CASE IH Magnum 215, 245, 275, 305 Series Tractor Service Repair Manual Instant Download

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  1. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 NOTE: Engine repair information is not contained within this tractor Repair Manual. For engine repair, refer to publication number 87515687 for the 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System. BOOK 1 - General, Electrical, Engine, Steering - 87525613 STANDARD TORQUE SPECIFICATIONS ........................................................................................SECTION 1000 TORQUE SPECIFICATIONS - METRIC HARDWARE ............................................................................... 1000-4 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ................................................................ 1000-5 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ................................................................ 1000-6 SAFETY, GENERAL INFORMATION, MAINTENANCE SCHEDULE ...............................................SECTION 1001 SAFETY ...................................................................................................................................................... 1001-3 GENERAL INFORMATION ......................................................................................................................... 1001-5 LUBRICATION/MAINTENANCE CHART ................................................................................................... 1001-6 SYSTEM CAPACITIES ............................................................................................................................... 1001-7 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION.....................................................SECTION 2001 COOLING SYSTEM MODULE REMOVAL ................................................................................................. 2001-3 COOLING SYSTEM MODULE INSTALLATION ......................................................................................... 2001-7 ENGINE REMOVAL AND INSTALLATION........................................................................................SECTION 2002 SPECIAL TORQUES .................................................................................................................................. 2002-3 ENGINE REMOVAL .................................................................................................................................... 2002-4 ENGINE INSTALLATION .......................................................................................................................... 2002-21 VISCOUS FAN DRIVE TEST.............................................................................................................SECTION 2003 REQUIRED TOOLS .................................................................................................................................... 2003-3 DIAGNOSTIC PROCEDURE ...................................................................................................................... 2003-4 FAN SPEED TEST ..................................................................................................................................... 2003-7 FUEL TANK / FUEL SENDER REMOVAL AND INSTALLATION......................................................SECTION 3001 SPECIAL TORQUES .................................................................................................................................. 3001-3 FUEL TANK REMOVAL AND INSTALLATION .......................................................................................... 3001-3 FUEL LEVEL SENDER REMOVAL AND INSTALLATION........................................................................ 3001-10 ELECTRICAL SCHEMATIC POSTER - Prior to P.I.N. Z6RZ04001 ...........................................................87389708 ELECTRICAL SCHEMATIC POSTER - P.I.N. Z6RZ04001 and After.........................................................87588600 ELECTRICAL SCHEMATIC POSTER - P.I.N. Z7RZ01521 and After.........................................................87624272 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING.........................................SECTION 4001 SPECIAL TOOLS ........................................................................................................................................ 4001-4 FUSES AND RELAY IDENTIFICATION ..................................................................................................... 4001-5 Cab Fuses/Relay Location ........................................................................................................................ 4001-5 Engine Compartment Fuse/Relay Identification (Power Distribution Box) ................................................ 4001-5 Fuse Identification ..................................................................................................................................... 4001-6 Relays ....................................................................................................................................................... 4001-7 INSTRUMENTATION AND CONTROLS .................................................................................................... 4001-8 CONNECTOR AND COMPONENT LOCATIONS .................................................................................... 4001-12 ELECTRICAL CONNECTORS ................................................................................................................. 4001-35 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ............................................................. 4001-142 Power Distribution System Circuit Operation ........................................................................................ 4001-142 Power Distribution Circuit Troubleshooting ........................................................................................... 4001-142 Power Distribution Schematic ............................................................................................................... 4001-142 87710917 - TOC - 1

  2. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 POWER DISTRIBUTION SYMPTOM CHART ....................................................................................... 4001-143 Diagnostic Tests .................................................................................................................................... 4001-144 AUDIO SYSTEM ..................................................................................................................................... 4001-146 Audio System Circuit Operation ............................................................................................................ 4001-146 Audio System Circuit Troubleshooting .................................................................................................. 4001-146 Audio System Symptom Chart .............................................................................................................. 4001-146 Audio System Diagnostic Tests ............................................................................................................ 4001-148 CHARGING SYSTEM ............................................................................................................................. 4001-152 Charging System Circuit Operation ....................................................................................................... 4001-152 Charging System Circuit Troubleshooting ............................................................................................. 4001-152 Charging System Symptom Chart ......................................................................................................... 4001-153 Charging System Diagnostic Tests ....................................................................................................... 4001-154 EXTERIOR LIGHTING SYSTEM ............................................................................................................ 4001-158 Exterior Lighting System Circuit Operation ........................................................................................... 4001-158 Exterior Lighting System Circuit Troubleshooting ................................................................................. 4001-158 Exterior Lighting System Symptom Chart ............................................................................................. 4001-159 Exterior Lighting System Diagnostic Tests ............................................................................................ 4001-159 INSTRUMENTATION AND WARNING SYSTEM ................................................................................... 4001-164 Instrumentation and Warning System Circuit Troubleshooting ............................................................. 4001-164 Instrumentation and Warning System Symptom Chart ......................................................................... 4001-164 Instrumentation and Warning System Diagnostic Tests ....................................................................... 4001-165 INTERIOR LIGHTING AND HORN SYSTEM ......................................................................................... 4001-168 Interior Lighting and Horn System Circuit Operation ............................................................................. 4001-168 Interior Lighting and Horn System Circuit Troubleshooting ................................................................... 4001-168 Interior Lighting and Horn System Symptom Chart ............................................................................... 4001-169 Interior Lighting and Horn System Diagnostic Tests ............................................................................. 4001-169 POWER MIRROR SYSTEM ................................................................................................................... 4001-173 Power Mirror Circuit Operation .............................................................................................................. 4001-173 Power Mirror Circuit Troubleshooting .................................................................................................... 4001-173 Power Mirror System Symptom Chart ................................................................................................... 4001-174 Power Mirror System Diagnostic Tests ................................................................................................. 4001-176 POWER SEAT SYSTEM ........................................................................................................................ 4001-185 Power Seat System Circuit Operation ................................................................................................... 4001-185 Power Seat System Circuit Troubleshooting ......................................................................................... 4001-185 Power Seat System Symptom Chart ..................................................................................................... 4001-186 Power Seat System Diagnostic Tests ................................................................................................... 4001-187 STARTING SYSTEM .............................................................................................................................. 4001-191 Starting System Circuit Operation ......................................................................................................... 4001-191 Starter Motor Circuit Troubleshooting ................................................................................................... 4001-191 Starting System Symptom Chart ........................................................................................................... 4001-191 Starting System Diagnostic Tests ......................................................................................................... 4001-193 WIPER/WASHER SYSTEM .................................................................................................................... 4001-198 Wiper/Washer System Circuit Operation .............................................................................................. 4001-198 Wiper/Washer System Circuit Troubleshooting .................................................................................... 4001-198 Wiper/Washer System Symptom Chart ................................................................................................ 4001-199 Wiper/Washer System Diagnostic Tests ............................................................................................... 4001-200 STEERING COLUMN AND STEERING HAND PUMP......................................................................SECTION 5001 SPECIAL TOOLS ........................................................................................................................................ 5001-2 SPECIAL TORQUES .................................................................................................................................. 5001-3 STEERING COLUMN AND STEERING HAND PUMP .............................................................................. 5001-3 REMOVAL .................................................................................................................................................. 5001-3 STEERING HAND PUMP SERVICE .......................................................................................................... 5001-7 STEERING COLUMN ASSEMBLY ............................................................................................................. 5001-9 INSTALLATION ........................................................................................................................................ 5001-10 87710917 - TOC - 2

  3. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BOOK 1A - Electrical (continued) - 87611218 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING, P.I.N. Z6RZ04001 AND AFTER SPECIAL TOOLS ........................................................................................................................................... 4002-4 FUSES AND RELAY IDENTIFICATION ......................................................................................................... 4002-5 Cab Fuses/Relay Location .......................................................................................................................... 4002-5 Engine Compartment Fuse/Relay Identification (Power Distribution Box) .................................................. 4002-5 Fuse Identification ....................................................................................................................................... 4002-6 Relays ......................................................................................................................................................... 4002-7 INSTRUMENTATION AND CONTROLS ....................................................................................................... 4002-8 CONNECTOR AND COMPONENT LOCATIONS ........................................................................................ 4002-12 ELECTRICAL CONNECTORS ..................................................................................................................... 4002-34 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ................................................................ 4002-141 Power Distribution System Circuit Operation .......................................................................................... 4002-141 Power Distribution Circuit Troubleshooting ............................................................................................. 4002-141 Power Distribution Schematic ................................................................................................................. 4002-141 POWER DISTRIBUTION SYMPTOM CHART ........................................................................................... 4002-142 Diagnostic Tests ..................................................................................................................................... 4002-143 AUDIO SYSTEM ........................................................................................................................................ 4002-145 Audio System Circuit Operation .............................................................................................................. 4002-145 Audio System Circuit Troubleshooting .................................................................................................... 4002-145 Audio System Symptom Chart ................................................................................................................ 4002-145 Audio System Diagnostic Tests .............................................................................................................. 4002-147 CHARGING SYSTEM ................................................................................................................................ 4002-151 Charging System Circuit Operation ........................................................................................................ 4002-151 Charging System Circuit Troubleshooting .............................................................................................. 4002-151 Charging System Symptom Chart .......................................................................................................... 4002-152 Charging System Diagnostic Tests ......................................................................................................... 4002-153 EXTERIOR LIGHTING SYSTEM ............................................................................................................... 4002-157 Exterior Lighting System Circuit Operation ............................................................................................. 4002-157 Exterior Lighting System Circuit Troubleshooting ................................................................................... 4002-157 Exterior Lighting System Symptom Chart ............................................................................................... 4002-158 Exterior Lighting System Diagnostic Tests ............................................................................................. 4002-158 INSTRUMENTATION AND WARNING SYSTEM ...................................................................................... 4002-163 Instrumentation and Warning System Circuit Troubleshooting ............................................................... 4002-163 Instrumentation and Warning System Symptom Chart ........................................................................... 4002-163 Instrumentation and Warning System Diagnostic Tests ......................................................................... 4002-164 INTERIOR LIGHTING AND HORN SYSTEM ............................................................................................ 4002-167 Interior Lighting and Horn System Circuit Operation .............................................................................. 4002-167 Interior Lighting and Horn System Circuit Troubleshooting .................................................................... 4002-167 Interior Lighting and Horn System Symptom Chart ................................................................................ 4002-168 Interior Lighting and Horn System Diagnostic Tests ............................................................................... 4002-168 POWER MIRROR SYSTEM ....................................................................................................................... 4002-172 Power Mirror Circuit Operation ............................................................................................................... 4002-172 Power Mirror Circuit Troubleshooting ..................................................................................................... 4002-172 Power Mirror System Symptom Chart .................................................................................................... 4002-173 Power Mirror System Diagnostic Tests ................................................................................................... 4002-175 POWER SEAT SYSTEM ............................................................................................................................ 4002-184 Power Seat System Circuit Operation .................................................................................................... 4002-184 Power Seat System Circuit Troubleshooting .......................................................................................... 4002-184 Power Seat System Symptom Chart ...................................................................................................... 4002-185 Power Seat System Diagnostic Tests ..................................................................................................... 4002-186 87710917 - TOC - 3

