Service Manual

Service Manual

Engine 460 V-8 used in

various New Holland Bale
Wagons

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

FORD OR IT’S SUCCESSORS. FORD AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

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

FO-S-ENG 460
NEW HOLLAND REPAIR
MANUAL
1089
1095
Section 1 - Engine
Section 2 - Fuel and Induction Systems
Section 3 - Transmission

86617373 7/00 IReprinted I

 1089, 1095 BALE WAGON
REPAIR MANUAL
CONTENTS
~ SECTION 1 - ENGINE
~ SECTION 2 - FUEL AND INDUCTION SYSTEMS
SECTION 3 - TRANSMISSION
SECTION 4 - REAR AXLE AND SUSPENSION
SECTION 5 - FRONT AXLE AND SUSPENSION
SECTION 6 - BRAKE SYSTEM

SECTION 7 - STEERING SYSTEM

SECTION 8 - HYDRAULIC SYSTEM

SECTION 9 - ELECTRICAL SYSTEM

SECTION 10 - ELECTRONIC CONTROL SYSTEM
SECTION 11 - AIR CONDITIONING SYSTEM

234 © 2000 NEVV HOLLAND NORTH AMERICA, INC.

 SECTION 1
ENGINE
CONTENTS

ENGINE DESCRIPTION AND OPERATION II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1-3

ENGINE SPECIFICATIONS II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1-4.
ENGINE SPECIAL TOOLS II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1·14
ENGINE LUBRICATION II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II • II II 1·19
ENGINE TROUBLESHOOTING II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1·24
ENGINE DISASSEMBLY AND REPAIR II. II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1111 II II II II II II II II II II 1·28
COOLING SYSTEM DESCRIPTION AND OPERATION II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II • II II 1-88
COOLING SYSTEM TROUBLESHOOTING II II II II II II II II II • II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II II 1·90
COOLING SYSTEM SPECIFICATIONS II • II II •• II II ••• II •• II • II II II ••••• II • II II II II • II • II II •• II II II II ~ II II II II II II 1-91
COOLING SYSTEM DISASSEMBLY AND REPAIR •••••• II II • II • II II II II II II • II •• II • II • II II II II II II •• II II II II 1-92

1-1
 SECTION 1 - ENGINE

ENGINE SPECIFICATIONS·
*A single figure indicates the same specification for both engines; n/a = not applicable.

GENERAL ENGINE SPECIFICATIONS NON·EMISSIONIZED EMISSloNIZED

Number of Cylinders I I I I • I I I I 6 in-line
I I I I I I I I6 in-line
I I I I I I I • I I I I I I D I I ••

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 111.8 mm . . . . . . . . . . . . . . .. 111.8 mm

(4.4 in.) (4.4 in.)
Stroke 127.0 mm 127.0 mm
(5.0 in.) (5.0 in.)
Displacement I I I • I • I • 7.5 LI I I • D 7.5 L I I ••••• "' ••••

(456 cu. in.) (456 cu. in.)

Compression Ratio 17.5-1 I •••••••• 17.5-1 I • • • • • ••

Firing Order 153624 153624 I • • • • • • • ••

Low Idle Speed 790 - 840 rpm . . . . . . . . . . .. 700 - 800 rpm

High Idle Speed . . . . . . . . . . . . . . . . . . . . . . • . .. 2625 - 2675 rpm . . . . . . . . . . 2675 - 2725 rpm
Rated Engine Speed D • • • • 2100 rpm . . . . . . . . . . . . . . .. 2500 rpm
• • • • • • • ••

Max. Hp @ Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . 160 166 I ••••••••••••••

CYLINDER BLOCK
Taper of Cylinder Bore:
Repair Limit: 0.03 mm (0.001")
Wear Limit: 0.13 mm (0.005")
Cylinder Bore Out of Round
Repair Limit ~ . . . . . . . . . . . . . . . . . . . . . . . . .. 0.038 mm (0.0015")
Wear Limit 0.127 mm (0.0050") I ••

Cylinder Bore Diameters 111.778 - 111.841 mm (4.4007 4.4032") &>

Rear Oil Seal Bore Diameter . . . . . . . . . . . . . . . . . .. 140.77 - 140.87 mm (5.542 5.546") II

Block-to-Head Surface Flatness . . . . . . . . . . . . . . . . 0.08 mm (0.003") in any 152 mm (6")

0.03 mm (0.001") in any 25.4 mm (1")

CYLINDER HEAD
Valve Guide Bore Diameter . . . . . . . . . . . . . . . . . . .. 9.469 - 9.495 mm (0.3728 - 0.3738")
Head-to-Block Surface Flatness 0.03 mm (0.001") in any 25.4 mm (1")
or 0.13 mm (0.005") overall limit

EXHAUST VALVES
Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 0 15' - 44 0 30' relative to the valve head
Stem Diameter
Std: 9.401 - 9.421 mm (0.3701 - 0.3709")
0.08 mm (0.003") Oversize: 9.477 - 9.497 mm (0.3731 - 0.3739")
0.38 mm (0.015") Oversize: 9.781 - 9.802 mm (0.3851 - 0.3859")
Head Diameter. . . . . . . .. . . . .. . . . . . . . . . . . . . . . . .. 42.88 - 43.18 mm (1.688 - 1.698")
Stem to Guide Clearance. . . . . . . . . . . . . . . . . . . . .. 0.048 - 0.094 mm (0.0019 - 0.0037")
Lash Clearance (cold) 0.43 - 0.53 mm (0.017 - 0.021 ")

1-4
 SECTION 1 - ENGINE

Figure 1-4
Engine Lubrication System With Turbocharger Fitted

Both engines use rotor-type oil pumps, which

move 83L1min (22 gals/min), to maintain lubrica-
tion of the engine. The pump mounts to the rear of
the engine block, in front of the flywheel on the left
side, with retaining bolts, 1.

Figure 1-5

1-20
 SECTION 1 - ENGINE

Valve Guide Inspection "and Repair

1. Using a telescopic gauge, 1, and micrometer,
2, measure the valve guide bore clearance
and make sure it is in the range:
0.023 - 0.069 mm (0.0009 - 0.00'27") on the
intake valve stem
0.048 - 0.094 mm (0.0019 - 0.0037") on the
exhaust valve stem
NOTE: Production cylinder heads may
have one or more machined, oversized
valve guide bores, or valves installed.
Such cylinder heads have 15 or V0150S
stamped on the cylinder head exhaust
manifold side adjacent to the affected Figure 1-55
valve.
2. Using a suitable reamer, ream out the valve
stem guide with three reamer and pilot
combinations as follows:
0.076 mm (0.003") oversize reamer, and
standard diameter pilot
0.38 mm (0.015") oversize reamer,' and
0.076 mm (0.003") oversize pilot
0.76 mm (0.030") oversize reamer, and 0.38
mm (0.015") oversize pilot
NOTE: When going from a standard to an
oversized valve stem always use reamers
in sequence.

