11 1, A and H
F12 1, C and M
F13 2, A and H
F14 2, C and M
F15 1, B and H
F16 2, B and H
F17 1, C and H
F18 2, C and H
R1 R, A and L
R2 R, B and L
R3 R, A and M
R4 R, C and L
R5 R, B and M
R6 R, A and H
R7 R, C and M
R8 R, B and H
SM 8-12471 Issued 09-2004

12 SECTION 10006
CIRCUIT TESTING
General Information

switches may occur.
of shor ting between the connector pins or terminals.
made.
SM 8-12471 Issued 09-2004

SECTION 10006 13
Transmission Controller Error Codes
Error Code 2
Fault Description
Current to Clutch ’L’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
4. The maximum supply current to the solenoid valve has been reached by the transmission controller due to
an open or short circuit to ground of the solenoid, feed or return wires.
5. Resistance of the solenoid coil is too high.
1. Check the Clutch ’L’ solenoid feed wire (L) Red and return wire (L) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch ’L’ solenoid coil.
- If the resistance is above 10.1 ohms at 20°C (68° F) replace the solenoid coil.
3. When the fault has been corrected, clear computer neutral state, turn the key on, put the F/N/R/P lever in
PARK then move the lever to Neutral.
Error Code 3
Fault Description
Current to Clutch 'L' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
1. The minimum supply current to the solenoid valve has been reached by the transmission controller due to a
short circuit to 12 volts on the solenoid feed or return wires.
1. With the key ON (Engine Not Running) check the Clutch 'L' solenoid feed wire (L) Red and return wire (L)
Brown for 12 volts.
- If 12 volts is detected check the transmission and fender harnesses for damage.
Error Code 4
Fault Description
Current to Clutch 'M' solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
1. Check the Clutch 'M' solenoid feed wire (M) Red and return wire (M) Brown for open or short circuit to
ground.
2. Check the resistance of the Clutch 'M' solenoid coil.
SM 8-12471 Issued 09-2004

14 SECTION 10006
Error Code 5
Fault Description
Current to Clutch ’M’ solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
short circuit to 12 volts on the solenoid, feed or return wires.
1. With the key ON (Engine Not Running) check the Clutch ’M’ solenoid feed wire (M) Red and return wire (M)
Brown for 12 volts.
- If 12 volts is detected check the transmission harness for damage.
Error Code 6
Fault Description
Current to Clutch ’H’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
1. Check the Clutch ’H’ solenoid feed wire (H) Red and return wire (H) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch ’H’ solenoid coil.
Error Code 7
Fault Description
Current to Clutch 'H' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
2. With the key ON (Engine Not Running) check the Clutch 'H' solenoid feed wire (H) Red and return wire (H)
Brown for 12 volts.
SM 8-12471 Issued 09-2004

SECTION 10006 15
Error Code 8
Fault Description
Current to Clutch ’1’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
1. Check the Clutch ’1’ solenoid feed wire (1) Red and return wire (1) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch ’1’ solenoid coil.
Error Code 9
Fault Description
Current to Clutch '1' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
1. With the key ON check the Clutch '1' solenoid feed wire (1) Red and return wire (1) Brown for 12 volts.
Error Code 10
Fault Description
Current to Clutch '2' solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
1. Check the Clutch '2' solenoid feed wire (2) Red and return wire (2) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch '2' solenoid coil.
SM 8-12471 Issued 09-2004

16 SECTION 10006
Error Code 11
Fault Description
Current to Clutch ’2’ solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
short circuit to 12 volts on the solenoid, feed or ground wires.
1. With the key ON check the Clutch ’2’ solenoid feed wire (2) Red and return wire (2) Brown for 12 volts.
2. When the fault has been corrected, clear computer neutral state (turn the key on, put the F/N/R/P lever in
Error Code 12
Fault Description
Current to Clutch ’R’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
1. Check the Clutch ’R’ solenoid feed wire (R) Red and return wire (R) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch ’R’ solenoid coil.
Error Code 13
Fault Description
Current to Clutch 'R' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
short circuit to 12 volts on the solenoid feed or ground wires in the transmission harness.
1. With the key ON check the Clutch 'R' solenoid feed wire (R) Red and return wire (R) Brown for 12 volts.
SM 8-12471 Issued 09-2004

SECTION 10006 17
Error Code 14
Fault Description
Current to Clutch ’A’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
an open or short circuit to ground of the solenoid feed or ground wires.
1. Check the Clutch ’A’ solenoid feed wire (A) Red and return wire (A) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch ’A’ solenoid coil.
Error Code 15
Fault Description
Current to Clutch 'A' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
1. With the key ON check the Clutch 'A' solenoid feed wire (A) Red and return wire (A) Brown for 12 volts.
Error Code 16
Fault Description
Current to Clutch 'B' solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
an open or short circuit to ground of the solenoid feed or ground wires.
1. Check the Clutch 'B' solenoid feed wire (B) Red and return wire (B) Brown for open or short circuit to ground.
2. Check the resistance of the Clutch 'B' solenoid coil.
SM 8-12471 Issued 09-2004

18 SECTION 10006
Error Code 17
Fault Description
Current to Clutch ’B’ solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
short circuit to 12 volts on the solenoid feed or return wires in the transmission harness.
1. With the key ON check the Clutch ’B’ solenoid feed wire (B) Red and return wire (B) Brown for 12 volts.
Error Code 18
Fault Description
Current to Clutch ’C’ solenoid (Powershift) unable to reach maximum specified current.
Possible Cause
3. Check the Clutch ’C’ solenoid feed wire (C) Red and return wire (C) Brown for open or short circuit to ground.
1. Check the resistance of the Clutch ’C’ solenoid Coil.
Error Code 19
Fault Description
Current to Clutch 'C' solenoid (Powershift) unable to fall to minimum specified current.
Possible Cause
1. With the key ON check the Clutch 'C' solenoid feed wire (C) Red and return wire (C) Brown for 12 volts.
SM 8-12471 Issued 09-2004

SECTION 10006 19
Error Code 20
Fault Description
The transmission controller has received an invalid gear change request from the cab controller.
Possible Cause
1. CAN open or short circuit.
2. Cab controller software problem.
3. Transmission controller software problem.
1. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green between the cab controller and
transmission controller for open or short circuit.
2. Reprogram the transmission controller and calibrate the transmission.
3. Reprogram the cab controller.
4. When the fault has been corrected recalibrate the transmission.
Error Code 21
Fault Description
During calibration of the transmission controller has detected the transmission oil temperature reading is below
the specified temperature of 50°C (120°F).
Possible Cause
1. Transmission oil below 50°C (120°F).
2. Bad transmission temperature sensor circuit.
3. Bad transmission temperature sensor.
1. Heat the transmission oil to the correct temperature and recalibrate the transmission.
2. Check the transmission temperature sensor ground circuit open circuit.
3. Check the transmission temperature sensor feed circuit open circuit or shorting to ground.
4. Check between terminals A and B of the transmission oil temperature sensor connector.
The readings should be as follows:
25°C (77°F) = 2820 OHMS ± 5%
100°C (212°F) = 180 OHMS ± 2.5%
125°C (257°F) = 89 OHMS ± 3%
If the reading is not correct replace the transmission oil temperature sensor.
Error Code 22
Fault Description
During calibration of the transmission controller has detected the engine speed is set above 1300 rpm.
Possible Cause
1. Transmission input shaft speed sensor (engine speed) wiring defective.
2. Bad transmission input shaft speed sensor (engine speed).
1. Calibrate the transmission with the engine speed set at 1250 to 1300 rpm.
2. Check the transmission input shaft speed sensor feed wire (ENG) Yellow and ground wire 483 Brown for
open or short circuit.
3. Check between terminals A and B of the transmission input shaft speed sensor connector.
- A reading of 450 to 550 Ohms should be obtained. If the reading is not correct replace the transmission
input shaft speed sensor, tighten the sensor to a torque of 14 Nm (0.3 lb.ft).
SM 8-12471 Issued 09-2004

20 SECTION 10006
Error Code 23
Fault Description
During calibration of the transmission controller has detected engine speed is set below 1150 rpm.
Possible Cause
1. Transmission input shaft speed sensor (engine speed) wiring open circuit.
1. Calibrate the transmission with the engine speed set at 1250 to 1300 rpm.
open circuit.
Error Code 24
Fault Description
During calibration of the transmission controller has detected transmission output shaft speed is above 100 rpm.
Possible Cause
1. Park lock and park brake not engaged prior to calibration.
2. Park brake not engaged during calibration.
3. Transmission output shaft speed sensor wiring open or short circuit.
4. Bad transmission output shaft speed sensor.
1. Prior to commencing calibration make sure the F/N/R/P lever is in Park the park brake is engaged.
2. Calibrate the transmission with the park brake engaged.
3. Check the transmission output shaft speed sensor feed wire (FWD) Yellow and ground wire 483 Brown open
or short circuit.
4. Check between terminals A and B of the transmission output speed sensor connector.
output speed sensor, tighten the sensor to a torque of 14 Nm (0.3 lb.ft).
Error Code 25
Fault Description
The transmission controller has used default settings during calibration.
Possible Cause
2. Bad Transmission controller.
4. If the error remains replace the transmission controller and calibrate the transmission.
SM 8-12471 Issued 09-2004

SECTION 10006 21
Error Code 26
Fault Description
The transmission controller has detected an invalid rear PTO output shaft speed (pulses per rev).
Possible Cause
1. Incorrect rear PTO output shaft speed sensor installed.
1. Check the resistance between the terminals of the PTO output shaft speed sensor (see table below).
Replace the sensor as necessary.
SENSOR SENSOR
RESISTANCE RESISTANCE
TERMINAL TERMINAL
READING READING
MULTIMETER MULTIMETER
(OHMS) (OHMS)
CONNECTION CONNECTION
+ - - +
1 2 NO CONTINUITY 1 2 NO CONTINUITY
2 3 NO CONTINUITY 2 3 14.3 M OHMS
1 3 14.3 M OHMS 1 3 NO CONTINUITY
Error Code 27
Fault Description
The transmission controller has not detected the speed of the transmission 5th stage (clutch can ’L’) during
phase 1, 2 and 3 of the calibration procedure.
Possible Cause
1. Bad connection of calibration connector.
2. Intermediate (calibration) speed sensor feed and return wiring open or short circuit.
3. Bad Intermediate (calibration) speed sensor.
4. Bad solenoid.
5. Low clutch pressure.
6. Transmission mechanical failure.
7. Bad transmission controller.
1. Check the connection of calibration connector and repair as necessary.
2. Check the Intermediate (calibration) speed sensor feed wire (INT) Red and return wire 483 Brown for open
or short circuit.
3. Check between terminals A and B of the Intermediate (calibration) speed sensor connector.
- A reading of 450 to 550 Ohms should be obtained. If the reading is not correct replace the Intermediate
(calibration) speed sensor, tighten the sensor to a torque of 14 Nm (0.3 lb.ft).
4. Check the resistance of the following Powershift Clutch solenoid coils: ’2’ ’B’, ’C’ and ’R’.
5. Pressure check the Powershift transmission, refer to Service Manual Section 8001.
6. Check for mechanical failure of the Powershift transmission.
SM 8-12471 Issued 09-2004

22 SECTION 10006
Error Code 28
Fault Description
The transmission controller has detected an incorrect forward speed of the transmission 5th stage (powershift
clutch can ’L’) during phase 2 and 3 of the calibration procedure.
Possible Cause
3. Bad solenoid.
or short circuit.
3. Check the resistance of the following clutch solenoid coils: ’2’ ’B’ and ’C’.
4. Pressure check the powershift transmission, refer to Service Manual Section 8001.
5. Check for mechanical failure of the powershift transmission.
Error Code 29
Fault Description
The transmission controller has detected an incorrect reverse speed of the transmission 5th stage (powershift
clutch can 'L') during phase 1 of the calibration procedure.
Possible Cause
3. Bad solenoid.
or short circuit.
3. Check the resistance of the following powershift clutch solenoid coils, 'R' and 'C'.
SM 8-12471 Issued 09-2004

SECTION 10006 23
Error Code 30
Fault Description
The transmission controller has not detected a decrease in speed of the transmission 5th stage (powershift
clutch can ’L’) during phase 4 to 12 of the calibration procedure.
Possible Cause
1. Bad solenoid valve stuck open.
2. Transmission hydraulic failure.
2. Check the solenoid valves corresponding to the stage being calibrated.
- During the calibration phase 4 to 12 the clutches 1, 2, R, A, B, C, L, M and H are pressurised (phase 4
being clutch 1 and phase 12 being clutch H).
Error Code 31
Fault Description
The pressure in the engaging clutch is above 5.1 bar (75 psi).
Possible Cause
1. High powershift system pressure.
2. Bad solenoid valve.
2. Check the solenoid valves corresponding to the stage being calibrated.
- During the calibration phase 4 to 12 the clutches 1, 2, R, A, B, C, L, M and H are pressurised (phase 4
being clutch 1 and phase 12 being clutch H).
SM 8-12471 Issued 09-2004

24 SECTION 10006
Error Code 32
Fault Description
Clutch ’1’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’1’ pressure.
2. Bad Clutch ’1’ solenoid.
2. Check the Clutch ’1’ solenoid valve.
Error Code 33
Fault Description
Clutch ’2’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’2’ pressure.
2. Bad Clutch ’2’ solenoid.
2. Check the Clutch ’2’ solenoid valve.
Error Code 34
Fault Description
Clutch ’R’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’R’ pressure.
2. Bad Clutch ’R’ solenoid.
2. Check the Clutch ’R’ solenoid valve.
SM 8-12471 Issued 09-2004

SECTION 10006 25
Error Code 35
Fault Description
Clutch ’A’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’A’ pressure.
2. Bad Clutch ’A’ solenoid.
2. Check the Clutch ’A’ solenoid valve.
Error Code 36
Fault Description
Powershift Clutch ’B’ fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’B’ pressure.
2. Bad Powershift Clutch solenoid ’B’.
2. Check the Powershift Clutch solenoid valve ’B’.
3. Check for mechanical failure of the Powershift transmission.
Error Code 37
Fault Description
Clutch ’C’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’C’ pressure.
2. Bad Clutch ’C’ solenoid.
2. Check the Clutch ’C’ solenoid valve.
SM 8-12471 Issued 09-2004

26 SECTION 10006
Error Code 38
Fault Description
Clutch ’L’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’L’ pressure.
2. Bad Clutch ’L’ solenoid.
2. Check the Clutch ’L’ solenoid valve.
Error Code 39
Fault Description
Clutch ’M’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’M’ pressure.
2. Bad Clutch ’M’ solenoid.
2. Check the Clutch ’M’ solenoid valve.
Error Code 40
Fault Description
Clutch ’H’ (Powershift) fast fill calibration failed.
Possible Cause
1. Low powershift regulator or Clutch ’H’ pressure.
2. Bad Clutch ’H’ solenoid.
2. Check the Clutch ’H’ solenoid valve.
SM 8-12471 Issued 09-2004

SECTION 10006 27
Error Code 41
Fault Description
The transmission controller has detected clutch slippage.
Possible Cause
1. Prolonged overuse of the inching pedal.
2. Starting in too high a gear for the tractor load.
3. Low system pressure.
4. Bad powershift clutch solenoid valve.
1. Avoid slipping the clutch with the inching pedal.
2. Start in a lower gear.
4. Check the powershift clutch solenoid valves for the gear indicating the fault, e.g. if the fault appeared in
forward speed 8 check solenoid valves ’1’, ’B’ and ’M’, refer to “Powershift Clutch/Speed Chart” on page 11.
Error Code 45
Fault Description
The filtered battery signal is above specified limits.
Possible Cause
Alternator output above 15.5 Volts.
Error Code 46
Fault Description
The filtered battery signal is below specified limits.
Possible Cause
1. Supply Voltage to the transmission controller is below 11 volts.
2. Transmission controller power supply open or short circuit.
2. Check the transmission controller power supply circuit between the fuse 34 and the transmission controller
connector B terminal J.
SM 8-12471 Issued 09-2004