  4. https://www.ebooklibonline.com Hello dear friend! Thank you very much for reading. Enter the link into your browser. The full manual is available for immediate download. https://www.ebooklibonline.com

  5. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 STARTING SYSTEM .................................................................................................................................. 4002-190 Starting System Circuit Operation ........................................................................................................... 4002-190 Starter Motor Circuit Troubleshooting ..................................................................................................... 4002-190 Starting System Symptom Chart ............................................................................................................. 4002-190 Starting System Diagnostic Tests ........................................................................................................... 4002-192 WIPER/WASHER SYSTEM ....................................................................................................................... 4002-197 Wiper/Washer System Circuit Operation ................................................................................................ 4002-197 Wiper/Washer System Circuit Troubleshooting ...................................................................................... 4002-197 Wiper/Washer System Symptom Chart .................................................................................................. 4002-198 Wiper/Washer System Diagnostic Tests ................................................................................................. 4002-199 BOOK 1B - Electrical (Continued) - 87678524 ELECTRICAL SCHEMATIC POSTER - P.I.N. Z7RZ01521 and After.........................................................87624272 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING, P.I.N. Z7RZ01521 AND AFTER .........................................................................................................SECTION 4003 SPECIAL TOOLS ........................................................................................................................................ 4003-4 FUSES AND RELAY IDENTIFICATION ..................................................................................................... 4003-5 Cab Fuses/Relay Location ........................................................................................................................ 4003-5 Engine Compartment Fuse/Relay Identification (Power Distribution Box) ................................................ 4003-5 Fuse Identification ..................................................................................................................................... 4003-6 Relays ....................................................................................................................................................... 4003-7 INSTRUMENTATION AND CONTROLS .................................................................................................... 4003-8 CONNECTOR AND COMPONENT LOCATIONS .................................................................................... 4003-12 Cab Exterior ............................................................................................................................................ 4003-12 Cab Interior ............................................................................................................................................. 4003-15 Engine/Engine Compartment .................................................................................................................. 4003-20 Transmission ........................................................................................................................................... 4003-27 Hitch System ........................................................................................................................................... 4003-31 ELECTRICAL CONNECTORS ................................................................................................................. 4003-33 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ............................................................. 4003-141 Power Distribution System Circuit Operation ........................................................................................ 4003-141 Power Distribution Circuit Troubleshooting ........................................................................................... 4003-141 Power Distribution Schematic ............................................................................................................... 4003-141 POWER DISTRIBUTION SYMPTOM CHART ....................................................................................... 4003-142 Diagnostic Tests .................................................................................................................................... 4003-143 AUDIO SYSTEM ..................................................................................................................................... 4003-147 Audio System Circuit Operation ............................................................................................................ 4003-147 Audio System Circuit Troubleshooting .................................................................................................. 4003-147 Audio System Symptom Chart .............................................................................................................. 4003-147 Audio System Diagnostic Tests ............................................................................................................ 4003-149 CHARGING SYSTEM ............................................................................................................................. 4003-153 Charging System Circuit Operation ....................................................................................................... 4003-153 Charging System Circuit Troubleshooting ............................................................................................. 4003-153 Charging System Symptom Chart ......................................................................................................... 4003-154 Charging System Diagnostic Tests ....................................................................................................... 4003-155 EXTERIOR LIGHTING SYSTEM ............................................................................................................ 4003-159 Exterior Lighting System Circuit Operation ........................................................................................... 4003-159 Exterior Lighting System Circuit Troubleshooting ................................................................................. 4003-159 Exterior Lighting System Symptom Chart ............................................................................................. 4003-160 Exterior Lighting System Diagnostic Tests ............................................................................................ 4003-160 INSTRUMENTATION AND WARNING SYSTEM ................................................................................... 4003-165 Instrumentation and Warning System Circuit Troubleshooting ............................................................. 4003-165 Instrumentation and Warning System Symptom Chart ......................................................................... 4003-165 Instrumentation and Warning System Diagnostic Tests ....................................................................... 4003-166 87710917 - TOC - 4

  6. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 INTERIOR LIGHTING AND HORN SYSTEM ......................................................................................... 4003-169 Interior Lighting and Horn System Circuit Operation ............................................................................. 4003-169 Interior Lighting and Horn System Circuit Troubleshooting ................................................................... 4003-169 Interior Lighting and Horn System Symptom Chart ............................................................................... 4003-170 Interior Lighting and Horn System Diagnostic Tests ............................................................................. 4003-170 POWER MIRROR SYSTEM ................................................................................................................... 4003-174 Power Mirror Circuit Operation .............................................................................................................. 4003-174 Power Mirror Circuit Troubleshooting .................................................................................................... 4003-174 Power Mirror System Symptom Chart ................................................................................................... 4003-175 Power Mirror System Diagnostic Tests ................................................................................................. 4003-177 POWER SEAT SYSTEM ........................................................................................................................ 4003-186 Power Seat System Circuit Operation ................................................................................................... 4003-186 Power Seat System Circuit Troubleshooting ......................................................................................... 4003-186 Power Seat System Symptom Chart ..................................................................................................... 4003-187 Power Seat System Diagnostic Tests ................................................................................................... 4003-188 STARTING SYSTEM .............................................................................................................................. 4003-192 Starting System Circuit Operation ......................................................................................................... 4003-192 Starter Motor Circuit Troubleshooting ................................................................................................... 4003-192 Starting System Symptom Chart ........................................................................................................... 4003-192 Starting System Diagnostic Tests ......................................................................................................... 4003-194 WIPER/WASHER SYSTEM .................................................................................................................... 4003-199 Wiper/Washer System Circuit Operation .............................................................................................. 4003-199 Wiper/Washer System Circuit Troubleshooting .................................................................................... 4003-199 Wiper/Washer System Symptom Chart ................................................................................................ 4003-200 Wiper/Washer System Diagnostic Tests ............................................................................................... 4003-201 BOOK 2 - Power Train - 87678525 POWERSHIFT TRANSMISSION SYSTEM - HOW IT WORKS AND TROUBLESHOOTING...........SECTION 6000 TRANSMISSION SYSTEM INTRODUCTION ............................................................................................ 6000-3 TRANSMISSION SYSTEM CONTROLS .................................................................................................... 6000-5 TRANSMISSION SYSTEM COMPONENTS .............................................................................................. 6000-6 TRANSMISSION LUBE AND DISTRIBUTION TUBES .............................................................................. 6000-8 POWERSHIFT TRANSMISSION CLUTCH LAYOUT ............................................................................... 6000-10 POWERSHIFT VALVE CLUTCH ENGAGEMENTS ................................................................................. 6000-11 POWER FLOW (REVERSE SPEEDS) ..................................................................................................... 6000-30 POWER FLOW (REVERSE SPEEDS) ..................................................................................................... 6000-32 POWER FLOW (FORWARD CREEPER DRIVE SPEEDS) ..................................................................... 6000-34 POWER FLOW (REVERSE CREEPER DRIVE SPEEDS) ...................................................................... 6000-40 INCHING VALVE OPERATION ................................................................................................................ 6000-42 INSTRUMENTATION CLUSTER - TRANSMISSION LEAKAGE CHECK ................................................ 6000-46 MASTER CLUTCH PRESSURE CHECK ................................................................................................. 6000-49 TRANSMISSION INPUT SHAFT AND DRIVE PLATE.......................................................................SECTION 6001 SPECIAL TORQUES .................................................................................................................................. 6001-3 TRANSMISSION INPUT SHAFT AND DRIVE PLATE REMOVAL ............................................................ 6001-4 TRANSMISSION INPUT SHAFT AND DRIVE PLATE INSTALLATION .................................................... 6001-8 INPUT DROP BOX.............................................................................................................................SECTION 6002 SPECIAL TOOLS ........................................................................................................................................ 6002-3 SPECIAL TORQUES .................................................................................................................................. 6002-3 INPUT DROP BOX ..................................................................................................................................... 6002-4 DISASSEMBLY ........................................................................................................................................... 6002-6 87710917 - TOC - 5