Valve Spring Inspection and

Replacement
1. Springs should stand upright and square to a 1
flat surface. With the spring upright and the
bottom placed on a flat surface and against
the square, the top of the spring should not
be more than 1.52 mm (0.060") away from
the square, 1.
Check the length of the valve springs for both
free length and loaded length. Free length
should be 60.7 mm (2.39"), and installed
length should be 47.2 - 49.5 mm (1.86 -
1.95"). Loaded length should be 48.26 mm o
(1.9") with a weight of 28 - 31 kg (62 - 68Ibs.). o
With a greater weight of 61 - 69 kg (135 - 153
Ibs) , loaded length should be 35.69 mm Figure 1-56
(1.4").

Make sure the valve spring retainer locks are

in good condition and replace if worn or
damaged.

1-48
 SECTION 1 - ENGINE
BOOK 1
INDEX
Bearings 1-62 0 ••••••• 0 Fan blade 0 ••••••••• 0 ••••••• 1-98 0 • • ••

Belts 1-99 0 Flywheel 0 0 •1-74

• • • • ••

Camshaft 0 0 • • • • • • • • • • • 1-85
• • • • • • • • • • • • •• Flywheel removal 1-75
0 • • • ••

Camshaft assembly 1-18 Flywheel specifications . . . . . . . . . . . . . . . . . . . .. 1-9

Camshaft bearings 1-86 Fuel system special tools . . . . . . . . . . . . . . . . .. 1-14
Camshaft idler gear specifications 1-6 Idler pUlley 1-100
Camshaft gear specifications .. 1-6 0 • • • • • • • • • • •• Installing the engine 01-36
••••••

Camshaft specifications . . . . . . . . . . . . . . . . . . .. 1-6 Intake valve specifications 0 0 ••• 0 0 1-5

0 ••••••

Component locations 1-16 Main bearings 0 •••••••••• 00 1-74

•• 0 0 •••

Connecting rod bushing replacement 1-64 Main bearing removal. 0 ••••••••••••••••••• 1-74
Connecting rods 1-18, 1-62 Main bearing specifications . . . . . . . . . . . . . . . .. 1-8
Connecting rod specifications .. . . . . . . . . . . . .. 1-6 Main V-belt and fan belt .. . . . . . . . . . . . . . . . .. 1-52
Cooling capacities 1-91 0 • • • • • • • • • •• Manifolds 1-18
Coolant flow . . . . . . . . . . . . . . . . .. 1-91 Oil filter support .assemb,ly . . . . . . . . . . . . . . . .. 1-80
Coolant specifications . . . . . . . . . . . . . . . . . . . .. 1-11 Oil pan 1-61
Cooling system capacity 1-11 Oil pressure with engine at operating
Cooling system description and operation 1-88 temperature 1-10
Cooling system disassembly and repair 1-92 Oil pump 1-77
Cooling system specifications . . . . . . . . . . . . .. 1-91 Oil pump specifications 1-9
Cooling system troubleshooting 1-90 Piston assembly 1-73
Crankpin bearing specifications 1-9 Piston pin specifications . . . . . . . . . . . . . . . . . . .. 1-6
Crankshaft 1-74 Piston rings '.' . . .. 1-62
Crankshaft assembly 1-18 Piston ring specifications 1-7
Crankshaft drive gear specifications 1-8 Pistons 1-18, 1-62
Crankshaft reassembly . . . . . . . . . . . . . . . . . . .. 1-83 Piston specifications 1-7
Crankshaft regrinding specifications 1-9 Radiator 1-92
Crankshaft removal 1-81 Radiator cap specifications 1-11, 1-91
Crankshaft speci'fications . . . . . . . . . . . . . . . . . .. 1-8 Rear cover plate 1-76
Cylinder block 1-65 RemOVing the engine 1-31
Cylinder block assembly 1-18 Rocker arm shaft specifications 1-6
Cylinder block specifications . . . . . . . . . . . . . . .. 1-4 Rocker arm specifications 1-6
Cylinder bore 1-67 Rocker shaft inspection a • • • • •1-49
• • • • ••

Cylinder head assembly 1-18 Rocker shaft installation . . . . . . . . . . . . . . . . . .. 1-49

Cylinder head disassembly 1-42 Separating the engine from the
Cylinder head disassembly and repair 1-37 transmission 1-30
Cylinder head inspection 1-44 Sleeving-boring and Honing 1-68
Cylinder head installation " 1-50 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-14
Cylinder head reassembly . . . . . . . . . . . . . . . .. 1-50 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-4
Cylinder head removal 1-37 Tappet specifications ~ . . . . . . . . . . . . . .. 1-6
Cylinder head repair . .. 1-44 Temperature warning sender. . . . . . . . . . . . . .. 1-97
Cylinder head specifications 1-4 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-95
Engine description . . . . . . . . . . . . . . . . . . . . . . . .. 1-3 Thermostat specifications 1-10, 1-91
Engine disassembly and repair " 1-28 Timing gears . . . . . . . . . . . . . . . . . . . . . . . . 1-18, 1-54
Engine front cover and timing gear 1-54 Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-12
Engine installation . . . . . . . . . . . . . . . . . . . . . . .. 1-36 Valve identification 1-47
Engine lubrication 1-19 Valve insert inspection and replacement . . . .. 1-46
Engine oil capacity 1-10 Valve inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-46
Engine oil specifications . . . . . . . . . . . . . . . . . .. 1-10 Valve guide inspection and repair . . . . . . . . . .. 1-48
Engine operation . . . . . . . . . . . . . . . . . . . . . . . . .. 1-3 Valve spring inspection and repair .. . . . . . . .. 1-48
Engine removal 1-31 Valve spring specifications . . . . . . . . . . . . . . . . .. 1-5
Engine special tools 1-14 Valve seat specifications 1-5, 1-46
Engine specifications 1-4 Valve timing 1-5
Engine timing gears 1-87 V-belt specifications 1-91
Engine troubleshooting . . . . . . . . . . . . . . . . . . .. 1-24 V-belt tensioner 1-98
Exhaust valve specifications 1-4 Water pump 1-101
Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-52 Water pump specifications . . . . . . . . . . .. 1-11, 1-91
 SECTION 2 - FUEL AND INDUCTION SYSTEMS
BOOK 1
INDEX
Adjustment of high idle speed 2-9 a a a a a a •• a_a a a a a a High-pressure fuel lines installation ~. 2-27 0 a • 0 a a.

Adjustment of low idle and antisurge 2-9 a a a a a a a a a High-pressure fuel lines removal . 2-26 a ••• a a a a a a

Air cleaner a a a a a 2-61

a a a a a • a a a a a a a a a a a a a a a a • a a Induction and turbocharger description and
Air filter
a a a a a a a a 2-68
a a a a a a a a a a a a a a a a a a • a a a a a a operation: all models. 2-61 a 0 a • a • a a 0 0 a a a a • a • a

Air leakage test a 2-45

a a a a a a a a a a a a a a a a a a a a •• a a • Induction and turbocharger disassembly
Axial clearance check . 2-75 a a •••• a ••••••••• a • • • and repair . 0 a a • a a 2-68
a a a • a • a a a 0 • a a a 0 • 0 a • a •

Bleeding the fuel system ... 2-8 a a •• a •••• a •• a a • a Induction and turbocharger specifications 2-67 a ••

Bosch A2000 System 2-4 a a a a a a • a a •• a a • a ••• a • a a Induction and turbocharger troubleshooting . 2-65 a