28 SECTION 10006
Error Code 49
Fault Description
Temperature sensor is above specified limits.
Possible Cause
1. Transmission oil temperature too high.
2. The temperature sensor ground wire open circuit.
3. The temperature sensor signal wire open or short circuit.
1. Check the transmission oil cooler and by-pass valve.
2. Check the temperature sensor ground wire 267 Brown for open circuit.
3. Check temperature sensor signal wire 267 Yellow for open circuit or shorting to 12 volts.
Error Code 50
Fault Description
Temperature sensor is below specified limits.
Possible Cause
1. The temperature sensor signal short circuit.
1. Check temperature sensor signal wire 267 Yellow for short circuit to ground.
Error Code 53
Fault Description
Rear PTO solenoid fine control current (current 11) above specified limits.
Possible Cause
1. Rear PTO solenoid return wire short circuit.
1. Check the Rear PTO solenoid return wire (RPTO) Brown for short circuit to 12 volts.
Error Code 54
Fault Description
Rear PTO solenoid fine control current (current 11) below specified limits.
Possible Cause
1. Rear PTO solenoid return wire short circuit.
1. Check the Rear PTO solenoid return wire (RPTO) Red for short circuit to ground.
SM 8-12471 Issued 09-2004

SECTION 10006 29
Error Code 55
Fault Description
Rear PTO Brake solenoid fine control current (current 10) above specified limits.
Possible Cause
1. Rear PTO Brake solenoid return wire short circuit.
1. Check the Rear PTO Brake solenoid return wire 593 Brown for short circuit to 12 volts.
Error Code 56
Fault Description
Rear PTO solenoid fine control current (current 9) below specified limits.
Possible Cause
1. Rear PTO Brake solenoid return wire short circuit.
1. Check the Rear PTO Brake solenoid return wire 593 Brown for short circuit to ground.
Error Code 57
Fault Description
Clutch ’C’ (Powershift) solenoid fine control current (current 9) above specified limits.
Possible Cause
1. Clutch ’C’ solenoid return wire short circuit.
1. Check the Clutch ’C’ solenoid return wire (C) Brown for short circuit to 12 volts.
Error Code 58
Fault Description
Clutch ’C’ (Powershift) solenoid fine control current (current 9) below specified limits.
Possible Cause
1. Clutch ’C’ solenoid return wire short circuit.
1. Check the Clutch ’C’ solenoid return wire (C) Brown for short circuit to ground.
SM 8-12471 Issued 09-2004

30 SECTION 10006
Error Code 59
Fault Description
Clutch ’R’ (Powershift) solenoid fine control current (current 8) above specified limits.
Possible Cause
1. Clutch ’R’ solenoid return wire short circuit.
1. Check the Clutch ’R’ solenoid return wire (R) Brown for short circuit to 12 volts.
Error Code 60
Fault Description
Clutch ’R’ (Powershift) solenoid fine control current (current 8) below specified limits.
Possible Cause
1. Clutch ’R’ solenoid return wire short circuit.
1. Check the Clutch ’R’ solenoid return wire (R) Brown for short circuit to ground.
Error Code 61
Fault Description
Clutch ’A’ (Powershift) solenoid fine control current (current 7) above specified limits.
Possible Cause
1. Clutch ’A’ solenoid return wire short circuit.
1. Check the Clutch ’A’ solenoid return wire (A) Brown for short circuit to 12 volts.
Error Code 62
Fault Description
Clutch ’A’ (Powershift) solenoid fine control current (current 7) below specified limits.
Possible Cause
1. Clutch ’A’ solenoid return wire short circuit.
1. Check the Clutch ’A’ solenoid return wire (A) Brown for short circuit to ground.
SM 8-12471 Issued 09-2004

SECTION 10006 31
Error Code 63
Fault Description
Clutch ’2’ (Powershift) solenoid fine control current (current 6) above specified limits.
Possible Cause
1. Clutch ’2’ solenoid return wire short circuit.
1. Check the Clutch ’2’ solenoid return wire (2) Brown for short circuit to 12 volts.
Error Code 64
Fault Description
Clutch ’2’ (Powershift) solenoid fine control current (current 6) below specified limits.
Possible Cause
1. Check the Clutch ’2’ solenoid return wire (2) Brown for short circuit to ground.
Error Code 65
Fault Description
Clutch ’B’ (Powershift) solenoid fine control current (current 5) above specified limits.
Possible Cause
1. Clutch ’B’ solenoid return wire short circuit.
1. Check the Clutch ’B’ solenoid return wire (B) Brown for short circuit to 12 volts.
Error Code 66
Fault Description
Clutch ’B’ (Powershift) solenoid fine control current (current 5) below specified limits.
Possible Cause
1. Clutch ’B’ solenoid return wire short circuit.
1. Check the Powershift Clutch ’B’ solenoid return wire (B) Brown for short circuit to ground.
SM 8-12471 Issued 09-2004

32 SECTION 10006
Error Code 67
Fault Description
Clutch ’1’ (Powershift) solenoid fine control current (current 4) above specified limits.
Possible Cause
1. Check the Clutch ’1’ solenoid return wire (1) Brown for short circuit to 12 volts.
Error Code 68
Fault Description
Clutch ’1’ (Powershift) solenoid fine control current (current 4) below specified limits.
Possible Cause
1. Check the Clutch ’1’ solenoid return wire (1) Brown for short circuit to ground.
2. Replace the transmission controller.
Error Code 69
Fault Description
Differential lock solenoid fine control current (current 3) above specified limits.
Possible Cause
1. Differential lock solenoid return wire short circuit.
1. Check the Differential lock solenoid return wire (DIFF) Brown for short circuit to 12 volts.
Error Code 70
Fault Description
Differential lock solenoid fine control current (current 3) below specified limits.
Possible Cause
1. Differential lock solenoid return wire short circuit.
1. Check the Differential lock solenoid return wire (DIFF) Brown for short circuit to ground.
SM 8-12471 Issued 09-2004

SECTION 10006 33
Error Code 71
Fault Description
Clutch ’M’ (Powershift) solenoid fine control current (current 2) above specified limits.
Possible Cause
1. Clutch ’M’ solenoid return wire short circuit.
1. Check the Clutch ’M’ solenoid return wire (M) Brown for short circuit to 12 volts.
Error Code 72
Fault Description
Clutch ’M’ (Powershift) solenoid fine control current (current 2) below specified limits.
Possible Cause
1. Clutch ’M’ solenoid return wire short circuit.
1. Check the Clutch ’M’ solenoid return wire (M) Brown for short circuit to ground.
Error Code 73
Fault Description
Clutch ’H’ (Powershift) solenoid fine control current (current 1) above specified limits.
Possible Cause
1. Clutch ’H’ solenoid return wire short circuit.
1. Check the Clutch ’H’ solenoid return wire (H) Brown for short circuit to 12 volts.
Error Code 74
Fault Description
Clutch ’H’ (Powershift) solenoid fine control current (current 1) below specified limits.
Possible Cause
1. Clutch ’H’ solenoid return wire short circuit.
1. Check the Clutch ’H’ solenoid return wire (H) Brown for short circuit to ground.
SM 8-12471 Issued 09-2004

34 SECTION 10006
Error Code 75
Fault Description
Clutch ’L’ (Powershift) solenoid fine control current (current 0) above specified limits.
Possible Cause
1. Clutch ’L’ solenoid return wire short circuit.
1. Check the Clutch ’L’ solenoid return wire (L) Brown for short circuit to 12 volts.
Error Code 76
Fault Description
Clutch ’L’ (Powershift) solenoid fine control current (current 0) below specified limits.
Possible Cause
1. Clutch ’L’ solenoid return wire short circuit.
1. Check the Clutch ’L’ solenoid return wire (L) Brown for short circuit to ground.
Error Code 77
Fault Description
Loss of CAN message.
Possible Cause
1. Bad CAN circuit.
2. Bad CAN termination resistor(s).
3. Bad Cab controller.
1. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green for open or short circuit.
2. Check the termination resistor connectors.
3. Check the resistance of the termination resistors.
4. Reprogram the cab controller and calibrate the transmission.
5. If the error remains replace the cab controller and calibrate the transmission.
SM 8-12471 Issued 09-2004

SECTION 10006 35
Error Code 78
Fault Description
CAN Bus off.
Possible Cause
1. Bad CAN circuit.
1. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green for open or short circuit.
Error Code 79
Fault Description
Missing CAN message.
Possible Cause
1. CAN circuit open circuit or short circuit.
2. Transmission controller switched power circuit shorted to unswitched battery power.
1. Check the CAN high wire 900 yellow and CAN low wire 900 Light Green for open circuit between the cab and
transmission controllers.
2. Check the transmission controller switch power circuit for shorting to 12 volts with the key in the OFF
position.
Error Code 80
Fault Description
Checksum error in serial EEPROM.
Possible Cause
Error Code 81
Fault Description
Unrecoverable checksum error in serial EEPROM.
Possible Cause
SM 8-12471 Issued 09-2004

36 SECTION 10006
Error Code 82
Fault Description
Transmission hour meter majority rule error.
Possible Cause
1. Turn the key to the OFF position then back to the ON position.
Error Code 83
Fault Description
Unrecoverable Transmission hour meter majority rule error.
Possible Cause
1. Turn the key to the OFF position then back to the ON position.
Error Code 84
Fault Description
Transmission hour meter tenths, majority rule error.
Possible Cause
1. Turn the key to the OFF position then back to the ON position and cycle the inching pedal.
Error Code 85
Fault Description
Unrecoverable Transmission hour meter tenths majority rule error.
Possible Cause
1. Turn the key to the OFF position then back to the ON position and cycle the inching pedal.
SM 8-12471 Issued 09-2004

SECTION 10006 37
Error Code 86
Fault Description
The transmission controller has detected low powershift transmission oil pressure.
Possible Cause
1. Low powershift transmission oil pressure.
2. Powershift transmission oil pressure switch circuit short circuit to ground.
3. Bad powershift transmission 17 bar oil pressure switch.
1. Check the powershift transmission oil pressure, refer to Section 8001.
2. Check the powershift transmission oil pressure switch signal wire (17R) Yellow for short circuit to ground.
3. Check the powershift transmission 17 bar oil pressure switch and replace as necessary.
Error Code 87
Fault Description
The transmission controller has detected low transmission oil pressure.
Possible Cause
1. Low transmission oil pressure.
2. Transmission oil pressure switch circuit short circuit to ground.
3. Bad transmission oil 17 bar pressure switch.
1. Check the transmission oil pressure, refer to Section 8001.
2. Check the transmission oil pressure switch signal wire (17G) Yellow for short circuit to ground.
3. Check the transmission 17 bar oil pressure switch and replace as necessary.
Error Code 88
Fault Description
Transmission controller programming error.
Possible Cause
1. Reprogramming procedure attempted with the engine running.
1. Stop the engine, turn the key ON and reprogram the transmission controller.
2. Calibrate the transmission.
Error Code 89
Fault Description
Transmission controller low side stuck off.
Possible Cause
SM 8-12471 Issued 09-2004

38 SECTION 10006
Error Code 90
Fault Description
The transmission controller has not detected a PTO clutch speed signal.
Possible Cause
1. PTO Clutch speed sensor circuit open or short circuit.
2. Bad PTO clutch speed sensor.
1. Check the transmission calibration connector.
2. Check the PTO clutch speed sensor adjustment, refer to Section 9001.
3. Check between terminals A and B of the PTO clutch speed sensor connector.
- A reading of 405 to 495 Ohms should be obtained. If the reading is not correct replace and adjust the PTO
clutch speed sensor, refer to Section 9001.
4. Check the PTO speed sensor signal wires (CAL) Yellow and (PTO) Yellow for open circuit between the PTO
speed sensor and the transmission controller.
5. Check the PTO speed sensor ground wire 483 Brown for open circuit between the PTO speed sensor and
splice T-SP3.
6. Check the PTO speed sensor signal wires (CAL) Yellow and (PTO) Yellow for short circuit to 12 volts.
7. Check the PTO speed sensor signal wires (CAL) Yellow and (PTO) Yellow for short circuit to ground.
8. Check the PTO speed sensor ground wire 483 Brown for short circuit to 12 volts.
Error Code 91
Fault Description
The transmission controller has not detected the engine speed signal.
Possible Cause
1. Transmission input shaft speed sensor (engine speed) circuit open or short circuit.
3. Transmission input shaft mechanical failure.
1. Check the transmission input shaft speed sensor signal wire (ENG) yellow and ground wire 483 Brown for
open circuit between the transmission input shaft speed sensor and the transmission controller.
2. Check the transmission input shaft speed sensor signal wire (ENG) yellow for short circuit to 12 volts.
3. Check the transmission input shaft speed sensor signal wire (ENG) yellow for short circuit to ground.
4. Check the transmission input shaft speed sensor ground wire 483 Brown for short circuit to 12 volts.
6. Check for mechanical failure.
SM 8-12471 Issued 09-2004

SECTION 10006 39
Error Code 92
Fault Description
The engine speed drops 50% when the PTO is engaged.
Possible Cause
1. Load on PTO too high.
2. PTO clutch and output shaft speed sensors open circuit.
3. PTO clutch speed sensor out of adjustment.
4. Low PTO clutch oil pressure.
1. STOP the tractor and check the implement attached to the PTO shaft is not seized or damaged.
2. Reduce the load on the PTO.
3. Check the PTO clutch oil pressure; refer to Service Manual Section 8001.
SENSOR SENSOR
TERMINAL TERMINAL
READING READING
(OHMS) (OHMS)
+ - - +
7. Check the PTO clutch speed sensor signal wire (PTO) Yellow and ground wire 483 Brown for open circuit
between the transmission controller and the PTO clutch speed sensor.
8. Check the PTO output shaft speed sensor feed wire 550 Red, signal wire 224 Yellow and ground wire (PTO)
Brown for open circuit.
SM 8-12471 Issued 09-2004

40 SECTION 10006
Error Code 93
Fault Description
The transmission controller has detected PTO clutch slippage.
Possible Cause
1. Load on PTO too high.
2. Low PTO clutch oil pressure.
3. PTO clutch and output shaft speed sensors open circuit.
4. PTO clutch speed sensor out of adjustment.
1. STOP the tractor and check the implement attached to the PTO shaft is not seized or damaged.
2. Reduce the load on the PTO.
3. Check the PTO clutch oil pressure; refer to Service Manual Section 8001.
SENSOR SENSOR
TERMINAL TERMINAL
READING READING
(OHMS) (OHMS)
+ - - +
7. Check the PTO clutch speed sensor signal wire (PTO) Yellow and ground wire 483 Brown for open circuit
between the transmission controller and the PTO clutch speed sensor.
8. Check the PTO output shaft, speed sensor feed wire 550 Red, signal wire 224 Yellow and ground wire (PTO)
Brown for open circuit.
SM 8-12471 Issued 09-2004

SECTION 10006 41
Error Code 94
Fault Description
PTO shaft continues to turn when the PTO is disengaged.
Possible Cause
1. High inertia implement connected to the PTO.
2. PTO brake not engaging.
3. PTO brake solenoid feed and return wires open circuit.
4. Bad PTO solenoid valve.
5. Bad PTO brake solenoid valve.
6. PTO brake mechanical failure.
1. Stop the engine, disconnect the implement and check the PTO shaft stops when the PTO is disengaged.
2. Check the PTO clutch oil pressure.
3. Check the PTO brake oil pressure.
4. Check the PTO brake feed and return wires for open circuit between the transmission controller and the PTO
brake solenoid.
5. Check the PTO clutch solenoid valve is not stuck open.
6. Check the PTO clutch solenoid valve is not stuck closed.
7. Check for mechanical failure of the PTO brake.
Error Code 95
Fault Description
The transmission regulated oil pressure is below 9 bar (130.5 psi) for more than 2 seconds.
Possible Cause
1. Low transmission regulated oil pressure.
2. Transmission 17 bar oil pressure switch signal wire short to ground.
3. Bad 17 bar oil pressure switch.
1. Check the transmission regulated oil pressure, refer to Section 8001.
2. Check the transmission 17 bar oil pressure switch signal wire (17R) Yellow for short circuit to ground.
3. Check the transmission 17 bar oil pressure switch.
Error Code 96
Fault Description
The PTO solenoid still receiving current after the transmission controller has deactivated the PTO.
Possible Cause
1. Rear PTO circuit shorted to 12 Volts.
1. Disconnect connector B from the transmission controller, turn the key ON and check for 12 volts at terminal
G. If 12 Volts is detected check wire (RPTO) Red for damage between the transmission controller and the
rear PTO solenoid.
SM 8-12471 Issued 09-2004