  7. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 ENGINE FRAME AND DROP BOX SPLIT.........................................................................................SECTION 6003 SPECIAL TORQUES .................................................................................................................................. 6003-3 SPECIAL TOOLS ........................................................................................................................................ 6003-3 ENGINE FRAME AND DROP BOX SPLIT ................................................................................................. 6003-4 REMOVAL .................................................................................................................................................. 6003-4 INSTALLATION .......................................................................................................................................... 6003-6 SPEED TO RANGE TRANSMISSION SPLIT ....................................................................................SECTION 6005 SPECIAL TOOLS ........................................................................................................................................ 6005-3 SPECIAL TORQUES .................................................................................................................................. 6005-3 SPEED TO RANGE TRANSMISSION SPLIT ............................................................................................. 6005-4 REMOVAL .................................................................................................................................................. 6005-4 INSTALLATION .......................................................................................................................................... 6005-7 SPEED TRANSMISSION...................................................................................................................SECTION 6006 PICTORIAL INDEX - SPEED TRANSMISSION ......................................................................................... 6006-3 SPECIFICATIONS ...................................................................................................................................... 6006-4 SPECIAL TORQUES .................................................................................................................................. 6006-4 TROUBLESHOOTING AFTER SPEED TRANSMISSION REPAIR ........................................................... 6006-4 SPECIAL TOOLS ........................................................................................................................................ 6006-5 SPEED TRANSMISSION WITH CREEP OPTION ..................................................................................... 6006-6 ASSEMBLING THE COUNTERSHAFT WITH CREEPER SPEED CLUTCH .......................................... 6006-14 TRANSMISSION ASSEMBLY WITH CREEP OPTION ............................................................................ 6006-78 TRANSMISSION ASSEMBLY WITHOUT CREEP OPTION .................................................................... 6006-80 RANGE TRANSMISSION TO REAR FRAME SPLIT.........................................................................SECTION 6007 SPECIAL TOOLS ........................................................................................................................................ 6007-3 SPECIAL TORQUES .................................................................................................................................. 6007-3 RANGE TRANSMISSION TO REAR FRAME SPLIT ................................................................................. 6007-4 DISASSEMBLY ........................................................................................................................................... 6007-4 ASSEMBLY ................................................................................................................................................. 6007-7 RANGE TRANSMISSION ..................................................................................................................SECTION 6008 SPECIFICATIONS ...................................................................................................................................... 6008-3 TROUBLESHOOTING AFTER RANGE TRANSMISSION REPAIR .......................................................... 6008-3 SPECIAL TORQUES .................................................................................................................................. 6008-3 SPECIAL TOOLS ........................................................................................................................................ 6008-4 RANGE TRANSMISSION ........................................................................................................................... 6008-5 Removing the Shaft Master Clutch ........................................................................................................... 6008-5 Removing the Input Shaft, Countershaft and Mechanical Front Drive (MFD) / Park Brake Assembly ..... 6008-7 Disassembly of the Master Clutch ........................................................................................................... 6008-12 Exploded View of the Master Clutch ....................................................................................................... 6008-14 Assembly of the Master Clutch ............................................................................................................... 6008-15 Disassembly of the Range Transmission Input Shaft ............................................................................. 6008-16 Exploded View of the Range Transmission Input Shaft .......................................................................... 6008-22 Assembly of the Range Transmission Input Shaft .................................................................................. 6008-23 Cross-Section of Input Shaft ................................................................................................................... 6008-32 Disassembly of the Range Transmission Countershaft .......................................................................... 6008-33 Exploded View of the Range Transmission Countershaft ....................................................................... 6008-37 Assembly of the Range Transmission Countershaft ............................................................................... 6008-38 Mechanical Front Drive (MFD) - Emergency Brake Disassembly ........................................................... 6008-45 Exploded View of MFD and Emergency Brake ....................................................................................... 6008-51 Assembly of the MFD / Emergency Brake .............................................................................................. 6008-52 Exploded View of the Range Transmission Countershaft, Input Shaft, and MFD Input Shaft ................ 6008-66 Installing the Range Transmission Countershaft, Input Shaft, and MFD Input Shaft into the Range Transmission Housing .................................................................. 6008-67 87710917 - TOC - 6

  8. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 SETTING THE END PLAY OF THE RANGE TRANSMISSION COUNTERSHAFT AND INPUT SHAFT ................................................................................................... 6008-73 Installing the Range Input Master Clutch ................................................................................................ 6008-75 TRANSMISSION CONTROL VALVES AND INCHING VALVE .........................................................SECTION 6009 SPECIAL TORQUES .................................................................................................................................. 6009-3 POWERSHIFT TRANSMISSION CONTROL VALVES .............................................................................. 6009-3 TRANSMISSION CONTROL VALVE CONFIGURATION .......................................................................... 6009-4 INCHING VALVE ...................................................................................................................................... 6009-15 REAR FRAME....................................................................................................................................SECTION 6011 (NOTE: Book 2A contains updated information in Section 6011. Use Section 6011 in Book 2A in place of this original section.) HYDRAULIC PUMP DRIVE ...............................................................................................................SECTION 6012 SPECIAL TORQUES .................................................................................................................................. 6012-3 SPECIFICATIONS ...................................................................................................................................... 6012-3 PUMP DRIVE .............................................................................................................................................. 6012-3 Removal .................................................................................................................................................... 6012-3 Disassembly .............................................................................................................................................. 6012-4 Assembly ................................................................................................................................................... 6012-7 Installation ............................................................................................................................................... 6012-12 MECHANICAL FRONT DRIVE (MFD) CONTROL SYSTEM - HOW IT WORKS ..............................SECTION 6013 MECHANICAL FRONT DRIVE (MFD) ........................................................................................................ 6013-3 ELECTRONIC MFD CONTROL ................................................................................................................. 6013-5 MFD CONTROL MODES ........................................................................................................................... 6013-7 MFD FUNCTIONAL TESTS ........................................................................................................................ 6013-8 MFD Valve ................................................................................................................................................ 6013-9 Solenoid Cartridge Valve .......................................................................................................................... 6013-9 TROUBLESHOOTING .............................................................................................................................. 6013-10 DIFFERENTIAL LOCK CONTROL SYSTEM - HOW IT WORKS......................................................SECTION 6014 ELECTRONIC DIFFERENTIAL LOCK CONTROL ..................................................................................... 6014-5 DIFFERENTIAL LOCK CONTROL MODES ............................................................................................... 6014-7 DIFFERENTIAL LOCK CONTROL ............................................................................................................. 6014-8 DIFFERENTIAL LOCK FUNCTIONAL TESTS ........................................................................................... 6014-9 TROUBLESHOOTING .............................................................................................................................. 6014-12 PTO/DIFFERENTIAL LOCK VALVE CIRCUIT ......................................................................................... 6014-15 87710917 - TOC - 7

  9. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BOOK 2A - Power Train (Continued) - 87710918 REAR FRAME....................................................................................................................................SECTION 6011 SPECIFICATIONS ...................................................................................................................................... 6011-3 SPECIAL TORQUES .................................................................................................................................. 6011-3 SPECIAL TOOLS ........................................................................................................................................ 6011-3 DIFFERENTIAL .......................................................................................................................................... 6011-4 Removal .................................................................................................................................................... 6011-4 Disassembly ............................................................................................................................................ 6011-10 PINION SHAFT ......................................................................................................................................... 6011-14 Removal and Disassembly ...................................................................................................................... 6011-14 Assembly and Installation ....................................................................................................................... 6011-16 HEAVY DUTY PINION SHAFT ................................................................................................................. 6011-23 Removal and Disassembly ...................................................................................................................... 6011-23 Assembly and Installation ....................................................................................................................... 6011-25 DIFFERENTIAL ASSEMBLY .................................................................................................................... 6011-31 DIFFERENTIAL INSTALLATION .............................................................................................................. 6011-36 ADJUSTING THE DIFFERENTIAL PRELOAD ......................................................................................... 6011-43 ADJUSTING THE RING AND PINION BACKLASH ................................................................................. 6011-45 BEVEL PINION AND GEAR TOOTH CONTACT CHECK ........................................................................ 6011-46 BOOK 3 - Power Train (Continued), Brakes - 87689443 MFD OUTPUT SHAFT .......................................................................................................................SECTION 6015 SPECIAL TORQUES .................................................................................................................................. 6015-3 MFD OUTPUT SHAFT ................................................................................................................................ 6015-4 MFD DRIVE SHAFT...........................................................................................................................SECTION 6016 SPECIAL TORQUES .................................................................................................................................. 6016-3 MFD DRIVE SHAFT REMOVAL ................................................................................................................. 6016-4 MFD DRIVE SHAFT INSTALLATION ......................................................................................................... 6016-6 LIMITED SLIP MFD DIFFERENTIAL .................................................................................................SECTION 6017 SPECIFICATIONS ...................................................................................................................................... 6017-2 SPECIAL TORQUES .................................................................................................................................. 6017-2 SPECIAL TOOLS ........................................................................................................................................ 6017-2 DIFFERENTIAL CARRIER ASSEMBLY REMOVAL .................................................................................. 6017-3 DIFFERENTIAL DISASSEMBLY ................................................................................................................ 6017-4 Pinion Disassembly ................................................................................................................................... 6017-8 DIFFERENTIAL ASSEMBLY .................................................................................................................... 6017-11 DIFFERENTIAL CARRIER ASSEMBLY ................................................................................................... 6017-15 Pinion Position and Assembly ................................................................................................................. 6017-15 Shim Pack Thickness Chart .................................................................................................................. 6017-16 Setting The Pinion Depth ........................................................................................................................ 6017-17 Adjusting Bearing Preload ....................................................................................................................... 6017-20 DIFFERENTIAL INSTALLATION .............................................................................................................. 6017-22 Checking Backlash .................................................................................................................................. 6017-23 Ring Gear and Pinion Tooth Pattern Interpretation ................................................................................. 6017-25 Installation of Carrier Assembly to Axle Housing .................................................................................... 6017-27 87710917 - TOC - 8