Bosch VE distributor-type fuel injection Injection nozzle .... a 2-32

• a • a • a a a ••• a a • a a a a • a a

system a a a a a • 2-39
a a a a a a a a a a • a a a a a a a a a a a a a a Injection nozzles chatter and spray test .0. 2-35 a •

Bosch VE system 2-38a a a a a a a • a a a a a a • a a a a a •• a a Injection nozzles nozzle seat leakage test 2-35 a. a

Center shaft radial check 2-74 a a a a a a a a • a a a a •• a • a Injection nozzles nozzle test, installation,
Electric supply pump 2-39 a a a a a a a a a • a a a a a a • a a a a a engine running a a • 2-32
0 0 a a a a a a a a ••• 0 0 a 0 a a a •

Fuel filter a •••• a 2-30, 2-41

a ••• a •••••• a a a •• a a • a • Injection n~zzles opening pressure test 2-34 a. a • a

Fuel filter manifold. 2-31 a a •• a ••• a a a • a a. a a a a. a a a Injection nozzles preliminary set-up .... 2-34 a • a a •

Fuel filter manifold installation 2-31 a. a a a a • a a •• a a a Injection nozzles removal and reinstallation 2-32 a a

Fuel filter manifold removal 2-31 a a a a a • a a ••• a a ••• Injection nozzles surging . 2-36 0 • a a •• a 0 a a a a 0 • a • a

Fuel filter removal and installation 2-30 a a •• a •• a a. Injection nozzles testing and repair 2-33 a a a a 0 0 • a.

Fuel filter/water separator/primer pump a..... 2-5 Injection pump inspection and repair 2-54 0 • a a 0 • a •

Fuel injection lines ... 2-24 a • a a a • a •••••• a • • • • • •• Injection pump installation 2-21, 2-50 0 a a a 0 •• a a a ••

Fuel injection pump 2-5,2-18,2-41 a ••• a •• a •••••• Injection pump reassembly . 2-56 a • a •• a •••••• a a 0

Fuel injection pump installation 2-21 a ••••• a a •••• a Injection pump removal . 2-47 0 0 a •••••••• 0 a • a a a •

Fuel injection pump: post-installation Injection pump timing 2-48

0 a • 0 0 a 0 0 ••• a 0 0 0 • a • 0 o.

connections and setup . 2-24 a a • a 00 ••• a 0 0 a •• 0 Injection system bleeding . 2-44 0 • a ••• a 0 •• 0 0 a 0 • a •

Fuel injection pump removal . 2-19 0 0 • a a 0 a a 0 a • a 0 a' Injector disassembly . 2-53

0 a • 0 a a 0 0 a • a a 0 0 a 0 0 a 0 a a

Fuel injector assemblies . 2~6 0 ••••••••••••••• a •• Injector leak-off line 0 0 2-29

a a a 0 0 a a a a •• 0 a a 0 0 • a a • a

Fuel injectors . 0 0 2-42

0 •• , • 0 a •••• a 0 0 a a •••• 0 0 • •• Injector leak-off line installation 2-30 a • a ••

Fuel sedimenter 0 2-41

• 0 a 0 0 0 0 0 0 0 ••• a 0 a 0 • 0 ••• a 0 a Injector leak-off line removal 2-29 000 II. a ••• 0 0 a a a a

Fuel shutoff solenoid check for Injector installation a 0 2-57

0 a a 0 0 0 a 0 .00 a 0 a a a a 0 0 a 0

electrical feed 2-17

0 0 0 •• 0 0 • 0 0 0 • 0 0 • a • 0 • a 0 • • •• Injection reinstallation 2-36
a a 0 0 a 0 0 a ••••• a a a. a a 0 a

Fuel shutoff solenoid diagnosis and repair 2-16 II 0 0 Injector removal a 0 a • a 2-51
a a 0 a 0 a a 0 a • 0 a a • 0 a 0 a a 0 0

Fuel shutoff solenoid installation .... 2-18 0 0 • 0 • • •• Injector testing and overhaul . 2-52 a 0 0 a a a • a 0 0 a a 0 0

Fuel shutoff solenoid preliminary checks 2-16 .0.0 Inner element a •• a • a a 2-61
0 •• a • a • a • a a a • a ••• 0 a a a

Fuel shutoff solenoid removal . 2-14 0 0 0 • a 0 a 0 0 0 • •• Low idle and antisurge adjustment 2-9 0 •• a 0 a • 0 a a 0

Fuel shutoff solenoid specifications 2-16 0 a a 0 a •• 0 0 Low-pressure fuel injection lines . 2-25 0 0 a 0 a •• a a a.

Fuel shutoff solenoid verify linkage Low-pressure fuel injection I·ines installation 2-25 a

adjustment 0 2-18
•••••••• · ••••••• a a 0 0 0 • 0 • a o. Low-pressure fuel injection lines removal 2-25 0 • a 0

Fuel supply pump 2~9 0 0 •••••• a • 0 a 0 0 •• Low-pressure fuel lines 2-7 0 a a 0 a a 0 a • a 0 0 • a • a a a a.

Fuel supply pump air leakage test ..... 2-12 a 0 a • 0 Plumbing a •• a •••••• 2-7, 2-42
a a a a •• 0 a a ••• a • a • a •

Fuel supply pump installation 2-11 .0.00. a a •••• 0. Primer pump a 0 0 a 0 0 a 0 2-5
•• a •• a 0 a 0 •• a .. 0 0 0 • 0 • a a 0

Fuel supply pump output test .. 2-11 0 a 0 a 0 • a a 0 • 0 0 Removal, diagnosis and repair ..... 2-7 a a a 0 • a a a a

Fuel supply pump overflow valve test o. 2-12 0 0 0 • 0 Special tools 0 a a 0 0 a 0 • 2-59
a 0 a a 0 a •• 0 •• 0 a 0 • a 0 • a a •

Fuel supply pump removal 2-9 0 0 0 0 0 0 0 0 • 0 • 0 0 0 0 0 It 0 Specifications .. 0 a 0 a2-59, 2-67

a a a a 0 0 a 0 a 0 0 0 0 • a 0 •

Fuel supply pump testing .. 2-1 0 a •• a •••••• a • a •• 0 Testing for leakback (injection
Fuel system description and operation ..... 2-3 0 0 pump to tank) .. 02-13, 2-46
a a a ••• a a 0 •••• 0 •••

Fuel system specifications 2-58 0 0 a 0 0 0 0 0 a 0 ••• a a 0 0 Throttle cable adjustment 2-7,2-43 0 a. a a 00. a a • a • a

Fuel system special tools 2-59 0 0 0 0 0 0 0 0 a a 0 a 0 • 0 0 0 0 TrOUbleshooting 0 0 0 0 a 2-65

a a a a a a 0 a 0 a •• 0 a • 0 a a a a 0

Fuel system torque chart 2-59 0 0 0 0 • 0 0 0 • a a • 0 0 0 0 0 0 Turbocharger a a a a 0 0 a 2-61

0 a a 0 a a a a a •• a a • a • a a a a a

Fuel tank 0 • 0 0 0 0 0 02-30 0 0 0 0 0 0 0 0 0 • 0 0 a 0 0 0 • a 0 0 0 0 0 0 Turbocharger disassembly 2-71 a a a a a a a a 0 a 0 a 0 0 0 a