42 SECTION 10006
Error Code 97
Fault Description
The transmission controller has detected PTO solenoid over voltage.
Possible Cause
1. Battery voltage over 16 volt.
Error Code 98
Fault Description
The Park Lock switch indicates the Park Lock is engaged when the transmission controller has disengaged the
Park Lock.
Possible Cause
1. Park Lock solenoid ground wire open circuit.
2. Park Lock solenoid feed wire short circuit to 12 volts.
3. Bad Park Lock solenoid valve.
4. Park Lock indicator switch feed wire short to ground.
5. Park Lock indicator switch ground wire open circuit.
6. Bad Park Lock indicator switch.
7. Mechanical failure of the Park Lock.
1. Check the Park Lock solenoid ground wire (LOCK) Brown for open circuit.
2. Check the Park Lock solenoid feed wire (LOCK) Red for short circuit to ground.
3. Check the Park Lock solenoid feed wire (LOCK) Red for short circuit to 12 volts.
4. Check the Park Lock solenoid.
5. Check the Park Lock indicator switch feed wire 254 Yellow for short to ground.
6. Check the Park Lock indicator switch ground wire 254 Brown for open circuit.
7. Check the Park Lock indicator switch.
8. Check for mechanical failure of the park lock.
Error Code 99
Fault Description
The Park Lock switch does not change state when the Park Lock is disengaged.
Possible Cause
1. Park is engaged.
2. Park Lock indicator switch circuit open or short circuit.
1. Disengage the park brake.
2. Check the Park Lock indicator switch feed wire 254 Yellow for short circuit to ground.
SM 8-12471 Issued 09-2004

SECTION 10006 43
Error Code 100

Fault Description
The MFD actuator has detected an error.
Possible Cause
1. MFD solenoid circuit open or short circuit.
1. Check the MFD solenoid feed wire (4WD) Red for open circuit.
2. Check the MFD solenoid ground wire 543 Brown for open circuit.
3. Check the MFD solenoid feed wire (4WD) Red for short circuit to 12 volts.
Error Code 101

Fault Description
Low pressure detected during Clutch ’1’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’1’ oil pressure.
2. Bad Clutch ’1’ solenoid valve.
1. Check the Clutch ’1’ oil pressure, refer to Section 8001.
2. Check the Clutch ’1’ solenoid valve and o-rings.
3. Check for transmission mechanical failure.
Error Code 102

Fault Description
Low pressure detected during Clutch ’2’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’2’ oil pressure.
2. Bad Clutch ’2’ solenoid valve.
1. Check the Clutch ’2’ oil pressure, refer to Section 8001.
2. Check the Clutch ’2’ solenoid valve and o-rings.
SM 8-12471 Issued 09-2004

44 SECTION 10006
Error Code 103

Fault Description
Low pressure detected during Clutch ’R’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’R’ oil pressure.
2. Bad Clutch ’R’ solenoid valve.
1. Check the Clutch ’R’ oil pressure, refer to Section 8001.
2. Check the Clutch R solenoid valve and o-rings.
Error Code 104

Fault Description
Low pressure detected during Clutch ’A’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’A’ oil pressure.
2. Bad Clutch ’A’ solenoid valve.
1. Check the Clutch ’A’ oil pressure, refer to Section 8001.
2. Check the Clutch ’A’ solenoid valve and o-rings.
Error Code 105

Fault Description
Low pressure detected during Clutch ’B’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’B’ oil pressure.
2. Bad Clutch ’B’ solenoid valve.
1. Check the Clutch ’B’ oil pressure, refer to Section 8001.
2. Check the Clutch ’B’ solenoid valve and o-rings.
SM 8-12471 Issued 09-2004

SECTION 10006 45
Error Code 106

Fault Description
Low pressure detected during Clutch ’C’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’C’ oil pressure.
2. Bad Clutch ’C’ solenoid valve.
1. Check the Clutch ’C’ oil pressure, refer to Section 8001.
2. Check the Clutch ’C’ solenoid valve and o-rings.
Error Code 107

Fault Description
Low pressure detected during Clutch ’L’ (Powershift) hold calibration.
Possible Cause
1. Low transmission oil pressure.
2. Bad Clutch ’L’ solenoid valve.
1. Check the Clutch ’L’ oil pressure, refer to Section 8001.
2. Check the Clutch ’L’ solenoid valve and o-rings.
Error Code 108

Fault Description
Low pressure detected during Clutch ’M’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’M’ oil pressure.
2. Bad Clutch ’M’ solenoid valve.
1. Check the Clutch ’M’ oil pressure, refer to Section 8001.
2. Check the Clutch ’M’ solenoid valve and o-rings.
SM 8-12471 Issued 09-2004

46 SECTION 10006
Error Code 109

Fault Description
Low pressure detected during Clutch ’H’ (Powershift) hold calibration.
Possible Cause
1. Low Clutch ’H’ oil pressure.
2. Bad Clutch ’H’ solenoid valve.
1. Check the Clutch ’H’ oil pressure, refer to Section 8001.
2. Check the Clutch ’H’ solenoid valve and o-rings.
Error Code 110

Fault Description
Solenoid low side driver stuck on.
Possible Cause
1. One of the transmission controller solenoid circuits shorted to ground.
1. Check the Powershift Clutch, rear PTO, PTO brake and differential lock solenoid feed and ground circuits for
short circuit to ground.
Error Code 111

Fault Description
Clutch ’1’ (powershift) duty cycle against current test failed.
Possible Cause
1. Resistance in the solenoid circuit too high due to poor connections or damaged harness.
2. Clutch ’1’ solenoid short circuit to ground or 12 volts.
3. Bad solenoid coil.
1. Check the Clutch ’1’ solenoid feed wire (1) Red and return wire (1) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch ’1’ solenoid feed wire (1) Red and return wire (1)
Brown for 12 volts.
3. Check the resistance of the Clutch ’1’ solenoid feed wire (1) Red and return wire (1) Brown.
- If the resistance is too high check the transmission harness for damage.
SM 8-12471 Issued 09-2004

SECTION 10006 47
Error Code 112

Fault Description
Clutch ’2’ (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch ’2’ solenoid short circuit to ground or 12 volts.
1. Check the Clutch ’2’ solenoid feed wire (2) Red and return wire (2) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch ’2’ solenoid feed wire (2) Red and return wire (2)
Brown for 12 volts.
3. Check the resistance of the Clutch ’2’ solenoid feed and return wire (2) Brown.
Error Code 113

Fault Description
Clutch 'R' (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch 'R' solenoid short circuit to ground or 12 volts.
1. Check the Clutch 'R' solenoid feed wire (R) Red and return wire (R) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch 'R' solenoid feed wire (R) Red and return wire (R)
Brown for 12 volts.
3. Check the resistance of the Clutch 'R' solenoid feed wire (R) Red and return wire (R) Brown.
4. Check the resistance of the Clutch 'R' solenoid coil.
SM 8-12471 Issued 09-2004

48 SECTION 10006
Error Code 114

Fault Description
Clutch ’A’ (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch ’A’ solenoid short circuit to ground or 12 volts.
1. Check the Clutch ’A’ solenoid feed wire (A) Red and return wire (A) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch ’A’ solenoid feed wire (A) Red and return wire (A)
Brown for 12 volts.
3. Check the resistance of the Clutch ’A’ solenoid feed wire (A) Red and return wire (A) Brown.
4. Check the resistance of the Clutch ’A’ solenoid coil.
Error Code 115

Fault Description
Clutch 'B' (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch 'B' solenoid short circuit to ground or 12 volts.
1. Check the Clutch 'B' solenoid feed wire (B) Red and return wire (B) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch 'B' solenoid feed wire (B) Red and return wire (B)
Brown for 12 volts.
- If 12 volts is detected check the transmission harnesses for damage.
3. Check the resistance of the Clutch 'B' solenoid feed wire (B) Red and return wire (B) Brown.
- If the resistance is too high check the transmission harnesses for damage.
4. Check the resistance of the Clutch 'B' solenoid coil.
SM 8-12471 Issued 09-2004

SECTION 10006 49
Error Code 116

Fault Description
Clutch ’C’ (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch ’C’ solenoid short circuit to ground or 12 volts.
1. Check the Clutch ’C’ solenoid feed wire (C) Red and return wire (C) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch ’C’ solenoid feed wire (C) Red and return wire (C)
Brown for 12 volts.
3. Check the resistance of the Clutch ’C’ solenoid feed wire (C) Red and return wire (C) Brown.
4. Check the resistance of the Clutch ’C’ solenoid coil.
Error Code 117

Fault Description
Clutch 'L' (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch 'L' solenoid short circuit to ground or 12 volts.
1. Check the Clutch 'L' solenoid feed wire (L) Red and return wire (L) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch 'L' solenoid feed wire (L) Red and return wire (L)
Brown for 12 volts.
3. Check the resistance of the Clutch 'L' solenoid feed wire (L) Red and return wire (L) Brown.
4. Check the resistance of the Clutch 'L' solenoid coil.
SM 8-12471 Issued 09-2004

50 SECTION 10006
Error Code 118

Fault Description
Clutch ’M’ (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch ’M’ solenoid short circuit to ground or 12 volts.
1. Check the Clutch ’M’ solenoid feed wire (M) Red and return wire (M) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch ’M’ solenoid feed wire (M) Red and return wire (M)
Brown for 12 volts.
3. Check the resistance of the Clutch ’M’ solenoid feed wire (M) Red and return wire (M) Brown.
4. Check the resistance of the Clutch ’M’ solenoid coil.
Error Code 119

Fault Description
Clutch 'H' (powershift) duty cycle against current test failed.
Possible Cause
2. Clutch 'H' solenoid short circuit to ground or 12 volts.
1. Check the Clutch 'H' solenoid feed wire (H) Red and return wire (H) Brown for open or short circuit ground.
2. With the key ON (Engine Not Running) check the Clutch 'H' solenoid feed wire (H) Red and return wire (H)
Brown for 12 volts.
3. Check the resistance of the Clutch 'H' solenoid feed wire (H) Red and return wire (H) Brown.
4. Check the resistance of the Clutch 'H' solenoid coil.
SM 8-12471 Issued 09-2004

SECTION 10006 51
Cab Controller (MCC) Error Codes
Error Code 121

Fault Description
The filtered battery signal is above specified limits.
Possible Cause
1. Alternator output above 16 Volts.
Error Code 122

Fault Description
The filtered battery signal is below specified limits.
Possible Cause
1. Supply Voltage to the cab controller is below 11 volts.
Error Code 123

Fault Description
The F/N/R/P switch forward signal is below specified limits.
Possible Cause
1. The forward signal wire open or short circuit to ground.
1. Check the forward signal circuit (wires 511 Tan) between the F/N/R/P switch and the cab controller for open
circuit.
2. Check the forward signal circuit (wires 511 Tan) between the F/N/R/P switch and the cab controller for short
circuit to ground circuit.
Error Code 124

Fault Description
The F/N/R/P switch forward signal is above specified limits.
Possible Cause
1. The forward signal circuit short circuit to voltage above 5 volts.
1. Check the forward signal circuit (wires 511 Tan) between the F/N/R/P switch and the cab controller for short
circuit to voltage above 5 volts.
SM 8-12471 Issued 09-2004

52 SECTION 10006
Error Code 125

Fault Description
The inching pedal potentiometer signal is below specified limits.
Possible Cause
1. The inching pedal potentiometer signal wire open or short circuit to ground.
1. Check the inching pedal potentiometer signal circuit (wires 656 Yellow) between the inching pedal
potentiometer and the cab controller for open circuit.
potentiometer and the cab controller for short circuit to ground circuit.
Error Code 126

Fault Description
The inching pedal potentiometer signal is above specified limits.
Possible Cause
1. The inching pedal potentiometer signal wire short circuit to voltage above 5 volts.
potentiometer and the cab controller for short circuit to voltage above 5 volts.
Error Code 128

Fault Description
The cab controller has received a CAN engine speed message of 0 rpm from the transmission controller while
receiving an engine oil pressure message higher than 0.7 bar (10 psi).
Possible Cause
1. Transmission input shaft speed sensor (engine speed) wiring defective.
open or short circuit.
Error Code 129

Fault Description
The cab controller has received a CAN engine speed message above 4000 rpm.
Possible Cause
SM 8-12471 Issued 09-2004

SECTION 10006 53
Error Code 130

Fault Description
The cab controller detects 12 volts on the top of pedal inching pedal switch circuit when the inching pedal is
depressed.
Possible Cause
1. The top of pedal inching pedal switch out of adjustment.
2. Bad top of inching pedal switch.
3. The top of pedal inching pedal switch short circuit to 12 volts.
1. Check the top of pedal inching pedal switch adjustment.
2. Check for continuity across the top of pedal inching pedal switch terminals with the inching pedal held down.
- If continuity is detected replace the switch.
3. With the inching pedal held down check the signal circuit (wires 657 Yellow) between the top of pedal inching
pedal switch and the cab controller for short circuit to 12 volts.
Error Code 131

Fault Description
The cab controller detects 12 volts on the bottom of pedal inching pedal switch circuit when the inching pedal is
released.
Possible Cause
1. The bottom of pedal inching pedal switch out of adjustment.
2. Bad bottom of pedal inching pedal switch.
3. Bad bottom of clutch relay.
4. The bottom of pedal inching pedal switch short circuit to 12 volts.
1. Check the bottom of pedal inching pedal switch adjustment.
2. Check for continuity across the bottom of pedal inching pedal switch terminals with the inching pedal held
down. - If continuity is detected replace the switch.
3. With the inching pedal held down check the signal circuit (wires 660 Yellow) between the inching pedal
switch and the bottom of pedal relay for short circuit to 12 volts.
4. With the bottom of pedal relay removed the inching pedal held down, check the signal circuit (wires 653 Red)
between the bottom of pedal relay and the cab controller for short circuit to 12 volts.
Error Code 132

Fault Description
Cab controller-programming error.
Possible Cause
1. Reprogramming procedure attempted with the engine running.
1. Stop the engine, turn the key ON and reprogram the cab controller.
SM 8-12471 Issued 09-2004

54 SECTION 10006
Error Code 133

Fault Description
CAN Bus off.
Possible Cause
1. CAN high or CAN low wires open circuit.
2. CAN high and CAN low wires shorted together.
3. CAN High or CAN low wires shorted to ground or another circuit.
5. Another controller connected to the CAN Bus is not programmed correctly.
1. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green for open circuit.
2. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green for short circuit to ground or another
circuit.
5. Disconnect each controller in turn that is connected to the CAN Bus circuit to isolate the faulty controller.
Error code 133 will no longer be displayed when the faulty controller is disconnected (other CAN errors may
be displayed). Reprogram the faulty isolated controller.
Error Code 134

Fault Description
Loss of CAN message.
Possible Cause
1. CAN circuit open circuit.
3. Check the CAN high and CAN low wires for short circuit to ground or another circuit.
4. Check the CAN high and CAN low wires for short circuit to ground or another circuit.
Error Code 135

Fault Description
The cab controller has received a CAN transmission output speed message above 4000 rpm.
Possible Cause
1. Bad transmission output speed sensor.
1. Check between terminals A and B of the transmission output speed sensor connector.
output speed sensor, tighten the sensor to a torque of 14 Nm (0.3 lb.ft).
SM 8-12471 Issued 09-2004

SECTION 10006 55
Error Code 136

Fault Description
Engine hour meter majority rule error.
Possible Cause
1. Cab controller has detected an engine hour meter error.
2. If the error remains replace the cab controller.
Error Code 137

Fault Description
Checksum error in serial EEPROM.
Possible Cause
2. Cab controller hardware problem.
1. Reprogram the cab controller.
2. Replace the cab controller.
Error Code 138

Fault Description
Normal CAN communications with the transmission controller has failed.
Possible Cause
1. Damaged PTO output shaft speed sensor harness (feed wire short circuit to ground).
2. Transmission controller switched power open circuit.
3. Bad CAN circuit between the transmission controller and the cab controller.
1. Check fuse 34, if fuse 34 is OK go to check 3.
2. Check the PTO output shaft speed sensor harness for damage. Replace fuse 34.
3. Check the transmission controller switched power wire 500 Red for open circuit.
4. Check the CAN high wire 900 Yellow and CAN low wire 900 Light Green for open circuit between the
transmission controller and the cab controller.
circuit.
SM 8-12471 Issued 09-2004

56 SECTION 10006
Error Code 139

Fault Description
The cab controller does not detect 12 volts on the inching pedal (top of clutch) switch circuit when the inching
pedal is released.
Possible Cause
1. The top of pedal inching pedal switch out of adjustment.
2. Bad top of pedal inching pedal switch.
3. Bad inching pedal potentiometer.
4. Top of pedal Inching pedal switch open circuit.
5. Top of pedal Inching pedal switch short circuit to ground.
1. Check fuse 5.
2. Check the top of pedal inching pedal switch adjustment.
3. Check for continuity across the top of pedal inching pedal switch terminals with the inching pedal released.
- If continuity is not detected replace the switch.
4. Check the circuit (wires 657 Red) between fuse 5 and the top of pedal inching pedal switch.
5. Check the operation of the inching pedal potentiometer.
6. Check the top of pedal inching pedal switch signal wires (657 Yellow) for open circuit.
7. Check the top of pedal inching pedal switch signal wires (657 Yellow) for short circuit to ground.
Error Code 140