  10. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 LOCKING MFD DIFFERENTIAL........................................................................................................SECTION 6018 SPECIFICATIONS ...................................................................................................................................... 6018-3 SPECIAL TORQUES .................................................................................................................................. 6018-3 SPECIAL TOOLS ........................................................................................................................................ 6018-3 REMOVAL OF THE FRONT DIFFERENTIAL CARRIER ASSEMBLY ....................................................... 6018-4 REMOVAL OF THE FRONT DIFFERENTIAL FROM THE CARRIER HOUSING ..................................... 6018-5 DISASSEMBLY OF THE DIFFERENTIAL .................................................................................................. 6018-7 PINION DISASSEMBLY ............................................................................................................................. 6018-9 ASSEMBLY OF THE DIFFERENTIAL ...................................................................................................... 6018-12 DIFFERENTIAL CARRIER ASSEMBLY ................................................................................................... 6018-16 SETTING THE PINION DEPTH ................................................................................................................ 6018-18 ADJUSTING BEARING PRELOAD .......................................................................................................... 6018-21 DIFFERENTIAL INSTALLATION .............................................................................................................. 6018-23 REAR AXLE AND PLANETARIES.....................................................................................................SECTION 6019 SPECIAL TOOLS ........................................................................................................................................ 6019-3 SPECIAL TORQUES .................................................................................................................................. 6019-5 SPECIFICATIONS ...................................................................................................................................... 6019-5 GENERAL INFORMATION ......................................................................................................................... 6019-5 REAR AXLE ................................................................................................................................................ 6019-6 AXLE HOUSING DISASSEMBLY ............................................................................................................... 6019-9 PLANETARY DISASSEMBLY .................................................................................................................. 6019-11 DIFFERENTIAL CARRIER SEAL REPLACEMENT ................................................................................. 6019-13 PLANETARY ASSEMBLY - THREE PIN .................................................................................................. 6019-14 PLANETARY ASSEMBLY - FOUR PIN .................................................................................................... 6019-15 AXLE HOUSING ASSEMBLY ................................................................................................................... 6019-18 HOW TO DETERMINE RAM PRESSURE ............................................................................................... 6019-23 AXLE INSTALLATION .............................................................................................................................. 6019-26 AXLE SEAL WEAR SLEEVE INSTALLATION (4-Inch Axle Only) ........................................................... 6019-30 POWER TAKE OFF CONTROL SYSTEM - HOW IT WORKS ..........................................................SECTION 6020 POWER TAKE OFF .................................................................................................................................... 6020-3 ELECTRONIC PTO CONTROL .................................................................................................................. 6020-4 PTO SYSTEM CONTROL .......................................................................................................................... 6020-7 PTO CONTROL MODES ............................................................................................................................ 6020-8 PTO VALVE OIL SUPPLY ........................................................................................................................ 6020-10 PTO/DIFFERENTIAL LOCK VALVE ......................................................................................................... 6020-11 TROUBLESHOOTING .............................................................................................................................. 6020-12 PTO CLUTCH ENGAGED ........................................................................................................................ 6020-13 TROUBLESHOOTING .............................................................................................................................. 6020-14 MFD PLANETARY HUB, STEERING KNUCKLE AND DRIVE SHAFT.............................................SECTION 6022 SPECIFICATIONS ...................................................................................................................................... 6022-3 SPECIAL TORQUES .................................................................................................................................. 6022-3 SPECIAL TOOLS ........................................................................................................................................ 6022-3 PLANETARY HUB DISASSEMBLY ............................................................................................................ 6022-4 STEERING KNUCKLE AND KINGPIN DISASSEMBLY ............................................................................. 6022-9 AXLE DRIVE SHAFT DISASSEMBLY ...................................................................................................... 6022-13 AXLE SHAFT ASSEMBLY ........................................................................................................................ 6022-14 KINGPIN ASSEMBLY ............................................................................................................................... 6022-16 STEERING KNUCKLE ASSEMBLY ......................................................................................................... 6022-20 PLANETARY HUB ASSEMBLY ................................................................................................................ 6022-24 Ten Bolt Axle Only .................................................................................................................................. 6022-29 Twelve Bolt Axle Only ............................................................................................................................. 6022-33 All Axles .................................................................................................................................................. 6022-38 87710917 - TOC - 9

  11. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 SUSPENSION MFD AXLE.................................................................................................................SECTION 6023 SPECIAL TORQUES .................................................................................................................................. 6023-2 SUSPENSION MFD AXLE ......................................................................................................................... 6023-3 Disassembly .............................................................................................................................................. 6023-3 Assembly ................................................................................................................................................. 6023-13 Position Sensor Adjustment .................................................................................................................... 6023-25 SUSPENSION MFD AXLE SYSTEM - HOW IT WORKS AND TROUBLESHOOTING.....................SECTION 6024 SUSPENDED MFD AXLE OPERATION .................................................................................................... 6024-3 SUSPENDED MFD AXLE- CALIBRATION MODE .................................................................................... 6024-9 ERROR TABLE ......................................................................................................................................... 6024-11 SUSPENDED MFD AXLE- MANUAL OPERATION MODE (TEST MODE) ............................................ 6024-13 SUSPENDED MFD AXLE- DEMONSTRATION MODE .......................................................................... 6024-16 PTO CLUTCH ASSEMBLY SINGLE, REVERSIBLE AND DUAL SPEED.........................................SECTION 6025 (NOTE: Book 3A contains updated information in Section 6025. Use Section 6025 in Book 3A in place of this original section.) BRAKE VALVE...................................................................................................................................SECTION 7001 SPECIAL TORQUES .................................................................................................................................. 7001-2 BRAKE VALVE ........................................................................................................................................... 7001-3 Removal .................................................................................................................................................... 7001-3 Disassembly .............................................................................................................................................. 7001-4 Assembly ................................................................................................................................................... 7001-6 Installation ................................................................................................................................................. 7001-8 BRAKE CYLINDERS..........................................................................................................................SECTION 7002 SPECIAL TORQUES .................................................................................................................................. 7002-3 SPECIFICATIONS ...................................................................................................................................... 7002-3 BRAKE CYLINDERS .................................................................................................................................. 7002-3 Disassembly .............................................................................................................................................. 7002-3 Assembly ................................................................................................................................................... 7002-5 87710917 - TOC - 10

  12. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BOOK 3A - Power Train (Continued), Brakes - 87710919 PTO CLUTCH ASSEMBLY SINGLE, REVERSIBLE AND DUAL SPEED.........................................SECTION 6025 SPECIAL TOOLS ........................................................................................................................................ 6025-3 SPECIAL TORQUES .................................................................................................................................. 6025-3 PTO CLUTCH ASSEMBLY ......................................................................................................................... 6025-4 General ..................................................................................................................................................... 6025-4 PTO CLUTCH SERVICE ............................................................................................................................ 6025-4 Removal .................................................................................................................................................... 6025-4 Disassembly .............................................................................................................................................. 6025-6 Assembly ................................................................................................................................................. 6025-16 Exploded View of PTO Clutch ................................................................................................................. 6025-16 Cross Section of PTO Clutch and Output Shaft Assembly ..................................................................... 6025-33 SINGLE SPEED REVERSIBLE SHAFT PTO ........................................................................................... 6025-34 Disassembly ............................................................................................................................................ 6025-34 Assembly ................................................................................................................................................. 6025-37 Exploded View of PTO Output Shaft and Driven Gear Assembly ........................................................... 6025-37 SINGLE SPEED REVERSIBLE SHAFT PTO DRIVEN GEAR ................................................................. 6025-41 Removal .................................................................................................................................................. 6025-41 Assembly ................................................................................................................................................. 6025-43 Reversible PTO Output Shaft Bearing Adjustment ................................................................................. 6025-45 SINGLE SPEED REVERSIBLE SHAFT PTO ........................................................................................... 6025-47 Cross Section of PTO Output Shaft Assembly ......................................................................................... 6025-47 BOOK 4 - Hydraulics, Chassis - 87710920 HYDRAULIC SCHEMATIC - NORTH AMERICAN......................................................................................87518874 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ...........................................................SECTION 8000 SIMPLE SCHEMATIC ............................................................................................................................... 8000-13 COMMON SYMBOLS ............................................................................................................................... 8000-15 HYDRAULIC SYSTEM - HOW IT WORKS AND TROUBLESHOOTING ..........................................SECTION 8001 GENERAL INTRODUCTION ...................................................................................................................... 8001-3 REAR CHARGE/LUBE PUMP PRESSURE TEST ................................................................................... 8001-19 REAR CHARGE/LUBE PUMP FLOW TEST ............................................................................................ 8001-21 REGULATED SYSTEM PRESSURE TEST AND ADJUSTMENT PROCEDURE ................................... 8001-22 FRONT/REGULATED SYSTEM PUMP FLOW TEST .............................................................................. 8001-26 STEERING RELIEF PRESSURE TEST AND ADJUSTMENT PROCEDURE ......................................... 8001-28 STEERING SYSTEM PROBLEMS ........................................................................................................... 8001-30 PRIORITY AND REGULATOR VALVE .................................................................................................... 8001-32 PFC AXIAL PISTON PUMP ...................................................................................................................... 8001-35 PFC PUMP HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE ....................... 8001-45 PFC PISTON PUMP FLOW CHECK AT REMOTE COUPLERS ............................................................. 8001-46 PFC PISTON PUMP FLOW TEST ........................................................................................................... 8001-48 TWINFLOW PFC PISTON PUMP FLOW TEST ....................................................................................... 8001-50 PFC PISTON PUMP FLOW COMPENSATOR SETTING ........................................................................ 8001-52 PUMP COMPENSATOR VALVE INSPECTION ....................................................................................... 8001-54 POWER BEYOND SYSTEM .................................................................................................................... 8001-55 FLOW CHECK AT POWER BEYOND COUPLERS ................................................................................. 8001-57 PFC PUMP OPERATIONAL PROBLEMS ................................................................................................ 8001-59 87710917 - TOC - 11