High idle speed adjustment 2-9 a 0 0 • 0 ••• a •• 0 • 0 0 0 0 Turbocharger removal 2-70 a 0 a • a a a • a a a a a a a a a a 0 0

High-pressure fuel lines 2-7, 2-26 o. a •• 0 • 0 a 0 0 a a 0 0 Water separator a a • a a 2-5

• a a 0 a a • a ••• a a • a • a a a •• a
 SECTION 3 - TRANSMISSION
BOOK 1
INDEX
Automatic downshifts .. , I I I I I • I I I I I I I I I I I I 3-11 Oil and oil filter change procedures 3-18 I I I I I I • I I

Automatic upshifts I I I I •• I •• I I 1.1 I I I I I I I I I I 3-11 Oil check procedure . I 3-15

I I I • I • I I I I I I • I • I I I I I

Auxiliary filter I I • I • I •••• I I I • I ••• I I I I • I I I I I 3-17 Oil contamination. I I I • 3-17

I I I • I I I I I • I • I I I • I I I I

Breather "" I I I • I •• I ••• I I I I I • I • I I I I • I • I I I 3-18 Oil filter, pump circuit I 3-10

I I •• I I I I • I I • I I I I I I I •

Clean reservoir suction screens "' I I I I I I •• I • 3-23 Oil pan and oil filter I I ••• 3-9 I •• I I I I I I I • I I I I • I ••

Clutch circuits .... I ••••• I I •• I • I I I I • I •••• I. 3-11 . Oil pump assembly I I I 3-6
I I ••• I I • I • • • • • • • • • • ••

Control valve assembly . I I •• I I I I I •• I • I • I •• I 3-9 Oil recommendations I 3-16

I I I • I I I I I I I ••• I • I I I •

Converter-in, converter-out, lubrication Oil system specifications . 3-29 I •• I • I I • I I • I I • I • I

circuits I ••••••• I • I I I • I •• I I • I I • I 3-1 0 Periodic inspection and care ... 3-15 I I I I • I I I I • I I

Converter operation I • I ••• I I I • I I •• I I I I 3-13 Planetary gear unit I. I 3-9

I I I • I • I I I I I I I I I I I I I I I

Downshift inhibiting I • I •• I I ••••• I I •• 3-12 Preservation and storage . 3-19 I I I I I I I I •• I I • I I I I

First clutch ..... I I •••••••••••• I • • • • • • • • • •• 3-8 Preventive Maintenance 3-15 I ••• I I I I • I I I •• I I I I •

First-gear operation I I I I I • I I I I I • 3-13 Principles of operation . 3-6 I ••• I I •••• I I I I I I I I ••

Forward clutch and turbine shaft ... I •••••••• 3-7 Priority valve I I • I I • I I I 3-12
I I • • •••• I ••• I • • • • • • •

Fourth clutch ..... I •• I I • • • • • • • • • • • • • • • • • •• 3-7 Range selector positions . 3-4 I • I • I I •• I ••• I • I I ••

Fourth-gear operation I I I • • • • • • • • •• 3-14 Ratings specifications . . . . . . 3-29 I I I I I ••• I • I • I • •

Gearing specifications I • I ••• I • • • • • •• 3-29 Reservoir suction screens 3-23 I •••• I ••• I I

General information I ••••••• 3-3 Reverse-gear operation 3-14 I I ••••• I • I I ••• I • I • I

Governor · I • • • • • • • • • •• 3-9 Second and third clutch and center support 3-8 I • I

Governor valve, governor circuit. I I ••••••.••• 3-10 Second-gear operation . 3-13 I I • I I I • I • I •••• I • • • •

Hold regulator valve I I • "'" I •• "' 3-11 Sele~to~ valve, neutral, forward regulator
Hot check 3-16 circuit 1.1 I •• I I I ••• 3-10
I I ••••••• I ••••••••••

Hydraulic oil and filter change I • • 3-23 Size specifications I 3-29

I ••• I I •• I ••••••••• I •

Hydraulic Schematic I • I • I •• I • • 3-28 Speedometer drive . . . . . . . . . . . . . . . . .. 3-9

Hydraulic system ... I ••• I ••••• I • I • • • • • • • • • 3-1 0 System functions .. I I •• 3-10 I • I •••• I ••••••••• I •

Importance of proper oil level . I •• I I • II ••• I • 3-15 Third-gear operation 1.1 3-13 •••• I ••••••• I • I • I ••

Input drive I ••• I • • • • • • • • • • •• 3-6 Torque converter assembly .. 3-6 I • I • I ••• I ••• I "'

Internal and external filters change 3-21 Torque converter specifications ... 3-29 I •• I • • • • •

Keeping oil clean I • I I • I 3-16 Torque paths through transmission .. 3-13 I I •• I I I

Main pressure circuit I ••••••• 3-10 Transmission cross-section

Manual selector lever linkage I ••••••••• 3-19 components (Part A & B). 3-25, 3-27 I ••••• I I I •

Mechanical Modulator I • I • I •••••• " 3-9 Transmission cross-section

Mechanical Modulator linkage . . . . . . . . . . . . . . 3-19 diagram (Part A & B) . 3-24, 3-26 I •• I • I •• I I I • I

Modulator pressure circuit I ••••• 3-10 Transmission housing I 3-6

••••• I I I I I ••• I I I •• I ••

Mounting I I I •••••• I ••••••••••••• 1.1 I '3-6 Transmission oil change 3-21 I I ••• I • I •••

Mounting specifications I I • I I • I •• I • • • • • 3-29 Trimmer regulator valve 3-12 I • I ••••••

Neutral operation I •••••••• I • • • • • 3-13 Troubleshooting - Before removal/operation -