Fault Description
F/N/R/P shift lever switch out of neutral error.
When the F/N/R/P lever is out of neutral the cab controller detects the F/N/R/P switch is in neutral.
Possible Cause
1. Bad the F/N/R/P switch.
2. Forward, neutral or reverse wires open circuit between the F/N/R/P switch and the cab controller.
1. Check the F/N/R/P switch.
2. Check the forward, neutral and reverse circuits for continuity between the F/N/R/P switch and the cab
controller.
Error Code 141

Fault Description
F/N/R/P shift lever switch out of neutral error.
When the F/N/R/P lever is in neutral the cab controller detects the F/N/R/P switch is out of neutral.
Possible Cause
1. Bad the F/N/R/P switch.
2. Forward, neutral or reverse wires open circuit between the F/N/R/P switch and the cab controller.
1. Check the F/N/R/P switch.
2. Check the forward, neutral and reverse circuits for continuity b between the F/N/R/P switch and the cab
controller.
SM 8-12471 Issued 09-2004

SECTION 10006 57
Error Code 142

Fault Description
The cab controller has not received an engine load CAN message from the engine controller in the specified
time.
Possible Cause
1. Bad CAN circuit between the engine controller and the cab controller.
4. Check the CAN high, 900 Yellow and CAN low wire 900 Light Green for short circuit to ground or another
circuit.
Error Code 143

Fault Description
The cab controller detects both MFD ON and AUTO signals from the MFD switch.
Possible Cause
1. Bad MFD switch.
2. Short circuit to 12 volts of the MFD AUTO circuit.
3. Short circuit to 12 volts of the MFD ON circuit.
1. Check the MFD switch.
2. Check for 12 volts on the MFD ON circuit (wire 541 Light Blue) with the MFD switch in the AUTO position. If
voltage is detected check the right hand console and fender harnesses for damage.
3. Check for 12 volts on the MFD AUTO circuit (wire 565 Light Blue) with the MFD switch in the ON position. If
voltage is detected check the right hand console and fender harnesses for damage.
4. Check between wires 541 Light Blue (MFD ON) and 565 Light Blue (AUTO MFD) for continuity with the MFD
switch in the OFF position. If continuity is detected check the right hand console and fender harnesses for
damage.
Error Code 144

Fault Description
The cab controller detects both Differential Lock ON and AUTO signals from the Differential Lock switch.
Possible Cause
1. Bad Differential Lock switch.
2. Short circuit to 12 volts of the Differential Lock AUTO circuit.
3. Short circuit to 12 volts of the Differential Lock ON circuit.
1. Check the Differential Lock switch.
2. Check for 12 volts on the Differential Lock ON circuit (wire 532 Light Blue) with the Differential Lock switch in
the AUTO position. If voltage is detected check the right hand console and fender harnesses for damage.
3. Check for 12 volts on the Differential Lock AUTO circuit (wire 546 Light Blue) with the Differential Lock switch
in the ON position. If voltage is detected check the right hand console and fender harnesses for damage.
4. Check between wires 532 Light Blue (AUTO Differential) and 546 Light Blue (Differential ON) for continuity
with the differential lock switch in the OFF position. If continuity is detected check the right hand console and
fender harnesses for damage.
SM 8-12471 Issued 09-2004

58 SECTION 10006
Error Code 145

Fault Description
Cab controller power down error.
Possible Cause
1. Battery disconnected when the key switch is turned ON.
2. Battery disconnect switch (if equipped) turn OFF when the key switch is in the ON position.
3. Fuse 38 Blown.
4. Cab controller battery power circuit open or short circuit to ground.
1. Check the fuse 38.
2. Check the cab controller battery power circuit (wires 500 Red) for open circuit.
3. With fuse 38 removed, check the cab controller battery power circuit (wires 500 Red) for short circuit to
ground.
Error Code 146

Fault Description
The cab controller has detected the park lock or park brake is engaged when forward or reverse is selected.
This error may be displayed if the operator requires a park brake assisted start (holding the tractor on an incline)
and will clear as soon as the park brake is fully released.
Possible Cause
1. Bad park brake switch.
2. Park brake wiring shorted to ground.
3. Bad park lock indicator switch.
4. Park lock indicator switch feed wire short circuit to ground.
5. Bad CAN circuit.
1. Check the operation of the park brake switch.
2. Check check the park brake wiring for short circuit to ground between the instrument cluster and the park
brake switch.
5. Check the CAN circuit between the instrument cluster and the cab controller for open circuit.
Error Code 147

Fault Description
The F/N/R/P switch reverse signal is below specified limits.
Possible Cause
1. The reverse signal wire open or short circuit to ground.
1. Check the reverse signal circuit (wires 513 Tan) between the F/N/R/P switch and the cab controller for open
circuit.
2. Check the reverse signal circuit (wires 513 Tan) between the F/N/R/P switch and the cab controller for short
circuit to ground.
SM 8-12471 Issued 09-2004

SECTION 10006 59
Error Code 148

Fault Description
The F/N/R/P switch reverse signal is above specified limits.
Possible Cause
1. The reverse signal wire short circuit to voltage above 5 volts.
1. Check the reverse signal circuit (wires 513 Tan) between the F/N/R/P switch and the cab controller for short
circuit to voltage above 5 volts.
Error Code 149

Fault Description
The calibration/diagnostics CAN Bus buffer is full.
Possible Cause
1. CAN high or CAN low wires open circuit.
2. CAN high and CAN low wires shorted together.
5. Another controller connected to the CAN Bus is not programmed correctly.
circuit.
5. Disconnect each controller connected to the CAN Bus circuit in turn, to isolate the faulty controller. Error
code 146 will no longer be displayed when the faulty controller is disconnected (other CAN errors may be
displayed). Reprogram the faulty isolated controller.
Error Code 162

Fault Description
The cab controller has entered computer neutral.
Possible Cause
1. An error or multiple errors have occurred causing the cab controller to remain in computer neutral.
1. With the key ON put the F/N/R/P lever in neutral and cycle the inching pedal.
2. If the error code remains, identify further error codes and correct any faults.
3. With all faults corrected turn the key ON and put the F/N/R/P lever in neutral and cycle the inching pedal.
SM 8-12471 Issued 09-2004

60 SECTION 10006
This Page Has Been Left Blank.
SM 8-12471 Issued 09-2004

SECTION 10006 61
Instrument Panel Components
2 3
4 5
17
6 8 10
16 7
9
11
15
12
14
13
G1
MI04D011
1. FUSE BOX 10. PROGRAMMING CONNECTOR

2. INSTRUMENT CLUSTER CONNECTOR C2 11. BATTERY POWER STUD (UNSWITCHED)
3. SWITCHED POWER STUD 12. CONNECTOR 33 (STALK SWITCH)
4. INSTRUMENT CLUSTER CONNECTOR C1 13. CONNECTOR 32 (STALK SWITCH)
5. CAN DIAGNOSTIC CONNECTOR 14. TURN SIGNAL SELF CANCELLING MODULE CONNECTOR
6. CAB POWER RELAY 15. INCHING PEDAL POSITION POTENTIOMETER
7. LEFT HAND BRAKE SWITCH 16. INCHING PEDAL SWITCH (TOP OF PEDAL)
8. KEY SWITCH 17. INCHING PEDAL SWITCH (BOTTOM OF PEDAL)
9. RIGHT HAND BRAKE SWITCH
SM 8-12471 Issued 09-2004

62 SECTION 10006
Right Hand Console Harness Components
7 9
5 8 10
6
4
3
2 11
14
15
16
1
12
17
13
18
20
G2 19
22 21
23
25
24
26
MI04J041
1. HITCH MAIN SETTING LEVER (HEIGHT/DEPTH) 15. HITCH DIAGNOSTIC LIGHT

4. REAR PTO INDICATOR LIGHT 18. AUDIBLE ALARM
5. REAR PTO SWITCH 19. SEAT CONNECTOR
6. RIDE CONTROL SWITCH 20. CONNECTOR 52 (FENDER HARNESS)
7. SLIP CONTROL SWITCH 21. CONNECTOR 53 (FENDER HARNESS)
8. DIFFERENTIAL LOCK SWITCH 22. CONNECTOR 51 (FENDER HARNESS)
9. MFD SWITCH 23. CONNECTOR 26 (INSTRUMENT PANEL HARNESS)
10. SUSPENDED FRONT AXLE ON/OFF SWITCH 24. CONNECTOR 27 (INSTRUMENT PANEL HARNESS)
11. CIGAR LIGHTER 25. CONNECTOR 28 (INSTRUMENT PANEL HARNESS)
12. AUXILIARY POWER SOCKET 26. CONNECTOR 29 (INSTRUMENT PANEL HARNESS)
14. HITCH MODE CONTROL (INTERMIX) G2. CHASSIS GROUND CONNECTION G2
SM 8-12471 Issued 09-2004

SECTION 10006 63
Arm Rest Components
5 6
4
3
8 9
10
14
13 15 16
12
11
MI02F149A
17 18 19 20
MI02F151A

SM 8-12471 Issued 09-2004

64 SECTION 10006
1
2
3
7 8
6
5
G5
MI04J048

2. HITCH CONTROLLER 6. CONNECTOR 53 (RIGHT HAND CONSOLE HARNESS)
3. CAB (MCC) CONTROLLER 7. CONNECTOR 51 (RIGHT HAND CONSOLE HARNESS)
4. CONNECTOR 50 (ARMREST) 8. CONNECTOR 40 (TRANSMISSION HARNESS)
G5. CHASSIS GROUND CONNECTOR G5.
SM 8-12471 Issued 09-2004

SECTION 10006 65
Transmission Component Identification
17 24
25 23
18
19 20
2 26 22
1
21
3
8
4
16
7
6 5
G3
150 L/MIN. HYDRAULIC PUMP TRACTORS
3
15
5
4
14
7 6 11
9 10
9 10
13
8 12
150 L/MIN. HYDRAULIC PUMP TRACTORS 150 L/MIN. HYDRAULIC PUMP TRACTORS 110 L/MIN. HYDRAULIC PUMP TRACTORS
1. PTO OUTPUT SHAFT SPEED SENSOR 8. 5 BAR HYDRAULIC OIL PRESSURE SWITCH (GREEN) 15. POWERSHIFT SOLENOID ‘A’ 22. TEMPERATURE SENDER
2. PTO CLUTCH SPEED SENSOR 9. HYDRAULIC FILTER RESTRICTION SWITCH 16. TRANSMISSION CONTROLLER 23. TRANSMISSION INPUT SPEED SENSOR (ENGINE SPEED)
3. 17 BAR HYDRAULIC OIL PRESSURE SWITCH (RED) 10. PARK LOCK SOLENOID 17. POWERSHIFT SOLENOID ‘B’ 24. CALIBRATION SPEED SENSOR
4. REAR PTO BRAKE SOLENOID 11. FORWARD SPEED SENSOR 18. POWERSHIFT SOLENOID ‘R’ 25. CREEPER SWITCH
5. REAR PTO SOLENOID 12. POWERSHIFT SOLENOID ‘M’ 19. POWERSHIFT SOLENOID ‘C’ 26. CONNECTOR 40 (FENDER HARNESS)
6. DIFFERENTIAL LOCK SOLENOID 13. POWERSHIFT SOLENOID ‘H’ 20. POWERSHIFT SOLENOID ‘1’
7. MFD SOLENOID 14. POWERSHIFT SOLENOID ‘2’ 21. POWERSHIFT SOLENOID ‘L’ G3. CHASSIS GROUND CONNECTION G3
SM 8-12471 Issued 09-2004

66 SECTION 10006
Transmission Controller Schematic Circuit
INCHING PEDAL BOTTOM OF PEDAL SWITCH PARK LOCK, MFD, REAR PTO, PTO BRAKE AND TRANSMISSION TEMPERATURE SENDER
1 2 3
C
13
A B
F
8
9 10 11 12
MI03G041
Key
1. FUSE 5 (5 AMP) 12. PTO BRAKE SOLENOID (8.75 TO 10.6 OHMS) 22. HYDRAULIC FILTER RESTRICTION SWITCH A. TO F/N/R/P SWITCH
2. FUSE 26 (30 AMP) 13. TRANSMISSION CALIBRATION CONNECTOR 23. POWERSHIFT SOLENOID ‘C’ (10.1 OHMS AT 20°C/68°F) B. TO BRAKE PEDAL SWITCHES
3. FUSE 34 (7.5 AMP) 14. POWERSHIFT CALIBRATION SPEED SENSOR 24. POWERSHIFT SOLENOID ‘A (10.1 OHMS AT 20°C/68°F) C. TO AUXILIARY/REMOTE VALVES CAN BUS CIRCUIT
4. BOTTOM OF PEDAL INCHING PEDAL SWITCH 15. PTO CLUTCH SPEED SENSOR 25. POWERSHIFT SOLENOID ‘B (10.1 OHMS AT 20°C/68°F) D. TO CAN BUS CIRCUIT
(NORMALLY CLOSED) 16. POWERSHIFT INPUT SHAFT SPEED SENSOR 26. POWERSHIFT SOLENOID ‘1 (10.1 OHMS AT 20°C/68°F) E. TO MFD SWITCH
5. BOTTOM OF PEDAL RELAY (ENGINE SPEED) 27. POWERSHIFT SOLENOID ‘H (10.1 OHMS AT 20°C/68°F) F. TO DIFFERENTIAL LOCK SWITCH
6. CAN TERMINATION RESISTOR 2 17. POWERSHIFT OUTPUT SHAFT SPEED SENSOR 28. POWERSHIFT SOLENOID ‘L (10.1 OHMS AT 20°C/68°F) G. TO INCHING PEDAL SWITCH (TOP OF PEDAL)
7. TRANSMISSION TEMPERATURE SENDER 18. PTO OUTPUT SHAFT SPEED SENSOR 29. POWERSHIFT SOLENOID ‘M (10.1 OHMS AT 20°C/68°F) H. TO CAB CONTROLLER
8. PARK LOCK INDICATOR SWITCH 19. TRANSMISSION 3 BAR OIL PRESSURE SWITCH (GREEN) 30. POWERSHIFT SOLENOID ‘2 (10.1 OHMS AT 20°C/68°F)
9. PARK LOCK SOLENOID (8.14 TO 8.46 OHMS) 20. TRANSMISSION 17 BAR OIL PRESSURE SWITCH (RED) 31. POWERSHIFT SOLENOID ‘R (10.1 OHMS AT 20°C/68°F)
10. MFD SOLENOID (8.75 TO 10.6 OHMS) 21. POWERSHIFT TRANSMISSION 17 BAR OIL PRESSURE SWITCH 32. DIFFERENTIAL LOCK SOLENOID (8.75 TO 10.6 OHMS) (#) EARLY
EARLY PRODUCTION
PRODUCTION
EUROPEAN
EUROPEAN
SPECIFICATION
SPECIFICATION
TRACTORS
TRACTORS ONLY
11. REAR PTO SOLENOID (10.1 OHMS AT 20°C/68°F) (##)ONLY
EARLY PRODUCTION AMERICAN SPECIFICATION TRACTORS ONLY
SM 8-12471 Issued 09-2004
SECTION 10006 67
POWERSHIFT SOLENOIDS AND SPEED SENSORS HYDRAULIC PRESSURE SWITCHES AND CREEPER SWITCH
19 20 21 22
14 15 16 17 18
33
23 24 25 26 27 28 29 30 31 32
MI03G0412
Transmission Controller Pin Identification