  13. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 PTO AND DIFFERENTIAL LOCK VALVE..........................................................................................SECTION 8002 SPECIAL TORQUES .................................................................................................................................. 8002-2 SPECIFICATIONS ...................................................................................................................................... 8002-2 PTO AND DIFFERENTIAL LOCK VALVE .................................................................................................. 8002-3 REMOTE VALVE AND COUPLER SERVICE....................................................................................SECTION 8003 SPECIAL TORQUES .................................................................................................................................. 8003-2 REMOTE VALVE AND COUPLER SERVICE ............................................................................................ 8003-3 REMOTE VALVE REMOVAL AND SERVICE ............................................................................................ 8003-5 REMOTE COUPLERS .............................................................................................................................. 8003-13 REMOTE HYDRAULIC SYSTEM - HOW IT WORKS AND TROUBLESHOOTING..........................SECTION 8004 REMOTE HYDRAULIC SYSTEM INTRODUCTION .................................................................................. 8004-3 REMOTE VALVE SYSTEM COMPONENTS ............................................................................................. 8004-5 REMOTE VALVE SYSTEM CONTROLS ................................................................................................. 8004-11 REMOTE VALVE OPERATION ................................................................................................................ 8004-15 REMOTE VALVE PROBLEMS AND WHERE TO LOOK ......................................................................... 8004-24 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION .............. 8004-26 PFC PISTON PUMP FLOW CHECK AT REMOTE COUPLERS .............................................................. 8004-27 REMOTE VALVE SYSTEM TESTING ...................................................................................................... 8004-29 PFC VALVE HIGH PRESSURE TEST ..................................................................................................... 8004-30 PFC HIGH PRESSURE STANDBY CHECK AND ADJUSTMENT PROCEDURE ................................... 8004-31 STANDARD PUMP COMPENSATOR VALVE INSPECTION .................................................................. 8004-32 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK .......................................................... 8004-33 REMOTE VALVE COUPLER TEST ......................................................................................................... 8004-34 LOAD CHECK INSPECTION .................................................................................................................... 8004-35 OPERATIONAL PROBLEMS ................................................................................................................... 8004-36 PRIORITY AND REGULATOR VALVE..............................................................................................SECTION 8005 SPECIAL TORQUES .................................................................................................................................. 8005-3 PRIORITY VALVE AND REGULATOR ...................................................................................................... 8005-4 Removal .................................................................................................................................................... 8005-4 Disassembly .............................................................................................................................................. 8005-6 Assembly ................................................................................................................................................... 8005-9 Installation ............................................................................................................................................... 8005-12 CROSS SECTION OF PRIORITY AND REGULATOR VALVE ................................................................ 8005-14 CHARGE PUMP.................................................................................................................................SECTION 8006 CHARGE PUMP ......................................................................................................................................... 8006-3 Removal .................................................................................................................................................... 8006-3 Installation ................................................................................................................................................. 8006-4 PFC PISTON PUMP AND HYDRAULIC FILTER...............................................................................SECTION 8007 SPECIAL TORQUES .................................................................................................................................. 8007-3 PFC PISTON PUMP ................................................................................................................................... 8007-3 Removal .................................................................................................................................................... 8007-3 Installation ................................................................................................................................................. 8007-5 HITCH SYSTEM - HOW IT WORKS..................................................................................................SECTION 8008 THREE POINT HITCH ................................................................................................................................ 8008-3 ELECTRONIC HITCH CONTROL .............................................................................................................. 8008-4 HITCH CONTROL VALVE ........................................................................................................................ 8008-14 General ................................................................................................................................................... 8008-14 Raise and Lower Solenoids .................................................................................................................... 8008-14 Raise and Lower Pilot Spools ................................................................................................................. 8008-14 Raise Spool ............................................................................................................................................. 8008-14 Lower Poppet .......................................................................................................................................... 8008-14 87710917 - TOC - 12

  14. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 Load Check Poppet ................................................................................................................................. 8008-14 Manual Raise or Lower Control Pins ....................................................................................................... 8008-14 Overload Relief Valve ............................................................................................................................. 8008-14 Neutral Function and Troubleshooting .................................................................................................... 8008-16 Raise Function and Troubleshooting ...................................................................................................... 8008-18 Lower Function and Troubleshooting ...................................................................................................... 8008-20 Troubleshooting Hitch Leaks Down Over Time ....................................................................................... 8008-22 Hitch Leak Down Inspection Points ......................................................................................................... 8008-23 SETUP / ADJUSTMENT SEQUENCE ...................................................................................................... 8008-24 HITCH CONTROL VALVE .................................................................................................................SECTION 8009 Removal .................................................................................................................................................... 8009-3 Disassembly .............................................................................................................................................. 8009-5 Assembly ................................................................................................................................................... 8009-7 Installation ................................................................................................................................................. 8009-9 HITCH CONTROL VALVE CROSS SECTION ......................................................................................... 8009-11 TRACTOR HITCH..............................................................................................................................SECTION 8010 SPECIAL TORQUES .................................................................................................................................. 8010-3 TRACTOR HITCH ....................................................................................................................................... 8010-3 EDC PIN ASSEMBLY ............................................................................................................................... 8010-20 POTENTIOMETER (HITCH POSITION SENSOR) .................................................................................. 8010-21 CAM SWAY LIMITER ............................................................................................................................... 8010-23 CAM BUMPERS FOR DRAFT ARM ......................................................................................................... 8010-25 DRAWBAR, HIGH VERTICAL CAPACITY ............................................................................................... 8010-26 TRAILER BRAKE SYSTEMS - HOW IT WORKS ..............................................................................SECTION 8011 HYDRAULIC BRAKE SYSTEMS ................................................................................................................ 8011-4 European / NAO Hydraulic Trailer Brakes ................................................................................................ 8011-4 Italian Hydraulic Trailer Brakes ................................................................................................................. 8011-8 PNEUMATIC BRAKE SYSTEMS ............................................................................................................. 8011-11 Pneumatic Trailer Brakes ........................................................................................................................ 8011-11 European Pneumatic Trailer Brakes ....................................................................................................... 8011-11 Italian Pneumatic Trailer Brakes ............................................................................................................. 8011-14 ROW (Rest of World) Pneumatic Trailer Brakes (NAR, ANZ, CIS, LAR, EEAA) .................................... 8011-17 Italian Hydraulic Trailer Brake Schematic ................................................................................................. 8011-19 Italian Pneumatic Trailer Brake Schematic ............................................................................................... 8011-21 PEDAL AND PEDAL SWITCH ADJUSTMENTS................................................................................SECTION 9001 INCHING PEDAL SWITCH ADJUSTMENT ................................................................................................ 9001-3 BRAKE PEDAL ADJUSTMENTS ............................................................................................................... 9001-4 CAB RAISE / REMOVAL AND INSTALLATION.................................................................................SECTION 9005 SPECIAL TORQUES .................................................................................................................................. 9005-3 SPECIAL TOOLS ........................................................................................................................................ 9005-3 CAB RAISE PROCEDURE ......................................................................................................................... 9005-4 CAB LOWERING PROCEDURE ................................................................................................................ 9005-7 CAB REMOVAL ........................................................................................................................................ 9005-10 CAB INSTALLATION ................................................................................................................................ 9005-17 HOOD REMOVAL..............................................................................................................................SECTION 9008 Hood Removal .......................................................................................................................................... 9008-3 Hood Installation ....................................................................................................................................... 9008-4 87710917 - TOC - 13