Oil and oil filter chang~ intervals . . . . . . . . . . . . 3-17 of transmission 3-20 I I • I • I • • • • • • • •
 SECTION 4 - REAR AXLE AND SUSPENSION
BOOK 2
INDEX
Adjustment specifications a a •• a •• a • a a a a • a. 4-89 Planetary assembly. a a a a a • a a a • a a • 0 a a • a • a a 4-15
Axle .... a a a a •• a. a a a a ••••••• a. a a a a a a a a a. 4-22 Rear axle housing a a a • a • a a a •• a • a a a a a a • a a a 4-64
Axle housing bent a a • a a a a ••• a a • a a a a a a a a a a 4-20 Rear axle lubricant a a a •• a a • a aa a a a a a a • • • •• 4-89
Axle shaft .. a •••• a •••••• a a a • a a •••• a •••• a 4-19 Rear axle springs a a a a •• a • a a a a • a a a a • a • a • a 4-65
Description and operation a a a a a a • a a a a •• a • a 4-2 Repair and/or replacement procedures . a a • a 4-21
Differential and planetary gear ... a ••• a a a a. 4-28 Ring and pinion backlash. a a •••• a • a a a a •••• 4-10
Differential carrier . a a a • a • a a a a a a • a •• a • a a •• 4-17 Ring gear and drive pinion teeth a a • a •• a a a a a 4-10
Differential carrier removal . a ••• a a a • a •• a • •• 4-25 Ring gear backlash .. a • a • a a a a • a •• a • a a • a • a 4-54
Differential gear fail ures a a • a a • a a a • • a • a a a a a 4-13 Ring gear runout . a a a a • a a a •• 0 •••• a • a a • a a a 4-54
Drive pinion oil seal. a a • a •• 00 •• a • a a a a •• a • a 4-21 Scored and scuffed teeth a a a a a •••• a •• a •• a. 4-11
Electric shift circuit . a • a •• a •• a • a •• a a a a a a •• 4-67 Scored or worn surfaces on thrust washers a 4-15
Electric shift control . a a •••••••• a ••••••••• a 4-67 Scoring and seizure of spider arm and side
Electric shift system .. a • a a a a • a •••• a • a a ••• 4-68 pinions ... a ••• a a •••• a • a a a a a • • • • • • • • • •• 4-14
Electric shift testing. a •••••• a • a • a • a a a • • • •• 4-71 Shift fork position and alignment a •• a a 4-74
Electrical operation a ••••••••• a a a • a a 4-69 Shift unit a a • a a • a •• a • a • a • a a • a • a • a. 4-75
Fatigue fractured side gears a ••• a 4-14 Shock fractured side gears and pinions a ••• 4-13
Fracture of axle shaft at flange a • a ••••• a 4-19 Slider block inspection .... a •• a • • • • • • • • • •• 4-73
Fractured drive pinion teeth 4-13 Specifications ... a •••••••••••• a • • • • • • • • •• 4-88
Fractured ring gear teeth 4-1 0 Torque specifications a ••• a •• a •••••••• a • •• 4-88
Gear support case assembly 4-18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .. 4-4
Harshness a a •••• a •• a ••• a 4-4 Troubleshooting chart a • a • • • • • • • • • • • • • • • •• 4-7
Hypoid ring gear tooth contact a. a •• a • • • • •• 4-55 Twisted or broken axle shaft . a •••• a ••••• a. 4-19
Labor guide 4-90 Vibration a •••••••• 0 • • • • • • • • •• 4-5
Loose bearing adjuster lock .. a •••••• a • • • •• 4-17 Vibration diagnosis procedure. . . . . . . . . . . .. 4-6
Maintenance a • • • • • • • • • • • •• 4-21 Vibration road test a •• a • • • • • • • • • • • • •• 4-6
Mechanical operation a ••••••• a a •• a. 4-70 Wheel bearings 4-23
Noise 4-4 Worn bearing hub in gear support case 4-18
Overheated ring gear and pinion a ••••• a 4-12 Worn bearing rollers ... a •• a •••••••••••• a. 4-18
Parts inspection . . . . . . . . . . . . . . . . . . . . . . . .. 4-10 Worn or scored bronze pinion pins a •• 4-16
Pinion bearing preload adjustment a • • • •• 4-41 Worn pinion pilot bearing bore 4-17
Pinion shaft a • • • • •• 4-35 Worn splines in the side gears a • • • • • • •• 4-15
Pitted drive pinion teeth 4-12 Worn teeth in the differential bearing adjuster 4-16
Pitted teeth on the sliding clutch gear and Worn teeth in the high speed clutch plate . .. 4-15
idler pinions 4-16
 SECTION 5 - FRONT AXLE AND SUSPENSION
BOOK 2
INDEX
End play of the wheel assembly . . . . . . . . . .. 5-27 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-3
Front suspension . . . . . . . . . . . . . . . . . . . . . . .. 5-32 Removing a knuckle 5-14
Front wheel bearings 5-4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-2 Spring assembly 5-32
Knuckle bushing 5-28 Steering knuckle and spindle 5-12
Knuckle bushing wear 5-12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .. 5-34
Labor guide 5-35 Wheel lug bolts 5-3

SECTION 6 - BRAKE SYSTEM

BOOK 2
INDEX
Adjustments and repairs 6-28 Hydraulic brake system, description 6-2
Automatic brake shoe adjustment (drum) 6-16 Hydraulic leak test . I • I • I •••• I ••• I • I I • • • •• 6-27
Backing off shoes to remove drum . . . . . . . .. 6-50 Hydro-Max assembly torque valves 7-73
Brake bleeding . . . . . . . . . . . . . . . . . . . . . . . . .. 6-28 Hydro-Max booster, description ... I • • • • • •• 6-4
Brake drum refinishing 6-60 Hydro-Max booster/master cylinder . . . . . . .. 6-68
Brake pad removal and inspection Hydro-Max booster/parking brake system .. 6-3
(disc brakes) '. 6-38 Initial setting of read drum brakes I •• 6-49
Brake pad replacement and Inoperable electric motor pump I •••••••••• 6-79
reinstallation (disc brakes) 6-40 Labor gUide 6-98
Brake shoe adjustment (drum) 6-19 Manual bleeding - parking brak~ system 6-31
Brake shoe adjustment (front disc) 6-19 Manual bleeding - service brake system . . .. 6-28
Brake shoe and lining . . . . . . . . . . . . . . . . . . .. 6-50 Manual braking, operation 6-12
Brake system preliminary checks .' . . . . . . . .. 6-27 Master cylinder ..... I • I • I I I I I I •• I I I I I I I I 6-74
Caliper installation I • I •• '. 6-46 Master cylinder diagnosis chart I I I I I I I • I •• 6-76
Caliper removal and disassembly I • • • • •• 6-42 . Measuring shoe to drum clearance I I I I • I • I 6-49
Description, hydraulic brake system . I • • • •• 6-2 Operation I I I • I I • I • I I • I I I I I I •• I • I I I I • I I I 6-9
. Diagnosis and testing I • • • • •• 6-27 Parking brake spring chamber I I I •• I I I •• I I 6-60
Electric motor operates with little or no boost 6-81 Parking brake system, description . I I • I • I I I 6-8
Electric motor pump .... I •••• I • • • • • • • • • •• 6-82 Parking brake system, operation I I I I I I II • I 6-20
Electric motor pump runs continuously . I • •• 6-80 Power braking, operation I I I I I I I • I • I I I I I • I 6-9
Electrical system I ••••••••••• I • • •• 6-78 Pressure bleeding - service brake system I I 6-29
Fitting and tube seat leak inspection ... I • •• 6-27 Rear drum brakes, adjustments I. I I I I I I I I. 6-49
Fluid leak check I •• I •••• I • • • • • • • •• 6-27 Rear drum brakes, description I I I I I I I I I • I I 6-7
Fluid level check - service brake system . . .. 6-30 Rear drum brakes, operation I •• I I • I I I I I I I. 6-15
Front brake (disc), operation ..... I •••••• I. 6-14 Relay valve and control valve I I • I I I •• I I • •• 6-68
Front brake (drum), operation .. I I I I ••••• I. 6-13 Removing brake shoes (front brakes, drum) 6-32
Front brake reassernbly and. Service brake master cylinder system I • I • I I 6-3
reinstallation (drum) . I •• I ••••• I ••••••••• 6-34 Troubleshooting' ~ I I I • • I I I I I I I I I I •• I I •• I • I 6-83
Front disc brakes, description .... I • I I •• I I. 6-6 Wheel cylinder/adjuster .. I I I I I I I I I I I • • • •• 6-56
Front drum brakes, description . I • • • • • • • • •• 6-5 Wheel cylinder/parking brake expander .... 6-57
Hydraulic brake fluid color I • • • • •.•• 6-28 Wheel cylinder servicing ..... I • • • • • • • • • •• 6-36
 SECTION 7 - STEERING SYSTEM
BOOK 3
INDEX
Adjustments 7-5 Patents, hydrapower 7-24
Approved hydraulic fluids, hydrapower 7-33 Poppet component replacement,
Assembly, hydrapower 7-66 hydrapower 7-74
Assembly preparation, hydrapower 7-66 Poppet readjustment, hydrapower 7-50
Caster/camber 7-5 Poppet resetting, hydrapower 7-90
Chart your way to easy steering directory, Reinstallation, hydrapower 7-90
hydrapower 7-28 Replace housing ports, plugs,
Contents, hydrapower 7-25 screws, fittings, hydrapower 7-84
Design features, hydrapower 7-23 Roller bearing or retaining ring
Disassembly, hydrapower 7-57 replacement, hydrapower 7-83
Disassembly preparation, hydrapower 7-56 Section 1, general information,
Disclaimer, hydrapower 7-24 hydrapower 7-26
Drag link 7-6,7-8 Section 2, initial installation, hydrapower 7-37
Filling and air bleeding the system, Section 3, on-vehicle service, hydrapower 7-43
hydrapower . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 -41 Section 4, reseal and repair, hydrapower 7-54
Final adjustments, hydrapower 7-85 Section 5, reinstallation, hydrapower 7-88
Flexible coupling 7 -14 Sector shaft adjustment, hydrapower 7-48
Gear specification numbers, hydrapower 7-33 Service parts list, hydrapower 7-36
General design, hydrapower 7-31 Steering column 7-18
General Information 7-2 Steering gear. . . . . . . . . . . .. . . . . . . . . . .. 7-7,7-12
General operation, hydrapower 7-32 Steering gear arm ... . . . . . . . . . . . . . . . . . . . .. 7-11
Glossary, hydrapower . . . . . . . . . . . . . . . . . . . .. 7-92 Steering gear service 7-21
Hazard warning definitions, hydrapower 7-24 Steering wheel 7-17
Hydrapower integral power steering gear 7-22 Stop bolts " II. • • • • 7-7
• • • • • • ••