CONNECTOR A CONNECTOR B CONNECTOR C CONNECTOR D CONNECTOR E
A-A POWERSHIFT SOLENOID ‘C’ FEED B-A GROUND C-A POWERSHIFT SOLENOID ‘C’ RETURN D-A CAN HIGH E-A TRANSMISSION HYDRAULIC 17 BAR OIL PRESSURE SWITCH
A-B POWERSHIFT SOLENOID ‘A’ FEED B-B INCHING PEDAL (BOTTOM OF PEDAL) C-B POWERSHIFT SOLENOID ‘A’ RETURN D-B NOT USED E-B POWERSHIFT HYDRAULIC 17 BAR OIL PRESSURE SWITCH
A-C POWERSHIFT SOLENOID ‘B’ FEED B-C PARK LOCK SOLENOID FEED C-C POWERSHIFT SOLENOID ‘B’ RETURN D-C NOT USED E-C CREEP SWITCH FEED
A-D DIFFERENTIAL LOCK SOLENOID FEED B-D REAR PTO SOLENOID RETURN C-D POWERSHIFT SOLENOID ‘1’ RETURN D-D NOT USED E-D PTO CLUTCH/POWERSHIFT CALIBRATION SPEED SENSOR
A-E POWERSHIFT SOLENOID ‘H’ FEED B-E PTO BRAKE SOLENOID RETURN C-E POWERSHIFT SOLENOID ‘H’ RETURN D-E NOT USED E-E POWERSHIFT INPUT SHAFT SPEED SENSOR (ENGINE SPEED)
A-F POWERSHIFT SOLENOID ‘L’ FEED B-F PTO BRAKE SOLENOID FEED C-F POWERSHIFT SOLENOID ‘L’ RETURN D-F PARK LOCK INDICATOR SWITCH E-F POWERSHIFT OUTPUT SHAFT SPEED SENSOR
A-G POWERSHIFT SOLENOID ‘M’ FEED B-G REAR PTO SOLENOID FEED C-G POWERSHIFT SOLENOID ‘M’ RETURN D-G TRANSMISSION TEMPERATURE SENDER RETURN E-G PTO OUTPUT SHAFT SPEED SENSOR
A-H POWERSHIFT SOLENOID ‘1’ FEED B-H MFD SOLENOID FEED C-H POWERSHIFT SOLENOID ‘2’ RETURN D-H NOT USED E-H SPEED SENSOR COMMON GROUND
A-J POWERSHIFT SOLENOID ‘2’ FEED B-J SWITCHED B+ C-J POWERSHIFT SOLENOID ‘R’ RETURN D-J TRANSMISSION TEMPERATURE SENDER FEED E-J HYDRAULIC FILTER RESTRICTION SWITCH
A-K POWERSHIFT SOLENOID ‘R’ FEED B-K GROUND C-K DIFFERENTIAL LOCK SOLENOID RETURN D-K CAN LOW E-K TRANSMISSION HYDRAULIC 3 BAR OIL PRESSURE SWITCH
SM 8-12471 Issued 09-2004

68 SECTION 10006
Cab Controller (MCC) Schematic Circuit
FORWARD/NEUTRAL/REVERSE/PARK (F/N/R/P) SWITCH INCHING PEDAL SWITCHES BRAKE PEDAL SWITCHES MFD AND DIFFERENTIAL LOCK SWITCHES INCHING PEDAL POTENTIOMETER
14 15
1 2
7 9 10
8
B D
13
4
11 12
5
MI03j024
Key
1. FUSE #5 (5 AMP) 11. MFD SWITCH 19. OPERATOR PRESENCE SWITCH E. TO ARM REST CONTROL
2. FUSE #26 (30 AMP) 12. DIFFERENTIAL LOCK SWITCH 20. AUTO PTO SWITCH F. TO AUXILIARY/REMOTE VALVE CONTROLLER
3. F/N/R/P SWITCH 13. INCHING PEDAL POTENTIOMETER 21. PTO INDICATOR LIGHT G. TO AUXILIARY/REMOTE VALVE CONTROLLER
4. BOTTOM OF PEDAL INCHING PEDAL SWITCH 14. FUSE 38 (7.5 AMP) 22. PTO SWITCH H. TO TRANSMISSION CONTROLLER
(NORMALLY CLOSED) 15. FUSE 27 (7.5 AMP) 23. LEFT HAND REMOTE PTO SWITCH (IF EQUIPPED) J. TO CAN BUS CIRCUIT
5. BOTTOM OF PEDAL RELAY 16. FUSE 35 (7.5 AMP) 24. RIGHT HAND REMOTE PTO SWITCH (IF EQUIPPED) K. TO 540/1000 PTO INDICATOR SWITCH
6. TOP OF PEDAL INCHING PEDAL SWITCH 17. FUSE 37 (7.5 AMP) - EARLY PRODUCTION TRACTORS 25. SUSPENDED AXLE HARNESS CONNECTORS L. FROM IMPLEMENT INTERFACE CONNECTOR
(NORMALLY OPEN) FUSE 33 (7.5 AMP) - LATER PRODUCTION TRACTORS M. FROM SUSPENDED AXLE SWITCH
7. LEFT HAND BRAKE PEDAL SWITCH 18. MULTI FUNCTION LEVER A. FROM KEY SWITCH TERMINAL 2 N. FROM AUXILIARY/REMOTE VALVE CONTROLLER
8. RIGHT HAND BRAKE PEDAL SWITCH 18a. GEAR UP SWITCH B. TO STARTER RELAY P. FROM AUXILIARY/REMOTE VALVE DIAGNOSTIC CONNECTOR
9. LEFT HAND BRAKE RELAY 18b. GEAR DOWN SWITCH C. TO HITCH CONTROLLER Q. FROM ARM REST CONTROL
10. RIGHT HAND BRAKE RELAY 18c. GEAR SKIP SWITCH D. TO BRAKE LIGHT CIRCUIT
SM 8-12471 Issued 09-2004
SECTION 10006 69
MULTI-FUNCTION LEVER GEAR SHIFT OPERATOR PRESENCE AND PTO CONTROL SWITCHES
E
F
G
16 17
K
18a
19 22
18 18c 20
21
18b
23 24
J L
N
P R
H 25
Q
MI03J025
CAB CONTROLLER (MCC) PIN IDENTIFICATION

CONNECTOR J1 (Black - 32 Pin) CONNECTOR J2 (Grey - 32 Pin) CONNECTOR J3 (Black- 18 Pin)
J1 - A1 UNSWITCHED BATTERY B+ J1 - F1 NOT USED J2 - A1 PTO STOP SIGNAL J2 - F1 NOT USED J3 - A1 UNSWITCHED BATTER B+ J3 - D1 NOT USED
J1 - A2 CLEAN GROUND J1 - F2 INCHING PEDAL POTENTIOMETER 5V J2 - A2 DIFFERENTIAL LOCK ON SIGNAL J2 - F2 NOT USED J3 - A2 CLEAN GROUND J3 - D2 NOT USED
J1 - A3 AUTO REAR PTO J1 - F3 INCHING PEDAL POTENTIOMETER SIGNAL J2 - A3 MFD ON SIGNAL J2 - F3 NOT USED J3 - A3 AUTO DIFFERENTIAL LOCK LIGHT J3 - D3 NOT USED
J1 - B1 F/N/R/P REVERSE SIGNAL J1 - G1 INCHING PEDAL POTENTIOMETER GROUND J2 - B1 PARK LOCK SIGNAL J2 - G1 NOT USED J3 - B1 NOT USED J3 - E1 NOT USED
J1 - B2 NOT USED J1 - G2 SWITCHED B+ J2 - B2 AUTO DIFFERENTIAL LOCK SIGNAL J2 - G2 NOT USED J3 - B2 AUTO MFD LIGHT J3 - E2 NOT USED
J1 - B3 NOT USED J1 - G3 NOT USED J2 - B3 AUTO MFD SIGNAL J2 - G3 NOT USED J3 - B3 NOT USED J3 - E3 NOT USED
J1 - C1 GEAR SHIFT DOWN SIGNAL J1 - H1 NOT USED J2 - C1 AUTO REAR PTO SIGNAL J2 - H1 NOT USED J3 - C1 AUTO REAR PTO LIGHT J3 - F1 NOT USED
J1 - C2 NOT USED J1 - H2 F/N/R/P NEUTRAL SIGNAL J2 - C2 REMOTE PTO OFF SIGNAL J2 - H2 NOT USED J3 - C2 NOT USED J3 - F2 NOT USED
J1 - C3 GEAR SKIP SHIFT J1 - H3 REMOTE PTO ON SIGNAL J2 - C3 GEAR SHIFT UP SIGNAL J2 - H3 NOT USED J3 - C3 REAR PTO INDICATOR LIGHT J3 - F3 NOT USED
J1 - D1 NOT USED J1 - J1 INCHING PEDAL (TOP OF PEDAL) J2 - D1 CAN HIGH J2 - J1 NOT USED
J1 - D2 NOT USED J1 - J2 INCHING PEDAL (BOTTOM OF PEDAL) J2 - D2 CAN LOW J2 - J2 NOT USED
J1 - D3 OPERATOR PRESENCE SWITCH J1 - J3 RIGHT HAND BRAKE SIGNAL J2 - D3 NOT USED J2 - J3 NOT USED
J1 - E1 NOT USED J1 - K1 LEFT HAND BRAKE SIGNAL J2 - E1 NOT USED J2 - K1 NOT USED
J1 - E2 F/N/R/P 5V SUPPLY J1 - K2 REAR PTO ON SIGNAL J2 - E2 NOT USED J2 - K2 NOT USED
J1 - E3 F/N/R/P FORWARD SIGNAL J1 - K3 RESERVED - FRONT PTO J2 - E3 NOT USED J2 - K3 NOT USED
SM 8-12471 Issued 09-2004

70 SECTION 10006
MI03k001
Key
SM 8-12471 Issued 09-2004

SECTION 10006 71
MAIN CONNECTORS
477I96 MI04J044

SWITCH
3 656Y INCHING PEDAL
D 500 R HITCH B+
5 600 Y BOTTOM OF PEDAL SWITCH
SWITCHED B+
6 233 Y FUEL LEVEL SENDER
7 656 BR INCHING PEDAL
H 810 R SEAT B+
SWITCHED B+
10 ----- OPEN
N ----- OPEN
FENDER HARNESS
CONNECTOR (*) OR

UNSWITCHED B+
V ----- OPEN

VP IN

SM 8-12471 Issued 09-2004

72 SECTION 10006
MI04J045 478I96

CONNECTOR KEY SENSING E 590 R PTO B+
5 (IIC) R IMPLEMENT INTERFACE F 161 R AUXILIARY/REMOTE VALVE
CONNECTOR BATTERY B+ CONTROLLER SWITCHED B+
6 513 T F/N/R - REVERSE G 134 R IMPLEMENT INTERFACE
BATTERY B+
SWITCHED B+
L 900 Y CAN HIGH
M 900 LG CAN LOW
P ----- OPEN
R ----- OPEN
W ----- OPEN
SWITCHED B+
Z ----- OPEN
SM 8-12471 Issued 09-2004

SECTION 10006 73
Connector 40
MI04A090


BR/W
SENDER
BR/W
H (VP) R VP OUT B+
J 900 Y CAN HIGH
K 900 LG CAN LOW
SWITCHED B+
U ----- OPEN
SM 8-12471 Issued 09-2004

74 SECTION 10006
Connector 45a (Black) Connector 45c (Black)

Location: Rear Cab Panel Location: Rear Cab Panel
MI04A058 MI04A058
TRANSMISSION CONTROLLER CONNECTOR A TRANSMISSION CONTROLLER CONNECTOR A

A (C) R POWERSHIFT SOLENOID ‘C’ A (C) BR POWERSHIFT SOLENOID ‘C’
B (A) R POWERSHIFT SOLENOID ‘A’ B (A) BR POWERSHIFT SOLENOID ‘A’
C (B) R POWERSHIFT SOLENOID ‘B’ C (B) BR POWERSHIFT SOLENOID ‘B’
D (DIFF) R DIFFERENTIAL LOCK SOLENOID D (1) BR POWERSHIFT SOLENOID ‘1’
E (H) R POWERSHIFT SOLENOID ‘H’ E (H) BR POWERSHIFT SOLENOID ‘H’
F (L) R POWERSHIFT SOLENOID ‘L’ F (L) BR POWERSHIFT SOLENOID ‘L’
G (M) R POWERSHIFT SOLENOID ‘M’ G (M) BR POWERSHIFT SOLENOID ‘M’
H (1) R POWERSHIFT SOLENOID ‘1’ H (2) R POWERSHIFT SOLENOID ‘2’
J (2) R POWERSHIFT SOLENOID ‘2’ J (R) BR POWERSHIFT SOLENOID ‘1’
K (R) R POWERSHIFT SOLENOID ‘R’ K (DIFF) BR DIFFERENTIAL LOCK SOLENOID
Connector 45b (Gray) Connector 45d (Gray)

MI04A059 MI04A059
TRANSMISSION CONTROLLER CONNECTOR A TRANSMISSION CONTROLLER CONNECTOR A

A BR GROUND A 900 Y CAN HIGH
B 662 R INCHING PEDAL SWITCH B ----- OPEN
(BOTTOM OF PEDAL)
C ----- OPEN
C 280 Y POWERSHIFT SOLENOID ‘B’
D ----- OPEN
D (RPTO) BR REAR PTO SOLENOID RETURN
E ----- OPEN
E 593 BR PTO BRAKE SOLENOID RETURN
F 254 Y PARK LOCK INDICATOR SWITCH
F 593 R PTO BRAKE SOLENOID FEED
G 267 BR TRANSMISSION TEMPERATURE
G (RPTO) R REAR PTO SOLENOID FEED SENDER RETURN
H (4WD) R MFD SOLENOID FEED H ----- OPEN
J 550 R SWITCHED B+ J 267 Y TRANSMISSION TEMPERATURE
K BR GROUND SENDER FEED
K 900 LG CAN LOW
SM 8-12471 Issued 09-2004

SECTION 10006 75
Connector 45e (Black) Connector 46 (Black - J1)

MI04A058
TRANSMISSION CONTROLLER CONNECTOR A

A (17R) Y 17 BAR HYDRAULIC OIL
PRESSURE SWITCH MI04A061
B (17G) Y 17 BAR POWERSHIFT OIL CAB CONTROLLER CONNECTOR J1

PRESSURE SWITCH
C 481 Y CREEPER INDICATOR SWITCH Cavity Wire No Circuit
FEED A1 500 R UNSWITCHED BATTERY B+
D (CAL) Y PTO CLUTCH SPEED/ A2 BR/W CLEAN GROUND
POWERSHIFT CALIBRATION
A3 594 DB AUTO PTO
SENSOR
B1 513 T REVERSE SIGNAL
E (ENG) BR POWERSHIFT INPUT SHAFT
SPEED SENSOR (ENGINE SPEED) B2 ----- OPEN
F (FWD) Y POWERSHIFT OUTPUT SHAFT B3 ----- OPEN
SPEED SENSOR C1 524 DB GEAR SHIFT DOWN
G 224 Y PTO OUTPUT SHAFT SPEED C2 ----- OPEN
SENSOR
C3 527 DB GEAR SKIP SHIFT
H 483 BR SPEED SENSOR COMMON
GROUND D1 ----- OPEN
J 267 Y HYDRAULIC RESTRICTION D2 ----- OPEN

SWITCH D3 303 T OPERATOR PRESENCE SWITCH
K (BOO) Y 3 BAR HYDRAULIC OIL PRESSURE E1 ----- OPEN
SWITCH
E2 510 T F/N/R/P 5V SUPPLY
E3 511T FORWARD SIGNAL
F1 ----- OPEN
F2 656 R INCHING PEDAL POTENTIOMETER
5V SUPPLY
F3 656 Y INCHING PEDAL POTENTIOMETER
SIGNAL
G1 656 BR INCHING PEDAL POTENTIOMETER
GROUND
G2 590 R SWITCHED B+
G3 ----- OPEN
H1 ----- OPEN
H2 514 T NEUTRAL SIGNAL
H3 590 DB REMOTE PTO ON
J1 657 Y INCHING PEDAL SWITCH
(TOP OF PEDAL)
J2 663 R INCHING PEDAL SWITCH
(BOTTOM OF PEDAL)
J3 531 LB RIGHT HAND BRAKE SIGNAL
K1 536 LB LEFT HAND BRAKE SIGNAL
K2 591 LB REAR PTO ON
K3 551 LB FRONT PTO (RESERVED)
SM 8-12471 Issued 09-2004

76 SECTION 10006
Connector 47 (Black - J2) Connector 48 (Grey - J3)

MI04A062
MI04A060
CAB CONTROLLER CONNECTOR J2 CAB CONTROLLER CONNECTOR J3

A1 592 LB REAR PTO STOP A1 500 R UNSWITCHED B+
A2 532 LB DIFFERENTIAL LOCK ON A2 BR/W CLEAN GROUND
A3 541 LB MFD ON A3 539 LB AUTO DIFFERENTIAL LOCK
B1 254 Y PARK LOCK INDICATOR LIGHT
B2 546 LB AUTO DIFFERENTIAL LOCK B1 ----- OPEN
B3 565 LB AUTO MFD B2 566 LB AUTO MFD INDICATOR LIGHT