  15. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BOOK 5 - Air Conditioning - 87525617 AIR CONDITIONING SYSTEM - TROUBLESHOOTING AND FAULT CODES................................SECTION 9010 SAFETY PROCEDURES ............................................................................................................................ 9010-5 SPECIAL TOOLS ........................................................................................................................................ 9010-6 A/C THERMAL OPERATION ...................................................................................................................... 9010-7 A/C SYSTEM COMPONENTS ................................................................................................................... 9010-9 Cab HVAC Box Components - Automatic Temperature Control ............................................................... 9010-9 Chassis Components .............................................................................................................................. 9010-11 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ............................................................. 9010-12 Operation Modes ..................................................................................................................................... 9010-15 Automatic Mode ...................................................................................................................................... 9010-15 Defog Mode ............................................................................................................................................. 9010-15 Automatic Operation Summary ............................................................................................................... 9010-16 Defog/Dehumidify Operation Summary .................................................................................................. 9010-17 ATC FAULT CODES ................................................................................................................................. 9010-18 ATC Fault Code 111 ............................................................................................................................... 9010-18 ATC Fault Code 112 ............................................................................................................................... 9010-19 ATC Fault Code 115 ............................................................................................................................... 9010-19 ATC Fault Code 116 ............................................................................................................................... 9010-20 ATC Fault Code 120 ............................................................................................................................... 9010-20 ATC Fault Code 121 ............................................................................................................................... 9010-21 ATC Fault Code 122 ............................................................................................................................... 9010-21 ATC Fault Code 125 ............................................................................................................................... 9010-22 ATC Fault Code 126 ............................................................................................................................... 9010-22 ATC Fault Code 127 ............................................................................................................................... 9010-23 ATC Fault Code 128 ............................................................................................................................... 9010-23 ATC Fault Code 129 ............................................................................................................................... 9010-24 ATC Fault Code 130 ............................................................................................................................... 9010-24 ATC Fault Code 131 ............................................................................................................................... 9010-25 ATC Fault Code 132 ............................................................................................................................... 9010-25 ATC Fault Code 133 ............................................................................................................................... 9010-26 ATC Fault Code 134 ............................................................................................................................... 9010-26 LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ............................................................... 9010-27 Controller-Based Resistance Tests ......................................................................................................... 9010-27 ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) ............................................................... 9010-29 ATC Field Reported Symptoms/Causes ................................................................................................. 9010-32 COMPRESSOR AND CLUTCH ................................................................................................................ 9010-33 Operational Check ................................................................................................................................. 9010-33 Electrical Test ........................................................................................................................................ 9010-36 Compressor Clutch Control Circuit Test Procedure .............................................................................. 9010-36 Service Note: Adjusting Clutch Air Gap ................................................................................................. 9010-38 HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ................................................. 9010-39 Background ............................................................................................................................................. 9010-39 Possible Failure Modes - Fault Codes 129 and 134 ............................................................................... 9010-40 Electrical Test .......................................................................................................................................... 9010-41 High Pressure Switch and Circuit Test .................................................................................................... 9010-41 Low Pressure Switch and Circuit Test .................................................................................................... 9010-42 HEATER CONTROL VALVE .................................................................................................................... 9010-43 Operational Check .................................................................................................................................. 9010-43 Electrical Test .......................................................................................................................................... 9010-44 Heater Control Valve Power, Signal and Ground Test ............................................................................ 9010-44 BLOWER SPEED AND TEMPERATURE CONTROL POTENTIOMETERS ........................................... 9010-45 Background ............................................................................................................................................. 9010-45 Possible Failure Modes - Fault Codes 120, 121 ..................................................................................... 9010-45 Electrical Test .......................................................................................................................................... 9010-46 Common Control Potentiometer and Circuit Test Procedure .................................................................. 9010-46 87710917 - TOC - 14

  16. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BLOWER AND BLOWER SPEED DRIVER ............................................................................................. 9010-47 Background ............................................................................................................................................. 9010-47 Power, Signal and Ground Circuit ........................................................................................................... 9010-47 Possible Failure Modes ........................................................................................................................... 9010-47 Blower Motor/Blower Driver Power, Signal and Ground Test ................................................................. 9010-48 CAB AND EVAPORATOR TEMPERATURE SENSORS ......................................................................... 9010-49 Background ............................................................................................................................................. 9010-49 Electrical Test .......................................................................................................................................... 9010-51 Power Circuit ........................................................................................................................................... 9010-51 Possible Failure Modes - Fault Codes 111, 115 and 116 ....................................................................... 9010-52 Cab Temperature Sensor and Circuit Test ............................................................................................. 9010-53 Evaporator Temperature Sensor and Circuit Test .................................................................................. 9010-54 CONTROLLER POWER, GROUND, AND ATC SWITCH ........................................................................ 9010-56 Background ............................................................................................................................................. 9010-56 Power and Ground Circuit ....................................................................................................................... 9010-56 Possible Failure Modes ........................................................................................................................... 9010-56 Controller Power Supply and Ground Test ............................................................................................. 9010-56 ATC Switch and Circuit Test ................................................................................................................... 9010-57 Defog/Defrost Switch and Circuit Test .................................................................................................... 9010-57 CAB PRESSURIZER BLOWER ............................................................................................................... 9010-58 Background ............................................................................................................................................. 9010-58 Power and Ground .................................................................................................................................. 9010-58 Cab Pressurizer Blower & Relay Power Supply and Ground Test .......................................................... 9010-58 ACCESSING THE HVAC BOX ................................................................................................................. 9010-59 STANDARD AIR CONDITIONING (STD) TROUBLESHOOTING ............................................................ 9010-60 Standard A/C Operation .......................................................................................................................... 9010-61 Smart Pressure Switch Cycling System ................................................................................................ 9010-61 Standard A/C Controls and Their Function ........................................................................................... 9010-62 Symptom-Based Standard A/C Troubleshooting .................................................................................... 9010-63 Controller Power, Ground And A/C Switch ............................................................................................. 9010-65 Background ........................................................................................................................................... 9010-65 Power and Ground Circuit ..................................................................................................................... 9010-65 Possible Failure Modes ......................................................................................................................... 9010-65 Controller Power Supply and Ground Test ............................................................................................ 9010-65 A/C Switch and Circuit Test ................................................................................................................... 9010-66 Compressor And Clutch .......................................................................................................................... 9010-67 Operational Check ................................................................................................................................. 9010-67 Electrical Test Compressor Clutch ..................................................................................................... 9010-70 Clutch Relay Power Supply and Ground Test ....................................................................................... 9010-71 Service Note: Adjusting Clutch Air Gap ................................................................................................. 9010-72 High And Low Pressure Switch Clutch Latching Circuit .......................................................................... 9010-73 Background ........................................................................................................................................... 9010-73 Possible Failure Modes - Flashing Pressure Warning Lamp ................................................................ 9010-74 Electrical Test Pressure Switches ...................................................................................................... 9010-75 High Pressure Switch and Circuit Test .................................................................................................. 9010-75 Low Pressure Switch and Circuit Test ................................................................................................... 9010-76 Heater Control Valve ............................................................................................................................... 9010-77 Operational Check ................................................................................................................................. 9010-77 Electrical Test ........................................................................................................................................ 9010-78 Temperature Control Potentiometer ........................................................................................................ 9010-79 Background ........................................................................................................................................... 9010-79 Electrical Test ........................................................................................................................................ 9010-79 Blower Speed Switch And Blower Motor ................................................................................................. 9010-80 Background ........................................................................................................................................... 9010-80 Power and Ground Circuit ..................................................................................................................... 9010-80 Possible Failure Modes ......................................................................................................................... 9010-80 Blower Speed Switch and Power Circuit Test ....................................................................................... 9010-81 87710917 - TOC - 15

  17. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 Blower Motor Power, and Control Circuit Test ...................................................................................... 9010-81 Evaporator Temperature Sensor ............................................................................................................. 9010-83 Background ........................................................................................................................................... 9010-83 Electrical Test Sensor ........................................................................................................................ 9010-83 Power Circuit ......................................................................................................................................... 9010-84 Service Note: Too Little Cooling/Too Much Heating without Symptoms ............................................... 9010-84 Evaporator Temperature Sensor and Circuit Test ................................................................................. 9010-84 Controller Power, Ground And A/C Switch ............................................................................................. 9010-86 Background ........................................................................................................................................... 9010-86 Power and Ground Circuit ..................................................................................................................... 9010-86 Possible Failure Modes ......................................................................................................................... 9010-86 Controller Power Supply and Ground Test ............................................................................................ 9010-86 A/C Switch and Circuit Test ................................................................................................................... 9010-87 Cab Pressurizer Blower .......................................................................................................................... 9010-88 Background ........................................................................................................................................... 9010-88 Power and Ground ................................................................................................................................ 9010-88 Cab Pressurizer Blower & Relay Power Supply and Ground Test ........................................................ 9010-89 AIR CONDITIONER SYSTEM SERVICE...........................................................................................SECTION 9020 SPECIFICATIONS ...................................................................................................................................... 9020-4 SPECIAL TORQUES .................................................................................................................................. 9020-4 SPECIAL TOOLS ........................................................................................................................................ 9020-4 SAFETY PROCEDURES ............................................................................................................................ 9020-9 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY .................................................................. 9020-10 RECOVERING PURE 134A REFRIGERANT ........................................................................................... 9020-12 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 ...................................................... 9020-16 Preparing the Tank .................................................................................................................................. 9020-16 Recovery Process ................................................................................................................................... 9020-20 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ........................................................ 9020-26 AIR CONDITIONING TEMPERATURE/PRESSURE CHART .................................................................. 9020-33 LEAK DETECTION ................................................................................................................................... 9020-34 Electronic Testing with OEM1437 ........................................................................................................... 9020-35 Florescent Leak Detection ...................................................................................................................... 9020-36 Fluorescent Dye Injection ........................................................................................................................ 9020-36 Fluorescent Leak Testing ........................................................................................................................ 9020-42 A/C SYSTEM FLUSHING PROCEDURE ................................................................................................. 9020-43 Required Tools ........................................................................................................................................ 9020-44 Precautions ............................................................................................................................................. 9020-45 Component Flushing Procedure with Power Flush 17550 ...................................................................... 9020-46 Complete Circuit Flushing Procedure with Power Flush 17550 .............................................................. 9020-50 Back Flushing the Thermal Expansion Valve or Refrigerant Line ........................................................... 9020-55 Post Flushing Procedures ....................................................................................................................... 9020-57 Flushing Solvent Disposal ....................................................................................................................... 9020-59 A/C SYSTEM COMPONENTS ................................................................................................................. 9020-60 Cab HVAC Box Components - Automatic Temperature Control ............................................................. 9020-60 Cab HVAC Components - Standard Systems ......................................................................................... 9020-62 Chassis Components .............................................................................................................................. 9020-64 A/C COMPRESSOR CLUTCH ................................................................................................................. 9020-65 Clutch Removal ....................................................................................................................................... 9020-65 Exploded View of Clutch ......................................................................................................................... 9020-71 Compressor Clutch Replacement ........................................................................................................... 9020-71 A/C COMPRESSOR ................................................................................................................................. 9020-79 Oil Level Check or Adjustment ................................................................................................................ 9020-79 Compressor Removal ............................................................................................................................. 9020-82 Compressor Installation .......................................................................................................................... 9020-85 87710917 - TOC - 16