Hydraulic System 7-4 System component replacement 7-8

Initial poppet setting, hydrapower 7-39 TAS series exploded view -
Initial TAS installation, hydrapower 7-39 typical, hydrapower 7-35
Input shaft seal replacement, hydrapower 7-42 lie rod 7-10
Inspection, hydrapower a ••• 7-64 Toe-in 7-5
Introduction, hydrapower 7-29 Torque chart, hydrapower 7-34
Labor guide 7-98 Troubleshooting 7-94
0• • • • • • • • • • • • • • • • • •

Maintenance tips, hydrapower 7-40,7-91 Valve housing/worm screw disassembly,

Oil Flow II ••••••••••••••••••••••••• 7-4 hydrapower 7-76
OU flow illustration, hydrapower 7-30 Verify the problem . . . . . . . . . . . . . . . . . . . . .. 7-3
 SECTION 8 - HYDRAULIC SYSTEM
BOOK 3

INDEX
Cartridge replacement 8-66 Piston pump parts inspection ........•.... 8-105
Cartridge valves . . . . . . . . . . . . . . . . . . . . . . . .. 8-57 Piston pump installation 8-108
Case drain 'flow test (piston pump) 8-132 Piston pump reassembly 8-1 07
Check valves 8-71 Piston pump removal 8-101
Circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . .. 8-26 Piston pump repair information 8-100
Closed-center system . . . . . . . . . . . . . . . . . . .. 8-12 Piston pump start-up procedure 8-108
Compensator adjustment . . . . . . . . . . . . . . . .. 8-1 09 Pressure testing . . . . . . . . . . . . . . . . . . . . . . . .. 8-129
Component location 8-3 Pump output test . . . . . . . . . . . . . . . . . . . . . . .. 8-132
Cylinders 8-121 Reading diagram symbols . . . . . . . . . . . . . . .. 8-4
Filtration 8-9 Relief valve adjustment 8-69
First and second table cylinder air check Relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-68
valve service . . . . . . . . . . . . . . . . . . . . . . . . .. 8-128 Rolling rack and auxiliary first table cylinders 8-126
First table cylinder installation. . . . . . . . . . . .. 8-124 Second table cushion adjustment. . . . . . . . .. 8-129
First table, push-off, and bale loader Solenoid coil replacement 8-47,
cylinders 8-122 8-62
Flow dividers 8-70 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-158
Flow testing 8-131 Spool valves . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-45
Gear pump 8-79 Steering/brakecircuit 8-11
Gear pump disassembly 8-80 System diagram . .. . . . . . . . . . . . . . . . . . . . . .. 8-8
Gear pump installation 8-83 System oil flow (closed-center system) 8-12
Gear pump parts inspection 8-81 System oil flow (open-center system) 8-10
Gear pump reassembly 8-82 System operation (closed-center system) . .. 8-14
Gear pump removal 8-79 System operation (open-center system) .... 8-10
Gear pump start-up procedure 8-84 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-129
Hydraulic system cycle times 8-160 Tie. spike cylinder 8-126
Introduction " . . . . . . . . . . .. 8-2 Troubleshooting, bale loader 8-136
Labor guide 8-161 Troubleshooting, closed-center system 8-140
Load rack and second table cylinders 8-124 Troubleshooting, cross conveyor 8-138
Load rack/push-off foot interlock linkage Troubleshooting, first table 8-143
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-78 Troubleshooting, load rack "0 ••••••• 8-152
Load rack valve 8-77 Troubleshooting, open-center system 8-134
Load sensing 8-12, Troubleshooting, push-off feet. . . . . . . . . . . .. 8-154
8-86 Troubleshooting, rolling rack D' • a •••••••••• 8-155
Open-center system 8-10 Troubleshooting, second table 8-147
Orbit motors . 'I • • • • • • • • • • •8-110'
• • • • • • • • • • • • • •• Troubleshooting, tie spikes 8-151
Orbit motors. disassembly 8-112 Valve disassembly and assembly . . . . . . . . .. 8-54
Orbit motors parts inspection 8-116 Valve manifold 8-17
Orbit motors reassembly 8-116 Valve manifold component identification 8-19
Orifices 8-74 Valve manifold component information 8-25
Piston nut torque chart . . . . . . . . . . . . . . . . . .. 8-126 Valve manifold identification codes 8-18
Piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-85 Valve removal and replacement 8-52
Piston pump disassembly 8-102
 SECTION 9 - ELECTRICAL SYSTEM
BOOK 4
INDEX
Accessories and miscellaneous circuits 0000 9-133 Load rack control lever 00000000000. 0009-90, 9-93
Air conditioning component locations 0000000 9-10 Power distribution 00000000 0 0000 I0 0 9-20 I I I I I I I I

Alternator assembly . 0. 0. 0000000000.. 00.. 0 9-83 Protecting the electrical/electronic systems

Alternator disassembly and repair .000.00000 9-78 during charging or welding 0 00000 9-33 I I I I I I I I

Alternator removal and installation 0. 000. 00. 0 9-77 Push-off foot extend/retract switch 0. 0 9-95 I I I I I I I