C1 592 DB AUTO REAR PTO B3 ----- OPEN
C2 592 LB REMOTE PTO OFF C1 595 LB AUTO REAR PTO INDICATOR LIGHT
C3 525 DB GEAR SHIFT UP C2 ----- OPEN

D1 900 Y CAN HIGH C3 590 R REAR PTO INDICATOR LIGHT
D2 900 LG CAN LOW D1 ----- OPEN
D3 ----- OPEN D2 ----- OPEN

E1 ----- OPEN D3 ----- OPEN
E2 ----- OPEN E1 ----- OPEN
E3 ----- OPEN E2 ----- OPEN

F1 ----- OPEN E3 ----- OPEN
F2 ----- OPEN F1 ----- OPEN
F3 ----- OPEN F2 ----- OPEN

F3 ----- OPEN
G1 ----- OPEN
G2 ----- OPEN
G3 ----- OPEN
H1 ----- OPEN
H2 ----- OPEN
H3 ----- OPEN
J1 ----- OPEN
J2 ----- OPEN
J3 ----- OPEN
K1 ----- OPEN
K2 ----- OPEN
K3 ----- OPEN
SM 8-12471 Issued 09-2004

SECTION 10006 77
Connector 50
DI99A036


2 540 BR ARM REST POTENTIOMETER 0V SIGNAL
28 516 DB AUXILIARY VALVE JOYSTICK 1B
SIGNAL

SWITCHED B+
GROUND
37 ----- OPEN
38 ----- OPEN
39 ----- OPEN
40 ----- OPEN
41 ----- OPEN
42 ----- OPEN
43 ----- OPEN
44 ----- OPEN
45 ----- OPEN
46 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12471 Issued 09-2004

78 SECTION 10006
Connector 51
DI99A036


SWITCHED B+
CONTROLLER VP B+
30 590 R 540/1000 PTO SWITCH B+
9 ----- OPEN
32 ----- OPEN
13 510 T F/N/R B+
INDICATOR LIGHT
43 900 Y CAN HIGH
SWITCHED B+
44 900 LG CAN LOW
22 590 R CAB CONTROLLER SWITCHED B+ 45 663 R BOTTOM OF PEDAL SIGNAL (CAB
CONTROLLER)
CONTROLLER BATTERY B+ 46 644 R REMOTE THROTTLE (5V)
24 276 LB 540/1000 PTO SWITCH
SM 8-12471 Issued 09-2004

SECTION 10006 79
Connector 52


C ----- OPEN
J ----- OPEN
K ----- OPEN
P ----- OPEN
R ----- OPEN
S ----- OPEN
SWITCHED B+
UNSWITCHED B+
cc ----- OPEN
ee ----- OPEN
ff ----- OPEN
gg ----- OPEN
hh ----- OPEN
3 ----- OPEN
4 ----- OPEN
SM 8-12471 Issued 09-2004

80 SECTION 10006
Connector 53
DI99A036


POTENTIOMETER (0V)
GROUND
39 ----- OPEN
GROUND
16 ----- OPEN
42 ----- OPEN

POTENTIOMETER HIGH
47 ----- OPEN
20 ----- OPEN
48 ----- OPEN
24 ----- OPEN
SM 8-12471 Issued 09-2004

10010
Section
10010
CONTROLLER PROGRAMMING
ZTX Series Tractors

SM 8-12530 June 2004
2 SECTION 10010
TABLE OF CONTENTS
SPECIAL TOOLS .....................................................................................................................................................3
GENERAL INFORMATION ......................................................................................................................................4
1014T1 AVG COMMUNICATIONS ADAPTER

CONNECTION .....................................................................................................................................................5
AUXILIARY/REMOTE VALVE
CONTROLLER PROGRAMMING ........................................................................................................................7
AUXILIARY/REMOTE VALVE CONFIGURATION ...................................................................................................9
INSTRUMENT CLUSTER PROGRAMMING .........................................................................................................12
HITCH, CAB (MCC) AND TRANSMISSION

CONTROLLER PROGRAMMING .....................................................................................................................16
SM 8-12530 Issued 06-2004

SECTION 10010 3
SPECIAL TOOLS
MD04C017 MD04E083
1025T1 MCCORMICK DIAGNOSTIC CENTRE 1028T1 CLUSTER PROGRAMMING LEAD

1026T1 USB COMMUNICATIONS LEAD
MD04E082
1004T2 PROGRAMMING LEAD

1029T1 ADAPTER HARNESS (EARLY PRODUCTION
TRACTORS ONLY)
SM 8-12530 Issued 06-2004

4 SECTION 10010
GENERAL INFORMATION
The tractor control systems may require the controller software to be reprogrammed, also if a new controller
(supplied without software) is to be installed it to will have to be programmed with the correct version of software.
The hitch (EHR), cab (MCC) and transmission (TC) controllers are programmed using the CAN Bus connection
located behind the instrument panel right hand side cover. The instrument cluster and auxiliary valve (AVC)
controller are programmed directly using individual download leads.
COMPUTER SCREEN MAIN DIALOGUE WINDOW
SM 8-12530 Issued 06-2004

SECTION 10010 5

CONNECTION
D
C
B
MD04E001
A. 1014T1 AVG COMMUNICATIONS ADAPTER C. CONNECT TO COMPUTER USB CONNECTION

B. 1026T1 USB COMMUNICATIONS LEAD D. CONNECT TO TRACTOR 9 PIN DIAGNOSTIC CONNECTOR
E. SERIAL CONNECTION (NOT USED)
IMPORTANT: The AVG serial por t connection is only used to download software into the AVG. When
downloading software into the tractor controllers requir ing the AVG communications adapter, the
connection MUST BE MADE using the USB communications lead 1026T1.
The AVG communications adapter 1014T1 provides STEP 3
the interface between the diagnostics software
installed on the lap top computer and the tractor. This 3
communication to the tractor is made using ‘CAN
bus’ or ‘K Line’ systems.
2
The AVG communications adapter connects to the
tractor using 9 pin diagnostics connector. The AVG
receives unswitched battery power from the tractor
through the 9 pin diagnostics connector to enable the
AVG to operate.
Checking The AVG Connection 1
STEP 1 MD04E084
Connect the AGV communications adapter 1014T1

Park the tractor on hard level ground, apply the (1) to the CAN bus connector (2). Connect USB
parking brake, turn the key to the OFF position and communications lead 1026T1 (3) between the USB
put blocks in front and behind the rear wheels. ports of laptop computer and the AGV
communications adapter.
STEP 2
NOTE: On early production tractors the CAN
bus connector is located behind the instrument
Remove the instrument panel right hand side cover.
cluster. To gain access to the CAN bus
connector it will be necessary to remove the
cluster from the instrument panel (DO NOT
disconnect the cluster from the harness).
SM 8-12530 Issued 06-2004
6 SECTION 10010
STEP 4 STEP 7
MH04D033
Turn the computer ON and select the McCormick

Diagnostics icon. The main window shown on Page 4
will appear.
MH04E027
STEP 5 If the above dialogue box appears the AVG
communication between the tractor and the lap top
computer has failed. Click ‘OK’ and exit the
A McCormick Diagnostics program. Shut down the
B computer and check the following:
1. The 9 pin diagnostic connector
2. Fuse 39.
MH04D036 3. Wire 900 Red between fuse 39 and the 9 pin
Click open the ‘AVG’ box (A) on the main window and diagnostic connector. (Refer to the schematic in
click open the ‘Version Info’ box (B) as shown. Section 10009).
4. Wire 900 Brown between the 9 pin diagnostic
STEP 6 connector and chassis ground. (Refer to the
schematic in Section 10009).
MH04E035
If the AVG information appears as shown the AVG

communication between the tractor and the lap top
computer has been made. Click the ‘OK’ box to return
to the main window.
SM 8-12530 Issued 06-2004

SECTION 10010 7
AUXILIARY/REMOTE VALVE
IMPORTANT: The McCormick Diagnostic Centre STEP 5
will only operate using the correct programming
leads, refer to “SPECIAL TOOLS” on page 3. A
USB to serial adapter can not be used to
programme the Auxiliary Valve controller.
STEP 1
A
parking brake, turn the key to the OFF position and
put blocks in front and behind the rear wheels.
B
STEP 2 C
MH04D036
Click open the ‘Select Tractor Type’ box (A) on the

1 main window to expand the model tree. Click open the
ZTX box (B) then double click ZTX (C) as shown.
STEP 6
3 4
D
2
MDO4E085
Remove the retaining nuts and remove cab rear

MH04D037
panel. Connect programming lead 1004T2 (1) to the
auxiliary/remote valve controller diagnostic When the above window appears select ‘Download’
connectors (2) and (3). (D) as shown.
NOTE: For early production tractors it will be

STEP 7
necessary to connect the adapter harness 1029T1
(4) between the programming lead 1041T1 and the
tractor.
STEP 3
E
Route the programming lead through the cab rear
window and connect the programming lead 1004T2 to
the laptop computer serial port.
STEP 4
F
MH04E003
Highlight AVC in the select controller window, click on

MH04D033
button (E) to enter AVC in the reprogramme controller
Turn the computer ON and select the McCormick window. Click the ‘Download History’ button (F) to
Diagnostics icon. The main window shown on Page 4 open the controller history file.
will appear.
SM 8-12530 Issued 06-2004

8 SECTION 10010
STEP 8 STEP 11
MH04D039
When ‘Download History’ file opens, scroll through

the file to identify the correct software to be
downloaded into the selected controller. Make a note J
of the correct software to be downloaded then close
the ‘Download History’ file. K
IMPORTANT: Before selecting software to be
downloaded, check any relevant Service Bulletins. MH04E006
Make sure the correct file is displayed in the

STEP 9 ‘Reprogramme ECU’ window (J) and click the
‘Download’ button (K).
STEP 12
G
MH04E007
When the above dialogue box appears, press and

hold push button switch on the programming lead
MH04E004
1004T2. Turn the key to the ON position, release the
Click on the ‘BROWSE’ button (G) to open the ‘Select switch and click on the ‘OK’ button.
Hex File to Download’ window as shown.
STEP 13
STEP 10
MH04E005
Highlight the correct software file as noted in STEP 8 H04E008

and click on the ‘Open’ button (H). The software will begin to download into the controller.
When the software downloading is complete the
‘Download Information’ dialogue box (L) shown will
appear, click ‘OK’ on the dialogue box.
SM 8-12530 Issued 06-2004

SECTION 10010 9
STEP 14
Turn the key to the OFF position, exit the McCormick

Diagnostics program, shut down the computer and
disconnect the programming lead 1004T2. Install the
plugs to the tractor auxiliary/remote valve controller
diagnostic connectors.
AUXILIARY/REMOTE VALVE CONFIGURATION

STEP 1 STEP 5

STEP 2
A
STEP 3
B
3 C
2 MH04D036

main window to expand the model tree. Click open the
STEP 6
1 D
MD04E084
Connect the AGV communications adapter 1014T1

(1) to the CAN bus connector (2). Connect USB
MH04D037
communications lead 1026T1 (3) between the USB
ports of laptop computer and the AGV When the above window appears select ‘ECU
communications adapter, refer to Page 5. Configuration’ (D) as shown.
On early production tractors the CAN bus STEP 7

connector is located behind the instrument
cluster. To gain access to the CAN bus Turn the key to the ON position.
disconnect the cluster from the harness.
STEP 4
MH04D033
Turn the computer ON and select the McCormick

will appear.
SM 8-12530 Issued 06-2004

10 SECTION 10010
STEP 8 STEP 10
F G H
MH04E038
If the configuration mode has been entered the ‘Start

MH04E035
Configuration’ box will change to the ‘Stop
Highlight and double click on AVC in the ‘ECU’s Configuration’ box (F), the ‘Read Configuration’ box
Available’ window. The auxiliary valve configuration (G) and the ‘Write Configuration’ box (H) will become
information will appear in the Configuration active. Also the auxiliary valve enable light on the
Commands window. armrest will illuminate. Go to Step 12.
STEP 9 STEP 11
MH04D039
E If the above dialogue box appears the configuration

mode has failed, click ‘OK’. If the configuration mode
fails again, check the AVG connection with the key in
MH04E036
the OFF and ON positions, refer to “1014T1 AVG
COMMUNICATIONS ADAPTER CONNECTION” on
page 5.
STEP 12
MH04E037
Click on the ‘Start Configuration’ (E) as shown. When

the above information dialogue box appears, follow
the instructions as shown.
MH04E040
Click on the ‘Read Configuration’ box (G) as shown

and the stored values will appear in the Configuration
commands window.
SM 8-12530 Issued 06-2004
SECTION 10010 11
STEP 13 STEP 15
H
MH04E041
Click on the number of valves, ‘New Value’ box (J) as

shown.
MH04E043
Click on the ‘Write Configuration’ box (H) and the

STEP 14 ‘Reset Configuration Mode’ box will appear as shown.
Follow the instructions in the Reset Configuration
Mode’ box to store the new values.
STEP 16
Turn the key to the OFF position, exit the McCormick
K Diagnostics program, shut down the computer and
MH04D042 disconnect the AGV controller interface 1014T1 from
When the drop down window (K) appears select the the CAN Bus connector.
number corresponding to the number of auxiliary
valves installed on the tractor.
SM 8-12530 Issued 06-2004

12 SECTION 10010
INSTRUMENT CLUSTER PROGRAMMING

IMPORTANT: The McCormick Diagnostic Centre STEP 5
will only operate using the correct programming
leads, refer to “SPECIAL TOOLS” on page 3. A
USB to serial adapter can not be used to
programme the Instrument Cluster.
STEP 1
A
B
STEP 2 C
MH04D036
STEP 3
STEP 6
1 D
2
MH04D037
When the above window appears select ‘Download’

DD00A005
(D) as shown.
Connect the cluster programming lead 1028T1 (1) to
the cluster programming connector (2) and to the STEP 7
laptop computer serial port.
NOTE: On early production tractors the cluster
programming is located behind the instrument
cluster. To gain access to the cluster
programming connector it will be necessary to E
remove the cluster from the instrument panel
(DO NOT disconnect the cluster from the
harness).
STEP 4
F
MH04E009
Highlight ‘Cluster’ in the select controller window, click
MH04D033
on button (E) to enter ‘Cluster’ in the reprogramme
Turn the computer ON and select the McCormick controller window. Click the ‘Download History’ button
Diagnostics icon. The main window shown on Page 4 (F) to open the controller history file.
will appear.
SM 8-12530 Issued 06-2004

SECTION 10010 13
STEP 8 STEP 11
MH04D039

of the correct software to be downloaded then close
the ‘Download History’ file. K
downloaded, check any relevant Service Bulletins. MH04E012

STEP 12
G
MH04E007
When the above dialogue box appears turn the key to

the ON position.
MH04E010
Click on the ‘BROWSE’ button (G) to open the ‘Select STEP 13

STEP 10
L
MI04E016
If the instrument cluster digital display (L) is displaying

information, switch the run/programming toggle
MH04E011
switch on the programming lead 1028T1 to the
Highlight the correct software file as noted in STEP 7 programming position. The digital display (L) will
and click on the ‘Open’ button (H). become blank.
SM 8-12530 Issued 06-2004

14 SECTION 10010
STEP 14 STEP 16
MH04E007
M
Momentarily press the reset switch on the
programming lead T1028T1 then click the ‘OK’ button.
STEP 15
MI04E017
Switch the run/programming toggle switch on the

programming lead 1028T1 to the Run position. Turn
M the key to the OFF position then to the Accessory
position. The instrument cluster digital display will
momentarily display the cluster software number (M).
STEP 17
If the software number is not correct, repeat the

programming procedure. If the software number is
correct, turn the key to the OFF position, exit the
McCormick Diagnostics program, shut down the
computer and disconnect the programming lead
H04E013 1028T2.
The software will begin to download into the controller.
Download Information dialogue box (M) shown will
appear, click ‘OK’ on the dialogue box.
SM 8-12530 Issued 06-2004

SECTION 10010 15
STEP 18 STEP 20
MI04D054 MI04D052
Turn the key to the accessory position. When the When the computer disc symbol and ‘11’ appear in
M.P.H./KPH symbol appears in the centre of the instrument cluster main digital display, press and
instrument cluster main digital display (L) as shown, hold the menu button (N) for 2 seconds to store the
simultaneously press buttons (N) and (P). settings.
STEP 19 STEP 21
MI04D054
MI04D052
When the computer disc symbol and ‘10’ appear in When the M.P.H./KPH symbol appears in the centre of
the instrument cluster main digital display, release instrument cluster main digital display (L) as shown,
buttons (N) and (P). turn the key to the OFF position.
N P
L
MI04D053
SM 8-12530 Issued 06-2004

16 SECTION 10010
HITCH, CAB (MCC) AND TRANSMISSION

NOTE: The illustrations shown in the following STEP 5
procedure are for the Hitch (EHR) controller
programming. The programming procedure is
the same for the Hitch (EHR), Cab (MCC) and
Transmission (TC) controllers, unless otherwise
stated.
STEP 1
A
put blocks in front and behind the rear wheels. B
C
STEP 2
MH04D036
Remove the instrument panel right hand side cover. Click open the ‘Select Tractor Type’ box (A) on the
STEP 3 ZTX box (B) then double click ZTX (C) as shown.
3 STEP 6
2
D
MH04D037
1 When the above window appears select ‘Download’
(D) as shown.
MD04E084
Connect the AGV communications adapter 1014T1 STEP 7

(1) to the CAN bus connector (2). Connect USB
communications lead 1026T1 (3) between the USB
ports of laptop computer and the AGV
communications adapter, refer to Page 5.
NOTE: On early production tractors the CAN
E
bus connector is located behind the instrument
cluster. To gain access to the CAN bus
disconnect the cluster from the harness.
STEP 4 F
MH04D038
Highlight the controller to be programmed in the select
controller window, click on button (E) to enter selected
controller in the reprogramme controller window. Click
MH04D033 the ‘Download History’ button (F) to open the
Turn the computer ON and select the McCormick controller history file.
will appear.
SM 8-12530 Issued 06-2004

SECTION 10010 17
STEP 8 STEP 12
MH04D039

of the correct software then close the ‘Download
History’ file. K
downloaded, check any relevant Service Bulletins. MH04D042

Turn the key to the ON position.
STEP 13 Hitch Controller
STEP 10
MH04D043
When the above dialogue box appears, click the ‘OK’

button, turn the key to the OFF position and back to
G the ON position, as instructed.
STEP 14
MH04D040
Click on the ‘BROWSE’ button (G) to open the ‘Select

STEP 11 L
H MH04D045
The software will begin to download into the controller.