  18. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 CONDENSER AND RECEIVER-DRIER ................................................................................................... 9020-87 Condenser ............................................................................................................................................... 9020-87 Receiver-Drier ......................................................................................................................................... 9020-89 ACCESSING THE HVAC BOX ................................................................................................................. 9020-90 THERMAL EXPANSION VALVE TESTING .............................................................................................. 9020-92 THERMAL EXPANSION VALVE REPLACEMENT .................................................................................. 9020-93 EVAPORATOR AND CAB TEMPERATURE SENSOR LOCATION ........................................................ 9020-95 BLOWER MOTOR REPLACEMENT ........................................................................................................ 9020-96 HEATER CONTROL VALVE REPLACEMENT ........................................................................................ 9020-97 EVAPORATOR/HEATER ASSEMBLY ..................................................................................................... 9020-98 Evaporator/Heater Assembly Removal ................................................................................................... 9020-98 Evaporator/Heater Assembly Installation .............................................................................................. 9020-101 Post Replacement Procedures ............................................................................................................. 9020-104 EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING ...................................................... 9020-105 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION ............................................................ 9020-106 CONTROLLER AND BLOWER SPEED DRIVER REPLACEMENT ..................................................... 9020-107 ATC Controller ...................................................................................................................................... 9020-107 Standard A/C Controller ........................................................................................................................ 9020-107 Blower Speed Driver (ATC Units Only) ................................................................................................. 9020-108 CAB AIR FILTER SERVICE ................................................................................................................... 9020-109 CAB RECIRCULATION AIR FILTER SERVICE ..................................................................................... 9020-110 CAB PRESSURIZATION TEST .............................................................................................................. 9020-111 CAB PRESSURIZER MOTOR REPLACEMENT .................................................................................... 9020-113 VISCOUS FAN DRIVE ............................................................................................................................ 9020-116 BOOK 6 - Controller Fault Codes - 87609375 INSTRUMENTATION CONTROLLER FAULT CODES ...................................................................SECTION 10001 FAULT CODE INST 1015 ....................................................................................................................... 10001-10 FAULT CODE INST 3010 ....................................................................................................................... 10001-12 FAULT CODE INST 3020 ....................................................................................................................... 10001-13 FAULT CODE INST 3022 ....................................................................................................................... 10001-13 FAULT CODE INST 5010 ....................................................................................................................... 10001-13 FAULT CODE INST 5011 ....................................................................................................................... 10001-14 FAULT CODE INST 10031 ..................................................................................................................... 10001-15 FAULT CODE INST 10032 ..................................................................................................................... 10001-15 FAULT CODE INST 10033 ..................................................................................................................... 10001-15 FAULT CODE INST 10034 ..................................................................................................................... 10001-16 FAULT CODE INST 10035 ..................................................................................................................... 10001-16 FAULT CODE INST 10036 ..................................................................................................................... 10001-16 FAULT CODE INST 10037 ..................................................................................................................... 10001-17 FAULT CODE INST 10038 ..................................................................................................................... 10001-17 FAULT CODE INST 11011 ..................................................................................................................... 10001-18 FAULT CODE INST 12011 ..................................................................................................................... 10001-19 FAULT CODE INST 12043 ..................................................................................................................... 10001-21 FAULT CODE INST 12051 ..................................................................................................................... 10001-23 FAULT CODE INST 12071 ..................................................................................................................... 10001-25 FAULT CODE INST 12091 ..................................................................................................................... 10001-27 FAULT CODE INST 12111 ..................................................................................................................... 10001-29 FAULT CODE INST 13010 ..................................................................................................................... 10001-31 FAULT CODE INST 13011 ..................................................................................................................... 10001-32 FAULT CODE INST 13012 ..................................................................................................................... 10001-33 FAULT CODE INST 13021 ..................................................................................................................... 10001-34 FAULT CODE INST 13022 ..................................................................................................................... 10001-35 FAULT CODE INST 13040 ..................................................................................................................... 10001-36 FAULT CODE INST 13051 ..................................................................................................................... 10001-37 87710917 - TOC - 17

  19. MX AND MAGNUM 215/245/275/305 MASTER TABLE OF CONTENTS - 87710915 BOOK 7 - Controller Fault Codes (Continued) - 87678527 INSTRUMENTATION CONTROLLER FAULT CODES, P.I.N. Z7RZ01521 AND AFTER...............SECTION 10006 FAULT CODE INST 1015 ......................................................................................................................... 10006-4 FAULT CODE INST 3010 ......................................................................................................................... 10006-5 FAULT CODE INST 3020 ......................................................................................................................... 10006-6 FAULT CODE INST 3022 ......................................................................................................................... 10006-6 FAULT CODE INST 5010 ......................................................................................................................... 10006-6 FAULT CODE INST 5011 ......................................................................................................................... 10006-7 FAULT CODE INST 10031 ....................................................................................................................... 10006-8 FAULT CODE INST 10032 ....................................................................................................................... 10006-8 FAULT CODE INST 10033 ....................................................................................................................... 10006-8 FAULT CODE INST 10034 ....................................................................................................................... 10006-9 FAULT CODE INST 10035 ....................................................................................................................... 10006-9 FAULT CODE INST 10036 ....................................................................................................................... 10006-9 FAULT CODE INST 10037 ..................................................................................................................... 10006-10 FAULT CODE INST 10038 ..................................................................................................................... 10006-10 FAULT CODE INST 11011 ..................................................................................................................... 10006-11 FAULT CODE INST 12011 ..................................................................................................................... 10006-12 FAULT CODE INST 12043 ..................................................................................................................... 10006-14 FAULT CODE INST 12051 ..................................................................................................................... 10006-16 FAULT CODE INST 12071 ..................................................................................................................... 10006-18 FAULT CODE INST 12091 ..................................................................................................................... 10006-20 FAULT CODE INST 12111 ..................................................................................................................... 10006-22 FAULT CODE INST 12121 ..................................................................................................................... 10006-24 FAULT CODE INST 13010 ..................................................................................................................... 10006-26 FAULT CODE INST 13011 ..................................................................................................................... 10006-27 FAULT CODE INST 13012 ..................................................................................................................... 10006-28 FAULT CODE INST 13021 ..................................................................................................................... 10006-29 FAULT CODE INST 13022 ..................................................................................................................... 10006-30 FAULT CODE INST 13040 ..................................................................................................................... 10006-31 FAULT CODE INST 13051 ..................................................................................................................... 10006-32 FAULT CODE INST 13052 ..................................................................................................................... 10006-33 FAULT CODE INST 53001 ..................................................................................................................... 10006-34 FAULT CODE INST 53005 ..................................................................................................................... 10006-34 FAULT CODE INST 65535 ..................................................................................................................... 10006-34 AUX/HITCH/PTO FAULT CODES, TRACTOR MULTI FUNCTION (TMF) CONTROLLER, P.I.N. Z7RZ01521 AND AFTER.......................................................................................................SECTION 10007 AUX/HITCH/PTO FAULT CODE 2 ........................................................................................................... 10007-7 AUX/HITCH/PTO FAULT CODE 4 ........................................................................................................... 10007-8 AUX/HITCH/PTO FAULT CODE 5 ........................................................................................................... 10007-9 AUX/HITCH/PTO FAULT CODE 7 ......................................................................................................... 10007-10 AUX/HITCH/PTO FAULT CODE 11 ....................................................................................................... 10007-11 AUX/HITCH/PTO FAULT CODE 12 ....................................................................................................... 10007-13 AUX/HITCH/PTO FAULT CODE 14 ....................................................................................................... 10007-14 AUX/HITCH/PTO FAULT CODE 15 ....................................................................................................... 10007-15 AUX/HITCH/PTO FAULT CODE 17 ....................................................................................................... 10007-16 AUX/HITCH/PTO FAULT CODE 18 ....................................................................................................... 10007-17 AUX/HITCH/PTO FAULT CODE 19 ....................................................................................................... 10007-18 AUX/HITCH/PTO FAULT CODE 21 ....................................................................................................... 10007-18 AUX/HITCH/PTO FAULT CODE 22 ....................................................................................................... 10007-19 AUX/HITCH/PTO FAULT CODE 23 ....................................................................................................... 10007-20 AUX/HITCH/PTO FAULT CODE 24 ....................................................................................................... 10007-21 AUX/HITCH/PTO FAULT CODE 25 ....................................................................................................... 10007-22 AUX/HITCH/PTO FAULT CODE 26 ....................................................................................................... 10007-23 87710917 - TOC - 23