Armature servicing o. 00' 00.00.0.000 ... 0.. 0 9-65 Radio 0 0 0 00000 0 000 "0 00
I I I I 0 9-133 I I I I I I I • I I I I • I

Bale loader control lever . 0. 0. 000. 9-90, 9-93 D • D , Relays 00000000000000.0.0 .. 00.0. 0•. 9-13,9-152
Bale loader lift switch 0000000. 0000000000000 9-92 Resistance test for electrical components 0 0 9-36 I

Battery 00000000 0 000 0000 0 00 00 9-38 I I I I I I I I I I I I I Rolling rack forward/reverse switch 000 0000 9-94 I I

Battery charge, fast 000 000000 0000 00 0 0 9-48 I I I I I I Safety gate 000 00000 I 000 00. 00000. 000 0 9-5 I • I I I I

Battery charge, slow 0000 0000000000000 000 9-45 I I Safety gate switch 0000 000• 0 00000 009-90, 9-92 I I I

Battery charge, standard 000000 00000 0000 9-48 I I I Seat air compressor 00 0000000 000 00 9-148 I I D D I I I

Battery charging 0000000000000000000000000 9-45 Selecting battery charge method . 000000000 9-46 I

Battery charging precautions 000000000000000 9-49 Sender and sensor replacement .. 0000000009-120
Battery failure 0 00 00 000 0 000000000 00 9-39
I I I I I I I I Sending units 0 0 001 100 00 0000 0100
I I I 9-16 I I I I I I I

Battery size and rating 0 0 000 0000 00 00 9-38 I I I I I I I Slow charge procedure 10 0 0000.0 00 9-45 I I I I • I "'

Battery slow charge 0000 00000 000000 0000 9-45 I I I Solenoid checks 00 00• 00 00 000• 0000 9-67
I I I I I I I I

Battery slow charge procedure 000000000 000 9-47 I Solenoid, three-terminal 0 0000000000000 9-68 I I I I •

Battery specifications 000000000000000000000 9-49 Special tool requirements 00000000• 00• 000 9-4 I I.

Battery testing 00 00000000 0000 0000 0000 9-42 I I I I I Specifications 0000000• 00• 00000• 00000000• 9-153 I

Battery troubleshooting 00 00000000 1000000 9-38 I I Speedometer calibration .0.000 00 00 9-120 I •• I I I •

Brake light switch, replacing 00000 10 000000 9-127 I Starting circuit troubleshooting 0 0 9-52 I I ••• I I I I • I

Cab component locations 00000000000 00 000 9-9 I I Starting motor 000 0 0 0000000
I 0 9-50
I I I I I I I •• I I • I

Charging system 1000000 00000 0000000000 9-73 I I I Starting motor armature servicing 00• 00 9-65 I I I • •

Charging system, operation 00000000 10000000 9-74 Starting motor cleaning 9-64 I I • I • I 0 ••••• 0 I • 0 I 0 •

Charging system, precautions 000• 0000000000 9-75 Starting motor disassembly, testing
Charging system, troubleshooting 0000000000 9-75 and repair . 00• 0•• 0•• 0 0• 0000 00 9-60
I I I I I I I • I

Charging the battery 000 10000 0 10 9-45 I I I I I I I I I I I Starting motor, lubrication . 0010 0•• 00 000 9-69 I I I I

Circuit breakers 0000 00 0000 19-14,9-152 I I I I I I I I I Starting motor, pinion clearance .. 00.0 0 00 9-70 I I I

Circuit description and operation, loading 0 9-92 I I I Starting motor, reassembly .00 00 10 0 9-69 I I •• I I I I

Circuit diagram information 0000000000 00000 9-18 I Startingsystem 101 0•• 0 00 0000 9-50 I I I II •• I I • I I I

Cold. start aid 000 00000000000000 000 0000 9-141 I I I Starting system specifications 00• 00000000000 9-72
Cold start system 0 00 00 0 9-51 I I I I I I I I I I I I I I I I I I I Starting system tests .. 0 0 0 00 0000000 9-56 I I I I • I I

Continuity test for open circuits 0 0 0 9-34 I I I I I I I I I I Switch description 0000 0 00

I 9-91
I I I I I I • I I I I • I I I I

Continuity test for short to ground 0 0 9-35 I I I I I I I I Switch replacement 0 00 0 9-96 I • I •• I I •• I I I I • I I I I.

Definition of terms 00 0 0 9-3 I I I I I I I I I I I I I I I I I I I I. I Test procedures, electrical 0 0 0 10 9-33 I I I I I I I I I • I I

Electrical component locations 0 00 00 9-5 I I I I I I I I I Testing the battery 0 0 0I 9-42

I I I I I I I I I I I I I I I I I I I.

Electronic component locations 0 0000000 9-5 I I I I I Troubleshooting, battery 0 10 0000 9-38 I I I I I • I I I I I

Electrical test procedures 0 0 9-33 I I I I I I I I I I I I I I I I Troubleshooting, bale loader 0000• 00 0 0009-102 I I I

Field coil checks, starting motor 00 0 0 9-66 I I I I I I I I Troubleshooting, cold start circuit 00 0 9-143 I I I I I I I

Field coil removal, starting motor 0 0 9-66 I I I I I I I I I Troubleshooting, gauges 0 100 1000 9-115 I I I I I I I I I

Fuel shut-off solenoid 10 0 100 9-51 I I I I I I I I I I I I I I I Troubleshooting, instrument panel 9-112 I. I I I. DO I

Fuses I I I 0 00
I I I100I I0 09-15,9-152
I I I I I I I I I I I I I Troubleshooting, lights and bulbs 0 9-129 I I I I I I I I I

Gauges 0000 000000000 0000000000000 9-111

I I I I I I Voltage drop test 000000 0 0 0•• 000 0 9-44 I I I I I I I I I I

Gauges, troubleshooting 0 0 0 9-115 I I I I I I I I I I I I I I Voltage measurement . 0 0 000000 000• 00000 9-37 I I a

General information 00 0 000 0 9-3 I I I I I I I I I I I I I I I I Windshield wiper 0 00 I 0 0010100 9-134

I I I I I I I I I I • I

Grounds 00000 00 0 0 00 000 00 0 9-12

I I I I I I I I I I I I I I I Wire color identification 00 0• 0 0 9-17 I I I I I I I I • I I O.