Download Information dialogue box (L) shown will
appear, click ‘OK’ on the dialogue box. Turn the key to
the OFF position, exit the McCormick Diagnostics
MH04D041 program, shut down the computer and disconnect the
Highlight the correct software file as noted in STEP 8 AGV controller interface 1014T1 from the CAN Bus
and click on the ‘Open’ button (H). connector.
SM 8-12530 Issued 06-2004

10012
Section
10012
AUTOMATIC TEMPERATURE CONTROL

and Schematics
ZTX Series Tractors

SM 8-12550 September 2004
2 SECTION 10012
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 3
AUTOMATIC TEMPERATURE CONTROL GENERAL INFORMATION
SYSTEM OPERATION ............................................................................................................................................ 5
CENTIGRADE/FAHRENHEIT DISPLAY.................................................................................................................. 6
CIRCUIT TESTING
General Information ............................................................................................................................................. 7

Temperature Control Module Error Codes 8
Error Code 01 .................................................................................................................................................. 8
Error Code 02 .................................................................................................................................................. 9
Error Code 03 ................................................................................................................................................ 10
Error Code 04 ................................................................................................................................................ 10
Error Code 05 ................................................................................................................................................ 11
Error Code 06 ................................................................................................................................................ 12
Error Code 07 ................................................................................................................................................ 12
Error Code 08 ................................................................................................................................................ 13
Error Code 10 ................................................................................................................................................ 13
Air Conditioning Components (Cab Front)......................................................................................................... 15
Air Conditioning Components (Rear and Left Hand Side of Cab)...................................................................... 16
AUTOMATIC TEMPERATURE CONTROL SCHEMATIC CIRCUIT...................................................................... 17
MAIN CONNECTORS............................................................................................................................................ 19
SM 8-12550 Issued 09-2004

SECTION 10012 3
SPECIAL TOOLS
DD98H120 DD97E383
MC2616 MULTIMETER KIT includes: MC31000B HARNESS REPAIR KIT (EUROPE)

MC2616-2 TEST LEADS
DD99A051
SM 8-12550 Issued 09-2004

4 SECTION 10012
AUTOMATIC TEMPERATURE CONTROL GENERAL INFORMATION
1 2 3 4
MI03C095
1. TEMPERATURE CONTROL 4. RECIRCULATING AIR CONTROL

2. DIGITAL DISPLAY 5. AUTOMATIC TEMPERATURE CONTROL SWITCH
3. BLOWER MOTOR CONTROL
The function of the automatic temperature control module is to maintain the cab temperature at a level set by the
operator. The cab temperature control system operates in three modes, OFF, AUTO and DEFROST. To enable
correct operation of the cab temperature control system the controller processes and monitors signals directly from
the following components:
• Temperature control potentiometer.
• Recirculating air control potentiometer.
• Blower motor control potentiometer.
• Cab temperature sensor.
• Evaporator freeze control sensor.
• Air conditioning mode switch.
• System high pressure switch.
• System low pressure switch.
The automatic temperature controller directly controls the operation of the following components:
• Blower motors.
• Air conditioning compressor.
• Water control valve motor.
• Air recirculating door control motor.
The automatic temperature controller also transmits the following information the digital display:
• Cab temperature setting and scale (Centigrade or Fahrenheit).
• Automatic temperature mode selection (AUTO or DEFROST).
• Service indication and error codes.
SM 8-12550 Issued 09-2004

SECTION 10012 5
SYSTEM OPERATION
4 5
2 3
1
1. TEMPERATURE SETTING 4. FAHRENHEIT/CENTIGRADE INDICATOR

2. DEFROST MODE INDICATOR 5. SERVICE INDICATOR
3. AUTO MODE INDICATOR
OFF Mode.
When the air conditioning mode switch is set to the OFF position, the operator can manually operate and control
the blower motor speed and recirculating door position by using the blower motor control knob and recirculating air
control knob. The cab temperature control will not change the position of the heater valve and the air conditioning
compressor will not operate.
Auto Mode.
When the air conditioning mode switch is set to the AUTO position, the temperature set point (1) and mode
indicator A (3) will appear on the digital display, also the temperature centigrade/fahrenheit scale symbol C or F will
appear at (4). The operator can adjust the cab temperature set point using the temperature control from a minimum
temperature of 16°C (30°F) to a maximum temperature of 32°C (90°F).
The automatic temperature control module monitors the cab temperature and automatically adjusts the blower
motor speed, air conditioning compressor engagement/disengagement, heater valve and recirculating door
position to maintain the cab set point temperature.
If the operator manually adjusts the blower speed or the recirculating air door position the mode indicator A (3) will
no longer be displayed. The adjusted feature will no longer be controlled automatically i.e. if the blower motor
control is adjusted, the blower motor will not change speeds automatically. To return the system to full auto mode
the air conditioning mode switch must be cycled to the OFF position and back to the Auto position.
Defrost Mode.
When the air conditioning mode switch is set to the DEFROST position the temperature setpoint (1) and mode
indicator (2) will appear on the digital display. The recirculating air door will automatically close and the blower
motor will go to maximum speed. If the evaporator freeze sensor temperature is above 1.1°C (34°) the a ir
conditioning compressor will engage. The operator can adjust the cab temperature set point using the temperature
control.
Error Codes.
When an error occurs in the system the service indicator (5) will appear on the digital display, the temperature set
point (1) will alternate between displaying the temperature setpoint and the recorded error code.
SM 8-12550 Issued 09-2004

6 SECTION 10012
CENTIGRADE/FAHRENHEIT DISPLAY
NOTE: The temperature display can be set to STEP 3
read the temperature in degrees Centigrade or
degrees fahrenheit. To change the temperature
display carry out the following procedure. 4
STEP 1
brake, put the F/N/R/P lever in park and stop the
engine.
STEP 2
MD04D049
1 Locate the Centigrade/Fahrenheit connector (4).

Disconnect or connect the terminals as required.
Cover any exposed terminals with suitable insulation
3 tape.
For Centigrade - connect the terminals.
2
For Fahrenheit - disconnect the terminals.
STEP 4
MD04D049
Install the cover, tighten the retaining screws and
Remove the coat hook cover (1) and screw cap (2), install the screw cap and coat hook cover.
remove the retaining screws and remove cover (3).
SM 8-12550 Issued 09-2004

SECTION 10012 7
CIRCUIT TESTING
General Information

switches may occur.
made.
SM 8-12550 Issued 09-2004

8 SECTION 10012
Temperature Control Module Error Codes
Error Code 01
Fault Description
High pressure switch has cycled twice within 60 seconds.
System Response.
The air conditioning compressor will shut down immediately.
Possible Cause
1. System pressure too high.
2. High pressure switch open circuit.
3. Bad high pressure switch.
4. Wrong high pressure switch installed.

NOTE: If the front and rear wipers, interior light, right hand console light, front position lights, lower
front work lights and cab mounted headlights fail to operate, check the wire (GND) Brown between the
main cab chassis ground splice 11 and the chassis ground connection. Also check the chassis ground
connection.
1. Using suitable air conditioning test gauges check the system pressure, refer to gauge manufactures instruc-
tions.
- If the system locks out and error code 01 appears and the system pressure is too high, carry out the
necessary repairs to the system.
- If the system locks out and error code 01 appears and the system pressure is normal, go to check 2.
2. Turn the key to the OFF position and disconnect the high pressure switch from the harness. Check for
continuity between terminals A and B of the high pressure switch.
- If continuity is detected, go to check 3.
- If continuity is not detected, replace the high pressure switch.
WARNING: Always wear safety goggles when working with liquid

! refrigerant. Liquid refrigerant in the eyes may cause blindness.
WARNING: Always wear protective gloves when working with liquid

! refrigerant. Small amounts of liquid refrigerant on the skin will cause
severe and painful frostbite.
3. Check for continuity between ground and the high pressure switch connector terminal B for wire 804 Orange.
4. Disconnect connector 10 (engine harness to instrument panel harness) and check for continuity between
connector 10 pin 3 and the high pressure switch connector terminal B for wire 804 Orange.
- If continuity is not detected check the engine harness wire 804 Orange.
5. Disconnect connector 1 (cab harness to instrument panel harness) and check for continuity between ground
and connector 1 pin E (cab harness side) for wire 924 Black.
- If continuity is not detected check wire 924 Black between connector 1 and the main cab chassis ground
splice 11.
6. Disconnect connector 10 (engine harness to instrument panel harness) and check for continuity between
connector 10 pin 1 and the high pressure switch connector terminal A for wire 802 Orange.
- If continuity is not detected check the engine harness wire 802 Orange.
continued......
SM 8-12550 Issued 09-2004

SECTION 10012 9
7. Disconnect connector 1 (cab harness to instrument panel harness) and turn the key to the ON position.
Check the voltage reading at connector 1 pin F (cab harness side) for wire 923 Orange.
- If a voltage reading of 5 volts is detected check the instrument panel harness wire 802 Orange between
connector 1 and connector 10.
- If a reading of 5 volts is not detected check cab harness wire 923 Orange between connector 1 and the
automatic temperature control module.
8. Replace the automatic temperature control module.
Error Code 02
Fault Description
Low pressure switches cycled four times within 60 seconds.
System Response.
The air conditioning compressor will shut down immediately.
Possible Cause
1. System pressure too low.
2. Low pressure switch open circuit.
3. Bad low pressure switch.
4. Wrong low pressure switch installed.

NOTE: If the front and rear turn signal lights, front and rear upper work lights and beacon light fail to
operate, check the wire (GND) Brown between the main cab chassis ground splice 12 and the chassis
ground connection. Also check the chassis ground connection.
1. Using suitable air conditioning test gauges check the system pressure, refer to gauge manufactures instruc-
tions.
- If the system locks out and error code 02 appears and the system pressure is too low, carry out the
necessary repairs to the system.
2. Turn the key to the OFF position and disconnect the low pressure switch from the harness. Check for
continuity between terminals A and B of the low pressure switch connector.
- If continuity is not detected, replace the low pressure switch.
WARNING: Always wear safety goggles when working with liquid

! refrigerant. Liquid refrigerant in the eyes may cause blindness.
WARNING: Always wear protective gloves when working with liquid

! refrigerant. Small amounts of liquid refrigerant on the skin will cause
severe and painful frostbite.
3. Check for continuity between ground and the low pressure switch connector terminal A for wire 922 Black.
- If continuity is not detected check wire 922 Black between the low pressure switch connector and the main
cab splice 12.
4. Turn the key to the ON position. Check the voltage reading at the low pressure switch connector terminal B
for wire 921 Orange.
- If a reading of 5 volts is not detected check cab harness wire 921 Orange between the low pressure switch
connector and the automatic temperature control module.
5. Replace the automatic temperature control module.
SM 8-12550 Issued 09-2004

10 SECTION 10012
Error Code 03
Fault Description
Blower motor current too high.
System Response.
The blower motor control will shut down immediately.
Possible Cause
1. Seized blower motor(s).
2. Bad blower motor ground circuit.
3. Bad blower motor PWM control module.

1. Check for a seized blower motor and replace as necessary.
2. Disconnect the blower motors and blower motor PWM control module from the harness. Check for continuity
between terminal B of the left hand blower motor and terminal B of the blower motor PWM connector for wire
945 Black.
- If continuity is not detected check wire 945 Black between the left hand blower motor and the blower motor
PWM control module.
3. Check for continuity between terminal B of the right hand blower motor and terminal G of the blower motor
PWM connector for wire 955 Black.
- If continuity is not detected check wire 955 Black between the right hand blower motor and the blower
motor PWM control module.
4. Replace the blower motor PWM control module.
Error Code 04
Fault Description
Blower motor control potentiometer resistance too high (above 11000 Ohms).
System Response.
No manual control of the blower motor speed.
Possible Cause
1. Blower motor control potentiometer signal open circuit.
2. Blower motor control potentiometer ground open circuit.
3. Bad blower motor control potentiometer.

1. Check for error codes 05, 06, 08 and 10.
- If error codes 05 and 06 are present, check wire 964 Black between splice C-SP20 and splice C-SP21.
- If error codes 08 and 10 are also present, check wire 942 Black between splice C-SP21 and the automatic
temperature control module connector terminal F3.
2. Disconnect the blower motor control potentiometer from the harness, turn the blower motor control to the
OFF position. Check the resistance reading between terminals B and C of the potentiometer.
- If a reading of 0 OHMS is not detected, replace the potentiometer.
3. Slowly turn the blower motor control from the OFF position to the maximum blower speed position and check
the resistance reading between terminals B and C of the potentiometer.
- A steadily increasing resistance from 0 Ohms to 10,000 Ohms should be observed. If the reading is
incorrect or an intermittent reading is detected replace the potentiometer.
continued......
SM 8-12550 Issued 09-2004

SECTION 10012 11
4. Disconnect the automatic temperature control module from the harness and check for continuity between the
automatic temperature control module connector terminal E1 and terminal B of the blower motor control
potentiometer connector for wire 925 Orange.
- If continuity is not detected check wire 925 Orange between the automatic temperature control module and
the blower motor control potentiometer.
5. Check for continuity between the automatic temperature control module connector terminal F3 and terminal
C of the blower motor control potentiometer connector for wires 942 Black and 926 Black.
- If continuity is not detected check wire 933 Black between the blower motor control potentiometer and
splice C-SP20.
Error Code 05
Fault Description
Temperature control potentiometer resistance too high (above 11000 Ohms).
System Response.
No manual temperature control cab temperature defaults to 20°C (68°F).
Possible Cause
1. Temperature control potentiometer signal open circuit.
2. Temperature control potentiometer ground open circuit.
3. Temperature control potentiometer.

2. Disconnect the temperature control potentiometer from the harness, turn the temperature control to the
maximum cooling position. Check the resistance reading between terminals B and C of the potentiometer.
3. Slowly turn the temperature control from maximum cooling to the maximum heat position and check the
resistance reading between terminals B and C of the potentiometer.
automatic temperature control module connector terminal D2 and terminal B of the temperature control
the temperature control potentiometer.
C of the temperature control potentiometer connector for wires 942 Black and 933 Black.
- If continuity is not detected check wire 933 Black between the temperature control potentiometer and splice
C-SP20.
SM 8-12550 Issued 09-2004

12 SECTION 10012
Error Code 06
Fault Description
Recirculating air control potentiometer resistance too high (above 11000 Ohms).
System Response.
No manual recirculating air control.
Possible Cause
1. Recirculating air control potentiometer signal open circuit.
2. Recirculating air control potentiometer ground open circuit.
3. Recirculating air control potentiometer.