  20. 1001 Section 1001 SAFETY, GENERAL INFORMATION / MAINTENANCE SCHEDULE January, 2006

  21. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 1001-3 SAFETY 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 To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. WARNING: Before starting engine study Operator s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulations. Operator and Service Manuals may be obtained from your equipment dealer. Put the warning tag shown below on the key for the key switch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags are available from your service parts supplier. ! Before servicing a machine, park the machine on hard level ground. Turn off the engine, apply the parking brake and remove the key from the key switch. Put blocks in front of and behind either the front or rear wheels. M103A WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be 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. ! M492 WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. M493 ! WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. ! 201L95 M494 WARNING: Read the Operator s Manual to familiarize yourself with the correct control functions. WARNING: When putting the hydraulic 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. ! M489 ! WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. M495 ! M490 WARNING: This machine is for one operator, no riders allowed. ! M491A

  22. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 1001-4 WARNING: Alwayswear heat protective gloves to prevent burning your hands when handling heated parts. WARNING: When servicing or repairing the machine. Keep the shop floor and operator s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and or shop cloths as required. Use safe practices at all times. ! SM121A ! M500 WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. ! WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in the Service Manual. M496 ! M501 WARNING: Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the door and get outside air into the area. ! ! M502 WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. SM171A ! WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. ! M503 M497 WARNING: Batteries contain acid and explosive gas. Explosions can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine see the Operator s Manual. Failure to follow these instructions can cause serious injury or death. WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). ! ! M498 M504 WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in placed with suitable safety stands. ! M499

  23. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 1001-5 GENERAL INFORMATION Cleaning Gears Clean all metal parts except bearings, in mineral spirits or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Check all gears for excessive wear or damage. Replace gears as necessary. Oil Seals, O-rings and Gaskets Inspection Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings. Check all parts when the parts are disassembled. Replace all parts that have excessive wear or are damaged. Small scoring or grooves can be removed with a hone or crocus cloth. Complete visual inspection for indications of wear, pitting and the replacement of parts necessary will prevent early failures. Shafts Check all shafts for excessive wear or damage. Check the bearing and oil seal surfaces on the shafts for excessive wear or damage. Replace shafts as necessary. Bearings Service Parts Clean bearings with a good clean solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR. Check bearings for smooth easy action. If the bearing has a loose fit or rough action, the bearing must be replaced. Always install genuine Case service parts. When ordering refer to the Parts Catalog for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty. Needle Bearings Lubrication Before you press needle bearings into a bore, always remove any metal protrusions in the bore or the edge of the bore. Before you press bearings into position, put petroleum jelly on the inside and outside diameter of the bearing. Use only the oils and lubrication specified in the Operator s or Service Manual. Failures due to the use of non specified oils and lubricants are not covered by warranty.

  24. Section 2001 COOLING SYSTEM MODULE REMOVAL AND INSTALLATION 2001 January, 2006

  25. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-3 COOLING SYSTEM MODULE REMOVAL Remove the hood. See the Hood Removal section of this manual for information. Remove the freon from the A/C system. See A/C service information in this service manual. Drain the coolant from the engine cooling system. Cap or plug all open tubes and lines during disassembly. Tag all wires and hoses for easier assembly. NOTE: This procedure shows how to remove and install the cooling system module, which is an assembly of heat exchangers for engine cooling and climate control that includes the radiator, fuel cooler, hydraulic oil cooler, air-to-air aftercooler and air- conditioning condenser. Each of these individual heat exchangers can then be also removed from the module assembly for service or replacement. Before removing the cooling system module, do the following: STEP 1 Remove the left and right hand shields. RD05E038 STEP 2 Remove the left and right hand retaining bolts (1) from the plumbing seal (2) and remove the seal. 2 1 RD05E022 STEP 3 Remove the left and right hand air intake retaining bolts (1) and remove the air intake (2). 2 1 RD05E023

  26. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-4 STEP 4 Remove the air-to-air aftercooler outlet tube. RD05E028 STEP 5 Remove the air-to-air aftercooler inlet tube. RD05E029 STEP 6 Disconnect the horn wire (1), fuel cooler inlet/outlet lines (2) and the A/C condenser inlet (3) and receiver dryer outlet (4) lines. 2 3 1 4 RD05E030 STEP 7 Disconnect the hydraulic oil cooler inlet and outlet lines. RD05E031

  27. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-5 STEP 8 Disconnect the upper radiator tube. RD05E034 STEP 9 Disconnect the lower radiator tube. RD05E033 STEP 10 Attach lift brackets and a sling to the top of the radiator. RD05E036 STEP 11 Remove the four assembly mounting bolts. RD05E035

  28. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-6 STEP 12 Slide the assembly forward until the fan shroud clears the fan. Lift the assembly off the tractor. RD05E037

  29. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-7 COOLING SYSTEM MODULE INSTALLATION STEP 13 Position the engine cooling module on the front bolster. Lower and slide back while making sure the fan clears the shroud. Align the mounting bolt holes. RD05E037 STEP 14 Install and tighten the four assembly mounting bolts. RD05E035 STEP 15 Remove the sling and lift brackets. RD05E036

  30. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-8 STEP 16 Install the lower radiator tube. RD05E033 STEP 17 Install the upper radiator tube. RD05E034 STEP 18 Connect the hydraulic oil cooler inlet and outlet lines. RD05E031 STEP 19 Connect the horn wire (1), fuel cooler inlet/outlet lines (2) and the A/C condenser inlet (3) and receiver dryer outlet (4) lines. 2 3 1 4 RD05E030

  31. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2001-9 STEP 20 Install the plumbing seal (1) and left and right hand retaining bolts (2). Tighten the bolts. 1 2 RD05E022 STEP 21 Install the left and right hand shields. RD05E038 After installing the cooler assembly, do the following: Install the proper coolant into the cooling system. Evacuate and recharge the A/C system. See the A/C service information in this service manual. Install the hood. See hood installation information in this section.

  32. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2002-4 ENGINE REMOVAL AND INSTALLATION General Remove the hood. For hood removal, see Hood Removal and Installation Section in this service manual. Evacuate the A/C system. For A/C evacuation and recharge, see A/C Service Section in this service manual. Cap or plug all open tubes and lines during disassembly. Tag all wires and hoses for easier assembly. ENGINE REMOVAL STEP 1 Park the tractor on a hard, level surface. Put the transmission in PARK. Turn off the engine and remove the keys. Place blocks in front and behind the rear wheels. 96RS28A STEP 2 Remove the battery cover. Disconnect the negative (-) then the positive (+) battery cables. RD02E069

  33. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2002-5 STEP 3 Remove the left and right side shields. RD05E038 STEP 4 Remove the cooling system pressure cap from the deaeration tank. WARNING: Check and service cooling system according to maintenance instructions. Hot coolant can spray out if the deaeration tank cap is removed while system is hot. To remove the deaeration tank cap, let system cool, turn to the first notch, then wait until all the pressure is released. Scalding can result from the fast removal of the deaeration tank cap. ! M855 RD05E057 STEP 5 Drain the coolant into a clean container. NOTE: Total coolant capacity is approximately 6-1/2 gallons. RD05E028

  34. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2002-6 STEP 6 Remove right and left hose/tube mounting bracket bolts. Remove bracket and foam seal. RD05E022 STEP 7 Remove the horn wire harness (1). Remove the fuel cooler inlet and return hoses (2). Remove the A/C condenser inlet (3) and A/C dryer outlet hose (4). Discard the O-rings. 2 3 4 1 RD05E030 STEP 8 Remove the two air inlet scoop mounting bolts (1). Remove the air scoop (2). 1 2 RD05E023

  35. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2002-7 STEP 9 Remove the charge-air cooler outlet-to-intake- manifold inlet tube (1). Remove the engine-coolant-out to radiator-inlet tube (2). 1 2 RD05E028 STEP 10 Remove the turbo-outlet-to-charge-air-cooler inlet tube (1). Remove the radiator-out-to-engine-inlet tube (2). 1 2 RD05E029 STEP 11 Remove the A/C line clamp located on top of the radiator. RD05E032

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  37. Template Name: SM_2_col Template Date: 1994_04_05 Alt= to hide template information Alt+ to display template information 2002-8 STEP 12 Disconnect the hydraulic cooling lines. RD05E031 STEP 13 Remove exhaust shield mounting bolts (1) and nut (2). Remove shield. 1 2 RD05E043 STEP 14 Disconnect the exhaust pipe (1) at the turbo outlet (2) and exhaust elbow inlet (3). Remove the pipe. 2 3 1 RD05E044

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