Heater I I I I I00 0 0 00 0 09-140

I I I I I I I I I I I I I I I I I I I I Wire harness identification 0 0 000• 0 9-17 I I I I I • I I • I

Instrument panel, gaining access 0 00 9-112 I I I I I I I Wire harnesses 0 0 I I 000 00 I 9-11 I I • I • I I I I I I I I I I I

Key off current drain 000000000000000000000 9-43 I Wire identification 0 0 0 0 0000000 9-17 I I I I I I I I I I I I I

Labor guide 00000000000 000 00 000000000 9-150 I I I Wiring diagram circuit explanation 00 0000000 9-20 I

Ughts 10 1.0 1010 00 1000000000 9-123

I I I I I I I I I I I I I Wiring diagram index 0 100000000000000 9-18 I I I I I

Ughts and bulbs, replacing 0 9-124 I I I I I I I I I I I I I I Wiring diagram key 010 101 I 9-18 I I I I I I I I I I I I I I I I

Loading and unloading control switche~ 9-90 I I I I I Wiring diagram information 0 0 0 9-17 I. I I I I I I • I I I I
 SECTION 10 - ELECTRONIC CONTROL SYSTEM
BOOK 4
INDEX
Alarm removal and installation I I I • I •••• 10-13 I I • Load rack down sensor ..... 10-35 I I •• I •••• I I I I

Automatic I. I • I I • I I • I I • I I I •••• I I I I I I 10-14

I • I I Machine interlocks . I 10-6
•••••• I ••• I I I •••• I I • I

Bale loader ... I ••••• I •••• I ••• I •• I I I 10-4, 10-22 Manual I I I I I I ••• I. I 10-15
•••• I I I I •••• I I ••••• I

Bale loader and first table I I • I •• 10-6 I I I I Operating modes I I • I 10-14

• I •• I ••• I • I I I I •• I •• I

Bale loader sensor .. I • I • I • I • I I • I •••• 10-28

I •• I Operation I I I I I • I • I •• 10-4 I •••• I I • I ••• I •••• I ••

Controller removal and installation I I • I I • 10-1 0 • •• Program .... I I I •• I • 10-16

I I •••• I ••••• I •••••• I

Controls ... I •• I ••••••• I ••• I ••••••••• I 10-9 •• "' Program view ..... I I 10-16
I • I I I •••• I •• I • I •• I I I

Cross conveyor and first table I I I ••• I I • • 10-4 • • •• Right trip I I • I I I I I • I I 10-23
•••• I I I I I • I I' I I I I I I • I

Description, electronic controrter I • 10-7 I ••• Right trip sensor I. I I 10-27

• I I • I • II I ••• I I I I •• "'

Diagnostic modes ..... I •••••••••• I • I •10-1 7 • •• Safety gate . I I • I I I •• 10-20

I •••• I I I I I I I I I • I • • • •

Display .. I I I • • • • • • • • • • • • • ". 1.1 ••••••••••• 10-8 Second table ... I I 10-4,10-24

••••••• II ••••• I ••

Display removal and installation 10-12 I Second table 50° sensor 10-32 I I I •• I • • • • •

Display test ... I • I ••••• I ••••• I • I • I • I • I10-19 •• I Second table down sensor 10-34 I ••••• I • • • • • • • •

Electronic control system I •••• 10-1 I ••• Second table limit sensor . 10-33 I I I •• I • I I •• I ••• I

Electronic controller ... I •• I ••• I •• I •• I • 10-7 I ••• Select 10-14 I •• I ••••

Eprom removal and installation I ••••••• I 10-11 •• ' I Sensor and switch test '. 10-17 I ••• I ••• I •• I •• I • ••

First table I ••••••••••• 10-23 I Software revision level ... 10-19 I • • • • • • • • • • • • • ••

First table and second table I • • • • • 10-6 • • •• Solenoid test ... I 10-17
•••••••••••• I • I ••••• I I •

First table and tie spikes I •••• I 10-6 •• I. Special tool requirements 10-3 I • • • • • • • ••

First table limit sensor .. I ••• I •••• I •• I •••• 10-29 I Spikes down sensor .. 10-30 I •••••••• I I •• I • • • • •

General information I • 10-3 I • I I Stacking I •••••••••••• 10-5 I ••••••• I I I • • • ••

Hall effect sensors I 10-21 • I • Start up 10-4 I • • • • • • • • ••

Introduction, general information I I 10-3 ••• I Switches and sensors 10-20 I • • • • • • • • • • • • • •

Introduction, machine interlocks I. 10-6 Testing the solenoid circuits 10-18 I ••••••••••••••

Introduction, operation I • • • • • • • 10-4 • • •• lie spikes 10-4,10-23 I • • ••

Left trip ..... I ••• I • • • • • • • • • • • • • • • • • • • 10-22 • •• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

Left trip sensor I •••• 10-31 Wait 10-15
Load rack I • • • • • • • • • • •• 10-6,10-24
 SECTION 11 - AIR CONDITIONING SYSTEM
BOOK 4
INDEX
Air-conditioning process . . . . . . . . . . . . . . . . .. 11-4 High pressure switch replacement . . . . . . . .. 11-48
Air-conditioning system performance test Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-2
diagnostic chart . . . . . . . . . . . . . . . . . . . . . .. 11-31 Labor guide 11-64
Blower fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-14 Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-26
Blower fan switch 11-16 Low pressure switch replacement 11-48
Blower motor and fan assembly replacement 11-52 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 -17 '
Cab air filters 11-8 Manifold gauge readings and interpretations 11-34
Checking refrigerant for excess air 11 ~21 Manifold gauge set 11-27
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-18 Operational check diagnostic chart 11-24
Clutch assembly and shaft seal 11-56 Operational checks . . . . . . . . . . . . . . . . . . . . .. 11-23
Component replacement 11-46 Precautions 11-2
Compressor 11-9 Pressure/temperature relationship chart . . .. 11-34
Compressor and clutch a • • • • • • • •• 11-53 Receiver/drier. . . . . . . . . . . . . . . . . . . . . . . . . .. 11-10
Compressor replacement . . . . . . . . . . . . . . . .. 11-53 Receiver/drier replacement . . . . . . . . . . . . . .. 11-47
Compressor protection switches . . . . . . . . . .. 11-16 Recharging the system . . . . . . . . . . . . . . . . . .. 11 -30
Condenser 11-9 Recycled versus reclaiming . . . . . . . . . . . . . .. 11-18
Condenser replacement . . . . . . . . . . . . . . . . .. 11-46 Recycling equipment 11-20
Containers for the storage of recycled Refrigerant (R-134a) . . . . . . . . . . . . . . . . . . . .. 11-17
refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-20 Refrigerant extraction and recycling
Containment of mobile air-conditioning equipment 11-19
system refrigerants . . . . . . . . . . . . .. . . . . .. 11-20 Refrigerant handling 11-18
Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-18 Refrigerant recovery procedure 11-28
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-6 SAE standards . . . . . . . . . . . . . . . . . . . . . . . . .. 11-22
Discharging the system 11-28 Safety and service precautions . . . . . . . . . . .. 11-2
Disposal of empty or near-empty disposable Service and safety precautions . . . . . . . . . . .. 11-2
containers . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-22 Stabilizing the system . . . . . . . . . . . . . . . . . . .. 11-28
Electrical power flow . . . . . . . . . . . . . . . . . . . .. 11-7 System component location 11-6 .
Evaporator 11-14 System components ..... . . . . . . . . . . . . . . .. 11-8
Evaporator core replacement 11-50 System performance tests and service 11-26
Expansion valve 11-11 Temperature control 11-15
Expansion valve replacement . . . . . . . . . . . .. 11-49 Test ports 11-27
Extraction equipment 11-19 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-23
Flushing 11-29 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-15
Function 11-4 Thermostat replacement 11-51
Gauge readings and interpretation . . . . . . . .. 11-35 Transport of refrigerant. . . . . . . . . . .. . . . . . . .. 11-21
General information 11-4 Troubleshooting and testing .... D • • • • • • • •• 11-23