1. Check for error codes 04, 05, 08 and10.
2. Disconnect the recirculating air control potentiometer from the harness, turn the recirculating air control to
the maximum fresh air intake position. Check the resistance reading between terminals B and C of the
potentiometer.
3. Slowly turn the recirculating air control from maximum fresh air intake to the maximum recirculating air
position and check the resistance reading between terminals B and C of the potentiometer.
automatic temperature control module connector terminal F2 and terminal B of the recirculating air control
the recirculating air control potentiometer.
C of the recirculating air control potentiometer connector for wires 942 Black and 936 Black.
- If continuity is not detected check wire 936 Black between the recirculating air control potentiometer and
splice C-SP20.
Error Code 07
Fault Description
Resistance measured at terminal B3 of the automatic temperature control module too high.
System Response.
System operates normally.
Possible Cause
1. Ground signal wire from terminal B3 of the automatic temperature control module open circuit.

1. Check wire 938 Black between splice C-SP21 and the automatic temperature control module connector
terminal B3.
SM 8-12550 Issued 09-2004

SECTION 10012 13
Error Code 08
Fault Description
Cab temperature sensor open circuit or shorted high.
System Response.
The automatic temperature control module defaults to 20°C (68°F) setpoint. The automatic temperature c ontrol
will not operate.
NOTE: Error code 08 will be displayed if the cab temperature is below -19°C (-2°F), as the cab
temperature increases error code 08 will no longer be displayed.
Possible Cause
1. Cab air temperature sensor wiring open circuit.
2. Damaged cab air temperature sensor.

- If error codes 04,05, 06 and 10 are present, check wire 942 Black between splice C-SP21 and the
automatic temperature control module connector terminal F3.
2. Check the cab air temperature sensor for damage and replace as necessary.
3. Disconnect the cab air temperature sensor from the harness and check the resistance reading between the
terminals of the sensor, refer to “Temperature Sensor Resistance Chart” on page 14.
- if the readings are incorrect replace the sensor.
4. Disconnect the automatic temperature control module from the harness and check for continuity between
terminal A of the cab air temperature sensor connector and terminal C2 of the automatic temperature control
module connector for wire 930 Orange.
the cab air temperature sensor.
5. Check for continuity between terminal B of the cab air temperature sensor connector and terminal F3 of the
automatic temperature control module connector for wires 924 Black and 931 Black.
- If continuity is not detected check wire 931 Black between splice C-SP21 and the cab air temperature
sensor.
Error Code 10
Fault Description
Evaporator freeze sensor open circuit or shorted high.
System Response.
The automatic temperature control will only control the heater valve, the compressor will not operate.
Possible Cause
1. Evaporator freeze sensor wiring open circuit.
2. Damaged evaporator freeze sensor.

- If error codes 04,05, 06 and 08 are present, check wire 942 Black between splice C-SP21 and the
automatic temperature control module connector terminal F3.
2. Check the evaporator freeze sensor for damage and replace as necessary. Make sure the freeze sensor is
positioned correctly into the evaporator.
3. Disconnect the evaporator freeze sensor from the harness and check the resistance reading between the
terminals of the sensor, refer to “Temperature Sensor Resistance Chart” on page 14.
- if the readings are incorrect replace the sensor.
continued...
SM 8-12550 Issued 09-2004

14 SECTION 10012
4. Disconnect the automatic temperature control module from the harness and check for continuity between
terminal B of the evaporator freeze sensor connector and terminal B1 of the automatic temperature control
module connector for wire 920 Orange.
the cab air temperature sensor.
5. Check for continuity between terminal A of the evaporator freeze sensor connector and terminal F3 of the
automatic temperature control module connector for wires 924 Black and 959 Black.
- If continuity is not detected check wire 959 Black between splice C-SP21 and the evaporator freeze sensor.
Temperature Sensor Resistance Chart
TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
°C °F OHMS °C °F OHMS
0 32 65300 - 66600 13.33 56 33500 - 34700
0.56 33 63500 - 64800 13.89 57 32600 - 33800
1.11 34 61700 - 63000 14.44 58 31700 - 32300
1.67 35 59900 - 61300 15.00 59 30900 - 32100
2.22 36 58200 - 59600 15.56 60 30100 - 31300
2.78 37 56600 - 57900 16.11 61 29300 - 30500
3.33 38 55000 - 56300 16.67 62 28600 - 29700
3.89 39 53400 - 54800 17.22 63 27800 - 29000
4.44 40 51900 - 53300 17.78 64 27100 - 28300
5.00 41 50500 - 51900 18.33 65 26400 - 27600
5.56 42 49100 - 50500 18.89 66 25800 - 26800
6.11 43 47800 - 49100 19.44 67 25100 - 26200
6.67 44 46400 - 47800 20.00 68 24500 - 25600
7.22 45 45200 - 46500 20.56 69 23900 - 24900
7.78 46 44300 - 45600 21.11 70 23300 - 24300
8.33 47 42700 - 44100 21.67 71 22700 - 23700
8.89 48 41600 - 42900 22.22 72 22100 - 23200
9.44 49 40500 - 41800 22.78 73 21600 - 22600
10.00 50 39400 - 40700 23.33 74 21000 - 22100
10.56 51 38300 - 39600 23.89 75 20500 - 21500
11.11 52 37300 - 38600 24.44 76 20000 - 21000
11.67 53 36300 - 37600 25.00 77 19500 - 20500
12.22 54 35300 - 36600 25.56 78 19000 - 20000
12.78 55 34400 - 35600 26.11 79 18600 - 19500
SM 8-12550 Issued 09-2004

SECTION 10012 15
Air Conditioning Components (Cab Front)
11 3
10
9 13
8
12
6 4
5
1
MI04F104
1. RIGHT HAND BLOWER MOTOR 7. EVAPORATOR fREEZE SENSOR CONNECTOR

2. LEFT HAND BLOWER MOTOR 8. AIR CONDITIONING MODE SWITCH
3. LOW PRESSURE SWITCH 9. RECIRCULATING AIR CONTROL POTENTIOMETER
4. BLOWER MOTOR PWM CONTROLLER 10. BLOWER MOTOR CONTROL POTENTIOMETER
5. HEATER CONTROL VALVE 11. TEMPERATURE CONTROL POTENTIOMETER
6. AUTOMATIC TEMPERATURE CONTROL MODULE 12. DIGITAL DISPLAY
13. LOCKOUT RELAY
SM 8-12550 Issued 09-2004

16 SECTION 10012
Air Conditioning Components (Rear and Left Hand Side of Cab)
16
G4
14
15
MI04F098
14. RECIRCULATING AIR DOOR MOTOR 16. CENTIGRADE/FAHRENHEIT CONNECTOR

15. CAB TEMPERATURE SENSOR G4. CHASSIS GROUND CONNECTION G4
SM 8-12550 Issued 09-2004

SECTION 10012 17
Automatic Temperature Control Schematic Circuit

BLOWER MOTORS, BLOWER MOTOR PWM CONTROL, LOCKOUT RELAY PRESSURE SWITCHES, HEATER VALVE MOTOR, RECIRCULATING DOOR MOTOR, TEMPERATURE SENSORS CONTROL POTENTIOMETERS, MODE SWITCH, DIGITAL DISPLAY
21
2 3
5 8
18 19
16 17
10 13
E
F
A 12
B
14
20
9
6 11
7
C 15
D
MI04F009
Key
1. CIRCUIT BREAKER 12. MAIN CAB CHASSIS GROUND SPLICE 12 - CAB WORK LIGHTS, A. FROM ENGINE COLD START RELAYS AUTOMATIC TEMPERATURE CONTROL MODULE CONNECTOR
2. LEFT HAND BLOWER MOTOR REAR TURN SIGNAL LIGHTS, LH FRONT TURN SIGNAL LIGHT, B. FROM INSTRUMENT CLUSTER PIN IDENTIFICATION
3. RIGHT HAND BLOWER MOTOR BEACON LIGHT, AERIAL C. TO ENGINE CONTROLLER
A1 LOCKOUT RELAY D1 HIGH PRESSURE SWITCH SIGNAL
4. BLOWER MOTOR PWM CONTROLLER 13. RECIRCULATING AIR DOOR MOTOR D. TO SPLICE 7 - HEADLIGHTS, A2 AIR CONDITIONING MODE SWITCH (DEFROST D2 TEMPERATURE CONTROL POTENTIOMETER
5. LOCKOUT RELAY 14. EVAPORATOR FREEZE SENSOR WORKLIGHTS, STARTER RELAY SIGNAL) SIGNAL
6. SUPPRESSION DIODE 15. CAB TEMPERATURE SENSOR E. FROM AIR FILTER RESTRICTION SWITCH A3 RECIRCULATING DOOR CONTROL SIGNAL D3 SWITCHED POWER
7. AIR CONDITIONING COMPRESSOR 16. TEMPERATURE CONTROL POTENTIOMETER F. FROM COOLANT LEVEL SENDER B1 EVAPORATOR FREEZE SENSOR E1 BLOWER MOTOR CONTROL POTENTIOMETER
SIGNAL
8. LOW PRESSURE SWITCH 17. BLOWER MOTOR CONTROL POTENTIOMETER
B2 AIR CONDITIONING MODE SWITCH (AUTO SIG- E2 HEATER VALVE CONTROL SIGNAL
9. HIGH PRESSURE SWITCH 18. RECIRCULATING AIR DOOR CONTROL POTENTIOMETER NAL)
10. HEATER VALVE MOTOR 19. AIR CONDITIONING MODE SWITCH B3 GROUND SIGNAL E3 GROUND
11. MAIN CAB CHASSIS GROUND SPLICE 11 - FRONT LOWER WORK 20. CENTIGRADE/FAHRENHEIT CONNECTOR C1 LOW PRESSURE SWITCH SIGNAL F1 BLOWER MOTOR PWM CONTROLLER SIGNAL
LIGHTS, CAB HEADLIGHTS, FRONT AND REAR WIPERS, RADIO, 21. DIGITAL DISPLAY C2 CAB TEMPERATURE SENSOR F2 RECIRCULATING DOOR CONTROL
INTERIOR LIGHT, RH CONSOLE LIGHT, No PLATE LIGHT
C3 OPEN F3 CONTROL POTENTIOMETER COMMON GROUND
SM 8-12550 Issued 08-2004

18 SECTION 10012
SM 8-12550 Issued 08-2004

SECTION 10012 19
MAIN CONNECTORS
Connector 1
Location: Instrument panel
477I96
INSTRUMENT PANEL TO CAB HARNESS

(CAB HARNESS SIDE)

A 830 R FRONT WIPER MOTOR B+
B 835 O FRONT WIPER/WASHER
C 871 R INTERIOR LIGHT, RADIO
D 923 O A/C HIGH PRESSURE SWITCH
E 924 O A/C HIGH PRESSURE SWITCH
F 962 O A/C COMPRESSOR
G 870 R RADIO SWITCHED B+
H 756 P LH TURN SIGNAL
J 757 P RH TURN SIGNAL
K 784 V LOWER CAB WORK LIGHTS
L 776 P ROTARY BEACON LIGHT
M 794 P LH REAR CAB WORK LIGHTS
N 794 P RH REAR CAB WORK LIGHTS
P 726 P RH POSITION LIGHT/NO PLATE LIGHT
R 707 P LH POSITION LIGHT
S 840 R REAR WINDSCREEN WIPER B+
T 842 O REAR WINDSCREEN WASHER
U 952 B BLOWER MOTOR PWM CONTROLLER CLEAN GROUND
V 953 B BLOWER MOTOR PWM CONTROLLER CLEAN GROUND
W 781 V RH FRONT CAB WORK LIGHTS
X 791 V LH FRONT CAB WORK LIGHTS
Y 747 P CAB HEADLIGHTS (HIGH)
Z 746 P CAB HEADLIGHTS (LOW)
SM 8-12550 Issued 09-2004

20 SECTION 10012
Connector 10
DI99A036

(ENGINE HARNESS DE)

4 162 R UNSWITCHED B+ - CLOCK, 25 280 BR RADAR GROUND

RADIO AND INSTRUMENT 26 281 Y RADAR SIGNAL
CLUSTER
27 280 R RADAR B+
6 803 O A/C COMPRESSOR CLUTCH 29 603 R VP44 POWER (10A)
30 600 R BATTERY B+ (7.5A)
7 ----- OPEN
8 ----- OPEN
32 601 R BATTERY B+ (7.5A)
33 132 R SWITCHED B+
ENGINE RPM 34 602 R BATTERY B+ (7.5A)
11 ----- OPEN 35 603 R VP44 POWER (10A)
12 ----- OPEN 36 900 Y CAN HIGH
13 266 Y AIR FILTER RESTRICTION 37 900 LG CAN LOW
SWITCH 38 ----- OPEN
14 121 Y ALTERNATOR D+ TERMINAL,
39 ----- OPEN
WARNING LIGHT AND EXCITE
40 644 Y REMOTE THROTTLE SIGNAL
15 829 BR/W ATC CLEAN GROUND
16 890 R HORN B+
42 ----- OPEN
17 890 BR HORN GROUND
43 ----- OPEN
18 828 BR/W ATC CLEAN GROUND
19 738 P RH HEADLIGHT - LOW BEAM
45 ----- OPEN
20 741 P RH HEADLIGHT - HIGH BEAM
46 ----- OPEN
21 ----- OPEN
47 ----- OPEN
48 ----- OPEN
SM 8-12550 Issued 09-2004

SECTION 10012 21
Connector 90
Location: Cab Roof
MI04A062
AUTOMATIC TEMPERATURE CONTROL MODULE CONNECTOR

A1 919 O LOCKOUT RELAY
A2 928 O AIR CONDITIONING MODE SWITCH (DEFROST SIGNAL)
A3 937 O RECIRCULATING DOOR CONTROL SIGNAL
B1 920 O EVAPORATOR FREEZE SENSOR
B2 929 O AIR CONDITIONING MODE SWITCH (AUTO SIGNAL)
B3 938 B GROUND SIGNAL
C1 921 O LOW PRESSURE SWITCH SIGNAL
C2 930 O CAB TEMPERATURE SENSOR
C3 ----- OPEN
D1 923 O HIGH PRESSURE SWITCH SIGNAL
D2 932 O TEMPERATURE CONTROL POTENTIOMETER SIGNAL
D3 940 R SWITCHED POWER
E1 925 O BLOWER MOTOR CONTROL POTENTIOMETER SIGNAL
E2 934 O HEATER VALVE CONTROL SIGNAL
E3 941 B GROUND
F1 927 O BLOWER MOTOR PWM CONTROLLER SIGNAL
F2 935 O RECICULATING DOOR CONTROL POTENTIOMETER
SIGNAL
F3 942 B CONTROL POTENTIOMETER COMMON GROUND
SM 8-12550 Issued 09-2004

McCormick ZTX230 Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

McCormick ZTX230 Service Manual

Uploaded by

Copyright:

Available Formats

Table of Contents

ZTX Series Tractors

9 CHASSIS AND MOUNTED EQUIPMENT

SAFETY, GENERAL INFORMATION

© 2001 McCormick Tractors International Limited.

STANDARD TORQUE DATA FOR NUTS AND BOLTS

SM 8-10080 Issued 03-2001

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

To prevent injury always follow the Warning,

observe pertinent laws and regulations.

Operator’s and Service Manuals may be

DO NOT OPERATE WARNING: If you wear clothing that is too

WARNING: When working in the area of

WARNING: Use insulated gloves or

SM 8-10080 Issued 03-2001

CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

SM 8-10080 Issued 03-2001

SM 8-10080 Issued 03-2001

STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

Chart 2 (Phosphate Coated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

GENERAL SPECIFICATIONS AND TORQUES

ZTX Series Tractors

© 2004 McCormick Tractors International Limited.

SM 8-12501 Issued 06-2004

Lubricants and Capacities

AIR CONDITIONER SYSTEM

BATTERY SAE (COLD CRANKING AMPERE RESERVE

644 660 Amps 440 Amps 400 Amps 95 180 mins

Alternator ..................................................................................................................................... 12 Volt, 150 Amp

SM 8-12501 Issued 06-2004

DIFFERENTIAL AND DIFFERENTIAL LOCK

SM 8-12501 Issued 06-2004

COMPRESSOR AND SYSTEM LUBRICATION

HIGH PRESSURE SWITCH

LOW PRESSURE SWITCH

SM 8-12501 Issued 06-2004

MFD DRIVE SHAFT

Cab and Chassis

SM 8-12501 Issued 06-2004

ZTX Series Tractors

© 2004 McCormick Tractors International Limited.

Page!2 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!3

Page!4 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!5

Page!6 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!7

Page!8 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!9

Page!10 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!11

Page!12 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!13

Page!14 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!15

Page!16 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!17